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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a marine propulsion system and, in particular, to an improved shifting mechanism.
2. Background of the Invention
Some conventional outboards motor include the following basic components: an engine, a crankshaft, a power transmission, a propeller, and a shifting mechanism. The engine may be contained within a protective cowling that includes an upper cover and a lower tray. Extending below the tray is a drive shaft housing that supports the engine and houses the drive shaft. Below the drive shaft housing is a lower unit that carries the transmission and the propeller. The transmission is located inside the lower unit and transmits power from the drive shaft to the propeller. Rotation of a shift rod, which depends into the transmission, shifts the transmission between gears.
The shift rod may be controlled by an operator. For instance, an actuator controlled by the operator may be coupled together with the shift mechanism and a shift lever. The shift lever, in turn, may be coupled to the shift rod such that circular rotation of the shift lever rotates the shift rod. Thus, the watercraft operator uses the actuator and the shift mechanism to selectively determine the gear of the transmission.
Shift mechanisms often include a shift position detection sensor to detect the circular motion of the shift lever. The sensor may be used to determine when the shift lever is in the neutral position. In such instances, the engine may be designed to start only when it receives a signal from the shift position sensor that the shift lever is in a neutral position. This helps to reduce abrupt movement upon ignition start-up. In addition, as disclosed in U.S. Pat. No. 5,050,461, the shift mechanism may also be configured to temporarily reduce the engine speed during shifting. This type of engine control aids shifting between gears.
SUMMARY OF THE INVENTION
Earlier shift mechanisms, however, suffer from several drawbacks. For example, the shift position sensor may be located in a space within the lower tray, between the engine and the drive shaft housing. This space is very narrow, making assembly and maintenance of the shift position detection sensor difficult. Furthermore, the recent trend in the industry is to reduce the size of the outboard motor by compacting the cowling. This exacerbates the cramped space in the lower tray. Therefore, there is a need to reduce the size and complexity of the shift mechanism and to reposition the shift mechanism such that it can be assembled and maintained easier.
In addition, the shift position sensor is preferably positioned at a right-angle relative to the motion of the shift lever in order to detect more accurately the position of the shift lever. However, due to the arcuate paths of many shift levers, properly configuring such a right-angle relationship has proven difficult.
Thus, one object of the present invention is to overcome some or all of the aforementioned limitations of the prior art and to provide an improved shift control mechanism
Accordingly, one aspect of the present invention involves a marine propulsion system comprising a transmission with at least two operating states. A shift mechanism is coupled to the transmission and establishes the operating state of the transmission. The shift mechanism moves between at least a first shift position and a second shift position with the first shift position corresponding to the first operating state of the transmission and the second shift position corresponding to the second operating state of the transmission. An operator unit is disposed remotely relative to the shift mechanism and is adapted to move between at least a first and second control position. The operator unit is coupled to the shift mechanism such that movement of the operator unit to the first control position positions the shift mechanism in the first shift position, and movement of the operator unit to the second control position positions the shift mechanism in the second shift position. The shift mechanism includes a member that moves along a substantially linear path. A shift position sensor is arranged to cooperate with the member so as to detect at least one of the shift positions.
Another aspect of the present invention involves a marine propulsion system comprising an engine and a transmission that is coupled to the engine and has at least two operating states. A shift mechanism is coupled to the transmission and establishes the operating state of the transmission. The shift mechanism is capable of moving between at least a first shift position and a second shift position with the first shift position corresponding to the first operating state of the transmission and the second shift position corresponding to the second operating state of the transmission. An operator unit is disposed remotely relative to the shift mechanism. The operator unit is adapted to move between at least first and second control positions and is coupled to the shift mechanism. Movement of the operator unit to the first control position positions the shift mechanism in the first shift position, and movement of the operator unit to the second control position positions the shift mechanism in the second shift position. A shift position sensor is arranged to detect at least one of the shift positions. The sensor is arranged on a side of the engine and to an outer side of the shift mechanism.
For purposes of summarizing the invention and the advantages achieved over the prior art, certain features, aspects, objects and advantages of the invention have been described above. Of course, none of these features, aspects, objects or advantages should be considered essential. Also, any one embodiment of the present invention may employ one or more of these features, aspects, objects or advantages. Thus, for example, those of ordinary skill in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other features, aspects, objects or advantages, as may be taught or suggested herein.
All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus summarized the general nature of the invention and some of its features, aspects, objects, and advantages, certain preferred embodiments and modifications thereof will become apparent to those skilled in the art from the detailed description herein having reference to the figures that follow, of which:
FIG. 1 is a side elevation view of an outboard motor constructed in accordance with an embodiment of the invention;
FIG. 2 is a partially sectioned top plan view showing a shifting mechanism configured with certain features, aspects, and advantages of the present invention;
FIG. 3 is a partially sectioned side elevation view of the shifting mechanism shown in FIG. 2 taken along line 3 — 3 ;
FIG. 4 is a partially sectioned top plan view of the shifting mechanism shown in FIG. 2, with portions removed, and showing the mechanism in a neutral drive position;
FIG. 5 is a partially sectioned top plan view of the shifting mechanism shown in FIG. 2, with portions removed, and showing the mechanism in a reverse drive position;
FIG. 6 is a schematic top view of the engine and the shifting mechanism shown in FIG. 2, with a cowling outline shown in phantom lines;
FIG. 7 is a partially sectioned top plan view showing another shifting mechanism, configured in accordance with certain features aspects and advantages of the present invention;
FIG. 8 partially sectioned side elevation view of the shifting mechanism shown in FIG. 7 taken along line 8 — 8 ;
FIG. 9 is a partially sectioned top plan view of the shifting mechanism shown in FIG. 7, with portions removed, and showing the mechanism in a neutral drive position;
FIG. 10 is a partially sectioned top plan view of the shifting mechanism shown in FIG. 7, with portions removed, and showing the mechanism in a reverse drive position;
FIG. 11 is a schematic top plan view of the engine with a cowling outline shown in phantom lines and another shifting mechanism configured in accordance with certain features aspects and advantages of the present invention; and
FIG. 12 is a more detailed top plan view of the shifting mechanism shown in FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts an outboard motor 10 constructed in accordance with certain features, aspects, and advantages of the present invention. While the present invention is described in conjunction with an outboard motor, those of ordinary skill in the art will appreciate that the invention may be used in other applications.
The outboard motor 10 has a powerhead 11 which includes an internal combustion engine 14 . A protective cowling 12 surrounds the engine 14 . The cowling 12 includes a lower tray 16 . The tray 16 and the cowling 12 together define a compartment which houses the engine 14 with the lower tray 16 encircling a lower part of the engine 14 .
The motor 10 is moveably mounted to a hull 22 of the watercraft 8 . Preferably, a steering shaft 24 is connected to the motor 10 . The steering shaft 24 is supported for steering movement about a vertically extending axis (not shown) within a swivel bracket 26 . This mounting permits the watercraft to be steered by turning the motor 10 about the vertically extending axis that passes through the swivel bracket 26 .
The swivel bracket 26 is connected to a clamping bracket 28 . The clamping bracket enables movement of the motor 10 about a generally horizontally extending pin 30 . The clamping bracket 28 is connected to the hull 22 of the watercraft. The mounting about the pin 30 permits the motor 10 to be trimmed or tilted up and down with respect to the water 31 in a vertical plane about a horizontal axis extending through the pin 30 .
As is typical with outboard motor practice, the engine 14 is supported so that its output shaft 32 (e.g., crankshaft) rotates about a generally vertical axis 20 . The crankshaft 32 drives a drive shaft 34 which depends from the powerhead 11 and also rotates about the generally vertical axis 20 . The driveshaft 34 extends through a drive shaft housing 18 and is suitably journalled therein for rotating about the vertical axis 20 . As seen in FIG. 1, the drive shaft housing extends from the lower tray 22 and terminates in a lower unit 36 .
The drive shaft 34 continues into the lower unit 36 where it drives a transmission 38 through an input gear (not shown). The transmission 38 selectively couples the drive shaft 34 to a propulsion shaft (not shown). The propulsion shaft is coupled to the propeller 40 . The transmission 38 advantageously is a forward/neutral/reverse-type transmission. In this manner, the drive shaft 34 drives the propulsion shaft in any of these operational states as described below.
The operational details of the transmission 38 are not essential to the present invention. Typically, in marine propulsion systems, “dog-clutch” type transmissions are used which allow the outboard motor 10 to operate in forward, neutral, and reverse drive. This type of transmission is well known in the art and thus the details are not illustrated but the main components of the transmission are described.
Within the transmission 38 is a bevel gear affixed to the lower end of the drive shaft 34 . The bevel gear meshes with a pair of counter rotating driven gears which are journalled in a suitable manner for rotation on the propeller shaft. The propeller shaft is, in turn, journalled in a suitable manner in the lower unit 36 . A dog-clutching sleeve has a splined connection to the propeller shaft located between the bevel gears and is axially moveable. If the dog-clutching sleeve is positioned so that the dog-clutching teeth are out of engagement with the teeth of the bevel gears, the transmission is in neutral. When the dog clutch sleeve is shifted forward along the axis of the propeller shaft, the dog clutching teeth are engaged with one of the bevel gears and the propeller shaft is driven in one direction. Alternatively, when the dog clutching sleeve is shifted backwards along the axis of the propeller shaft, it engages the other bevel gear and the propeller shaft is driven in an opposite direction.
The dog clutching sleeve is reciprocated by a shift mechanism 46 (FIG. 2) that includes a shift control lever 42 (FIG. 1 and FIG. 2) that is affixed to a shift control rod 44 (FIG. 1 ). As will be described in detail later, the shift mechanism 46 rotates the control lever 42 and therefore rotates the shift control rod 44 . The shift control rod 44 depends into the transmission 38 . Within the transmission 38 , by means well known in the art, rotation of the shift control rod 44 causes reciprocating movement of the dog clutch sleeve. Accordingly, rotation of the control lever 42 shifts the transmission between forward, neutral and reverse positions.
With reference to FIGS. 2-6, the shift mechanism 46 will be described in detail. The shift mechanism 46 cooperates with a remotely located operator unit 48 that controls the shifting mechanism 46 . In an exemplifying embodiment, the operator unit 48 is located on the steering shaft 24 (FIG. 1) of the outboard motor 10 ; however, the operator unit 48 may also lie either in the hull 22 of the watercraft or within or adjacent to the power head 11 of the outboard motor 10 .
A Bowden-wire-type shift cable 50 desirably couples the operator unit 48 to the shifting mechanism 46 . In the illustrated embodiment, the cable 50 has an outer casing 52 . A bracket (not shown), which is mounted within the cowling 12 , supports a portion of the cable 50 near the shift control mechanism 46 and prevents movement of the outer casing 52 of the cable 50 relative to the cowling 12 .
The illustrated shifting mechanism 46 includes a fitting 54 positioned at the end of the shift cable 50 . The fitting 54 is coupled to an end of a link 56 . A pivot pin 58 of the shift control mechanism 46 interconnects the cable fitting 54 and the link 56 in order to permit relative rotational movement between these components.
A slider 60 supports the pivot pin 58 within an elongated aperture 62 . A guide 64 supports the slider 60 . As best seen in FIG. 3, the guide 64 includes a slot or cam groove 66 . Preferably, the slot 66 defines a substantially linear path, in which the slider 60 translates. A bracket 68 supports the guide 64 and is attached by a bolt 70 to the crankcase 72 of the engine 14 .
As shown in FIG. 2, a shift position sensor 74 is located along a side of the guide 64 . Moreover, the shift position sensor has a portion that is preferably positioned at a substantially right-angle relative to the substantially linear path of the slider 60 . The shift position sensor 74 is generally comprised of a detection lever 76 and a sensor body 78 . During operation of the outboard motor, the shift position sensor 74 transmits a signal to a control unit 80 . The function and purpose of the shift position sensor 46 will be described later. The guide 64 , slider 60 and sensor 74 together comprise a guide mechanism 65 .
An opposite end of the link 56 is connected to an end of the shift control lever 42 . A pivot pin 82 couples together the ends of the link 56 and the lever 42 to allow relative rotational movement between these components of the shifting mechanism 46 .
As best seen in FIG. 3, the shift lever 42 has a vertical jog. A portion of the lever 42 thus lies below the end coupled to the link 56 . The shift control rod 44 is fixed to the lower portion of the shift lever 42 . As understood from FIG. 1, the shift control rod 44 depends from the power head 16 to the transmission 38 . The shift control rod 44 operates the transmission 38 to change the drive condition of the transmission 38 as described above.
As best understood from FIGS. 3 and 6, parts of the shift mechanism 46 , such as the link 56 and the control lever, 42 are preferably arranged and operate vertically below the crankcase 72 within a space 17 between the engine 14 and the drive shaft housing 18 . The guide mechanism, however, 65 is preferably arranged on a side of the engine 14 and crank case 72 . More preferably, the guide mechanism 65 is located in a space between the engine 14 and the cowling 12 . Moreover, as is best shown in FIG. 6, the shift position sensor 74 is preferably arranged on the outer side of the shift mechanism relative the engine 14 . More preferably, the guide 64 and slider 60 are interposed between the sensor 74 and the engine 14 . As such, the shift mechanism 46 produces a compact arrangement within the space 17 between the lower tray 16 and the cowling 12 . This location also protects the link 56 and the control lever 42 , shift rod 44 and position sensor 74 while still allowing access for assembly and repairs.
The operation of the shift control mechanism will now be described in detail. With reference to FIG. 2, the cable 50 is interlocked with the operator unit 48 . The shift lever 42 is in the forward position “FO”. The slider 60 is located at one end of the guide 64 . The pivot pin 58 is located at one end 62 a of the elongated aperture 62 . In this position, the detection lever 76 of the shift position sensor 74 physically engages the slider 60 . Thus, the slider 60 is secured in this position. At this position, the sensor 76 prohibits the engine from starting by transmitting a signal to the control unit 80 . Accordingly, the sensor 76 prevents the watercraft from abruptly moving forward when started.
As the cable 50 begins to move in a direction “A”, the pivot pin 58 slides from one end 62 a of the aperture toward the other end 62 b, but the slider 60 remains still and does not slide in the “C” direction. In such a manner, play is provided in the shift mechanism 46 and the slider 60 remains still despite small movements of the cable 50 . Thus, the shift mechanism 46 includes a lost motion coupling. Preferably, this lost motion coupling is interposed between the operator unit and the shift lever. More preferably, the lost motion coupling is interposed between the operator unit 48 and the sensor 74 . Furthermore, the direction of the lost motion is preferably in the same direction as the motion of the slider.
When the cable 50 moves further in the “A” direction, the pivot pin 58 eventually reaches the other end 62 b of the aperture 62 , and the slider 60 moves in the “C” direction. As shown in FIG. 4, when the cable 50 moves in the “A” direction for a certain distance, the shift lever 52 rotates to a neutral position “N” through the link 56 and pivot pin 82 as described above. The transmission 38 then shifts to the neutral position, and the engine 14 ceases power transmission to the propeller 40 .
When the shift lever 52 is positioned in the neutral position “N”, the detection lever 76 of the sensor 74 is physically engaged with an etched or recessed portion 84 of the slider 60 . Because of this engagement, the slider 60 is secured in this position. While in this position, the sensor 74 transmits a signal to the control unit 80 that allows the engine 14 to start.
As the cable 50 further slides in the “A” direction, the shift lever 42 interlocks with the movement of the cable 50 as described above and pivots to a reverse position “R” (See FIG. 5 ). Accordingly, the transmission 38 shifts into reverse gear allowing the watercraft to move in a reverse direction.
In the position depicted in FIG. 5, the slider 60 is located at the end of the guide 64 in the “C” direction. Although the detection lever 76 is disengaged from the recessed portion 84 of the slider 60 , the detection lever 76 is still in physical contact with the slider 60 . Therefore, the slider 60 is secured in its position at the end of the guide 64 . In this position, the sensor 74 transmits a signal to the control unit 80 that prevents the engine 14 from starting.
The shift lever 42 returns in order from the reverse position “R” to the neutral position “N” and forward position “FO” when the cable 50 slides in the “B” direction and the slider 60 correspondingly slides in the “D” direction to return to its original position as illustrated in FIGS. 2, 5 and 6 . Because the slider 60 slides in a linear direction, the sensor 74 can be positioned at a substantially right angle to the slider 60 and be more securely and accurately arranged as compared to prior art. Advantageously, the illustrated sensor can transmit a signal to prevent ignition or allow ignition with only two positions due to component positioning and gearing. It is envisioned, however, that other arrangements are also possible.
Another arrangement having certain features, aspects, and advantages in accordance with the present invention is depicted FIGS. 7-10. The illustrated arrangement is similar to that described above and similar parts have been given the same reference numbers. The following description will focus on the additional features, which are not present in the above described arrangement.
In addition to the shift mechanism 46 described above, there is further provided a pivot detection sensor 86 , which cooperates with the shift mechanism 46 so as to provide a signal when the transmission 38 is being shifted from either the forward drive position or the reverse drive position . This sensor forms a portion of a mechanism that will operate to slow the speed of the engine 14 and make disengagement of the dog clutching teeth easier. As with the first arrangement, this shift mechanism 46 includes a guide mechanism 65 that includes a guide 64 which defines a slot or cam groove 66 in which a pivot pin 58 and a slider 60 are journalled.
As best shown in FIG. 8, the guide mechanism 64 is journalled on a bracket assembly 68 that is affixed to the crank case 72 in a suitable manner, as by bolts 70 (FIG. 7 ). With reference to FIG. 8, the bracket 70 has a pivot shaft 88 . The pivot shaft 88 is preferably threaded into a pivot rod 90 formed in the base of the guide 64 . Thus, the guide 64 is journalled for pivotal movement about an axis 92 defined by the pivot shaft 88 and pivot rod 90 .
A torsional spring 94 encircles the pivot rod 90 and has its ends engaged with the bracket 70 and the guide 64 for urging the guide 64 for rotation about the axis 92 in a clockwise direction into engagement with a fixed stop 96 (FIG. 7) formed on the bracket assembly 58 . This is the normal position for the member 47 and corresponds to the neutral position of the shift lever 42 and slider 60 as shown in FIG. 9 .
As shown in FIG. 7, when shifting to the neutral position from the forward drive position, the guide 64 will be rotated in a counterclockwise direction and engage a another limit stop 98 also formed on the bracket 58 . This movement of the guide 64 is shown by the dashed lines of FIG. 7 that are referenced by the number 87 . When this rotation occurs, the pivot detection sensor 86 detects the rotation and sends a signal to the control unit 80 which will cause the slowing of the speed of the associated engine in a known manner such as by effecting misfiring of its spark plug or spark plugs. This type of circuit is well known and any of the known circuits used for this purpose may be employed.
Because of the angular inclination of the link 56 and the cooperation of the slider 60 with it, the counterclockwise pivotal movement will be effected regardless of whether the device is being shifted from forward or reverse drive position as may be best seen in FIG. 10 . As shown, when the slider 60 is moved in the “D” direction from its reverse position a component force is applied to the guide 64 and the guide 64 pivots from its position illustrated by a solid line to the position illustrated by the dashed line 87 . As described above, the pivot detection sensor 86 detects this movement and inputs a signal to the control unit 80 , whereby the engine 14 is disabled temporarily.
A third arrangement of the present invention is depicted in FIGS. 11 and 12. Elements of this arrangement that are similar to the other arrangements will be given the same reference numbers. A Bowden-wire-type shift cable 50 desirably couples the operator unit to the shifting mechanism 46 . As in the previous arrangements, the cable has an outer casing 52 . The cable 50 and the outer casing 52 are fitted to a guide 64 . A fitting 54 is positioned at the end of the cable 50 and coupled to an end of a shift control lever 42 . A pivot pin 82 of the shift mechanism 46 interconnects the cable fitting 54 and the shift control lever 42 in order to permit relative rotational movement between these components. As best shown in FIG. 11, the shift lever 42 is linked to the shift rod 44 and thus movement of the cable 50 rotates the shift rod 44 and shifts the gear of the transmission 38 as described above.
As shown in FIG. 12, the guide 64 is located on the cable 50 so that the cable 50 slides only in a linear direction. Furthermore, sliders 60 are mounted on the cable 30 . The sliders 60 are situated within a groove (not shown) in the guide member 64 so that they slide within the guide 64 in a linear direction.
A shift position detection sensor 74 is located along one side of the guide 64 at a right angle to the sliders 60 and the cable 50 . The shift position detection sensor 74 is comprised of a detection lever 76 and a sensor body 78 . During operation, the shift position sensor 74 transmits signals to a control unit 80 . The function and purpose of the shift position detection sensor 74 is as described above. Furthermore, as with the embodiments described above, the detection lever 76 physically restrains the gliders 60 in a particular position.
As illustrated by the dashed lines in FIG. 12, the sensor 74 detects the motion of the cable in an “A” or “B” direction by sensing the movement of the sliders 60 through the guide 64 . As such, the sensor can detect the forward, neutral and reverse positions of the shift lever 42 . The guide member 64 , sliders 60 and sensor 76 can be located anywhere on the cable 50 . This provides flexibility as to the location of the sensor 46 . As such, the sensor 46 may be located further to the side of the engine 12 as shown in FIG. 11 . Thereby, assembly and maintenance of the sensor 46 is made easier.
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.
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An improved shift mechanism for a marine propulsion transmission is provided. The shift mechanism includes a guide that defines a slot that receives a member of a linkage that connects an operator unit with a shift rod. Movement of the shift mechanism is converted into substantially linear motion and a shift position sensor is located at a substantially right angle to that movement. Information from the sensor is transmitted to a control unit and is employed to prevent abrupt starts. The shift position sensor is located on the side of an engine for ease of assembly and maintenance. Movement of the shift mechanism may also cause pivotal movement of the guide and this pivotal movement may be employed to reduce the engine speed and assist shifting.
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CROSS-REFERENCE TO RELATED APPLICATION
This Continuation application claims the priority benefit of U.S. Non-Provisional patent application Ser. No. 12/702,887, filed Feb. 9, 2010, and Provisional Patent Application Ser. No. 61/151,122, filed Feb. 9, 2009, the entire scope and content of which are hereby incorporated herein by reference.
BACKGROUND
The present invention in general relates to fencing and railing systems, and in particular relates to connectors for fencing and railing systems.
SUMMARY
Briefly described, in a first example embodiment the present invention relates to a fencing/railing assembly adapted to be positioned between a pair of posts and mounted thereto. The assembly includes a plurality of pickets, a plurality of rails extending transverse to the pickets, and a connection between the pickets and the rails. The picket/rail connection is slidably mounted to the rail and pivotally connected to the picket to permit a sliding, pivotal motion. The sliding, pivotal connection allows the pickets to be oriented at greater angles relative to the rails (i.e., it allows the assembly to rack to a greater degree, thereby allowing the fencing/raining to follow more steeply changing terrain or contours).
In one preferred form, the fencing/railing assembly includes one or more elongated connector strips that are each concealed by the rail and that each span a corresponding set of multiple adjacent pickets. In another preferred form, the fencing/railing assembly includes a plurality of shorter connectors, one for each picket/rail connection.
The connectors, be they shorter individual-picket connectors or longer multi-picket connector strips, can include small projections (e.g., bosses) that extend from one surface thereof and engage holes (e.g., recesses) formed in the pickets. Advantageously, this provides a fastener-less but still pivotal connection. Preferably, the rails each have an inner profile that is sized and shaped to slidably retain or capture the connector between the rail and the picket, while permitting the connector strip to slide relative to the rail and be concealed by the rail during normal use. For example, the rail can have an inwardly extending shelf or ledge that slidingly supports the connector strip so that the connector strip slides atop the shelf.
The fencing/railing assembly, including the pickets, the rails, and the concealed connectors, can be made of extruded aluminum, plastic, or other materials. Also, the rails can be generally U-shaped and have picket openings formed in one portion thereof for receiving the pickets therethrough. Optionally, a leading, inner edge of the railing may be beveled or eased to facilitate slipping the rail over the connector during assembly.
In another aspect, the present invention relates to a pre-assembled fencing/railing assembly adapted to be positioned between a pair of posts and mounted thereto. The assembly includes the same components as those described above. But these components are pre-assembled at a factory or other assembling facility. And the assembly is shipped in this pre-assembled state, ready for installation, so this part of the assembly process is not done on-site in the field.
In yet another aspect, the present invention relates to a method of manufacturing a fencing/railing assembly to be positioned between a pair of posts and mounted thereto. One such example method includes the steps of: (a) providing a series of pickets each with one or more connector holes formed therein; (b) providing a connector strip with a series of connector bosses formed on at least one side thereof; (c) attaching the connector strip to the series of pickets by aligning and inserting the connector bosses into the connector holes formed in the pickets; (d) providing an at least three-sided rail (e.g., a generally U-shaped rail) with picket openings formed in an upper portion thereof; and (e) slipping the rail over the pickets and over the connector strip to secure the connector strip in place and conceal the connector strip.
These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of the invention are exemplary and explanatory of preferred embodiments of the invention, and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of a fencing/railing assembly according to a first example embodiment of the present invention.
FIG. 2 is a side view of the fencing/railing assembly of FIG. 1 .
FIG. 3 is a side sectional view of a portion of the fencing/railing assembly taken at line 3 - 3 of FIG. 1 .
FIG. 4 shows the left portion of the fencing/railing assembly of FIG. 3 , with hidden features shown in phantom lines.
FIG. 5 is a perspective, exploded view of the fencing/railing assembly of FIG. 1 , depicting the fencing/railing assembly being assembled.
FIGS. 6A-6E are front, top, back, side, and perspective views of a connector strip of the fencing/railing assembly of FIG. 1 .
FIGS. 7A-7B are schematic illustrations depicting the range of movement of a prior art picket-and-rail arrangement.
FIGS. 7C-7D are schematic illustrations depicting the range of movement of a picket-and-rail arrangement of the fencing/railing assembly of FIG. 1 .
FIG. 8 is a perspective view of a connector of a fencing/railing assembly according to a second example embodiment of the invention.
FIGS. 9-12 are plan, side, bottom, and perspective views of a connector boss strip of a fencing/railing assembly according to a third example embodiment of the invention.
FIG. 13 is a side view of a boss of the connector boss strip of FIG. 10 .
DETAILED DESCRIPTION
The present invention may be understood more readily by reference to the following detailed description taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.
Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.
Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views, FIGS. 1-6E and 7 C- 7 D show a fencing and/or railing assembly 10 according to a first example embodiment of the present invention. The railing assembly 10 is typically used to enclose yard spaces, decks, porches and the like.
Generally, the railing assembly 10 comprises a plurality of horizontally spaced pickets 20 and at least one support rail 30 . The pickets 20 are typically arranged generally vertically with the rail 30 transverse to them. In the depicted embodiment, the railing assembly comprises three support rails 30 a , 30 b , 30 c (as seen in FIG. 1 ) to space, align, and secure the pickets 20 and to provide for structural rigidity. Each picket 20 can also include an endcap 40 coupled to the top of the same (or formed in the top portion itself) to close off the top of the picket and/or to provide a decorative element to the railing assembly 10 . In example embodiments, the pickets 20 and railing 30 are formed from extruded aluminum, however, in alternative embodiments, the pickets and railing can be formed from solid aluminum, other metals and/or metal alloys, wood, rubber, plastic, and/or other materials known in the art. In example embodiments, the pickets 20 are hollow, square aluminum extrusions and the railings 30 roughly rectangular (but U-shaped) aluminum extrusions; however, in alternative embodiments, the pickets and railing can be formed in different shapes.
As seen in FIGS. 3 and 4 , the rails 30 can have a substantially “U” shaped cross-section and, in use, are generally oriented open-side-down such that the “bottom” of the “U” forms the top of the rail 30 . In alternative embodiments, the rails 30 can have a substantially “J” shaped cross-section or rectangular-shaped cross-section. In still other embodiments, the rails 30 can include other cross-section shapes as desired. The top wall of the rail 30 includes a series of horizontally spaced picket openings 39 through which the pickets extend. In depicted example embodiments the rail 30 is shown having a decorative bulge 38 on the exterior surface of the rail, however, in alternative example embodiments other exterior shapes can be utilized as desired.
As shown in FIGS. 3 and 4 , the rails 30 include at least one concealed ledge or shelf 32 for supporting a connector or boss strip 34 (or alternatively referred to as a dimpled strip) thereon. The shelf or shelves 32 extend inwardly from the inner surface of one or both sidewalls of the rail 30 . Optionally, the lower leading edges of the shelf 32 (or another portion of the rail 30 ) can be chamfered, ramped, or beveled to facilitate a slight outward deflection and smooth movement over the boss strip 34 during assembly. Once in place, the boss strip 34 is securely held there by the shelf 32 with the boss strip supported by the shelf and secured in place between the shelf and the top wall of the rail 30 . The boss strip 34 is captured between the corresponding sidewall of the rail 30 and the picket 20 but permitted to slide horizontally between the two and along the rail atop the shelf 32 . Additionally, the connector strip 34 can be made of a metal, plastic, or any other suitable material.
In addition, the boss strip 34 includes at least one inwardly extending boss (e.g., a nub, pin, or other protruding structure) 36 that is received in a pivot or connector hole 22 (e.g., a recess, through-hole, or slotted channel) in one of the pickets 20 for rotatably coupling the boss strip to that picket (as will be described in greater detail below with reference to FIGS. 7C-7D ). In an alternative embodiment, the boss/nub extends outward from the picket and the pivot hole is formed in the connector strip (this is an “opposite” or “vice versa” arrangement of that described above). In another alternative embodiment, aligning pivot holes are formed in the connector strip and the picket, a pivot pin is provided, and the two ends of the pivot pin are inserted into the two pivot holes. In yet another alternative embodiment, the pivot hole is horizontally slotted to provide for additional sliding motion.
And in still another alternative embodiment, the connector/boss strip is eliminated, the pickets each include at least one horizontally slotted connector hole, and the rails each include at least one inwardly extending boss that is received into the slotted connector hole. In this embodiment, the pickets pivot about the boss and the boss slides along the slotted connector hole such that the rail/boss and picket slide too. The opposite or vice versa arrangement can alternatively be provided, with the boss on the pickets and the slots in the pickets. As no connector strips are provided, and the strips in the above-described embodiments provide structural support for the overall fence/railing assembly, the rails and/or pickets of this embodiment are designed with relatively greater strength (e.g., a stronger material and/or thicker walls).
Thus, the railings 30 each have an inner profile that is sized and shaped to retain the connector or boss strip 34 between the rail and the picket while permitting it to slide and pivot relative to the pickets. With this construction, a sliding, pivoting connection is obtained and also concealed. The connection is also achieved without the use of any threaded fasteners.
In use, the railing assembly 10 can be assembled as partially demonstrated in FIG. 5 . For example, the plurality of pickets 20 are first inserted into and extended through the picket openings 39 of the rails 30 . Next, the connector or boss strips 34 (better seen and understood by viewing FIGS. 6A-6E ) are coupled to pickets 20 by inserting the bosses/nubs 36 into the corresponding holes 22 formed in the pickets. Finally, the rails 30 are lowered (from the depicted positions of FIG. 5 ) vertically along the pickets 20 and over the boss strips 34 , where they are snapped into place by forcing each rail ledge or shelf 32 over the boss strip, for example, by the beveled or ramped leading edge riding over the strip and deflecting slightly thereby.
As shown in FIG. 5 , multiple connector boss strips 34 can be used with each rail in the railing assembly 10 , with each boss strip being long enough that it is coupled to a set of multiple of the pickets 20 . The set of pickets can include all of the pickets 20 in a fence/rail section (between posts) or only some of them. In the typical commercial embodiment depicted, each boss strip is long enough that it is coupled to approximately five pickets 20 , and thus it has five bosses/nubs 36 . This coordinates together the pivoting of all of the pickets 20 engaged by a connector strip 34 (those in the picket set) relative to the rail 30 and that connector strip 34 . For example, if a connector strip 34 were to be in engagement with five pickets 20 , movement of a single picket amongst the five pickets would result in the other four pickets moving in synchronization with the single picket that is originally moved. In addition, by spanning multiple pickets 20 , the connector strips 34 provide structural support for the overall fence/rail assembly 10 , so the pickets and/or rails 30 can be designed to provide less overall structural strength (e.g., with thinner walls and/or less-strong materials).
In alternative embodiments, longer or shorter boss strips 34 can be utilized as desired, such that each boss strip can accommodate less than five pickets or more than five pickets. In still other alternative embodiments, a relatively short, single boss strip or connector is used for each picket/rail connection. As seen in FIG. 8 , for example, a short boss or connector strip 134 according to a second example embodiment is so short that it doesn't span from one picket to another and it only includes a single boss/nub 136 .
In manufacturing the product, a simplified technique or method is accomplished. In an example method, a pre-assembled section of fencing/railing assembly is constructed and shipped for sale. This allows the sections to be assembled under factory conditions, rather than under field conditions, for maximum efficiency and quality control. The pre-assembled fencing/railing assembly includes a length of fencing/railing ready to be installed between a pair of posts or uprights. Thus, the user would install the pre-assembled section of fencing/railing between the posts in the field.
The manufacturing method for constructing the pre-assembled section can include the steps of:
(a) providing a series of pickets with connector holes formed therein;
(b) providing at least one connector strip with one or a series of connector bosses formed on at least one side thereof;
(c) attaching the connector strip to the one or series of pickets by aligning and inserting the connector bosses into the connector holes formed in the pickets;
(d) providing a rail with picket openings formed in an upper portion thereof and with at least one shelf formed on an inner surface thereof; and
(e) slipping the rail over the pickets (with the pickets extending through the picket openings) and over the connector strip to secure the connector strip in place on the shelf and conceal the connector strip.
This manufacturing method allows for easy and economical manufacture, as well as providing a consistently good manufacturing quality. Also, when the pre-assembled section of fencing/railing is assembled, the connector strip is not readily visible (it is concealed by the rail).
In addition to concealing the connection and being readily pre-assembled in a factory for later field-installation by a user, a fencing/railing assembly according to the present invention also adjusts to follow rising or falling terrain better than known fencing/railing. As demonstrated by comparing a known prior art railing assembly ( FIGS. 7A-7B ) to the present invention ( FIGS. 7C-7D ), it can be seen that the present invention is better able to pivot the pickets relative to the rails in comparison to known railing assemblies. For instance, known railing assemblies incorporate screws S and/or bolts to rotatably couple pickets P to rails R, as shown in FIGS. 7A-7B . Such couplings are time consuming to install and only allow for a limited range of rotation and little if any horizontal movement. In fact, the known railing assembly of FIGS. 7A-7B only allows the pickets to rotate about 15 degrees in either direction before being obstructed by the edge of the picket opening.
In stark contrast, the present invention utilizes a sliding pivotal connection between the pickets 20 and the rails 30 that is very easy and fast to install and allows for limited horizontal movement of the pickets 20 along the rails 30 . In particular, the connector boss strip 34 slides within the rail 30 in the transverse directions denoted by the arrows X when the pickets 20 are pivoted in the angular directions denoted by the arrows Y, thereby allowing the pivot point between the connector hole 22 of the picket and the rail to slide one way or the other, as shown in FIGS. 7C-7D . Because of this, the picket 20 is afforded a higher degree of rotation within the picket openings 39 of the rail, while the pickets and picket openings are the same size as in prior art systems. In typical commercial embodiments, utilizing the present invention permits the pickets 20 to rotate about the boss 36 at least 36 degrees (as compared to the known railing assembly's typical rotational limit of about 15 degrees), using a similar opening gap between the picket and the edge of the picket opening in the railing—the additional freedom of motion is not due to simply making the opening larger. The amount of rotation depicted in FIGS. 7C-7D is meant to be exemplary of the capabilities of the present invention and is in no way meant to limit the scope of the present invention.
The above-described embodiments can be provided pre-assembled, with the cost of the materials and assembly being about the same as the prior art systems unassembled. Alternatively, the above-described embodiments can be provided unassembled and assembled on-site in the field during installation.
FIGS. 9-13 show a connector or boss strip 234 of a fence/rail assembly according to a third example embodiment of the invention. The connector boss strip 234 can be used in fence/rail assemblies that are pre-assembled or field-assembled. In this embodiment, the connector boss strip 234 includes bosses 236 with ribs 250 that better secure the bosses into the connector holes of the pickets. This is particularly beneficial when used in fence/rail assemblies that are field-assembled. In addition, the connector boss strip 234 includes internal openings 252 that reduce the amount of material used without reducing the structural integrity of the connector strips. It will be understood that the dimensions shows in FIGS. 9-13 are representative of typical commercial embodiments and are not limiting of the invention; the connector boss strip 234 can be provided with other dimension ins larger or smaller sizes.
While the invention has been described with reference to preferred and example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.
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A fencing/railing assembly adapted to be positioned between a pair of posts and mounted thereto. The assembly includes a plurality of pickets, a plurality of rails extending transverse to the pickets, and one or more pivoting, sliding connectors for connecting a picket to a rail, with the sliding, pivotal connection concealed by the rail. The connector is slidably mounted to the rail and is pivotally connected to the picket. The sliding, pivotal connection allows the pickets to be oriented at greater angles relative to the rails (i.e. it allows the assembly to rack to a greater degree, thereby allowing the fencing/raining to following more-steeply changing terrain or contours). In one embodiment, an elongated connector strip is concealed by the rail and spans multiple pickets. In another embodiment, the assembly includes a plurality of shorter connectors, one for each picket/rail connection.
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BACKGROUND OF THE INVENTION
The present invention relates to a transmission and a shift mechanism for operating a transmission such as the inventive transmission. The invention will be described in connection with its use on a multi-speed bicycle, but its utility is not so limited.
It is known and common for transmissions for multi-speed bicycles to make use of a rear and main sprocket derailleur, the transmission when shifted disengaging a chain from one sprocket and engaging it with another. This requires a mechanism that will lift a chain and drop it into engagement with a larger or smaller sprocket, designedly but not necessarily the next larger or smaller sprocket. Operation of the prior art transmission is by an exposed or outside flexible cable which easily and constantly gets out of adjustment.
It is therefore an important object of the present invention to provide a transmission which completely eliminates the use of outside cables.
Another important object of the invention is to provide such a transmission which includes a housing in which all moving parts are totally enclosed.
A still further object of the invention is to provide such a transmission in which nothing can go out of adjustment.
An additional object of the invention is to provide such a transmission which eliminates the need for caliper brakes and enables a reversion to the old tried and true coaster brake hub on the rear bicycle wheel.
Yet another object of the invention is to provide an improved shift mechanism for use in operating the inventive transmission.
A still further object to the invention is to provide a shift mechanism which is such that in the shifting process, no gear can be skipped. For example, one can not go from first gear to third gear without stopping in second gear. This is a safety feature which prevents damage to the gears through jamming.
Further objects are to provide a transmission device and a shift mechanism which are relatively simple and economical in construction.
Additional objects and advantages will appear hereinafter.
SUMMARY OF THE INVENTION
A transmission embodying the invention transmits rotary motion from an input shaft to an output location. The transmission, which comprises an output shaft at the output location, also has a compound face gear assembly including a back plate having an axis and rotatable with the input shaft about the axis. The back plate has radially inner and outer arcuate openings therethrough centered on the axis and radially innermost and outer circumferentially continuous gear rings providing a first gear and a second gear, respectively. The radially outer gear ring surrounds and is contiguous with the innermost gear ring. Each gear ring has on the entirety of one face radial gear teeth and on the opposite face a lug. The gear teeth, which are somewhat elliptical, are all of the same pitch. The lugs of the innermost and outer gear rings extend through the inner and outer arcuate openings, respectively, and each gear ring is independently rotatable a limited circumferential distance relative to the back plate as determined by the difference in circumferential extent between its lug and its associated arcuate opening. Resilient means urge each lug toward a neutral central position spaced from each end of its associated arcuate opening. The transmission further has means for transmitting rotation from the input shaft to the gear teeth of a selected one of the gear rings and thence to the output shaft, and means for changing the selected one of the gear rings engaged by the transmitting means.
The rotation transmitting means comprises a sliding pinion having external gear teeth which are somewhat elliptical and are engageable with the gear teeth of any gear ring, and a spline shaft which is perpendicular to the output shaft and on which the sliding pinion is slidably mounted. Thus, the sliding pinion and the spline shaft are rotatable by whatever gear ring is in engagement with the sliding pinion. The rotation transmitting means also includes a first bevel gear mounted on an end of the spline shaft and meshing with a second bevel gear which is mounted on the output shaft.
The sliding pinion has an external circumferential groove and the means for changing the engaged gear ring includes a shift rod parallel to the spline shaft, a yoke immovably mounted on the shift rod and engaging the external circumferential groove of the sliding pinion, the shift rod being movable lengthwise of itself to move the yoke, causing the yoke to move the sliding pinion perpendicular to the axis of the back plate. The means for changing the engaged gear ring further includes an inner actuator, a link pivotally connected to the shift rod and to the inner actuator, and an external actuator.
The transmission is disclosed as also having third, fourth, fifth and sixth gear rings. The sixth gear ring provides the disclosed transmission with an outermost gear ring. Thus, the disclosed transmission is a six-speed transmission.
The invention further includes a shift mechanism for manipulating an actuator of a transmission having a second gear between a first gear and a third gear to shift the transmission from any of the gears to an adjacent gear. The shift mechanism comprises a fixedly mountable shift segment plate, a shift arm pivotally mounted about a main axis which is fixed with respect to the shift segment plate and providing an additional axis parallel to the main axis. A shift rod is pivotally connectible to the transmission actuator and is pivotally connected to the shift arm at the additional axis. The shift segment plate has an arcuate surface confronting and coaxial with the main axis, a plurality of like barrels spaced from each other and having free ends projecting toward the main axis from the arcuate surface and crests projecting upwardly from the shift segment plate. The barrels include one barrel which is adjacent and spaced from one end of the arcuate surface and another barrel which is adjacent and spaced from the other end of the arcuate surface, whereby each barrel has a portion of said arcuate surface on each side thereof. The shift mechanism further comprises a shift lever pivotally mounted with respect to the shift arm and having a forwardly facing surface overlying the shift arm and generally facing the shift segment plate. A pawl is mounted for limited movement lengthwise of the shift arm and has a trailing end of width sufficiently narrow to fit between the free ends of adjacent ones of the barrels and between the free end of said barrel which is adjacent the one end of the arcuate surface and between the free end of the barrel which is adjacent the other end of the arcuate surface. Spring means urge the pawl away from the main axis. A pusher block is mounted for limited movement lengthwise of the shift arm and having a trailing end. Pusher block resilient means urge the pusher block against the forwardly facing surface of the shift lever. A pusher is carried by the pusher block and is movable therewith lengthwise of the shift arm and having a forward end confronting the main axis and engageable with the pawl. The pusher is pivotally mounted to the pusher block about a pusher axis perpendicular to the main axis, and resilient means urge rotation of the pusher about the pusher axis in the direction urging the forward end of the pusher toward the shift segment plate. The forward end of the pusher is engageable in abutting fashion with the trailing end of the pawl and with the shift segment plate and is liftable away from the shift segment plate by passing over the crest of any barrel during shifting and into overlaping engagement with the trailing end of the pawl. This permits the trailing end of the pawl to engage the arcuate surface and prevents further shifting until the shift lever is released to allow the pusher block resilient means to push the pusher block and the pusher away from the main axis to move the forward end of the pusher past the trailing end of the pawl and the resilient means which urge rotation of the pusher to move the forward end of the pusher into engagement with the shift segment plate and abutting relationship with the trailing end of the pawl.
DESCRIPTION OF THE DRAWING
FIG. 1 is a right side elevation of a bicycle equipped with the inventive transmission and the inventive shift mechanism, with the parts in the fifth speed position;
FIG. 2 is an enlarged cutaway left side view of the transmission of FIG. 1, with the parts in the sixth speed position;
FIG. 3 is an enlarged partly broken away right side elevation of the shift mechanism, with the shift mechanism shown in the sixth speed position;
FIG. 3A is an enlarged fragmentary view on line 3A--3A of FIG. 3;
FIG. 4 is an enlarged partly fragmentary cross section of certain components of the shift mechanism;
FIG. 5 is a side elevation of a shift arm which is a component of the shift mechanism;
FIG. 6 is a cutaway top view of the transmission, showing the drive sprocket, chain and rear wheel, with the parts in the sixth speed position;
FIG. 7 is a rear view of a back plate assembly which is a component of the transmission and showing guide rods, springs and keys in position;
FIG. 8 is a face view of the back plate;
FIG. 9 is a sectional view of line 9--9 of FIG. 8;
FIG. 10 is a broken away axial sectional view of the back plate taken substantially on line 10--10 of FIG. 8 and also showing gears and certain other parts;
FIG. 11 a perspective broken away view of the pinion and the yoke;
FIG. 12 is an elevational view showing the pinion and the yoke assembled;
FIG. 13 is an exploded, partially cut away view of a gear ring lug detail for gear six, also showing a spring guide rod therefore one of two springs therefor and a key therefor;
FIG. 14 is a view taken on line 14--14 of FIG. 13; and
FIG. 15 is an enlarged perspective view of the key of FIGS. 13 and 14.
DESCRIPTION OF THE INVENTION
The invention will be described as applied to a multi-speed bicycle 20 which is shown in right side elevation in FIG. 1. Bicycle 20 comprises a frame which includes a horizontal frame member 22, a rear stem 24, a front stem 26, a diagonal frame member 28, a rear upper fork 30, a rear lower fork 32 and a front fork 34. Bicycle 20 also comprises a seat 36, a handlebar 38, a rear wheel 40 secured to the lower end of rear upper fork 30 and to the rearward end of rear lower fork 32, and a front wheel 42 secured to the lower end of front fork 34. Rear wheel 40 has a coaster brake hub 44 and a sprocket 46 is coaxial and rotatable with rear wheel 40.
Bicycle 20 further includes a pair of crank arms 48 which are rigidly secured to opposite ends of a horizontal shaft 50 and which extend in opposite radial directions therefrom. Pedals 52 are affixed to the radially outer ends of crank arms 48. Shaft 50 is an input shaft which is rotatable by torque applied to pedals 52.
Bicycle 20 additionally comprises a sprocket 54 which is located between shaft 50 and hub 44 and a chain 56 passes over and engages sprockets 46 and 54, whereby rotation of sprocket 54 in the driving direction, indicated by arrow A in FIG. 1, causes movement of chain 56 and rotation of sprocket 46, and with it rotation of wheel 40 in the same direction.
Torque applied to sprocket 54 in the anti-driving direction, i.e., the direction opposite that indicated by arrow A in FIG. 1, will activate coaster brake hub 44, to stop or prevent rotation of rear wheel 40.
Bicycle 20 also is provided with a special transmission 60, which is located almost entirely within a housing 62, and a special shift mechanism 64 for actuating transmission 60. Transmission 60 is detailed in FIGS. 2 and 6-15, and shift mechanism 64 is detailed in FIGS. 1, 3, 3A, 4 and 5.
Housing 62 is in fixed position with respect to the frame of bicycle 20 and is made up of a deep body member 66 and a plate-like cover member 68 closing member 66 and forming therewith a chamber 70 best seen in FIGS. 2 and 6. Member 66 is fixedly joined, as by welding, to rear stem 24, diagonal frame member 28 and rear lower fork 32.
As stated above, sprocket 54, when rotated in the driving direction indicated by arrow A in FIG. 1, drives rear wheel 40 to propel bicycle 20 in a forward direction. Transmission 60 provides an intermediary between crank arms 48 and sprocket 54 for accomplishing that end, when crank arms 48 are rotated in the direction indicated by arrow B in FIG. 1. When torque is applied to crank arms 48 in the direction opposite that indicated by arrow B, coaster brake hub 44 is activated.
Sprocket 54 is rigidly mounted on an output shaft 72 which is parallel to shaft 50. Shaft 72 will be deemed an element of transmission 60. Except for their ends, shafts 50 and 72 are entirely within housing 62.
Transmission 60 is shiftable into any of six speed positions, so that bicycle 20 is a six-speed bicycle, but the invention is not limited to a six-speed bicycle, or to any bicycle.
The ends of shaft 50 extend outwardly of housing 62 through ball bearings 79 and 76 which are mounted in the walls of body member 66 and cover member 68, respectively. As also shown in FIG. 6, one end of shaft 72 is mounted in a ball bearing 78 in a recess in cover member 68 and the other end of shaft 72 passes through the wall of body member 66 where it is mounted in a ball bearing 80, and sprocket 54 is rigidly mounted on the last-mentioned end of shaft 72, as aforesaid.
The construction of transmission 60 will be described initially with particular reference to FIGS. 2 and 6. As stated, FIG. 2 is an enlarged cutaway left side view of transmission 60, shown in the sixth speed position, and FIG. 6 is a cutaway top view of transmission 60.
Transmission 60 includes a circular compound face gear assembly 82 which provides the six gears of transmission 60 and which is fixedly mounted on shaft 50 and rotates therewith. Compound face gear assembly 82 appears in plan view in FIG. 2, in edge view in FIG. 6, in rear view in FIG. 7, and in section in FIG. 10, which is taken substantially on line 10--10 of FIG. 8. FIG. 8 shows an element of compound face gear assembly 82, namely a back plate 84, which is also seen in FIGS. 2, 6, 7, 9 and 10. Compound face gear assembly 82 will be described initially with particular reference to FIG. 10, which shows elements of compound face gear assembly 82 in addition to back plate 84. Back plate 84 has a central cylindrical hole 86, which receives bicycle shaft 50 (FIGS. 2 and 7) and is rotatable therewith. Back plate 84 further has inner and outer confronting coaxial cylindrical flange surfaces 88 and 90, respectively, joined by a depressed planar front surface 92 perpendicular to surfaces 88 and 90. Back plate 84 also has a planar back surface 94 parallel to front surface 92. Additionally, back plate 84 has a radially recessed shallow arcuate groove 96 spaced from surface 92 and terminating cylindrical surface 88 throughout its circumference. As best seen in FIGS. 7 and 8, back plate 84 has therethrough six arcuate openings 98, 100, 102, 104, 106 and 108 coaxial with hole 86 and of roughly the same circumferential extent but of differing arcuate extents, varying from a low of about 45° for opening 98 to a high of about 120° for opening 108. The outer arcuate edge of opening 98 coincides with outer cylindrical flange surface 90 and the inner arcuate edge of opening 108 coincides with inner cylindrical flange surface 88. Openings 98, 100, 102, 104, 106 and 108, which are centered on the same diameter, are all of the same radial dimension.
The inner arcuate edge of opening 98 and the outer arcuate edge of opening 100 are the same distance from the axis of back plate 84. The inner arcuate edge of opening 100 and the outer arcuate edge of opening 102 are the same distance from the axis of back plate 84. The inner arcuate edge of opening 104 and the outer arcuate edge of opening 106 are the same distance from the axis of back plate 84. The inner arcuate edge of opening 104 and the outer arcuate edge of opening 106 are the same distance from the axis of back plate 84. The inner arcuate edge of opening 106 and the outer arcuate edge of opening 108 are the same distance from the axis of back plate 84. Furthermore, openings 98, 102, and 106 are centered on the same side of the axis of back plate 84 and openings 100, 104 and 108 are centered on the opposite side of the axis of back plate 84.
Furthermore, the radial distance between openings 98 and 102 and between openings 102 and 106 and between opening 106 and flange surface 88 and between flange surface 90 and opening 100 and between openings 100 and 104 and between openings 104 and 108 is the same.
As shown in FIGS. 2 and 10, compound face gear assembly 82 further comprises six contiguous gear rings 110, 112, 114, 116, 118 and 120, each having on one face, radial gear teeth 122 throughout 360° thereof. Teeth 122 are of the same pitch on all rings 110, 112, 114, 116, 118 and 120. Gear rings 110, 112, 114, 116, 118 and 120 provide transmission 60 with first gear, second gear, third gear, fourth gear, fifth gear and sixth gear, respectively Each gear ring 110, 112, 114, 116, 118 and 120 has a lug on its face opposite the face with teeth 122, these lugs being lugs 124, 126, 128, 130, 132 and 134 for gear rings 110, 112, 114, 116, 118 and 120, respectively, as shown in FIG. 7. Lugs 124, 128 and 132 are also visible in FIG. 10, but lugs 126, 130 and 134 are not, it being noted that lugs 126, 130 and 134 would be seen in FIG. 10 if it were continued on the other side of its axis. Each of gear teeth 122, when viewed in the direction perpendicular to the one face of its particular gear ring, is somewhat elliptical with the direction of elongation oriented radially.
Lugs 124, 126, 128, 130, 132 and 134 are arcuate and are adapted to fit in an protrude through openings 98, 100, 102, 104, 106 and 108, respectively. Each of these lugs is shorter in the circumferential direction than its respective opening, so that each of gear rings 110, 112, 114, 116, 118 and 120 is movable a predetermined distance about the axis of back plate 84, with its lug sliding in its opening.
Furthermore, lugs 124, 126, 128, 130, 132 and 134 have circumferentially extending holes 135 therethrough (FIG. 10), each of which is everywhere equidistant from the center of its respective gear ring.
Except for their differing diameters, gear rings 110, 112, 114, 116, 118 and 120 are shaped substantially alike in axial section. In this connection, reference is made to FIG. 10, from which it will be appreciated that the lugs are all shaped the same, and that the portions of gear rings 112, 114, 116 and 118 on and above surface 92 are the same. These will be described with particular reference to gear ring 114 as it appears in FIG. 10. It will be seen that gear ring 114 has an inwardly projecting flange with an upper floor 136, the flange being of predetermined thickness and having an outwardly projecting ceiling 138 substantially coplanar with floor 136 and of substantially the same radial width. Gear ring 110 is the same as gear ring 114 in this respect except that gear ring 110 has an outwardly projecting ceiling 140 which is positioned below the plane of floor 136 a distance substantially equal to the predetermined flange thickness. Gear ring 120 is the same as gear ring 114 in this respect except that gear ring 120 has an inwardly projecting flange with an upper floor (unnumbered for clarity) such that the last-mentioned flange is somewhat thicker than the corresponding flange of gear ring 114.
As seen in FIGS. 7 and 9, the rear face of back plate 84 is provided with six circumferentially spaced pairs of lugs 142, 144, 146, 148, 150 and 152. The members of each of these pairs of lugs are equally spaced from the axis of cylindrical hole 86 and are also equally spaced on opposite sides of a plane P--P (FIG. 7) which includes the axis of hole 86 and which is common to all pairs of lugs 142, 144, 146, 148, 150 and 152. Each of these lugs is provided with a circumferential circular hole 154 therethrough (see FIG. 9). Lugs 142 are spaced from the axis of hole 86 a distance substantially the same as that of arcuate opening 98 which is circumferentially between lugs 142. Lugs 144 are spaced from the axis of hole 86 a distance substantially the same as that of arcuate opening 100. Lugs 146 are spaced from the axis of hole 86 a distance substantially the same as that of arcuate opening 102. Lugs 148 are spaced from the axis of hole 86 a distance substantially the same as that of arcuate opening 104. Lugs 150 are spaced from the axis of hole 86 a distance substantially the same as that of arcuate opening 106. Lugs 152 are spaced from the axis of hole 86 a distance substantially the same as that of arcuate opening 108.
Additional elements of face gear assembly 82 include spring guide rods 155, 156, 158, 160, 162 and 164 (FIG. 7), twelve coil springs 166 (FIG. 7), keys 168, 170, 172, 174, 176 and 178, which are given different reference numbers because they may differ in their included angles, six grip rings 180 (FIG. 7) and a wire lock ring 182 (FIG. 10) for securely locking face gear assembly 82 together.
The manner of assembling face gear assembly 82 will now be described, with particular reference to FIGS. 7-10 and 13-15, the latter three views also showing further details of some of the parts. The assembly is started with gear ring 110 by inserting its lug 124 through arcuate opening 98. It will be noted from FIGS. 13 and 14 that lug 124 is provided with similar sharp-sided radial slots 184 which are spaced from the annular portion of gear ring 110 a distance substantially equal to the thickness of back pate 84, which is shown in phantom in FIG. 13. Lug 124 also has a circular hole 135 therethrough and extending arcuately from one circumferential end of lug 124 to the other. The lower half of hole 135, i.e. the half adjacent the annular portion of gear ring 110, intersects the bottoms of slots 184, i.e., the portions of slots 184 nearest each other, while the top half of hole 135, i.e., the half remote from the annular portion of gear ring 110, intersects the circumferential ends of lug 124. Lug 124 is typical of lugs 126, 128, 130, 132 and 134.
When lug 124 is properly seated in opening 98, lug 124 and the rest of gear ring 110 will be rotatable with respect to opening 98, limited by the ends of opening 98.
Next, key 168 is slid into position. Key 168, which is typical of keys 170, 172, 174, 176 and 178, is of one piece construction, having an arcuate body portion 188 and two spaced tine portions 190 extending radially outwardly from opposite ends of body portion 188. Corresponding faces of tine portions 190 have therein semi-cylindrical grooves 192 which are arcuately aligned with each other. Tine portions 190 are shaped, spaced and sized to fit fairly snugly into slots 184 of lug 124, with grooves 192 furnishing the bottom halves of the ends of hole 186, the diameter of grooves 192 being the same as the diameter of hole 186. Key 168 securely locks gear ring 110 in place. FIGS. 13 and 14 depict key 168 about to be assembled with lug 124.
Guide rod 155 is typical of guide rods 156, 158, 160, 162 and 164. Guide rod 155 has a head 194 at one end and an arcuate body 196 extending from head 194 to a free end 198. The length of body 196 is sufficient to extend arcuately from one lug 142 to the other lug 142 and a little therebeyond, while the diameter of body 196 is chosen for sliding fit within hole 135 (FIGS. 10, 13 and 14) of lug 124 as augmented by grooves 192 of key 168 and within holes 154 of lugs 142.
Body 196 of guide rod 155 is inserted, free end 198 first, through hole 154 of one lug 142. Then, a first of the twelve springs 166 is passed over free end 198 and compressed on body 196. With key 168 in place on lug 124 as aforesaid, free end 198 is then passed through hole 135 of lug 124 as augmented by grooves 192 of key 168. A second of the twelve springs 166 is passed over free end 198 and compressed on body 196. Free end 198 is then passed through hole 154 of the other lug 142. A first grip ring 180 is installed on body 196 of rod 155, over free end 198 thereof, thus to lock gear ring 110 in place.
Next, gear ring 112 is installed in similar fashion, followed in order and in similar fashion by gear ring 114, gear ring 116, gear ring 118 and gear ring 120, with ceiling 138 of gear ring 112 overlapping floor 136 of gear ring 110, ceiling 138 of gear ring 114 overlapping floor 136 of gear ring 112, ceiling 138 of gear ring 116 overlapping floor 136 of gear ring 114, ceiling 138 of gear ring 118 overlapping floor 136 of gear ring 116 and ceiling 138 of gear ring 120 overlapping floor 136 of gear ring 118. Also, ceiling 140 of gear ring 110 rests on front surface 92 of back plate 84, as does the entire bottom surface of gear ring 120.
Finally, wire lock ring 182 is installed in groove 96, securely to lock the entire assembly together.
Gear rings 110, 112, 114, 116, 118 and 120 are shown in their neutral positions in FIG. 7, being held that way by substantially uniform pressure exerted by a pair of springs 166 on both sides of each of lugs 124, 126, 128, 130, 132 and 134. Gear rings 110, 112, 114, 116, 118 and 120 may be moved a sufficient distance in either circumferential direction to allow shifting from one gear to an adjacent gear as will now be described, with particular reference to FIGS. 2, 6, 11 and 12.
Transmission 60 further includes a shift rod 200 which passes through a guide hole 201 through a flange 202 which is integral with cover member 68 and projects inwardly therefrom within chamber 70 alongside shaft 50. Shift rod 200 is slidably movable in guide hole 201, relative to flange 202. :Transmission 60 further includes a yoke 204, best seen in FIGS. 2, 11 and 12 but also being visible but unnumbered in FIG. 6. Yoke 204 is securely fastened to shift rod 200 and has a cylindrical hole 206 therethrough through which shift rod 200 passes. Yoke 204 also has a smaller diameter cylindrical hole 208 therethrough. The axes of holes 206 and 208 intersect each other at right angles. Shift rod 200 has a diametral hole 210 therethrough of the same diameter as hole 208. Hole 208, as clearly seen in FIG. 12, exists in two equal halves, interrupted by hole 206. Yoke 204 is assembled with shift rod 200 by a drive pin 212 driven into one half of hole 208, hole 210 and the other half of hole 208. Thus, yoke 204 is immobilized relative to shift rod 200. Yoke 204 also has two downwardly projecting arcuate, tine-like members 214 which are mirror images of each other and provide equal parts of an internal semi-cylindrical surface 216 the axis of which is parallel to the axis of hole 206. Yoke 204 is symmetrical with respect to a plane containing the axes of hole 206 and cylindrical surface 216, and has like parallel face surfaces 218 and 220.
Transmission 60 further includes a spline shaft 222 one end of which is bearinged in flange 202 and the other end of which is bearinged in bearing support 224, which, like flange 202, projects inwardly from cover member 68 within chamber 70. Shift rod 200 also extends through a hole 226 (FIG. 6) through bearing support 224. From hole 226, shift rod 200 extends to a first end 228. Shift rod 200 also extends, on the side of flange 202 opposite rear end 228, to a second end 230 which is pivotally connected as indicated at 232 to an end of a link 234. The other end of link 234 is pivotally connected as indicated at 236 to an end of an inner actuator 238 which passes lengthwise through and is bearinged in a cylindrical support member 240 which is integral with deep body member 66 and passes through the wall thereof to end 242 outside housing 62. The axis of support member 240 is parallel to the axes of shafts 50 and 72. Inner actuator 238 may be of one-piece or multi-piece construction.
An external actuator 244 (FIGS. 1 and 6) is integrally connected to inner actuator 238 adjacent its end 242 outside housing 62. When external actuator 244 is rotated in a clockwise direction (as seen in FIG. 1) about the axis of cylindrical support member 240, shift rod 200 will be moved to the left as viewed in FIGS. 2 and 6, and when external actuator 244 is rotated in a counterclockwise direction (as seen in FIG. 1) about the axis of cylindrical support member 240, shift rod 200 will be moved to the right as viewed in FIGS. 2 and 6.
Shift rod 200 also has, adjacent free end 228 and on the side of shift rod 200 confronting cover member 68, six evenly spaced like detents 246, detents 246 being spaced apart a distance substantially the same as the radial distance between gear teeth 122 on adjacent gear rings 110, 112, 114, 116, 118 and 120. Within an internally threaded bore extending from the exterior of cover member 68 into bearing support 224 is a detent ball 248 (FIG. 6) positioned to engage at any time a selected one of detents 246. Ball 248 is engaged and held impositively against shift rod 200 by a coil spring 250 which is in turn held in place by a set screw 252 in threaded engagement with the threaded bore.
Transmission 60 further includes a sliding pinion 260 (FIGs. 2 and 6 and best seen in FIGS. 11 and 12) having an axial, internally-splined bore 262 extending from one axial face of pinion 260 to the other. Splined bore 262 engages the splines of spline shaft 222, in driving engagement therewith. Pinion 260 has three coaxial sections between its axial faces, including a first section 264 of largest outside diameter and having external axial gear teeth 266 evenly spaced circumferentially completely therearound, a second section or groove 268 of smallest outside diameter axially adjacent section 264 and a third section 270 of outside diameter intermediate the outside diameters of sections 264 and 268 and axially adjacent groove 268 which is axially between sections 264 and 270. External gear teeth 266 are sized, shaped, spaced and positioned to mesh with gear teeth 122 on any selected one of gear rings 110, 112, 114, 116, 118 and 120. Like gear teeth 122, each of gear teeth 266, when viewed in the direction toward the axis of pinion 260, is somewhat elliptical with the direction of elongation oriented parallel to the axis of pinion 260, as shown in FIG. 11.
Yoke 204 is, as aforesaid, immobilized with respect to shift rod 200. Further, arcuate, tine-like members 214 extend into the axial space between sections 264 and 270 of pinion 260 with semi-cylindrical surface 216 in groove 268 of sliding pinion 260. In result, sliding pinion 260 slides along spline shaft 222 in response to movement of yoke 204, which, as aforesaid, moves with shift rod 200. Not all of the parts of sliding pinion 260 are numbered in all of the views depicting same.
Transmission 60 further includes meshing bevel gears 272 and 274 (FIGS. 2 and 6) which are identical. Bevel gear 272 is mounted on shaft 72 and rotates therewith, and bevel gear 274 is mounted on spline shaft 222 and rotates therewith.
In operation, rotation is transmitted from pedals 52 to shaft 50, from shaft 50 to face gear assembly 82, from face gear assembly 82 to sliding pinion 260, from sliding pinion 260 to spline shaft 222, from spline shaft 222 to bevel gear 274, from bevel gear 274 to bevel gear 272, from bevel gear 272 to shaft 72, from shaft 72 to sprocket 54, from sprocket 54 to chain 56 and from chain 56 to rear wheel 40. The gear, and hence pedaling difficulty, is determined by which one of gear rings 110, 112, 114, 116, 118 and 120 is engaged by gear teeth 266 of sliding pinion 260.
To effect shifting, shift rod 200 is moved longitudinally, through the action of external actuator 244, internal actuator 238 and link 234, thus moving yoke 204 and sliding pinion 260 to achieve engagement of gear teeth 266 and gear teeth 122 of the desired one of gear rings 110, 112, 114, 116, 118 and 120. More specifically, when external actuator 244 moves in the clockwise direction as seen in FIG. 1, the number of the engaged gear ring goes down. The shifting action will now be described in greater detail.
No matter which one of gear rings 110, 112, 114, 116, 118 and 120 is engaged by sliding pinion 260, every one of gear rings 110, 112, 114, 116, 118 and 120 will rotate about the axis of shaft 50 as long as shaft 50 is being rotated. However, the so engaged one of gear rings 110, 112, 114, 116, 118 and 120 will be in a circumferentially advanced, out-of-neutral position relative to the other five gear rings which are in neutral position, and the lug of the engaged gear ring will be out of alignment with the lugs of the other gear rings. Thus, during shifting, the engagement of sliding pinion 260 shifts from one moving gear ring to an adjacent moving gear ring. The fact that the gear rings are resiliently relatively movable aids the transfer of sliding pinion 260 from engagement with gear teeth 122 of one gear ring to gear teeth 122 of an adjacent gear ring.
If the gear rings were not circumferentially movable relative to each other, they would lock solid as soon as sliding pinion 260 attempted to engage an adjacent gear ring.
The somewhat elliptical shape of gear teeth 122 and gear teeth 266 greatly facilitates the engagement of these gear teeth with each other, and also serves to overcome the effect of progressively smaller diameters of the gear rings. The shifting of pinion 260 from engagement with one gear ring to engagement with another gear ring can be felt by an operator. Also, to help overcome the differential of rotation due to progressively smaller or larger gear rings, each successive gear ring can move slightly with its rotation while pinion 260 is momentarily engaged with two adjacent gear rings at once. This avoids the need for the operator to stop pedaling during shifting. A slight lessening of pressure will suffice, although shifting can be effected during a cessation of pedaling.
Shift mechanism 64 will now be described, with reference to FIGS. 1, 3, 3A, 4 and 5. FIG. 1 shows shift mechanism 64 in the fifth speed position, whereas FIG. 3 shows shift mechanism 64 in the sixth speed position.
Shift mechanism 64 includes a shift segment plate 280 (FIGs. 1 and 3) which is suitably mounted on bicycle 20. More particularly, shift segment plate 280 is secured to horizontal frame member 22 and to diagonal frame member 28 adjacent front stem 26 and is stationary relative to those parts. Shift segment plate 280 has a central cutout portion 282 best seen in FIG. 3.
Shift mechanism 64 also includes a shift arm 284 (FIGS. 1, 3, 4 and 5) which is pivotally mounted with respect to shift segment plate 280 at aligned pivot holes 286 and 288, respectively, by means of a shift arm pivot bolt 290, a washer 292 and a nut 294, all as best seen in FIG. 4. Pivot holes 286 and 288 and bolt 290 define a main or fixed axis of shift arm 284. Shift arm 284 extends from hole 286 across cutout portion 282 and thence beyond shift segment plate 280. Central cutout portion 282 of shift segment plate 280 is in part defined by an arcuate surface 296 about 60 degrees in arcuate extent and centered on the axis of bolt 290 (FIG. 3). Arcuate surface 296 is provided with five like barrels 298 which protrude equally from arcuate surface 296 toward the axis of bolt 290 and are spaced equally from each other. Barrels 298 have free inner ends 299 which define a circle centered on the axis of bolt 290. The two extreme barrels 298 are also equally spaced from the two extremeties of arcuate surface 296. Each barrel 298 has a rounded crest 300 which projects upwardly from the upper surface of shift segment plate 280, as best seen in FIG. 3A.
As will appear more clearly hereinafter, the space between the lowermost barrel 298 (as seen in FIG. 3) and the adjacent arcuate end of arcuate surface 296 represents the first speed position, and the space between the uppermost barrel 298 (as seen in FIG. 3) and the adjacent arcuate end of arcuate surface 296 represents the sixth speed position. Further, the spaces between adjacent barrels 298 represent in order the second through the fifth speed positions as one proceeds from the lowermost barrel 298 to the uppermost barrel 298.
As seen in FIG. 5, shift arm 284 includes, at the end thereof remote from hole 286, which end is beyond shift segment plate 280, a hand grip portion 302. Between hand grip portion 302 and hole 286, shift arm 284 includes aligned keyholes 304, 306, 308 and 310 therethrough, keyhole 304 being a double keyhole and keyholes 306, 308 and 310 being single keyholes. Keyhole 304 is adjacent hand grip portion 302, keyhole 310 is adjacent hole 286, keyhole 306 is between keyhole 304 and keyhole 310, and keyhole 308 is between keyhole 306 and keyhole 310.
Shift arm 284 also includes a sidewardly bulged portion 312 adjacent keyhole 304 and a sidewardly bulged portion 314 adjacent hole 286. Portions 312 and 314 are located on the same side of shift arm 284 and portion 312 has therethrough a larger hole 316 and a smaller hole 318. Portion 314 has therethrough a hole 320 spaced a predetermined distance from hole 286. The axes of holes 316, 318 and 320 are parallel to the main or fixed axis defined by holes 286 and 288 and bolt 290, and may be deemed additional axes.
Shift mechanism 64 further includes a shift lever 322 (FIGs. 1 and 3), a spring support 324 (FIGS. 3 and 4), a pawl 326 having a trailing end 327 (FIGS. 3 and 4), a pawl spring 328 (FIGS. 3 and 4) which is a coil spring under compression with its ends in blind confronting holes 330 and 332 in spring support 324 and pawl 236, respectively, a lever support 334 a pusher block 336 having a trailing end 337, a pusher 338, a pusher spring 340, two pusher block springs 342 which are coil springs each of which is under compression in aligned blind holes 344 and 346 in lever support 334 and pusher block 336, respectively. Only one set of blind holes 344 and 346 is visible, in FIG. 4. Trailing end 327 of pawl 326 is of width sufficiently narrow to fit between free ends 299 of barrels 298 and between free ends 299 of extreme barrels 298 and the extremities of arcuate surface 296.
Pusher 338 is mounted for limited rotation about a pusher pivot pin 348 which is mounted in aligned holes in pusher block 336.
Shift lever 322 is pivotally mounted about a pivot pin 350 which passes through a hole through shift lever 322 and through hole 316 in shift arm 284. Shift lever 322 also has an upstanding forwardly facing surface 352 which passes through the axis of pivot pin 350 and which engages trailing end 337 of pusher block 336. Shift lever 322 further has an upwardly facing surface 354 substantially at right angles to surface 352, and a pin 356 is set in hole 320 of shift arm 284 and projects laterally therefrom. Pin 356 is a stop for shift lever 322. More particularly, pin or stop 356 serves to limit rotation of shift lever 322 in the counterclockwise direction about pivot pin 350 as seen in FIG. 3 by engaging upwardly facing surface 354. Finally, shift mechanism 64 includes a shift rod 358 (FIGS. 1 and 3) which is pivotally connected at its upper end to a pivot pin 360 secured in hole 320 of shift arm 284 and is connectible at its lower end to external actuator 244 at 362. Thus, at its upper end shift rod 358 is pivotally connected to shift arm 284 at the additional axis provided by hole 320.
It is evident that as shift rod 358 is moved longitudinally upwardly, external actuator 244 will be moved clockwise as viewed in FIG. 1, thus lowering the number of the engaged gear, as stated above.
The manner of assembly of shift mechanism 64 will now be described further, with particular reference to FIG. 4. Spring support 324 has a bottom lug 364 which is inserted into keyhole 310 in shift arm 284 with blind spring hole 332 facing hand grip portion 302, and is then slid all the way to the right as seen in FIG. 4. Pawl 326 has bottom lugs 366 and 368 which are inserted into keyholes 310 and 308, with blind spring hole 330 confronting blind spring hole 332 of spring support 324 , and with pawl spring 328 captured in holes 330 and 332.
Shift arm 284 is now assembled with shift segment plate 280 by compressing spring 328 with pawl 326, engaging bolt 290 in holes 286 and 288 and securing bolt 290 with washer 292 and nut 294. Pawl 326 is now released, allowing it to engage in any of the six shift positions.
Lever support 334 has a bottom lug 370 and forwardly facing lips 372. Lug 370 is now engaged in keyhole 306 with its blind holes 344 facing away from pawl 326. Lever support 334 is then slid along keyhole 306 until lips 372 come into overlapping engagement with shift segment plate 280, thus locking shift arm 284 firmly against shift segment plate 280.
Pusher 338 is now assembled to pusher block 336 by first inserting pusher spring 340 into an upwardly facing cavity 372 in pusher block 336 and then inserting pusher 338 into pusher block 336, compressing pusher spring 340 until pusher pivot pin 348 can be inserted as shown in FIG. 4 and described above.
Pusher block 336 has bottom lugs 374, and the assembly is now mounted to shift arm 284 by inserting lugs 374 into double keyhole 304 and inserting pusher block springs 342 into blind holes 344 and 346.
Shift lever 322 is now assembled to shift arm 284 in the manner described above. Surface 352 engages the rear end of pusher block 336, so that springs 342 urge pusher block 336 against surface 352 and surface 354 against pin 356.
It should also be mentioned that pusher 338 has a forward end 376 which normally, under the urging of pusher spring 340, urges forward end into a gap between pawl 326 and lever support 334.
In operation, assume that shift mechanism 64 is in the sixth position, as shown in FIG. 3. Shift rod 358 will be in position whereby transmission 60 will be in the sixth speed gear as shown in FIG. 6. Assume further that it is desired to shift to the fifth speed gear. This shift is accomplished by grasping hand grip portion 302 of shift arm 284 and shift lever 322 and squeezing these parts together. This moves forwardly facing surface 352 of shift lever 322 forwardly against trailing end 337 of pusher block 336, compressing lever support 334 and pusher block 336, compressing springs 342 and moving pusher 338 forward, causing forward end 376 of pusher 338 to move pawl 326 forward out of engagement with the uppermost one of barrels 298. That is, pawl 326 will be moved forward so that trailing end 327 of pawl 326 will be within the circle defined by inner ends 299 of barrels 298. This allows shift arm 284 to be moved downward, to shift to the fifth position. As this downward movement of shift arm 284 occurs, forward end 376 of pusher 338 rides up over crest 300 of uppermost barrel 298 and thus becomes disengaged from trailing end 327 of pawl 326 which now presses against the inner end 299 and rides on top thereof in overlapping engagement with uppermost barrel 298. As shift arm 284 is moved downward, trailing end 327 of pawl 326 passes from engagement with inner end 299 of uppermost barrel 298 and is forced by pawl spring 328 to engage between uppermost barrel 298 and the next lower barrel 298. This is the fifth speed, and shift arm 284 cannot be moved to another speed position (in this case either the fourth speed position or back to the sixth speed position) until shift lever 322 is operated again, i.e., until shift arm 284 and shift lever 322 are released to permit springs 342 to retract pusher 338 relative to pawl 326 so that the overlapping engagement of pawl 326 and pusher 338 is ended and spring 340 re-establishes the original abutting relationship of ends 327 and 376. This permits a new shifting operation to take place when shift arm 284 and shift lever 322 are once again squeezed together. This is a safety feature which prevents damage to the gears by jamming.
It is evident that the invention attains the stated objects and advantages and others.
The disclosed details are exemplary only and are not to be taken as limitations on the invention except as those details are included in the appended claims.
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A multi-speed transmission has particular usefulness in bicycles, completely eliminating the use of the commonly used derailleur and the exposed flexible cable and the readjustment problems inherent with that prior structure. The transmission includes separate concentric gear rings which to a certain extent operate independently of each other. A shift mechanism for shifting the transmission is such the transmission can not be shifted from one gear to a non-adjacent gear without stopping at a gear therebetween. That is, no gear can be skipped. This is accomplished by a particular relationship of a pawl, a pusher, a shift segment plate and barrels mounted on the shift segment plate, among other parts.
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FIELD OF THE INVENTION
The present invention relates to paper towels and dispensers for paper towels, and more particularly to paper towel dispensers holding a roll of paper towels.
The subject invention relates generally to holders for rolled sheet products and, specifically, to holders for retaining and dispensing a paper towel roll.
BACKGROUND
Devices for supporting a conventional roll of paper towels are numerous. Paper towel dispensers are well known consumer products. Typically such dispensers are wall mounted and comprise a back panel and spaced apart arms extending outward from opposite ends of the back panel. The arms of different dispensers accommodate receipt of paper towels in roll form there between in a different ways. One commercial dispenser has arms that pivot outward to receive a towel roll, and then pivot inward to capture the roll with ends of the arms having lugs that fit into the core of the towel roll, providing pivot pins about which the roll can rotate. Another approach teaches the incorporation of spring biased lugs mounted into the ends of the dispenser arms. The lugs recess inwardly as the towel roll is inserted there against and, when the roll is at its final position, the lugs eject outward and into the roll core. The roll can then rotate about the lugs as individual sheets of paper are withdrawn.
With existing paper towel dispensers, the problem exists that, with the paper towel in the dispenser, as the roll gets used, and the diameter of the roll reduces, it no longer pushes against the holder rail with sufficient pressure, and the end of the roll comes loose.
The following represents a list of known related art:
U.S. Pat. No. 4,487,376 issued to Compton, Dec. 11, 1984;
U.S. Pat. No. 5,297,750 issued to Hunt, May 29, 1994;
U.S. Pat. No. 5,605,304 issued to Ahern, Feb. 25, 1997;
U.S. Pat. No. 4,030,676 issued to Bardsley, Jun. 21, 1977;
U.S. Design Pat. No. 161,985 issued to Woodworth, Feb. 13, 1951;
U.S. Pat. No. 4,012,007 issued to Cunningham, Mar. 5, 1977;
U.S. Pat. No. 4,487,376 issued to Compton, Dec. 11, 1984;
U.S. Design Pat. No. 326,580 issued to Brazis, Jun. 2, 1992;
U.S. Pat. No. 5,149,003 issued to Tharp, Sep. 22, 1992;
U.S. Pat. No. 5,727,750 issued to Kelly, Mar. 17, 1998;
U.S. Pat. No. 5,311,986 issued to Putz, May 17, 1994;
U.S. Pat. No. 5,292,083 issued to Ridenour, Mar. 8, 1994;
U.S. Pat. No. 5,878,976 issued to Duck, Mar. 9, 1999;
U.S. Pat. No. 5,950,961 issued to Duck, Sep. 14, 1999;
U.S. Pat. No. 4,741,486 issued to Ancona et al., May 3, 1988;
U.S. Pat. No. 4,600,162 issued to Hidle, Jul. 15, 1986;
U.S. Pat. No. 4,535,948 issued to Gillen, Aug. 20, 1985;
U.S. Pat. No. 4,535,947 issued to Hidle, Aug. 20, 1985;
U.S. Pat. No. 3,806,057 issued to Whatley, Apr. 23, 1974;
U.S. Pat. No. 4,030,676 issued to Bardsley, Jun. 21, 1977; and
U.S. Pat. No. 2,917,249 issued to MacLelland, Dec. 15, 1959.
The teachings of each of the above-listed citations (which does not itself incorporate essential material by reference) are herein incorporated by reference. None of the above inventions and patents, taken either singularly or in combination, is seen to describe the instant invention as claimed.
SUMMARY AND ADVANTAGES
A paper towel holder is provided that comprises a flattened base, a support rod connectable to said base and insertable through the core of a conventional paper towel role, and a pressure member connectable to said base at any one of a plurality of pressure member insertion holes in said base, wherein the pressure member is for making contact with said paper towel roll and impeding the loose unrolling of the paper towels on said roll. Paper towel holder can be used freely located on a horizontal countertop, or alternatively can be wall mounted. Base can optionally be provided with gripping legs, preferably formed of silicone material, attachable to the undersurface of base to help prevent slipping on a counter surface. The base and the support rod are separable for packing and storage for efficient and economical packaging for sale and/or storage when disassembled.
A paper towel holder according to the invention disclosed herein has numerous advantages. Advantage obtains from being able to keep the loose paper towel end of a conventional paper towel roll from flapping freely on a holder. Advantage obtains from having an easily assembled and disassembled paper towel holder for ease of sale and/or storage. Advantage obtains from having a paper towel holder that can be mounted on the wall or left free standing on a horizontal countertop.
Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. Further benefits and advantages of the embodiments of the invention will become apparent from consideration of the following detailed description given with reference to the accompanying drawings, which specify and show preferred embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an embodiment of the present invention.
FIG. 2 shows a exploded view of the embodiment of the present invention shown in FIG. 1 .
FIG. 3 shows another embodiment of the present invention.
FIG. 4 shows the base and support rod of FIG. 1 attached with a nail or friction fitted.
FIG. 5 shows the base and support rod of FIG. 1 attached with glue.
FIG. 6 shows the base and support rod of FIG. 1 attached with a screw or friction fitted.
DETAILED DESCRIPTION
Before beginning a detailed description of the subject invention, mention of the following is in order. When appropriate, like reference materials and characters are used to designate identical, corresponding, or similar components in differing figure drawings. The figure drawings associated with this disclosure typically are not drawn with dimensional accuracy to scale, i.e., such drawings have been drafted with a focus on clarity of viewing and understanding rather than dimensional accuracy.
A paper towel holder is provided. Referring to FIG. 1, a paper towel holder 10 is shown as it would be used on a horizontal countertop or other such horizontal surface. Paper towel holder according to the present invention is shown, in use, comprising a flattened base 12 , a support rod 14 extending perpendicularly from the approximate center of the base, and a removable pressure member 16 extending perpendicularly from any one of a plurality of insertion holes 18 in said base. A paper towel roll T is supported on the support rod. The holder is adapted for use on a horizontal surface or may be mounted with screws on a vertical wall such that the towel roll T is perpendicular to the vertical surface.
In the preferred embodiment, support rod 14 is made of wood. Support rod can be made of other suitable materials, including steel, plastic, and metal, to name a few. As shown in FIG. 2, the base and the support rod are separable for packing and storage. In the preferred embodiment rod includes a threaded lower end which screws into a threaded aperture in the center of base. As seen in FIGS. 4-6, other conventional means for attaching the rod to the base include metal screws 34 , bolts, glue 30 , etc. Alternatively, center aperture of base can be unthreaded, and rod can be loosely friction fit into center aperture. See FIGS. 4 and 6 without the nail and screw. In the preferred embodiment, center aperture is formed by tool drilling. Center aperture can also be formed during the molding process, and other tooling processes, to name a few. By having separable components the holder is compact for efficient and economical packaging for sale and/or storage when disassembled.
The base 12 includes a flat undersurface. As previously mentioned, the base has an outer diameter greater than the diameter of the towel roll T. Support rod is insertable through paper towel roll T. In the preferred embodiment, base is made of wood. Base can be made of other suitable materials, including steel, plastic, and metal, to name a few. Base can be provided with gripping legs (not shown), attachable to the undersurface of base to help prevent slipping on a counter surface. The gripping legs are preferably formed of a silicone material which is particularly effective at gripping a smooth surface such as a cabinet or countertop. If it is desired to mount the holder on a wall or other vertical surface, the base is mounted with screws or nails through apertures to the desired wall or surface. Operation of the holder is otherwise the same.
Base is provided with a plurality of insertion holes 18 into which pressure member 16 is inserted. Insertion holes are provided at varying distances between center aperture of base and the edge of said base. In preferred embodiment, insertion holes spiral outward from a point near the center of the stand to the edge of the base. In the preferred embodiment, insertion holes are threaded apertures into which pressure member provided with a threaded lower end can be screwed. Alternatively, insertion holes can be unthreaded, and pressure member lower member can be loosely friction fit into insertion holes. In the preferred embodiment, insertion holes are formed by tool drilling. Insertion holes can also be formed during the molding process, and other tooling processes, to name a few.
Pressure member 16 is initially in one of the outermost insertion holes closest to the outer edge of the roll T. As the roll gets used, and its roll diameter diminishes, the insertion member is removed, and inserted into the next inward insertion hole closest in proximity to the outer edge of the roll T. In the preferred embodiment, pressure member has a insertion portion 20 , a spring portion 22 , and a contact portion 24 . Insertion portion connects to said base at said insertion holes. Spring portion connects insertion portion to contact portion and provides tension to said contact portion against said roll T. Spring portion can be any of several springs known in the art. In the simplest embodiment, insertion portion is a wood peg that inserts in lower part of a spring, and contact portion inserts in top part of spring. Spring portion can also be rigid material with elasticity. Contact portion can curve inward terminating in a terminus. In the preferred embodiment, contact portion and insertion portion are made of wood. Pressure member portions can be made of other suitable materials, including steel, plastic, and metal, to name a few. In another embodiment, pressure member can be a peg 26 , as shown in FIG. 3 .
In operation, as shown in FIG. 1, and the alternative embodiment in FIG. 3, paper towel holder is placed on a surface, the base contacting the surface with the support rod extending upward, perpendicular to the base. Support rod is insertable into a paper towel roll T, and the roll T rests on the base with the rod projecting through it. Pressure member is inserted into the outermost insertion hole that is closest in proximity to the edge of the towel roll T to place pressure on the towel roll T. Spring portion of pressure member puts pressure on the body of the towel roll to keep the loose towel end of the roll from flapping free. When towels are needed, the desired length is unrolled and detached. As the size of the roll diminishes, pressure member is moved from one insertion hole to another insertion hole closer to the roll T, each move corresponding to keeping the pressure member proximal to the edge of the roll T as the diameter of the roll decreases.
Those skilled in the art will recognize that numerous modifications and changes may be made to the preferred embodiment without departing from the scope of the claimed invention. It will, of course, be understood that modifications of the invention, in its various aspects, will be apparent to those skilled in the art, some being apparent only after study, others being matters of routine mechanical, chemical and electronic design. No single feature, function or property of the preferred embodiment is essential. Other embodiments are possible, their specific designs depending upon the particular application. As such, the scope of the invention should not be limited by the particular embodiments herein described but should be defined only by the appended claims and equivalents thereof.
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A support for conventional roll of perforated paper toweling includes a base for mounting on a vertical or horizontal surface, a support rod perpendicular to said base for holding the towel roll, and a pressure member insertable into one of a plurality of insertion holes in said base for contacting a conventional roll of perforated paper to impede the unrolling of the towels when one is being torn off the roll.
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FIELD OF THE INVENTION
[0001] The present invention is in the field of lighting devices for illuminating the work area for a tool with a shaft such as a screwdriver.
BACKGROUND OF THE INVENTION
[0002] It is often desirable to use a tool such as screwdriver inside a cabinet, attic, or other tight location where inadequate lighting exists. A flash light or drop light may be used to provide lighting in some circumstances, but in tight spots, neither of these lights will work, if an extra hand is not available, a flashlight may not work, and if an AC power source is not available, a drop light will not work.
[0003] Also, use of a flashlight in one hand while operating a hand tool with another, particularly when the hand tool is normally operated with two hands, e.g., power drill, may be dangerous. Further, as is frequently done, when a flashlight is balanced on a shelf or other support surface not intended to support a flashlight and the flashlight tips over or shifts positions, the tool user's lighted view can be suddenly terminated as the flashlight moves away, creating an inherently dangerous situation where the user is now using a potentially dangerous hand or power tool in inadequate lighting conditions.
[0004] U.S. Pat. Nos. 5,038,481, 5,348,359, and 5,525,842 disclose lighting devices for lighting the work area for a saber saw, a retriever tool, and an air tool, respectively. A problem with these lighting devices is that they are not readily mountable to a variety of different tools, especially tools with a shaft such as screwdrivers.
[0005] Accordingly, a need exists for a simple tool light that is readily mountable to a variety of different tools including a shaft such as a screwdriver and that illuminates the working area for the tool, even in tight working conditions.
SUMMARY OF THE INVENTION
[0006] The present invention is generally directed to a tool light and method of use that may be used with a variety of different tools including a shaft.
[0007] An additional aspect of the invention involves a tool light for illuminating a work area for a tool. The tool light includes a mounting mechanism to be mounted to a shaft of the tool, a housing carried by the mounting mechanism, at least one light source and at least one power source housed within the housing, and the at least one light source powered by the at least one power source to illuminate the work area for the tool. In a preferred implementation of the above, the at least one light source includes at least one Light Emitting Diode (“LED”).
[0008] Another aspect of the invention involves a method of illuminating a work area for a tool. The method includes mounting the tool light to a shaft of the tool, and illuminating the work area with at least one light source of the tool light. In a preferred implementation of the above, the at least one light source includes at least one Light Emitting Diode (“LED”).
[0009] Further objects and advantages will be apparent to those skilled in the art after a review of the drawings and the detailed description of the preferred embodiments set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a side-elevational view of an embodiment of a tool light mounted to a shaft of a screwdriver.
[0011] [0011]FIG. 2 is an end view of the tool light illustrated in FIG. 1.
[0012] [0012]FIG. 3 is an end view of a tool light constructed in accordance with an additional embodiment of the invention.
[0013] [0013]FIG. 4 is a side-elevational view of another embodiment of a tool light mounted to a screwdriver.
[0014] [0014]FIG. 5 is a side-elevational view of a further embodiment of a tool light mounted to a screwdriver.
[0015] [0015]FIG. 6 is an end view of the tool light illustrated in FIG. 5.
[0016] [0016]FIG. 7 is a side-elevational view of a still further embodiment of a tool light that may be mounted to a screwdriver.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] With reference to FIGS. 1 and 2, a tool light 100 constructed in accordance with an embodiment of the invention will now be described. The tool light 100 includes a light housing 102 carried by a mounting mechanism 104 . The mounting mechanism 104 is used to mount the tool light 100 to a shaft 108 of a tool such as a screwdriver 112 . Although the shaft 108 is shown as an elongated, circular shaft, the shaft 108 may have other lengths and configurations. For example, but not by way of limitation, the shaft 108 may have a square cross-section.
[0018] The screwdriver 112 includes a handle 116 at one end 118 of the shaft 108 and a head 120 at an operative or working end 122 of the shaft 108 . In the embodiment shown, the screwdriver 112 is a cross-headed tip (e.g., Phillips) screwdriver. The screw driver 112 may be used to screw a screw 126 into a surface 130 . Although the illustrated tool is a cross-headed tip screwdriver 112 , the tool light 100 may be applied to shafts of tools other than the cross-headed tip screwdriver such as, but not by way of limitation, a flat-tip screwdriver, a square-headed tip screwdriver, other types of screwdrivers, a power drill, a chisel, a caulking gun, a soldering torch, a soldering gun, a cutting torch, a welding torch, and a voltage tester.
[0019] The light housing 102 is preferably cylindrical and houses a light source 134 and a power source 138 . The light source 134 is preferably one or more wide-angle (i.e., 40 degrees or greater), white LEDs; however other light sources, e.g., incandescent light bulbs, other angle LEDs, other types of LEDs, e.g., flat, pointed, and other color LEDs may be used. In the embodiment shown, the power source 138 is preferably a single AA, AA, or AAAA battery. In alternative embodiments, power sources other than batteries, e.g., miniature fuel cells, different types of batteries, e.g., rechargeable batteries, flat watch batteries such as alkaline 625 cells and NiCd batteries, and different numbers of batteries, e.g., two or more may be used.
[0020] A contact spring 142 may be located in a proximal portion 146 of the housing 102 for contacting the negative terminal of the battery 138 . A first electrical coupling 150 may connect the contact spring 142 to the LED 134 . A second electrical coupling 154 may connect a positive terminal contact 158 to an electrical on/off switch 162 . A third electrical coupling 166 may connect the switch 162 to the LED 134 . In an alternative embodiment, the electrical circuitry may include a motion sensor mechanism to activate the LED 134 when motion is detected and deactivate the LED 134 when no motion occurs for a prolonged period of time. The electrical circuitry may also include a dimmer mechanism, e.g., variable resistor, for controlling the intensity of the emitted light from the LED 134 .
[0021] The mounting mechanism 104 may include a dual-collar member 170 . The member 170 may include a first collar 174 that carries the light housing 102 at a predetermined or adjustable angle. The light housing 102 may be connected within the first collar 174 by a pair of spot welds 178 or by another connecting means. A second collar 182 receives the shaft 108 of the screwdriver 112 . The second collar 182 may come in a variety of different sizes for accommodating different-sized shafts, tools. The second collar 182 includes an open end 186 . The dual-collar member 170 includes an intermediate section 190 . The intermediate section 190 may include a tightening mechanism 194 for increasing the holding force of the second collar 182 on the shaft 108 in the direction of the arrows shown in FIG. 2. The tightening mechanism 194 may include a threaded fastener 198 that is threadingly engaged within holes in the intermediate section 190 .
[0022] The tool light 100 will now be described in use. The tool light 100 is mounted or applied to the shaft 108 of the screwdriver 112 by inserting the head 120 of the screwdriver 112 through the second collar 182 and sliding the tool light 100 forward or rearward on the shaft 108 to a position where the working end 122 of the screwdriver 112 and/or the working area is optimally lit by the light source 134 , i.e., the light is optimally focused. Alternatively, the second collar 182 may be clamped onto the shaft 108 by snapping the collar 182 onto the shaft 108 through the open end 186 of the second collar 182 . The light source 134 is activated by moving the switch 162 to an “on” position and deactivated by moving the switch 162 to an “off” position. The tool light 100 may be slid forward or rearward on the shaft 108 to a position where the working end 122 of the screwdriver 112 and/or the working area is optimally lit by the light source 134 . When the tool light 100 is located in a desired position, the tightening mechanism 194 may be actuated to secure the tool light 100 to the shaft 108 by rotating and tightening the threaded fastener 198 in a clockwise direction. The tool light 100 may be removed from the shaft 108 of the screwdriver 112 by rotating and loosening the threaded fastener 198 in a counterclockwise direction. The tool light 100 may then be mounted to a different tool in the same manner as that described above or stored for later use.
[0023] With reference to FIG. 3, a tool light 300 constructed in accordance with an additional embodiment of the invention will now be described. Elements similar to those described above with respect to FIGS. 1 and 2 are identified with like reference numerals, but with an “a” suffix. The tool light 300 is similar to the tool light 100 described above with respect to FIGS. 1 and 2, except the light housing 102 a is rotatably attached to the mounting mechanism 104 a . The first collar 174 a may include a support 304 that rotatably receives a rotating pin 308 . The rotating pin 308 supports the light housing 102 a for general rotation of the light housing 102 a with the pin 308 in a horizontal plane H.
[0024] Use of the tool light 300 is similar to that described above for the tool light 100 , except the light housing 102 a may be additionally rotated in a horizontal plane for adjusting the orientation of the light source 134 a to an optimal condition for lighting the work area.
[0025] With reference to FIG. 4, a tool light 400 constructed in accordance with another embodiment of the invention will now be described. Elements similar to those described above with respect to FIGS. 1 - 3 are identified with like reference numerals, but with a “b” suffix. The tool light 400 is similar to the tool light 300 described above with respect to FIG. 3, except a rotating support 404 is rotatably mounted to the mounting mechanism 104 b by rotating pin 308 b for general rotation of the light housing 102 b in horizontal plane H. The light housing 102 b is pivotally mounted to the support 404 through a pin 408 for pivotal movement of the light housing 102 b in a vertical plane in the direction shown by the arrows.
[0026] Use of the tool light 400 is similar to that described above for the tool light 300 , except the light housing 102 b may be additionally rotated in a vertical plane in the direction of the arrows for adjusting the orientation of the light source 134 b . In this embodiment (and the embodiment described with respect to FIGS. 1 and 2), the mounting mechanism 104 b may be attached to the shaft 108 so that the light housing 102 b is below the screwdriver 112 . The mounting mechanism 104 b may be loosely attached to the shaft 108 so that the tool light 400 hangs from the shaft 108 , but does not rotate therewith during rotation of the screwdriver 112 . The collar 182 b may include bearings or a similar mechanism that allow the tool light 400 to hang from the screwdriver 112 to illuminate the working end 120 and/or working area while the shaft 108 freely rotates within the collar 182 b , without the tool light 400 rotating with rotation of the shaft 108 .
[0027] With reference to FIGS. 5 and 6, a tool light 500 constructed in accordance with a further embodiment of the invention will be described. The tool light 500 includes a ring-shaped light housing 504 that houses one or more light sources 508 and one or more power sources 512 . In the embodiment shown, the one or more light sources 508 include a pair of LEDs oriented 180 degrees apart from each other and the one or more power sources 512 include a pair of watch batteries oriented 180 degrees apart from each other. The power sources 512 are offset 90 degrees from the light sources 508 . The LEDs 508 may be angled inwardly, towards the center of the tool light 500 . Electrical circuitry (not shown) connects the power sources 512 to the light sources 508 for powering the light sources 508 . The electrical circuitry may include an on/off switch 514 for turning the light sources 508 on or off. In an alternative embodiment, the electrical circuitry of the tool light 500 may include a motion sensor mechanism to activate the light sources 508 when motion is detected and deactivate the light sources 508 when no motion occurs for a prolonged period of time. The electrical circuitry may also include a dimmer mechanism, e.g., variable resistor, for controlling the intensity of the emitted light from the light source(s) 508 . A mounting mechanism 516 is located in a central portion of the tool light 500 . In the embodiment shown, the mounting mechanism 516 is a flexible rubber grommet 518 .
[0028] The tool light 500 will now be described in use. The shaft 108 of the screwdriver 112 is slidably inserted through the rubber grommet 518 of the tool light 500 until the tool light 500 a located at a desired longitudinal position on the shaft 108 . If the LEDs 508 are angled inwardly, adjusting the longitudinal position of the tool light 500 changes the light focus on the working area. As a result, the tool light 500 may be used on a variety of different length tool shafts simply by adjusting the longitudinal position of the tool light 500 on the shaft for optimal light focusing. The rubber grommet 518 is flexible enough to accommodate different diameter and/or shaped shafts 108 , while providing sufficient frictional resistance to hold the tool light 500 to the shaft 108 . In alternative embodiments, replaceable rubber grommets 518 or different tool lights 500 having different inner diameters may accommodate different diameter and/or shaped shafts 108 . The tool light 500 is activated and deactivated through the on/off switch 514 and/or through the motion detection mechanism. The tool light 500 preferably rotates with rotation of the shaft 108 . In an alternative embodiment, an annular bearing mechanism may be located between the rubber grommet 108 and the inner central surface of the annular housing 504 so that the rubber grommet 108 , but not the tool light 108 , rotates with rotation of the shaft 108 .
[0029] With reference to FIG. 7, a tool light 600 constructed in accordance with a still further embodiment of the invention will be described. The tool light 600 includes a cylindrical plastic or rubber sleeve 604 . The sleeve 604 includes a proximal end 608 , a distal end 612 , and an elongated, ring-shaped wall 616 . The wall 616 include an inner surface 620 . The proximal end 608 may house one or more power sources 624 such as, but not limited to, one or more watch batteries. The distal end 612 may carry one or more retractable light sources 628 , e.g. LED(s), in recessed areas 630 . Each retractable light source 628 may be pivotally connected to the wall for pivotal movement between an outwardly pivoted or “on” position and a retracted or “off” position. Electrical circuitry (not shown) connects the power source 624 to the light sources 628 for powering the light sources 628 . The electrical circuitry may include an on/off switch 632 for turning the light sources 628 on or off. In an alternative embodiment, the electrical circuitry of the tool light 600 may include a motion sensor mechanism to activate the light sources 628 when motion is detected and deactivate the light sources 628 when no motion occurs for a prolonged period of time. The electrical circuitry may also include a dimmer mechanism, e.g., variable resistor, for controlling the intensity of the emitted light from the light source(s) 628 . Further, pivoting the light sources 628 to the outward position may automatically activate the light sources 628 and retracting the light sources 628 may automatically deactivate the light sources 628 .
[0030] In use, the cylindrical sleeve 604 of the tool light 600 is slid over the handle 116 of the screwdriver 112 , and the light sources 628 are actuated by pivoting them to the outward position, switching the on/off switch 632 , and/or by automatic motion detection. When the light sources 628 are not in use, they may pivoted to a retracted or “off” position so that the light sources 628 are flush with the wall 604 . During use, the tool light 600 rotates with rotation of the screwdriver 112 .
[0031] In further embodiments, the features described above with respect to FIG. 7 may be incorporated into the handle 116 of the screwdriver or the light sources 628 may be fixed relative to the sleeve 604 or handle 116 (if incorporated into the handle 116 ).
[0032] It will be readily apparent to those skilled in the art that still further changes and modifications in the actual concepts described herein can readily be made without departing from the spirit and scope of the invention as defined by the following claims.
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A tool light and method of using the same for illuminating a work area for a tool. The tool light includes a mounting mechanism to be mounted to a shaft of a tool, a housing carried by the mounting mechanism, at least one light source and at least one power source housed within the housing, and the at least one light source powered by the at least one power source to illuminate the work area for the tool. The method includes mounting the tool light to the shaft of the tool, and illuminating the work area with the at least one light source of the tool light. The at least one light source is preferably at least one Light Emitting Diode (“LED”).
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This application is the U.S. national phase of International Application No. PCT/IB2012/056113 filed 2 Nov. 2012 which designated the U.S. and claims priority to EP Patent Application No. 11188705.5 filed 10 Nov. 2011, the entire contents of each of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The invention relates to the transcutaneous administration of a product by means of a pump mounted on a patch and connected to an infusion set.
More specifically, the invention relates to a set constituted of a patch and an infusion set.
PRIOR ART
Patch and infusion set assemblies are particularly disclosed in patent documents EP 1 970 091 A1 and US 2004/0158207.
The utilization of such assemblies enables a pump near the infusion set to be easily connected, disconnected and reconnected by eliminating the kind of tubing between the pump and the set.
Placement of the adaptation patch on the infusion set must be as easy as possible for the patient, but also must guarantee correct positioning in all cases.
As a general rule, the adhesive patch is first placed on the skin of the patient, and then a cannula or infusion set is inserted in the patch which serves as a fluid connection between the pump and the patient. This requires an inserter for the cannula, an inserter which must be adapted to the patch in order to place the cannula precisely before its insertion.
GENERAL DESCRIPTION OF THE INVENTION
The problems identified in the previous chapter may be resolved by the present invention, the object of which is described in the claims.
The present invention simplifies and improves the positioning of the patch and/or insertion device of the infusion set. The invention offers the possibility to the user of initially carrying out a step of inserting the infusion set without being bothered by the patch and placing the infusion set in the desired orientation. Said patch may be placed in a second step. Thus, a simplified and more economical inserter may be used for inserting the infusion set.
In the present invention, an infusion set is an element installed on a patient, comprising a cannula (or needle(s) or microneedle(s)), means for connecting to a solution administration or sample collection system and, preferentially, an adhesive to be fixedly stuck to the skin of the patient. Said infusion set enables a fluid path between said system and the patient to be created. Said connection means of the infusion set also comprise a septum to guarantee proper connection and sealing between the infusion set and said system. An inserter, automatic or manual, may be used for the installation of said infusion set. A patch is an element installed on a patient and at least partially comprising an adhesive to be stuck to said patient. Said patch enables said solution administration or sample collection system to be easily installed on said patient. Said solution administration or sample collection system may be a pump for the administration of a solution such as insulin. In this application, the terms “pump” and “solution administration system” will be used indifferently.
Each subassembly has one or more given functions, the infusion set ensures the fluid connection of the pump or collection system to the patient and the patch ensures the proper positioning and therefore the proper connection of the pump or collection system with the infusion set. It may also ensure, at least partially, the mechanical attachment of the pump or collection system to the skin of the patient.
The present invention also enables the patch to be positioned as precisely as possible after insertion of the infusion set. Thus, preferentially, the patient uses an inserter which facilitates insertion of the cannula (or needle(s) or microneedle(s)) of the infusion set into the patient. The infusion set (installed and temporarily stuck to the patient) may then be assembled with said patch that will also be temporarily stuck to said patient. Said infusion set and said patch thereby form an assembly intended to receive a pump or collection system, said assembly being composed of two portions to facilitate its installation. In addition, once the assembly is installed on the patient, said pump or said collection system may be easily connected to or disconnected from the assembly according to the needs and/or activities of the patient.
In another embodiment, the infusion set is manually inserted without using an inserter (automatic or not).
Locking of the patch and infusion set also guarantees, for each connection of the pump or collection system with the infusion set, that the needle of the pump is aligned with the septum of the set even if the site chosen by the patient is not absolutely flat.
Given that the assembly according to the invention guarantees optimal positioning of the patch with relation to the infusion set, a device for detecting the effective connection of the infusion pump or collection system to the set may be considered via detection of the connection of the pump or collection system to the patch. By way of example, the pump or collection system may detect (by a Hall effect detector) the presence of a magnet situated on the patch, thus indicating a correct connection to the infusion set. Due to the locking of the infusion set to the patch, a magnet placed either on the infusion set or on the patch will have the same function, knowing that it may be preferable to place said magnet on the patch.
The present invention particularly facilitates the placement of a patch and guarantees that it is correctly positioned.
Said patch also comprises a lower face disposing an adhesive portion and another non-adhesive portion in order to facilitate assembly with the infusion set and removal of said assembly.
The invention will be better understood below by means of a non-limiting embodiment illustrated by a few figures.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 represents an infusion set (without the cannula) according to the invention.
FIG. 2 represents a patch according to the invention that may be used with the set from FIG. 1 .
FIG. 3 illustrates the approach of the patch from FIG. 2 towards the set from FIG. 1 .
FIG. 4 shows the contact zone of the two portions and the direction of sliding of the patch.
FIG. 5 presents the flared shape of a patch zone in which two lugs are disposed.
FIG. 6 illustrates a mechanism enabling an accidental pulling down of the patch against the skin to be prevented.
FIG. 7 shows the positioning of the patch that precedes its rotation to its final position.
FIG. 8 presents the patch in its final position.
FIG. 9 presents the contact zone between the set and the patch.
FIG. 10 represents the assembly according to the invention on which a pump is mounted.
FIG. 11 illustrates a section of a portion of the object from FIG. 10 .
NUMERICAL REFERENCES USED IN THE FIGURES
1 . Infusion set
2 . Patch
3 . Upper face of the patch
4 . Lower face of the patch
5 . Septum
6 . Lugs
7 . Inter-lug space
8 . Tracks
9 . Pump
10 . Adhesive portion
11 . Non-adhesive portion
12 . Stop
13 . Ramp
14 . Gripping zone
15 . Magnet
16 . Sensor
17 . Passage
18 . Recess
In order to facilitate understanding of the invention, patch 2 particularly presented in FIG. 2 does not comprise means to ensure fixation of a pump 9 .
Also to be noted is the absence of an illustration of the adhesive zone on the lower face 4 of patch 2 . Before use, this adhesive zone is covered with a protective film.
The infusion set 1 particularly illustrated in FIG. 1 comprises a septum 5 that closes a channel (not illustrated) ensuring fluid communication between a pump and a cannula. The infusion set 1 also comprises a passage for the introduction and removal of a mandrel. Preferentially, it lastly comprises patch-guiding elements that are presented in the form of tracks 8 .
In a preferred embodiment (not illustrated), the infusion set comprises a base, the lower face of which comes into contact with the skin of the patient and the upper face may come into contact with a portion of the patch. The lower face of said infusion set may contain an adhesive on at least one portion of its surface in order to be fixedly held to the skin of the patient.
FIG. 2 presents a patch 2 that is compatible with the infusion set 1 from FIG. 1 . Said patch 2 comprises a base in which the lower face 4 is in contact with the skin and the upper face 3 is intended to receive a pump. Patch 2 comprises two removal zones 14 to facilitate gripping of the patch 2 with the fingers. The front portion of patch 2 comprises a flared zone 7 at the edge of which two lugs 6 are disposed, intended to slide in the tracks 8 of the infusion set 1 .
Patch 2 comprises an adhesive 10 on at least one portion of the lower face 4 ( FIG. 3 ) of said patch. A non-adhesive portion 11 of said patch 2 is located at the level where the infusion set 1 and the patch 2 are or may be in contact.
Preferentially, the base of said patch 2 is shaped so as to enable fitting of the base of said patch 2 and the base of said infusion set 1 and to create a continuous or semi-continuous flat part formed by the two bases to facilitate insertion of the pump by sliding on the patch 2 in the direction of the infusion set 1 .
In another embodiment (not illustrated), the adhesive protrudes beyond the lower face of said patch 2 . This embodiment produces less stress on the patch when it is installed on a non-compliant zone to the lower face 4 of said patch. It thus ensures proper maintenance since the entire adhesive zone is in contact with the skin. The patch may also have a reduced size or even a size smaller than the pump. This embodiment prevents the patient from being disturbed or experiencing discomfort caused when the patient is resting or moving.
Following removal of its protective film disposed on lower face 4 (see FIG. 3 ), the patch 2 approaches the infusion set 1 (already installed on the skin of the patient) while maintaining a certain angle with the surface of the skin. Ideally, such an angle is 30° to 60°, but preferably greater than 15°. The end of patch 2 engages the infusion set 1 and thus offers a first placement reference.
Patch 2 is maintained in contact with the infusion set 1 and may slide in the direction of septum 5 . The flared shape of the front portion 7 of the patch 2 enables it to easily pass the septum portion 5 of the infusion set 1 in its center.
This same shape 7 (see FIG. 5 ) also enables the positioning of the patch 2 to be fine-tuned as it slides.
Two lugs 6 disposed on patch 2 (see FIG. 4 ) will then slide between tracks 8 of set 1 , in the direction of septum 5 .
Either by a specific design for lugs 6 and/or tracks 8 or by any other system, it is preferable that patch 2 cannot be pulled down against the skin until it has reached its final position. In fact, a poorly positioned patch 2 may make the connection of a pump with the infusion set 1 impossible.
The assembly according to the invention as illustrated prevents this accidental pulling down of patch 2 when it is displaced to its final position.
As may be seen in particular in FIG. 6 , once the lugs 6 are engaged in tracks 8 , the patch 2 can only translate in the direction of tracks 8 . As the lugs 6 are oriented along a direction oblique in relation to the main orientation of the patch 2 , the latter can only be displaced by staying along a direction oblique in relation to the surface of the skin when it is displaced in the tracks 8 .
FIG. 7 illustrates the end of the course of the patch 2 , against a stop 12 , before it is lowered. This is made possible since the ends of tracks 8 comprise at least one recess 18 in which at least one lug 6 may be housed along a direction oblique in relation to the surface of the skin, the angle thus formed by said lugs 6 is substantially equivalent to the angle of rotation produced by the patch 2 to adhere to the skin.
FIG. 8 shows patch 2 in its final position.
FIG. 9 illustrates the contact zone of patch 2 with the infusion set 1 , ready to receive a pump.
FIG. 10 shows a pump 9 mounted to patch 2 .
FIG. 11 also illustrates a magnet 15 disposed on the set 1 and a Hall effect detector 16 mounted to the pump, these two elements being positioned so as to verify the status of the connection between pump 9 and infusion set 1 . Any other embodiment of this connection detection system may be contemplated. The magnet may, for example, be mounted to the pump 9 and the detector to the infusion set 1 , or even to patch 2 .
The assembly according to the invention ensures that patch 2 is correctly positioned on infusion set 1 , without risk of inadvertently sticking patch 2 onto the skin of the patient. The final placement of patch 2 onto the skin may only be obtained by rotation of the patch 2 along an axis, the direction of which is defined by the lugs 6 only when the latter are housed in recesses 18 . As it turns out, patch 2 is secured to the infusion set 1 with an angle ensuring a correct position of pump 9 to be connected subsequently to the infusion set 1 by means of patch 2 .
The present invention offers, in particular, the following advantages:
The lugs/tracks guiding attaches the patch to the infusion set even if the patch does not have adhesive at the surface close to the set. The curvature of the infusion site no longer plays a role in guaranteeing a correct pump/set connection. The patch and the infusion set are integral when they are perfectly fitted but, given that a zone of the patch lacks adhesive, they may easily be disconnected. Their locking is thus mechanically reversible. If one of the two elements is damaged during installation, only one part of the assembly has to be changed, not the entire assembly. The patch is solidly fixed to the infusion set thanks to the lugs and to the skin of the patient thanks to the adhesive. False positives are excluded. The patient cannot be found in a scenario where he thinks he has correctly placed his patch when this is not the case. In fact, the lugs 6 and tracks 8 pair forces the user to position the patch perfectly with relation to the infusion set. Any error is impossible since, if the assembly is poorly positioned, then the patch cannot be pulled down onto the skin and the pump cannot be installed on the patch. The utilization of a subassembly of two pieces in which the precision of positioning one with relation to the other is sufficient to plan to detect, with the pump, only the presence of the patch and therefore not necessarily the presence of the infusion set. Great ease of handling:
Installation in only three simple steps: Positioning of the infusion set; Installation of the patch; Connection of the pump onto the patch. Removal is just as simple and pain-free. After disconnection of the pump and patch, two possibilities: removal of the assembly; Or removal in two steps by removing the patch and then the infusion set. The infusion set is smaller and thus easier to install. The patch comprises a gripping zone, also facilitating its installation.
The upper faces of the base of the infusion set and of the patch base are shaped so as to facilitate installation of the pump onto the assembly. The patch cannot be accidentally stuck to the skin of the patient prematurely before having reached its final position with relation to the infusion set. The possibility of using a simplified inserter, for example without a particular reference device with relation to the patch. Only an indication of the orientation of the infusion set may be desirable so that the patient knows in which direction the patch will be oriented. The patch is not limited to an adhesive function. It is a support that enables the pump to be integral with the infusion set. In addition, the pump may be easily connected to and disconnected from the assembly.
The act of positioning the infusion set and then the patch is important since insertion of the infusion set is easier and does not require sophisticated insertion equipment that is costly to the patient and reduces the potential size of the insertion means. In addition, the patch disposes two security elements, the lugs that guarantee proper coupling of the assembly and the magnet that guarantees proper connection to the pump. Devices from the prior art are more complex, necessarily requiring expensive, complex and bulky insertion equipment. Such devices do not dispose security elements guaranteeing to the patient the proper installation of the assembly and the proper connection of the pump. Therefore, without these security elements, the patient may believe that he has correctly installed his pump but in reality the pump may not infuse into the patient, generating serious complications. Our device thus prevents these problems in particular thanks to the lugs and guiding tracks.
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The invention relates to an assembly that includes an infusion set and a patch intended for receiving a pump for the transcutaneous administration of a product, said patch including an adhesive portion and a non-adhesive portion, the assembly being characterized in that said set includes patch-guiding elements and sliding elements intended for sliding along the guiding elements.
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BACKGROUND OF THE INVENTION
This invention relates to the distribution of cutting teeth in boring apparatus useful, e.g., in earth or rock, and in particular in such apparatus in which the surface swept by the teeth during operation is oblique to the direction of overall advance of the apparatus, as in the generally conically shaped apparatus disclosed in my copending patent application Ser. No. 448,245, filed Mar. 5, 1974, now U.S. Pat. No. 3,897,837, the disclosure of which is hereby incorporated by reference.
SUMMARY OF THE INVENTION
This invention, it its various aspects, provides highly efficient cutting, without substantial formation of rock ridges (either circumferential, i.e. extending in the general direction of cutter rotation, or axial, i.e. extending in the general direction of overall advance of the apparatus) such as would increase the required cutting forces or interfere with the cutter body. Tool life is extended, and wear is balanced. Chip size tends to be uniform. As a result of the low cutting forces required, the cutters can be skewed to make the apparatus self-advancing.
In general, the invention features, in boring apparatus of the type having cutters mounted for rotation about respective cutter axes in a frame which is in turn rotatable about a frame axis, each cutter having a body carrying teeth which in operation sweep a surface which is oblique to the axis of advance of the apparatus, that improvement wherein each cutter has selected tooth regions spaced along the respective cutter axis, the tooth regions of the cutters are arranged in an ordered cycle progressing along the frame axis, and regions adjacent each other in the cycle are on different cutters and overlap each other along the frame axis. In another aspect, the invention features a plurality of selected tooth regions arranged in an ordered cycle progressing along the frame axis, and the regions, taken in order in the cycle, have alternately high and low effective tooth densities to counteract the tendency of teeth of one region to track the chip spaces left by teeth of the previous region. In preferred embodiments, there are three cutters, and no set of three regions adjacent each other in the cycle contains more than one region from each cutter; each region consists of a single row of teeth arranged circumferentially about the respective cutter axis; the extent of each region in the direction along the surface and in the plane of the cutter axis is less than the tooth height divided by the tangent of the angle between the surface and the axis of advance; each pair of regions which are adjacent each other in the cycle have respective numbers of teeth in the relation N H/2 < N L < N H , where N H is the number of teeth in the high effective density region of the pair and N L is the number of teeth in the low effective density region of the pair (preferably N H/1 .9 < N L < N H/1 .1, and even more preferably N H/1 .75 < N L < N H/1 .25); there are three cutters and the cycle proceeds from cutter to cutter, whereby on each cutter, regions of high and low tooth densities alternate along the respective cutter axis; and the cutter axes are skewed relative to the frame axis, are equally angularly spaced thereabout, and slant to cause the overall envelope of the apparatus to taper along the cutters.
Other advantages and features of the invention will be apparent from the description and drawings herein of a preferred embodiment thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of boring apparatus connected to a fragment of a pipe string;
FIG. 2 is a view similar to FIG. 1, from a different angle, with the pipe string and pilot bit omitted;
FIG. 3 is an enlarged view of a portion of FIG. 1, partially in section;
FIGS. 4-8 are sectional views taken respectively along 4--4, 5--5, 6--6, 7--7, and 8--8 of FIG. 1;
FIG. 9 is a sectional view taken along 9--9 of FIG. 3 with the cutter shafts removed;
FIG. 10 is an enlarged view of a cutter fragment showing a cutting tooth in dashed lines in a first position in the hole being bored, and showing the same tooth in solid lines in a later, axially advanced position; and
FIG. 11 is a layout of three cutters showing one example of a tooth distribution according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there is shown a main frame 10 connected at its top through externally threaded connector 12 to pipe string 14 which extends back to the surface drill rig, and at its bottom through internally threaded connector 16 to conventional tricone pilot bit 18. Frame 10 tapers from top to bottom along three circumferentially spaced struts 20 extending between upper and lower frame portions 22 and 24. Three cutters 26, 28, and 30 are respectively arranged between struts 20.
Each cutter has tooth inserts 32 in a body 33 mounted to rotate about shaft 34 (FIG. 3) having an axis 35 which not only generally follows the taper of struts 20 but is also skewed (e.g., by 2°-4°, FIG. 2) with respect to the vertical axis 36 of frame 10. The tooth distribution shown in FIG. 1-3 is schematic and not that of the present invention, which is shown in FIG. 11. In overall operation rotation of frame 1 causes cutters 26, 28, and 30 to rotate and to enlarge the pilot hole produced by bit 18. The skew of the cutters produces vertical force components between the hole wall and the cutters, causing the apparatus to be at least partially self-advancing.
Body 33 is tapered where it receives inserts 32, and has fixed itself in counterbores 40 and 42 annular upper and lower thrust bearings 44 and 46 and, on the inside cylindrical surface of its central bore 48, axially spaced radial bearing inserts 50 and 52. The upper bearing 44 runs against enlarged upper portion 54 of shaft 34, which acts as a thrust collar integral with the shaft. Lower thrust bearing 46 runs against a thrust collar 55 inserted in cutter body counterbore 42 and pinned (not shown) to the shaft to prevent rotation of the collar about the shaft while allowing relative axial movement between collar and shaft. O-rings 62 and 64 respectively provide the primary dynamic seals between stationary collars 54 and 55 and the rotating cutter body. Static seal 70 is provided between the collar 55 and shaft 34, to keep dirt out of the internal system and to hold lubricant in. The location of the thrust collars within counterbores in the ends of the cutter bodies minimizes the overall length of the assembly, including the length of the struts and shafts, thereby increasing strength.
The lower ends of shafts 34 extend into cylindrical bores 80 in frame portion 24. The upper shaft ends are notched at 82 (and at 82', to allow for 180° rotation of the shaft after wear) to receive generally annular retainer collar 84, which holds all three shafts in place and prevents them from rotating. In particular, collar 84 has three pockets 86 (FIG. 4) to receive the notched shaft ends, collar surfaces 88 acting against the shaft flats to prevent shaft rotation. Collar 84 is press fitted around frame portion 22 just below connector 12. Threaded pipe string portion 92 screwed on connector 12 acts as a hold down, pressing collar 84 against the shafts and frame portion 22.
Provision is made for supplying flushing fluid (e.g., air, clear water, or mud, etc.) to pilot bit 18 and to cutters 26, 28, and 30, to flush the rock removed during the drilling process. Thus, axial fluid inlet passage 100 communicates with a diagonal inlet 104 in each shaft 34 and an axial passage 106 in each strut 20. (Each shaft 34 has a second inlet 104' for use when the shaft is rotated.) Inlet 104 in turn feeds axial passage 108 within the shaft. Passages 108 dead end at the bottoms of the shafts. Plug 110 (FIG. 3) fits (without sealing) in the top of passage 108, and is cut off obliquely at its lower end extending into inlet 104. Rotation of the plug changes the effective flow cross-section between inlet 104 and passage 108, thus metering the rate of fluid flow to passage 108. Cap 112 on plug 110 can be indented into recess 114 in the end of shaft 34 to fix the angular position of the plug once it has been adjusted. Collar 84 seals against the pipe string at 116 and against the frame at 118 to prevent leakage of flushing fluid to the atmosphere.
Passage 108 communicates in the region of thrust collar 54, through radial holes 120 in shaft 34, with generally annular buffer chamber 122 formed in the outer surface of the collar, just above seal 62. A narrow clearance 124 (e.g., 0.005 inch radially) is provided between collar 54 and cutter body 33, communicating with chamber 122 and thus providing for a continuous small escape of fluid from the buffer chamber, so that clean fluid is always kept outside seal 62, despite the dirty environment in which the apparatus operates.
Just below thrust collar 55 passage 108 communicates, through radial holes 130 in shaft 34 and aligned radial slots 132 (FIG. 9) in the frame below shoulder 60, with annular buffer chamber 134. Relatively large clearance 136 (e.g., 0.02 inch) is provided between cutter body 33 and frame portion 24, so that a substantial amount of fluid flows through chamber 134 and upwardly past teeth 32. Not only is clean fluid thus kept outside of seal 64, but the cutter is cooled, the conical portion of the hole being drilled is flushed, and the jet pump effect of the upwardly flowing fluid helps to draw upwardly further chips and fluid from the region of the pilot bit. To precisely control the size of clearance 136 (which thus acts as a nozzle), replaceable split ring insert 138 fits in frame portion 24 surrounding (but spaced from) cutter body 33. Flange 140 of ring 138 fits in frame slot 142. The thickness of ring 138 thus determines the nozzle width. The relative rotation between the opposing nozzle-defining walls of clearance 136 gives the nozzle an advantageous self-cleaning quality in use.
Collar 84 seals the tops of strut passages 106, which at their other ends communicate with lower plenum 150. Plenum 150 in turn communicates with axial passage 152 (FIG. 1) and, through that passage, with conventional flushing jets 154 in pilot bit 18. Bores 80 communicate through reduced diameter extensions 80a with plenum 150, simply to provide access to the bottoms of shafts 34 (e.g., with a push rod) for disassembly. Shafts 34 rest against shoulders 80b to prevent fluid communicating between bore 80 proper and plenum 150.
A removable jet fitting 160 extends axially through the bottom wall 162 of plenum 102. The fitting has an axial orifice 164 to project a jet of flushing fluid down the center of frame 10, adjacent the three cutters 26, and three radial orifices 166 to flush between frame wall 162 and the tops of the cutters.
A system for distribution of pressurized lubricant (e.g., grease) is also provided. A grease reservoir 170 (FIG. 3) extends in the wall of each shaft 34, parallel to passage 108. A movable pressure piston 172 is located at the upper end of each reservoir 170, with O-ring 174 providing a seal between the piston and the inner wall of the reservoir. Flushing fluid communicates with the top of piston 172 to pressurize the grease in the reservoir at the flushing fluid pressure. Lube passage 176 extends down from the reservoir, and provides grease through holes 178 to lube grooves 180 at opposite sides of the shaft 34. Grooves 180 may be provided by flats on shaft 34, or may be of any other suitable shape. From grooves 180 the lubricant moves along the outside of the shaft to feed the thrust and radial bearing areas. Seal 70 isolates the lubricant from the atmosphere.
As shown in FIG. 8, upper and lower portions 22 and 24 of frame 10 are of reduced diameter between the positions of the three cutter shafts 34, thus providing, in effect, recesses along which can flow rock cuttings produced by the drilling process. Carbide inserts 200 in the frame periphery at portions 22 and 24 protect the frame against wear.
According to the invention, teeth 32 are distributed in cutter bodies 33 so as to (1) prevent circumferential ridges from building up as the boring progresses, which ridges would have to be climbed by successive teeth and would thus destroy the self-advancing characteristic of the apparatus, and (2) reduce the tendency of teeth to track the chip spaces left by previous teeth and thus cut a "gear", with ridges extending generally in the direction of overall advance of apparatus.
Referring to FIG. 11, the teeth on each cutter body are arranged in circumferential rows about the respective cutter axes 35. The rows R 1 -R 18 progress in numbered order in a cycle along the overall axis of advance 36 of the apparatus. In each of these rows the teeth define a tooth region having a width W (shown in the drawings for R 7 , e.g.) along the cutter body surface. Excluded from the ordered cycle are rows G, and a-c at or near the ends of the cutter, as to which special conditions discussed below apply.
According to one aspect of the invention, all regions R i and R i +1 adjacent each other in the ordered cycle are on different cutters and overlap each other along axis 36. As a result of the overlap, the chip spaces in the rock left by teeth of successive regions will similarly overlap along the vertical axis of the hole being bored, preventing circumferential ridges from forming between tooth regions.
According to another aspect of the invention regions R i , taken in order in the cycle, have alternately high and low effective tooth densities to counteract the tendency of teeth of one region to track the chip spaces left by teeth of the previous region. This prevents gear cutting, by causing the teeth of one region to remove material between the chip spaces left by teeth of the previous regions. Since it is undesirable for one region to have exactly twice (or any other integer multiple) the number of teeth as in an adjacent region (an integer multiple relationship would not prevent chip space tracking), and since it is also desirable to have as many teeth as possible in the low density regions, the preferred arrangement is for adjacent high and low density regions to have respective numbers of teeth N H and N L related as follows:
N.sub.H/2 < N.sub.L < N.sub.H.
Thus, we may have N H/1 .9 < N L < N H/1 .1 ; or, even more preferably, N H/1 .75 < N L < N H/1 .25.
At the tops and bottoms of the cutters special requirements will often result in departure from the above relationship. E.g., at the bottom, it is necessary to have teeth in the same axial position on all three cutters so that all may be guided into the pilot hole; and at the top, it is desirable to have virtually as many teeth as possible to minimize wear, since wear of these teeth results in reduction of the bored hole diameter.
Thus, each cutter has at matching axial positions a bottom tooth row c 1 , c 2 , c 3 , and a top row G 1 , G 2 , G 3 . The teeth in rows G 1 -3 are gage teeth located above the cutter body crown line 202, and are inactive until the teeth just below the crown wear, and then act to maintain hole diameter. In addition, extra tooth rows a and b are provided respectively on cutters 30 and 26, for balance.
It should be understood that, within the cycle of regions governed by the overlap and density relationships of the invention, the teeth of a given region need not be in a single circumferential row as shown, but may be staggered relative to the cutter axis.
According to a further aspect of the invention, the width W (i.e., extent along surface 33a of body 33) of each tooth region should be limited to avoid excessive ridges and even interference with the cutter body. FIG. 10 shows schematically a cutter in dashed lines in a first, beginning position, and in solid lines in a later position after several revolutions of the cutter. It can be seen that if a row of teeth 32 happens to start a rock gear, a considerable ridge height H R can be formed before the next tooth row has a chance to break up the axial ridge. Since H R must remain less than the tooth height H T (i.e., the distance that the teeth project from the cutter body), and since the maximum H R that can develop in one tooth width W is H R =W tan α, where W is the width of the tooth row and α is the angle between the axis 36 and the frusto-conical envelope 300 of the three cutter bodies, a critical requirement is that
W H.sub.T /tan α
In practice it is preferable that the tooth width be well below that critical value.
In the embodiment shown, tanα = 0.2; H T = 0.25; W = 0.625; and tooth density and positioning are as follows:
Distance in Inches Angular Angularof Tooth Centerline Number Tooth Position ofRow Below Crown Line of Teeth Spacing First Tooth______________________________________G.sub.1* 11 32°43'12" 0°G.sub.2* 15 24° 0°G.sub.3* 12 30° 0°a .480 6 60° 15°R.sub.1 .293 11 32°43'12" 16°21'36"R.sub.2 .668 15 24° 12°R.sub.31.043 12 30° 0°R.sub.41.418 15 24° 9°R.sub.51.793 11 32°43'12" 21°R.sub.62.168 15 24° 3°R.sub.72.543 11 32°43'12" 0°R.sub.82.918 15 24° 30°R.sub.93.293 11 32°43'12" 12°R.sub.103.668 15 24° 21°R.sub.114.043 11 32°43'12" 6°16'48"R.sub.124.480 15 24° 15°R.sub.134.918 8 45° 21°R.sub.145.355 11 32°43'12" 22°38'24"R.sub.155.793 8 45° 18°R.sub.166.230 12 30° 28°30'R.sub.176.668 8 45° 0°R.sub.187.105 6 60° 25°30'b 7.105 6 60° 43°30'c.sub.17.417 6 60° 13°30'c.sub.27.417 8 45° 22°30'c.sub.37.417 6 60° 53°30'______________________________________
Other embodiments (e.g., using the tooth distribution of the invention in apparatus of the sort shown in Peterson U.S. Patent Application Ser. No. 441,418, "Mining Machine and Method", filed February 11, 1974, the disclosure of which is hereby incorporated by reference) are within the following claims.
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In boring apparatus of the type having cutters mounted for rotation about respective cutter axes in a frame which is in turn rotatable about a frame axis, each cutter having a body carrying teeth which in operation sweep a surface which is oblique to the axis of advance of the apparatus, that improvement wherein each cutter has selected tooth regions, preferably of alternating high and low tooth densities, spaced along the respective cutter axis, the tooth regions of the cutters are arranged in an ordered cycle progressing along the frame axis, and regions adjacent each other in the cycle are on different cutters and overlap each other along the frame axis.
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The present invention concerns pumping systems incorporating fluidic devices.
BACKGROUND OF THE INVENTION
Pumping systems incorporating fluidic devices are attractive for pumping hazardous liquids as the fluidic devices do not include moving parts which could require repair or replacement with consequent risk to maintenance personnel. One known pumping system incorporates a fluidic device known as a reverse flow diverter RFD. An RFD comprises two opposed nozzles separated by a gap which opens into or communicates with the liquid which is to be pumped and examples of RFD's and their manner of operation are given in British patent specification No 1480484.
The present invention seeks to provide pumping systems incorporating fluidic devices and having improved means of control.
FEATURES AND ASPECTS OF THE INVENTION
According to the present invention a pumping system comprises a vessel for a liquid to be pumped, a reverse flow diverter positioned at a level below the level of liquid to be pumped and inserted between a charge vessel and a delivery pipe, compressed air supply means for the charge vessel and control means for effecting alternate pressurising and venting of the charge vessel to effect pumping of the liquid, in which the control means comprises a duct leading to the charge vessel and means for generating signals along the duct for detecting the liquid level at at least one position in the operating cycle.
DESCRIPTION OF THE DRAWINGS
The invention will be described further, by way of example, with reference to the accompnaying drawings; in which:
FIG. 1 is a schematic arrangement of a pumping system according to the invention;
FIG. 2 is an embodiment of a control unit included in the pumping system;
FIG. 3 is an alternative embodiment of a control unit;
FIG. 4 is an alternative schematic arrangement of a pumping system;
FIG. 5 is a further schematic embodiment of a pumping system.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1, RFD 1 is immersed in a liquid 2 contained within a vessel 3. The RFD comprises two opposed, co-axial conical nozzles separated by a gap which opens into the liquid 2. One nozzle is connected to a charge vessel 4 having air link pipe 5. The other nozzle of the RFD is connected to a delivery pipe 6 for the liquid. The pipe 5 communicates with a compressed air supply line 7 by way of a primary controller 8 and solenoid valves 9 and 10.
With reference to FIG. 2, the primary controller 8 comprises a body 11 having a straight bore 12 of substantially uniform cross-section which is intersected by a bore 13. The bores 12 and 13 are not necessarily at right angles to one another. The bore 12 is connected at one end to the pipe 5 and at its opposite end to a conduit 14. The conduit 14 (FIG. 1) carries an ultrasonic transducer 15 and communicates with the solenoid valve 9.
The bore 13 comprises a jet nozzle 16 at one side of the bore 12 and a cylindrical mixing tube 17 terminating in a diffuser 18 at the opposite side of the bore 12. The diameter of the nozzle 16 and the mixing tube 17 is small compared to the diameter of the bore 12. Again with reference to FIG. 1, the nozzle 16 is connected by conduit 19 to the solenoid valve 10 and the diffuser 18 opens into a vent pipe 20 from the vessel 3.
The ultrasonic transducer 15 is so mounted on or side the conduit 14 that a signal generated by the transducer will travel along the conduit 14, through the bore 12 in the controller 8 and along the pipe 5 towards the charge vessel 4. With no liquid in the pipe 5 the signal reflected back to the transducer is altered in a characteristic manner, (there are changes in time, amplitude and phase). With liquid in the pipe 5, the signal is reflected back along the same path to the transducer 15. The ultrasonic transducer functions to determine the presence of liquid in the pipe 5 and acts as a switch. An associated electronic unit creates the signal and interprets the echos. An output from the electronic unit is supplied to a secondary controller which controls the operation of the solenoid valves 9 and 10.
The pumping system operates in the following manner. Initially, the valves 9 and 10 are closed and the charge vessel 4 is partially filled with liquid. On opening the valve 10 compressed air from the supply line 7 flows through the conduit 19 and is directed by the nozzle 16 across the bore 12 and into the mixing tube 17. From the mixing tube 17 the air is vented to atmosphere. The air issuing from the nozzle 16 creates a suction in the pipe 5. As a result, liquid 2 in the vessel 3 is drawn through the gap between the nozzles of the RFD 1 and into the charge vessel 4. The liquid level rises in the charge vessel to enter the end of the pipe 5. When the liquid enters the pipe 5 the ultrasonic signals produced by the transducer 15 and directed down the pipe 5 into the charge vessel 4 are reflected back along the pipe 5 to the transducer 15. The reflected ultrasonic signals are detected and generate an electrical signal input to an electronic control unit. The control unit functions to close the valve 10 and to open the valve 9 for a predetermined time interval, which can be 5 seconds. Compressed air can now pass along the pipe 14, the bore 12 in the primary controller 8 and the pipe 5 to pressurise the charge vessel 4. During this phase of operation the liquid in the charge vessel is urged across the RFD 1 and along the delivery pipe 6. A fraction of the compressed air supply will escape to vent 20 along the bore 13.
At the end of the predetermined time interval the control unit again functions to close the valve 9 and the valve 10 remains closed. The charge vessel is vented to atmosphere through line 5, bore 12 and 13. After a second predetermined time interval sufficient to allow the pressure in the charge vessel to fall to a pressure just above the pressure in the vent, generally atmospheric, the control unit again functions to open the valve 10 to initiate a further cycle of pumping operation.
Fluidic pumping systems have the advantage of utilising components which do not include moving parts which require maintenance or replacement. Such systems are favoured for pumping toxic and hazardous liquids such as radioactive effluent. In FIG. 1, the vessel 3 and the controller 8 are located behind a wall 21 of shielding material. The ultrasonic transducer 15 and the valves 9 and 10 can be located within secondary containment, such as a glovebox, positioned on the opposite side of the wall 21 and away from the radioactive or toxic region. The transducer and valves are thereby readily accessible. Further the compressed air supply path to the vessel 4 constituted by the pipe 14, the bore 12 in the controller 8 and the pipe 5 serves as a waveguide for the ultrasonic signals. It is not required to provide a separate path through the shielding wall 21 for the ultrasonic signals and this results in significant simplification of the system.
Another advantage is that the system is arranged such that liquid is not allowed to rise to any appreciable height in the pipe 5. The system can be such that the liquid level does not rise substantially beyond the junction of the pipe 5 with the vessel 4. As a result the bore of the pipe 5 remains dry and the vented air does not pick up liquid from the pipe.
FIG. 3 shows an alternative arrangement of a primary controller. In FIG. 3, the passage 25 corresponds to the bore 12 in the controller 8 of FIG. 2. Nozzle 26, mixing tube 27 and diffuser 28 corresponds to the respective parts 16, 17 and 18 in FIG. 2. At the junction of the nozzle 26 and the mixing tube 27 a branch passage 29 communicates with the passage 25. The controller shown in FIG. 3 is connected to the pipes 14, 19, 5 and vent in a manner identical to that shown in FIG. 2.
A modified pumping system is shown in FIG. 4. In FIG. 4 the ultrasonic waveguide path by-passes the controller 8. Thus the pipe 5 is coupled to the transducer 15 by a pipe 30. The remaining reference numerals in FIG. 4 denote the same component parts as in FIG. 1. The modification enables the use of a number of different controllers but has the disadvantage of requiring an additional path through the shielding wall 21.
A further embodient is shown in FIG. 5 in which a transducer 31, which can be an ultrasonic or sonic transducer, is arranged in the pipe 5. In this embodiment a combined nozzle and diffuser 32, similar to the nozzle 26 and diffuser 28 of FIG. 3 is connected to vent and the vessel 3. A valve assembly comprising valves 33, 34 and 35 is arranged as shown between the member 32, the transducer 31 and the compressed air supply 7. Initially, the valve 34 is closed with valves 33 and 35 open so that compressed air issuing from the nozzle of the member 32 into the diffuser creates a suction in the pipe 5 to fill the charge vessel 4. When the liquid level reaches the lower end of the pipe 5 the reflected signals from the transducer 31 cause the valves 33 and 35 to close and valve 34 to open for the predetermined time interval whereby compressed air from line 7 flows down pipe 5 to pressurise the charge vessel 4. At the end of the predetermined time interval the valve 34 closes and the valve 35 opens to vent the charge vessel to atmosphere. After a further predetermined time interval the valve 33 again opens to initiate a further cycle of pumping operation.
Although reference is made to the use of ultrasonics for initiating the pumping cycle it is possible to utilise sonic signals. Further, signals comprising electromagnetic radiation, for example, radio frequency, light or coherent light (laser) could be used. Although reference is made to a transducer being a combined transmitter and receiver it is possible to employ separate transducers to transmit and to receive the signals.
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A fluidic pumping system comprises a reverse flow diverter positioned below the level of a liquid to be pumped and inserted between a charge vessel and a delivery pipe. Control means including signal generating means, conveniently an ultrasonic transducer, effect alternate pressurizing and venting of the charge vessel for pumping the liquid. A pipe for the supply of compressed air to the charge vessel serves as a waveguide for the signals from the signal generating means.
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RELATED APPLICATIONS
This application is a 371 national stage application of PCT/US12/034980, filed Apr. 25, 2012, which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/480,668 filed Apr. 29, 2011. The entire contents of each of these applications are hereby incorporated by reference.
FIELD OF THE INVENTION
The invention relates to the identification and characterization of various portions of the jute lignin biosynthetic pathway. More specifically, the invention relates to polynucleotides from jute plants that encode enzymes responsible for lignin synthesis, and methods for using these polynucleotides and enzymes for gene regulation and manipulation of lignin production to give fibers with desired lignin content and other characteristics.
BACKGROUND OF THE INVENTION
Lignin is a collective name for a complex aromatic heteropolymer of monolignol (hydroxycinnamyl alcohols), usually derived from phenylalanine in a multistep process. (Whetten, R. and Sederoff, R., (1995) Lignin Biosynthesis, Plant Cell, 7, pp. 1001-1013). These polymers, deposited primarily in cell walls, ensure the necessary mechanical strength of plant stems and most importantly, the hydrophobicity of a plant's vascular tissues. (Vanholme, R. et al. (2010) Lignin biosynthesis and structure, Plant Physiol, 153, pp. 895-905). Due to its hydrophobic nature, lignin serves as a major component of the vascular tissues and plays an essential role in water transport. In addition to its structural and transport-oriented role, lignin is a key component of a plant's defense system. (Goujon, T. et al. (2003) Genes involved in the biosynthesis of lignin precursors in Arabidopsis thaliana, Plant Physiology and Biochemistry, 41, pp. 677-687). Not surprisingly, environmental conditions influence the amount of lignin deposited. (Boerjan, W. et al. (2003) Lignin biosynthesis, Annu Rev Plant Biol, 54, pp. 519-546). For example, lignin biosynthesis is induced in response to various stress conditions like wounding, abiotic stress, and pathogen infection. Lignin limits pathogen invasion and protects the cell wall polysaccharides against microbial degradation. (Vanholme et al., 2010).
A large part of our current understanding of lignin biosynthesis comes from the complete understanding of this pathway in A. thaliana and P. trichocarpa . (Goujon, et al., 2003; Shi, et al. (2010) Towards a systems approach for lignin biosynthesis in Populus trichocarpa : transcript abundance and specificity of the monolignol biosynthetic genes, Plant Cell Physiol, 51, pp. 144-163). There are three basic monolignol monomers: p-coumaryl, coniferyl, and sinapyl alcohols. These monolignols are incorporated into the three lignin units, or building blocks: p-hydroxyphenyl (H), guaiacyl (G), and syringyl (S). See FIG. 1 . These monolignols differ in the number of methoxy groups. P-hydroxyphenyl (H) has no methoxy group, guaiacyl (G) has one methoxy group, and syringyl (S) has two methoxy groups. (Goujon et al., 2003). However, in addition to these three monolignols, a few other phenylpropanoids, such as hydroxycinnamyl aldehydes, hydroxycinnamyl esters, and hydroxycinnamyl acetates may also be incorporated. (Boerjan et al., 2003).
After the biosynthesis of these basic lignin building blocks, they are transported to lignifying zones. In the lignifying zones, polymerization occurs by oxidative free-radical-based coupling by peroxidases or laccases and a mesh-like structure is formed by cross-linking with cellulose and hemicellulose. (Boerjan et al., 2003; Vanholme, R. et al. (2008) Lignin engineering, Curr Opin Plant Biol, 11, pp. 278-285). Lignification occurs in different phases during the secondary thickening of the cell wall when the polysaccharide matrix formation is complete. Lignin deposition is influenced by the nature of the polysaccharide matrix. In the primary cell wall, it is found as spherical structures; whereas in the secondary cell wall, it forms lamellae. (Boerjan et al., 2003).
Notwithstanding the indispensable role of lignin in the life of a plant, it is a major limiting factor in the cost-effective/efficient use of plant material in the pulp and biofuel industries. Lignin also limits the use of biomass for fiber, chemical, and energy production. Removal of lignin is a very expensive process and these industries would benefit from access to biomass having less lignin, or a lignin that is easy to degrade. In the last few decades, some understanding of the lignin biosynthetic pathway has been achieved, although portions of the process are not fully understood.
Despite the importance of lignin synthesis to the overall welfare of the jute plant, as well as its impact on several aspects of fiber quality, at present there is no available information detailing lignin biosynthesis in jute. Therefore, a need exists to identify, isolate and utilize genes and enzymes from the jute plant that are involved in the biosynthesis of lignin. The present invention addresses this need.
SUMMARY OF THE INVENTION
One aspect of the invention is an isolated nucleic acid molecule having at least 90% sequence identity to a nucleic acid sequence selected from the group consisting of: SEQ ID NO: 1, 3, 5, 7, 9, 11, 13, 15, 16, 18, 20, 22, 24, 25, 26, 28, 29, 31, 33, 35, 37, 39, 40, 42, 44, 45, 47, 49, and 51.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 1, 3, 5, 7, 9, 11, 13, and 15.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 16, 18, and 20.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 22, 24, 25, 26, 28, and 29.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 31.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 33.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 35, 37 and 39.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 40 and 42.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 44, 45, and 47.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 49.
In one embodiment, an isolated nucleic acid molecule is selected from the group consisting of: SEQ ID NO: 51.
One aspect of the invention is an isolated polypeptide molecule having at least 90% sequence identity to an amino acid sequence selected from the group consisting of SEQ ID NO: 2, 4, 6, 8, 10, 12, 14, 17, 19, 21, 23, 27, 30, 32, 34, 36, 38, 41, 43, 46, 48, 50, and 52.
In one embodiment, a pair of forward and reverse primers useful for the amplification of cDNA selected from the group consisting of SEQ ID NO 53 and SEQ ID NO 54; SEQ ID NO 55 and SEQ ID NO 56; SEQ ID NO 57 and SEQ ID NO 58; SEQ ID NO 59 and SEQ ID NO 60; and SEQ ID NO 61 and SEQ ID NO 62.
In certain embodiments, the present invention relates to any one of the aforementioned polynucleotide sequences or polypeptide sequences, wherein said sequence has at least 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% sequence identity to any of the sequences identified by a SEQ ID NO.
One aspect of the invention is an expression vector comprising an isolated nucleic acid molecule of the present invention.
One aspect of the invention is an isolated antibody or antigen binding fragment thereof that specifically binds to a polypeptide molecule of the present invention.
One aspect of the invention is a transfected plant cell transfected by a vector of the present invention.
One aspect of the invention is a material derived from a transgenic plant of the present invention.
One aspect of the invention is a seed from a plant transfected by a vector of the present invention.
One aspect of the invention is a method for making a transgenic plant, comprising the steps of transfecting at least one plant cell with a vector of the present invention, and growing at least one plant cell into a plant.
One aspect of the invention is a method of improving growth, fiber yield, fiber strength, disease resistance, or water utilization in a jute plant, comprising incorporating in to a jute plant a non-native nucleic acid sequence of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : Proposed monolignol biosynthesis pathway of jute.
FIGS. 2 a and 2 b : Protein sequence alignment of ColCAD1, ColCAD2, ColCAD3, ColCAD4, ColCAD5, ColCAD6, and ColCAD7 with plant CAD protein sequences. FIGS. 2 a and 2 b disclose SEQ ID NOS 2, 4, 63-64, 6, 65, 10, 66, 12, 67, 14, 68, 8 and 69, respectively, in order of appearance.
FIG. 3 : Protein sequence alignment of ColCCoAOMT1, ColCCoAOMT2 and ColCCoAOMT3 with plant CCoAOMT protein sequences. FIG. 3 discloses SEQ ID NOS 19, 70-71, 17, 21 and 72, respectively, in order of appearance.
FIG. 4 : Protein sequence alignment of Col4CL1, Col4CL4 and Col4CL6 with plant 4CL protein sequences. FIG. 4 discloses SEQ ID NOS 23, 73, 27, 74, 30 and 75, respectively, in order of appearance.
FIG. 5 : Protein sequence alignment of Col6HCT1 with plant 6HCT protein sequences. FIG. 5 discloses SEQ ID NOS 32 and 76-77, respectively, in order of appearance.
FIG. 6 : Protein sequence alignment of ColC3H with plant C3H protein sequences. FIG. 6 discloses SEQ ID NOS 78-79, 34 and 80, respectively, in order of appearance.
FIG. 7 : Protein sequence alignment of ColC4H1 and ColC4H2 with plant C4H protein sequences. FIG. 7 discloses SEQ ID NOS 81-82, 36 and 38, respectively, in order of appearance.
FIG. 8 : Protein sequence alignment of ColPAL1 and ColPAL2 with plant PAL protein sequences. FIG. 8 discloses SEQ ID NOS 43, 83, 41 and 84, respectively, in order of appearance.
FIG. 9 : Protein sequence alignment of ColCCR2 with plant CCR protein sequences. FIG. 9 discloses SEQ ID NOS 85-86, 46, and 87, respectively, in order of appearance.
FIG. 10 : Protein sequence alignment of ColCCR3 with plant CCR protein sequences. FIG. 10 discloses SEQ ID NOS 48 and 88-89, respectively, in order of appearance.
FIG. 11 : Protein sequence alignment of ColF5H with plant F5H protein sequences. FIG. 11 discloses SEQ ID NOS 90, 50 and 91, respectively, in order of appearance.
FIG. 12 : Protein sequence alignment of ColCOMT with plant COMT protein sequences. FIG. 12 discloses SEQ ID NOS 52 and 92-93, respectively, in order of appearance.
FIG. 13 : DNA gel of ColCAD2. Lane 1 shows the isolated ColCAD2 DNA. Lane 2 shows a molecular weight marker.
FIG. 14 : DNA gel of ColCCoAOMT1. Lane 2 shows the isolated ColCCoAOMT1 DNA. Lane 1 shows a molecular weight marker.
FIG. 15 : DNA gel of Col4CL1. Lane 1 shows the isolated Col4CL1 DNA. Lane 2 shows a molecular weight marker.
FIG. 16 : DNA gel of ColCCR3. Lane 1 shows the isolated ColCCR3 DNA. Lane 2 shows a molecular weight marker.
FIG. 17 : DNA gel of ColF5H. Lane 1 shows the isolated ColF5H DNA. Lane 2 shows a molecular weight marker.
DETAILED DESCRIPTION OF THE INVENTION
Ten known enzyme families are associated with monolignol biosynthesis. (Goujon et al., 2003). The families are PAL (phenylalanine ammonia-lyase), C4H (cinnamate-4-hydroxylase), 4CL (4-coumarate:CoA ligase), HCT (p-hydroxycinnamoyl-CoA:shikimate/quinate p-hydroxycinnamoyl transferase), C3H (4-coumarate 3-hydroxylase), CCoAOMT (caffeoyl-CoA O-methyltransferase), CCR (cinnamoyl-CoA reductase), F5H (ferulate 5-hydroxylase), COMT (caffeic acid O-methyltransferase), and CAD (cinnamyl alcohol dehydrogenase). A proposed schematic of the monolignol biosynthetic pathway in Jute is shown in FIG. 1 .
The lignin biosynthesis pathway in jute owes its complexity, in part, to the presence of several multifunctional enzymes, and to the constituent enzymes spanning several diverse gene families. The first enzyme of the phenylpropanoid pathway is PAL (phenylalanine ammonia-lyase), which causes the deamination of phenylalanine, producing cinnamic acid. The second enzyme of the pathway, C4H (cinnamate 4-hydroxylase), converts cinnamic acid to 4-hydroxycinnamic acid, which is followed by subsequent hydroxylation and methylation steps as the pathway becomes branched. The enzyme 4CL catalyzes the CoA ligation of hydroxycinnamic acids, generating activated phenolic precursors for lignin biosynthesis. (Hu et al. (1999) Repression of lignin biosynthesis promotes cellulose accumulation and growth in transgenic trees, Nat Biotech, 17, pp. 808-812.).
The next enzyme in the monolignol pathway (HCT) catalyses the production of p-coumaroyl-shikimate/quinate esters, which are the substrates for C3H. HCT was shown to transfer the acyl group of p-coumaroyl-CoA to shikimate or quinate. (Hoffman et al. (2005) Plant Biosystems, v. 139, No. 1, pp. 50-53). The hydroxylation steps at C3 and C5 are performed by two cytochrome P450 enzymes, 4-coumarate 3-hydroxylase (C3H) and ferulate 5-hydroxylase (F5H), respectively. The methylation steps are performed by CCoAOMT (caffeoyl-coenzyme A (CoA) O-methyltransferase) and COMT (caffeic-O-methyltransferase). CCoAOMT is a bifunctional enzyme which converts caffeoyl-CoA to feruloyl-CoA and 5-hydroxyferuloyl-CoA to sinapoyl-CoA and plays a role in the synthesis of feruloylated polysaccharides. (Inoue et al., 1998). CCoAOMT has been shown to be involved in lignin biosynthesis in the differential tracheary elements of Zinnia elegans . (Ye, Z. H. and Varner J. E. (1995) Differential expression of two O-methyltransferases in lignin biosynthesis in Zinnia elegans, Plant Physiol. 108, pp. 459-467). CCoAOMT is involved in the reinforcement of the plant cell wall, and is also involved in responses to wounding or pathogen challenge by the increased formation of cell wall-bound ferulic acid polymers.
Additional enzymes involved in the monolignol biosynthesis pathway are cinnamoyl coenzyme A reductase (CCR) and cinnamyl alcohol dehydrogense (CAD). CCR catalyzes the reduction of the hydroxycinnamoyl CoA esters to produce cinnamaldehydes, whereas CAD catalyzes their reduction to cinnamyl alcohols. (Goujon et al., 2003).
One of the last enzymes involved in the monolignol pathway is cinnamyl alcohol dehydrogenase (CAD), which catalyzes the NADPH dependent conversion of coniferaldehyde, 5-hydroxy-coniferaldehyde, and sinapaldehyde to the corresponding alcohols. (Kim, S. J. et al. (2004) Functional reclassification of the putative cinnamyl alcohol dehydrogenase multigene family in Arabidopsis, Proc. Natl. Acad. Sci. USA, 101, pp. 1455-60). In Arabidopsis , single mutants of the CAD genes AtCAD-C and AtCAD-D were found to have lower CAD activities, and the double-mutant, obtained by crossing the two mutants, had a 40% decrease in stem lignin content, thus demonstrating that these are the main CAD genes involved in stem lignin synthesis. (Sibout, R. et al. (2005) Cinnamyl Alcohol Dehydrogenase-C and -D are the primary genes involved in lignin biosynthesis in the floral stem of Arabidopsis, Plant Cell, 17, pp. 2059-76).
Two enzymes are specific to the monolignol biosynthesis pathway. They are caffeic acid O-methyltransferase (COMT) and cinnamoyl coenzyme A reductase (CCR). COMT was first identified in angiosperms. COMT is capable of converting caffeic acid to ferulic acid, as well as converting 5-hydroxyferulic acid to sinapic acid. (Dixon, R. A., et al. (2001) The biosynthesis of monolignols: a “metabolic grid,” or independent pathways to guaiacyl and syringyl units? Phytochemistry, 57, pp. 1069-1084). Down regulation of the COMT gene in maize ( Zea mays ) has been shown to cause a significant reduction of COMT activity (a fall of 70 to 85%), resulting in the modification of lignin content and composition, indicating that this enzyme is a key enzyme for lignin synthesis.
Ferulic acid generated by COMT can be hydroxylated by ferulate 5 hydroxylase (F5H), which is a cytochrome P450-dependent monooxygenase, to form 5-hydroxy-ferulic acid. F5H is also capable of hydroxylating coniferaldehyde and coniferyl alcohol to form 5-hydroxy-coniferaldehyde and 5-hydroxy-coniferyl alcohol, respectively. (Meyer, K. et al. (1996) Ferulate-5-hydroxylase from Arabidopsis thaliana defines a new family of cytochrome P450-dependent monooxygenases, Proc. Natl. Acad. Sci. USA, 93, pp. 6869-74). F5H is believed to be a rate limiting step in syringyl lignin biosynthesis, a proposal supported by the observation that an Arabidopsis mutant deficient in F5H expression is also affected at the level of sinapate esters accumulation in siliques and seeds. (Ruegger, M. et al. (1999) Regulation of ferulate-5-hydroxylase expression in Arabidopsis in the context of sinapate ester biosynthesis, Plant Physiol., 119, pp. 101-10).
The second enzyme specifically involved in lignol biosynthesis, CCR, catalyzes the conversion of feruloyl CoA and 5-hydroxy-feruloyl CoA into coniferaldehyde and 5-hydroxy-coniferaldehyde, respectively. This step leads directly to the biosynthesis of G (coniferaldehyde) and S (5-hydroxy-coniferaldehyde) lignin units. (Ma et al., 2005). In tobacco, down regulation of the CCR gene using antisense constructs, produced plants with abnormal development and reduced growth, as well as abnormal leaf morphology and collapsed vessels. There was also an associated reduction in the level of G lignin compounds. (Ralph, J. et al. (1998) NMR characterization of altered lignins extracted from tobacco plants down-regulated for lignification enzymes cinnamylalcohol dehydrogenase and cinnamoyl-CoA reductase, Proc. Natl. Acad. Sci USA, 95, pp. 12803-8).
Computational Identification of Genes and Transcripts
Remarkably, we have determined the sequences of the jute enzymes involved in lignin biosynthesis. The pathway of lignin biosynthesis has been well characterized and each enzyme is encoded by a gene family in most of the plant species. A total of 106 gene sequences of A. thaliana and P. trichocarpa were retrieved from NCBI and P. trichocarpa genome database (Goujon et al., 2003; Shi et al., 2010). Jute monolignol biosynthesis genes were identified from the gene models of the Corchorus olitorius genome assembly and transcriptome data of C. olitorius and C. capsularis using the program BLASTN with the e-value cut-off at 1e-20. (Altschul, S. F., et al. (1990) Basic local alignment search tool, J Mol Biol, 215, pp. 403-410). The resulting gDNA contigs were subjected to gene model prediction using the software AUGUSTUS. (Stanke, M. et al. (2004) AUGUSTUS: a web server for gene finding in eukaryotes, Nucleic Acids Research, 32, W309-W312). The gene models and the isotigs from the transcriptome data of C. olitorius and C. capsularis were searched against the NCBI nr (non-redundant) database for further confirmation.
An amino acid sequence alignment of putative proteins encoded by the ColCAD genes with other CAD proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIGS. 2 a and 2 b . The following is a list of the proteins aligned with the putative ColCAD proteins, with the GeneBank Accession Numbers in parentheses: PtcCADL4 ( Populus tricocarpa cinnamyl alcohol dehydrogenase-like protein, CADL4, gi224138226); RcoCAD ( Ricinus communis alcohol dehydrogenase, putative, gi25558709); FraCAD ( Fragaria×ananassa , cinnamyl alcohol dehydrogenase, gi13507210) (Chandler et al. (2002) Cloning, expression and immunolocalization pattern of a cinnamyl alcohol dehydrogenase gene from strawberry ( Fragaria×ananassa ), J. Exp. Bot., 53 (375), pp. 1723-1734); GhiCAD5 ( Gossypium hirsatum , cinnamyl alcohol dehydrogenase 5, gi268528129); PtcCAD ( Populus tricocarpa , gi183585165) ((2010) Towards a systems approach for lignin biosynthesis in Populus trichocarpa : transcript abundance and specificity of the monolignol biosynthetic genes, Plant Cell Physiol., 51 (1), pp. 144-163); GhiCAD3 ( Gossypium hirsatum , gi229368450) (Genes of phenylpropanoid pathway cloning and expression in developing cotton fibre); and GhiCAD ( Gossypium hirsatum , gi166865124) ((2009) Molecular and biochemical evidence for phenylpropanoid synthesis and presence of wall-linked phenolics in cotton fibers, J Integr Plant Biol, 51 (7), pp. 626-637).
An amino acid sequence alignment of putative proteins encoded by the ColCCoAOMT genes with other CCoAOMT proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 3 . The following is a list of the proteins aligned with the putative ColCCoAOMT proteins, with the GeneBank Accession Numbers in parentheses: PtrCCoAOMT ( Populus tremuloides , gi3023436); GhiCCoAOMT2 ( Gossypium hirsatum , gi229368460); and GhiCCoAOMT1 ( Gossypium hirsatum , gi253509567).
An amino acid sequence alignment of putative proteins encoded by the Col4CL genes with other 4CL proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 4 . The following is a list of the proteins aligned with the putative Col4CL proteins, with the GeneBank Accession Numbers in parentheses: Ccap4CL1 ( Corchorus capsularis , gi294514718); Rco4CL ( Ricinus communis , gi255565415); and Ptc4CL ( Populus tricocarpa , gi224074401).
An amino acid sequence alignment of putative proteins encoded by the Col6HCT genes with other Col6HCT proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 5 . The following is a list of the proteins aligned with the putative Col6HCT proteins, with the GeneBank Accession Numbers in parentheses: CycarHCT ( Cynara cardunculus , gi:73671233) ((2007) Isolation and functional characterization of a cDNA coding a hydroxycinnamoyltransferase involved in phenylpropanoid biosynthesis in Cynara cardunculus, BMC Plant Biol. 7, 14); and PtcHCT ( Poplus tricocarpa , gi183585181).
An amino acid sequence alignment of putative proteins encoded by the ColC3H genes with other C3H proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 6 . The following is a list of the proteins aligned with the putative ColC3H proteins, with the GeneBank Accession Numbers in parentheses: EglC3H ( Eucalyptus globulus , gi:295413824); PtcC3H ( Poplus tricocarpa , gi:224139664); and Pal×PgrC3H ( Poplus alba×Populus grandidentata , gi166209291).
An amino acid sequence alignment of putative proteins encoded by the ColC4H genes with other C4H proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 7 . The following is a list of the proteins aligned with the putative ColC4H proteins, with the GeneBank Accession Numbers in parentheses: GarC4H ( Gossypium arborium , gi9965897) and GarC4H ( Gossypium arborium , gi9965899).
An amino acid sequence alignment of putative proteins encoded by the ColPAL genes with other PAL proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 8 . The following is a list of the proteins aligned with the putative ColPAL proteins, with the GeneBank Accession Numbers in parentheses: JcoPAL ( Jatropha curcas , gi113203757) and PtrPAL ( Populus trichocarpa , gi:183585195).
An amino acid sequence alignment of putative proteins encoded by the ColCCR2 genes with other CCR proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 9 . The following is a list of the proteins aligned with the putative ColCCR2 proteins, with the GeneBank Accession Numbers in parentheses: AthCCR ( Arabidopsis thaliana , gi:15237678); CofCCR ( Camellia oleifera gi228480464); and AlyCCR ( Arabidopsis lyrata , gi:297793385).
An amino acid sequence alignment of putative proteins encoded by the ColCCR3 genes with other CCR proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 10 . The following is a list of the proteins aligned with the putative ColCCR3 proteins, with the GeneBank Accession Numbers in parentheses: RcoCCR ( Ricinus communis , gi:255556687) and AthCCR ( Arabidopsis thaliana , gi:15226955).
An amino acid sequence alignment of putative proteins encoded by the CoIF5H genes with other F5H proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 11 . The following is a list of the proteins aligned with the putative ColF5H proteins, with the GeneBank Accession Numbers in parentheses: EgIF5H ( Eucalyptus globules , gi:255970299) and PtcF5H ( Poplus tricocarpa , gi:6688937).
An amino acid sequence alignment of putative proteins encoded by the ColCOMT genes with other COMT proteins available in the NCBI database, using the CLUSTAL W program, is shown in FIG. 12 . The following is a list of the proteins aligned with the putative ColCOMT proteins, with the GeneBank Accession Numbers in parentheses: GhiCOMT ( Gossypium hirsutum , gi:253509569) and EcaCOMT ( Eucalyptus camaldulensis , gi:262474806).
Motif Analysis of the Promoter Regions
For each of the predicted gene models, both strands of the upstream regions of 2000 bp were extracted and searched for cis-motif sequences against the PlantCARE database (Lescot, M., et al. (2002) PlantCARE, a database of plant cis-acting regulatory elements and a portal to tools for in silico analysis of promoter sequences, Nucleic Acids Res, 30, pp. 325-327). If any portion of the selected sequences were found to be overlapping with a nearby gene, that part of the upstream region was excluded from further analysis. A list of important motifs was compiled that are known to be involved in the response to various developmental processes and stress (Table 1).
TABLE 1
List of motifs found in the promoter region of jute monolignol biosynthetic genes
Tran-
Gibberellin-
Low temp
Salicylic
respon-
Myb
scription
Abscisic
responsive
respon-
Gene model
acid
siveness
binding
Wound
enhancer
acid
Ethylene
Auxin
element
siveness
PAL
contig_310473_g31
*
contig_301819_g4
*
contig_302040_g24
*
*
*
*
contig_309920_g2
*
*
*
C4H
contig_311419_g56
contig_307848_g46
*
*
contig_384302_g42
4CL
contig_331398_g112
contig_299467_g73
*
*
contig_337813_g88
*
contig_306165_g86
*
*
contig_309926_g132
*
*
contig_304308_g125
*
*
*
*
contig_305998_g57
*
*
HCT
contig_308231_g128
*
C3H
contig_597141_g180
*
CCoAOMT
contig_306979_g168
*
*
contig_308402_g160
contig_296218_g172
*
*
*
*
contig_311951_g178
*
CCR
contig_310406_g194
*
contig_297048_g201
*
*
contig_294439_g187
*
contig_309320_g191
*
F5H
contig_304192_g207
*
contig_595270_g204
*
COMT
contig_299952_g235
*
CAD
contig_335778_g278
*
contig_95812_g280
contig_321021_g281
*
contig_808760_g282
*
contig_808760_g284
*
contig_356907_g287
*
contig_356907_g288
*
*
contig_355903_g289
*
contig_306706_g300
*
*
*
contig_304576_g307
*
*
*
*
Polynucleotides of the present invention were isolated by high-throughput sequencing of cDNA libraries comprising jute plant tissue collected from Corchorus olitorius L. Some of the polynucleotides of the present invention may be partial sequences, in that, they do not represent a full-length gene encoding a full-length polypeptide. Such partial sequences may be extended by analyzing and sequencing various DNA libraries using primers and/or probes and well known hybridization and/or PCR techniques. Partial sequences may be extended until an open reading frame encoding a polypeptide, a full-length polynucleotide, a gene capable of expressing a polypeptide, or another useful portion of the genome is identified.
Identification of genomic DNA and heterologous species DNA can be accomplished by standard DNA/DNA hybridization techniques, under appropriately stringent conditions, using all or part of a polynucleotide sequence as a probe to screen an appropriate library. Alternatively, PCR techniques using oligonucleotide primers that are designed based on known genomic DNA, cDNA, or protein sequences can be used to amplify and identify genomic and cDNA sequences.
Polypeptides of the present invention may be produced by inserting a polynucleotide sequence of the present invention encoding the desired polypeptide into an expression vector and expressing the polypeptide in an appropriate host. Any of a variety of expression vectors known to those of ordinary skill in the art could be employed. Expression may be achieved in any appropriate host cell that has been transformed or transfected with an expression vector containing a polynucleotide molecule that encodes a recombinant polypeptide. Suitable host cells include prokaryotes, yeast, and higher eukaryotic cells.
Polypeptides that comprise the lignin biosynthetic pathways purified from jute, or produced by recombinant methods, may be used to generate monoclonal antibodies, antibody fragments or derivatives as defined herein, according to known methods. Antibodies that recognize and bind fragments of the polypeptides that comprise the lignin biosynthetic pathways of the invention are also contemplated, provided that the antibodies are specific for polypeptides that comprise the lignin biosynthetic pathway.
The genetic constructs of the present invention may also contain a selection marker that is effective in plant cells, to allow for the detection of transformed cells containing the inventive construct. Such markers, which are well known in the art, typically confer resistance to one or more toxins or create visual signals for its presence under fluorescent microscope. Alternatively, the presence of the desired construct in transformed cells can be determined by means of other techniques well known in the art, such as Southern and Western blots. The genetic construct of the present invention may be linked to a vector having at least one replication system, for example, E. coli or yeast ( Saccharomyces cerevisiae ), whereby after each manipulation, the resulting construct can be cloned and sequenced.
The genetic constructs of the present invention may be used to transform a variety of plants, such as monocotyledonous (e.g., rice) and dicotyledonous (e.g., jute, Arabidopsis ). In a preferred embodiment, the inventive genetic constructs are employed to transform jute. As discussed above, transformation of a plant with a genetic construct of the present invention can be used to produce modified lignin content in the plant.
Techniques for stably incorporating genetic constructs into the genome of target plants are well known in the art and include Agrobacterium tumefaciens mediated introduction, electroporation, injection into meristematic tissue or reproductive organs, injection into immature embryos, and the like. The choice of technique will depend upon the target plant/tissue/host to be transformed.
The term “plant” includes whole plants, shoot vegetative organs/structures (e.g., leaves, stems, and tubers), roots, flowers, and floral organs/structures (e.g., bracts, sepals, petals, stamens, carpels, anthers, and ovules), seed (including embryo, endosperm, and seed coat) and fruit (the mature ovary), plant tissue (e.g., vascular tissue, ground tissue, and the like) and cells (e.g., guard cells, egg cells, trichomes and the like), and progeny of same. The class of plants that can be used in the method of the invention is generally as broad as the class of higher and lower plants amenable to transformation techniques, including angiosperms (monocotyledonous and dicotyledonous plants), gymnosperms, ferns, bryophytes, and multicellular algae. It includes plants of a variety of ploidy levels, including aneuploid, polyploid, diploid, haploid, and hemizygous.
DNA gels of PCR reactions using forward and reverse primers for several jute enzymes are shown in FIGS. 13-17 . In FIG. 13 , the DNA gel is of CAD2 from Corchorus olitorius . Lane 1 is the PCR product of CAD2 using cDNA as a template. The forward primer and reverse primer are SEQ ID NO. 53 and 54, respectively. Lane 2 is the 1 Kb+ladder. In FIG. 14 , the DNA gel is of CCoAOMT1 from Corchorus olitorius . Lane 1 is the 1 Kb+ladder, and Lane 2 is the PCR product of CCoAOMT1 using cDNA as a template. The forward primer and reverse primer are SEQ ID NO. 55 and 56, respectively. In FIG. 15 , the DNA gel of 4CL1 from Corchorus olitorius . Lane 1 is the 1 Kb+ladder, and Lane 2 is the PCR product of 4CL1 using cDNA as a template. The forward primer and reverse primer are SEQ ID NO. 57 and 58, respectively. In FIG. 16 , the DNA gel is of CCR3 from Corchorus olitorius . Lane 1 is the 1 Kb+ladder, and Lane 2 is the PCR product of CCR3 using cDNA as a template. The forward primer and reverse primer are SEQ ID NO. 59 and 60, respectively. In FIG. 17 , the DNA gel is of F5H from Corchorus olitorius . Lane 1 is the 1 Kb+ladder, and Lane 2 is the PCR product of F5H using cDNA as a template. The forward primer and reverse primer are SEQ ID NO. 61 and 62, respectively.
DEFINITIONS
A cell has been “transformed” or “transfected” by exogenous or heterologous DNA when such DNA has been introduced inside the cell. The transforming DNA may or may not be integrated (covalently linked) into the genome of the cell. In prokaryotes, yeast, and mammalian cells for example, the transforming DNA may be maintained on an episomal element such as a plasmid. With respect to eukaryotic cells, a stably transformed cell is one in which the transforming DNA has become integrated into a chromosome so that it is inherited by daughter cells through chromosome replication. The practice of the present invention contemplates a wide variety of stably transformed plant cells.
An “expression cassette” refers to a nucleic acid construct, which when introduced into a host cell, results in transcription and/or translation of a RNA and/or polypeptide, respectively. The expression cassette may include a nucleic acid comprising a promoter sequence, with or without a sequence containing mRNA polyadenylation signals, and one or more restriction enzyme sites located downstream from the promoter allowing insertion of heterologous gene sequences. The expression cassette is capable of directing the expression of a heterologous protein when the gene encoding the heterologous protein is operably linked to the promoter by insertion into one of the restriction sites. The recombinant expression cassette allows expression of the heterologous protein in a host cell when the expression cassette containing the heterologous protein is introduced into the host cell. Expression cassettes can be derived from a variety of sources depending on the host cell to be used for expression. For example, an expression cassette can contain components derived from a viral, bacterial, insect, plant, or mammalian source. In the case of both expression of transgenes and inhibition of endogenous genes (e.g., by antisense, or sense suppression) the inserted polynucleotide sequence need not be identical and can be “substantially identical” to a sequence of the gene from which it was derived. Preferably the recombinant expression cassette allows expression at an early stage of infection and/or it allows expression in substantially all cells of an organism, such as a plant. Examples of expression cassettes suitable for transformation of plants can be found in U.S. Pat. Nos. 5,880,333 and 6,002,072; International Patent Publications Nos. WO/1990/002189 and WO/2000/026388; Ainley and Key (1990) Plant Mol . Biol., 14, pp. 949-967; and Birch (1997) Annu. Rev. Plant Physiol. Plant Mol. Biol., 48, pp. 297-326, all of which are herein incorporated by reference.
The term “host cell” refers to a cell from any organism. Preferred host cells are derived from plants, bacteria, yeast, fungi, insects, or other animals. The term “recombinant host cell” (or simply “host cell”) refers to a cell into which a recombinant expression vector has been introduced. It should be understood that the term “host cell” is intended to refer not only to the particular subject cell but to the progeny of such a cell. Because certain modifications may occur in succeeding generations due to either mutation or environmental influences, such progeny may not, in fact, be identical to the parent cell, but are still included within the scope of the term “host cell” as used herein. Methods for introducing polynucleotide sequences into various types of host cells are well known in the art. Provided are host cells or progeny of host cells transformed with the recombinant expression cassettes of the present invention. The host cells may be plant cells. Preferably, the plant cells are jute cells.
The term “operably linked” or “operably inserted” means that the regulatory sequences necessary for expression of the coding sequence are placed in a nucleic acid molecule in the appropriate positions relative to the coding sequence so as to enable expression of the coding sequence. This same definition is sometimes applied to the arrangement of other transcription control elements (e.g., enhancers) in an expression cassette. Transcriptional and translational control sequences are DNA regulatory sequences, such as promoters, enhancers, polyadenylation signals, terminators, and the like, that provide for the expression of a coding sequence in a host cell.
The terms “promoter,” “promoter region,” or “promoter sequence” refer generally to transcriptional regulatory regions of a gene, which may be found at the 5′ or 3′ side of the coding region, or within the coding region, or within introns. Typically, a promoter is a DNA regulatory region capable of binding RNA polymerase in a cell and initiating transcription of a downstream (3′ direction) coding sequence. The typical 5′ promoter sequence is bounded at its 3′ terminus by the transcription initiation site and extends upstream (5′ direction) to include the minimum number of bases or elements necessary to initiate transcription at levels detectable above background. Within the promoter sequence is a transcription initiation site (conveniently defined by mapping with nuclease S1), as well as protein binding domains (consensus sequences) responsible for the binding of RNA polymerase.
The term “nucleic acid construct” or “DNA construct” is sometimes used to refer to a coding sequence or sequences operably linked to appropriate regulatory sequences and inserted into an expression cassette for transforming a cell. This term may be used interchangeably with the term “transforming DNA” or “transgene”. Such a nucleic acid construct may contain a coding sequence for a gene product of interest, along with a selectable marker gene and/or a reporter gene. The term “selectable marker gene” refers to a gene encoding a product that, when expressed, confers a selectable phenotype such as antibiotic resistance on a transformed cell. The term “reporter gene” refers to a gene that encodes a product which is easily detectable by standard methods, either directly or indirectly.
A “heterologous” region of a nucleic acid construct is an identifiable segment (or segments) of the nucleic acid molecule within a larger molecule that is not found in association with the larger molecule in nature. When the heterologous region encodes a plant gene, the gene will usually be flanked by DNA that does not flank the plant genomic DNA in the genome of the source organism. In another example, a heterologous region is a construct where the coding sequence itself is not found in nature (e.g., a cDNA where the genomic coding sequence contains introns, or synthetic sequences having codons different than the native gene). Allelic variations or naturally-occurring mutational events do not give rise to a heterologous region of DNA as defined herein. The term “DNA construct” is also used to refer to a heterologous region, particularly one constructed for use in transformation of a cell.
The term “vector” is intended to refer to a nucleic acid molecule capable of transporting another nucleic acid to which it has been linked. One type of vector is a “plasmid,” which refers to a circular double-stranded DNA loop into which additional DNA segments may be ligated. Another type of vector is a viral vector, where additional DNA segments may be ligated into the viral genome. Certain vectors are capable of autonomous replication in a host cell into which they are introduced (e.g., bacterial vectors having a bacterial origin of replication and episomal mammalian vectors). Other vectors can be integrated into the genome of a host cell upon introduction into the host cell, and thereby are replicated along with the host genome. Moreover, certain vectors are capable of directing the expression of genes to which they are operatively linked. Such vectors are referred to herein as “recombinant expression vectors” (or simply, “expression vectors”). In general, expression vectors of utility in recombinant DNA techniques are often in the form of plasmids. In the present specification, “plasmid” and “vector” may be used interchangeably as the plasmid is the most commonly used form of vector. However, the invention is intended to include such other forms of expression vectors, such as viral vectors (e.g., replication defective retroviruses, adenoviruses and adeno-associated viruses), which serve equivalent functions.
“Percentage of sequence identity” is determined by comparing two optimally aligned sequences over a comparison window, where the portion of the polynucleotide sequence in the comparison window may comprise additions or deletions (i.e., gaps) as compared to the reference sequence (which does not comprise additions or deletions) for optimal alignment of the two sequences. The percentage is calculated by determining the number of positions at which the identical nucleic acid base or amino acid residue occurs in both sequences to yield the number of matched positions, dividing the number of matched positions by the total number of positions in the window of comparison, and multiplying the result by 100 to yield the percentage of sequence identity.
The term “substantial identity” of polynucleotide sequences means that a polynucleotide comprises a sequence that has at least 25% sequence identity compared to a reference sequence as determined using the programs described herein; preferably BLAST using standard parameters, as described. Alternatively, percent identity can be any integer from 25% to 100%. More preferred embodiments include polynucleotide sequences that have at least: 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% sequence identity compared to a reference sequence. These values can be appropriately adjusted to determine corresponding identity of proteins encoded by two nucleotide sequences by taking into account codon degeneracy, amino acid similarity, reading frame positioning, and the like.
The term “substantial identity” of amino acid sequences (and of polypeptides having these amino acid sequences) normally means sequence identity of at least 40% compared to a reference sequence as determined using the programs described herein; preferably BLAST using standard parameters, as described. Preferred percent identity of amino acids can be any integer from 40% to 100%. More preferred embodiments include amino acid sequences that have at least 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% sequence identity compared to a reference sequence. Polypeptides that are “substantially identical” share amino acid sequences as noted above except that residue positions which are not identical may differ by conservative amino acid changes. Conservative amino acid substitutions refer to the interchangeability of residues having similar side chains. For example, a group of amino acids having aliphatic side chains is glycine, alanine, valine, leucine, and isoleucine; a group of amino acids having aliphatic-hydroxyl side chains is serine and threonine; a group of amino acids having amide-containing side chains is asparagine and glutamine; a group of amino acids having aromatic side chains is phenylalanine, tyrosine, and tryptophan; a group of amino acids having basic side chains is lysine, arginine, and histidine; and a group of amino acids having sulfur-containing side chains is cysteine and methionine. Preferred conservative amino acids substitution groups are: valine-leucine-isoleucine, phenylalanine-tyrosine, lysine-arginine, alanine-valine, aspartic acid-glutamic acid, and asparagine-glutamine.
INCORPORATION BY REFERENCE
All of the U.S. patents, U.S. published patent applications, and published PCT applications that designate the U.S. cited herein are hereby incorporated by reference.
EQUIVALENTS
While several embodiments of the present invention have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto; the invention may be practiced otherwise than as specifically described and claimed.
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Disclosed are polynucleotides encoding polypeptides that comprise the biosynthetic pathway for lignin in the jute plant. The present invention relates generally to the field of plant lignin biosynthesis genes, polypeptides encoded by such genes, and the use of such polynucleotide and polypeptide sequences for controlling plant lignin production. Also disclosed are methods for using the polynucleotides and polypeptides to influence the quality and amount of fiber produced by jute.
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GOVERNMENT INTEREST
The invention described herein was made in the performance of work under FAA Agreement #DTFAWA-09-00001. The Government may have rights to portions of this invention.
BACKGROUND OF THE INVENTION
Several collision accidents have occurred at airports where an aircraft or vehicle has entered a runway environment which is already occupied by another aircraft that is moving at significant speed. Airborne collision protection and mitigation is provided by Traffic Collision and Avoidance System (TCAS), however the algorithms used in TCAS systems are not well suited to the airport surface operations problem; on airports, near runways, aircraft commonly operate at relatively high speeds in close proximity to other aircraft and vehicles. For example, an aircraft waiting to enter a runway is commonly stopped within a distance of the order of 100 feet from a runway that may be occupied by a landing aircraft traveling at speeds greater than 100 knots, thereby confusing TCAS algorithms. Also, on the ground at normal taxi speeds, an airplane can change its direction of travel much more rapidly than can an airborne aircraft.
SUMMARY OF THE INVENTION
The present invention uses knowledge of the geographic position, speed, rate of change of speed, heading (or track-angle) and/or altitude of own-aircraft (or vehicle) and another, potentially conflicting aircraft (or vehicle) to calculate the predicted distance between the two aircraft (or vehicles) at given point of time in the future. If separation distance is predicted to be less than a predetermined acceptable value, then an alert message (aural, visual or both) is issued to the pilot or operator of the vehicle. The required information from the potentially conflicting traffic is obtained over a data communication channel, such as Automatic Dependent Surveillance-Broadcast (ADS-B), Automatic Dependent Surveillance-Rebroadcast (ADS-R) or Traffic Information Service-Broadcast (TISB) data. The information required from own-aircraft is readily available from on-board systems such as Global Positioning Systems and Air Data Systems.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings:
FIG. 1 illustrates a schematic diagram of an example system for performing traffic proximity alerting in the airport environment in accordance with an embodiment of the present invention;
FIG. 2 illustrates a flow diagram for performing traffic proximity alerting in the airport environment using the system shown in FIG. 1 ;
FIG. 3 illustrates runway proximity zone used by the present invention;
FIG. 4 is a flow diagram of an example process for testing alerting status of traffic;
FIGS. 5A and B a flowchart of an example process used to calculate the predicted separation distance between ownship and the target at a future time;
FIG. 6 illustrates caution and warning target icons presented on a display of a host vehicle; and
FIGS. 7 and 8 illustrate plan views of an airport area displaying caution and warnings in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an example vehicle collision alerting system 20 for providing warning and/or caution alerts to vehicle operators if ground based trajectories of own and other vehicles might lead to a collision. The system 20 includes a processor 24 , an air data system (ADS) 26 , a position determining device (e.g. global positioning system (GPS) 30 ), a transponder 32 and one or more output device 34 .
The processor 24 sends and receives state information over a data channel via the transponder 32 . Using own-vehicle information (from the GPS 30 and the ADS 26 ) and target vehicle state information (position, velocity, acceleration and track-angle), the processor 24 calculates predicted range between the two vehicles for a set of future times. If the predicted range is less than a pre-determined “allowable miss distance” at a time less than Tw, then a Warning alert is generated and outputted to one of the output device(s) 34 . If the predicted range is less than the “allowable miss distance” at a time less than Tc, then a Caution alert is generated and outputted to one of the output device(s) 34 .
The processor 24 provides predictions for many scenarios—i.e. for converging runway traffic as well as same runway traffic. However, to avoid missed alerts when either own-vehicle or the target vehicle is changing track-angle rapidly—which happens on the ground—the predicted positions are calculated at a set of future times—e.g. every three seconds out to 30 seconds, i.e. 10 calculations. This frequency can vary. Also, the accelerations (rate of change of speed) of own-vehicle and target vehicle are used to provide more accurate predictions. Acceleration of the target vehicle is calculated from reported velocity (or geographic position), and filtered to reduce noise.
In another embodiment, the processor 24 uses track-angle data from own-vehicle and traffic vehicle to calculate track-angle rate to improve the prediction of position when own-vehicle and/or target vehicle is turning. Since the relative positions of the own-vehicle and the traffic vehicle are known, the direction from which the target vehicle is converging is also calculated, and the direction can be included in the alert message: e.g. “Traffic left”, or “Traffic 9 o'clock”.
FIG. 2 illustrates an example process 50 performed by the system 20 shown in FIG. 1 . When a vehicle (e.g. aircraft, ground crew vehicle) is on the ground, a ground signal is transmitted over a data communication channel, see block 54 . Next at block 56 , for all vehicles receiving the ground signal transmission that are less than threshold altitude above an associated runway altitude value, locations at a set of times in the future of the vehicle receiving the ground signal transmission and vehicle transmitting the ground signal are predicted. Then at block 58 , distance between the locations at corresponding times are determined.
At a decision block 62 , the processor 24 determines if one of the determined distances between corresponding times is below a predefined threshold. If one of the determined distances is below the threshold, then at decision block 64 , the processor 24 determines if the time corresponding to the determined distance is below a first time threshold. If the corresponding time is below the first time threshold, the system 20 outputs a warning alert, see block 66 . If none of the determined distances are below the predefined threshold, the process 50 is delayed at block 63 and returned to block 56 .
If the corresponding time is not below the first time threshold, then at decision block 70 , the processor 24 determines if the time corresponding to the determined distance is between the first time threshold and a second time threshold. If the corresponding time is not between the first and second time threshold, the process 50 is delayed at block 72 then returned to decision block 64 . If the corresponding time is between the first and second time threshold, the system 20 outputs a caution alert at block 74 .
FIG. 3 illustrates an example of runway proximity zone, which defines the volume of interest around a runway. A primary condition for triggering an alert is that both “ownship” and a traffic target must be in the proximity zone. In one embodiment, the width of the zone increases if the velocity component of ownship or target towards the runway is above a predefined value(s).
FIG. 4 is a flowchart of an example process 80 for testing alert status of a traffic target. If the target aircraft/vehicle is within the proximity zone, T A is made equal to the time interval between calculations (dT—e.g., 1 second). T A varies between dT and TCaution in steps of dT. If T A is less than or equal to TCaution, then range of target from ownship is predicted at T A seconds. In one embodiment, TCaution is ˜30 seconds and TWarn is ˜15 seconds. If the predicted range is greater than a predefined clearance distance, the process 80 increments T A by dT and repeats the analysis. If the predicted range is less than the predefined clearance distance, the process 80 outputs a warning alert if T A is greater than a predefined TWarn, otherwise caution alert is outputted. A warning alert may include a visual symbol (e.g., red icon) or an aural message (e.g., “Traffic Ahead”). A tactile alert may also be outputted.
If T A is not less than or equal to TCaution or the target is not inside the proximity zone, then the process 80 proceeds to analyze the next target aircraft/vehicle based on observed ADS-B traffic targets.
FIGS. 5A and B illustrate a flowchart of an example process 90 used to calculate the predicted separation distance between ownship and the target at a future time. T P is the same as T A . The average accelerations (rate of change of forward velocity) of ownship and traffic targets are calculated using the following algorithm. The algorithm averages the acceleration value over N samples, where N is typically of the order of 10.
AvgAccel
K
=
∑
i
=
0
N
-
1
(
V
K
-
i
-
V
k
-
i
-
1
)
/
dT
Where AvgAccel K is the average acceleration in the K th time interval, N is the number of averaging samples, V K-i is the velocity at the i th sample before the current time interval, V K-i-1 is the velocity at the (i-1) th sample before the current time interval, and dT is the time step used in the calculations (typically 1 second).
FIG. 6 illustrate icons 140 and 142 that are presented on an own aircraft display in plan view for representing any target aircraft/vehicles. The first icon 140 includes a triangular vehicle symbol inside a circular perimeter that is presented when a vehicle associated with the first icon 140 has triggered a caution alert. In one embodiment, the first icon 140 is presented as a distinct color (e.g., yellow). The second icon 142 includes a triangular vehicle symbol inside a square perimeter that is presented when a vehicle associated with the second icon 142 has triggered a warning alert. In one embodiment, the second icon 142 is presented as a distinct color (e.g., red). Relevant and proximate traffic would be displayed without the encompassing circle/square and would not be displayed in the distinct color—yellow or red.
FIG. 7 illustrates a plan view radar display with the own aircraft 150 center in circular range circles. In this situation, the alerting system on the own aircraft 150 has received a ground signal from a target aircraft associated with the aircraft icon 154 and determined that the target meets the criteria of a caution alert. Thus, the aircraft icon 154 appears similar to icon 140 as shown in FIG. 6 . Also, a line 158 that extends along the direction of travel from the icon 154 is presented on the display. The line 158 is determined based on status information received from the target aircraft. The line 158 is presented in the same color as the icon 154 .
FIG. 8 illustrates a situation where the alerting system on the own aircraft 150 has received a ground signal from a target aircraft associated with an aircraft icon 154 - 1 and determined that the target meets the criteria of a warning alert. Thus, the aircraft icon 154 - 1 appears similar to icon 142 as shown in FIG. 6 . Also, a line 160 that extends along the direction of travel from the icon 154 - 1 is presented on the display. The line 150 is determined based on status information received from the target aircraft as described above. The line 150 is presented in the same color as the icon 154 - 1 .
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.
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Systems and methods for alerting to traffic proximity in the airport environment. Knowledge of the geographic position, speed, rate of change of speed, heading (or track-angle) and/or altitude of own-aircraft (or vehicle) and another, potentially conflicting aircraft (or vehicle) are used to calculate a predicted distance between the two aircraft (or vehicles) at given point of time in the future. If separation distance is predicted to be less than a predetermined acceptable value, then an alert message (aural, visual or both) is issued to the pilot or operator of the vehicle.
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This invention relates to fixtures for veterinary and laboratory animal cages, and in particular, to a universal length shelf for mounting in the cages.
BACKGROUND OF THE INVENTION
Cages used in holding small animals such as dogs, cats, rabbits, monkeys and the like used for laboratory research and as temporary holding structures for veterinary purposes often employ a shelf extending between the opposite side walls of the cage for animals, particularly cats, to perch on. In the case of felines, a litter box is emplaced on the bottom wall of the cage and a shelf for perching placed an upward distance from the cage bottom.
Heretofore, shelves used in cages were not universal in fit and merely existed of a tray cut to size with an end flange and fastened through existing or otherwise formed hole or bolt patterns in the cage walls. When the shelves and cages were produced by different manufacturers, particular cutting and shaping to size was required and drilling through the cage wall was needed. Thus, fitting shelves was often a difficult and time consuming job even though apparently quite simple at the outset.
OBJECTS OF THE INVENTION
The principle objects of the present invention are: to provide a universal length animal shelf which is adjustable to fit cages of various widths; to provide such an animal shelf which may be emplaced in a cage at any desired height and location from front to rear of the cage; to provide such an animal shelf which quickly converts shelfless cages to cages with shelves therein for use by cats; to provide such an adjustable shelf which is of abuse resistant material; to provide such an animal shelf of a suitable configuration for the comfort of the animal; to provide such an animal shelf having first and second shelf portions which telescopically interfit to provide an adjustable length shelf and have a force-apart mechanism therebetween for urging the opposite end portions of the shelf into engagement with the cage side walls; to provide such an animal shelf having pivotally mounted end plates on the opposite end portions of the shelf to provide a positive facing fit with the opposite side walls of the cage, even on cages with tapered side walls; and to provide such an adjustable length shelf which is relatively inexpensive, sturdy and efficient in use and particularly well adapted for the intended purpose.
Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings wherein is set forth, by way of illustration and example, a certain embodiment of this invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, environmental view of a veterinary or laboratory animal cage having a shelf mounted therein embodying the present invention.
FIG. 2 is a plan view of the adjustable length animal shelf and showing underneath portions thereof in phantom lines
FIG. 3 is a cross-sectional view taken along lines 3--3, FIG. 2.
FIG. 4 is a longitudinal sectional view taken along lines 4--4, FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As required, a detailed embodiment of the present invention is disclosed herein, however, it is to be understood that the disclosed embodiment is merely exemplary of the invention which may be embodied in various forms, therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a repesentative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
Referring to the drawings in more detail: The reference number 1 generally indicates an adjustable length shelf embodying the present invention and, FIG. 1, shown emplaced within an animal cage 2. The adjustable length shelf 1 has at least first and second shelf portions 3 and 4 which telescopically interfit and have an adjustment or force-apart means 5 extending between the first and second shelf portions 3 and 4 to urge or spread the shelf portions apart so that the opposite ends thereof snugly engage the opposite walls of the cage 2.
In the illustrated example, the cage 2 is particularly adapted for housing small animals such as dogs, rabbits, cats and the like for laboratory or veterinary purposes and includes a frame 7 connecting adjoining cage structures. Each cage 2 has a top wall 8, bottom wall 9 forming a floor of the cage, and opposite side walls 10 and 11. The walls 8, 9, 10 and 11 are arranged to provide a generally rectangular enclosure closed by a cage door 12 and a back wall 13. In the illustrated example, the cage 2 is of molded fabrication and of a material such as fiberglas or suitable synthetic plastic resin wherein the open interior area of the cage is formed by a male mold member having sloping sides so that the resultant molded member can be pulled therefrom. Therefore, the cage walls 8, 9, 10 and 11 flare outwardly or diverge toward the front of the cage and narrow to the back wall 13.
Each shelf portion 3 and 4 is generally rectangular in cross-section, FIG. 3, and has a relatively wide, such as seven inches, top wall 15 providing an upper surface for an animal to perch. The shelf portions 3 and 4 are comprised of a relatively sturdy material, such as stainless steel for resistance to gnawing abuse by the animals and urine corrosion. Each top wall 15 has upper and lower planar surfaces 16 and 17. Each shelf portion 3 and 4 further has opposite inner and outer ends 18 and 19 with the respective ends 18 telescopically interfitting and the respective ends 19 being free. The shelf portions 3 and 4 each have spaced side walls 20 and 21 extending longitudinally therealong and respectively having inturned flanges 22 and 23 connected thereto. Preferably, the side walls 20 and 21 and flanges 22 and 23 are formed integrally with the top wall 15 of the shelf portions 3 and 4 as by extrusion and bending as by a metal brake or the like.
As clearly depicted in FIG. 3, the second shelf portion 4 has a cross-sectional area less than the cross-sectional area of the first shelf portion 3 for telescoping interconnection of the inner ends 18 of the first and second shelf portions 3 and 4 to provide the adjustable length shelf 1. When telescopically interfitted and downward stress is exerted, as by the weight of the combined shelf portions 3 and 4 and the weight of an animal thereon, the interfitted top walls 15 tend to bind together and exert force upon the respective combined flanges 22 and 23 to maintain structural rigidity of the shelf 1.
The lower area or bottom portion of the shelf 1 is open, FIGS. 3 and 4 for access to the adjustment means or force-apart means 5 which adjusts the extent of the telescoping interfit between the shelf portions 3 and 4 and urges the shelf outer or free ends 19 apart and toward the cage side walls 10 and 11. In the illustrated example, the means 5 includes an abutment block or member 26 attached to one of the shelf portions 3 and 4 and an adjustment screw means 27 mounted to the other of the shelf portions 3 and 4. The adjusment block or member 26 is shown in the form of an angle member having one flange 28 detachably affixed against the lower planar surface 17 of the top wall 15 of the first shelf portion 3 as by bolt and nut fasteners 29. The depending flange 30 extends downwardly of the lower planar surface 17 and terminates upwardly of the spaced flanges 22 and 23 for engagement by the adjustment screw means 27. In the illustrated example, the adjustment block or member 26 is selectively positionable or adjustable in position along the length of the first shelf portion 3. The first shelf portion 3 has a series of bores 31 extending longitudinally therealong and the fasteners 29 are easily removable and connectable to affix the abutment block or member 26 to selective ones of the series of the bores 31 and mount the abutment block or member 26 at selected lengths from the inner end 18 to accomodate variously sized cages.
The adjustment screw member 27 is mounted in a bracket 33 also in the form of an angle having an upper flange 34 secured to the lower planar surface 17 of the second shelf portion 4 as by rivets or the like (not shown). The depending flange 35 has an aperture 36 therethrough substantially centrally positioned and oversized to the adjustment screw means. A threaded nut 37 is secured to the flange 34 so that the bore thereof communicates with the aperture 36. An elongate adjustment screw 39 is threaded through the nut 37 and extends through the aperture 36 and into selective contacting relationship with the flange 30 of the abutment block or member 26 to control the positioning of the abutment block or member 26 relative to the bracket 33. The screw 39 has a knurled head 40 suitable for grasping and manipulation.
For engagement with the cage side walls 10 and 11, the free ends 19 of the respective shelf portions 3 and 4 each have an end plate 42 pivotally mounted thereto. In the illustrated example, each end plate 42 has spaced, oppositely turned, angled portions 44 and 45 joined by a plate member 46 having bent over or turned margins 47 to embrace the outward flanges of the angle portions 44 and 45. The remaining flanges of the angled portions 44 and 45 extend in the form of arms 48 over the ends 19 and a pivotal connection means such as a rivet 50 connects the arms 48 to the respective shelf portion 3 or 4 top wall 15 for pivotal mounting of the end plate 42 thereto. The pivotal mounting of the end plates 42 relative to the shelf portions 3 and 4 permits the end plates 42 to swivel or rotate and engage the cage side walls 10 and 11 in parallel, facing relationship, as for cages with sloping side walls 10 and 11 formed by molding of the cage.
To aid engagement, the plate 46 has a pad 52 of soft rubbery material affixed thereto for gripping engagement with the opposite side walls 10 and 11. Such a suitable material is a synthetic, plastic resinous material available under the trademark Dycem and manufactured by Dycem, Ltd., Bristol, England. The gripping pad 52 may be secured to the plate member 46 by any suitable means such as adhesive or the like and, in the illustrated example, is secured by a double sided sticky tape layer 53.
In the use of the adjustable length shelf, the shelf is positioned as necessary within the cage and the shelf portions 3 and 4 telescoped outwardly or inwardly to generally correspond to the cage interior width. The adjustment screw 39 is rotated until meeting the abutment block or member 26 and rotation is continued until the respective end plates 42 bear forcefully against the side walls 10 and 11 sufficiently to maintain the shelf 1 at the selected position. In position, the resilient, soft pads 52 grippingly engage the surfaces of the side walls 10 and 11 and inhibit slipping or undesired movement of the shelf 1. If necessary, during the setting up phase, the abutment block or member 26 is adjusted longitudinally on the first shelf portion 3 for mounting in selected ones of the series of apertures 31 for properly fitting the shelf 1 to the cage interior.
Removal of the adjustable length shelf 1 from the animal cage 2 is accomplished by mere reversal of the above steps.
It is to be understood that while one form of this invention has been illustrated and described, it is not to be limited to the specific form or arrangement of parts herein described and shown, except insofar as such limitations are included in the following claims.
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An adjustable length shelf for a small animal cage having opposite wall members comprises first and second shelf portions which are fitted together in an expansible and contractible telescoping relationship to fit between the opposite wall members of virtually any commonly used veterinary or laboratory animal cage. An adjustment mechanism for forcing the first and second shelf portions apart includes one part mounted on the first shelf portion and a second and coordinating part mounted on the second shelf portion for urging the opposite free ends of the shelf into contact with the cage walls. Opposite end plates are pivotally mounted to the free ends of the shelf for facing engagement with the cage wall members.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 286,918 filed Dec. 20, 1988 which is a continuation-in-part of Ser. No. 132,495 filed Dec. 14, 1987 all now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a composition and a process for the production of ignition resistant or flame retardant polycarbonates and/or carbonate polymers wherein the ignition resistant additives are first compounded into a polycarbonate carrier resin then blended with a low molecular weight or moldable polycarbonate.
It is known from U.S. Pat. No. 4,626,563 that aromatic sulfimide metal salts, monomeric or polymeric halogenated aromatic compounds, metal salts of inorganic acids having a pKa from 1 to 5, and fibril forming polytetrafluoroethyene are useful to render carbonate polymers ignition resistant or flame retardant. Other flame retardant additives are known from and listed in U.S. Pat. No. 4,650,823. These patents are incorporated by reference herein.
SUMMARY OF THE INVENTION
The present invention is broadly directed to a process for dispersing one or more powdered ignition resistant or flame retardant additives into carbonate polymers wherein the impact properties of the ignition resistant carbonate polymers is improved.
More specifically, the invention is directed to a process for dispersing one or more powdered ignition resistant or flame retardant additives into carbonate polymers which comprises the steps of preparing a base concentrate having about 5 to about 50 weight percent of said additives by blending said additives with a carbonate polymer having a melt flow rate from about 3 to about 80 and preferably a MFR in the range of 3 to 20, pelletizing said base concentrate having said ignition resistant additive dispersed therein, dry blending said concentrate pellets with carbonate polymer pellets having a melt flow rate from about 1 to about 80 whereby said polymer/concentrate blend has an amount of said additive dispersed therein effective to render said blend ignition resistant, and pelletizing or molding said carbonate polymer/concentrate blend.
The process of this invention has the following steps:
(A) making a polymer/concentrate by pelletizing a carbonate polymer having a melt flow rate in the range from about 3 to about 80 with the composition comprising,
(i) 2.0 to 10% by weight of a metal salt of an aromatic sulfur containing compound,
(ii) 10 to 80% by weight of a monomeric, oligomeric or polymeric halogenated aromatic compound,
(iii) 2.0 to 10.0% by weight of compound selected from the group consisting of a metal salt of an inorganic compound and a free aromatic sulfimide, and
(iv) 6 to 40% by weight of a fibril forming polytetrafluoroethyene,
(B) blending said concentrate pellets with carbonate polymer pellets having a melt flow rate from about 1 to about 80 and substantially lower than said first carbonate polymer whereby said polymer/concentrate blend has an amount of said additives dispersed therein effective to render said blend ignition resistant, and
(C) pelletizing or molding said carbonate polymer/concentrate blend.
The advantages of the invention over the known techniques are that significant improvement is seen in the toughness of the final product as measured by improved Izod impact tests when the polymer concentrate is first made and diluted down with additional polymer. In addition, the generation of dust particles which is commonly found in additive compounding is eliminated.
DETAILED DESCRIPTION OF THE INVENTION
The carbonate polymers employed in the present invention are advantageously aromatic carbonate polymers such as the trityl diol carbonates described in U.S. Pat. Nos. 3,036,036; 3,036,037; 3,036,038 and 3,036,039; polycarbonates of bis(ar-hydroxyphenyl) alkylidenes (often called bisphenol-A type diols) including their aromatically and aliphatically substituted derivatives such as disclosed in U.S. Pat. Nos. 2,999,835; 3,038,365 and 3,334,154; and carbonate polymers derived from other aromatic diols such as described in U.S. Pat. No. 3,169,121.
It is understood, of course, that the polycarbonate may be derived from (1) two or more different dihydric phenols or (2) a dihydric phenol and a glycol or a hydroxy- or acid-terminated polyester or a dibasic acid in the event a carbonate copolymer or heteropolymer rather than a homopolymer is desired. Also suitable for the practice of this invention are blends of any one of the above carbonate polymers. Also included in the term carbonate polymer are the ester/carbonate copolymers of the types described in U.S. Pat. Nos. 3,169,121; 4,105,633; 4,156,069; 4,225,556; 4,260,731; 4,287,787; 4,330,662; 4,355,150; 4,360,656; 4,374,973; and 4,388,455. Of the aforementioned carbonate polymers, the polycarbonates of bisphenol-A and derivatives, including copolycarbonates of bisphenol-A, are preferred. Methods for preparing carbonate polymers for use in the practice of this invention are well known, for example, several suitable methods are disclosed in the aforementioned patents which are hereby incorporated by reference in their entirety.
The monomeric, oligomeric or polymeric halogenated aromatic compound used in this invention can be virtually any halogenated organic compound commonly used as a fire retardant additive. The preferred compounds are the halo-substituted aromatic compounds (halo is fluoro, chloro, or bromo). Suitable compounds include, for example, decabromo diphenyloxide, tris(tribromophenoxy) triazine, decabromodiphenylcarbonate, an oligomer or polymer of tetrabromobisphenol A, and a copolymer of bisphenol A/tetrabromobisphenol A. Combinations of the above identified compounds can be employed. Examples of other suitable monomeric and polymeric halogenated compounds are disclosed in U.S. Pat. No. 4,263,201, which is incorporated herein by reference.
The metal salts of sulfur compounds used herein include metal salts of aromatic sulfonates, sulfates, sulfonamides, and sulfimides. Suitable metals are the metals of Groups I and IIA of the Periodic Chart as well as copper, aluminum, and antimony. The preferred metal is an alkali metal such as sodium or potassium.
The preferred group of aromatic sulfur compounds are sulfimides having the formula ##STR1## wherein Ar is an aromatic group and M is a metal cation.
Examples of the sulfimide salts are the alkali metal salts of saccharin, N-(p-tolylsulfonyl)-p-toluene sulfimide, N-(N'-benzylaminocarbonyl)sulfanilimide, N-(phenylcarboxyl)-sulfanilimide, N-(2-pyrimidinyl)-sulfanilimide, and N-(2-thiazolyl)sulfanilimide. These salts and similar ones are disclosed in U.S. Pat. No. 4,254,015 which is incorporated herein by reference in its entirety.
The free aromatic sulfimides useful in this invention are those having a pKa in the range from about 1 to about 3. Examples of such free aromatic sulfimides are saccharin, N-(p-tolylsulfonyl)-p-toluene sulfimide, N-(N'-benzylaminocarbonyl)sulfanilimide, N-(phenylcarboxyl)-sulfanilimide, N-(2-pyrimidinyl)sulfanilimide, and N-(2-thiazolyl)sulfanilimide. They are further illustrated by the formula ##STR2## wherein R is carbonyl, arylcarbonyl, arylaminocarbonyl, aralkylaminocarbonyl, or arylsulfonyl. Specific examples of these groups are benzoyl, benzylaminocarbonyl and tolylsulfonyl groups.
In general, the additive package has a fixed weight ratio of components so that after the polymer concentrate is made it can be readily shipped without dust formation to desired locations where it can be diluted down or let down with more polymer to the final ignition resistant product. The preferred ratio of components is; metal salt of an aromatic sulfur containing compound:monomeric, oligomeric or polymeric halogenated aromatic compound:metal salt of an inorganic compound:fibril forming polytetrafluoroethyene (1:10:1:3). For example, a 15% additive/polymer concentrate is blended with more polymer at a 10:1 ratio to give a useful ignition resistant blend.
In addition to the aforementioned fire retardant additives, other additives can be included in the carbonate polymer composition of the present invention such as fillers (i.e. glass fibers), pigments, dyes, antioxidants, stabilizers, ultraviolet light absorbers, mold release agents, impact modifiers and other additives commonly employed in carbonate polymer compositions.
The following examples and controls are presented to further illustrate the invention.
EXAMPLE 1
A fifteen percent ignition resistant (IR) polycarbonate concentrate is prepared by adding 1 gram (1%) potassium paratolylsulfimide (KPTSM) 1 gram (1%) potassium bisulfate (KHSO 4 ), 3 grams (3%) fibril forming polytetrafluoroethylene (Teflon 6C) and 10 grams (10%) tetrabromobisphenol-A oligomer (TBBPA), all in one masterbatch, to 85 gms (85%) heat stabilized polycarbonate resin having a 22 gms/10 min MFR (melt flow rate). The KPTSM is represented by the formula: ##STR3## wherein Ar is a paratolyl group and M is potassium.
The additive masterbatch and polycarbonate pellets are blended on a rotating blender (Lightnin blender) for one minute with agitation. The resultant blended material is gradually fed to a 30 mm twin screw extruder having a 250° C. barrel temperature. The extruded pellets are post blended on a paint shaker to ensure uniform mixing.
The 15% IR concentrate is let down in or blended with a base polycarbonate at 10 to 1 ratio. The base polycarbonate had a 15 gms/10 minute melt flow rate (MFR). The mixture was blended on Lightnin blender for 1 minute. The blended pellets are extruded on 30 mm twin screw extruder at 275° C. barrel temperature to make a 15 MFR ignition resistant polycarbonate product. The final product is dried in an oven for 3 hours at 125° C. and molded into bars for flammability and Izod impact tests. If desired the IR concentrate and base polycarbonate can be fed separately into the twin screen extruder or can be directly molded into various parts.
EXAMPLE 2
The procedure for Example 1 was repeated using 1 gm (1%) paratolylsulfimide (HPTSM) in place of the KHSO 4 .
EXAMPLE 3
The procedure for Example 1 was repeated using a 30 weight % IR concentrate. This concentrate contained:
2% potassium paratolylsulfimide,
2% potassium bisulfate,
6% fibril forming polytetrafluoroethylene and
20% tetrabromobisphenol-A oligomer.
This 30% concentrate was blended with a base polycarbonate at a 20 to 1 letdown ratio.
EXAMPLE 4
The procedure for Example 2 was repeated using the above 30% IR concentrate at a 20 to 1 letdown ratio.
Control A
The procedure for Example 1 was repeated using only the base resin without either IR concentrate or IR masterbatch.
Control B
The procedure for Example 1 was repeated using only 1.5% IR additive masterbatch without concentrate.
The above examples and controls were tested for Izod impact strength and the results are shown in Table I.
TABLE I______________________________________ PC carrier Izod Impact (10 mil (MFR notched at 25° C.; ASTM in D-259-84) gms/10 %Sample min.) Izod Impact Brittle______________________________________Cntrl A N.A. 15.0 0(Base Polymer) ft.lb./in.Cntrl B N.A. 3.0 100(Cntrl A + 1.5% IR ft.lb./in.Masterbatch)Example 1 22 14.5 015% I.R. ft.lb./in.concentrate with10:1 letdownExample 2 22 14.7 015% I.R. ft.lb./in.concentrate with10:1 letdownExample 3 22 13.0 1030% I.R.concentrate with20:1 letdownExample 4 22 13.3 1030% I.R.concentrate with20:1 letdown______________________________________
Table 1 shows that the use of IR concentrate at either 10 to 20 to 1 letdown (15 or 30%) resulted in improved Izod impact properties without any brittle breaks versus IR additive masterbatch which resulted in very low Izod impact with 100% brittle breaks. The improvement of Izod impact via the use of IR concentrate is attributed to more uniform additive dispersion using IR concentrate than using IR masterbatch.
The above examples and controls were further tested for ignition resistance or flammability using the well known UL-94 test. The results are shown in Table II.
TABLE II______________________________________ UL-94 Test (1/16") Number Avg. T- ofSample Sec Drips Rating______________________________________Control A 10.3 5/5 V-2Control B 1.0 0/5 V-0Example 1 1.2 0/5 V-0Example 2 1.5 0/5 V-0Example 3 1.1 0/5 V-0Example 4 1.3 0/5 V-0______________________________________ Note: TSec means time in seconds for a flame out
Table II shows the use of IR concentrate does not detract from the flammability properties of final product.
EXAMPLE 5
The procedure for Example 3 was repeated using a 20 MFR polycarbonate carrier.
EXAMPLE 6
The procedure for Example 4 was repeated using a 15 MFR polycarbonate carrier.
EXAMPLE 7
The procedure for Example 4 was repeated using a 10 MFR polycarbonate carrier.
Control C
The procedure for Example 3 was repeated using a 40 MFR polycarbonate carrier.
Control D
The procedure for Example 3 was repeated using a 80 MFR polycarbonate carrier.
The above examples and controls were tested for Izod impact strength and the results are shown in Table III.
TABLE III______________________________________ Izod Impact (10 mil notched at 25° C.; ASTM D-259-84) Izod PC Impact Carrier (ft.lb./ %Sample (MFR) in) Brittle______________________________________Cntrl A (Base N.A. 15.0 0Polymer)Cntrl C (Cntrl A + 40 7.5 5030% IR concentrate at20 to 1 ratio)Cntrl D (Cntrl A + 80 3.0 10030% IR concentrate at20 to 1 ratio)Example 5 (Cntrl A + 20 13.0 030% IR concentrateat 20 to 1 ratio)Example 6 (Cntrl A + 15 14.5 030% IR concentrate at20 to 1 ratio)Example 7 (Cntrl A + 10 14.0 1030% IR concentrate at20 to 1 ratio)______________________________________
The above controls and/or examples show that high melt flow rate polycarbonates are not effective as carriers as the low MFR carriers.
The above examples and controls were further tested for ignition resistance using the UL-94 test. The results are shown in Table IV.
TABLE IV______________________________________ UL-94 Test (1/16") Number Avg. T- ofSample Sec Drips Rating______________________________________Control A 10.3 5/5 V-2Control C 1.0 0/5 V-0Control D 2.0 0/5 V-0Example 5 1.0 0/5 V-0Example 6 1.0 0/5 V-0Example 7 1.0 0/5 V-0______________________________________ Note: TSec means time in seconds for a flame out
Tables III and IV show that lower MFR polycarbonate carriers help to improve the Izod impact strength of the polymer better than higher MFR PC carriers without sacrificing the flammability property of the final product.
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A process for dispersing one or more powdered ignition resistant or flame retardant additives into carbonate polymers which comprises the steps of preparing a base concentrate having about 5 to about 50 weight per cent of said additives by blending said additives with a carbonate polymer having a melt flow rate from about 3 to about 20, pelletizing said base concentrate having said ignition resistant additive dispersed therein, dry blending said concentrate pellets with carbonate pellets having a melt flow rate from about 1 to about 80 whereby said polymer/concentrate blend has an amount of said additive dispersed therein effective to render said blend ignition resistant, and pelletizing or molding said carbonate polymer/concentrate blend. The use of this method gives ignition resistant carbonate polymers with improved impact properties as measured by Izod impact tests.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a method and apparatus for the simultaneous centralized control of capsule-like yarn brakes of several twist spindles of a two-for-one twisting machine.
[0002] DE 44 08 262 C2 discloses an apparatus for the central control of a capsule-like yarn brake of a twisting machine, especially a two-for-one twisting machine. This conventional apparatus includes a control device and a common compressed air unit which is communicated with the twist spindles via connecting units each associated with a respective twist spindle and operable to deliver air pulses to a pressurized air cylinder coupled to a brake ring of the respective twist spindle, the control device controlling the common compressed air unit to deliver pressurized air pulses to the pressurized air cylinders, whereby the pressurized air cylinders, upon receipt of the air pulses, effect an axial displacement of the rotatable brake rings of all of the capsule-like yarn brakes over a predetermined extent.
[0003] DE PS 32 43 157 discloses a twist spindle having a capsule-like yarn brake, which is supported between upper and lower brake rings. The upper brake ring is mounted to a support body at the lower end of a yarn intake conduit of a twist spindle and is resiliently biased by a spring in the direction of the lower, second brake ring. The support body is provided with a plurality of support shoulders distributed around its circumference at different axial positions so that a respective one of the support shoulders is supported on a stationary detent. An adjustment of the braking force of the capsule-like yarn brake is effected in a manner such that the yarn intake conduit is raised against the force of the spring which biases the support body and, thereafter, the yarn intake conduit is rotated through a pre-determined angular range of traverse such that another support shoulder of the support body comes to rest against the detent. This conventional device is thus directed to an individual adjustment and, especially, a manual individual adjustment, of each individual capsule-like yarn brake.
SUMMARY OF THE INVENTION
[0004] The present invention offers a solution to the challenge of providing a method and an apparatus for the simultaneous centralized controlled adjustment of the capsule-like yarn brakes of a plurality of twist spindles of a two-for-one twisting machine such that the need for a dedicated pressurized air system can be avoided.
[0005] Summarizing the prevalent characteristics of the present invention, the present invention is particularly characterized in that it exerts, in a purely mechanical operation implemented via a plurality of yarn balloon guides commonly supported on a support frame, a sufficiently high pressure on the yarn intake conduits of a plurality of twist spindles such that the yarn intake conduits, which each support one of the two respective brake rings of the respective twist spindle, are axially displaced against the bias of a spring force to an extent such that a brake ring rotation advances the brake ring to a different axial position relative to the other, second respective brake ring following each release of the yarn intake conduit from the axial pressure thereon.
[0006] An embodiment of the present invention is described in the following description taken in connection with the figures of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a sectional view of a two-for-one twisting machine having a plurality of yarn balloon guides commonly mounted on a yarn guide frame, which is movable upwardly and downwardly;
[0008] [0008]FIG. 2 is an enlarged sectional view of a twist spindle having a hollow shaft in which a capsule-like yarn brake is disposed;
[0009] [0009]FIGS. 3 a - 3 c are each an enlarged perspective view of a portion of the adjustment unit at a respective different position thereof during movement of the adjustment unit to adjust the braking force of the twist spindle relative to a stationary detent;
[0010] [0010]FIG. 4 is an enlarged perspective view of a variation of the one embodiment of the adjustment unit; and
[0011] [0011]FIG. 5 is an enlarged perspective view of a twist spindle having a variation of the embodiment of a yarn balloon guide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0012] [0012]FIG. 1 shows a sectional view of a two-for-one twisting machine which supports the yarn balloon guides 9 of a plurality of twist spindles S arranged in neighboring relation to one another, the yarn balloon guides 9 being commonly mounted to a common yarn guide frame 11 which is movable—in a not illustrated guide—upwardly and downwardly parallel to the axes of the twist spindles S in the direction of the double arrow F 1 .
[0013] The yarn guide frame 11 is suspended by means of suspension hangers 12 on a shaft 13 , which is rotatably driven by a rotation drive 14 operatively coupled to a motor 15 . The downward movement of the yarn guide frame 11 is effected under the influence of gravity by corresponding controlled actuation of the motor 15 . The possibility thus exists to position the yarn balloon guides 9 at differing heights over the yarn intake conduits 3 , whereby, to exert an influence on the yarn twisting process, the formation of yarn balloons can be controlled. In accordance with the present invention, the yarn balloon guides 9 can be displaced downwardly through corresponding adjustment of the yarn guide frame 11 to such an extent that the yarn balloon guides 9 exert a downward pressure on the yarn intake conduits 3 of a plurality of the twist spindles S, whereby the yarn intake conduits 3 are pressed downwardly. In this manner, as will be hereinafter described, the possibility exists to provide a centrally controlled adjustment of the yarn brakes of a plurality of spindles S arranged in neighboring relationship to one another.
[0014] [0014]FIG. 2 shows a portion of the hollow shaft 2 of a rotationally symmetric housing 16 in which is disposed a capsule-like yarn brake 11 and an adjustment unit 18 which is responsive to downward pressure on the yarn intake conduit 3 , the adjustment unit 18 being operable to effect a variation of the braking force of the capsule-like yarn brake 11 . The adjustment unit 18 is secured to the bottom end of the yarn intake conduit 3 and comprises a cylindrical housing 27 open towards its bottom for receipt therein of a helical spring 28 which biases the adjustment unit 18 upwardly.
[0015] The housing 16 is closed on its topside by a threaded cover 19 through which the yarn intake conduit 3 is guided outwardly of the housing 16 . The capsule-like yarn brake 11 includes a bullet-like brake which, in conventional manner, is comprised of two displaceable tube portions 11 . 1 and 11 . 2 biased by a spring to move axially away from one another and each of which includes a cup or cap-shaped end portion. The lower tube portion 11 . 2 is supported against a brake ring 20 , which is disposed in a brake ring carrier 21 disposed in an axial guide or groove 21 . 1 . The brake ring carrier 21 , which is supported against a helical spring 22 , is sealingly guided in a housing bore 16 . 2 formed in the housing 16 such that, for purposes of effecting a pneumatic yarn threading or intake of yarn, an under-pressure is created below the yarn ring carrier 21 so as to effect downward movement of the yarn ring carrier. The lowered yarn ring 20 thus releases the bullet-like yarn brake 11 to fall whereupon it is then caught by a support ring 16 . 3 stationarily mounted in the housing; the support ring 16 . 3 has a partial opening 16 . 31 such that a yarn introduced through the yarn intake conduit 3 can be suctioned in through the yarn intake 8 into the bore 21 . 1 and guided past the released bullet-like brake 11 . A yarn threading system of this type is described in DE 44 08 262 C2 and is, in any event, the basic configuration of the yarn intake assembly as described in the hereinafter-described adjustment unit 18 .
[0016] A first annular upper toothed rim 40 is disposed on the adjustment unit 18 above the housing 27 and a second annular lower tooth rim 41 is disposed above the housing 27 as well. The upwardly directed teeth of the lower toothed rim 41 form therebetween axial spaces in the form of openings/slots whose bases or bottoms form notches or, respectively, support shoulders which are distributed about the circumference of the toothed rim at differing axial heights therearound and each notch or support shoulder is engaged upon its turn by a radially inwardly projecting detent 29 as a function of the rotational position of the adjustment unit 18 .
[0017] The downwardly directed teeth of the upper-toothed rim 40 form therebetween axially extending slots opening downwardly or, respectively, form downwardly opening notches.
[0018] Reference is now had to FIGS. 3 a - 3 c for a description of the configuration of the teeth of the two toothed rims 40 and 41 ; the arrow F 2 indicates the rotational direction of the adjustment unit 18 .
[0019] The flanks 40 . 1 and 41 . 1 of the teeth of the upper and lower toothed rims 40 and 41 which extend in the rotational direction F 2 have substantially axial extents. The down sloping flanks 40 . 2 or, respectively, 41 . 2 of the upper and lower toothed rims 40 and 41 are configured as respective rising or falling angled surfaces which form an angle of approximately 45° relative to the rotational direction. The tips or peaks of the teeth of the upper-toothed rim 40 are offset from the tips or peaks of the teeth of the lower toothed rim 41 in the rotational direction by an amount which is slightly greater than the diameter of the detent 29 .
[0020] [0020]FIG. 3 a shows an operational condition in which the lower toothed rim 41 is engaged by the detent 29 such that the detent is seated in a notch I between two neighboring teeth of the lower toothed rim with the portion of the adjustment unit 18 comprised of the lower toothed rim 41 being upwardly biased by the spring 28 . If the adjustment unit 18 is displaced downwardly in the direction of the arrow F 3 via a downward pressure on the yarn intake conduit 3 , the detent initially assumes the position shown by the broken lines 29 ′ seen in FIG. 3 b. Upon further downward pressure on the yarn intake conduit 3 , the detent traverses along the toothed flank 40 . 2 extending away from the rotational direction f 2 to thereafter achieve the intermediate position 29 ″ shown in FIG. 3 c in correspondence with the partial rotation of the adjustment unit 18 in the direction of the rotation direction F 2 . The movement of the detent 29 relative to the adjustment unit 18 follows thus along the path of the bent arrow F 5 shown in FIG. 3 a. It is to be understood that the stationary detent 29 does not axially change its position but, rather, the adjustment unit 18 undergoes a partial rotation during this process.
[0021] If, thereafter, the yarn intake conduit 3 is again released, the adjustment unit 18 is again biased upwardly, as seen in FIG. 3 c, in the direction of the arrow F 4 due to the biasing action of the spring 28 so that the detent 29 —following the path shown by the bent arrow F 6 —seats into the next following notch 11 , whereby there follows a sliding movement of the detent 29 along the flank 41 . 2 in the direction of the rotation direction F 2 upon a further partial rotation of the adjustment unit 18 .
[0022] By virtue of the lowering and subsequent release of the yarn intake conduit 3 and, thus, of the adjustment unit 18 , there follows a sectional rotation of the adjustment unit 18 in the rotational direction F 2 . Since each notch is lower than the immediately preceding notch, it follows, as the detent 29 seats into the respective next following notch, that the brake ring 23 is disposed in progressively lower positions following each operation to lower and release the yarn conduit 3 , thus leading to an increase in the braking force.
[0023] The braking force can thus be adjusted in a step-wise manner through individual downward pressure and release sequences of the yarn intake conduit 3 until the braking force has been increased to a maximum value, which value is predetermined by the depth of the deepest notch in the lower toothed rim 41 .
[0024] Through multiple sequential actuation—that is, multiple actuation involving downward pressure and release of the yarn intake conduit 3 —the yarn braking force can be increased until the detent 29 is eventually seated in the deepest notch of the lower toothed rim 41 .
[0025] By sequential or subsequent activation of the yarn intake conduit 3 , the detent 29 is moved into the next following—that is—the highest disposed notch—of the lower toothed rim 41 , which corresponds to the braking force adjustment position of the lowest value.
[0026] The toothed rims 40 ′, 41 ′, as seen in FIG. 4, can be configured as lower components freely rotatable relative to the remainder of the adjustment unit 18 but not, however, adjustable relative thereto in the axial direction, with the toothed rims 40 ′, 41 ′ being supported by, from below, a collar of the housing 27 and, from above, a detent body 60 which is securely mounted via, for example, a threaded screw 61 , on the yarn intake conduit 3 .
[0027] The yarn balloon guides can alternatively be configured to be self-centering with respect to the associated yarn intake conduits 3 —e.g., as truncated ball-shaped yarn balloon guides 9 ′, as seen in FIG. 5.
[0028] The specification incorporates by reference the disclosure of German priority document DE 100 45 909.9.
[0029] The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
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A method and apparatus for the simultaneous centralized controlled adjustment of the braking force of yarn brakes of a plurality of twist spindles of a two-for-one twisting machine are provided, whereby each twist spindle is of the type having, in its hollow shaft, a yarn brake supported between two brake rings with one of the brake rings being rotatable in response to a downward axial pressure thereon in a manner such that the brake ring undergoes a discrete axial displacement to a new axial position. A support frame to which yarn balloon guides are mounted exerts a downward axial force such that the yarn balloon guides simultaneously exert downward axial pressure on the yarn intake conduits of the twist spindles which, in turn, effects axial displacement of the rotatable and axially adjustable brake ring on the yarn intake conduit of each twist spindle into new axial positions.
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This invention relates to a chemically amplified resist composition suited for micropatterning technology. More particularly, it relates to a polymer useful as a base polymer in such resist compositions, a chemically amplified resist composition comprising the same, and a patterning process using the resist composition.
BACKGROUND OF THE INVENTION
In the drive for higher integration and operating speeds in LSI devices, the pattern rule is made drastically finer. The rapid advance toward finer pattern rules is grounded on the development of a projection lens with an increased NA, a resist material with improved performance, and exposure light of a shorter wavelength. In particular, the change-over from i-line (365 nm) to shorter wavelength KrF laser (248 nm) brought about a significant innovation, enabling mass-scale production of 0.18 micron rule devices. To the demand for a resist material with a higher resolution and sensitivity, acid-catalyzed chemical amplification positive working resist materials are effective as disclosed in U.S. Pat. No. 4,491,628 and U.S. Pat. No. 5,310,619 (JP-B 2-27660 and JP-A 63-27829). They now become predominant resist materials especially adapted for deep UV lithography.
Resist materials adapted for KrF excimer lasers enjoyed early use on the 0.3 micron process, went through the 0.25 micron rule, and currently entered the mass production phase on the 0.18 micron rule. Engineers have started investigation on the 0.15 micron rule, with the trend toward a finer pattern rule being accelerated. A wavelength change-over from KrF to shorter wavelength ArF laser (193 nm) is expected to enable miniaturization of the design rule to 0.13 μm or less. Since conventionally used novolac resins and polyvinylphenol resins have very strong absorption in proximity to 193 nm, they cannot be used as the base resin for resists. To ensure transparency and dry etching resistance, some engineers investigated acrylic and alicyclic (typically cycloolefin) resins as disclosed in JP-A 9-73173, JP-A 10-10739, JP-A 9-230595 and WO 97/33198. With respect to F 2 excimer laser (157 nm) which is expected to enable further miniaturization to 0.10 μm or less, more difficulty arises in insuring transparency because it was found that acrylic resins are not transmissive to light at all and those cycloolefin resins having carbonyl bonds have strong absorption. It was also found that polyvinylphenol is somewhat improved in transmittance in proximity to 160 nm, but far below the practical level, and reducing carbonyl and carbon-to-carbon double bonds is essential for insuring a transmittance. However, cyclic structures and carbon-to-carbon double bonds greatly contribute to an improvement in dry etching resistance. A polymer for use with an ArF excimer laser, in which a benzene ring is excluded and instead, an alicyclic structure is introduced for improving etching resistance, is difficult to provide transparency since it acquires solubility by relying on carboxylic acid.
The use of a fluorine-substituted polymer was found effective as a means for improving transparency. Making a study to improve the transparency of an acrylic polymer used in ArF resist compositions, the inventor proposed the use of an acrylic derivative having a fluorine-substituted backbone.
In most cases, dry etching resistance is conventionally discussed in conjunction with the selection ratio of etching. As described in many reports, for example, J. Photopolymer Sci. and Technol., Vol. 5, No. 3 (1992), p. 439, J. Electrochem. Soc.: Solid-State Sci. and Technol., Vol. 130, No. 1, January 1983, p. 143, and SPIE, Vol. 2724, p. 365 (1996), engineers attempted to express the dry etching selection ratio of a single layer resist using various parameters. Typical are Onishi parameter and ring parameter.
It was recently reported in SPIE, Vol. 3678, p. 1209 (1999) that micro-roughness develops on the resist surface after dry etching and is transferred after substrate processing and resist removal. Making extensive studies, the inventor found that the development of roughness after etching occurs when dry etching of SiO 2 is carried out with a fluorocarbon gas such as CF 4 , CHF 3 , C 2 F 6 , C 3 F 8 or C 4 F 10 and that roughness increases under the high throughput conditions where the RF power is increased for high etching selection ratio, that is, fast etching of oxide film. It was further found that roughness largely differs depending on the type of polymer used in ArF single layer resist. A noticeable roughness develops with acrylic polymers. In contrast, roughness declines with cycloolefin polymers such as norbornene homopolymers and alternating copolymers of norbornene with maleic anhydride. In particular, norbornene homopolymers give small values of roughness even compared with polyhydroxystyrene for KrF. Herein, acrylic polymers with pendant adamantane exhibit a satisfactory value of etching speed, that is, selection ratio, fully comparable to cycloolefin polymers. When high selectivity etching was effected in an etching speed ratio of at least 3 between oxide film and resist, the surface roughness Rms of the etched surface as measured by atomic force microscopy (AFM) was more than 15 nm for acrylic polymers and less than 3 nm for cycloolefin polymers. These results indicate that the selection ratio of etching does not necessarily coincide with the roughness after etching.
It is pointed out that what becomes a problem as a result of wavelength reduction is a lowering of transparency, and in the case of a positive resist material, a negative working phenomenon that the exposed areas become insoluble as the dose of exposure is increased. Those portions which have turned negative are insoluble not only in alkali developers, but also in organic solvents such as acetone. This indicates that gel forms as a result of crosslinking of molecules together. Radical generation is probably one cause of crosslinking. As a result of wavelength reduction, the exposure energy is increased so that even C—C bonds and C—H bonds may be excited in the case of F 2 exposure (157 nm). As a result of excitation, radicals are generated with a possibility that molecules are bonded together. For polymers having an alicyclic structure for use in ArF exposure, for example, polynorbornene, an outstanding negative working phenomenon was observed. It is believed that these polymers have a structure susceptible to crosslinking since the alicyclic group has many C—H bonds at the bridgehead. On the other hand, it is well known that α-methylstyrene and derivatives thereof are effective for preventing crosslinking. Alpha-methylstyrene can mitigate the negative working phenomenon, but fail to completely eliminate the phenomenon. Moreover, since oxygen absorption is considerable in the VUV region, exposure is effected under the conditions that oxygen is purged, with an inert gas such as nitrogen or argon, to an oxygen concentration of 1 ppm or lower. Since oxygen is an effective radical trapping agent, this means that the radicals generated have a long lifetime and more crosslinking takes place.
SUMMARY OF THE INVENTION
An object of the invention is to provide a novel polymer useful as the base polymer in resist compositions, a chemical amplification resist composition comprising the polymer, and a patterning process using the same, which polymer or resist composition has a high transmittance to vacuum ultraviolet radiation of up to 300 nm, especially an F 2 excimer laser beam (157 nm), Kr 2 excimer laser beam (146 nm), KrAr excimer laser beam (134 nm) and Ar 2 excimer laser beam (126 nm), as well as improved negative conversion-preventing effect and dry etching resistance.
The inventor has found that using a cycloolefin polymer having fluorinated alkyl groups as the base polymer, a resist composition featuring transparency, negative-conversion preventing effect, and dry etching resistance is obtained.
In one aspect, the invention provides a polymer comprising recurring units of the following general formula (1)
Herein A is a divalent aliphatic or alicyclic hydrocarbon group of 2 to 20 carbon atoms, R 1 is an alkyl group containing at least one fluorine atom, which may contain a hetero atom such as oxygen, nitrogen or sulfur to form an ether, ester, carbonate, alcohol, acetoxy or thioester, “a” is a positive number of 1 to 3, R is a single bond, methylene group, oxygen atom, NH group or sulfur atom, and R 2 and R 3 each are a single bond or methylene group.
The polymer may further comprise recurring units containing acid labile groups.
In another aspect, the invention provides a chemically amplified resist composition comprising the polymer defined above, and specifically, a chemically amplified positive resist composition comprising (A) the polymer defined above, (B) an organic solvent, and (C) a photoacid generator. In preferred embodiments, the resist composition further includes a basic compound and/or a dissolution inhibitor.
In a further aspect, the invention provides a process for forming a resist pattern comprising the steps of applying the resist composition defined above onto a substrate to form a coating; heat treating the coating and then exposing it to high-energy radiation having a wavelength of up to 180 nm or electron beams through a photo mask; and optionally heat treating the exposed coating and developing it with a developer.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Polymer
According to the invention, the polymer or high molecular weight compound is defined as comprising recurring units of the following general formula (1).
Herein A is a divalent aliphatic or alicyclic hydrocarbon group of 2 to 20 carbon atoms, R 1 is an alkyl group containing at least one fluorine atom, which may contain a hetero atom such as oxygen, nitrogen or sulfur to form an ether, ester, carbonate, alcohol, acetoxy or thioester, “a” is a positive number of 1 to 3, R is a single bond, methylene group, oxygen atom, NH group or sulfur atom, and R 2 and R 3 each are a single bond or methylene group.
Preferred among the polymers of formula (1) are those polymers of the following formulas (2)-1 to (2)-9.
Herein R 4 is a methylene group, oxygen atom, NH group or sulfur atom.
Examples of the fluorine-containing substituents represented by R 1 include those of the following formulas (3)-1 to (3)-9.
Herein, R 5 is a fluorinated alkyl group which may contain an ether or ester bond; R 6 and R 11 each are hydrogen or a straight alkyl group of 1 to 10 carbon atoms, R 7 is hydrogen, a straight alkyl group of 1 to 10 carbon atoms, or —C═O—R 12 wherein R 12 is hydrogen or a straight alkyl group of 1 to 10 carbon atoms; R 8 is an alkylene group of 1 to 10 carbon atoms; either one or both of R 9 and R 10 are alkyl groups of 1 to 5 carbon atoms having at least one fluorine atom substituted thereon.
Preferably, R 5 is a straight, branched or cyclic alkyl group of 1 to 20 carbon atoms which contains at least one fluorine atom and which may contain an ether or ester bond. Illustrative examples are substituents of the following formulas (4)-1 to (4)-11.
In a preferred embodiment, the inventive polymer comprises recurring units containing acid labile groups in addition to the above units.
The recurring units containing acid labile groups are desirably those units having a carbon-to-carbon double bond and capable of copolymerizing with the recurring units of formula (1), for example, units of (meth)acrylic derivatives, styrene derivatives, norbornene derivatives, tricyclodecene derivatives, tetracyclododecene derivatives, maleimide derivatives, and vinyl alcohol derivatives.
The (meth)acrylic derivatives are exemplified by the following formulas (5)-1 and (5)-2.
Herein, R 13 is an acid labile group, each of R 14 , R 15 and R 16 is a hydrogen atom, fluorine atom, or a straight, branched or cyclic alkyl group of 1 to 10 carbon atoms, which may be substituted with fluorine.
The styrene derivatives are exemplified by the following formula (6).
Herein, R 13 , R 14 , R 15 and R 16 are as defined above, R 17 is a hydrogen atom, fluorine atom, or a straight, branched or cyclic alkyl group of 1 to 10 carbon atoms, which may be substituted with fluorine, b is a positive number of 1 to 5, c and d each are 0 or a positive number of 1 to 4.
The norbornene derivatives are exemplified by the following formulas (7)-1 to (7)-7.
Herein, R 4 and R 13 are as defined above.
The tricyclodecene derivatives are exemplified by the following formulas (8)-1 to (8)-14.
Herein, R 4 and R 13 are as defined above.
The maleimide derivatives are exemplified by the following formulas (10)-1 and (10)-2.
Herein, R 4 and R 13 are as defined above.
The maleimide derivatives are exemplified by the following formulas (10)-1 and (10)-2.
Herein, R 13 is as defined above, R 14 is a single bond or an alkylene group of 1 to 10 carbon atoms, R 15 and R 16 each are hydrogen, fluorine, methyl or trifluoromethyl.
The vinyl alcohol derivatives are exemplified by the following formula (11).
Herein, R 13 , R 14 , R 15 and R 16 are as defined above.
The acid labile group represented by R 13 is selected from a variety of such groups, preferably from among the groups of the following formulas (12) and (13), tertiary alkyl groups with 4 to 40 carbon atoms of the following formula (14), trialkylsilyl groups whose alkyl groups each have 1 to 6 carbon atoms, and oxoalkyl groups of 4 to 20 carbon atoms.
In formulas (12) and (13), R 18 and R 21 each are a straight, branched or cyclic alkyl group of 1 to 20 carbon atoms, which may contain a hetero atom such as oxygen, sulfur, nitrogen or fluorine; R 19 and R 20 each are hydrogen, a straight, branched or cyclic alkyl group of 1 to 20 carbon atoms, which may contain a hetero atom such as oxygen, sulfur, nitrogen or fluorine; and n is 0 or an integer of 1 to 10. A pair of R 19 and R 20 , a pair of R 19 and R 21 or a pair of R 20 and R 21 may bond together to form a ring.
Preferably, R 18 to R 21 are as illustrated below.
R 18 is a tertiary alkyl group of 4 to 20 carbon atoms, preferably 4 to 15 carbon atoms, a trialkylsilyl group whose alkyl groups each have 1 to 6 carbon atoms, an oxoalkyl group of 4 to 20 carbon atoms or a group of formula (14). Exemplary tertiary alkyl groups are tert-butyl, tert-amyl, 1,1-diethylpropyl, 1-ethylcyclopentyl, 1-butylcyclopentyl, 1-ethylcyclohexyl, 1-butylcyclohexyl, 1-ethyl-2-cyclo-pentenyl, 1-ethyl-2-cyclohexenyl, and 2-methyl-2-adamantyl. Exemplary trialkylsilyl groups are trimethylsilyl, triethylsilyl, and dimethyl-tert-butylsilyl. Exemplary oxoalkyl groups are 3-oxocyclohexyl, 4-methyl-2-oxooxan-4-yl, and 5-methyl-5-oxooxolan-4-yl. Letter “a” is an integer of 0 to 6.
In formula (13), R 19 and R 20 are independently hydrogen or straight, branched or cyclic alkyl groups of 1 to 18 carbon atoms, preferably 1 to 10 carbon atoms, for example, methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, cyclopentyl, cyclohexyl, 2-ethylhexyl and n-octyl. R 21 is a monovalent hydrocarbon group of 1 to 18 carbon atoms, preferably 1 to 10 carbon atoms, which may have a hetero atom such as oxygen atom, for example, straight, branched or cyclic alkyl groups, and such groups in which some hydrogen atoms are replaced by hydroxyl, alkoxy, oxo, amino or alkylamino groups. Illustrative examples of the substituted alkyl groups are given below.
A pair of R 19 and R 20 1 , a pair of R 19 and R 21 , or a pair of R 20 and R 21 , taken together, may form a ring. Each of R 19 , R 20 and R 21 is a straight or branched alkylene group of 1 to 18 carbon atoms, preferably 1 to 10 carbon atoms, when they form a ring.
Illustrative examples of the acid labile groups of formula (12) include tert-butoxycarbonyl, tert-butoxy-carbonylmethyl, tert-amyloxycarbonyl, tert-amyloxycarbonyl-methyl, 1,1-diethylpropyloxycarbonyl, 1,1-diethylpropyloxycarbonylmethyl, 1-ethylcyclopentyl-oxycarbonyl, 1-ethylcyclopentyloxycarbonylmethyl, 1-ethyl-2-cyclopentenyloxycarbonyl, 1-ethyl-2-cyclopentenyl-oxycarbonylmethyl, 1-ethoxyethoxycarbonylmethyl, 2-tetrahydropyranyloxycarbonylmethyl, and 2-tetrahydro-furanyloxycarbonylmethyl.
Of the acid labile groups of formula (13), illustrative examples of the straight or branched groups are given below.
Of the acid labile groups of formula (13), illustrative examples of the cyclic groups include tetrahydrofuran-2-yl, 2-methyltetrahydrofuran-2-yl, tetrahydropyran-2-yl and 2-methyltetrahydropyran-2-yl. Preferred among the groups of formula (13) are ethoxyethyl, butoxyethyl and ethoxypropyl.
In formula (14), R 22 , R 23 and R 24 are independently monovalent hydrocarbon groups, for example, straight, branched or cyclic alkyl groups of 1 to 20 carbon atoms, which may contain a hetero atom such as oxygen, sulfur, nitrogen or fluorine. A pair of R 22 and R 23 , a pair of R 22 and R 24 , or a pair of R 23 and R 24 , taken together, may form a ring.
Examples of the tertiary alkyl group represented by formula (14) include tert-butyl, triethylcarbyl, 1-ethylnorbornyl, 1-methylcyclohexyl, 1-ethylcyclopentyl, 2-(2-methyl)adamantyl, 2-(2-ethyl)adamantyl, and tert-amyl.
Other illustrative examples of the tertiary alkyl group are given below as formulae (15-1) through (15-16).
Herein, each of R 25 and R 26 is a straight, branched or cyclic alkyl group of 1 to 6 carbon atoms, for example, methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, n-pentyl, n-hexyl, cyclopropyl or cyclopropylmethyl. R 27 is hydrogen, a monovalent hydrocarbon group of 1 to 6 carbon atoms which may contain a hetero atom, or a monovalent hydrocarbon group of 1 to 6 carbon atoms, typically alkyl, which may be separated by a hetero atom. The hetero atom is an oxygen, sulfur or nitrogen atom, which is contained or intervenes in the form of —OH, —OR, —O—, —S—, —S(═)—, —NH 2 , —NHR, —NR 2 , —NH—, or —NR— wherein R is an alkyl group of 1 to 20 carbon atoms, and especially 1 to 16 carbon atoms. R 28 is hydrogen or an alkyl, hydroxyalkyl, alkoxy or alkoxyalkyl group of 1 to 20 carbon atoms, especially 1 to 16 carbon atoms, which may be straight, branched or cyclic. Illustrative examples include methyl, hydroxymethyl, ethyl, hydroxyethyl, propyl, isopropyl, n-butyl, sec-butyl, n-pentyl, n-hexyl, methoxy, methoxymethoxy, ethoxy, and tert-butoxy.
Of the acid labile group represented by R 13 , the trialkylsilyl groups whose alkyl groups each have 1 to 6 carbon atoms include trimethylsilyl, triethylsilyl, and tert-butyldimethylsilyl.
The oxoalkyl groups of 4 to 20 carbon atoms include 3-oxocyclohexyl and groups of the following formulae.
Also included are fluorine-containing acid labile groups of the following general formula (16).
Herein, each of R 01 , R 02 , R 03 , and R 04 is a hydrogen atom, a fluorine atom or an unsubstituted or fluorinated, straight, branched or cyclic alkyl group of 1 to 20 carbon atoms.
More illustratively, the groups are shown by the following formulas (16)-1 to (16)-3.
When copolymers comprising units of formula (1) and acid labile group-containing units are prepared by polymerizing the corresponding monomers, there can be added an additional monomer, specifically a monomer having a substituent for improving adhesion, a monomer for improving dry etching resistance, and/or a (meth)acrylate monomer. The adhesion-improving monomer used herein is one containing a hydrophilic substituent such as a phenol, acid anhydride, ester (lactone), carbonate, alcohol, carboxylic acid, carboxylic amide, sulfonic amide or ketone group, for example, monomers of the following formulas (17)-1 to (17)-29.
Herein, each of R 05 , R 06 , R 07 , and R 08 is a hydrogen atom, a fluorine atom or an unsubstituted or fluorinated, straight, branched or cyclic alkyl group of 1 to 20 carbon atoms.
The polymer or high molecular weight compound is generally prepared by mixing a polymerizable monomer corresponding to the units of formula (1) and preferably, a monomer corresponding to the acid labile group-containing units, and an optional monomer corresponding to units of formulas (17)-1 to (17)-29 with a solvent, adding a catalyst thereto, and effecting polymerization reaction while heating or cooling the system if necessary. The polymerization reaction depends on the type of initiator or catalyst, trigger means (including light, heat, radiation and plasma), and polymerization conditions (including temperature, pressure, concentration, solvent, and additives). Commonly used for the polymerization of the monomers are radical polymerization of triggering polymerization with radicals of α,α′-azobisisobutyronitrile (AIBN) or the like, ion (anion) polymerization using catalysts such as alkyl lithium, and ring-opening polymerization using metal catalysts. Such polymerization may be effected in a conventional manner.
The polymer of the invention preferably has a weight average molecular weight of about 1,000 to 1,000,000, and especially about 2,000 to 100,000.
The polymer of the invention is useful in resist compositions, and especially chemical amplification type positive resist compositions.
Resist Composition
A second aspect of the invention is a resist composition comprising the polymer defined above as a base resin, and preferably a chemical amplification positive resist composition comprising (A) the polymer defined above as a base resin, (B) an organic solvent, and (C) a photoacid generator.
In preferred embodiments, the resist composition may further contain (D) a basic compound and/or (E) a dissolution inhibitor.
Component (B)
The organic solvent used as component (B) in the invention may be any organic solvent in which the photoacid generator, base resin (inventive polymer), dissolution inhibitor, and other components are soluble. Illustrative, non-limiting, examples of the organic solvent include ketones such as cyclohexanone and methyl-2-n-amylketone; alcohols such as 3-methoxybutanol, 3-methyl-3-methoxybutanol, 1-methoxy-2-propanol, and 1-ethoxy-2-propanol; ethers such as propylene glycol monomethyl ether, ethylene glycol monomethyl ether, propylene glycol monoethyl ether, ethylene glycol monoethyl ether, propylene glycol dimethyl ether, and diethylene glycol dimethyl ether; and esters such as propylene glycol monomethyl ether acetate, propylene glycol monoethyl ether acetate, ethyl lactate, ethyl pyruvate, butyl acetate, methyl 3-methoxypropionate, ethyl 3-ethoxypropionate, tert-butyl acetate, tert-butyl propionate, and propylene glycol mono-tert-butyl ether acetate.
Also useful are fluorinated organic solvents. Examples include 2-fluoroanisole, 3-fluoroanisole, 4-fluoroanisole, 2,3-difluoroanisole, 2,4-difluoroanisole, 2,5-difluoroanisole, 5,8-difluoro-1,4-benzodioxane, 2,3-difluorobenzyl alcohol, 1,3-difluoro-2-propanol, 2′,4′-difluoropropiophenone, 2,4-difluorotoluene, trifluoro-acetaldehyde ethyl hemiacetal, trifluoroacetamide, trifluoroethanol, 2,2,2-trifluoroethyl butyrate, ethyl heptafluorobutyrate, ethyl heptafluorobutylacetate, ethyl hexafluoroglutarylmethyl, ethyl 3-hydroxy-4,4,4-trifluoro-butyrate, ethyl 2-methyl-4,4,4-trifluoroacetoacetate, ethyl pentafluorobenzoate, ethyl pentafluoropropionate, ethyl pentafluoropropynylacetate, ethyl perfluorooctanoate, ethyl 4,4,4-trifluoroacetoacetate, ethyl 4,4,4-trifluorobutyrate, ethyl 4,4,4-trifluorocrotonate, ethyl trifluorosulfonate, ethyl 3-(trifluoromethyl)butyrate, ethyl trifluoropyruvate, S-ethyl trifluoroacetate, fluorocyclohexane, 2,2,3,3,4,4,4-heptafluoro-1-butanol, 1,1,1,2,2,3,3-heptafluoro-7,7-dimethyl-4,6-octanedione, 1,1,1,3,5,5,5-heptafluoropentane-2,4-dione, 3,3,4,4,5,5,5-heptafluoro-2-pentanol, 3,3,4,4,5,5,5-heptafluoro-2-pentanone, isopropyl 4,4,4-trifluoroacetoacetate, methyl perfluorodecanoate, methyl perfluoro(2-methyl-3-oxahexanoate), methyl perfluoro-nonanoate, methyl perfluorooctanoate, methyl 2,3,3,3-tetrafluoropropionate, methyl trifluoroacetoacetate, 1,1,1,2,2,6,6,6-octafluoro-2,4-hexanedione, 2,2,3,3,4,4,5,5-octafluoro-1-pentanol, 1H,1H,2H,2H-perfluoro-1-decanol, perfluoro-2,5-dimethyl-3,6-dioxane anionic acid methyl ester, 2H-perfluoro-5-methyl-3,6-dioxanonane, 1H,1H,2H,3H,3H-perfluorononane-1,2-diol, 1H,1H,9H-perfluoro-1-nonanol, 1H,1H-perfluorooctanol, 1H,1H,2H,2H-perfluorooctanol, 2H-perfluoro-5,8,11,14-tetramethyl-3,6,9,12,15-pentaoxaoctadecane, perfluorotributylamine, perfluorotrihexylamine, methyl perfluoro-2,5,8-trimethyl-3,6,9-trioxadodecanoate, perfluorotripentylamine, perfluorotripropylamine, 1H,1H,2H,3H,3H-perfluoroundecane-1,2-diol, trifluorobutanol-1,1,1-trifluoro-5-methyl-2,4-hexanedione, 1,1,1-trifluoro-2-propanol, 3,3,3-trifluoro-1-propanol, 1,1,1-trifluoro-2-propyl acetate, perfluoro-butyltetrahydrofuran, perfluoro(butyltetrahydrofuran), perfluorodecalin, perfluoro(1,2-dimethylcyclohexane), perfluoro(1,3-dimethylcyclohexane), propylene glycol trifluoromethyl ether acetate, propylene glycol methyl ether trifluoromethyl acetate, butyl trifluoromethylacetate, methyl 3-trifluoromethoxypropionate, perfluorocyclohexanone, propylene glycol trifluoromethyl ether, butyl trifluoroacetate, and 1,1,1-trifluoro-5,5-dimethyl-2,4-hexanedione. These solvents may be used alone or in combinations of two or more thereof.
Of the above organic solvents, preferred are diethylene glycol dimethyl ether, 1-ethoxy-2-propanol and ethyl lactate, in which the photoacid generator is most soluble, and propylene glycol monomethyl ether acetate which is safe, and mixtures thereof.
Component (C)
Suitable examples of the photoacid generator (C) include onium salts of general formula (18) below, diazomethane derivatives of formula (19), glyoxime derivatives of formula (20), β-ketosulfone derivatives, disulfone derivatives, nitrobenzylsulfonate derivatives, sulfonic acid ester derivatives, and imidoyl sulfonate derivatives.
(R 30 ) b M + K − (18)
In the formula, R 30 is a straight, branched or cyclic alkyl of 1 to 12 carbon atoms, an aryl of 6 to 12 carbon atoms, or an aralkyl of 7 to 12 carbon atoms; M + is iodonium or sulfonium; K − is a non-nucleophilic counter-ion; and the letter b is 2 or 3.
Illustrative examples of alkyl groups represented by R 30 include methyl, ethyl, propyl, butyl, cyclohexyl, 2-oxocyclohexyl, norbornyl, and adamantyl. Exemplary aryl groups include phenyl; alkoxyphenyl groups such as p-methoxyphenyl, m-methoxyphenyl, o-methoxyphenyl, ethoxy-phenyl, p-tert-butoxyphenyl, and m-tert-butoxyphenyl; and alkylphenyl groups such as 2-methylphenyl, 3-methylphenyl, 4-methylphenyl, ethylphenyl, 4-tert-butylphenyl, 4-butyl-phenyl, and dimethylphenyl. Exemplary aralkyl groups include benzyl and phenethyl. Examples of the non-nucleophilic nucleophilic counter-ion represented by K − include halide ions such as chloride and bromide; fluoroalkylsulfonate ions such as triflate, 1,1,1-trifluoroethanesulfonate, and nonafluorobutanesulfonate; arylsulfonate ions such as tosylate, benzenesulfonate, 4-fluorobenzenesulfonate, and 1,2,3,4,5-pentafluorobenzenesulfonate; and alkylsulfonate ions such as mesylate and butanesulfonate.
In the formula, R 31 and R 32 are straight, branched or cyclic alkyl or halogenated alkyl groups of 1 to 12 carbon atoms, aryl or halogenated aryl groups of 6 to 12 carbon atoms, or aralkyl groups of 7 to 12 carbon atoms.
Illustrative examples of alkyl groups represented by R 31 and R 32 include methyl, ethyl, propyl, butyl, amyl, cyclopentyl, cyclohexyl, norbornyl, and adamantyl. Exemplary halogenated alkyl groups include trifluoromethyl, 1,1,1-trifluoroethyl, 1,1,1-trichloroethyl, and nonafluoro-butyl. Exemplary aryl groups include phenyl; alkoxyphenyl groups such as p-methoxyphenyl, m-methoxyphenyl, o-methoxy-phenyl, ethoxyphenyl, p-tert-butoxyphenyl, and m-tert-butoxyphenyl; and alkylphenyl groups such as 2-methylphenyl, 3-methylphenyl, 4-methylphenyl, ethylphenyl, 4-tert-butylphenyl, 4-butylphenyl, and dimethylphenyl. Exemplary halogenated aryl groups include fluorobenzene, chlorobenzene, and 1,2,3,4,5-pentafluorobenzene. Exemplary aralkyl groups include benzyl and phenethyl.
In the formula, R 33 , R 34 , and R 35 are straight, branched or cyclic alkyl or halogenated alkyl groups of 1 to 12 carbon atoms, aryl or halogenated aryl groups of 6 to 12 carbon atoms, or aralkyl groups of 7 to 12 carbon atoms. R 34 and R 35 may together form a cyclic structure with the proviso that if they form a cyclic structure, each is a straight or branched alkylene group of 1 to 6 carbon atoms.
The alkyl, halogenated alkyl, aryl, halogenated aryl, and aralkyl groups represented by R 33 , R 34 , and R 35 are exemplified by the same groups as mentioned above for R 31 and R 32 . Examples of alkylene groups represented by R 34 and R 35 include methylene, ethylene, propylene, butylene, and hexylene.
Illustrative examples of the photoacid generator include:
onium salts such as diphenyliodonium trifluoro-methanesulfonate, (p-tert-butoxyphenyl)phenyliodonium trifluoromethanesulfonate, diphenyliodonium p-toluene-sulfonate, (p-tert-butoxyphenyl)phenyliodonium p-toluene-sulfonate, triphenylsulfonium trifluoromethanesulfonate, (p-tert-butoxyphenyl)diphenylsulfonium trifluoromethane-sulfonate, bis(p-tert-butoxyphenyl)phenylsulfonium trifluoromethanesulfonate, tris(p-tert-butoxyphenyl)-sulfonium trifluoromethanesulfonate, triphenylsulfonium p-toluenesulfonate, (p-tert-butoxyphenyl)diphenylsulfonium p-toluenesulfonate, bis(p-tert-butoxyphenyl)phenylsulfonium p-toluenesulfonate, tris(p-tert-butoxyphenyl)sulfonium p-toluenesulfonate, triphenylsulfonium nonafluorobutane-sulfonate, triphenylsulfonium butanesulfonate, trimethyl-sulfonium trifluoromethanesulfonate, trimethylsulfonium p-toluenesulfonate, cyclohexylmethyl(2-oxocyclohexyl)sulfonium trifluoromethanesulfonate, cyclohexylmethyl(2-oxocyclohexyl)sulfonium p-toluenesulfonate, dimethylphenyl-sulfonium trifluoromethanesulfonate, dimethylphenylsulfonium p-toluenesulfonate, dicyclohexylphenylsulfonium trifluoromethanesulfonate, and dicyclohexylphenylsulfonium p-toluenesulfonate;
diazomethane derivatives such as bis(benzenesulfonyl)-diazomethane, bis(p-toluenesulfonyl)diazomethane, bis(xylenesulfonyl)diazomethane, bis(cyclohexylsulfonyl)-diazomethane, bis(cyclopentylsulfonyl)diazomethane, bis(n-butylsulfonyl)diazomethane, bis(isobutylsulfonyl)-diazomethane, bis(sec-butylsulfonyl)diazomethane, bis(n-propylsulfonyl)diazomethane, bis(isopropylsulfonyl)-diazomethane, bis(tert-butylsulfonyl)diazomethane, bis(n-amylsulfonyl)diazomethane, bis(isoamylsulfonyl)diazomethane, bis(sec-amylsulfonyl)diazomethane, bis(tert-amylsulfonyl)-diazomethane, 1-cyclohexylsulfonyl-1-(tert-butylsulfonyl)-diazomethane, 1-cyclohexylsulfonyl-1-(tert-amylsulfonyl)-diazomethane, and 1-tert-amylsulfonyl-1-(tert-butylsulfonyl)diazomethane;
glyoxime derivatives such as bis-o-(p-toluene-sulfonyl)-α-dimethylglyoxime, bis-o-(p-toluenesulfonyl)-α-diphenylglyoxime, bis-o-(p-toluenesulfonyl)-α-dicyclohexyl-glyoxime, bis-o-(p-toluenesulfonyl)-2,3-pentanedioneglyoxime, bis-o-(p-toluenesulfonyl)-2-methyl-3,4-pentanedioneglyoxime, bis-o-(n-butanesulfonyl)-α-dimethylglyoxime, bis-o-(n-butanesulfonyl)-α-diphenylgyoxime, bis-o-(n-butanesulfonyl)-α-dicyclohexylglyoxime, bis-o-(n-butane-sulfonyl)-2,3-pentanedioneglyoxime, bis-o-(n-butane-sulfonyl)-2-methyl-3,4-pentanedioneglyoxime, bis-o-(methanesulfonyl)-α-dimethylglyoxime, bis-o-(trifluoro-methanesulfonyl)-α-dimethylglyoxime, bis-o-(1,1,1-trifluoro-ethanesulfonyl)-α-dimethylglyoxime, bis-o-(tert-butanesulfonyl)-α-dimethylglyoxime, bis-o-(perfluoro-octanesulfonyl)-α-dimethylglyoxime, bis-o-(cyclohexane-sulfonyl)-α-dimethylglyoxime, bis-o-(benzenesulfonyl)-α-dimethylglyoxime, bis-o-(p-fluorobenzenesulfonyl)-α-dimethylglyoxime, bis-o-(p-tert-butylbenzenesulfonyl)-α-dimethylglyoxime, bis-o-(xylenesulfonyl)-α-dimethylglyoxime, and bis-o-(camphorsulfonyl)-α-dimethylglyoxime;
β-ketosulfone derivatives such as 2-cyclohexyl-carbonyl-2-(p-toluenesulfonyl)propane and 2-isopropyl-carbonyl-2-(p-toluenesulfonyl)propane;
disulfone derivatives such as diphenyl disulfone and dicyclohexyl disulfone;
nitrobenzyl sulfonate derivatives such as 2,6-dinitrobenzyl p-toluenesulfonate and 2,4-dinitrobenzyl p-toluenesulfonate;
sulfonic acid ester derivatives such as 1,2,3-tris(methanesulfonyloxy)benzene, 1,2,3-tris(trifluoro-methanesulfonyloxy)benzene, and 1,2,3-tris(p-toluene-sulfonyloxy)benzene; and
imidoyl sulfonate derivatives such as phthalimidoyl triflate, phthalimidoyl tosylate, 5-norbornene-2,3-dicarboxyimidoyl triflate, 5-norbornene-2,3-dicarboxyimidoyl tosylate, and 5-norbornene-2,3-dicarboxyimidoyl n-butylsulfonate.
Preferred among these photoacid generators are onium salts such as triphenylsulfonium trifluoromethanesulfonate, (p-tert-butoxyphenyl)diphenylsulfonium trifluoromethane-sulfonate, tris(p-tert-butoxyphenyl)sulfonium trifluoro-methanesulfonate, triphenylsulfonium p-toluenesulfonate, (p-tert-butoxyphenyl)diphenylsulfonium p-toluenesulfonate, and tris(p-tert-butoxyphenyl)sulfonium p-toluenesulfonate; diazomethane derivatives such as bis(benzenesulfonyl)-diazomethane, bis(p-toluenesulfonyl)diazomethane, bis(cyclohexylsulfonyl)diazomethane, bis(n-butylsulfonyl)-diazomethane, bis(isobutylsulfonyl)diazomethane, bis(sec-butylsulfonyl)diazomethane, bis(n-propylsulfonyl)-diazomethane, bis(isopropylsulfonyl)diazomethane, and bis(tert-butylsulfonyl)diazomethane; and glyoxime derivatives such as bis-o-(p-toluenesulfonyl)-α-dimethyl-glyoxime and bis-o-(n-butanesulfonyl)-α-dimethylglyoxime. These photoacid generators may be used singly or in combinations of two or more thereof. Onium salts are effective for improving rectangularity, while diazomethane derivatives and glyoxime derivatives are effective for reducing standing waves. The combination of an onium salt with a diazomethane or a glyoxime derivative allows for fine adjustment of the profile.
The photoacid generator is preferably added in an amount of about 0.2 to 15 parts by weight, and especially about 0.5 to 8 parts by weight, per 100 parts by weight of the base resin. At less than 0.2 part, the amount of acid generated during exposure would be too small and the sensitivity and resolution be poor, whereas the addition of more than 15 parts would lower the transmittance of the resist and result in a poor resolution.
Component (D)
The basic compound used as component (D) is preferably a compound capable of suppressing the rate of diffusion when the acid generated by the photoacid generator diffuses within the resist film. The inclusion of this type of basic compound holds down the rate of acid diffusion within the resist film, resulting in better resolution. In addition, it suppresses changes in sensitivity following exposure, thus reducing substrate and environment dependence, as well as improving the exposure latitude and the pattern profile. See JP-A 5-232706, 5-249683, 5-158239, 5-249662, 5-257282, 5-289322, and 5-289340.
Examples of suitable basic compounds include primary, secondary, and tertiary aliphatic amines, mixed amines, aromatic amines, heterocyclic amines, carboxyl group-bearing nitrogenous compounds, sulfonyl group-bearing nitrogenous compounds, hydroxyl group-bearing nitrogenous compounds, hydroxyphenyl group-bearing nitrogenous compounds, alcoholic nitrogenous compounds, amide derivatives, and imide derivatives. Of these, aliphatic amines are especially preferred.
Examples of suitable primary aliphatic amines include ammonia, methylamine, ethylamine, n-propylamine, isopropyl-amine, n-butylamine, iso-butylamine, sec-butylamine, tert-butylamine, pentylamine, tert-amylamine, cyclopentylamine, hexylamine, cyclohexylamine, heptylamine, octylamine, nonylamine, decylamine, dodecylamine, cetylamine, methylene-diamine, ethylenediamine, and tetraethylenepentamine. Examples of suitable secondary aliphatic amines include dimethylamine, diethylamine, di-n-propylamine, di-iso-propylamine, di-n-butylamine, di-iso-butylamine, di-sec-butylamine, dipentylamine, dicyclopentylamine, dihexylamine, dicyclohexylamine, diheptylamine, dioctylamine, dinonylamine, didecylamine, didodecylamine, dicetylamine, N,N-dimethylmethylenediamine, N,N-dimethylethylenediamine, and N,N-dimethyltetraethylenepentamine. Examples of suitable tertiary aliphatic amines include trimethylamine, triethylamine, tri-n-propylamine, tri-iso-propylamine, tri-n-butylamine, tri-iso-butylamine, tri-sec-butylamine, tripentylamine, tricyclopentylamine, trihexylamine, tricyclohexylamine, triheptylamine, trioctylamine, trinonylamine, tridecylamine, tridodecylamine, tricetylamine, N,N,N′,N′-tetramethylmethylenediamine, N,N,N′,N′-tetramethylethylenediamine, and N,N,N′,N′-tetramethyl-tetraethylenepentamine.
Examples of suitable mixed amines include dimethyl-ethylamine, methylethylpropylamine, benzylamine, phenethyl-amine, and benzyldimethylamine. Examples of suitable aromatic and heterocyclic amines include aniline derivatives (e.g., aniline, N-methylaniline, N-ethylaniline, N-propylaniline, N,N-dimethylaniline, 2-methylaniline, 3-methylaniline, 4-methylaniline, ethylaniline, propylaniline, trimethylaniline, 2-nitroaniline, 3-nitroaniline, 4-nitroaniline, 2,4-dinitroaniline, 2,6-dinitroaniline, 3,5-dinitroaniline, and N,N-dimethyltoluidine), diphenyl(p-tolyl)amine, methyldiphenylamine, triphenylamine, phenylenediamine, naphthylamine, diaminonaphthalene, pyrrole derivatives (e.g., pyrrole, 2H-pyrrole, 1-methylpyrrole, 2,4-dimethylpyrrole, 2,5-dimethylpyrrole, and N-methylpyrrole), oxazole derivatives (e.g., oxazole and isooxazole), thiazole derivatives (e.g., thiazole and isothiazole), imidazole derivatives (e.g., imidazole, 4-methylimidazole, and 4-methyl-2-phenylimidazole), pyrazole derivatives, furazan derivatives, pyrroline derivatives (e.g., pyrroline and 2-methyl-1-pyrroline), pyrrolidine derivatives (e.g., pyrrolidine, N-methylpyrrolidine, pyrrolidinone, and N-methylpyrrolidone), imidazoline derivatives, imidazolidine derivatives, pyridine derivatives (e.g., pyridine, methylpyridine, ethylpyridine, propylpyridine, butylpyridine, 4-(1-butylpentyl)pyridine, dimethylpyridine, trimethylpyridine, triethylpyridine, phenylpyridine, 3-methyl-2-phenylpyridine, 4-tert-butylpyridine, diphenylpyridine, benzylpyridine, methoxypyridine, butoxypyridine, dimethoxypyridine, 1-methyl-2-pyridine, 4-pyrrolidinopyridine, 1-methyl-4-phenylpyridine, 2-(1-ethylpropyl)pyridine, aminopyridine, and dimethylaminopyridine), pyridazine derivatives, pyrimidine derivatives, pyrazine derivatives, pyrazoline derivatives, pyrazolidine derivatives, piperidine derivatives, piperazine derivatives, morpholine derivatives, indole derivatives, isoindole derivatives, 1H-indazole derivatives, indoline derivatives, quinoline derivatives (e.g., quinoline and 3-quinolinecarbonitrile), isoquinoline derivatives, cinnoline derivatives, quinazoline derivatives, quinoxaline derivatives, phthalazine derivatives, purine derivatives, pteridine derivatives, carbazole derivatives, phenanthridine derivatives, acridine derivatives, phenazine derivatives, 1,10-phenanthroline derivatives, adenine derivatives, adenosine derivatives, guanine derivatives, guanosine derivatives, uracil derivatives, and uridine derivatives.
Examples of suitable carboxyl group-bearing nitrogenous compounds include aminobenzoic acid, indolecarboxylic acid, and amino acid derivatives (e.g. nicotinic acid, alanine, alginine, aspartic acid, glutamic acid, glycine, histidine, isoleucine, glycylleucine, leucine, methionine, phenylalanine, threonine, lysine, 3-aminopyrazine-2-carboxylic acid, and methoxyalanine). Examples of suitable sulfonyl group-bearing nitrogenous compounds include 3-pyridinesulfonic acid and pyridinium p-toluenesulfonate. Examples of suitable hydroxyl group-bearing nitrogenous compounds, hydroxyphenyl group-bearing nitrogenous compounds, and alcoholic nitrogenous compounds include 2-hydroxypyridine, aminocresol, 2,4-quinolinediol, 3-indolemethanol hydrate, monoethanolamine, diethanolamine, triethanolamine, N-ethyldiethanolamine, N,N-diethyl-ethanolamine, triisopropanolamine, 2,2′-iminodiethanol, 2-aminoethanol, 3-amino-1-propanol, 4-amino-l-butanol, 4-(2-hydroxyethyl)morpholine, 2-(2-hydroxyethyl)pyridine, 1-(2-hydroxyethyl)piperazine, 1-[2-(2-hydroxyethoxy)ethyl]-piperazine, piperidine ethanol, 1-(2-hydroxyethyl)-pyrrolidine, 1-(2-hydroxyethyl)-2-pyrrolidinone, 3-piperidino-1,2-propanediol, 3-pyrrolidino-1,2-propanediol, 8-hydroxyjulolidine, 3-quinuclidinol, 3-tropanol, 1-methyl-2-pyrrolidine ethanol, 1-aziridine ethanol, N-(2-hydroxyethyl)phthalimide, and N-(2-hydroxyethyl)-isonicotinamide. Examples of suitable amide derivatives include formamide, N-methylformamide, N,N-dimethylformamide, acetamide, N-methylacetamide, N,N-dimethylacetamide, propionamide, and benzamide. Suitable imide derivatives include phthalimide, succinimide, and maleimide.
In addition, basic compounds of the following general formulas (21) and (22) may also be included.
In the formulas, R 41 , R 42 R 43 R 47 and R 48 are independently straight, branched or cyclic alkylenes of 1 to 20 carbon atoms; R 44 , R 45 , R 46 , R 49 and R 50 are hydrogen, alkyls of 1 to 20 carbon atoms, or amino; R 44 and R 45 , R 45 and R 46 , R 44 and R 46 , R 44 with R 45 and R 46 , and R 49 and R 50 may bond together to form rings; and S, T and U are each integers from 0 to 20, with the proviso that hydrogen is excluded from R 44 , R 45 , R 46 , R 49 and R 50 when S, T and U are equal to 0.
The alkylene groups represented by R 41 , R 42 , R 43 , R 47 and R 48 preferably have 1 to 20 carbon atoms, more preferably 1 to 10 carbon atoms, and most preferably 1 to 8 carbon atoms. Examples include methylene, ethylene, n-propylene, isopropylene, n-butylene, isobutylene, n-pentylene, isopentylene, hexylene, nonylene, decylene, cyclopentylene, and cyclohexylene.
The alkyl groups represented by R 44 , R 45 , R 46 , R 49 and R 50 preferably have 1 to 20 carbon atoms, more preferably 1 to 8 carbon atoms, and most preferably 1 to 6 carbon atoms, and may be straight, branched or cyclic. Examples include methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, isopentyl, hexyl, nonyl, decyl, dodecyl, tridecyl, cyclopentyl, and cyclohexyl.
Where R 44 and R 45 , R 45 and R 46 , R 44 and R 46 , R 44 with R 45 and R 46 , and R 49 and R 50 form rings, the rings preferably have 1 to 20 carbon atoms, more preferably 1 to 8 carbon atoms, and most preferably 1 to 6 carbon atoms, and may have branching alkyl groups of 1 to 6 carbon atoms, and especially 1 to 4 carbon atoms.
S, T, and U are each integers from 0 to 20, preferably from 1 to 10, and more preferably from 1 to 8.
Illustrative examples of the compounds of formulas (21) and (22) include tris{2-(methoxymethoxy)ethyl}amine, tris{2-(methoxyethoxy)ethyl}amine, tris[2-{(2-methoxy-ethoxy)methoxy}ethyl]amine, tris{2-(2-methoxyethoxy)-ethyl}amine, tris{2-(1-methoxyethoxy)ethyl}amine, tris{2-(1-ethoxyethoxy)ethyl}amine, tris{2-(1-ethoxypropoxy)-ethyl}amine, tris[2-{(2-hydroxyethoxy)ethoxy}ethyl]amine, 4,7,13,16,21,24-hexaoxa-1,10-diazabicyclo[8.8.8]hexacosane, 4,7,13,18-tetraoxa-1,10-diazabicyclo[8.5.5]eicosane, 1,4,10,13-tetraoxa-7,16-diazabicyclooctadecane, 1-aza-12-crown-4, 1-aza-15-crown-5, and 1-aza-18-crown-6. Especially preferred basic compounds are tertiary amines, aniline derivatives, pyrrolidine derivatives, pyridine derivatives, quinoline derivatives, amino acid derivatives, hydroxyl group-bearing nitrogenous compounds, hydroxyphenyl group-bearing nitrogenous compounds, alcoholic nitrogenous compounds, amide derivatives, imide derivatives, tris{2-(methoxymethoxy)ethyl}amine, tris{2-(2-methoxyethoxy)-ethyl}amine, tris[2-{(2-methoxyethoxy)methyl}ethyl]amine, and 1-aza-15-crown-5.
The above-described basic compound may be used singly or in combinations of two or more thereof, and is preferably formulated in an amount of about 0.01 to 2 parts, and especially about 0.01 to 1 part by weight, per 100 parts by weight of the base resin. At less than 0.01 part, the desired effects of the basic compound would not be apparent, while the use of more than 2 parts would result in too low a sensitivity.
Component (E)
The dissolution inhibitor (E) is a compound with a molecular weight of up to 3,000 which changes its solubility in an alkaline developer under the action of an acid. Typically, a compound obtained by partially or entirely substituting acid labile substituents on a phenol or carboxylic acid derivative having a molecular weight of up to 2,500 is added as the dissolution inhibitor.
Examples of the phenol or carboxylic acid derivative having a molecular weight of up to 2,500 include 4,4′-(1-methylethylidene)bisphenol, (1,1′-biphenyl-4,4′-diol)-2,2′-methylenebis(4-methylphenol), 4,4-bis(4′-hydroxyphenyl)-valeric acid, tris(4-hydroxyphenyl)methane, 1,1,1-tris(4′-hydroxyphenyl)ethane, 1,1,2-tris(4′-hydroxyphenyl)ethane, phenolphthalein, thimolphthalein, 3,3′-difluoro[(1,1′-biphenyl)-4,4′-diol], 3,3′,5,5′-tetrafluoro[(1,1′-biphenyl)-4,4′-diol], 4,4′-[2,2,2-trifluoro-1-(trifluoromethyl)ethylidene]bisphenol, 4,4′-methylenebis(2-fluorophenol), 2,2′-methylenebis(4-fluorophenol), 4,4′-isopropylidenebis(2-fluorophenol), cyclohexylidenebis(2-fluorophenol), 4,4′-[(4-fluorophenyl)methylene]bis(2-fluorophenol), 4,4′-methylenebis(2,6-difluorophenol), 4,4′-(4-fluorophenyl)methylenebis(2,6-difluorophenol), 2,6-bis[(2-hydroxy-5-fluorophenyl)methyl]-4-fluorophenol, 2,6-bis[(4-hydroxy-3-fluorophenyl)methyl]-4-fluorophenol, and 2,4-bis[(3-hydroxy-4-hydroxyphenyl)methyl]-6-methylphenol. The acid labile substituents are the same as illustrated above for R 13 .
Illustrative, non-limiting, examples of the dissolution inhibitors which are useful herein include 3,3′,5,5′-tetrafluoro[(1,1′-biphenyl)-4,4′-di-t-butoxy-carbonyl], 4,4′-[2,2,2-trifluoro-1-(trifluoromethyl)-ethylidene]bisphenol-4,4′-di-t-butoxycarbonyl, bis(4-(2′-tetrahydropyranyloxy)phenyl)methane, bis(4-(2′-tetrahydro-furanyloxy)phenyl)methane, bis(4-tert-butoxyphenyl)methane, bis(4-tert-butoxycarbonyloxyphenyl)methane, bis(4-tert-butoxycarbonylmethyloxyphenyl)methane, bis(4-(1′-ethoxy-ethoxy)phenyl)methane, bis(4-(1′-ethoxypropyloxy)phenyl)-methane, 2,2-bis(4′-(2″-tetrahydropyranyloxy))propane, 2,2-bis(4′-(2″-tetrahydrofuranyloxy)phenyl)propan 2,2-bis(4′-tert-butoxyphenyl)propane, 2,2-bis(4′-tert-butoxy-carbonyloxyphenyl)propane, 2,2-bis(4-tert-butoxycarbonyl-methyloxyphenyl)propane, 2,2-bis(4′-(1″-ethoxyethoxy)-phenyl)propane, 2,2-bis(4′-(1″-ethoxypropyloxy)phenyl)-propane, tert-butyl 4,4-bis(4′-(2″-tetrahydropyranyloxy)-phenyl)valerate, tert-butyl 4,4-bis(4′-(2″-tetrahydro-furanyloxy)phenyl)valerate, tert-butyl 4,4-bis(4′-tert-butoxyphenyl)valerate, tert-butyl 4,4-bis(4-tert-butoxycarbonyloxyphenyl)valerate, tert-butyl 4,4-bis(4′-tert-butoxycarbonylmethyloxyphenyl)valerate, tert-butyl 4,4-bis(4′-(1″-ethoxyethoxy)phenyl)valerate, tert-butyl 4,4-bis(4′-(1″-ethoxypropyloxy)phenyl)valerate, tris(4-(2′-tetrahydropyranyloxy)phenyl)methane, tris(4-(2′-tetrahydrofuranyloxy)phenyl)methane, tris(4-tert-butoxy-phenyl)methane, tris(4-tert-butoxycarbonyloxyphenyl)methane, tris(4-tert-butoxycarbonyloxymethylphenyl)methane, tris(4-(1′-ethoxyethoxy)phenyl)methane, tris(4-(1′-ethoxypropyloxy)phenyl)methane, 1,1,2-tris(4′-(2″-tetrahydropyranyloxy)phenyl)ethane, 1,1,2-tris(4′-(2″-tetrahydrofuranyloxy)phenyl)ethane, 1,1,2-tris(4′-tert-butoxyphenyl)ethane, 1,1,2-tris(4′-tert-butoxycarbonyloxy-phenyl)ethane, 1,1,2-tris(4′-tert-butoxycarbonylmethyloxy-phenyl)ethane, 1,1,2-tris(4′-(1′-ethoxyethoxy)phenyl)ethane, 1,1,2-tris(4′-(1′-ethoxypropyloxy)phenyl)ethane, t-butyl 2-trifluoromethylbenzenecarboxylate, t-butyl 2-trifluoromethylcyclohexanecarboxylate, t-butyl decahydro-naphthalene-2,6-dicarboxylate, t-butyl cholate, t-butyl deoxycholate, t-butyl adamantanecarboxylate, t-butyl adamantaneacetate, and tetra-t-butyl 1,1′-bicyclohexyl-3,3′,4,4′-tetracarboxylate.
In the resist composition according to the invention, an appropriate amount of the dissolution inhibitor (E) is up to about 20 parts, and especially up to about 15 parts by weight per 100 parts by weight of the base resin in the composition. With more than 20 parts of the dissolution inhibitor, the resist composition becomes less heat resistant because of an increased content of monomer components.
The resist composition of the invention may include, as an optional ingredient, a surfactant which is commonly used for improving the coating characteristics. Optional ingredients may be added in conventional amounts so long as this does not compromise the objects of the invention.
A nonionic surfactant is preferred, examples of which include perfluoroalkyl polyoxyethylene ethanols, fluorinated alkyl esters, perfluoroalkylamine oxides, and fluorinated organosiloxane compounds. Illustrative examples include Florade FC-430 and FC-431 from Sumitomo 3M Ltd., Surflon S-141, S-145, S-381 and S-383 from Asahi Glass Co., Ltd., Unidyne DS-401, DS-403, and DS-451 from Daikin Industries Ltd., Megaface F-8151, F-171, F-172, F-173 and F-177 from Dainippon Ink & Chemicals, Inc., and X-70-092 and X-70-093 from Shin-Etsu Chemical Co., Ltd. Preferred surfactants include Florade FC-430 from Sumitomo 3M Ltd. and X-70-093 from Shin-Etsu Chemical Co., Ltd.
Pattern formation using the resist composition of the invention may be carried out by a known lithographic technique. For example, the resist composition may be applied onto a substrate such as a silicon wafer by spin coating or the like to form a resist film having a thickness of 0.1 to 1.0 μm, which is then pre-baked on a hot plate at 60 to 200° C. for 10 seconds to 10 minutes, and preferably at 80 to 150° C. for ½ to 5 minutes. A patterning mask having the desired pattern may then be placed over the resist film, and the film exposed through the mask to an electron beam or to high-energy radiation such as deep-UV rays having a wavelength below 300 nm, an excimer laser, or x-rays in a dose of about 1 to 200 mJ/cm 2 , and preferably about 10 to 100 mJ/cm 2 , then post-exposure baked (PEB) on a hot plate at 60 to 150° C. for 10 seconds to 5 minutes, and preferably at 80 to 130° C. for ½ to 3 minutes. Finally, development may be carried out using as the developer an aqueous alkali solution, such as 0.1 to 5%, and preferably 2 to 3%, tetramethylammonium hydroxide (TMAH), this being done by a conventional method such as dipping, puddling, or spraying for a period of 10 seconds to 3 minutes, and preferably 30 seconds to 2 minutes. These steps result in the formation of the desired pattern on the substrate. Of the various types of high-energy radiation that may be used, the resist composition of the invention is best suited to micro-pattern formation with, in particular, deep-UV rays having a wavelength of 254 to 120 nm, an excimer laser, especially ArF excimer laser (193 nm), F 2 excimer laser (157 nm), Kr 2 excimer laser (146 nm), KrAr excimer laser (134 nm) or Ar 2 excimer laser (126 nm), x-rays, or an electron beam. The desired pattern may not be obtainable outside the upper and lower limits of the above range.
The resist composition comprising the polymer of the invention is sensitive to high-energy radiation, has excellent sensitivity and resolution at a wavelength of less than 200 nm, especially less than 170 nm, and excellent plasma etching resistance. Because these features of the inventive resist composition enable its use particularly as a resist having a low absorption at the exposure wavelength of a F 2 excimer laser, a finely defined pattern having sidewalls perpendicular to the substrate can easily be formed, making the resist ideal as a micropatterning material in VLSI fabrication.
EXAMPLE
Examples of the invention are given below by way of illustration and not by way of limitation. The abbreviations used herein are AIBN for α,α′-azobisisobutyronitrile, GPC for gel permeation chromatography, NMR for nuclear magnetic resonance, Mw for weight average molecular weight, and Mn for number average molecular weight.
Synthesis Example 1
Synthesis of 2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate
A 500-ml three-necked flask was charged with 62.0 g of cyclopentadiene resulting from pyrolysis of dicyclopentadiene. While the flask was placed in a water bath to keep the reaction temperature below 25° C., 125.6 g of 2,2,2-trifluoroethyl acrylate was added dropwise. The water bath was removed at the end of dropwise addition, and stirring was continued overnight. The resulting oily substance was distilled in vacuum, collecting 147.2 g of 2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate. The yield was 82.0%.
Synthesis Example 2
Synthesis of 1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate
In a 1-liter four-necked flask, 75.3 g of 1-ethylcyclopentanol was dissolved in 300 g of methylene chloride. While the flask was placed in an ice bath, 65.7 g of acrylic chloride and a spoonful of dimethylaminopyridine were admitted into the flask. While the reaction temperature was kept below 15° C., 113.4 g of triethylamine was added dropwise. The ice bath was removed at the end of dropwise addition, and stirring was continued for 3 hours, followed by ordinary post-treatment. The resulting oily substance was distilled in vacuum, collecting 86.8 g of 1-ethylcyclopentyl acrylate. The yield was 78.2%.
Using 85.0 g of 1-ethylcyclopentyl acrylate, reaction was carried out as in Synthesis Example 1. There was obtained 89.2 g of 1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate. The yield was 75.3%.
Synthesis Example 3
Synthesis of Monomer 1
A 1-liter three-necked flask was charged with 22.5 g of sodium hydride, and 350 g of dimethylformamide was admitted thereto. While the flask was placed in an ice bath to keep the reaction temperature below 0° C., 75.7 g of maleimide was added dropwise. The ice bath was removed at the end of dropwise addition, and the reaction solution was ripened for 2 hours. While the flask was placed in a water bath to keep the reaction temperature below 15° C., 123.3 g of tert-butyl chloroacetate was added dropwise. The water bath was removed at the end of dropwise addition, and stirring was continued for 3 hours, followed by ordinary post-treatment. The resulting oily substance was distilled in vacuum, collecting 134.2 g of Monomer 1 shown below. The yield was 81.5%.
Synthesis Example 4
Ternary Copolymerization Reaction of 2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate, 1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate, and Maleic Anhydride
A 1-liter flask was charged with 75 g of 2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate, 80 g of 1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate, 67 g of maleic anhydride and 43 g of dioxane as a solvent. The reactor was cooled to −70° C. in a nitrogen atmosphere, following which vacuum evacuation and nitrogen flow were repeated three times. The flask was warmed up to room temperature whereupon 9.0 g of an initiator AIBN was added. The flask was heated at 60° C., at which reaction was effected for 15 hours. The reaction solution was poured into 10 liters of isopropyl alcohol whereupon a white solid precipitated. The solid was collected by filtration and dried in vacuum at 60° C., obtaining 173.8 g of a white polymer.
The polymer was analyzed by 13 C-NMR, 1 H-NMR and GPC, with the following analytical results.
Copolymer Composition
2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate:1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate:maleic anhydride =25:25:50
Mw =8,700 Molecular weight dispersity (Mw/Mn) =1.63
Synthesis Example 5
Ternary Copolymerization Reaction of 2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate, 1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate, and N-methylmaleimide
A 1-liter flask was charged with 77 g of 2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate, 85 g of 1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate, 70 g of N-methylmaleimide and 43 g of dioxane as a solvent. The reactor was cooled to −70° C. in a nitrogen atmosphere, following which vacuum evacuation and nitrogen flow were repeated three times. The flask was warmed up to room temperature whereupon 8.4 g of an initiator AIBN was added. The flask was heated at 60° C., at which reaction was effected for 15 hours. The reaction solution was poured into 10 liters of isopropyl alcohol whereupon a white solid precipitated. The solid was collected by filtration and dried in vacuum at 60° C., obtaining 160.8 g of a white polymer.
The polymer was analyzed by 13 C-NMR, 1 H-NMR and GPC, with the following analytical results.
Copolymer Composition
2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate:1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate:N-methylmaleimide=25:25:50
Mw =8,400 Molecular weight dispersity (Mw/Mn)=1.59
Synthesis Example 6
Binary Copolymerization Reaction of 2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate and Monomer 1
A 1-liter flask was charged with 135.5 g of 2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate, 130.0 g of Monomer 1, and 74 g of dioxane as a solvent. The reactor was cooled to −70° C. in a nitrogen atmosphere, following which vacuum evacuation and nitrogen flow were repeated three times. The flask was warmed up to room temperature whereupon 8.1 g of an initiator AIBN was added. The flask was heated at 60° C., at which reaction was effected for 15 hours. The reaction solution was poured into 10 liters of isopropyl alcohol whereupon a white solid precipitated. The solid was collected by filtration and dried in vacuum at 60° C., obtaining 217.7 g of a white polymer.
The polymer was analyzed by 13 C-NMR, 1 H-NMR and GPC, with the following analytical results.
Copolymer Composition
2,2,2-trifluoroethyl bicyclo[2.2.1]hept-5-ene-2-carboxylate:Monomer 1=50:50
Mw =9,200 Molecular weight dispersity (Mw/Mn) =1.53
Comparative Synthesis Example 1
Binary Copolymerization Reaction of 1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate and N-methylmaleimide
In a 500-ml flask, 25 g of 1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate and 22 g of N-methylmaleimide were dissolved in 120 ml of toluene. Oxygen was thoroughly removed from the system, following which 0.66 g of an initiator AIBN was added. The flask was heated at 60° C., at which polymerization reaction was effected for 24 hours. For purifying the resulting polymer, the reaction solution was poured into methanol whereupon the polymer precipitated. The procedure of dissolving the collected polymer in acetone and pouring into 5 liters of methanol for precipitation was repeated twice. The polymer was separated and dried, which is designated Comparative Polymer 1.
Copolymer Composition
1-ethylcyclopentyl bicyclo[2.2.1]hept-5-ene-2-carboxylate:N-methylmaleimide=50:50
Mw=9,700 Molecular weight dispersity (Mw/Mn) =1.63
Comparative Synthesis Example 2
Binary Copolymerization Reaction of Ethyladamantane Methacrylate and γ-Butyrolactone Methacrylate
In a 500-ml flask, 20 g of ethyladamantane methacrylate and 16 g of γ-butyrolactone methacrylate were dissolved in 120 ml of toluene. Oxygen was thoroughly removed from the system, following which 0.66 g of an initiator AIBN was added. The flask was heated at 60° C., at which polymerization reaction was effected for 24 hours. For purifying the resulting polymer, the reaction solution was poured into methanol whereupon the polymer precipitated. The procedure of dissolving the collected polymer in acetone and pouring into 5 liters of methanol for precipitation was repeated twice. The polymer was separated and dried, which is designated Comparative Polymer 2.
Copolymer Composition
ethyladamantane methacrylate:γ-butyrolactone methacrylate=50:50
Mw=10,300 Molecular weight dispersity (Mw/Mn)=1.73
Comparative Polymers
A polymer, designated Comparative Polymer 3, was synthesized from a monodisperse polyhydroxystyrene having a molecular weight of 10,000 and a dispersity (Mw/Mn) of 1.10 by substituting tetrahydropyranyl groups for 30% of the hydroxyl groups. Comparative Polymer 4 was poly(methyl methacrylate) having a molecular weight of 15,000 and a dispersity of 1.7. Comparative Polymer 5 was a novolac polymer having a meta/para ratio of 40/60, a molecular weight of 9,000 and a dispersity of 2.5.
Polymer Transmittance Measurement
Next, each of the polymers of Synthesis Examples (SE) 4 to 6 and Comparative Polymers 1 to 5, 1 g, was thoroughly dissolved in 10 g of propylene glycol monomethyl ether acetate (PGMEA), and passed through a 0.2-μm filter, obtaining a polymer solution.
The polymer solution was spin coated onto a MgF 2 substrate and baked on a hot plate at 100° C. for 90 seconds, forming a polymer layer of 300 nm thick on the MgF 2 substrate. Using a vacuum ultraviolet spectrometer (VUV200S by Nihon Bunko K.K.), the polymer layer was measured for transmittance at 248 nm, 193 nm and 157 nm. The results are shown in Table 1.
TABLE 1
Transmittance (%) at
Polymer
248 nm
193 nm
157 nm
Polymer of SE4
88
85
33
Polymer of SE5
87
42
35
Polymer of SE6
86
40
38
Comparative Polymer 1
85
26
22
Comparative Polymer 2
92
86
10
Comparative Polymer 3
85
1
3
Comparative Polymer 4
90
70
1
Comparative Polymer 5
70
1
6
Dry Etching Test
Each of the polymers of Synthesis Examples (SE) 4 to 6 and Comparative Polymers 1 to 5, 2 g, was thoroughly dissolved in 10 g of propylene glycol monomethyl ether acetate (PGMEA), and passed through a 0.2-μm filter, obtaining a polymer solution.
The polymer solution was spin coated onto a silicon esgrt and baked at 100° C. for 90 seconds, forming a polymer film of 300 nm thick. Dry etching tests were carried out on the polymer films by etching them under two sets of conditions. The results are shown in Tables 2 and 3.
(1) Etching test with CHF 3 /CF 4 gas
Using a dry etching instrument TE-8500P (Tokyo Electron K.K.), the difference in polymer film thickness before and after etching was determined. The surface roughness of the etched film was measured by AFM.
The etching conditions are given below.
chamber pressure
40.0 Pa
RF power
1300 W
gap
9 mm
CHF 3 gas flow rate
30 ml/min
CF 4 gas flow rate
30 ml/min
Ar gas flow rate
100 ml/min
time
60 sec
(2) Etching test with Cl 2 /BCl 3 gas
Using a dry etching instrument L-507D-L (Nichiden Anerba K.K.), the difference in polymer film thickness before and after etching was determined.
The etching conditions are given below.
chamber pressure
40.0 Pa
RF power
300 W
gap
9 mm
Cl 2 gas flow rate
30 ml/min
BCl 3 gas flow rate
30 ml/min
CHF 3 gas flow rate
100 ml/min
O 2 gas flow rate
2 ml/min
time
60 sec
TABLE 2
CHF 3 /CF 4 gas
Cl 2 /BCl 3 gas
etching rate
etching rate
Polymer
(nm/min)
(nm/min)
Polymer of SE4
99
120
Polymer of SE5
95
122
Polymer of SE6
98
128
Comparative Polymer 1
97
122
Comparative Polymer 2
90
105
Comparative Polymer 3
90
103
Comparative Polymer 4
180
350
Comparative Polymer 5
88
100
TABLE 3
Surface roughness Rms after
Polymer
CHF 3 /CF 4 gas etching (nm)
Polymer of SE4
3.5
Polymer of SE5
3.8
Polymer of SE6
3.6
Comparative Polymer 1
3.6
Comparative Polymer 2
10.8
Comparative Polymer 3
2.2
Comparative Polymer 4
20.5
Comparative Polymer 5
1.5
Examples and Comparative Examples
Resist solutions were prepared in a conventional manner by formulating the polymer, photoacid generator (PAG1 or PAG2), basic compound, dissolution inhibitor (DRI) and solvent in the amounts shown in Table 4.
TBA:tributylamine TEA:triethanolamine
On silicon wafers, DUV-30 (Nissan Chemical K.K.) was coated to form films of 55 nm thick so that the reflectance to KrF light (248 nm) was reduced below 1%. On the coated substrates, the resist solutions were spin coated, then baked on a hot plate at 100° C. for 90 seconds to give resist films having a thickness of 300 nm.
The resist films were exposed to a line-and-space pattern through a chromium mask by means of an excimer laser stepper (NSR-S202A, from Nikon Corporation; NA 0.6, σ 0.75, 2/3 zone illumination). Immediately after exposure, the resist films were baked at 110° C. for 90 seconds and then developed for 60 seconds with a 2.38% aqueous solution of tetramethylammonium hydroxide, thereby giving positive patterns.
The resulting resist patterns were evaluated as described below. The results are shown in Table 4.
Evaluation:
The exposure dose which provided a 1:1 resolution at the top and bottom of a 0.20-μm line-and-space pattern was the optimum exposure dose (Eop), that is, a sensitivity (mJ/cm 2 ). The minimum line width (μm) of a line-and-space pattern which was ascertained separate at this dose was the resolution of a test resist.
TABLE 4
Dissolution
Photoacid
Basic
inhibitor/
Polymer
generator
compound
crosslinker
Solvent
Sensitivity
Resolution
(pbw)
(pbw)
(pbw)
(pbw)
(pbw)
(mJ/cm 2 )
(μm)
SE4
PAG1
TBA
—
PGMEA
40
0.18
(100)
(2)
(0.1)
(1000)
SE5
PAG1
TBA
—
PGMEA
40
0.18
(100)
(2)
(0.1)
(1000)
SE6
PAG1
TBA
—
PGMEA
32
0.17
(100)
(2)
(0.1)
(1000)
SE6
PAG1
TBA
DRI
PGMEA
30
0.18
(100)
(2)
(0.1)
(20)
(1000)
SE6
PAG2
TBA
—
PGMEA
22
0.17
(100)
(2)
(0.1)
(1000)
SE6
PAG1
TEA
—
PGMEA
38
0.17
(100)
(2)
(0.1)
(1000)
SE6
PAG1
TMMEA
—
PGMEA
40
0.17
(100)
(2)
(0.2)
(1000)
CSE1
PAG1
TBA
—
PGMEA
45
0.18
(100)
(2)
(0.1)
(1000)
CSE2
PAG1
TBA
—
PGMEA
25
0.16
(100)
(2)
(0.1)
(1000)
Note)
SE is Synthesis Example and
CSE is Comparative Synthesis Example.
As is evident from Tables 1 to 4, resist materials using the polymers of the invention have sufficient transparency at the wavelength (157 nm) of F 2 excimer laser and satisfy the resolution and sensitivity requirements. The difference in resist film thickness before and after etching is small and the surface roughness after etching is small enough, indicating superior dry etching resistance.
Japanese Patent Application No. 2000-127513 is incorporated herein by reference.
Although some preferred embodiments have been described, many modifications and variations may be made thereto in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described without departing from the scope of the appended claims.
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Polymers comprising recurring units of cycloolefin having fluorinated alkyl introduced therein are novel and have transparency and alkali solubility. Using the polymers, resist compositions featuring low absorption of F 2 excimer laser light are obtained.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to the information access over the World Wide Web (“WWW”), and to an improved method and apparatus for enabling off-line web access, i.e., while disconnected from the Internet.
[0003] 2. Description of the Prior Art
[0004] The World Wide Web (WWW or Web) is a network application that employs the client/server model to deliver information on the Internet to users. A Web server disseminates information in the form of Web pages. Web clients and Web servers communicate with each other via the standard Hypertext Transfer Protocol (HTTP). A (Web) browser is a client program that requests a Web page from a Web server and graphically displays its contents. Each Web page is associated with a special identifier, called a Uniform Resource Locator (URL), that uniquely specifies its location. Most Web pages are written in a standard format called Hypertext Markup Language (HTML). An HTML document is simply a text file that is divided into blocks of text called elements. These elements may contain plain text, multimedia content such as images, sound, and video clips, and even other elements. An important type of element, called anchor elements, enables a Web page to embed hyperlinks, i.e., links to other Web pages. A Web browser typically displays hyperlinks in a distinctive format: as underlined text, or in a different color. When a user clicks a link, the browser brings up the page referenced by that link, even if it is on a different server. The Web page containing a hyperlink is referred to as the source document. The page referenced by a hyperlink is known as the target document.
[0005] A useful mode of web browsing is disconnected web access, otherwise known as offline browsing, which permits a user to view web pages while he/she is disconnected from the Internet. Disconnected web access is needed when there is no networking capability available at the location of a (mobile) computer, or when the user wants to avoid use of the network to reduce network charges and/or to extend battery life. It is also a viable fallback position when network characteristics degrade beyond usability. Disconnected web access works by storing (hoarding) necessary Web pages on the hard disk of the client computer prior to disconnection and, disconnected, servicing user requests for Web pages with the local copies. To maximize content availability, the user often needs to explicitly specify a set of Web pages that he is likely to access. Before going offline, these specified Web pages, called base pages, are downloaded to the client computer, along with some other pages that are reachable by following hyperlinks from the base pages. It is not sufficient to hoard base pages only because the user typically does not stop at a base page: while offline, he may request a page that is several clicks away from a base page.
[0006] Conceptually, a base page and all the pages that can be reached from it form a tree whose edges correspond to hyperlinks: the root is the base page, the second-level tree nodes are the pages one click away from the base page, the third-level nodes are the pages two clicks away from the base page, et al. The size of such a tree is often excessively large, due to the dense interconnection of Web pages. Hoarding all the pages in the tree would require a prohibitively long time and a disk space far beyond the local disk's capacity. Therefore, only a small subset of those pages may be hoarded. Existing systems, such as Microsoft's Internet Explorer, limit hoarded pages to those that are within a certain number of links from the base page. They are effectively based on a breadth-first approach, giving the pages at the same level equal consideration. However, a user's browsing behavior typically follows a depth-first pattern and not all links are of equal importance to the user. This implies that existing systems either waste significant time and space hoarding Web pages that are not needed by the user, or leave a lot of necessary pages unavailable to the user while offline. Some existing systems allow a user to refine the selection of pages based on a page's attributes such as its file type and whether it is on the same server (or in the same directory) as the base page. However, these options alone are not sufficient to limit the hoard volume. They must be combined with the hoard-by-level approach and therefore, do not ameriolate the problem. Since it is inconvenient or even impossible for a user to explicitly specify all the Web pages he will possibly access offline, a method is needed that hoards Web pages in anticipation of the user's future requirements so that the limited resources of time and disk space can be devoted to hoarding the Web pages that are most likely to be needed by the user offline.
[0007] As is known in the art, one can try to model a user's interests and/or to predict a user's future needs based on the user's past behavior. For example, by observing users' past Web usage, a system can build a data structure that reflects the interrelationship between URL references. The system is then able to speculate, given a URL reference (i.e., an access to a Web page), what other URLs are likely to be referenced in the near future. The system can further prefetch the corresponding Web pages before the user actually demands them, reducing user-perceived access latency. One such technique is described by V. N. Padmanabhan and J. C. Mogul in an article entitled Using Predictive Prefetching to Improve World Wide Web Latency, Computer Communications Review, 26(3):22-36, July 1996. They construct a dependency graph which has a node for every URL that has been referenced. Correlation between URLs are captured by edges through the nodes weighted by the likelihood that one will be referenced soon after the other. D. Duchamp discusses a similar technique in Prefetching Hyperlinks, Proceedings of Second USENIX Symposium on Internet Technologies and Systems , Pages 127-138, USENIX, Boulder, Colo. His system prefetches hyperlinks embedded in a Web page based on a usage profile that indicates how often those links have been previously accessed relative to the embedding page. These prefetching techniques are designed to improve Web access performance in a connected environment and are not suitable for Web hoarding which aims at optimizing data availability during disconnection. Specifically, they can predict only the pages that have been previously referenced, severely limiting the demand references that can benefit from the techniques. In order to make a substantial number of useful predictions, they often rely on observing a plurality of users, as opposed to a single user. That potentially increases the number of false predictions at the same time and the wasteful consumption of precious resources thereof.
[0008] Instead of using URL references to model user behavior, an alternative is to observe the document content seen by users. Appropriately aggregating the content of the Web documents that a user has browsed over time will give a pretty accurate indication of the user's interests. Such learned model of user interests can be used for assisting the user browsing the Web, suggesting hyperlinks that are potentially interesting to the user. Two systems of this kind are described by H. Lieberman in Letizia: An Agent That Assists Web Browsing, Proceedings of International Joint Conference on Artificial Intelligence , Montreal, Canada, August 1995, and by D. Mladenic in Personal WebWatcher: Design and Implementation, Technical Report IJS - DP -7472 , Department for Intelligent Systems , J. Stefan Institute, Slovenia, respectively. Again these systems are targeted at a connected environment and have no pressing need to identify interesting hyperlinks to the fullest extent possible. They emphasize the actual interestingness of a hyperlink (i.e., the interestingness of the target document), instead of the perceived interestingness of the hyperlink (i.e., how interesting the link appears to the user in the context of the embedding page). Further, they consider the user's historical and persistent interests only and not the user's current, and possibly new, interests.
[0009] Although the content of a document says much about its reader's interests, so do other attributes associated with the document. In particular, the URL of a document describes the location of the document in terms of the server and the directory path on the server. The composition of a URL is potentially very useful because it reflects the hierarchical clustering of documents. Consider the following hypothetical usage pattern: a user frequently browses documents in the sports directory of one newspaper's Web site; but he seldom reads documents in the finance directory on the same Web site or sports documents on another newspaper's site. Chances are the user is very interested in the first newspaper's sports articles; more so than in the same newspaper's finance articles or the second newspaper's sports articles. Note how inferences can be made here regarding the user's interests without knowing the exact content of those articles.
[0010] As is also known in the art, it is possible to compare the relatedness, or similarity, of two entities with respect to certain properties of the entities. First, each entity is represented by a feature vector, where the elements of the vector are features characterizing the entity and each element has a weight to reflect its importance in the representation of the entity. Next, the relatedness of the two entities are computed as the distance between the two corresponding feature vectors. Such a technique is commonly used in text retrieval systems based on a comparison of content features (words and phrases) extracted from the text of documents and queries. The specifics of the feature selection procedures, feature weighting schemes, and similarity metrics are generally known to those of ordinary skill in the art. Feature selection and weighting techniques tailored for HTML content are described by D. Mladenic in Machine Learning on Non - Homogeneous. Distributed Text Data , Doctoral Dissertation, Faculty of Computer and Information Science, University of Ljubljana, Slovenia, 1998.
[0011] Accordingly, a need exists for a method for enabling a user's disconnected Web access that overcomes the deficiencies of the prior art. This method should hoard Web pages in the descending order of user-perceived interestingness, preferably considering the user's preferences on both document content and attributes.
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to provide a system and method for supporting disconnected Web access, where a user specifies a collection of base URLs that are likely to be needed while disconnected and prompts the computing system to hoard necessary Web pages on the client computer prior to going offline.
[0013] It is another object of the present invention to provide a method for hoarding Web pages in preparation for offline browsing, based on the perceived interestingness of the pages.
[0014] A further object of the present invention is to provide a method of determining the interestingness of Web pages as perceived by a user, without requiring explicit user specification of the interestingness for all possible pages.
[0015] A further object of the present invention is to provide a method of modeling a user's interests in Web page documents which considers both the document content and/or the attributes associated with the document such as the composition of the URL.
[0016] According to the principles of the invention, there is provided a system and method for supporting offline Web browsing. A user interests profile comprising content and attribute preferences of candidate Web pages the user may be interested in is provided. Based on that user's profile, there is generated an interestingness values for each of candidate Web pages. From a hoard request received one or more Web pages are selected and downloaded based on their respective interestingness values. These Web pages are stored for later viewing by the user when offline. The candidate Web pages include base Web pages which are supplied by the user in the hoard request, and linked Web pages which are reachable from the base pages. Thus, an interestingness value may be computed as the interestingness of a hyperlink associated with a Web page reachable from a base Web page, the interestingness value of a hyperlink being based upon the similarity of a linked Web page to the base Web page and/or to the user's interests profile.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Further features, aspects and advantages of the apparatus and methods of the present invention will become better understood with regard to the following description, appended claims, and the accompanying drawings where:
[0018] [0018]FIG. 1 is a block diagram of an overall system architecture in which the present invention can operate, formed in accordance with one embodiment of the present invention.
[0019] [0019]FIG. 2 is a diagram illustrating an exemplary interests profile.
[0020] [0020]FIG. 3 is a logical flow diagram illustrating how a demand request is processed by the observer.
[0021] [0021]FIG. 4 is a logical flow diagram illustrating how a hoard request is processed by the hoarder.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] The present invention may be more fully understood with reference to FIG. 1, which shows an overall system architecture in which a preferred embodiment of the invention can operate. The components of FIG. 1 includes a client system 1000 and the World-Wide-Web 1090 , which includes a collection of Web servers (not shown). The client system 1000 preferably includes a user agent 1010 operatively coupled to both an observer 1020 and a hoarder 1050 . The observer 1020 and the hoarder 1050 in turn are operatively coupled with a content extractor 1060 , an attribute extractor 1070 , an interests profile 1080 , and a proxy server 1030 . The proxy server 1030 , which is shown to have a cache memory storage 1040 , is enabled to communicate with the Web 1090 . It is to be appreciated that the component associations described above with respect to FIG. 1 are for illustrative purposes. The components may be readily reconfigured, including moving some of the components in the client system 1000 to another computer. Given the teachings of the present invention provided herein, and the teachings of commonly-owned, co-pending U.S. patent application Ser. No. ______ (YOR920020146US1, Attorney Docket 15623) entitled SYSTEM AND METHOD FOR SORTING EMBEDDED CONTENT, the contents and disclosure of which is incorporated by reference as if fully set forth herein, one of ordinary skill in the related art will contemplate these and various other configurations.
[0023] The user agent 1010 serves as the interface between a human user and the computing system. The user agent 1010 accepts commands from the user. A user command may comprise a demand request for accessing a Web page, or a hoard request for downloading a plurality of base Web pages and a subset of the pages that are reachable from the base pages. The user agent 1010 passes demand requests to the observer 1020 , and hoard requests to the hoarder 1050 . The user agent 1010 also presents to the user responses from the computer system, including the Web pages the user has demanded. It is to be appreciated that a hoard request may be issued in two separate steps: first, the URLs for the base Web pages are specified; next, a hoard command is issued to start the actual hoarding process. In such a case, the user agent 1010 saves the user-specified base URLs so that it can pass them to the hoarder 1050 when a hoard command is issued. It is further to be appreciated that the user agent 1010 may permit the user to specify a value of interestingness with each base URL. The “interestingness value” is a number between the range of 0 and 1 (inclusive) indicating how interesting the corresponding Web page is to the user, e.g., with 1 being the most interesting. If a user-specified interestingness is absent for a base URL, the user agent 1010 assumes a default value of 1.
[0024] The observer 1020 , which will be discussed in greater detail herein with respect to FIG. 3, functions to intercept all data traffic related to the user's demand requests. The hoarder 1050 , which will be discussed in greater detail herein with respect to FIG. 4, functions to examine the collection of base URLs that make up the hoard request and initiates the hoarding of individual Web pages. A hoarded page may be a base Web page or a page reachable from one of the base pages. The pages are hoarded in the descending order of user-perceived interestingness. As many pages are hoarded as possible, subject to certain resource limits. The resource limits may include, for example, the disk space used to store the pages or, the time spent on hoarding.
[0025] The proxy server 1030 functions as a relay system between the rest of the client system 1000 and the Web 1090 . For example, proxy server 1030 accepts URLs from the observer 1020 and the hoarder 1050 and returns the corresponding Web pages retrieved from the Web 1090 . It additionally maintains the cache storage 1040 , which includes recently retrieved Web pages. The cache 1040 is likely to reside on a hard disk or, in addition, reside in main memory so that its contents may survive system restarts. The art of implementation of the proxy server 1030 and its cache 1040 is well known to those skilled in the art.
[0026] The content extractor 1060 functions to construct a feature vector (hereinafter “content feature vector”) for characterizing the content of a Web page or a hyperlink. According to a preferred embodiment of the present invention, the content feature vector for a Web page is built from the entire text in the page, whereas the content feature vector for a hyperlink is built from text that appears in a window surrounding the anchor element in the embedding page (for example, the anchor element plus 50 words before and after the anchor element). One skilled in the art will recognize that there are other ways to construct a content feature vector for a Web page or for a hyperlink.
[0027] The attribute extractor 1070 constructs a feature vector (hereinafter “attribute feature vector”) for characterizing the attributes of a Web page or a hyperlink. The attributes of a Web page refer to the location, type, and size etc. of the page. The attributes of a hyperlink refer to the attributes of the corresponding target page. According to a preferred embodiment of the present invention, the attribute feature vector includes features that correspond to all possible prefixes of the corresponding URL. For example, if a Web page (hyperlink) has a URL http://www.ibm.com/research/mobile/projects.html, then its attribute feature vector will contain the following features: http://www.ibm.com/, http://www.ibm. com/research/, http://www.ibm.com/research/mobile/, and http://www.ibm.com/research/mobile/projects.html. One skilled in the art will recognize that there are other ways of decomposing a URL to form features in the attribute feature vector, and that attribute features may also be extracted from sources such as the HTTP headers and the head element of an HTML document.
[0028] The interests profile 1080 retains for storage a user's interests. It comprises a content feature vector 1065 and an attribute feature vector 1075 . The content feature vector characterizes the content of Web pages the user is likely to be interested in. The attribute feature vector characterizes the attributes of Web pages the user is likely to be interested in. FIG. 2( a ) depicts a representation of an example content feature vector 1065 that includes feature words 1063 and their corresponding weights 1068 . The right part of FIG. 2 is an example attribute feature vector 1075 including URL prefixes 1073 and their corresponding “interestingness” values or weights 1078 .
[0029] [0029]FIG. 3 illustrates the process by which the observer 1020 handles a demand request, in accordance with a preferred embodiment of the present invention. In a first step 2010 , the observer receives from the user agent 1010 the URL of a Web page that is demanded. In step 2020 , the observer obtains the Web page via the proxy server 1030 . In step 2030 , the observer constructs a content feature vector and an attribute feature vector for the Web page, particularly, by invoking the content extractor 1060 to construct the content feature vector and, invoking the attribute extractor 1070 to construct the attribute feature vector. In step 2040 , the observer updates the interests profile 1080 with the two feature vectors built in step 2030 . Preferably, the observer performs a sum of the content feature vector in the interests profile 1080 and the content feature vector for the Web page to generate the new content feature vector in the interests profile. It additionally performs a sum of the attribute feature vector in the interests profile 1080 and the attribute feature vector for the Web page to generate the new attribute feature vector in the interests profile. It is to be appreciated that the feature vectors may be aggregated in more sophisticated ways so that old interests may be forgotten over time. Finally, at step 2050 , the Web page is returned to the user agent 1010 .
[0030] In other embodiments within the scope of the invention, the interests profile 1080 generated by the observer 1020 may be complemented with, or replaced by, explicit specification by the user, possibly after the user specification is appropriately transformed. For example, the user specification may include a collection of key words identifying the user's interests in content, and the user's preferences on the attributes of Web pages such as document size, file type, and file location (server and directory). If the interests profile 1080 is to be completely based on user specification, then the observer component 1020 may be eliminated.
[0031] [0031]FIG. 4 illustrates a preferred method of how a hoard request is serviced by the hoarder 1050 , in accordance with the present invention. In step 3010 , the hoarder receives a hoard request. The hoard request includes a collection of base URLs, each of which is associated with a value of interestingness. In step 3020 , the hoarder creates a data structure, referred to as “HoardQ”, for maintaining URLs that are hoard candidates together with their interestingness value. The hoarder initializes HoardQ with the base URLs and their interestingness. In step 3030 , the hoarder makes a determination on whether it is possible to hoard more Web pages. Further hoarding is possible when there are entries in HoardQ and the resource limits have not been exceeded. If further hoarding is not possible, the process of servicing the current hoard request ends. If further hoarding is possible, the hoarder proceeds to step 3040 where the hoarder removes an entry in HoardQ that includes an unhoarded URL with the highest value of interestingness. The hoarder invokes the proxy server 1030 to fetch the corresponding Web page and its inline multimedia elements (pictures, animations, videos and sounds), in a manner generally known to those skilled in the art. This step effectively causes the Web page and its inline multimedia elements to be stored in the cache 1040 of the proxy server 1030 (FIG. 1), making them available to the user while offline. In step 3050 , the hoarder constructs a content feature vector and an attribute feature vector for the newly hoarded page. The hoarder particularly invokes the content extractor 1060 to construct the content feature vector and, invokes the attribute extractor 1070 to construct the attribute feature vector. In steps 3060 to 3100 , the hoarder iterates through all the hyperlinks embedded in the newly hoarded Web page. That is, at step 3070 , the hoarder locates the next embedded hyperlink that has not been hoarded. In step 3080 , the hoarder constructs a content feature vector and an attribute feature vector for the hyperlink particularly by invoking the content extractor 1060 to construct the content feature vector and, the attribute extractor 1070 to construct the attribute feature vector. In step 3090 , the hoarder computes the interestingness of the hyperlink, which represents perceived interestingness of the corresponding target document, in a manner to be described in greater detail herein. In step 3100 , the hoarder updates HoardQ with information about the current hyperlink. If an entry already exists in HoardQ for the hyperlink, the interestingness value is changed to the greater of the old interestingness value and the new interestingness value. If there is no entry in HoardQ for the link, an entry is created for the link and the interestingness value computed in step 3090 is provided. Thereafter, the process proceeds back to step 3060 where the process steps up to step 3100 are repeated for each of the hyperlinks embedded for that newly hoarded Web page.
[0032] In accordance with step 3090 , in a preferred embodiment, the hoarder computes the interestingness value of the hyperlink, referred to as L, that is embedded in a Web page, referred to as P as follows: For ease of description, some additional notations are introduced: Let U denote the interests profile. Let X denote one of P and U. The similarity of L and X with respect to their content, denoted S C L, X , is preferably calculated as the similarity between the content feature vector of L and the content feature vector of X. The similarity of L and X with respect to their attributes, denoted S A L, X , is preferably calculated as the similarity between the attribute feature vector of L and the attribute feature vector of X. It is to be appreciated that a number of vector similarity metrics may be used for computing S C L, X and S A L, X , for example, the cosine distance. It is to be understood that, since the interests profile U represent the user's accumulative interests, S C L, U and S A L, U should be computed in terms of only the features contained in the feature vectors of L. The overall similarity between L and X, denoted S L, X , is preferably computed as a weighted sum wS C L, X +(1−x)S A L, X , where w is a configurable parameter in the range of 0 to 1. The perceived interestingness of the Web page P, denoted I P , is input to the hoarder if P is one of the base pages, or preferably computed as the interestingness of the hyperlink via which P is reached. Finally, the interestingness of the hyperlink L, denoted I L , is preferably computed as I P (vS L,P +(1−v)S L,U ), i.e., the multiplication of P's perceived interestingness and a weighted sum that combines the overall similarity between L and P and the overall similarity between L and U. The weighting factor “v” is another configurable parameter in the range of 0 and 1. It is to be appreciated that the computation of interestingness as described above guarantees that a target document always has a smaller perceived interestingness value than its source document and therefore will never be hoarded ahead of the latter.
[0033] The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications, variations and extensions will be apparent to those of ordinary skill in the art. All such modifications, variations and extensions are intended to be included within the scope of the invention as defined by the appended claims.
[0034] What is claimed is:
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A system and method for supporting offline Web browsing. A user interests profile comprising content and attribute preferences of Web pages the user may be interested in is provided. Based on that user's profile, there is generated an interestingness values for each of candidate Web pages. From a hoard request initiated by a user, received one or more Web pages are selected and downloaded based on their respective interestingness values. These Web pages are stored for later viewing by the user when offline. The candidate Web pages include base Web pages which are supplied by the user in the hoard request, and linked Web pages which are reachable from the base pages. Thus, an interestingness value may be computed as the interestingness of a hyperlink associated with a Web page reachable from a base Web page, the interestingness value of a hyperlink being based upon the similarity of a linked Web page to the base Web page and/or to that user's interests profile.
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FIELD OF THE INVENTION
The present invention refers to the construction of pools and, more specifically, to pools made up of metallic modules of standardized dimensions.
BACKGROUND OF THE STATE OF THE ART
The growing popularity of pools for recreational, therapeutic and domestic use has resulted in the creation of a plurality of types and models, intended to meet the market's large variety of expectations. Among others, the most widely known are the following:
concrete pools, lined with tiles, miniature tiles or vinyl linings; fiberglass pools, manufactured according to standard dimensions and shapes; mixed-type pools, with a concrete base (bottom) and walls made of blocks, clay bricks or metallic sheets, usually waterproofed with vinyl lining or fiberglass skin.
However, constructing pools of the above mentioned types is a relatively complex, slow and expensive process, since, in addition to requiring specialized labor, they have disadvantages inherent to their nature.
In fact, it is known that concrete structures require the manufacture of molds that, once used, are disposed of, resulting in a substantial waste of material.
Fiberglass pools, although not having this shortcoming, require digging a hole in the ground with the proper dimensions, as well as the provision of a concrete support bottom.
Additionally, neither concrete nor fiberglass pools can be moved to another location, nor can they have their dimensions altered, leaving no choice for their owners but to live with the original dimensions forever. For instance, in a pool built for small children, it becomes impossible to increase its depth when these children grow up.
Conventional pools have other shortcomings, such as the need for special techniques to install underwater lighting (which must be planned before the construction begins), as well as the impossibility of altering the number or positions of these lighting fixtures after the construction is finished.
The above-mentioned inconveniences have led to the search for solutions based on modular techniques, in order to result in more accessible costs, as well as to reduce assembly time and to facilitate said assembly work. This trend is exemplified by patent documents U.S. Pat. No. 3,798,857 to Barrera (hereinafter “Barrera”), U.S. Pat. No. 3,820,174 to Rozanski (hereinafter “Rozanski”), U.S. Pat. No. 4,047,340 to Witte et al (hereinafter Witte) and DE 1264031 to Dr. Theodor Kootz (hereinafter “Kootz”).
The inventions described in the above-mentioned documents, however, have shortcomings that limit their usefulness, as discussed below. Barrera discloses a pool whose walls consist of modules made of steel sheets, equipped with coupling means between the vertical edges of adjacent modules, whose assembly results in the pool's side walls, as shown in FIG. 1 . Said coupling means comprise rectangular slots into which tabs are inserted, the retention between modules being provided by locking pins. The shapes of these tabs require expensive manufacturing processes. Moreover, as shown in FIG. 1 , the pool has to be placed inside a hole dug into the ground.
In addition, the modules of Barrera do not apply to the bottom of the pool, which is made of concrete and requires specialized as well as costly labor, which is also needed to manufacture the concrete blocks that provide support to the walls' anchor beams.
Rozanksi discloses a pool whose walls are made of steel sheet modules, complemented by a three-dimensional lattice structure as shown in FIGS. 2 and 3 . The object of this is to provide a supporting structure for the ladder's handrails, as well as supporting a concrete deck or pavement surrounding the edge of the pool. As in the previous example, the bottom of the pool requires specialized labor, which is also necessary to lay the concrete pavement. These operations are time consuming, due to the time needed for the concrete to harden.
Witte discloses a pool with walls made up of modular plate-shaped elements that have, in their vertical edges, grove and tongue joints. The horizontal forces are supported by X-shaped prefabricated elements, as shown in FIGS. 4 and 5 . As shown in FIG. 5 , a concrete bottom 90 must be provided to support the wall modules 32 as well as the internal edge of the deck 20 that surrounds the pool. The external edges of said deck rests upon one of the arms 50 of the X-shaped elements, whose bottom arm 50 d rests on a metallic footing 80 that is secured to the ground or according Witte—a concrete base, not shown in the drawing. Said base is necessary due to the fact that the thrust resulting from the water's pressure upon the walls is also unloaded on this footing. In the subject matter of this patent, the same considerations regarding the delay in the construction time are also applicable.
Kootz teaches a swimming pool having its bottom, as well as its sides, formed of metallic tray-like modules that are bolted together. The pool has two parts with different depths: in the shallower part, the walls are composed of a single row of panels, whereas in the deeper portion, the walls are higher, being formed of two superposed rows of panels. In the bottom of the pool, the tray-like panels are placed with their flanges facing up (i.e., the inside of the pool). This configuration is necessary due to the fact that said panels must be bolted together to form the bottom. However, to attain a uniform bottom surface, the trays must be filled with concrete covered with a fiberglass layer. Therefore, the pool cannot be disassembled, as the bolts which join said bottom panels are be encased in concrete. Moreover, said bottom panels have to be laid on a leveled surface, preferably, one that has been compacted or overlaid with a layer of concrete. Additionally, the horizontal thrust upon the side panels, due to the water pressure, may result in the outward bending of the walls of said deeper portion, mainly along the joints between the upper and lower rows of panels. This sets a limit to the number of panels that can be superposed to increase the height of said side walls and, therefore, the pool's depth.
The above-mentioned examples of the state of the art suffer from serious shortcomings due to the possibility of structural damages due non-uniform resistance from the ground on which the pool lies. Such is particularly the case with the objects of Barrera and Witte.
OBJECTS OF THE INVENTION
In view of the above, a first object of the invention is to provide a modular pool that is not affected by irregularities of the soil's compression resistance.
Another object is to provide a modular pool adapted to be easily and quickly assembled, without recourse to specialized labor.
Another object is to provide a modular pool adapted to be easily assembled and disassembled.
Yet another object is to provide a modular pool whose construction does not require the use of concrete walls or bottom, blocks or bricks.
Yet another object is to provide a modular pool that allows the inclusion of a deck.
Another additional object is to provide a modular pool that can be easily changed in dimensions and shape.
Another object is to provide a modular pool adapted to be assembled either below or above ground level.
SUMMARY OF THE INVENTION
The above-mentioned objects, as well as others, are attained by the present invention through a modular pool in which the bottom edges of the metallic modules that form the walls are attached by semi-permanent attaching means to a latticed base structure composed of a plurality of metallic sleepers placed crosswise at right angles to a plurality of parallel metallic beams running lengthwise, said metallic sleepers and said beams being “U” section shaped with the central portion being vertically oriented.
In accordance with an additional feature of the invention, the metallic modules that form the walls are made from sheet metal comprising a rectangular shaped center portion provided with flanges along the vertical and horizontal edges of said central portion.
According to another feature of the invention, said flanges are bent at a right angle relation to said central portion.
In accordance with an additional feature of the invention, said semi-permanent attaching means comprise angle irons having their vertical flange attached to the vertical central portion of said sleepers and beams, and their horizontal flange attached to the bottom flanges of the metallic modules that form the bottom tier of the pool's side walls.
According to another feature of the invention, the bottom of the pool comprises a plurality of modular bottom panels placed crosswise to the above-mentioned sleepers with their end portions being supported by the horizontal upper flange of said sleepers.
According to another feature of the invention, said modular bottom panels comprise modules provided with bottom draining openings.
According to yet another feature of the invention, said sleepers, beams and modular wall panels as well as said angle irons are joined by nuts and bolts.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional advantages and features of the invention will be better understood through the description of a preferred embodiment and the accompanying drawings, in which:
FIGS. 1 , 2 , 3 , 4 and 5 show pools built according to the previous art.
FIG. 6 is a general perspective view of the pool of the invention.
FIGS. 7 , 8 , 9 and 10 show side views of various combinations of modular side wall panels, providing different pool depths.
FIG. 11 shows a typical wall panel before folding of the flanges.
FIG. 12 shows the wall panel of the previous drawing, with the flanges folded and strengthening it in order to resist the water pressure.
FIG. 13 shows, by means of a top view, a corner where the side walls meet at an angle different from 90°.
FIG. 14 shows an exploded view of the assembly of the side walls of a pool.
FIG. 15 shows, by means of a partially exploded view, the assembly of sleepers and beams that comprise the latticed base structure of the pool.
FIG. 16 shows, by means of a perspective view, part of the assembled base structure of the pool and the positions of the angle irons, as well as the panels that form the bottom of the pool.
FIG. 17 shows by means of a cross-section view, the joint formed by the side panels of the pool, an angle iron and a sleeper.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 6 which shows a pool 10 built according to the invention, it can be seen that said pool comprises two side walls 11 and 12 , two head walls 13 and as well as a bottom 15 , all these parts consisting of constructive modular panels, as detailed below.
Considering that the exemplary embodiment shown in FIG. 6 has a standard depth of 1 meter, said side walls an said end walls are formed by three tiers of panels, all having the same standard length, such as, for example, one meter. Upper panels 17 have a useful height of 500 millimeters, intermediate panels 18 are 300 millimeters high and bottom panels 19 are 200 millimeters high. In order to leave a clearance of 130 millimeters between the water surface and the pool's upper edge, panels 17 are 630 millimeters high overall.
Still according to FIG. 6 , the pool's bottom surface is made up by panels 16 , hereinafter called “tiles”, which completely line the bottom's surface and are supported by the latticed base (not shown in this drawing).
Additionally, all said pools component parts have dimensions that allow them to be loaded in pick-ups or small trucks for low cost transportation. So, in the exemplary embodiment herein described, the largest parts are the beams that comprise the lengthwise beams, which are only 2 meters long. This allows them to be transported in building's elevators, substantially reducing vertical transportation costs for pools assembled in penthouses.
FIGS. 7 to 10 depict some exemplary arrangements of side panels of different heights, showing how the invention allows the construction of pools with various depths. FIG. 7 shows how a depth of 1 meter is attained by the superposition of panel 17 , with a useful height of 500 mm, panel 18 with a height of 300 mm and panel 19 which is 200 mm high. In FIG. 8 , a depth of 1.2 meters is attained by superposing a 500 mm panel 17 , a 400 mm panel 21 and a 300 mm panel 18 . A depth of 1.3 meters results from the superposition of one panel 17 , two 300 mm panels 18 and at the bottom one 200 mm panel 19 , as shown in FIG. 9 . Finally, FIG. 10 exemplifies a 1.5 meter depth attained by overlaying one panel 17 , one panel 21 and three panels 19 , having heights of 500 mm, 400 mm and 200 mm, respectively.
As a general rule, the larger panels should be placed closer to the surface, progressively narrower panels being used at greater depths, so that the panels having smaller height (such as panels 19 ) are placed next to the floor. It is also noted that in the present exemplary embodiment panel 17 has a height greater than 500 mm, the excess 24 corresponding to the clearance between the water surface 23 and the top 22 of the pool's side walls.
FIG. 11 shows how a panel 30 is formed from a rectangular metallic sheet. As shown, this sheet comprises a rectangular central portion 31 whose sides are contiguous with stripes 32 , 33 , 34 , 35 , the boundaries between said central portion and said stripes being the folding lines 31 a , 31 b , 31 c , 31 d . Said stripes have the same width and through-holes 36 placed at standardized positions, and are folded in the directions shown by arrows 37 .
FIG. 12 depicts the same panel after folding along said lines 31 a , 31 b , 31 c , 31 d , where it can be seen that the horizontal and vertical stripes act as flanges which absorb the bending stresses due to the water pressure 38 acting upon the central portion 31 . Additionally, the through-holes in said stripes are used to connect adjacent panels to form the pool's side walls.
The general layout of the elements that form part of the wall as well as a rectangular corner are shown in FIG. 14 . The first side wall comprises sets 40 , 41 and 42 , each one being formed by the superposition of modules 17 , 18 and 19 . As shown in this drawing, said vertically adjacent modules are joined by means of bolts 44 and nuts 45 . The same nut-bolt elements are used to join the vertical flanges of said sets.
The drawing in FIG. 14 is exploded horizontally to show a vertical member 65 which is interposed and bolted between adjacent assemblies 40 and 41 (formed by panels 17 , 18 and 19 vertically joined). This member 65 consists of a plate that may have the same width as the vertical flanges of said modular panels, and its height encompasses the total height of said assemblies. Said plate acts as a reinforcing member that resists the outward stresses acting upon the side walls, which tend to push outwardly central panels 18 . Lengthwise reinforcement at the top of the pool's wall is provided by a metal plate 64 whose through-holes 36 ′ are coincident with the through-holes of the upper flanges of the upper panels. Said metal plate 64 may be used to support a deck floor along the walls.
FIG. 14 also depicts a right-angle joint between two side walls of the pool. As shown, the vertical flanges of the identical modules at the free ends of assemblies 42 and 43 are bolted to the flanges of an angle iron 46 , which is provided with through-holes in positions coincident with the holes of said flanges.
It should be stressed that the pool's layout is not limited to right angles α=90° as shown in FIG. 14 . For instance, an angle of α=120° for hexagonal shaped pools is shown in FIG. 13 . In this case, side flanges 35 ′ adjacent to said angle iron 46 are folded at angles of 75° in relation to the central part of panels 17 ′. The corresponding upper and lower flanges of the panels 17 ′ have also been cut in accordance with this angle.
The floor of the pool comprises a supporting structure upon which the closing panels or “tiles” are placed. As depicted in FIG. 15 , said base structure consists of a rectangular lattice comprising a plurality of parallel metallic U-shaped beams 51 having metallic U-shaped sleepers 56 placed crosswise between them. In a preferred embodiment, said beams and said sleepers may have the same height. As shown, beams 51 are composed of several modular elements 52 (in the central part of the beams) and 53 (at the ends of the beams) butt-joined with side-plates 54 . Sleepers 56 are attached to said beams by means of L-shaped plates 55 . Standardized bolts and nuts (not shown) of the same type of the ones used for side wall assembly are used throughout.
FIG. 16 depicts part of the assembled pool's base structure, forming a rectangular lattice or grid with module m. This grid supports the pool's floor tiles 57 , 58 , whose ends rest upon the upper flanges of sleepers 56 . As shown in the drawing, said tiles are not bolted to their supporting members, and comprise flanges 57 a along the greater part of their long sides, said flanges providing the necessary rigidity to resist the vertical thrust due to the water pressure upon the bottom. In addition to the regular tiles 57 , special tiles are provided for various specific functions, such as tile 58 that has a central opening 59 to receive the bottom's draining valve assembly.
FIG. 16 also shows the angle irons 61 that comprise the semi-permanent attaching means between the side walls and the base structure. Said angle irons have through-holes 62 a on their vertical flanges, placed in coincident positions with holes 62 b on the sleepers as well as on the beams, to which they are attached by means of bolts 44 and nuts 45 . The horizontal flanges of said angle irons are provided with through holes 63 , which are coincident with holes 36 on the lower flange of the wall panels. According to the cross-section view of FIG. 17 , the bottom flanges of the panels of the lower tier 19 of the side walls are bolted to the horizontal flanges of said angle irons 61 , which have their vertical flanges bolted to the perimeter beams such as sleepers 56 of the base structure, allowing the horizontal stresses upon said side walls to be unloaded on the base structure.
Although the preceding description refers to swimming pools, the invention has a wider range of applications such as iced water reservoirs for air conditioning systems retrofitted into existing buildings. In this case, the reservoir can be placed over existing floors, such as in garages or courtyards, thermal insulation being provided by polyurethane or polystyrene sheets inserted between the walls and bottom and the inner vinyl lining of the reservoir.
Therefore, the object above described may be modified within the conceptual limits of the invention, being only limited by the following set of claims.
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Modular pool constructive design whose walls are constituted by metallic panels ( 17, 18, 19 ), made up by folding metallic sheets, comprising a bottom including a structure that supports a plurality of metallic panels-tiles ( 16 ) —said walls ( 11, 12, 13, 14 ) are connected to said bottom's structure, making up a unique and non-deformable structure, all the pool's elements are interlinked by semi-permanent connecting means, such as screws and nuts. The dimensions of the pool's elements allow its easy transport in small vehicles or buildings' elevators.
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BACKGROUND OF THE INVENTION
The present invention relates to a sheet reversing apparatus which can positively register sheets being fed and feed the sheets one by one. The sheet reversing apparatus is applicable to a laser beam printer for performing the recording or printing on both surfaces of the sheet, but is not limited to such application.
In printing machines such as a laser beam printer and the like, when the both-surface recording is effected, first of all, a first surface of a sheet is printed. Then, the sheet is fed, with the printed first surface turned over by a sheet reversing apparatus, from the sheet reversing apparatus to a printing station again, and a second surface of the sheet is printed at the printing station.
Conventional reversing apparatuses were divided into generally two types, in one of which the incoming sheet was continuously fed out as it was, and in the other of which a plurality of sheets were once stacked and thereafter the sheet was separated and fed one by one from the bottom of the sheet stack. Accordingly, in the past, there was no sheet reversing apparatus wherein the receipt of a next sheet and the feeding-out the previously received sheet were simultaneously and continuously effected while a plurality of sheets were stacked.
In the conventional reversing apparatus of the former type, for example, a continuously rotating rubber impeller is used as a sheet hold-down means, and a regulating means such as a stopper is also provided to cooperate with the hold-down means. The sheet is registered by these means and is continuously received by the reversing apparatus to be fed out as it is.
In the conventional reversing apparatus of the latter type, a stopper means is movably arranged in the vicinity of the stacking station, which stopper means serves to register and stack the sheets during the stacking operation. On the other hand, during the sheet separating and feeding operation, the stopper means is separated from the sheet stack to release the urging force of the stopper means acting on the sheet stack, thereby preventing the double-feeding of the sheets. Further, as disclosed in the U.S. Pat. No. 4,275,877, in a sheet reversing apparatus wherein the sheet separating and feeding operation is effected by using a vacuum suction, the whole stacking station is inclined downwardly with respect to a horizontal plane, and a rear guide is provided at the stacking station. In addition, an air blowing portion is arranged in confronting relation to the stacking station, and a feeding portion is disposed below the stacking station. Sheets fed to the stacking station are abutted against the rear guide to be registered and are successively stacked. Thereafter, by intermittently activating the air blowing portion and the feeding portion, an lowermost sheet in the sheet stack is attracted by the vacuum suction force, whereas the remaining sheets are floated to separate from the lowermost sheet, thereby preventing the multifeeds of the sheets.
However, the arrangement in the reversing apparatus of the former type arose a problem when it was used with a high speed printer. That is to say, in the high speed printer, it is necessary to previously convert the printing information into dots and store them in a memory. Thus, in order to continuously reverse the sheets, the memory means therefor becomes large-sized as that used in a large-sized computer, which leads in the increase in the cost of the whole printer.
On the other hand, in the conventional reversing apparatus of the latter type in which the sheets are separated and fed after they have previously been stacked, it is difficult to control the air system for separating the sheet from the bottom of the sheet stack and attracting the sheet intermittently at a high speed. Consequently, there arose a problem that it was impossible to reverse and feed the sheet at a high speed.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a sheet reversing apparatus which can receive and feed sheets from time to time with a simple construction even if the sheets are stacked.
Another object of the present invention is to provide a sheet reversing apparatus wherein, even when the incoming sheets are continuously fed as they are or when the sheets are temporarily stacked, the sheet can be registered and fed positively.
According to the present invention, a sheet reversing apparatus comprises a support means on which sheets are stacked, a hold-down guide means for guiding a sheet being fed toward the support means, a stopper means for stopping the sheet to position it on the support means in place, a feeding means for attracting a lowermost sheet in a sheet stack on the support means to feed it, and a blowing means for directing an air stream toward a bottom of the sheet stack on the support means to separate the lowermost sheet from the remaining sheets. The stopper means is pivotable so as to extend into and retract from a sheet feeding path to the support means so that the stopper means can abut against the incoming sheet at different positions in accordance with a continuous reversing mode wherein the incoming sheet is immediately fed and a stack reversing mode wherein while the sheets are being stacked the lowermost sheet is separated and fed.
Preferably, the stopper means can intersect with the support means to brake and position the sheet by using a gap formed therebetween when the continuous reversing mode is used, and brakes the sheet by abutting against a leading edge of the sheet when the stack reversing mode is used.
A first sensor for detecting the arrival of the sheet and a second sensor for detecting the sheet stacked on the support means may be provided, and the stopper means may be actuated on the basis of commands signals of the first and second sensors and a signal commanding the initiation of the feeding of the sheet.
It is preferable that a size of the sheet is determined on the basis of the signal from the first sensor and the stopper means intersects with the support means at an single according to the sheet size.
Further, preferably, the hold-down guide means may include two hold-down guides arranged in parallel along the support means and disposed on both sides of the support means adjacent thereto, and regulates the sheet (on the support means) floated by the air stream.
Further, it is preferable that the support means is inclined downwardly at a front portion thereof with respect to a sheet feeding direction to reduce a friction resistance to the sheet.
With the arrangement mentioned above, in the continuous reversing mode wherein only a single sheet is situated on the support means at all times, the stopper means can hold the incoming sheet down to positively brake and position the sheet. On the other hand, in the stack reversing mode, the stopper means can abut against the incoming sheet at the different position to brake the sheet without pressing the stacked sheets. Consequently, even in the stack reversing mode, it is possible to prevent the double-feeding of the sheets while braking the incoming sheet positively and to receive and feed the sheet from time to time.
Further, according to the preferred aspect mentioned above, when the incoming sheets are reversed at any time, the sheet is pinched by the gap formed by intersecting the stopper means with the support means. On the other hand, in the stack reversing mode wherein while a plurality of sheets are stacked the stacking operation and the reversing operation are continuously performed, the stopper means crossed with the support means in response to the signals from the sensors is shifted upwardly at a predetermined angle to regulate a stop position of the sheet at a portion of the stopper means opposing the leading end of the sheet.
In this way, in the continuous reversing mode, since the inertia force of the incoming sheet is absorbed by pinching the sheet by the gap between the stopper means and the support means, the bounce of the sheet due to the impingement of the sheet in a longitudinal direction or sheet feeding direction is eliminated, thereby stacking the sheets with high accuracy. Further, in the stack reversing mode, since the stopper means is shifted upwardly, a friction resistance or feeding resistance between the sheets is eliminated by the air stream, thereby preventing non-feeding and/or double-feeding of the sheets.
In addition, by providing two parallel hold-down guides in the vicinity of the support means, in the continuous reversing mode, these hold-down guides hold both ends of the sheet on the support means. Thus, it is possible to prevent the raising of the central portion of the sheet when the sheet is attracted by suction, and to prevent the poor attraction of the sheet due to a curl of the sheet caused by a change in the surrounding conditions, thereby feeding the sheet positively. On the other hand, in the sheet stacking operation, the position of the leading end of the sheet is not varied by the thickness of the sheet, thus improving the stacking accuracy. Further, since the guides hold both ends of the remaining sheets floated by the air stream, the rigidity of the sheets is increased, whereby the air layer between the lowermost sheet and the remaining sheets can extend to prevent the double-feeding of the sheets positively.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a main portion of a sheet reversing apparatus according to a first embodiment of the present invention;
FIG. 2 is a plan view of the apparatus shown in FIG. 1;
FIGS. 3 and 4 are side view for explaining a stacking operation of the apparatus of FIG. 1 in a continuous reversing mode;
FIGS. 5 and 6 are side views for explaining a stacking operation of the apparatus of FIG. 1 in a stack reversing mode;
FIG. 7 is a timing chart in the continuous reversing mode of the apparatus of FIG. 1;
FIG. 8 is a timing chart in the stack reversing mode of the apparatus of FIG. 1;
FIG. 9 is a side view for explaining the feeding of a letter-size sheet by the apparatus of FIG. 1 in the continuous reversing mode;
FIG. 10 is a side view for explaining the feeding of a letter-size sheet by the apparatus of FIG. 1 in the stack reversing mode;
FIG. 11 is a side view for explaining an operation of a sheet reversing apparatus according to a second embodiment in a continuous reversing mode;
FIG. 12 is a side view for explaining an operation of a sheet reversing apparatus according to the second embodiment in a stack reversing mode; and
FIG. 13 is a block diagram for explaining a device for determining a length of a sheet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be explained in connection with embodiments thereof with reference to the accompanying drawings. With reference to FIGS. 1 and 2, the sheet reversing apparatus 1 of the present invention is provided with an entrance section 10, a feeding section 20, a stacking section 30 and an ejecting section 40, and an incoming sheet moves through these sections.
The entrance section 10 includes lower pulleys 11 and lower rollers 13 which are mounted on a lower pulley shaft 18, upper pulleys 12 and upper rollers 14 which are mounted on an upper pulley shaft 19, and a sheet detector or sensor 15 (FIG. 3). Each lower roller 13 has a plurality of projections on its outer peripheral surface.
The lower and upper pulley shafts 18 and 19 are supported by a frame 3 in confronting relation to each other, and the lower pulley shaft 18 is rotated in a sheet feeding direction shown by the arrow S by means of a driving motor 5. On the other hand, the upper pulley shaft 19 is so supported that it can be slightly shifted upwardly and downwardly.
The lower pulleys 11 are two (only one of which is illustrated in the drawing) and are disposed on the lower pulley shaft 18 at a predetermined distance. The plurality of lower rollers 13 are arranged between two lower pulleys 11. Each lower roller 13 has a diameter larger than those of the lower pulleys.
The upper pulleys 12 are arranged to be opposed to and contact the corresponding lower pulleys 11. Each upper roller 14 is disposed between the adjacent lower rollers 13 to stagger with the latter and has a diameter equal to or smaller than those of the upper pulleys 12.
With this arrangement, the staggered lower and upper rollers 13 and 14 can flex a sheet in a wave form to increase the rigidity of the sheet. Thus, the sheet can be fed straightly to the stacking section 30 without depending downwardly at a leading portion thereof. The sensor 15 is arranged in the vicinity of a contacting area between the lower and upper pulleys 11 and 12 to detect the passage of the sheet through the entrance section 10.
The sheet feeding section 20 is provided with a vacuum chamber 21, a suction belt 22 and a blowing mechanism 23. The vacuum chamber 21 comprises an enclosed box having a plurality holes formed in an upper surface thereof, and is attached to a lower portion of the frame 3 in such a manner that the upper surface of the box is flush with a bottom plate 31 of the stacking section 30, described more fully hereinbelow, an shown in FIG. 3. The suction belt 22 comprises an endless belt wound around a pair of pulleys 24, 25 on both sides of the vacuum chamber 21 to surround the chamber 21. The pulleys 24, 25 are rotatably mounted on a bottom frame (not shown) of the apparatus, and are rotated in a sheet feeding direction shown by the arrow T by means of a driving motor (not shown). The suction belt 22 has a plurality of holes adapted to be communicated with the holes of the vacuum chamber 21.
The blowing mechanism 23 is mounted on the frame 3, and comprises a blower 50 and a blow-out portion 27, as shown in FIG. 3. To the blower 50, a suction tube 51 for drawing the air in the vacuum chamber 21 and a discharge tube 52 for discharging the drawn air are connected. The blow-out portion 27 is attached to the entrance section 10 adjacent and below the pulley shafts 18, 19 and is connected to the blower 50 through the discharge tube 52. Further, the blow-out portion 27 has a plurality of discharge ports 28 directing toward the stacking section 30. Accordingly, when the blower 50 is activated, the air drawn from the vacuum chamber 21 is sent to the blow-out portion 27, and is discharged from the discharge ports 28 toward a lowermost sheet of a sheet stack in the stacking section 30. If the sheets are stacked on the stacking section 30, the stacked sheets A are floated above from the suction belt 22.
Incidentally, in an blow-out portion 27, the discharge tube 52 is attached to the end of the blow-out portion, and a air stream discharged from each discharge port 28 has the faster speed as the distance between the discharge port and the discharge tube 52 is longer. Thus, the sheet or sheets A in the stacking section 30 are shifted laterally upon being floated, whereby the sheet or sheets are properly positioned by being abutted against a side plate 32, described more fully hereinbelow.
The stacking section 30 is disposed adjacent to the entrance section 10, and includes a bottom plate 31 serving as a support means for the sheets, a sensor 16 (FIG. 3) for detecting the stacking of the sheets A, a guide means 35 for preventing the floating of the sheets, and a plurality of stopper plates 37 for regulating the stop position of the sheet A. The bottom plate 31 is fixed to the frame 3, and is inclined downwardly at its rear portion as shown in FIG. 3, and further has a notch or cutout at its front portion to expose the suction belt 22. To the bottom plate 31, a pair of side plates 32 and 39 are attached on both sides of the botch, and a rear plate 33 is also attached at the rear portion thereof. The side plates 32 and 39 act as sides guide for the sheet A, and the side plate 39 can be shifted laterally in accordance with the size of the sheet.
The guide means 35 includes a plurality of guide rods 35a, 35b which are spaced apart from each other and disposed above the bottom plate 31. Each of the guide rods 35a, 35b is fixed to a shaft 34 at its one end, and the shaft 34 is rotatably supported by the frame 3 in the vicinity of the pulley shafts 18, 19. Further, the other end of each guide rod is inserted into a corresponding slot formed in the rear plate 33. Thus, the guide means 35 can be pivoted about the shaft 34 in a limited range defined by the slots formed in the rear plate 33 not vary the distance between the guide means 35 and the bottom plate 31 largely. The guide rods 35a positioned on both sides of the guide means 35 have configurations different from those of inner guide rods 35b and are bent toward the bottom plate 31 at their central portions.
On the other hand, plates 37 acting as a stopper means are spaced apart from each other and are arranged above the bottom plate 31 in the vicinity of the rear plate 33. Each plate 37 is attached to a shaft 36a at its one end. The shaft 36a is rotatably mounted on the frame 3 and is connected to a driving motor 36. Further, the other end of each plate 37 is bent downwardly to be inserted into a corresponding notch 31a (FIG. 2) formed in the bottom plate 31. Thus, the stopper plates 37 can be pivoted upwardly and downwardly by means of the driving motor 36 in a limited range defined by the notches 31a.
Incidentally, a discharger 38 for removing the electrostatic charge carried by the incoming sheet A is arranged in the vicinity of the entrance section 10 above the guide means 35.
The ejecting section 40 is disposed adjacent to the bottom plate 31 of the stacking section 30 and below the blow-out portion 27 of the feeding section 20, and includes two sets of paired upper and lower ejector pulleys 42 and 41 contacting each other, and upper and lower pulley shafts 49 and 48 on which the ejector pulleys 41 and 42 are respectively mounted. The shafts 48 and 49 are rotatably mounted on the frame 3, and the upper pulley shaft 49 is connected to the driving motor 5 like the lower pulley shaft 18 in the entrance section 10, to be rotated in a direction shown by the arrow T. Further, the lower ejector pulley shaft 48 can be shifted slightly for up-and-down movement like the upper pulley shaft 19 in the entrance section 10. A sensor 45 (FIG. 3) for detecting the ejection of the sheet is arranged in the vicinity of the contacting area between the ejector pulleys 41 and 42.
Next, an operation of the sheet reversing apparatus 1 according to the above-mentioned first embodiment will be explained with reference to FIGS. 3 to 6. The sheet reversing apparatus are operated in the following two modes in order to improve the operability thereof and to reduce the cost thereof by making the memory means of the printer small-sized, as mentioned above.
(1) A Continuous Reversing Mode
In this mode, as shown in FIGS. 3 and 4, the incoming sheet is fed as it is to the ejecting section 40.
(2) A Stack Reversing Mode
This mode is used when the speed of conversion of the printing information into dots is slower than the speed of the incoming sheet, i.e., when the receiving ratio for sheets is larger than the sheet feeding-out ratio dependent upon the printing condition of the associated printer. As shown in FIGS. 5 and 6, while the sheets A and B still remains on the stacking section 30, a further sheet C is stacked through the sheet feeding path. At the same time, in response to the conversion of the printing information into the dots, the sheet is fed to the ejecting section 40 successively from the sheet A to the sheet C.
First of all, the continuous reversing mode will be explained.
The sheet A fed in the direction S from the sheet feeding path (not shown) connected to the printer is pinched by the pulleys 11 and 12 (in the entrance section 10) rotated by the driving motor 5, and is fed straightly to the stacking section 30 by the feeding force of the pulleys 11, 12. In this case, the blower 50 is activated, with the result that the air is supplied to the blow-out portion 27 through the discharge tube 52 and is discharged from the plurality of discharge portion 28 as air streams of different speeds. Further, by the suction force of the blower 50, the negative pressure is created in the vacuum chamber 21.
The fed sheet A is detected by the sensor 15 in the entrance section 10 and by the sensor 16 in the stacking section 30. Each sensor 15 or 16 emits a detection signal so long as the sheet remains in a detection position therefor. On the other hand, the associated printer emits a reversing signal commanding the initiation of the feeding of the sheet. The signals from the sensors 15, 16 are compared on the basis of the reversing signal, whereby the receipt and feeding of the sheet in accordance with the printing condition is determined. This comparison is performed by judging whether the signals from the sensors 15, 16 coincide with each other or not when a predetermined set time t 1 from the generation of the reversing signal is elapsed after the sheet has been detected by the sensors 15, 16. On the basis of the comparison result, the position of the stopper plates 37 shifted by the motor 36 is determined.
As shown in FIG. 7, if the signals from the sensors 15, 16 do not coincide after the set time t 1 has been elapsed, it means that the previous sheet has already been fed out and does not remain in the apparatus when the next sheet A is received. In this case, the stopper plates 37 are shifted to the lower position as shown in FIG. 3 to be deeply inserted into the notches of the bottom plate 31 thereby intersecting with the bottom plate 31. The sheet A fed to the stacking section 30 is pinched by a gap between the stopper plates 37 and the bottom plate 31, thereby absorbing the kinematic energy of the incoming sheet to stop the sheet. In this way, the sheet reversing apparatus is in the continuous reversing mode.
Consequently, the sheet A is stopped on the bottom plate 31 in place without deviating in the longitudinal direction or in the transverse direction, and then is attracted or sucked by the suction belt 22 enclosing the vacuum chamber 21. In this case, since the outer guide rods 35a of the guide means 35 are disposed in the vicinity of the sheet support means, both side edges of the sheet is held by these rods, thus preventing the raising of the central portion of the sheet even if the sheet is thin. Accordingly, regardless of the thickness of the sheet, the sheet is always attracted stably.
After the sheet is attracted, the driving motor (not shown) in the feeding section 20 is activated to rotate the suction belt 22 through the pulley 24, thus feeding the attracted sheet to the ejecting section 40. In this ejecting section, the ejector pulleys 41, 42 are rotated by the activation of the driving motor 5, and, accordingly, the sheet pinched by the ejector pulleys 41, 42 is fed meanwhile, the sheet is detected by the sensor 45 in the ejecting section 40. The driving motor in the feeding section 20 is stopped when the detection signal from the sensor 45 disappears. This motor may be intermittently activated for a predetermined time without using the signal from the sensor 45. Also in this case, the same advantage can be obtained.
As shown in FIG. 4, the sheet is introduced into the entrance section for a predetermined cycle, and the introduction of the next sheet B is detected by the sensor 15. Also regarding the sheet B, as in the case of the sheet A, the position of the stopper plates 37 is determined on the basis of the detection signals from the sensors 15, 16, and the sheet B is also stopped by being pinched by the gap between the stopper plates 37 and the bottom plate 31. By repeating such operations for a predetermined cycle, the stable continuous reversing of the sheets can be achieved.
Next, the stack reversing mode will be explained.
First of all, when the first sheet is introduced, as in the case of the aforementioned continuous reversing mode, the sheet A fed from the sheet feeding path (not shown) is fed to the stacking section 30 by the feeding force at the entrance section 10, and then is stopped by the gap defined between the bottom plate 31 and the stopper plates 37. Thereafter, the sheet is attracted by the suction belt 22. After the sheet is attracted by the suction belt, while in the continuous reversing mode, the driving motor (not shown) in the feeding section 20 is activated to feed the sheet A to the ejecting section 40, in the stack reversing mode, by repeating the above operation again, the sheet B is stacked on the sheet A.
That is to say, as mentioned with respect to the continuous reversing mode, whenever each sheet is introduced, the signal from the sensor 15 in the entrance section 10 and the signal from the sensor 16 in the stacking section 30 are compared. If the previous sheet A is not fed before the next sheet B is introduced and, as shown in FIG. 8, the signals from the sensors 15, 16 are coincident even after the set time upon the generation of the reversing signal has been elapsed, the stopper plates 37 are shifted by the driving motor 36 for a certain angle to each the upper position as shown in FIG. 5. In this position, each stopper plate 37 is lifted above the guide means 35 although the bent end portion thereof is still inserted into the corresponding notch 31a of the bottom plate 31. Consequently, the stopper plates 37 abut against each sheet at a different position differ from the position in the case of the aforementioned continuous reversing mode, i.e., at the bent end portions thereof, thus absorbing the kinematic energy of the sheet. The bounce of the sheet caused by the engagement between the sheet and the stopper plates 37 is suppressed by the guide means 35. In this way, the sheet reversing apparatus is in the stack reversing mode.
Although the firstly stacked sheet A is attracted by the suction belt 22, the next sheet B and the other sheets stacked on the sheet A are floated from the sheet A by the air streams from the discharge ports 28, thus separating from the sheet A. Further, the next and subsequent sheets (remaining sheets) are separated from each other by creating air layers between two adjacent sheets and are registered with each other by the bent end portions of the stopper plates 37 and the side guide plate 32. Now, since the outer guide rods 35a of the guide means 35 hold the both side edges of the floating sheet B, the rigidity of the sheet B is increased so as not to be easily flexed, and the air layers created between the sheets increases to a large extent. Further, since the side plates 32, 39 are disposed on both sides of the sheet, the air cannot escape from the sides of the sheet, thus improving the service efficiency of the air stream.
The sheets are successively introduced into the sheet reversing apparatus for a given cycle, and, thus, subsequently to the sheet C, a sheet D is introduced. On the other hand, in response to the reversing signal, the driving motor (not shown) in the feeding section 20 is activated to rotate the suction belt 22 through the pulley 24, thus feeding the attracted lowermost sheet A to the ejecting section 40. In this case, since the sheets B, C, stacked in the stacking section 30, are separated from the sheet A by the air streams from the discharge ports 28 and the electrostatic charge on the sheets has been removed by the discharger 38 when they are introduced into the apparatus, the sheets B, C are not moved together with the sheet A by the feeding force of the sheet A and the electrostatic force between the sheets, and, thus, remain being registered along the stopper plates 37. By repeating such operations for a predetermined cycle to feed the sheets B, C, a stable stack reversing of the sheet can be achieved.
Incidentally, the comparison of the detection signals from the sensors 15, 16 is performed in an operator provided in the associated printer or in the sheet reversing apparatus itself. The operator may be a conventional one, and thus, the explanation thereof will be omitted.
Next, the treatment of the sheet having different sizes will be explained with reference to FIGS. 9 and 10. In the illustrated sheet reversing apparatus 1, as shown in FIG. 1, each sheet is fed in its transverse width direction. Accordingly, for example, when a letter size sheet is treated in place of A4 size sheet, since the letter size sheet has a width wider than that of the A4 size sheet by about 6 mm, if the stopper means or stopper plates 37 remain being positioned in the position corresponding to the width of the A4 size sheet, the letter size sheet on the bottom plate 31 will be stopped in a condition that it extends by 6 mm toward the ejecting section, and is attracted to the suction belt 22 at that condition. Thus, in order to accommodate with the letter size sheet, the position of the stopper plates 37 in the continuous reversing mode may be set more upwardly than the case of the A4 size sheet so that the stop position of the sheet is retarded rearwardly by about 6 mm. Further, with respect to the stack reversing mode, as shown in FIG. 10, the stopper plates 37 may be shifted more upwardly than the case of the A4 size sheet to completely clear from the bottom plate 31, and the rear plate 33 may be served as a sheet stopper means. In this way, it is possible to position the letter size sheet in a desired position.
In the sheet reversing apparatus according to the illustrated embodiment, it is possible to perform both continuous reversing of the single sheet one by one and the stack reversing of the plural sheets.
The sheet reversing apparatus of the second embodiment of FIGS. 11 and 12 is characterized in that two kinds of stopper plates 53, 54 are provided and that these stopper plates 53 and 54 are operatively connected to each other through gears 55. The other arrangement of the second embodiment may be the same as that of the first embodiment, and, thus the same elements are designated by the same reference numerals and the explanation thereof will be omitted.
The stopper plates 53 and 54 are arranged in staggered fashion in a direction perpendicular to a plane of FIG. 11, and are fixedly mounted at their one ends on two shafts disposed adjacent to each other, respectively. A pair of gears 55 are respectively attached to these two shafts and are meshed with each other to rotate in opposite directions.
In operation of the sheet reversing apparatus of the second embodiment, when the A4 size sheet is used, in the continuous reversing mode, the stopper plate 53 is moved to intersect with the bottom plate 31, so that the rebounce of the incoming sheet is suppressed by a gap formed between the stopper plate 53 and the bottom plate 31 as in the case of the first embodiment. In this case, since the other stopper plate 54 is retarded upwardly by the rotation of the gears 55, the introduction of the sheet in the continuous reversing mode is not affected by the other stopper plate.
When the A4 size sheet is used, in the stack reversing mode, when the stopper plate 53 is retracted upwardly for a certain angle, the other stopper plate 54 is powered by the rotation of the gears 55 to intersect the bent end portion of the stopper plate 54 with the bottom plate 31, thereby defined the stop position of the A4 size sheet in the stack reversing mode.
Further, when the letter size or regal size sheet is used, in the continuous reversing mode, the stopper plate 53 is shifted upwardly for a certain angle more than that in the case of the A4 size sheet to increase a length for the sheet to be pinched, thereby determining the stop position of the sheet in response to the increase in the width of the sheet.
On the other hand, in the stack reversing mode, the stopper plate is 53 retracted upwardly for a certain angle less than that in the case of the A4 size sheet, whereby the both stopper plates 53, 54 are separated from the bottom plate 31, thus stopping the sheet by the rear plate 33 acting as the stopper means.
FIG. 13 is a block diagram showing a detecting means for detecting the size of the sheet. In this example, the entrance sensor 15 or another upstream sensor is connected to an operator 56, where the passing time of the sheet and the sheet size are calculated on the basis of the signal from the sensor and the moving speed of the sheet. The operator or calculator 56 is connected to the driving motor through a controller 57, which activates the motor 36 in accordance with the calculated result, thus determining the swinging angles of the stopper plates.
As mentioned above, according to the present invention, even in the continuous reversing mode or stack reversing mode, the sheet can be abutted against the pivotable guide at different positions to be registered and reversed, thus providing a sheet reversing apparatus having both a continuous reversing function and a stack reversing function.
Further, it is not necessary to provide an additional guide shifting mechanism for various sizes of the sheets, and it is possible to reduce the cost of the apparatus, to prevent the non-feeding and/or double-feeding of the sheets by decreasing the feeding resistance and to improve the reliability of the apparatus.
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A sheet reversing apparatus comprises a support in which sheets are stacked, an entrance section for guiding the sheet to the support, a blowing mechanism for directing an air stream to a sheet stack on the support to separate a lowermost sheet from remaining sheets, and a feeding mechanism for attracting the sheet to feed it. Further, stopper plates are provided to be pivoted above the support so that it cooperates with the support to pinch and brake the sheet therebetween in a continuous reversing mode wherein the incoming sheet is immediately fed and that it abuts against the incoming sheet by a portion thereof opposing a leading end of the sheet in a stack reversing mode wherein while the sheets are being stacked the lowermost sheet is separated and fed.
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BACKGROUND OF THE INVENTION
This invention relates to a mechanical plating process and apparatus therefor. More particularly, the invention relates to an improved mechanical plating process of the type in which a tenaciously adherent metallic coating is applied on a surface of an object by subjecting metal particles to mechanical energy in a liquid medium to flatten and cold weld the metal particles to the object surface to build up a continuous adherent metallic coating on the surface. Such mechanical plating processes are described in my earlier U.S. Pat. Nos. Re. 23,861; 2,689,808; 2,640,002; 3,023,127; 3,132,043; and 3,479,209, and in my co-pending application Ser. No. 948,230, filed Oct. 3, 1978, now U.S. Pat. No. 4,202,915, which are herein incorporated by reference, and elsewhere.
The present invention relates to a portable type apparatus for depositing a variety of metal coatings using mechanical energy on metal objects. The coatings laid down with the various types of apparatus to be hereinafter described are of very high quality. The coatings are metallurgically integrated and bonded, are ductile, stand up well to hammering and should in no way be compared with paints, spray coatings or the like.
The coatings of this invention are laid down using mechanical energy in which the tool is very portable permitting the coating of objects of all sorts in situ. This portable plater to deposit solid metal coatings usually by means of a hand held apparatus is, so far as I am aware, unique. In the entire history of metal coatings on steel and other substances there has never been a hand held tool that can lay down solid metallurgically integrated coatings of top quality and desired depth of coating in very short times all without the application of electricity or of molten metal.
The National Bureau of Standards reports that metallic corrosion in the United States amounts to about seventy billion dollars annually. This is equal to approximately 4% of the gross national product. The Bureau report concludes that a substantial portion of this is avoidable.
The capability of the portable plater to lay down, not a paint, but a true galvanized metallic coating of desired depth of coating that is smooth and attractive on both small and large surfaces in very short intervals, constitutes a unique totally new means for attacking the staggering cost of corrosion not only to Americans but around the world, especially in humid, tropical countries where corrosion of metal surfaces is greatly intensified.
My co-pending application Ser. No. 948,230 is primarily directed at the plating of large areas of moving steel which must be galvanized. Such areas would be plate, strip, sheet, pipe, wire, rebars, structural shapes and the like. This work is done with a multiplicity of plating elements usually used in pairs or in sets of four or five to a plating tool, a large number of such plating tools constituting a unit and a number of units creating the plating line. What this instant invention discloses is the use of just one element of this plating line, namely one plating tool which may consist of one or a number of plating elements, brushes or the like which can be hand held, is very portable, and which may be of a variety of types all of which will hereinafter be described.
In addition, my co-pending application is directed at the chemical procedures necessary to produce extremely high rates of plating reaching desired thickness of coat in very short times. This is accomplished, for example, by control of chemical varients such as pH of solution, flocculation and the like.
The processing techniques and materials disclosed in co-pending application Ser. No. 948,230 may be similar to those used with the present portable plater. I refer to such things as control of pH and flocculation and the use of lubricants to prevent seizing, galling, etc. The present invention is directed more explicitly to a variety of types of plating tool which can be used to practice the invention. In particular, the plating tool of the present invention is portable.
BRIEF SUMMARY OF THE INVENTION
In one aspect, the invention relates to a method of mechanically applying a metal coating onto the surface of an object comprising: providing a portable plating device comprising: a housing; a mechanical plating member moveable relative to said housing and having a plating surface adapted to be urged against and moved relative to said object surface; means for moving said plating member relative to said housing with said plating surface urged against said object surface; and means for holding and guiding said device for movement by an operator over said surface, said device being portable and capable of being moved to said object for plating thereof; moving said device into operative position with said plating surface of said plating member urged against said object surface; supplying an admixture of mechanical plating promoter and particles of plating metal to said plating surface; and moving said plating member relative to said housing and relative to said object surface to provide a solid metallurgically integrated metallic coating derived from said plating metal particles onto said surface.
In another aspect the invention relates to a portable device for mechanically applying a metal coating on a surface of an object comprising: a housing; a mechanical plating member mounted on the device for movement relative to said housing and having a plating surface adapted to be urged against and moved relative to a surface of an object for mechanically applying a metal coating on said surface; means for supplying to said plating surface of said plating member an admixture comprising mechanical plating promoter and particles of a plating metal; means for moving said plating member relative to said housing with said plating surface urged against a surface of an object for mechanically applying to said object surface a solid metallurgically integrated metallic coating derived from the plating metal particles supplied to said plating surface; and means for holding and guiding said device for movement by an operator over said object surface to effect metal plating thereof, said device being portable and capable of being moved to said object for plating thereof.
In a further aspect, the invention relates to a portable device for mechanically applying a metal coating on a surface of an object comprising: a housing; a mechanical plating member mounted on the device for movement relative to said housing and having a plating surface adapted to be urged against and moved relative to a surface of an object for mechanically applying a metal coating on said surface, said plating surface comprising a plurality of plating elements with spaces therebetween said spaces forming a reservoir and containing an admixture comprising mechanical plating promoter and particles of metal to be plated on said object surface; means for moving said plating member relative to said housing with said plating surface urged against a surface of an object for mechanically applying to said object surface a solid metallurgically integrated metallic coating derived from the plating metal particles supplied to said plating surface; and means for holding and guiding said device for movement by an operator over said object surface to effect metal plating thereof, said device being portable and capable of being moved to said object for plating thereof.
In a further aspect, the invention relates to a mechanical plating member comprising a plating surface adapted to be urged against and moved relative to a surface of an object for mechanically applying a metal coating on a surface, said plating surface comprising a plurality of plating elements with spaces therebetween, said spaces forming a reservoir retaining particles of metal to be plated on said object surface, said metal particles being present in said plating member in an amount sufficient to effect plating of a substantial portion of said object surface.
In further aspect, the invention relates to a portable device for mechanically applying a metal coating on a surface of an object comprising: a housing; a mechanical plating member mounted on the device for movement relative to said housing and having a plating surface adapted to be urged against and moved relative to a surface of an object for mechanically applying a metal coating on said surface; means for supplying to said plating surface of said plating member an admixture comprising mechanical plating promoter and particles of a plating metal; means for moving said plating member relative to said housing with said plating surface urged against a surface of an object for mechanically applying to said object surface a solid metallurgically integrated metallic coating derived from the plating metal particles supplied to said plating surface; and means for retaining a supply of an admixture of mechanical plating promoter and metal particles adjacent said plating surface when the plating surface is urged against a surface of an object for mechanically applying said metallic coating thereto; means for holding and guiding said device for movement by an operator over said object surface to effect metal plating thereof, said device being portable and capable of being moved to said object for plating thereof.
DETAILED DESCRIPTION
There follows a detailed description of preferred embodiments of the invention including drawings in which:
FIG. 1 is a diagrammatic side elevation view of a portable plating device in accordance with the invention;
FIG. 2 is an enlarged diagrammatic side elevation view of the portion of the device according to FIG. 1;
FIG. 3 is a diagrammatic cross sectional elevation view of a plating member in accordance with the invention;
FIG. 4 is an enlarged diagrammatic view of a portion of the plating member of FIG. 3; and
FIGS. 5 and 6 are enlarged diagrammatic views of plating elements in accordance with the invention.
Broadly speaking, the portable plater will cover a wide range of capabilities. On very small tools, very small brushes or pads possibly 1/4" to 1/2" in diameter are mounted on a ball and socket joint so that it can penetrate into recesses and around curves and restore jewelry and the like up to large plating tools, possibly 12" or more in diameter and consisting of a number of revolving elements attached to a hand held tool or to a portable mechanically operated tool for more accurate control.
The end user using the portable plater would be able to galvanize a farmer's barn roof that had started to rust, and large corporations would coat farm equipment, industrial equipment, fences, tanks, piping and the like. In areas subjected to heavy corrosion, special corrosion resistant alloys such as cadmium tin could be applied by the portable plater.
The types discussed will range from dipping the matted fibers into a suspension of the promoter and metal powder with or without thickening to using the matted fibers to carry the material to the surface to be plated when it is exhausted dipping it again, the operation proceeding like simple painting. From this the types will range to larger apparatus in which the operator can carry a tank on his back like a scuba diver which will feed a continuous flow of plating slurry to the plating tools. The types will encompass small tanks, apparatus like gardening spray tanks used for spraying insecticide. In other words, the tank can be put under pressure with a hand pump and the material forced out by the air pressure to the tool.
The types will encompass means for retaining and confining the solution so that it doesn't run out of the apparatus. The types will encompass apparatus using a wide variety of different kinds of brushes, matted fibers, pads and the like made of different materials such as stainless steel, brass, bronze and the like. These brushes, pads and the like will be used for different and specific purposes such as abrasively cleaning, plating and polishing. The types will encompass the use of disposable pads which can be used once and thrown away and the purchaser can buy a kit similar to those supplied with propane torches which have a variety of different size nozzles. The portable plater kit would carry a variety of plating tools and equipment for a variety of purposes.
As set out and described above, I will now describe in greater detail the variety of types of apparatus which are hand held but which may or may not be connected to a portable cart, small truck or the like which can be moved around from place to place. This disclosure does not relate specifically to the chemical procedures which are used in carrying out the invention.
These are disclosed, for example, in the U.S. patents mentioned above and in my co-pending application Ser. No. 948,230 and elsewhere.
The various types of apparatus fall into distinct types which have been mentioned above but which will now be described in detail.
This invention also discloses mechanically actuated plating tools, hand held, which are portable and can be used from place to place on a wheeled cart, vehicle or the like. This type of portable plater will primarily be used by industry for larger jobs and may easily be moved from job to job.
TYPE I
This is the paint brush procedure, namely the repetitive dipping and stirring of slurry containing the metal powder to be plated by means of brushes, pads and the like of matted fibers with or without sponges, regular brushes of various metals with or without absorbent material incorporated in the tool to retain more of the plating metal slurry. As in painting, when one load of the absorbed material is used up, in applying a metal coating, the tool is again dipped in the slurry for a fresh supply; the process being repeated until the job is done.
TYPE I-A
In this category the matted fibers, pads, brushes and the like are made from a metal wire, ribbon or the like that is not incorporated into the plate. Such metals are stainless steel, bronze, brass, steel and the like.
Some of these metals such as brass, bronze and copper will pick up a coating of the plating metal which eliminates wear of the tool because as the applied coating wears away it is reformed from the slurry. In this case the metal is transferred from the tips of the brushes or the matted fibers of the pad to the work being coated along with particles of metal powder or the like which are implanted and cold welded to form a homogenous metallurgically integrated coating.
Others like stainless steel tend not to pick up a coating and are particularly suitable for prior cleaning of the work, removal of rust or other soil. These brushes with stainless fibers or bristles can also be used for plating and they can also be used for producing a high degree of polish on the coating being deposited. They may also be used for obtaining an especially high degree of consolidation of the surface of the coating which produces an especially high quality coating.
TYPE I-B
In this type of apparatus the matted fibers, bristles and the like are of the same material as the coating metal. In this way the metal can be worn away and transferred to the surface being coated.
Many metals such as zinc do not have the right physical properties to be used as wires in the conventional type of brush but if the wires are laid not on their ends but on their sides to form an interlocking mass of fibers then the fibers can be used to coat the article to be plated.
They may, of course, be used along with regular metal powder.
TYPE I-C
As an extension of Type I-B described above, Type I-C relates to the use of disposable pads. These disposable pads would be purchased by the user for use in his portable plater. They contain everything necessary to accomplish coating. The chemicals and the metal powder or metal ribbon of the metal to be used in coating or metal in other suitable forms which could act as a binder, are compressed into a compact, absorbent pad. The pad is equipped with a fitting to be attached to the shaft of an electric drill or the like.
These disposable pads sometimes can contain absorbent material to increase the amount of material contained in the disposable pad.
These disposable pads are sealed in plastic wrappers when sold to retain the plating slurry in the form of jelly or liquid or thixotropic mixture. Alternatively, the disposable pads consist of dry chemicals together with a suitable binder, in which case the pad would either be used as a dry plater tool or could be dipped in water, or a weak organic acid solution or the like. These solutions can be supplied separately with the disposable pads which would hold the film forming surfactants and the coating metal. The acid flux being in a separate container. This would simplify the problem of manufacturing the pads.
Alternatively, if only water is used to activate the disposable pad then the fluxing material is present as a water soluble based acid salt in powdered form such as sodium acid sulfate which generates sulfuric acid when it is immersed in water. Means are provided by absorption, emulsification and the like to control the rate of acid released to the plating operation which would control the pH to produce maximum plating rates and maximum speed of plating. Since the disposable pads are included in Type I they could be used by repeated dipping of the pad in the water or the flux or in a slurry of the plating chemicals that also contains the acid flux or they may be used in Type II to be hereinafter described.
The advantage of the disposable pad would be its great convenience to the small user. The solutions would be properly mixed and retained. The bulk of the coating may come from metal such as zinc in the form of thin narrow ribbons or it may come from fine powder or from a combination of both. The ribbons wear away and contribute zinc to the coating. The ribbons are preferably the sole source of metal for coating. One of the functions of the metal in ribbon form would also be to act as a binder because these ribbons having highly active surfaces mat together very well to form a porous but strong, durable mass of interlocking ribbon. The ribbons may be of any suitable metal and are easily made as alloys directly from the molten state and chill cast at high speed.
TYPE I-D
The Type I type of apparatus is particularly suited for the use of very small brushes which would be particularly useful to the small user. For example, there may be small rusting areas in certain locations on a car. To illustrate, a Ford Thunderbird had such small rusting areas. These were abrasively cleaned with a very small brush and then were plated with zinc by repetitive dipping of a small matted metal wire brush in the plating slurry. A substantial, smooth zinc coating was thus laid down over the previously rusted area and this was then touched up with paint making a permanent invisible repair.
Again, it should be emphasized that this mechanically deposited coating is not a paint. The coatings applied to this car are solid, metallurgically integrated coatings made by a modification of the process which has been in widespread worldwide use for decades and sold under the trademarks as "Peen Plate" and "Dyko".
Such small pads or brushes work well when fitted in a ball and socket type joint so that they can be moved against curved surfaces, recessed areas, convoluted shapes such as jewelry and the like. The small size of the pads permits intimate contact in recessed areas on even very samll objects.
These very small brushes and pads lend themselves to the use of multiple units, each unit comprising elements which preferably rotate in opposite directions. Since these brushes are small, it is possible to install 2, 4 or 6 or more of them in a small space. This provides more uniform contact, and better distribution. This space between the revolving brushes can also be filled with absorbent material which will hold substantial quantities of plating slurry. The commonly used plunger for cleaning toilets is a useful general type of apparatus to contain the revolving plating tools and to prevent spillage. In modifying the plunger type the wooden handle is replaced by a metal tube attached to the plunger in place of the wooden handle. The drive shaft from, for instance, an electric drill passes through the tube. The revolving plating tools are attached to the end of the drive shaft and are within the plunger. In place of the plunger other retaining devices can be used such as a flexible bellows. A sponge or other suitable absorber is fastened to the upper surface of the flexible bellows and plating slurry is admitted at controllable rates through the hollow tube. When pressure is applied to the plunger or flexible bellows a closed container is created. The flexible bellows can be slid or moved from area to area with minimum spillage.
As in all types of Type I plating systems, the revolving plating tool can be used with each repetitive dip to stir the contents of the container, to keep the plating slurry in suspension during use.
This can be done by using an electric drill having variable speeds, for example, as the power source. In all Type I examples the power source is an electric motor with a single drive shaft or with multiple shafts as in a mixing machine like a cake mixer.
TYPE II
Type II is intended for large industrial users who expect to plate large surfaces such as bridges, transmission towers, ships, structural shapes and the like.
Type II is characterized by carrying a supply of plating slurry in a separate container which may or may not be a part of the portable plater. This is fed to the plating tool under pressure or by gravity at controlled rates.
The Type II apparatus would be much larger and would preferably consist of multiple brushes revolving in opposite directions with or without absorbent material and preferably with a rubber apron or skirt surrounding the apparatus to handle the plating slurry in the vicinity of the brushes and to minimize spillage. The amount of slurry used is quite small and normally is not a problem.
When using an apparatus such as a floor polisher on flat surfaces, a simple framework, for example, four feet square can be laid down on the flat surface to be coated to confine the PG,16 solution within the framework. Since the volume of solution required is very small, this is not normally necessary but in some cases it would be a convenience. This framework may have suction pads to hold it securely to the area to be coated together with a soft rubber gasket. A small supply of plating slurry and metal powder can be retained in the enclosed barrier. The barrier preferably is made of light weight plastic or it can be of angle iron or the like for larger areas and bigger jobs. A portable tool such as a floor polisher could be moved to and fro to cover the area inside the barrier enclosure. A small amount of plating slurry would be put into the barrier. This barrier enclosure could be moved as each enclosed area is plated.
Most floor polishers come fitted with a bag or container to hold shampoo for rugs and this can be used to contain the plating promoter and acid fluxes separately or the plating metal powder can be mixed in with the promoter in the bag and can thus be fed to the revolving plating tools. The floor polisher is used as a very successful example but I have no desire to be limited in any way to any particular form such as a floor polisher.
Similarly, I have no desire to be limited in any way as to the type or kind of barrier which is made to hold the plating slurry. For example, the light weight barrier may be a part of the plating tool itself. Suitable brackets would permit its installation and removal. I do not wish to be limited in any way to means of sealing the barrier device or holding it in place. The small amount of unused material can be recliamed, for example, by a vacuum pump. In this way there is no wastage. The vacuum pump can be made a part of the floor polisher apparatus so that the plating slurry material could be pumped back into the floor polisher bag or container for reuse. In this way large areas that are flat could be covered quickly and expeditiously simply by moving the portable barrier from place to place over the surface. There may be some small overlap of coating at the joins.
Instead of the container for the plating solution being carried on a man's back or in a hand held tank, the apparatus is, when desirable, mounted on a wheeled truck or cart. This can carry a much larger supply of promoter. The truck is equipped with appropriate pumps and can be moved from place to place as the job proceeds. It will be noted that this differs from Type I which is a repetitive dipping into a container containing slurry. In Type II a continuous supply of plating slurry and metal powder is fed continuously at controlled rates to the plating tool. In this case it is more nearly analagous to the high speed continuous process described in my co-pending application No. 948,230.
Types I and II have one thing in common which distinguishes them from the high speed continuous industrial installation and that is that the actual tool itself is hand held.
In the case of a small truck or hand cart or the like having a substantial reserve supply of plating slurry then two or more individual plating tools can be operated at the same time from the same source of supply. In other words, 2, 3, 4 or more operators could be operating from a portable supply system.
Reserve tanks of the slurry can be held in convenient areas possibly in 55 gallon drums so that they could be drawn on to replenish the immediate source of supply used in the actual plating operation itself.
As to the type of container and pressure system used, I have no desire to be limited in any way to any special system. Purely by way of illustration, there is one on the market, a portable sprayer for fruit trees and the like. This is operated either by means of a pump or by means of a plunger set in an air-tight tank. The liquid is placed in the tank, usually about three-quarters full. The lid is closed and made air-tight against its gasket. The plunger is then moved manually up and down to build a substantial pressure inside the container which drives a steady flow of the liquid through a nozzle onto the fruit trees or whatever is being sprayed. This type of apparatus is usually used in a three gallon size but they also market a one gallon size which is a small and convenient tank which is easily carried and operates on the same pressure system.
By modifying the type of nozzle used, this can be locked into the plating tool in which the rotating shaft of the drill press is inside a stationary tube into which the promoter and metal powder from the tank would be conveyed. It would fall by gravity into the area of the plating brushes, pads or the like. The stationary shaft could be attached to the casing of the drill press so that it could be easily removed when not in use.
This same type of apparatus can be used for a wide variety of installations operating on the same general principle. Apparatus similar to the plating type can be used for abrasive cleaning either wet or dry. I find that stainless steel bristle brushes either wet or dry may be used for abrasive cleaning. The operation is similar to that used in the plating mode except that instead of plating promoter a suitable cleaning slurry with the appropriate fluxes, abrasives or the like would be used.
EXAMPLE NO. 1
A block of steel approximately 21/2 inches square and 2 inches thick was held in a rubber gloved hand. In the other hand the operator held a small electric drill with a short shaft to which was attached a brush having brass wire which had been compressed in a vice to make a mat of fibers. This brush was dipped into a small pail containing a plating slurry and the revolving brush containing the slurry was held against each face of the steel block. The brush being dipped repeatedly in the slurry as needed. In approximately one minute all sides of the thick block of steel were galvanized with an attractive galvanized coating about 0.001" (one mil) thick.
It is noteworthy that had this block of steel been hot dip galvanized the entire piece of steel would have had to be raised above the melting point of zinc by dipping it in a bath of molten metal.
EXAMPLE NO. 2
A length of one inch diameter steel reinforcing bar (rebar) was revolved slowly in a long tank containing plating slurry. The bar had been abrasively cleaned first. Then the plating tool of Example No. 1 was dipped into the slurry of metal powder and plating promoter and moved to and fro against the revolving rebar. In a very short time it was galvanized with a very bright and shiny galvanized coat about 0.0015 inches thick. All the crevices were nicely plated. There were no unplated areas.
Had this been hot dip galvanized not only would it have had to be immersed in a bath of molten zinc but the small criss-crossing ridges would have been filled or partly filled with zinc.
EXAMPLE NO. 3
A steel plate 3/8 inch thick by 10 inches wide and 131/2 inches long, approximately one square foot, was degreased then acid pickled in dilute sulfuric acid and rinsed. It was placed in a shallow flat pan with cleats on the corners to prevent it from moving. The plating tool was a floor polisher. The plating tool consisted of the two active elements rotating in opposite directions and driven by a 1/3 horsepower motor. Plating slurry containing zinc powder was added and a floor polisher equipped with brushes of brass wire was moved by hand briskly to and fro over the flat steel piece. In a matter of approximately 25 seconds the steel piece was coated with an attractive shiny galvanized coating.
In order to check the uniformity of this coating a substantial number of thickness readings were made at uniform intervals over the plated surface of this piece of steel. The thickness readings were as follows:
0.0008"; 0.00085"; 0.0008"; 0.0009"; 0.0011"; 0.0011"; 0.0011"; 0.0008"; 0.0007"; 0.0011"; 0.0011"; 0.00085"; 0.00085"; 0.0008"; 0.0008"; 0.00085"; 0.0008"; 0.0008"; 0.0008"; 0.00085". The maximum variation in thickness therefore was 0.0004".
EXAMPLE NO. 4
In a similar example a long piece of steel three inches wide and about 25 feet long was degreased and given a mild acid pickle. It was then given a copper flash. The pan of Example No. 3 which contained rollers and guides at opposite ends was covered with about 1/4 inch of plating slurry containing zinc. One end of the steel strip was run through the guides and under the rollers and was pulled slowly through the pan, while the floor polisher of Example No. 3 was moved briskly to and fro across the moving piece of steel strip. In this way the steel strip was covered with a smooth galvanized zinc coating 0.001" (1 mil) thick.
In this example and in Example No. 3 the floor polisher was equipped with a plastic container designed to hold rug shampoo. This was filled with water to increase the weight of the floor polisher.
It is obvious that the thick block of steel of Example No. 1 could have been a section of a bridge girder. On a vertical or overhead section the plunger type hereinabove described may be used.
It is evident that the rebar of Example No. 2 could have been a pipe or angle iron which could be part of a transmission tower, water cistern supports and the like.
The steel section of Example No. 3 might have been part of a ship hull, a barn roof, the landing deck of an aircraft carrier, also the repair and maintenance of autos as hereinabove described.
Preferred embodiments of apparatus in accordance with the invention are illustrated in the drawings.
In FIG. 1, a portable plater according to the invention is designated 10 and is similar in appearance and construction to a floor polisher. The device includes a housing 11, a mechanical plating member 12, a reservoir 13 for supplying an admixture of plating promoter and particles of plating metal to plating member 12 via conduit 14 having a valve operable by means (not shown) readily accessible to an operator handling the device by means of handle grip 16. The plating member has a plating surface 20 adapted to be urged against and moved relative to a surface 21 of an object 22 to be plated. An upstanding member 17 interconnects the housing and the handle and provides means for supporting reservoir 13 such as by clamps 18 and for supporting a powder cord for electric motor 19 and means for actuating valve 15. Motor 19 is actuated by a switch preferably located near grip 16 for ready access. Similarly, valve 15 is preferably actuated by a member adjacent grip 16. For example, in a simple arrangement, an elongate rod (not shown) is mounted in reservoir 13 with the lower end, carrying a valve member, positioned to close conduit 15. The upper end of the rod member protrudes above the top of reservoir 13 and is provided at its upper end with a handle or the like. The conduit is opended by simply raising the rod member to a desired extent until a quantity of the admixture passes into the area of the plating element 12.
The weight of the plating device 10 urges the plating surface 20 of plating member 12 against surface 21. Extra weights may be carried by the device for this purpose. Housing 20 includes a peripheral retaining wall 23 which surrounds plating member 12 and provides means for retaining a supply or admixture adjacent to the plating member 12 and plating surface 20 thereof. The lower end of peripheral wall 23 is preferably urged against surface 21 to facilitate retention of a supply of plating materials adjacent plating surface 20. This is readily accomplished by providing a peripheral wall 23 which is resilient in the vertical direction. Of course this urging force should be substantially less than that which urges plating surface 20 against object surface 21.
Motor 19 is actuated to move plating member 12 relative to housing 11 with plating surface 20 urged against surface 21 for plating thereof.
Frame member 17 and handle 16 provide means for holding and guiding the device for movement by an operator over the object surface to effect metal plating thereof. Thus, the device is portable and being capable of being moved to object 22, which may be massive and stationary, for plating thereof.
Although only one plating member 12 is shown in FIG. 1, it will be clear a pair of such members can be easily provided similarly as in a conventional floor polisher. In that event, the plating members preferably rotate in appropriate directions. It will also be clear that any number of plating members can be provided such as an odd number thereof or a plurality of pairs thereof.
FIG. 2 illustrates a modification applicable to embodiments of the invention in which the plating member is permitted to assume various attitudes relative to the device which allows access to object surfaces other than flat. To this end a ball and socket joint 24 may be provided adjacent the lower end of frame member 17 which interconnects plating member 12 via housing 11 and handle portion 16 by which the device is moved relative to the object surface.
A plating member in accordance with the invention is shown in FIGS. 3 and 4. Plating member 30 includes a plating surface 31 adapted to be urged against and moved relative to an object surface for mechanically applying a metal coating on the surface. Plating surface 31 comprises a plurality of plating elements 32, preferably elongate metallic elements such as fibers or wires. Spaces 33 function between the plating elements to form a reservoir retaining particles 34 of metal to be plated on the object surface, the metal particles being present in an amount sufficient to effect plating of a substantial portion of the object surface. Plating members 30 may be pre-packaged with a supply of plating metal particles present and may be provided with some or all of the mechanical plating promoters selected for a particular use. A pre-packaged plating member of this type is preferably packaged in a protective wrapper of plastic, foil, or the like, particularly if the plating admixture carried by the member includes an evaporable liquid. In many instances it will be desirable to provide a plurality of plating members in kit form in which case the plating members in a kit may vary in size, shape, type of plating element, type of plating material, etc.
The plating elements are secured to a backing member 36 in any convenient way such as by embedding wire elements into member 36 similarly as in a wire brush. The elongate plating elements, however, are preferably matted down to facilitate retention of plating metal particles and other materials.
An absorbent material, such as sponge pieces 35 may be provided in the reservoir spaces to facilitate retention of liquids.
Member 36 is preferably attached, in use, to a rotating member, such as a drill chuck. For this purpose the plating member is provided with a shaft 37 extending rearwardly and generally normal to plating surface 31.
In some instance it is desirable to feed a supply of plating material to the plating member during operation of the device. This is disclosed, for example, in connection with FIG. 1. In order to facilitate a supply of plating material to the area of the plating surface 31, plating member 30 may be provided with channels 38 for supplying plating material from an external source of supply.
Metal fibers 32 may take various forms such as shown in FIGS. 5 and 6. As shown in FIG. 5, the distal end 51 of each wire 52 is flattened such that, in use, the broad side of the flattened area 51 can be pressed against the work surface. As mentioned above, a preferred form of plating member is formed of a mat or pad of tangled wires. However, many other configurations are suitable. The essential requirements are: (1) to provide a substantial void space to form a reservoir for liquid plating medium and metal plating particles; and (2) to hammer and cold weld the metal particles rapidly onto the surface to be coated at a high rate. Where wire brushes are used, the bristles may assume various configurations. For example, a "paper clip" or U-shaped configuration as shown in FIG. 6 is suitable. As shown therein, individual U-shaped "bristles" 61 (only one of which is shown) are secured to a base portion 62 of a plating member in any suitable manner. The bottom 63 of the "U" is the distal end of the bristle which is urged against the surface to be coated. It will be readily appreciated that the void space 64 between the "legs" of the U-shaped wire together with spaces between individual wires, provide a substantial void volume for the plating materials. Distal end 63 may be flattened similarly as described in connection with FIG. 5 to reduce abrasiveness. Irrespective of the type of bristles employed, they can be randomly or regularly arrayed. Of course, the plating elements need not be in the form of bristles. Other forms, such as a sponge-like pad, a textile-like pad, or the like having a substantial amount of void space as mentioned above, may be employed.
A closure member, such as a peripheral plastic wall member 39 may be provided around member 36 to retain plating material in the vicinity of plating surface 31.
A plating member containing plating metal particles in accordance with the inventor may be provided in a portable plating device such as shown in FIG. 1 in which case it is not necessary to supply metal plating particles from supply reservoir 13. Where the plating member is provided with all of the plating materials required for a particular task, or where the plating materials are otherwise supplied, supply reservoir 13 may be eliminated or filled with water of the like solely for the purpose of increasing the weight of the portable device during use. Reservoir 13 is provided with a conventional filler cap 40 for admitting water, plating materials, etc.
As mentioned above, the device may include means for retaining a supply of plating admixture adjacent the plating member surface in use. For example, a wall may be provided surrounding the mechanical plating member such as peripheral wall 23 in FIG. 1 and wall 39 in FIG. 3. The portion of such a retaining member which contacts the surface of the object to be plated is preferably fabricated of a material having a low coefficient of friction such that the device can be easily moved over the object surface.
In use, a portable plater in accordance with the invention is moved into operative position with the plating surface of the plating member urged against the object surface. An admixture of mechanical plating promoter and plating metal particles is then moved relative to its housing and relative to the object surface to provide a solid metallurgically integrated metallic coating derived from the plating metal particles onto the object surface. The device itself may also be moved relative to the object surface. The plating admixture may be supplied in any of the various ways described above such as from an external supply, from a supply carried by the device, from a supply provided in the plating member itself, from combinations of these arrangements. Moreover, some of the materials may be supplied in one way and others in another way. For example, all but the liquid ingredients may be pre-provided in a plating member and the member simply dipped into a liquid prior to use. Where the device is provided with the plurality of different types of plating members, the method may be interrupted, a plating member replaced by a different type of plating member, and the process then resumed. When the device is large, such as a device suitable for plating a bridge or other massive structures, the device may be provided with a motor or the like for moving the device over the surface to be plated. Thus, the device is portable in that it is transported to the work site and, after positioning adjacent a work surface, the device is moved by means of a drive motor that may be mounted on the device itself.
The term "plating surface" which is used herein refers to the surface of the mechanical plating member of the apparatus.
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This invention relates to portable apparatus capable of being transported to a work site and which uses mechanical energy to lay down on a surface a solid metallurgically integrated massive metal coating that cannot be confused with paints, sprays or the like. The coating can be compared with hot dip galvanized coatings or electroplate coatings and done in tumbling barrels in industrial plants for years and sold under the trademarks Dyko and Peen Plate. The invention also relates to plating methods utilizing portable apparatus.
The invention relates to different types of apparatus useful for various purposes such as the repairing by galvanizing of small rust spots on cars, the regilding of jewelry with tiny brushes rigidly mounted or equipped with ball and socket type joints, the plating of bridges, tanks, transmission towers, structural shapes, and large scale industrial uses.
The invention also relates to the use of disposable pads especially adapted for the small time user.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application No. 61/868,432, filed Aug. 21, 2013.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to firefighting apparatuses and, more particularly to apparatuses for roof ventilation.
[0004] 2. Description of the Prior Art
[0005] Roof ventilation is a common practice preformed by firefighters when they arrive at the seen of a fire. The purpose of ventilation is to release heat and smoke from the building which provides better visibility and protects firefighters from backdraft. Backdraft is a burst of flames that occurs when oxygen is introduced into the environment. A common way that oxygen is introduced into the environment is when a door or window is opened. There are two types of ventilation: horizontal and vertical. Horizontal ventilation is the first choice as it provides better results, and causes less property damage. Horizontal ventilation is achieved by cutting a hole into the roof of the burning structure. The size of the hole is typically 4 feet by 4 feet.
[0006] The current methods and apparatuses that are used to preform horizontal ventilation are filled with problems. The traditional method of roof ventilation, using an ax or similar tool such as the tools outlined in U.S. Pat. No. 20130263710 and U.S. Pat. No. 5,165,659, is a long process that endangers firefighters because they are on a burning structure for extended periods of time.
[0007] While some fire departments now use gas powered chainsaws to accomplish the task, the firefighters are still on the roof for several minutes. The chainsaws also add one more problem. Because of the high smoke environment that the saws are used in, they have a shorted lifespan which is costly to fire departments, and has led to malfunctions while the firefighters one the roof Although the apparatus described U.S. Pat. No. 6,298,945 tried to solve some of the issues of roof ventilation by keeping fire fighters off the roof, that apparatus can cause massive structural damage to buildings. This endangers the live of firefighters who are entering the building as well as prospective occupants. Furthermore, it requires a ladder truck to operate, which means that buildings that are not close to the road are not able to be vented by that apparatus.
BRIEF SUMMARY OF THE INVENTION
[0008] The Robotic Roof Ventilation Apparatus of the present invention solves the issues that are currently presented by the current methods and apparatuses of roof ventilation. The present invention is a medium sized robot that is easily carried by one or two persons. To use the robot firefighters simply attach it to the ladder via a clasp system, and then lean the ladder on the roof They start the robot by using their RFID card. Once the correct RFID card has been to presented to the robot it will ascend the ladder. Once on the roof the robot will cut the desired 4 foot by 4 foot hole. Once the hole is completed the robot will then navigate back to the ladder, and wait for retrieval. While cutting the roof the robot will be monitoring the depth of the cut to ensure the blade does not erroneously cut a truss which will damage the structure of the building. Furthermore, the body of the robot will be airtight which will ensure that smoke does not enter the equipment. The present invention solves many issues including the danger of firefighters staying on the roof, shortened equipment life, excessive damage of the roof, and portability.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0009] FIG. 1 is a view of the robot making a cut into the roof
[0010] FIG. 2 is a side view of the robot ascending the ladder.
[0011] FIG. 3 is a side view of the robot on the roof before making a cut.
[0012] FIG. 4 is a flow chart illustrating the electrical components of the robot.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The Robotic Roof Ventilation Apparatus, of the present invention, in essence, comprises generally of: electrical components, mechanical components, and stationary components.
[0014] The electrical components consist of a control unit [ 29 ], inputs, outputs, power supply unit, and the components for video transmission.
[0015] The inputs are sensors that will be continually feeding raw data, using both digital and analog signals, to the control unit [ 29 ]. The control unit [ 29 ] will be programmed to complete the process of roof ventilation in a series of steps. Before moving on to the next step the control unit [ 29 ] will ensure that the conditions are correct inside the robot, and externally by using the incoming data. As the control unit [ 29 ] moves the robot through the steps of roof ventilation it will need to use the outputs for anything that requires motion. The control unit [ 29 ] will use its built-in high powered transistors, and H-bridges to control the outputs. Furthermore, the control unit [ 29 ] will have the option to abort the mission. Examples that would force an abortion of the mission include: the temperature on the roof is starting to exceed the robots maximum operating temperature, large bursts of flames on the roof, or a stop signal coming from the ground that has been transmitted by the operator. The above situations would come to the control units [ 29 ] notice via the temperature sensor [ 7 ], IR sensor [ 4 ] or wireless RX [ 10 ] respectively.
[0016] The power supply is another electrical component. Its very simple and will consists of a small bank of rechargeable batteries [ 27 ], and an appropriate battery charger [ 28 ]. The rechargeable battery [ 27 ] will send power to the control unit [ 29 ], and the camera [ 11 ]/transmitter [ 12 ] when the robot is turned on. The battery charger [ 28 ] will be inside of the robot making it easy to recharge the robot. Unlike some devices that require the removal of batteries to charge the device, the user will simply plug a wire coming form the robot into a standard American electrical outlet running at 125 v Ac.
[0017] The final electrical components are the video transmitter [ 12 ] , and camera [ 11 ]. When the robot is powered on, the video transmitter [ 12 ] will transmit live video from the camera [ 11 ] so that firefighters can evaluate the situation on the roof without having any personal on it.
[0018] The main mechanical components consist of saw components, wheel [ 37 ], and the components required to ascend the ladder.
[0019] The mechanical saw components include the blade [ 35 ], body [ 36 ], lever [ 34 ], and gear box. The lever [ 34 ] will be inside an oval cut out towards the back of the saw's body [ 36 ]. As the lever [ 34 ] moves up and down the saw blade [ 35 ] will do the same. The blade [ 35 ] will be connected to a gear box which will be connected to the motor [ 18 ]. Its important to note that in the images the saw is depicted as a chain saw, but the robot may use any type of saw blade that is deemed suitable for roof ventilation. The components would remain the same, but the blade [ 35 ] would be different.
[0020] Each wheel [ 37 ] will be connected to an axel which will each be connected to one of the drive motors [ 16 - 1 ] [ 16 - 2 ] [ 16 - 3 ] [ 16 - 4 ]. Its important to note that the images depict a four wheel drive robot, but the robot could also contain a track system. The operation would be the same.
[0021] The mechanical components for ascending the ladder include a S-hook that clips onto the top rung of a ladder that will, hereafter, be called “clip” [ 30 ]. The other components is a wire braided rope that, hereafter, will be called “rope” [ 31 ].
[0022] The main stationary components include a u-bolt, insulation, and the robot's body [ 33 ]. The u-bolt will be placed on the underside of the robot centered in-between the two back wheels [ 37 ]. The robot's body will be constructed of metal or another material that has a high melting point. The insulation will be inside the robot and cover the entire body which will help keep the electrical components from being exposed to high temperatures.
[0023] The Robotic Roof Ventilation Apparatus of present invention in preferred embodiment starts the first step of roof ventilation by ascending the ladder [ 32 ] as shown in FIG. 2 . To understand how the robot ascends the ladder [ 32 ] its essential that it is understood how the components link together. The winch [ 24 ] is attached to a rope [ 31 ] which has a clip [ 30 ] on the other end of it. The clip [ 30 ] is manually attached to the top rung of any standard firefighting ladder [ 32 ]. The robot is prevented from tipping backwards off the ladder [ 32 ] as the rope [ 31 ] passes under a small U-bolt who's location was previously described in paragraph [0029]. The operator starts the process of roof ventilation by attaching the clip [ 30 ] to the top rung of the ladder [ 32 ]. The operator then leans the ladder against the roof; at this point the robot will be at the bottom of the ladder [ 32 ] with its wheels [ 37 ] hanging off the edge. Then the operator places their RFID card near the robots RFID reader [ 6 ]. After the control unit [ 29 ] verifies that correct RFID card was shown the winch [ 24 ] will start pulling the robot up the ladder [ 32 ]. Its important to note that the drive system [ 15 ] and thus wheels [ 37 ] will remain idle while the winch [ 24 ] is puling the robot up the ladder [ 32 ]. As the front of the robot is pulled off the top of the ladder the gyro's [ 5 ] signals will change because of the downward motion and the control unit [ 29 ] will activate the front motors [ 16 - 1 ] [ 16 - 2 ] which will active the front wheels [ 37 ]. After a short preset duration of time the control unit [ 29 ] will turn the winch [ 24 ] off. The front wheels will pull the back wheels [ 37 ] the rest of the way onto the roof. Once the back of the robot lands on the roof the gyro's [ 5 ] signal will change again and the control unit [ 29 ] will engage the back motors [ 16 - 3 ] [ 16 - 4 ] which will power the back wheels [ 37 ]. The robot will pull a small distance up the roof, and then the control unit [ 29 ] will stop the drive system [ 15 ].
[0024] Once the robot is stopped the control unit [ 29 ] will closely monitor the signals coming from the distance sensors [ 8 - 1 ] [ 8 - 2 ] which are mounted in the front of the robot's body [ 33 ]. If the control unit [ 29 ] determines that there are any chimneys, pipes, vents or any other sizable object in the way of the cutting path the control system [ 29 ] will use the drive system [ 15 ] to activate the wheels [ 37 ] to move the robot over a few feet. The control unit [ 29 ] will keep moving the robot via the drive system [ 15 ] and wheels [ 37 ] until a clear space is found. Once a clear space is found, or if the robot was in a clear space to begin with, the control unit [ 29 ] will start the process of cutting into the roof via cutting system [ 17 ] and mechanical components [ 34 ] [ 35 ] [ 36 ]. Using lever [ 34 ] and motor [ 18 ], the saw blade [ 35 ] will be lowered towards the roof. Once the blade [ 35 ] is hovering above the roof the saw motor [ 19 ] will engage and the blade [ 35 ] and the saw will began to cut a hole as the lever [ 34 ] pushes the blade [ 35 ] into the roof. The control unit [ 29 ] will be monitoring the amperage sensor [ 9 - 5 ] to detect if the cutting system [ 17 ] is cutting into a truss or the shingles/plywood. If the blade [ 35 ] is cutting into the truss the saw blade [ 35 ] will be raised slightly until it is only cutting the plywood and shingles. After that the control unit [ 29 ] will activate the drive system [ 15 ]. The control unit, [ 29 ] monitoring the signals coming from the encoders [ 1 - 1 ] [ 1 - 2 ] [ 1 - 3 ] [ 1 - 4 ] on each wheel [ 37 ] and accelerometer, [ 3 ] will use the drive system [ 15 ] and wheels [ 37 ] to propel the robot 4.2 feet. Once that distance has been reached the saw blade [ 35 ] will be lifted out of the roof using the same components that lowered it into the roof. After that the control unit [ 29 ] will back the robot up 0.2 feet by way feet and then make a 90 degree turn using the drive system [ 15 ] and wheels [ 37 ]. It will use the compass [ 2 ], and encoders [ 1 - 1 ] [ 1 - 2 ] [ 1 - 3 ] [ 1 - 4 ] to ensure that the turn is precise. The robot will repeat the process of cutting and turning until the desired 4 foot by 4 foot hole is completed.
[0025] Once completed the control unit [ 29 ] will use a distance sensor [ 8 - 3 ] which is mounted on the camera arm [ 13 ] to inspect the hole. Using servos [ 14 - 1 ] [ 14 - 2 ] [ 14 - 3 ] [ 14 - 4 ] the control unit [ 29 ] will move the camera arm [ 13 ] around to ensure that the roofing material fell though. If it did the robot will return to the ladder again using its drive system [ 15 ] and wheels [ 37 ] and wait for retrieval. If not, the control unit [ 29 ] will utilize linear actuator [ 20 ] to push the material into the building. Its important to note that the linear actuator [ 20 ] is located on the side of the robot opposite of the cutting system [ 17 ] and when activated by the control unit [ 29 ] the movable rod in the linear actuator [ 20 ] will press onto the cut portion of the roof causing it to fall in. After that the robot will then return to the ladder, and wait for retrieval. At that point the display [ 25 ] will flash the time it took to complete the roof ventilation and other potentially useful data so that once the firefighters recover the robot they will be able to log the data to help them study the art of firefighting.
[0026] While the processes described in paragraphs [0030], [0031], and [0032] is happening, the control unit [ 29 ] will be doing a few other tasks at the same time. As described in paragraph [0022] the control unit [ 29 ] will be monitoring the inputs to see if the mission needs to aborted. The control unit [ 29 ] will also be monitoring the amperage sensors [ 9 - 1 ] [ 9 - 2 ] [ 9 - 3 ] [ 9 - 4 ] and temperature sensor [ 7 ] for signs that it needs to utilize the cooling system [ 21 ]. Each of the amperage sensors [ 9 - 1 ] [ 9 - 2 ] [ 9 - 3 ] [ 9 - 4 ] are connected to one of the motors [ 16 - 1 ] [ 16 - 2 ] [ 16 - 3 ] [ 16 - 4 ]. By monitoring the signals coming form the amperage sensors [ 9 - 1 ] [ 9 - 2 ] [ 9 - 3 ] [ 9 - 4 ] the control unit [ 29 ] will be able to determine the general pitch of the roof. If the pitch of the roof is very steep the control unit [ 29 ] will turn on the Peltier Coolers (refried to as PTC in FIG. 4 ) [ 22 - 1 ] [ 22 - 2 ] [ 22 - 3 ] [ 22 - 4 ]. Each of the Peltier Cooler [ 22 - 1 ] [ 22 - 2 ] [ 22 - 3 ] [ 22 - 4 ] is attached to one of the drive motors [ 16 - 1 ] [ 16 - 2 ] [ 16 - 3 ] [ 16 - 4 ]. When turned on, the Peltier Cooler [ 22 - 1 ] [ 22 - 2 ] [ 22 - 3 ] [ 22 - 4 ] will help keep the drive system [ 15 ] from over heating. Another trigger for the Peltier Coolers [ 22 - 1 ] [ 22 - 2 ] [ 22 - 3 ] [ 22 - 4 ] would be if the temperature sensor [ 7 ] is showing that the temperature is quickly rising inside the robot. If the temperature keeps rising the control unit [ 29 ] will turn on the fans [ 23 ] in a effort to avoid abortion of the mission due to excessive heat. Another thing that the control unit [ 29 ] will be monitoring is the wireless Rx [ 10 ] for a change of command signal. If it receives that it will turn over control to the operator on the ground who will have a remote control. The robot wireless TX [ 26 ] will be used so that the robot can remained linked to the remote control on the ground. The final thing the control unit [ 29 ] will be monitoring is for a sudden drop or kill command. By combing data from its various inputs the control unit [ 29 ] will be able to determine if it falls through the roof. If the robot does fall though the control unit [ 29 ] will shut off the drive system [ 15 ] and cutting system [ 17 ] so that it lessens the danger for anybody inside the building. Furthermore, if the control unit [ 29 ] receives a kill command which is different from the stop command described in paragraph [0022] it will again shut off its drive system [ 15 ] and cutting system [ 17 ].
[0027] Closing Statement:
[0028] Having thus described in detail a preferred embodiment of the Robotic Roof Ventilation Apparatus of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many changes not exemplified in the detailed description of the invention could be made without altering the inventive concepts and principles embodied therein. It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein. The presented embodiments are therefore to be considered in all respects exemplary and/or illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and all alternate embodiments and changes to the embodiments shown herein which come within the meaning and range of equivalency of the appended claims are therefore to be embraced therein.
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A Robotic Roof Ventilation Apparatus that preforms the process of roof ventilation to protect the lives of firefighters. By keeping the firefighters off the roof of a burning building this robot completely changes the current process of roof ventilation as it provides a reliable way for firefighters to preform roof venation without any risk or loss of life.
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TECHNICAL FIELD
[0001] The present invention relates to a compressor, in particular to a compressor having a reciprocating piston compressor.
BACKGROUND OF THE INVENTION
[0002] Mobile compressors are used for example on construction sites for manual work in which compressed air is required for connected compressed-air tools. One type of compressor that is often used is the piston compressor, in which air is sucked into one or more cylinders, compressed by a piston and discharged again as compressed air. The amount of air delivered from the piston compressors is usually adapted to the compressed air required in each case by adjusting the drive speed of the machine driving the compressor. DE 10 2004 007 882 B4 discloses for example a compressor having a compressed-air sensor, depending on the measured value of which the speed of a piston compressor is adjusted.
[0003] Due to the clocked operation thereof, piston compressors do not discharge compressed air continuously but rather generate compressed air in pulses. Conventionally, a specific compressed-air buffer volume is therefore retained in order to damp the compressed-air pulses by means of the compressor. This buffer volume is conventionally retained in separate storage containers so that compressed air at equally high pressure can be provided to a compressed-air consumer connected to the storage containers. DE 10 2009 052 510 A1 for example relates to a speed-variable piston compressor that has a lightweight and compact compressed-air tank made of plastics material.
[0004] Various other attachments are provided for the design of compressed-air tanks for piston compressors: U.S. Pat. No. 6,089,835 A for example discloses a piston compressor having a compressed-air tank that is formed by a cover housing placed on the outside of the motor housing. U.S. Pat. No. 5,370,504 A discloses a piston compressor in which the compressor cylinders are completely embedded in a storage tank for compressed air.
[0005] However, there is a need for solutions for compressors that have a lower weight and smaller dimensions so that they better suit manual transport.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the invention, a compressor is therefore provided, comprising a motor, a drive shaft driven by the motor and connected thereto, a crank mechanism connected to the drive shaft, at least one compressed-air generation apparatus that is driven by the crank mechanism and is designed to generate compressed air, a crankcase that has an inner chamber wall in the shape of a hollow body, which receives the drive shaft at least in portions, an outer chamber wall that is spaced apart from the inner chamber wall radially with respect to the drive shaft, an end wall, and a dividing wall, and a compressed-air storage container that is designed to receive compressed air generated by the compressed-air generation apparatus, wherein the compressed-air storage container is formed by the inner chamber wall, the outer chamber wall, the end wall and the dividing wall.
[0007] The basic concept of the invention is that of embedding the storage container for compressed air generated by the compressor in the crankcase of the compressor by using the space around the drive shaft. In this case, it is highly advantageous that a separate storage container can be omitted, which in turn contributes to a considerable saving in terms of weight and cost. The entire structure of the compressor is more compact, and therefore the compressor remains easy to handle and portable despite having a large storage volume.
[0008] In addition, by integrating the compressed-air storage container in the crankcase, the amount of components required is reduced, which in turn simplifies assembly of the compressor. By supporting the drive shaft in an integral crankcase portion, there is also no need for the complex adjustment of the individual bearing points with respect to one another. Furthermore, components that are required for operating the compressor, for example a pressure sensor, pressure indicator, safety valve, non-return valve or drain valve can be connected to the integrated compressed-air storage container in a cost-effective manner and without additional pipes.
[0009] According to one embodiment of the compressor according to the invention, the compressor may also comprise a motor mount that receives and retains the motor and is connected to the crankcase by forming the end wall between the crankcase and the motor.
[0010] According to another embodiment of the compressor according to the invention, the compressor may also comprise at least one first bearing that supports the drive shaft and is arranged within the hollow body formed by the inner chamber wall.
[0011] In this case, the compressor may comprise at least one second bearing that supports the drive shaft. According to one variant, the second bearing may be arranged between the motor and the first bearing within the hollow body formed by the inner chamber wall. According to another variant, the second bearing may be arranged in the motor outside the hollow body formed by the inner chamber wall. The first and/or second bearing may for example be grease-lubricated rolling bearings.
[0012] According to another embodiment of the compressor according to the invention, the crankcase may be monolithically formed with the inner chamber wall, the outer chamber wall and the dividing wall. In this case, the monolithic crankcase may be designed as a light metal cast part.
[0013] According to another embodiment of the compressor according to the invention, the compressor may also have at least one brace that extends axially with respect to the drive shaft between the inner chamber wall and the outer chamber wall and divides the compressed-air storage container into at least two storage portions.
[0014] According to another embodiment of the compressor according to the invention, the at least two storage portions may be fluidically interconnected by compressed-air lines, valves and/or constrictions.
[0015] According to another embodiment of the compressor according to the invention, the compressor may also have at least one longitudinal rib that is formed integrally with the crankcase on the outside of the compressed-air storage container.
[0016] According to another embodiment of the compressor according to the invention, the compressor may also comprise a motor mount that receives and retains the motor, wherein the crankcase is formed around the motor so as to be spaced apart from the motor mount, and wherein the compressed-air storage container extends at least in part around the motor between the crankcase and the motor mount.
[0017] According to another embodiment of the compressor according to the invention, the compressed-air storage container may enclose the drive shaft within an angular range of 360°.
[0018] According to another embodiment of the compressor according to the invention, the ratio of the distance between the axis of rotation of the drive shaft and the point on the inner wall of the compressed-air storage container that is furthest perpendicularly from the drive shaft to the distance between the axis of rotation of the drive shaft and the upper dead centre of a piston of the compressed-air generation apparatus may be between 0.2 and 1.
[0019] According to another embodiment of the compressor according to the invention, the ratio of the distance between the axis of rotation of the drive shaft and the point on the inner wall of the compressed-air storage container that is furthest perpendicularly from the drive shaft to the maximum axial extent of the compressed-air storage container 25 may be between 0.3 and 2.5.
[0020] According to another embodiment of the compressor according to the invention, the compressed-air generation apparatus may have at least one compressor chamber and the volume ratio between the volume of the compressed-air storage container and the sum of the geometric working volumes of the compressor chambers of the compressed-air generation apparatus may be between 5 and 25.
BRIEF SUMMARY OF THE DRAWINGS
[0021] The invention will be described in more detail below with reference to the embodiments and the accompanying drawings.
[0022] The accompanying drawings are used in order to better understand the present invention and show variants of the invention. They are used to explain principles, advantages, technical effects and possible variations. Of course, other embodiments and many of the intended advantages of the invention are likewise conceivable, in particular with reference to the detailed description of the invention set out below. The elements in the drawings are not necessarily shown to scale and are simplified in part or shown schematically for reasons of clarity. Like reference signs denote like or similar components or elements.
[0023] FIG. 1 is a schematic sectional view of a compressor according to one embodiment of the invention.
[0024] FIG. 2 is a schematic cross section through the compressor in FIG. 1 .
[0025] FIG. 3 is a detailed view of the compressor in FIG. 1 according to another embodiment of the invention.
[0026] FIG. 4 is a schematic sectional view of a compressor according to another embodiment of the invention.
[0027] FIG. 5 is a detailed view of the compressor in FIG. 4 according to another embodiment of the invention.
[0028] FIG. 6 is a schematic sectional view of a compressor according to another embodiment of the invention.
[0029] FIG. 7 is a schematic sectional view of a compressor according to another embodiment of the invention.
[0030] FIG. 8 is a schematic sectional view of a compressor according to another embodiment of the invention.
[0031] Although specific embodiments are described and shown herein, it is clear to a person skilled in the art that an abundance of other, alternative and/or equivalent implementations can be selected for the embodiments, essentially without departing from the basic concept of the present invention. In general, all of the variations, modifications and deviations of the embodiments described herein should likewise be considered to be covered by the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0032] FIG. 1 is a schematic sectional view of a compressor 100 . The compressor 100 generally has a motor 40 that can be retained in a motor mount 41 . The motor 40 may for example be an electric motor having speed control. In this case, it may possible to use the synchronous motors thereof such as brushless DC motors or asynchronous motors. The motor 40 drives a drive shaft 24 that extends from the motor 40 into a crankcase 20 . In this case, the drive shaft 24 may be arranged substantially concentrically with the cross section of the crankcase shape 20 in the centre thereof. The drive shaft 24 is used to drive a crank mechanism 6 that reciprocates a piston 4 in a cylinder 5 , i.e. the crank mechanism 6 converts the rotational movement of the drive shaft 24 into a linear movement in the direction of extension of the piston 4 in the cylinder 5 . For this purpose, the crank mechanism 6 may have a counterweight, a crank web, a connecting rod, a connecting rod bearing and/or a gudgeon pin. In this case, a compressor chamber 11 is formed at the head of the cylinder housing, in which chamber air can be compressed in accordance with the main function of the compressor 100 . A fanwheel 45 may then be arranged on the crank mechanism 6 .
[0033] The compressed-air storage container 25 , which is formed as an integral component of the crankcase 20 in FIG. 1 , is a key component of the crankcase 20 . The crankcase 20 also has an inner chamber wall 26 a that may be cylindrical, for example, with a circular or polygonal cross section and receives and supports the motor-side part of the drive shaft 24 such that it can rotate. At least one bearing 28 b is therefore arranged in a first bearing seat inside the chamber wall 26 a. The bearing 28 b in the first bearing seat may support a non-motor-side part of the drive shaft 24 between the motor 40 and crank mechanism 6 , i.e. the bearing 28 b supports the crank mechanism 6 in a floating manner.
[0034] In addition, an additional bearing 28 a may be formed in a second bearing seat inside the chamber wall 26 a and may support a motor-side part of the drive shaft 24 between the motor 40 and crank mechanism 6 , i.e. the bearing 28 a supports the motor 40 in a floating manner. Because the two bearings 28 a and 28 b are in the portion of the crankcase 20 that forms the compressed-air storage container 25 , the bearing seats of the bearings 28 a and 28 b can be better aligned to one another. This enables improved concentricity of the bearing seats with respect to one another. It is in this case possible for the two bearing seats of the bearings 28 a and 28 b in the crankcase 20 to be accessed from one side, in particular if the radial extent of the bearing 28 a is less than that of the bearing 28 b.
[0035] In order to illustrate the geometry of the compressed-air storage container 25 , FIG. 2 is an example of a cross section through the compressor 100 along the cross-sectional line AA in FIG. 1 . The compressed-air storage container is arranged in this case so as to be substantially annular around the drive shaft 24 . The compressed-air storage container 25 may enclose a minimum angle of 200°, preferably of at least 240°, around the drive shaft 24 . In the example in FIG. 2 , the crankcase 20 and therefore the compressed-air storage container 25 are in principle a hollow-cylindrical shape. The compressed-air storage container 25 is in this case delimited by the inner chamber wall 26 a on one side and an outer chamber wall 26 b on the other side in the radial direction relative to the axis of rotation of the drive shaft 24 .
[0036] The outer chamber wall 26 b is an outer wall of the crankcase 20 that completely receives the inner chamber wall 26 a in its interior. In other words, the topology of the case formed by the outer chamber wall 26 b and the inner chamber wall 26 a substantially resembles two cylinders mounted inside one another, for example circular cylinders, prismatic cylinders or cylinders having a polygonal cross-sectional area. The cover areas of the cylinder shell surfaces formed between the by the outer chamber wall 26 b and the inner chamber wall 26 a may be enclosed by one or more dividing walls 34 on the other side or one or more end walls 23 on the other side in order to form the volume of the compressed-air storage container 25 .
[0037] The dividing wall 34 or the dividing walls 34 each have a main direction of extension that substantially extends perpendicularly to the axial direction of the drive shaft 24 . The end wall 23 likewise has a main direction of extension that substantially extends perpendicularly to the axial direction of the drive shaft 24 and is spaced apart from the dividing wall 34 or the dividing walls 34 by a length that substantially corresponds to the longitudinal extent of the compressed-air storage container 25 .
[0038] In the lateral direction, the compressed-air storage container 25 may be divided by one or more braces 33 . In this way, the compressed-air storage container 25 can be stabilised on the one hand and can be divided into a plurality of partial storage volumes on the other hand. Said partial storage volumes may be interconnected via compressed-air lines or other connection lines such as constrictions. Advantageously, compressed-air coolers and/or valves may also be arranged in the connection lines. In the example in FIG. 2 , three braces 33 are shown that divide the completely surrounding compressed-air storage container 25 into three equal partial storage volumes that each cover 120° of the crankcase 20 . Of course, other divisions with more or fewer partial storage volumes or an asymmetrical division are likewise possible. The braces 33 may for example be integrally formed with the crankcase 20 , for example in a common metal cast part.
[0039] FIG. 3 is a detailed longitudinal section through the compressor 100 in FIG. 1 . The compressor 100 is shown in the example in FIG. 3 as a dry-compressing speed-variable piston compressor 100 that works in accordance with the principle of reciprocating piston compression. In this case, however, it is likewise possible to use an oil-lubricated compressor instead of a dry-compressing compressor. The compression can in this case, as shown by way of example in FIG. 3 , take place in one stage; however, it may also be possible to carry out the compression in a plurality of stages.
[0040] The compressor according to FIG. 3 , in a compressor portion 1 on the right-hand side of the figure, has a cylinder 5 in which a piston 4 is arranged in order to compress air from the surroundings. Air from the surroundings can be sucked through an intake air filter 2 into the compression chamber 11 via an inlet opening 3 having an inlet valve. This takes place when the piston 4 moves downwards.
[0041] The linear working movement for the piston 5 is produced by a crank mechanism 6 that is connected to the rotor 43 of the motor 40 by means of a drive shaft 24 . The drive shaft 24 may be mounted so as to rotate relative to the crankcase 20 by means of two bearings 28 a and 28 b, for example prelubricated rolling bearings having fixed/floating bearings. The crankcase 20 has a crank mechanism portion 21 that encloses the crank mechanism 6 at least in part and has a storage portion 22 that adjoins the crank mechanism portion 21 and is arranged axially between said portion and the motor 40 .
[0042] It is preferably provided for the dividing wall 34 to separate the compressed-air storage container 25 from the crank mechanism 21 inside the crankcase 20 , i.e. the crank mechanism 6 itself is not located in the air storage volume of the compressed-air storage container 25 . The storage portion 22 is therefore disjointedly formed with the crank mechanism portion 21 . In particular, it is also provided for the cylinder 5 and the piston 4 not to be arranged inside the storage portion 22 , i.e. for the volume of the compressed-air storage container not to include the cylinder 5 and the piston 4 .
[0043] The storage portion 22 has an inner chamber wall 26 a that is hollow or tubular in order to be arranged around the drive shaft 24 and receives the region of the drive shaft 24 leading through the storage portion 22 and at least one of the two bearings 28 a and 28 b. The inner chamber wall 26 a may have recesses for one or more bearing seats of the bearings 28 a and 28 b. Furthermore, more than two bearings 28 a and 28 b may be provided.
[0044] Furthermore, the storage portion 22 has an outer chamber wall 26 b that may be arranged so as to be concentric around the inner chamber wall 26 a and spaced apart therefrom. Preferably, the inner chamber wall 26 a and the outer chamber wall 26 b are integrally formed with the crankcase 20 , i.e. formed as an integral portion of the crankcase 20 .
[0045] The inner chamber wall 26 a and the outer chamber wall 26 b define, together with one or more dividing walls 34 , the extension plane of which extends substantially perpendicularly to the axis of rotation of the drive shaft 24 , a compressed-air storage container 25 of the compressor 100 . The compressed-air storage container 25 is arranged annularly around the inner chamber wall 26 a at least in portions so as to be concentric with the drive shaft 24 . In other words, the compressed-air storage container 25 therefore surrounds the drive shaft 24 at least in a partial angular range. In the example in FIG. 3 , the compressed-air storage container 25 is arranged completely, i.e. in an angular range of 360°, around the drive shaft 24 . However, it may also be possible to provide only partial angular ranges of less than 360° around the drive shaft 24 in which angular chambers are defined by the chamber walls 26 a and 26 b and the dividing walls 34 for the function of the compressed-air storage container 25 . On the motor side, the compressed-air storage container 25 is tightly sealed with respect to the motor region or the motor mount 41 by an end wall 23 of the crankcase 20 . The compressed-air storage container 25 thus defines a control volume that is used to receive and temporarily store compressed air generated by the piston compressor by means of the corresponding dimensions of the chamber walls 26 a and 26 b and the axial distance L 3 between the dividing walls 34 and the end wall 23 of the crankcase 20 .
[0046] The motor mount 41 may assume the function of supporting the torque between the rotor and stator of the motor 40 . The motor mount 41 may be a component that completely or only partially surrounds the motor 40 and may have closed bordering walls having braces, columns or the like. In this case, the motor mount 41 may also act as a completely closed motor housing.
[0047] The motor mount 41 may in addition form the end wall 23 , which is arranged between the motor 40 and the storage portion 22 in the example in FIG. 3 . However, it may also be provided for the end wall 23 to be arranged on the outside of the motor 40 so that the motor 40 is contained at least in part by the storage portion 22 , i.e. that the volume of the compressed-air storage container 25 extends at least in part in the axial direction of the drive shaft 24 , completely or in a partial angular range around the motor 40 .
[0048] After a suction cycle of the piston 4 , the sucked-in air is compressed in the compression chamber 11 in a compression cycle when the piston 4 moves upwards and is output via the outlet opening 7 and an outlet valve arranged therein. The compressed air that is discharged via the outlet opening 7 may be output into a compressed-air line 8 that may comprise a region having a cooling line 9 for cooling purposes. The compressed air passes via the cooling line 9 through the non-return valve 10 to reach a compressed-air storage container 25 of the compressor 100 .
[0049] Sealing with respect to the surroundings may expediently take place by means of seals 29 and 30 , for example O-rings. Both the crankcase 20 and the motor mount 41 may be reinforced by ribs 32 . Said ribs 32 , which can be attached to the outside of the crankcase 20 and/or of the motor mount 41 in a similar manner, contribute to better heat dissipation from the compressed air. In addition, it is possible to optimise the mechanical stability of the compressor 100 in this way.
[0050] A compressed-air discharge line, for example a compressed-air tube for a tool operated by compressed air through which the compressed air may be extracted as required from the compressed-air storage container 25 , may be connected via a compressed-air coupling 31 .
[0051] When the compressor is in operation, a compressor controller 60 may retrieve the pressure of the compressed air that is measured by a pressure sensor 27 arranged on the compressed-air storage container 25 via a control line 61 . If the measured target pressure in the compressed-air storage container 25 deviates from the target pressure stored in the compressor controller 60 , a target speed signal for the motor 40 can be determined from the control deviation, which signal is sent by the compressor controller 60 as an actuation signal via a control line 62 to a motor controller, for example to the frequency converter 70 of an electric motor 40 . The frequency converter 70 controls the speed of the motor 40 depending on the sent actuation signal.
[0052] When the speed of the motor 40 is adjusted and the amount of delivered air from the compressor 100 is adapted as a result, it is advantageous for the size of the compressed-air storage container 25 to be able to be reduced while the switching frequency remains the same. As an alternative, it is likewise possible to reduce the switching frequency while the size of the compressed-air storage container 25 remains the same. By adjusting the speed, it is moreover advantageously possible to reduce the minimum amount of delivered air from the compressor, which in turn can lead to a smaller size of the compressed-air storage container 25 or a lower switching frequency. Finally, it is also possible to fill the compressed-air storage container 25 more rapidly after an idle phase, in particular if the compressor 100 is operated in a speed-adjusted manner and can provide a greater amount of delivered air at a low pressure.
[0053] In the example in FIG. 3 , the motor 40 is an electronically commutated synchronous external rotor motor in which a frequency converter 70 is directly attached to the stator 44 . The stator 44 bears the stator winding 46 and may for example be connected to the motor mount 41 by screws. The torque required for the compression of the compressor 100 is generated by the alternating magnetic field generated in the stator winding 46 in a known manner by interaction with the permanent magnets 48 in the rotor 43 of the motor 40 .
[0054] FIG. 4 is a longitudinal section through a compact speed-variable piston compressor 100 having an alternative motor construction. Said compressor differs from the compressor 100 in FIG. 1 substantially in that the motor 40 is an internal rotor motor having an external frequency converter. FIG. 5 shows a more detailed view of the compressor from FIG. 4 . In this case, the motor 40 has an external frequency converter 70 that is connected to the motor 40 via a motor connection cable 47 . If, for assembly reasons, the motor 40 cannot be attached to the crankcase 20 by means of the motor mount 41 , a cover can additionally be provided as the end wall 23 in the case of the compressor from FIG. 5 . The cover 23 may attach the motor 40 to the motor mount 41 , which can then assume a housing function for the motor 40 . The cover 23 can also fluidically seal the compressed-air storage container 25 , which is located in the crankcase 20 .
[0055] Both for the compressor 100 in FIGS. 1 to 3 and the compressor 100 in FIGS. 4 and 5 , the maximum radial extent L 2 (distance between the axis of rotation of the drive shaft 24 and the point on the inner wall of the compressed-air storage container 25 that is furthest perpendicularly from the drive shaft 24 ) may be in a specific ratio to the compressor length L 1 (distance between the axis of rotation of the drive shaft 24 and the upper dead centre of the piston). In the simplest case, the extent L 2 may be smaller than or equal to the compressor length L 1 . A ratio of L 2 /L 1 ≦ 2 / 3 is advantageous. The ratio L 2 /L 1 may in this case be between 0.2 and 1, preferably between 0.4 and 0.66. In absolute terms, the extent L 2 may be smaller than 150 mm, in order to ensure the compactness and therefore the portability of the compressor 100 for example.
[0056] The maximum radial extent L 2 may also be in a specific ratio to the maximum axial extent L 3 of the compressed-air storage container 25 . If the compressed-air storage container 25 is arranged between the crank mechanism 6 and the motor 40 , the ratio L 2 /L 3 may be between 0.3 and 2.5, preferably between 0.5 and 1.33.
[0057] In addition, the volume ratio between the volume V R of the compressed-air storage container 25 and the geometric working volume V H of the compressor chamber 11 (or the sum V H of all the working volumes V Hi of all the compressor chambers 11 in the case of a plurality of cylinder 5 ) can be set in order to be able to eliminate the damping of the compressed-air pulses in an optimum manner. The ratio V R /V H may in this case be between 5 and 25.
[0058] The crankcase 20 including all the chamber walls 26 a, 26 b and end walls 23 and dividing walls 34 may be entirely formed in one piece in FIGS. 1 to 5 , for example by a dead-mould casting method or a rapid prototyping method such as selective laser melting, 3D printing, additive layer manufacturing, electron beam melting, laser deposition welding or similar methods. Alternatively, it may also be possible for the chamber walls 26 a, 26 b to be composed of a plurality of parts that are sealed with respect to one another and interconnected, for example screwed together. The crankcase 20 and the relevant components thereof, such as walls, dividing walls and end walls, may for example be produced in a pressure die casting method, for example from a light metal such as aluminium or magnesium.
[0059] FIGS. 6, 7 and 8 are schematic views of additional variants of a compressor 100 . The compressors 100 in FIGS. 6 and 7 differ from the compressors 100 in FIGS. 1 and 4 substantially in that the second bearing 28 a is housed in the motor 40 whereas in FIG. 6 is it on the non-crankcase-side of the motor 40 and in FIG. 7 it is on the crankcase-side of the motor 40 . The compressor 100 in FIG. 8 has a crankcase 20 that together with the motor mount 41 forms a compressed-air storage container 25 that is extended axially with respect to the drive shaft. The compressed-air storage container 25 extends around the motor 40 inside the crankcase 20 , which is correspondingly spaced apart from the motor mount 41 . In this case, the ratio L 2 /L 1 of the maximum radial extent L 2 to the maximum axial extent L 1 of the compressed-air storage container 25 is between 0.12 and 1, preferably between 0.2 and 0.5.
[0060] The compressed-air storage container 25 may enclose the motor 40 in a partial angular range of less than 360° or completely, i.e. over a circumference of 360°. It may also be possible for the compressed-air storage container 25 to completely enclose the motor 40 relative to the angular range around the drive shaft 24 , but to only partially enclose the motor 40 in the axial direction of the axis of rotation of the motor, i.e. is not completely formed up to the non-crankcase-end of the motor mount 40 .
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A compressor includes a motor, a drive shaft driven by the motor and connected thereto, a crank mechanism connected to the drive shaft, at least one compressed-air generation apparatus that is driven by the crank mechanism and is designed to generate compressed air, a crankcase that has an inner chamber wall in the shape of a hollow body, which receives the drive shaft at least in portions, an outer chamber wall that is spaced apart from the inner chamber wall radially with respect to the drive shaft, and a dividing wall, and a compressed-air storage container that is designed to receive compressed air generated by the compressed-air generation apparatus. The compressed-air storage container is formed by the inner chamber wall, the outer chamber wall, the end wall and the dividing wall.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 13,345,580, filed Jan. 6, 2012, which is a divisional of U.S. patent application Ser. No. 12/957,213, filed Nov. 30, 2010, now U.S. Pat. No. 8,132,823, which is a divisional of U.S. patent application Ser. No. 11/838,492, filed Aug. 14, 2007, now U.S. Pat. No. 7,871,094, all of which are incorporated herein in their entirety by this reference thereto.
FIELD OF THE INVENTION
This invention relates to wheelchairs. More particularly, the invention relates to a modular wheelchair assembly that is configurable to different tilt configurations and to features thereof.
BACKGROUND OF THE INVENTION
The designs of most wheelchairs are optimized to accommodate a particular level of disability. Persons with low disability tend to use relatively inexpensive wheelchairs that have no seat tilt or a fixed seat tilt and a footrest assembly that easily accommodates self-propulsion using the occupant's feet.
Persons with moderate disability may prefer a wheelchair that allows for optional self-propulsion but that can be tilted to offer a range of seating angles. Tilting the seat provides pressure relief to the occupant, reduces discomfort associated with sitting for long periods of time, and provides passive correction for deformities. The ability to self propel using the feet may be preserved despite various tilt angles by providing the axis of rotation near the front of the seat such that the distance from the knees to the ground remains relatively constant. A disadvantage of such a configuration is the force required in order to move the weight of the occupant about the axis of rotation. This is sometimes compensated for by a pneumatic assist mechanism extending between the base of the chair and the seat frame as described in commonly owned U.S. Pat. No. 6,447,064.
High disability individuals typically require a wheelchair with deeper tilt angles to improve trunk stability and head control. Some such wheelchairs also use mechanical actuators to accommodate the significant force sometimes required to move the weight of the occupant through deep tilt angles. It is also known in the prior art to minimize the effort required to tilt the occupant by providing a pivot point as close as possible to his center of gravity. U.S. Pat. No. 7,007,965 provides an example of such a system.
While various tilt configurations may be suited to particular types or levels of disability, many individuals suffer from disabilities that progress over time. Over the course of such a disability, the occupant may graduate through 3-4 different types of wheelchairs, each having different attributes. For example, a no-tilt or fixed tilt wheelchair may be used at the early onset of disability, a self-propellable tilting wheelchair can be used when the disability becomes moderate, and a deep tilt wheelchair can be used in the later stages of disability.
The present invention addresses the need for a reconfigurable modular wheelchair that is capable of being selectively configured in a fixed tilt configuration, a dynamic tilt-in-space configuration with the axis of rotation near the occupant's knees, or a dynamic tilt-in-space configuration with the axis of rotation near the occupant's center of gravity, as required to accommodate the evolving needs of the occupant.
SUMMARY OF THE INVENTION
The wheelchair according to the invention comprises a base frame, a seat frame, and interchangeable interface components adapted to assemble the base frame and seat frame to one another according to either a fixed tilt configuration, a dynamic tilt-in-space configuration with the axis of rotation near the front of the seat, or a dynamic tilt-in-space configuration with the axis of rotation near the center of gravity of the occupant.
In a first configuration, the wheelchair comprises a base frame assembly pivotally connected to a seat frame assembly about cooperating pivot elements at a pivot point located near the knees of the occupant. A support assembly extends between a base crossbar assembly and a seat crossbar assembly. The support assembly comprises a bracket removably attached to one of such crossbar assemblies, and an interface element attached between the brace and the other one of such crossbar assemblies. The interface element includes a plurality of attachment points arrayed to share a constant radius in relation to the pivot point. The selection of the attachment point allows the base frame and the seat frame assemblies to be assembled at a variety of fixed tilt angles to thereby provide adjustable static positioning for the user requiring minimal support and correction.
In a second configuration, the wheelchair again provides a pivot point near the knees of the occupant through cooperating pivot elements on the base frame and seat frame assemblies. A support assembly extending between the base crossbar assembly and the seat crossbar assembly comprises a bracket and a bias mechanism such as a gas strut to enable the occupant to be lifted from a low tilt angle more easily than would be the case without the mechanism. In one aspect, the pneumatic mechanism includes a bell crank arrangement to converts the longitudinal force from the gas strut to an upward force to lift the seat frame and to modulate the degree of resistance provided at different tilt angles as the centre of gravity of the occupant moves forward or backward and to translate.
In a third configuration, the chair may be tilted about an axis that approximately coincides with the centre of gravity of the occupant. The tilting is provided by suspending the seat frame from an axis of rotation supported on the base frame. This configuration has the advantage of making it very easy to tilt the wheelchair and obviates the need for pneumatic mechanisms or actuators.
The invention is also directed to a drive wheel system wherein the wheel lock assembly and the anti-tip assembly are connected to the axle mounting plate such that the change of drive wheel position on the base frame does not require consequent adjustment of the lock and anti-tip assemblies.
In yet a further aspect, the invention is directed to a telescoping crossbar assembly comprising an outer sleeve having a base with a non-straight cross-section, a hollow inner shaft having a base with a cross-section conforming to said non-straight cross-section, and a pair of aligned fastener holes in said outer sleeve, one of said fastener holes having a larger diameter than the other.
In yet a further aspect, the invention is directed to a mounting assembly for securing fasteners to an elongated hollow member such as a side tube of a wheelchair. The hollow member has a plurality of fastener apertures extending longitudinally of the hollow member. An elongated insertion member is adapted to be longitudinally inserted and retained in the hollow member. A plurality of nuts are retained in several seats provided along the length of the insertion member such that when it is inserted and retained in the hollow member with the nuts aligned to the fastener apertures, fasteners inserted into the apertures will engage the nuts and be retained without the need to traverse the opposing wall of the hollow member.
In a further aspect, the wheelchair has a seat frame assembly comprising opposed seat rails and at least one seat crossbar assembly extending between them. A base frame assembly comprises opposed base rails and at least one base crossbar assembly extending between the base rails. A forward portion of the seat frame assembly and a forward portion of the base frame assembly is adapted to receive opposed removable pivot assemblies to pivot the seat frame assembly in relation to the base frame assembly. The seat and base crossbar assemblies are adapted to removably receive a support assembly extending between them. A forward portion of each of the seat rails is adapted to selectively attach a pivot member thereto and a rearward portion of each of the base rails is adapted to receive a removable pivot arm thereon enabling reconfiguration of the wheelchair between a pivot point near the user's knees and a center of gravity pivot point.
In another aspect, a fixed tilt wheelchair comprises a seat frame assembly and a base frame assembly. A first pivot element is removably attached to a forward portion of the seat frame assembly. A second pivot element is removably attached to a forward portion of the base frame assembly and the first and second removable pivot elements, when installed, cooperate to define a pivot so point between them. A removable support assembly is connected between the seat frame assembly and the base frame assembly, the support assembly being configurable to define any one of a plurality of predetermined relative pivot angles between the seat frame and base frame assemblies.
Another aspect of the invention relates to a mounting assembly for an elongated hollow member. An elongated hollow member has a plurality of fastener apertures extending transversely of the hollow member. An elongated insertion member is adapted to be longitudinally inserted and retained in the elongated hollow member, the insertion member having a plurality of seats for retaining nuts therein. A plurality of nuts are seated in the seats and the insertion member is inserted into the hollow member to align said nuts with the fastener apertures.
In another aspect a dynamically tiltable wheelchair comprises a seat frame assembly, a base frame assembly, a first pivot element removably attached to a forward portion of the seat frame assembly and a second pivot element removably attached to a forward portion of the base frame assembly. The first and second removable pivot elements, when installed, cooperate to define a pivot point between them, said first and second pivot elements being operatively secured to one another. A removable support assembly is connected between the seat frame assembly and the base frame assembly, the support assembly comprising bias means between the seat frame assembly and the base frame assembly.
In another aspect the bias means comprises an extendible element one end of which is pivotally secured to a bell crank, and said bell crank is retained in operative relationship to said base frame assembly.
In another aspect, a dynamically tiltable wheelchair comprises a seat frame assembly having opposed seat rails and a base frame assembly having opposed base rails. A pivot arm is removably secured to a rearward portion of each of the base rails, said pivot arm extending upwards above said seat frame assembly. A hanger member is removably secured to a rearward portion of each of the seat rails and extends upwardly. The pivot arm and the hanger member cooperate to define a pivot point near the expected center of gravity of a wheelchair occupant for pivoting the seat frame assembly in relation to the base frame assembly.
In a method aspect of the invention, the wheelchair may be reconfigured from a fixed tilt configuration to a dynamically bitable configuration. By removing from the fixed tilt configuration an element that renders a removable support assembly configurable to any one of a plurality of predetermined relative pivot angles between the seat frame and the base frame. A biasing mechanism is also installed that provides a mechanical advantage in tilting the seat frame in relation to the base frame.
In another method aspect, the wheelchair is reconfigurable from a first dynamically tiltable configuration where the pivot axis is near the front of the wheelchair to a second dynamically tiltable configuration where the tilt axis is near the expected center of gravity of an occupant. The first dynamically tiltable configuration comprises a seat frame, a base frame, a removable forward pivot assembly pivotally attaching the forward portion of the seat frame to the forward portion of the base frame and a removable support assembly connected between the seat frame and the base frame, the support assembly comprising a biasing mechanism that provides a mechanical advantage in tilting the seat frame in relation to the base frame. The reconfiguration is accomplished by disengaging the forward pivot assembly and installing a center of gravity pivot assembly comprising a pivot point near the expected center of gravity of a seated occupant.
In another aspect, the invention comprises a kit for a reconfigurable wheelchair system comprising a seat frame assembly, a base frame assembly and a plurality of alternative support assemblies for supporting the seat frame assembly on the base frame assembly.
In an aspect of the invention relating to the crossbar assembly, there is provided a telescoping crossbar assembly for rigidly extending between structural elements at selectable degrees of extension comprising a hollow outer tube, an inner tube slidably receivable in the outer tube, the inner tube and the outer tube having generally corresponding cross-sectional shapes. A plurality of fasteners extend through the outer tube and the inner tube, each of the fasteners having a body portion and a head portion larger than the body portion, and wherein the head portion bears on the inner tube through an aperture in the outer tube.
In yet another aspect, the invention is a drive wheel assembly for a wheelchair comprising a mounting element adapted to be adjustably secured to a component of a base frame in one of a plurality of alternative positions. A wheel mountable on the mounting element and a rod having a wheel lock assembly mounted thereon is attached to the mounting element. Adjustment of the mounting element in relation to the base frame maintains the position of the wheel lock assembly in relation to the wheel without requiring separate adjustment thereof.
In a further aspect of the invention, there is provided a crossbar mounting system for the crossbar between opposed rails. The crossbar has a substantially hollow tube having opposed apertures therein and the rail has at least one aperture extending therethrough. An insert is adapted to be inserted through said opposed apertures, said insert having at least one aperture adapted to receive a fastener extending through said aperture and said rail for securing said crossbar to the rail.
The foregoing was intended as a broad summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiment and to the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the invention will be described by reference to the drawings thereof in which:
FIG. 1 is a front perspective view of the TF configuration of the wheelchair of the preferred embodiment;
FIG. 2 a is a side elevation of the TF configuration at a neutral (horizontal) tilt angle;
FIG. 2 b is a side elevation of the TF configuration at a different tilt angle than in FIG. 2 a;
FIG. 3 is a bottom rear perspective view of the TF configuration;
FIG. 4 is a front perspective view of the T20 configuration;
FIG. 5 a is a side elevation of the T20 configuration at a neutral (horizontal) tilt angle;
FIG. 5 b is a side elevation of the T20 configuration at a different tilt angle than in FIG. 5 a;
FIG. 6 is a front perspective view of the T50 configuration;
FIG. 7 a is a side elevation of the T50 configuration at a neutral (horizontal) tilt angle;
FIG. 7 b is a side elevation of the T50 configuration at a different tilt angle than in FIG. 7 a;
FIG. 8 is a perspective view of the base frame, seat frame, support and pivot assemblies of the TF configuration;
FIG. 8 a is a perspective view of the base frame assembly of the TF configuration, with the interface mount secured to the rear base crossbar assembly;
FIG. 9 is a perspective view of the base frame, seat frame, support and pivot assemblies of the T20 configuration;
FIG. 9 a is a partially sectioned side view of the support assembly of the T20 configuration;
FIG. 10 is a perspective view of the base frame, seat frame, support and pivot assemblies of the T50 configuration;
FIG. 10 a is a top perspective view of the base frame assembly of the T50 configuration, including the pivot arms mounted thereon;
FIG. 10 b is a partially sectioned, top perspective view of the support (lock) assembly for the T50 configuration;
FIG. 11 is a perspective view of a pivot support;
FIG. 12 is a side elevation of a pivot support;
FIG. 13 is a perspective view of a bracket used in the T20 and T50 configurations;
FIG. 14 is an exploded view showing the crossbar assembly and the mounting of the crossbar on a rail;
FIG. 15 is a bottom perspective view of the seat frame, pivot and support assemblies for the T50 configuration, using transit tie-down brackets;
FIG. 16 is an exploded view of the pivot assembly in relation to the base and seat frame assemblies in the T50 configuration;
FIG. 17 is a cross-sectional view of the crossbar assembly according to the preferred embodiment;
FIG. 18 is a partially sectioned view of the inner tube of the crossbar assembly;
FIG. 19 is a perspective view of a transit tie-down bracket;
FIG. 20 is side and end elevations of the transit tie-down bracket;
FIG. 21 is a side elevation of a rear crossbar mount;
FIG. 22 is a partially exploded view of rear base rail mounting system;
FIG. 23 is an exploded view of the rear (drive) wheel mounting assembly;
FIG. 24 is a partially sectioned view of the rear wheel mounting assembly;
FIG. 25 is a partially sectioned view of the rear wheel mounting assembly, including the wheel lock assembly;
FIG. 26 is an exploded view of back cane mounting assembly for the TF and T20 configuration; and,
FIG. 27 is a side elevation of a pivot hanger bracket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 , 2 a , 2 b and 3 illustrate the preferred embodiment of the fixed tilt configuration of the wheelchair according to the invention, which in this disclosure will be referred to as the “TF” configuration. In TF configuration, the wheelchair is set at one of several possible angles of tilt about a pivot axis 10 near the knees of the occupant. FIGS. 2 a and 2 b illustrate two alternative fixed tilt angles for the TF configuration.
FIGS. 4 , 5 a and 5 b illustrate the preferred embodiment of the dynamic tilt-in-space configuration of the wheelchair, in which the axis of rotation 12 is provided near the front of the seat frame assembly 14 . The preferred embodiment of this configuration is designed to ensure that the front of the occupant's knees move upward only a very small amount as the chair undergoes a full range of tilt of up to 20 degrees. In this disclosure, this configuration will be referred to as the “T20” configuration. FIGS. 5 a and 5 b illustrate two different degrees of tilt for the T20 configuration.
FIGS. 6 , 7 a and 7 b illustrate the preferred embodiment of the dynamic tilt-in-space configuration of the wheelchair, in which the axis of rotation 16 is provided near the center of gravity of the occupant. The preferred embodiment of this configuration is designed for tilt angles of up to 50 degrees. In this disclosure, that configuration will be referred to as the “T50” configuration. FIGS. 7 a and 7 b illustrate two different degrees of tilt for the T50 configuration
Each of the TF, T20 and T50 configurations is built around a set of sub-assemblies that is common to each of the configurations, and that are adapted to receive interchangeable components to modify the wheelchair to the desired configuration.
The principal sub-assemblies that are modified to effect a change in the configuration of the wheelchair are the support assemblies for providing load-bearing support between the base frame assembly and the seat frame assembly (or to lock the seat frame against pivoting), and the pivot assemblies that provide a pivot connection between the base frame assembly to the seat frame assembly. FIGS. 8 , 9 and 10 illustrate the base frame and seat frame assemblies for the TF, T20 and T50 configurations respectively, including their associated support and pivot assemblies.
TF Configuration
Referring to FIG. 8 , a seat frame consists of an assembly 18 comprising a left and right seat rails 20 , 22 joined by front and rear seat crossbar assemblies 24 , 26 . A base frame consists of an assembly 28 comprising left and right base rails 30 , 32 joined by front and rear base crossbar assemblies 34 , 36 . In the TF configuration, seat frame assembly 18 is set in pivoted relation to the base frame assembly 28 about opposed pivot points (only pivot point 38 is visible in FIG. 8 ) located near the front of the left and right seat rails 20 , 22 . The pivot points are located between 1⅝ and 6⅝ inches from the forward edge of a seat pan that is secured, as intended, to the seat crossbar assemblies 24 , 26 . to The pivot assembly in the TF configuration generally comprises two pivot elements that cooperate to define pivot point 38 between them: pivot supports 40 and pivot hanger brackets 42 .
The support assembly 44 for the TF configuration is attached between the front and rear seat crossbar assemblies 24 , 26 and the rear base crossbar assembly 36 . Support assembly 44 comprises brace bracket 46 and an interface mount element 48 . Different degrees of relative tilt between the seat frame and base frame are achieved by connecting the lower end of brace bracket 46 to one of several attachment points 50 on interface mount 48 that is in turn removably attached to the inner tube 52 of the rear base crossbar assembly 36 . The attachment points comprise apertures 50 arrayed at different angular positions along an arc of constant radius in relation to the pivot points 38 . Inner tube 52 of the rear base crossbar assembly 36 includes a centrally located aperture 54 to receive a removable fastener 56 for attachment of the interface mount 48 thereto. A better view of the interface mount 48 is provided in FIG. 8 a.
Referring to the pivot assembly, the pivot support 40 is illustrated in detail in FIGS. 11 and 12 . Pivot support 40 consists of a seating block one surface 58 of which is shaped to conform to the inside of a seat rail, and further including a downwardly extending tab 60 having an pivot pin hole 62 therethrough to receive a pivot pin. Seating block 40 includes two spaced apertures 64 , 66 for receiving fasteners 68 , 70 that are used to secure the front seat crossbar assembly 24 to the rail as will be discussed in more detail below.
The pivot hanger bracket 42 (shown in detail in FIG. 27 ) similarly includes a pivot pin hole to receive a pivot pin at pivot point 38 . Pivot hanger bracket 42 also has a base 72 through which extend two apertures for receiving fasteners 74 , 76 used to attach the lower end of the bracket to the front base crossbar assembly 26 . The pivot hanger bracket 42 is preferably provided with an oblong aperture 78 in the body thereof so as to be used as a transit tie-down bracket for optional use in securing the wheelchair to tie-down stations in vehicles. The pivot hanger bracket 42 has a portion thereof that is shaped to mate with a seat provided in a partial sleeve 80 that is welded to the front portion of each rail.
T20 Configuration
FIG. 9 illustrates the base frame, seat frame, support and pivot assemblies for the T20 configuration. As in the case of the TF configuration, the seat frame assembly 82 and the base frame assembly 84 are connected at pivot points 86 by means of pivot supports 88 mounted to the left and right seat rails 94 , 96 and pivot hanger brackets 98 , 100 mounted to the left and right base rails 102 , 104 . The pivot supports and pivot hanger brackets of the TF and T20 configurations are identical.
The T20 configuration uses a different support assembly than does the TF configuration. The T20 support assembly 106 comprises a bracket 108 (slightly different from the TF bracket 46 ) attached to the front and rear seat crossbar assemblies and to the rear base crossbar assembly by means of a bell crank 110 pivotally mounted to the inner tube 112 of the rear base crossbar assembly. The bell crank serves to modulate the degree of resistance provided at different tilt angles and to accommodate the change in spatial relationship between the bracket and the base frame as the seat frame is tilted.
Referring to FIGS. 9 , 9 a and 13 , bracket 108 has spaced shoulders 114 , 116 . The front 118 of the bracket includes a bridge 120 extending between the shoulders 114 , 116 . Bridge 118 has a fastener aperture for attachment of one end of a gas strut.
A gas strut 120 is mounted between the shoulders of the bracket. One end of gas strut 120 is secured to bridge 118 by means of a shoulder bolt while the other end is attached to another shoulder bolt 122 extending through the medial portion of the bell crank 110 . A trigger 124 is provided to control the gas strut. Because the gas strut is connected to the center of the bell crank, a pivoting of the base frame 84 in relation to the seat frame 82 will also cause a translation of the lower end of the bell crank in relation to the vertical plane. Such translation is accommodated by connecting the lower end of the bell crank to a slide 126 mounted on a guide tang 128 that is attached to the inner tube 112 of the rear base crossbar assembly by means of a fastener threaded through a suitable aperture in the inner tube 112 .
T50 Configuration
FIG. 10 illustrates the base frame, seat frame, support (lock) and pivot assemblies for the T50 configuration. In the T50 configuration, the forward pivot point that was a feature of the TF and T20 configurations is not present and the pivot hanger brackets are not used in the T50 configuration. The pivot supports on the seat rails may be replaced by transit tie-down brackets 132 (see FIG. 15 ) according to whether the wheelchair is intended to be attachable to tie-downs on public and private transit vehicles. The transit tie-down brackets also double as crossbar mounting elements. The pivot hanger brackets that would normally be seated in partial sleeve 80 on the base rails are replaced by filler blocks 134 .
The pivot assembly for the T50 configuration comprises a pivot arm 136 extending up from each of left and right base rails 138 , 140 to a height 142 above the seat pan. In the preferred embodiment, apart from being secured to the rails, each pivot arm is also braced by attachment to the rear base crossbar assembly 144 . The seat frame assembly is supported about pivot pins 146 at the upper end of the pivot arms by means of opposed pivot hanger plates 148 that are attached to the left and right seat rails 150 , 152 and that are pivotally suspended from the pivot pins 146 .
The pivot arm 148 comprises a base 154 having a surface conforming to the rear of the base rail (see FIG. 15 ). Apertures 156 are provided in the base 154 to enable the base to be secured by fasteners to selected apertures 158 in a longitudinal recess 160 formed in the rear portion of the base rails. Vertically spaced apertures 162 are adapted to secure the pivot arm 136 to the rear base crossbar assembly 144 . In the preferred embodiment, the pivot arm 148 extends generally upward to a forwardly extending elbow 164 to avoid interfering with the hardware used to secure the seat frame, then upwards to the pivot point 142 .
Pivot pin 146 extends through the pivot arm 136 and through the pivot aperture of the pivot hanger plate 148 .
The height of the pivot point 142 is selected by reference to the expected center of gravity of the occupant, as calculated using publicly available anatomical data. In the preferred embodiment, the height of this point is about 6.75 inches (171.4 mm) above the seat pan. Such height has been selected by accounting for a typical seat cushion of about 2″ in thickness and an anatomically typical occupant.
The precise location in the horizontal plane of the center of gravity of a occupant tends to vary more than does its location in the vertical plane. The invention accommodates such variation by providing means to adjust the horizontal position of the back rest and of the seat pan in the fore and aft directions. This allows the occupant or installer to optimize the coincidence of the pivot point 142 at the top of the pivot arm with the center of gravity of the occupant. A matrix of apertures 166 (see FIG. 6 ) is provided along the edge of the seat pan 168 allowing the seat pan to be located at different fore and aft positions in relation to the seat frame assembly. The pivot arm 136 is also adapted to be set at various horizontal positions on the base rails, for example to change the wheel base load distribution and to clear interference of the front rigging and front casters.
Referring to FIG. 16 , the pivot hanger plate 148 has a broad base 170 that tapers to a pivot aperture 172 in the top of the plate forming a generally triangular shape that can also serve as a guard to prevent the occupant's clothing from coming into contact with the rear wheel. The base 170 of the pivot hanger plate includes a bottom portion 174 that conform to the top surface of the rail 176 , and a downwardly extending flange 178 shaped to abut the outside of the rail. The flange 178 includes a plurality of apertures 180 the rearmost five of which are used to receive fasteners for releasably securing the back cane mounting to the pivot hanger plate 148 and the rail 178 . Two of the apertures are to receive fasteners extending through the hanger plate 148 , the rail 176 , the transit tie-down bracket 184 (for transit-ready chairs only) and a threaded insert 186 (see FIG. 14 ) extending laterally through the sleeve tube 188 of the rear crossbar assembly. A tab 190 extends downward from the center of the flange and is securable to the transit tie-down bracket by means of a fastener.
A plurality of cane mounting apertures are provided at the rear of the pivot hanger plate including three sets of apertures 192 arranged in diverging arcs. The apertures are used to mount a back cane at various angles and positions in relation to both the rail 176 and the pivot hanger plate 148 .
Referring again to FIG. 10 , the preferred embodiment, the support assembly for the T50 configuration comprises the same bracket as in the T20 configuration, as well as an extendible lock rod 193 attached between the rear ends 194 of the shoulders of the bracket. The rear end of the lock rod is pivotally attached to a rod mount 196 attached to the inner tube 198 of the base crossbar assembly. A trigger 200 is provided to selectively lock the rod against retraction or extension to prevent rocking of the seat frame about the pivot points.
Crossbar Assemblies
In order to provide adjustability in the width of the wheelchair, each of the seat and base crossbar assemblies are telescope assemblies in which an inner tube 202 is received within opposed sleeve tubes 188 as may appreciated by reference to FIGS. 14 and 17 . The inner and sleeve tubes have generally corresponding cross-sectional shapes and dimensions to facilitate the telescoping function.
Inner tube 202 is hollow save for a series of ribs 189 extending along the central longitudinal axis of the tube. A series of apertures 204 adapted to receive fasteners 206 are located between the ribs. The ribs provide rigidity against deformation when the inner and sleeve tubes are brought into engagement with one another by means of head screws 206 extending through selected ones of the apertures 208 and corresponding apertures in the sleeve tube.
A feature of the invention is the means by which the crossbar assemblies may be secured in a given telescoped position with a high degree of rigidity. Rather than the head of a fastener bearing on one side of the sleeve tube and a nut bearing on its opposite side, the invention provides apertures 208 in the top wall 210 of the sleeve tube 188 that are larger than the aligned apertures in the bottom wall (not visible) of the sleeve tube and that are sufficiently large that the head of the fastener bears directly on the top wall 212 of the inner tube 202 . This allows the inner tube 202 to bear against the inner bottom surface 214 of the sleeve tube thereby providing, a great deal of friction against relative displacement.
In addition, the inner tube shape and dimensions are selected to accommodate a small degree of elastic deformation of the inner tube to further lock the inner tube against the sleeve tube when the positioning fasteners are tightened. In the preferred embodiment, this is accomplished by providing non-flat mating bottom walls 216 , 218 of the inner and sleeve tubes respectively such that any deformation of the inner tube will result in several points and angles of contact between them. In the preferred embodiment such non-flat portions comprises opposed, spaced protuberances 220 , 222 .
In order to accommodate the elastic deformation of the inner tube, a small dimensional gap 224 or tolerance is provided between the inner and sleeve tube contact surfaces. It will be appreciated that the extent of the gap is selected according to the elastic range of the inner tube but it should not be so large as to allow plastic deformation to occur. The telescoping joint mechanism ensures that the joint stays tight even with continuous variations in loading (fatigue). Plastic deformation of the inner tube would compromise the joint integrity and allow the joint to become loose over time.
Crossbar Mounting
Referring to FIG. 14 , each seat crossbar assembly is secured to each rail by a mounting element 130 that interfaces between the rail 226 and the sleeve tube 188 of the crossbar assembly and by fasteners 228 that extend through the rail and the mounting element 130 to engage an insert 186 seated laterally through the sleeve tube.
The front seat crossbar mounting elements for all configurations are the pivot supports 40 . One side of each mounting element conforms to the inside of a rail 226 , and the opposite side is shaped to engage the outer end of the sleeve tube 188 . Two apertures 230 are provided in the mounting element and are spaced to correspond to the spacing of two mounting holes 232 in the rail so that fasteners 228 may be received through the rail and through the mounting element. The fasteners engage insert 186 that extends laterally through the hollow inside of the sleeve tube.
The mounting elements for the rear seat crossbar assemblies for all configurations consist of either a simple mounting element 130 as in FIG. 14 or a transit tie-down bracket 132 , best illustrated in FIGS. 19 and 20 that conform on one side to the inside of the rail and are configured on the other side to engage the end of the crossbar assembly.
In the case of the base crossbar assemblies, securement to the rails is by means of components that conform to a part of the rail and that include a seat to receive and secure the end of the crossbar assembly by means of fasteners. In the case of the TF and T20 configurations, the front base crossbar assembly is seated in and against partial sleeve 80 and the rear base crossbar assembly is seated in and against rear crossbar mount 81 . Rear crossbar mount 81 is shaped to conform to the outside and top of the rear portion of the rail, including recess 160 . Rear crossbar mount 81 also has a flat surface 83 for receiving and securing the end of the crossbar assembly, as seen in FIG. 21 . The rear base crossbar assembly is oriented such that its transverse breadth lies, in the vertical plane. This allows attachment of the interface mount 48 , the slider assembly 126 , 128 or the mechlok rod mount 196 (as the case may be) to be attached to the inner tube by a fastener through an aperture traversing the width of the inner tube.
In the case of the T50 configuration, the front base crossbar assembly is seated against a seat in a forward crossbar mount 80 that conforms to part of the front of the base rail and that has a seat adapted to receive and secure the end of the crossbar assembly.
The rear base crossbar assembly of the T50 configuration is seated in a seat provided on the inside of the base of the pivot arm 136 and is secured by two screws 162 .
Base Rail Mounting System
The invention provides adjustability of the wheel base as well as the location of the pivot point in the horizontal plane for the T50 configuration by a longitudinal recess 160 journaled in the rear portion of each base rail 233 . Referring to FIG. 22 , a plurality of aligned apertures 234 along the interior of the recess receive fasteners 236 that are used to secure the rear (drive) wheel axle mounting plate 238 , crossbar mounts or the base of the pivot arms as the case may be. The relative front to back position of those components can be adjusted by selecting the appropriate apertures. The edges of the channel include grooves 240 adapted to receive clip-on masking caps 242 (see for example FIG. 5 a ) to provide an aesthetic cover for those portions of the channel that are not otherwise covered by one of the foregoing components.
A mounting assembly is provided for securing the fasteners within the hollow interior of the rail. An elongated rod 244 is adapted to be longitudinally inserted and retained in the hollow rail 233 . A plurality of nuts 246 are retained in several spaced seats 248 provided along the length of the rod such that when it is inserted and retained in the rail with the nuts aligned to the fastener apertures 234 , fasteners 236 inserted into the apertures will engage the nuts and be retained without the need to traverse the opposing wall of the rail. This arrangement also avoids potential problems that might arise from securing the fasteners directly to the rail itself. As the rail and the fasteners may be of different materials, the potential for reaction between them is reduced by the invention.
The forward ends of the rails terminate in a caster clamp for retaining a standard caster assembly. The forward ends of the seat rails terminate in a front rigging hanger with an insertion tube adapted to telescope a selected depth into the front end of the rail and a vertically oriented sleeve adapted to receive a standard footrest assembly.
Drive/Wheel Assembly
The rear (drive) wheel assembly is illustrated in FIGS. 23 , 24 and 25 . The wheel assembly includes an axle mounting plate 250 secured to the base rail 252 and means to mount each of the wheel, the wheel lock assembly and the anti-tip assembly directly onto the axle mount. This allows the position of the wheel on the frame to be adjusted by changing the location of the axle mounting plate, rather than needing to separately adjust an anti-tip assembly 254 , an axle mounting plate and a wheel lock assembly 256 .
The axle mounting plate 250 has a base 258 with an inner dimension corresponding to the outer shape of the rail including the recess, and an extension 260 having a plurality of aligned vertical positioning apertures 262 for receiving a rear wheel axle receiver 264 in any one of several vertical positions. The axle mounting plate 250 is secured to the rail 252 by fasteners 266 extending through apertures in the base of the axle mounting plate and through apertures provided in the recess 160 .
The axle receiver 264 is inserted through a selected one of the vertically aligned apertures 262 according to the preferred ground clearance for the base frame of the wheelchair. A wheel lock tube 268 is secured between the rear wheel 270 and the axle mounting plate 250 by means of a mounting piece 272 that is adapted to provide a secure mating seat 274 for the side of the axle mount. A clearance aperture 276 through the mounting piece 272 provides a passageway for the axle receiver. The end of the axle receiver is threaded so as to receive a nut 278 used to tighten the wheel lock tube (through the mounting piece) to the axle mount. The axle 280 is inserted through the nut and the mounting piece 272 and into the hollow interior of axle receiver 264 . The end of axle 280 includes retainers 282 that project out of the end of axle receiver to hold the axle therein.
Retainers 282 are biased and may be manually depressed to allow the axle to be disengaged from the axle receiver. Upon doing so, removal of the nut is all that is required in order to remove the axle receiver 264 and mounting piece 272 so as to be able to reposition the axle receiver into a different vertical positioning aperture 262 .
The invention provides a simple means of repositioning the height of the rear wheel 270 in relation to the base frame with a minimum of tools and effort. In addition, since the anti-tip assembly 254 and the wheel lock assembly 256 are both mounted on the wheel lock tube 268 which in turn is mounted to the axle mounting plate, it is possible to adjust the horizontal position of the rear wheel on the base rail by repositioning the axle mount without the need to separately readjust the anti-tip assembly or the wheel lock assembly.
Back Cane Mounting
A back cane assembly illustrated in FIG. 26 . The assembly 284 is adapted to be mounted in various angular and fore and aft positions by providing a back plate 286 having plurality of suitable apertures to accommodate different orientations and positions of the cane 290 . Back plate 286 is secured to the inside of the seat rail 294 by means of two fasteners 296 on the inside of the back cane. A number of fore and aft positions can be selected using a plurality of apertures 298 provided on the rail. The cane is then secured to the back plate by a pivot fastener 300 and by a second fastener 302 inserted through one of several apertures 288 provided in an arc about the pivot fastener 300 , thereby enabling the cane to be mounted at different angles in relation to the rail.
In the TF and T20 configurations, a second back plate 302 is provided on the outside of the rail and all fasteners extend through both the inside and outside back plates. In the case of the T50 configuration, the outside back plate 302 is omitted but the pivot hanger plate 148 is provided with corresponding apertures and fulfills the same function as the outside back plate does in the TF and T20 configurations.
Converting from TF to T20 or T50
Reconfiguring a wheelchair from the TF fixed tilt configuration to a dynamically tiltable configuration (i.e. to either the T20 or the T50) is generally accomplished as follows.
The TF configuration comprises a support assembly (brace bracket 46 and interface mount element 48 ) connected between the seat frame assembly 18 and the base frame assembly 28 . The interface mount element 48 is configurable by the selection of different attachment points 50 to define any one of a plurality of predetermined relative pivot angles between the seat frame and the base frame. The interface mount element 48 is first removed by removing fasteners 56 and 57 . A bias mechanism is then installed to provide a mechanical advantage in tilting the seat frame in relation to the base frame, thereby providing a dynamically tiltable wheelchair. In the case of the T20, the bias mechanism is the assembly consisting of gas strut 120 , bell crank 110 and slide 126 . One end of gas strut 120 is secured to bell crank 110 . The other end of the gas strut is secured to the seat frame, or more particularly to a bracket 108 that is associated with the seat frame. Bell crank 110 is secured (through slide 126 and guide tang 128 ) to the same attachment point that received fastener 56 in the TF configuration. In the case of the T50m the bias mechanism is a mech lok.
Converting from T20 to T50
The conversion to the T20 to the T50 configuration involves both a change of the pivot assembly and of the support assembly.
In the T20, the pivot assembly consists of cooperating pivot elements, namely pivot supports 88 and pivot hanger brackets 98 , 100 , each of which is removably attached to the chair by fasteners 68 , 70 or fasteners 74 , 76 . The pivot assembly of the T20 is removed by disengaging fasteners 68 , 70 , 74 and 76 . A new centre of gravity pivot assembly is installed by mounting pivot arms 136 on the base rails and mounting pivot hanger plates 148 to the seat rails, and pivotally connecting the pivot arms to the hanger plates by pivot pins 146 . The pivot arm is secured to the base rails by inserting fasteners in to apertures that extend to the pivot arm and in to the base rails. The hanger plates are mounted by securing fasteners to the plate and into apertures in the seat rails. If desired, a transit tie down bracket can be installed where the pivot hanger brackets would normally be attached in the T20 configuration.
The preferred embodiment of the invention has been described in some detail. However, those skilled in the art will appreciate that various modifications to the constructional details of the embodiment may be practiced without departing from the spirit and scope of the invention, which scope is properly defined by the claims that follow. The following claims are nonetheless to be considered part of the disclosure herein.
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A modular wheelchair assembly is adapted to be reconfigured between a fixed angle of tilt, a dynamically adjustable tilt-in-space configuration with the tilt axis being near the user's knees and a dynamically adjustable tilt-in-space configuration with the tilt axis being near the user's center of gravity. The reconfiguration is achieved by modifying a limited number of selectively removable components of the support assembly or the pivot assembly of the wheelchair.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to wireless networks. More particularly it relates to multi-channel Media Access Control (MAC) operating on a multiple radio or Wireless Local Area Network (WLAN) device.
2. Description of Related Art
The WiMedia MAC and Physical layer (PHY) specification (ECMA, “Standard ECMA-368: High Rate Ultra Wideband PHY and MAC Standard,” 2005, incorporated herein by reference) has originated from the Multiband OFDM Alliance (MBOA) proposal.
The goal of a future WiMedia system will be to provide a usable MAC layer throughput in excess of 1 Gbps. For example, a future WiMedia PHY may achieve higher rates by bonding two channels together, providing 2 spatial streams with Multiple Input-Multiple Output (MIMO) and employing a higher rate channel code.
The WiMedia PHY transmits data in units of six Orthogonal Frequency Division Multiplexing (OFDM) symbols instead of the single OFDM symbol unit of 802.11a. The following equations can be used to calculate the characteristics of the highest rate future WiMedia PHY modes using the parameter values shown below in Table 1.
TABLE 1
Future maximum rate PHY mode parameters
N IBP6S = N D · N bits — carrier · N ss · R
Rate
=
N
IBP
6
S
N
interleaved
_
sym
·
T
sym
Parameter
Value
N D (Number of data sub-carriers)
Single channel
10
0
Bonded
21
channel 1
0
N bits — carrier (The number of bits per
2
subcarrier 2 )
N ss (Number of spatial streams)
2
R (Coding Rate)
7/8
T sym (OFDM symbol period)
312.5
ns
N interleaved — sym (Number symbols for
6
interleaving)
Notes:
1 Assuming that the 2 guard carriers at the centre of the individual channels and the 9 guard carriers between the individual channels are gained and that 1 carrier is lost to provide a guard carrier at the centre of the bonded channel.
2 Assuming DCM modulation (QPSK will also provide 2 bits per sub-carrier)
The characteristics of potential future WiMedia PHY modes are shown in Table 2.
TABLE 2
Future maximum rate PHY mode (single and bonded channels)
N IBP6S
Rate
(Info bits/6 OFDM
(Mbps)
symbols)
Single Channel
1120
2100
Bonded
2352
4410
channel
The introduction of MIMO to provide two spatial streams will result in an increase in the size of the physical layer convergence protocol (PLCP) preamble overhead. If the approach taken in the greenfield preamble of 802.11n is replicated, it can be assumed that a two spatial stream MIMO preamble for the WiMedia PHY will consist of the same synchronisation sequence but will now have two channel estimation sequences. This will result in the standard preamble increasing from 9.375 μs to 11.25 μs and the burst preamble increasing from 5.625 μs to 7.5 μs.
The PHY assumptions derived above can be used to determine the MAC layer throughputs that can be expected. The Wimedia MAC provides two main access methods. The first is Prioritised Channel Access (PCA), which is almost identical to 802.11's Enhanced Distributed Coordination Function (DCF) Channel Access (EDCA); the only differences being in the parameter values. The second access method is the Dynamic Reservation Protocol (DRP) which allocates timeslots to a particular user. Unacknowledged bursts may be described as a third access method; they employ the Minimum Inter Frame Space (MIFS) and the burst preamble and operate over a point-to-point link. The MIFS is shorter than the Short Inter Frame Space (SIFS) because it does not need to include the radio turnaround time. The burst preamble is shorter than the standard preamble because the synchronisation sequence can be reduced due to the retained knowledge that the receiver gained from the previous frame.
FIG. 1 shows two sets of results for the three access methods described above. Beacon overheads have been ignored for the sake of illustrating a theoretical maximum throughput. The first set of results is for a 1500 byte MAC Service Data Unit (MSDU). This is historically the original maximum Ethernet frame size. The maximum User Datagram Protocol (UDP) frame is typically 1024 bytes and the maximum Transmission Control Protocol (TCP) frame is 64 kbytes. TCP frames are segmented into Ethernet frames and then put into 802.11 frames. The second set of results is for a 4095 byte MSDU, which is the maximum MSDU size supported by the WiMedia MAC. If TCP or UDP protocols are employed then a 4095 byte MSDU can only be achieved by frame aggregation.
FIG. 1 illustrates that even with a 2.35 Gbps PHY a 1 Gbps MAC throughput (approximately 50% of the available PHY rate) can only be achieved with a single point-to-point link, without MAC overheads (control and management frames) and employing a frame size that is larger than what the upper layers may generate. It is therefore doubtful if a reliable service can be provided without control and management frames once the streaming has begun.
Getting such low medium capacity utilization is mainly a consequence of the need to spend time for carrier sensing, signal propagation (i.e. IFS) and channel estimation (e.g. PLCP preamble) in a high data rate PHY medium, regardless whether using bonded channels or not.
An improvement can be gained by increasing the amount of time spent transmitting data by increasing the maximum MSDU size beyond 4095 bytes, or, similarly, introducing/enhancing frame aggregation. This might be a valid technique for some of the application specific applications that will have requirements of 1 Gbps MAC throughputs. Packets of this size may not be as enormous as they first seem, because the probability of errors occurring is a function of the transmission time and not of the packet size directly. A packet of 4095 bytes takes only 15 μs to transmit on a 2.35 Gbps PHY, which is much shorter than the coherence time of the channels that will be encountered.
In: Luca De Nardis, Guerino Giancola, Maria-Gabriella Di Benedetto, “A power-efficient routing metric for UWB wireless mobile networks”, Vehicular Technology Conference 2003, VTC 2003-Fall. 2003, Volume: 5, pages 3105-3109, incorporated herein by reference, a method is discussed for setting up connections by optimizing a power-dependent cost function. Results show that the power-saving strategy leads to multi-hop communication paths between terminals within reach of each other (physical visibility) and by this way increases network performance.
Optimal power control, scheduling, and routing in UWB networks is discussed, for example, in Radunovic, B., Le Boudec, J.-Y., “Optimal power control, scheduling, and routing in UWB networks”, IEEE Journal on Selected Areas in Communications, September 2004, Volume: 22, Issue: 7, pages 1252-1270, incorporated herein by reference. In this certain approach the objective is to maximize flow rates under given node power constraints (there is a linear dependence between rate and signal-to-noise ratio at the receiver). The suggested optimal routing, scheduling and power control solution is characterized by the following assumptions:
1) When data is being sent over a link, it is optimal to have an exclusion region around the destination, in which all nodes remain silent during transmission, whereas nodes outside of this region can transmit in parallel, regardless of the interference they produce at the destination. Additionally, the source adapts its transmission rate according to the level of interference at the destination due to sources outside of the exclusion region.
2) The optimal size of this exclusion region depends only on the transmission power of the source of the link, and not on the length of the link or on positions of nodes in its vicinity.
3) Each node in a given time slot either sends data at the maximum power, or does not send at all.
4) As for the routing, by restricting to a subset of routes where on each successive hop the distance is decreased toward the destination, it is shown that relaying along a minimum energy and loss route is always better than using longer hops or sending directly, which is not obvious since rate is optimised and not power consumption.
5) Finally the design of the optimal MAC protocol is independent of the choice of the routing protocol.
For narrowband networks, assumptions 2), 4), and 5) do not hold, which shows that the design of an UWB network should be addressed in a different way than for narrowband.
However, this is just one approach to the multi-hop problem. For example, one could argue that in Non Line of Sight (NLOS) cases that relaying along minimum energy and loss routes may be inefficient as compared with lowering the rate and increasing the range. The MAC may therefore be dependent of routing decisions as we can dynamically decide whether to trade-off data-rate for robustness to multi-path (and improvement of performance in NLOS), which is needed in order to make good routing decisions. Also, in Line of Sight (LOS) case with (for instance) random node deployment it is still not clear whether multi-hop routing will always improve performance.
In order to improve the throughput performance of WLAN MAC schemes some researchers have proposed to split the single shared channel into two subchannels: a control subchannel and a data subchannel. The control subchannel is used for access reservation to the data subchannel over which the data packets are transmitted (J. Deng, Y. S. Han, and Z. J. Haas, Analyzing Split Channel Medium Access Control Schemes with ALOHA Reservation, Proc. Second Int'l Conf. AD-HOC Networks and Wireless, October 2003, incorporated herein by reference).
Generally, multi-channel MACs utilize more than one channel (e.g. a combination of data and signalling ones) in order to organize access in a more efficient manner. Multi-channel MACs usually address the optimisation problem of organising access with 2 or more channels within either single or multiple hops.
In the 802.11s Common Channel Framework (CCF) approach by Sung-Won Lee and Rakesh Taori; “Common Channel Framework: A Simple Multi-Channel MAC Framework for 802.11s Mesh Network”, IST Summit 2006, incorporated herein by reference, the gain in performance is due to different devices using the different channels at the same, but with a control channel used to assign “contention free” access to the other channels.
Multi-rate multi-channel MACs (Niranjan, S. Pandey, and A. Ganz, “Design and evaluation of multichannel multirate wireless networks,” Mobile Networks and Applications, Vol. 11, issue 5, pp. 697-709, 2006, incorporated herein by reference.) refer to the problem of having a given number of channels and trying to figure out how to optimally assign channels to links meeting certain traffic-based criteria (more specifically multiple traffic rates). The typical optimization objective is the reduction of multi-rate interference (i.e. “slow” rates “annoying” “high” rates).
Bonded channels have been considered in the 802.11n draft amendment to the standard by the IEEE task group TGn (IEEE P802.11n™/D1.02, Draft Amendment to STANDARD for Information Technology—Telecommunications and information exchange between systems—Local and metropolitan area networks—Specific requirements—Part 11: Wireless LAN Medium Access Control (MAC) and Physical Layer (PHY) specifications: Enhancements for Higher Throughput, incorporated herein by reference). This document describes a Phased Coexistence Operation (PCO) as an optional coexistence mechanism in which a BSS operates in alternating 20 MHz and 40 MHz phases under the control of a PCO AP. The PCO AP reserves the 20 MHz control channel and the 20 MHz extension channel in turn to start the 40 MHz phase and resets the NAV in the 20 MHz channels in the opposite order to start the 20 MHz phase.
Utilising dual WLAN channels for “double” transmission rates has been commercialised in the Atheros chip (Dynamic Turbo technology). The Atheros chips have been widely used within 802.11g wireless router/gateway products by many manufacturers (including Toshiba, Sony, Netgear, NEC, Fujitsu, Gigabyte, D-Link, etc). With this technology, manufacturers claim to have achieved maximum data rates of 2×54 Mps=108 Mps.
Dynamic Turbo is similar to trunking techniques used in Fast Ethernet networks (which use two or more wires to increase overall bandwidth). Briefly described, Dynamic Turbo is designed to automatically double the realized bandwidth when required by handling two channels as one. Dynamic Turbo is engaged based on network traffic requirements and environmental conditions. Access points switch dynamically to this high-performance mode when an associated wireless station requires greater bandwidth based on the sustained throughput between the link between the access point and the station pair. (Atheros Communications White Paper: Super G: Maximizing Wireless Performance, 2004, incorporated herein by reference).
The use of 2 channels in 802.11 to “double” the data rate comes at the expense of range. This is because the same Effective Isotropic Radiated Power (EIRP) (of 100 mW in Europe) is necessary (governed by regulation) and so we cannot increase power, just spread it across a larger bandwidth. For UWB the rules may be different (based more on power spectral density than EIRP) and this may mean we can gain both data rate and range with the “dual radios” or channel bonding approaches. Obviously at the expense of increased device complexity and cost.
It is an object of the present invention to obviate at least some of the above disadvantages and provide an improved network performance at high data rates.
BRIEF SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a method of transmitting data over a plurality of channels. The channels form a bonded channel comprising a bonded channel superframe. The bonded channel superframe comprises a bonded channel beacon period and a bonded channel data period. A control message is broadcast on a bonded channel superframe. The control message indicates that subsequent transmission will be over distinct channels, each of said channels comprising a distinct superframe comprising a beacon period and a data period. in each of the distinct channels a sequence of superframes is transmitted, each superframe comprising a distinct beacon period followed by a distinct data period.
In a first configuration of the above aspect, the control message is a management frame used to obtain access to the bonded channel medium.
In another configuration of this aspect, the control message comprises an information element broadcast in the bonded channel beacon period
In a further configuration of the first aspect the control message obtains priority over other potential MAC frames.
In a configuration of the above aspect further control messages are broadcast in each of the distinct channels indicating the termination of transmission over distinct channels.
In a further configuration of the above aspect, the bonded channel comprises two channels.
In another configuration of the above aspect each of the distinct channels operates a data protocol independent of the other channels.
In yet a further configuration of the first aspect the control message maps a device to at least one of the distinct channels
According to a second aspect of the present invention, there is provided a signal for transmission of data over a plurality of channels. The channels form a bonded channel comprising a bonded channel superframe. The bonded channel superframe comprises a bonded channel beacon period and a bonded channel data period.
The bonded channel superframe is adapted for transmitting a control message, said control message indicating that subsequent transmission will be over distinct channels. Each of the distinct channels is adapted for transmitting a sequence of distinct superframes, each superframe comprising a distinct beacon period and a distinct data period.
In a first configuration of the second aspect the control message is a management frame used to obtain access to the bonded channel medium.
In another configuration of the above aspect the control message comprises an information element broadcast in the beacon frame.
In a further configuration of the above aspect the control message obtains priority over other potential MAC frames.
In a configuration of the above aspect further control messages are broadcast in each of the distinct channels indicating the termination of split-channel transmission.
In another configuration of the second aspect the bonded channel comprises two channels.
In a further configuration of the above aspect each of the distinct channels operates a data protocol independent of the other channels.
In yet another configuration of the second aspect the control message maps a device to at least one of the distinct channels.
According to a third aspect of the present invention, there is provided a transmitter having a single or multiple, particularly dual, physical interface. The transmitter is configured for transmitting a signal over a plurality of channels in accordance with the first aspect of the present invention.
According to a fourth aspect of the present invention, there is provided a receiver having a single or multiple, particularly dual, physical interface. The receiver is configured for receiving a signal over a plurality of channels in accordance with the second aspect of the present invention.
According to a fifth aspect of the present invention, there is provided a device having a multiple, particularly dual, physical interface. The device is configured for transmitting a control message in the bonded channel, and is further adapted to transmit, receive and bridge further signals within each of the distinct channels, in accordance with the second aspect of the present invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
These and other aspects of the invention will now be further described, by way of example only, with reference to the accompanying figures.
FIG. 1 illustrates throughputs with 1500 byte (top) and 4095 byte (bottom) packets
FIG. 2 illustrates the CAT MAC protocol stack.
FIG. 3 depicts a WiMedia MAC superframe.
FIG. 4 is a diagram of a CAT MAC superframe in accordance with the present invention.
FIG. 5 depicts a CAT network architecture with one dual PHY node.
FIG. 6 shows a CAT network architecture with two dual PHY nodes.
FIG. 7 illustrates a CAT network architecture entirely with dual PHY nodes.
FIG. 8 is a flow chart of CAT MAC network configuration operations.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, an additional gain in system throughput is obtained by utilising two standard WiMedia channels for parallel transmissions rather than a single transmission over two bonded WiMedia channels. This technique mitigates some of the medium access time that is lost due to MAC and PHY overheads. This improvement is based on the fact that (say) two channels use lower (e.g. half) PHY data rate and the (traffic) assumption that same MSDU sizes are transmitted in both the bonded channel and the split ones.
The multi-channel MAC proposed in the present invention, coined as channel and time (CAT) MAC, dynamically allocates distinct channels to devices that could otherwise operate on a bonded channel, in order to get better MAC performance irrespective of distance, power, data rate adaptations, and without replacing current MAC (data/control channel) protocols. The CAT MAC operates on top of standard protocols, is fully compatible with legacy devices and very scalable in terms of incorporating further link adaptation techniques in multi-hop scenarios.
The CAT MAT uses a control mechanism within the standard channel (MAC superframe) to assign channels and still uses the same contention mechanism within each distinct (split or not) channel. Contrary to 802.11s CCF improvement, CAT MAC improvement is based on the fact that the two channels use lower (e.g. half) PHY data rate as well as the (traffic) assumption that same MSDU sizes will be transmitted in the bonded channel as they will in the split ones. This assumption may, for example, be realised if we have different devices sending certain MSDU frames in different channels as opposed to having them sending these same MSDU frames sequentially.
Current techniques such as frame aggregation and burst transmission are adequate for standard systems. However, in the future, when PHY data rates above 1 Gbps will be feasible (e.g. with channel bonding techniques), frame aggregation and block transmission may not be sufficient. This is where the CAT MAC according to the present invention is expected to further improve the MAC performance.
The invention described herein may be understood as a parallel channel frame aggregation scheme. Parallel channels operating on a portion of the overall bonded channel data rate may mitigate, under certain traffic conditions, the MAC/PHY time overheads and provide a MAC throughput improvement at high data rates. As opposed to frame aggregation (in the time domain), the present invention may additionally improve fairness (multi-user access), reduce delay and buffering and achieve similar results without the need of aggregating numerous MSDUs, which might not be feasible given certain network traffic. Having fewer devices contending for access in a channel may improve the delay for accessing the medium.
As far as the traffic conditions that presumably offer an opportunity for improvement the following comments can be made: Small MSDU frames such as the ones resulting from 40-byte TCP ACKs (layer 3) or (in a block ACK scheme) MAC ACKs (layer 2) enhance the importance of this IAR, since the smaller the packet and the higher the PHY data rate, the worse the efficiency. Bigger MSDU sizes as well as block (or no) ACK schemes, renders the discussed improvements less significant. Hence, a sequence consisting of large (fixed) MSDUs, is probably the most challenging case for demonstrating improvement.
It should be appreciated that frame aggregation may be operated in each one of the parallel channels, limited by the maximum MPDU size, which is expected to be larger in a bonded channel. The maximum size of MPDU (or—similarly—the maximum number of aggregated MSDU frames) is determined by the PHY's capability to transmit large frames (at high data rates) robustly. This capability is dependent on the maximum duration a distinct transmission may be robustly received given the transmitted (with the preamble) channel estimation parameters. This duration may be calculated assuming a certain environment and certain noise and interference models. For example, for 802.11 this is in the range of 1 ms. The maximum allowed MPDU size may be proportional to PHY data rate. The faster the PHY, the longer the MPDU may be allowed to be while maintaining robust transmissions. Hence it is reasonable to assume that the maximum MPDU size for parallel (split) channels should be smaller than the one for the bonded channel, accordingly.
The CAT MAC is superimposed on standard WLAN/WiMedia MAC protocols as shown in FIG. 2 . At least one multiple-PHY device is a prerequisite for CAT MAC, which is, however, fully compatible with legacy devices (without CAT functionality). Legacy devices may operate in one CAT channel (or a bonded channel) with standard MAC protocols being ignorant of any CAT MAC operations. Thus CAT MAC is backwards compatible with a bonded WLAN or a bonded WiMedia channel.
Initially CAT MAC will operate as a standard bonded channel operating a certain MAC protocol (i.e. an ECMA-368 PCA or DRP or even an 802.11 one such as the Hybrid Coordination Function (HCF)). FIG. 3 illustrates an example of a standard WiMedia superframe. Each superframe m−1, m, m+1 starts with a Beacon Period (BP).
With the WiMedia standard, each device in the channel (DEV 1-9) has to transmit a beacon. The beacon period consists of all these beacons. beacon period has a maximum length of mMaxbeacon periodLength beacon slots. Beacon slots in the beacon period are numbered in sequence, starting at zero. The first beacon slots of a beacon period are referred to as signalling slots and are used to extend the beacon period length of neighbours. A device shall announce its beacon period length, measured in beacon slots, in its beacon. The announced beacon period length shall include the device's own beacon slot and all unavailable beacon slots in the beacon period of the prior superframe. The largest beacon period length announced shall not exceed mMaxBPLength. The beacon period length reported by a device varies, as new devices become members of its extended beacon group, and as the device or other devices in its extended beacon group choose a new beacon slot for beacon collision resolution or beacon period contraction.
The CAT MAC period may be commenced at a certain time during the MAC superframe with a message that will be broadcast and all devices can receive and adhere to. For example this may be handled in the following ways:
Explicitly: The CAT MAC period starts following a CAT-MAP control message, broadcasted by the elected CAT controller (typically that is a device with multiple PHYs). The CAT-MAP is defined as a special management frame and gets access to the (bonded channel) medium after a PIFS period in order to get priority over other potential MAC frames ( FIG. 4 ). Implicitly: The CAT MAC period starts following a (bonded-channel) beacon period. The WiMedia Beacon contains Information Elements (IE) that convey certain control and management information. Any device may include IEs in its beacon frame. WiMedia defines Application-specific IEs (ASIEs) that can be used by applications following a request. The scope of the ASIE is dependent on the application. The application in this case may be the CAT MAC protocol stack (of a controlling CAT device) requesting a certain CAT configuration.
The request for a certain CAT network (either with CAT-MAP or with a CAT-ASIE message) may be broadcasted by an active node that has a dual PHY capability (and is CAT enabled). The CAT-MAP or CAT-ASIE contains information about the PHY channels that devices need to tune in and access.
Each one of the channels will be a WLAN or WiMedia compatible one. Thus, each channel will operate a distinct MAC protocol followed by distinct WiMedia beacon period transmission ( FIG. 4 ).
The beacon period transmissions within the distinct channels may all be operated in a WLAN/WiMedia distributed manner (each device transmitting in a certain Beacon slot). (Note: beacon periods have deliberately been drawn with irregular sizes to show that these may be constructed by varying numbers of devices within the respective distinct channels).
CAT transmission is terminated when a dual PHY device sends a CAT-END message in the channels (following a PIFS). The same (or another) dual PHY device will also transmit a CAT-END message in each one of the other channels. All devices can now participate in a bonded channel PHY the details of which may be included in both the CAT-END messages and/or in the subsequent bonded channel beacon period.
Examples of network architectures are shown in FIGS. 5 to 7 .
In FIG. 5 there is only one device with dual PHY. This device is the only one that can initiate a CAT period. In a CAT network the dual PHY node shall send a distinct beacon to both channels' beacon periods.
In FIG. 6 there are two devices with dual PHY. The CAT period can be initiated by any one.
In the first two examples as illustrated in FIG. 5 and FIG. 6 , devices are grouped in two (or more) logical single-hop channels. Inter-channel communications may be possible if either the bonded channel is preferred over CAT transmissions, or traffic is bridged over a dual PHY device (multi-hop).
In FIG. 7 all devices have dual PHY capability. The CAT period may be initiated by anyone. In this third example, any device will be able to communicate with any other over two possible channels (and two MACs).
It should be noted that the distinct channels do not have to be synchronised and each device should be able to access (concurrently) each channel according to its distinct MAC protocol.
The main operation of the present invention described therein is to choose whether to initiate CAT allocations, which devices to include in which channel and (if appropriate) whether to terminate CAT transmissions and switch to bonded channel ones. Such CAT protocol processes are illustrated in FIG. 8 .
Various CAT network configurations are illustrated as states. In each one of these states the CAT MAC process determines whether we stay to the same state or move to another one. In the second part of FIG. 8 we indicate input data that influence the CAT MAC dynamic network configuration operation.
The following remarks address the performance of the channel-and-time protocol according to the present invention:
The CAT system improves the bonded channel's MAC throughput for certain traffic scenarios.
For traffic scenarios discussed herein, a certain MPDU frame is expected to have shorter waiting (delay) time for accessing the medium.
By dividing the size of the network and allowing two devices (in different CAT channels) to transmit in parallel, improved fairness can be expected, considering that access to parallel channels is mainly scheduled for applications that will last for a period of time that is long as compared with the duration of a MAC superframe, e.g. HDD backup, HDV, etc.
The channel-and-time protocol may be further optimised as follows
Regarding the traffic scenario and MAC protocol, Certain MAC protocol/functions and a certain traffic scenario (e.g. MSDU sizes, network size, frame aggregation, block transmission, contention windows, control and management frames, etc) will directly dictate the balance between CAT and bonded PHY performance.
Concerning the Network architecture, certain CAT allocations may result in traffic being bridged over a dual PHY node, doubling the system's load. This results in reduced MAC throughput and end-to-end delay. The amount these performance figures are decreased depends on the traffic scenario and the network architecture (i.e. number of dual PHY nodes). Considering this traffic overhead, there is a certain point where certain performance of the CAT network and the bonded PHY one break even. For CAT performance degradation beyond that threshold, the bonded PHY should be preferred. This threshold will be defined further on in this IAR.
Regarding the network topology and cross layer optimisation, the comparison between the bonded channel and CAT depends on the PHY mode (data rate). In a single hop bonded channel network an increased BER may result in downgrading to a lower PHY data rate. However in a multi-hop scenario, a higher PHY data rate may be acceptable for CAT, rendering it better (e.g. due to shorter distances). In the same fashion CAT system may increase range. Also, an increased BER may suggest changing the traffic scenario (e.g. no block transmissions or no frame aggregation), which will subsequently change the balance between CAT and bonded PHY, as discussed. In overall, this is a routing and link adaptation cross-layer (1-2-3) optimisation problem that may take into account a variety of parameters such as distance, power, performance, etc.
The CAT MAC will decide which one of the bonded channel MAC and the CAT network MAC is supposed to perform better (MAC throughput; Delay and buffering; Fairness) based on all the criteria that influence these CAT performance figures (traffic scenario and MAC protocol; Network architecture; Network topology and cross layer optimisation).
CAT MAC throughput may be evaluated by using the Theoretical Maximum Throughput (TMT) technique (introduced in J. Jun, P. Peddabachagari, and M. Sichitiu, “Theoretical maximum throughput of IEEE 802.11 and its applications,” Second IEEE International Symposium on Network Computing and Applications, pp. 249-256, 2003, incorporated herein by reference.) for evaluating the fundamental 802.11 CSMA/CA protocol and further discussed in Y. Zang, G. R. Hiertz, J. Habetha, B. Otal, H. Sirin, and H.-J. Reumerman, “Towards High Speed Wireless Personal Area Network-Efficiency Analysis of MBOA MAC,” in International Workshop on Wireless Ad-hoc Networks. London, UK, 2005 incorporated herein by reference, for the ECMA-368 MAC).
To demonstrate how CAT MAC may operate in regards to throughput optimisation irrespective of multi-hop cross layer 1-2-3 considerations that have already been widely studied in literature, the following is assumed for the purpose of a case study: All nodes are relatively closely distanced. All devices operate on the same PHY mode irrespective of the assumed single/multi-hop network architecture and topology. The assumed PHY mode will operate with zero BER and packet loss. CAT and bonded PHY will always be compared on equivalent PHY modes.
A simple CAT look-up table may have the following format:
TABLE 3
Basic CAT look-up table format
Network
Network
Network
Architecture A
Architecture A
Architecture B
Traffic
Traffic
Traffic
Scenario A
Scenario B
Scenario A
. . .
CAT vs
Bonded PHY
Mode 1
Performance
Metric A -
Improvement
Performance
Metric B -
Improvement
. . .
CAT vs
Bonded PHY
Mode 2
Performance
Metric A -
Improvement
Performance
Metric B -
Improvement
. . .
The CAT MAC will perform the following operations:
Calculate the current network performance by consulting the CAT look-up table for the closest match {traffic scenario, network architecture}, which may be adjusted to the current {traffic scenario, network architecture} with a certain formula. Apply the same algorithm to calculate the network performance for possible {traffic scenario, network architecture} pairs, by keeping the current traffic scenario and varying the network architecture. Choose the network architecture that produces the best estimated performance and instantiate the CAT MAC control mechanism for switching to the new CAT network.
The simplest possible look-up table may only consider:
MAC protocols without control/management overheads and traffic scenarios with fixed MSDU sizes and frame aggregation. MAC throughput as the sole performance metric.
Modifying the TMT methodology described e.g. in Y. Zang, G. R. Hiertz, J. Habetha, B. Otal, H. Sirin, and H.-J. Reumerman (supra) for application to bonded channels and CAT MAC, the following look-up table may be constructed (Table 4).
Given Table 4 the following CAT MAC formula may determine the performance of a given {traffic scenario, network architecture}:
I
{
PHY
,
Traf
,
Net
}
=
I
{
PHY
,
Traf
,
1
hop
}
-
Traf
{
Multihop
}
_
(
1
)
I
{
PHY
,
Traf
,
1
hop
}
=
(
M
{
Traf
}
_
-
CTM
L
CTM
R
-
CTM
L
)
·
I
{
PHY
,
M
R
}
+
(
CTM
R
-
M
{
Traf
}
_
CTM
R
-
CTM
L
)
·
I
{
PHY
,
M
L
}
(
2
)
Where:
Traf{Multihop} is the amount of traffic that needs to be bridged from one CAT channel to another CAT channel, for the given (or wanted) {traffic scenario, network architecture}. I{PHY,Traf,1hop} is the performance of the same traffic scenario for a single-hop network architecture, which may be given from the CAT look-up table (Table 4). M{Traf} is the mean fixed-size MPDU that best approximates the current (or expected) traffic scenario. CTM L and CTM R are the left and right Closest Table MPDU sizes (M L and M R , respectively) in Table 4. I{PHY,M} is the look-up table value (throughput improvement) for the given M MPDU size (block transmitted or with Immediate ACK, according to the traffic scenario).
Formula (2) is a linear interpolation of the data rate values. This methodology is of limited importance and should be regarded as a simple implementation example. An alternative way of expressing improvement (as discussed before) is as a function of the fixed overheads (independent of data rate) and the variable overheads and transmission rate (dependent on the selected channel data rate). For certain traffic scenarios, the improved results can be obtained from a developed performance model.
TABLE 4
Example of a primitive CAT look-up table for a single-hop network
architecture
CAT × 2
Throughput
T C
Fixed MPDU size (Traffic scenario)
Bonded PHY
1500 bytes
4095 bytes
10000 bytes
Throughput
Improvement:
T B
T C − T B (Mbps) | (T C − T B )/T B (%)
320 × 2-672
95.68
52%
100.46
30%
56.61
12%
400 × 2-840
111.28
57%
126.29
33%
84.22
15%
480 × 2-1008
128.93
64%
157.16
38%
120.19
19%
1120 × 2-2352
176.11
82%
315.00
63%
365.19
39%
CAT × 2
Throughput
T C
5 × Block Transmission
Bonded PHY
Fixed MPDU size (Traffic scenario)
Throughput
1500 bytes
4095 bytes
10000 bytes
T B
T C − T B (Mbps) | (T C − T B )/T B (%)
320 × 2-672
92.72
29%
65.08
14%
15.77
3%
400 × 2-840
118.37
33%
83.08
15%
29.54
4%
480 × 2-1008
156.87
42%
119.06
19%
56.49
7%
1120 × 2-2352
294.25
65%
374.69
41%
286.20
20%
For single-hop architectures, CAT will always perform better than the equivalent bonded PHY network (in the simple situation there the total amount of bridged traffic load is zero).
For a multi-hop architecture, the previous equations suggest that a certain CAT network architecture is preferable up to a threshold where the improvement of the associated single-hop CAT network over the bonded channel is greater than the inter-channel traffic that needs to be bridged over a dual PHY node.
To calculate the needed threshold the following mechanism may be used (as an example): The performance of a single hop network may be approximated by calculating the mean MPDU size of the considering traffic scenario and determining whether an Immediate ACK or a Block transmission MAC protocol is operated. The CAT improvement for the mean MPDU size is then approximated by considering the closest MPDU sizes in the look-up table and weighting the improvements accordingly.
Calculating the I{PHY,Traf,Net} for a range of network configurations, the CAT MAC is in position to determine which network (i.e. allocations of nodes to CAT channels) may be most suitable.
CAT allocations offer improved MAC performance as compared to equivalent bonded PHY channel MACs, for particular traffic scenarios and potential network configurations that the existence of dual PHY nodes may handle.
The mechanisms described in this invention are fully compatible with legacy WLAN/WiMedia standards. This is attributed to the added flexibility to dynamically choose between various network and channel configurations.
The CAT MAC is very scalable in terms of incorporating other known optimisation technologies such as frame aggregation, burst transmission, link adaptation and multi-hop optimization and range extension.
The present invention may optionally be used in conjunction with such technologies in order to further improve MAC performance (e.g. link utilization).
No doubt many other effective alternatives will occur to the skilled person. It will be understood that the invention is not limited to the described embodiments and encompasses modifications apparent to those skilled in the art lying within the spirit and scope of the claims appended hereto.
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A method of transmitting data over a plurality of channels, said channels forming a bonded channel comprising a bonded channel superframe, the bonded channel superframe comprising a bonded channel beacon period and a bonded channel data period;
broadcasting a control message on a bonded channel superframe, said control message indicating that subsequent transmission will be over distinct channels, each of said channels comprising a distinct superframe comprising a beacon period and a data period, and transmitting in each of the distinct channels a sequence of superframes, each superframe comprising a distinct beacon period followed by a distinct data period.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] The invention relates generally to an improvement in the design of an oil and gas well perforating device. The improvement applies to a type of perforating device that is typically lowered into the well through the casing or tubing in the well to a position where the explosive charges are detonated at the desired depth. The improvement is a method of modifying the scallop that is cut on the exterior of the device, at the location of a perforating charge, so as to minimize the resistance to the explosive charge which in turn improves the performance of the perforating charge by increasing its depth of penetration and hole size.
[0005] After an oil or gas well is drilled, steel casing is lowered into the well and cemented to the adjoining rock formations. Typically, perforations are needed to allow the oil or gas from the desired rock formation to be able to flow into the casing and then out of the well. The perforations are made by lowering, on a wireline or tubing, the perforating gun containing explosive charges to the desired depth and detonating the charges. There are several different types of perforating guns.
[0006] One type of perforating gun is referred to as a casing gun. A casing gun is a hollow steel carrier that is lowered into the casing of the well with the perforations made through screwed in ports. These screwed in ports are used to allow the ports to be removed and the perforating gun used again. Since the present invention relates to an improvement in a scallop for the perforation, the present invention is not applicable to a casing gun.
[0007] A second type of perforating gun is an expendable casing gun. This is similar to the previously discussed casing gun with the addition of larger charges that will cause significant distortion to the hollow steel carrier. The distortion is sufficient to make the hollow steel carrier useable only one time and therefore expendable. The larger charges are sometimes needed when greater penetration is required such as when some of the rock formation has washed away and there is a greater amount of cement to penetrate. An expendable casing gun will have scallops cut for the perforations or may have no scallops at all which is referred to as run slick.
[0008] A third type of perforating gun is a tubing conveyed perforating gun. The tubing is a retrievable string of pipe inside of the casing that is permanently cemented in place. This is another type of casing gun except the carrier is made a part of the tubing string rather than being run on the wireline. The carrier can have scallops or be slick.
[0009] All of the previously discussed perforating guns are made to be lowered into the casing. There are also perforating guns made to be lowered into the tubing. These through tubing perforating guns are designed to be utilized while leaving the tubing inside the well and casing. In order for the perforating guns to be lowered inside of the tubing requires a smaller diameter perforating gun. The through tubing perforating guns are lowered through the tubing to a desired depth, below the bottom of the tubing, at the desired rock formation.
[0010] A fourth type of perforating gun is a through tubing strip gun run on wireline. This type of perforating gun includes a strip carrier on which capsule shaped charges may be mounted. The capsule shaped charges are sealed to protect the charges from the well environment. At detonation the strip gun is basically blown apart and the debris drops to the bottom of the well below the perforations. Any intact portion of the strip gun is then retrieved through the tubing. There is no hollow steel carrier needed for the through tubing strip gun and so the present invention is not applicable to this type of perforating gun.
[0011] A fifth type of perforating gun is the retrievable through tubing gun which is like the casing gun in that it uses a sealed carrier to hold the charges but is a smaller diameter to fit inside the tubing. These smaller diameter carriers utilize the scallops and the present invention would be applicable.
[0012] In summary, the present invention is applicable to all of the types of perforating guns with the exception of the casing gun that uses screwed in ports and the strip gun that has no carrier. All of the perforating guns discussed utilize a sealed carrier with the exception of the strip gun. The sealed carriers usually have recessed areas or scallops at the location of the charges. The recessed area was originally made to compensate for the burr formed on the outside of the carrier and also serves to reduce the amount of energy the charge loses in exiting the perforating gun. The recessed area of reduced wall thickness can be accomplished in different ways, such as removable plugs for the casing gun, but the most common method is to make a cut into the outer surface of the perforating gun at the location of each perforating charge. This type of cut is typically referred to as a scallop. Removing more steel in the scallop is limited by the decrease in strength of the carrier.
[0013] There are no known attempts to modify the scallop, cut in the carrier, in order to further reduce the thickness of the steel by changing the geometrical shape of the scallop to make it structurally stronger. Schlumberger has two patents related to shaped geometry recesses to reduce or control reflection of compression waves generated from the explosive jet. Schlumberger has a method of making the recess by drilling a round hole perpendicular to the carrier with a resulting flat bottom and a ninety degree angle between the flat bottom and side. This is the prior art as described and drawn by Schlumberger. Schlumberger then offers in U.S. Pat. Nos. 6,460,463 B1 and 6,523,474 B2 a variety of different geometrical shapes, usually with sloping sides, that could reduce the compression waves generated by use of Schlumberger's prior art. The prior art and improvements described in that patent are unique to the way that Schlumberger makes their recesses.
[0014] The normal method utilized in the industry is the scallop which removes more steel over a larger area. The compression waves are not considered of any consequence in such a design as there is little to no sides to constrict the compression waves. The industry standard scallop method does not require as much accuracy in aiming the perforating charges as the Schlumberger method. The present invention adds a geometric cut to the scallop to remove more steel while increasing the mechanical strength of the carrier to withstand the internal and external pressures.
[0015] There continues to be a need to be able to minimize the energy lost by the perforating jet in exiting the sealed hollow steel carrier of the perforating guns. Any reduction in the energy lost exiting the carrier is available to the perforating jet to be able to penetrate deeper into the rock formation. Increasing the depth of penetration and hole size are the most important factors in the performance of a perforating gun. The method of reducing the lost energy must also maintain sufficient integrity of the carrier housing.
SUMMARY OF THE INVENTION
[0016] The present invention is an improvement for a well perforating device and method of manufacture to make a modification to the industry standard method of cutting a scallop on the outer surface of the hollow steel carrier that contains the perforating charges. The scallops are made at the location of each charge to reduce the energy needed to exit the carrier. The present invention is the use of an arching geometric cut for the scallop. The thickness of the carrier at the location of the scallop can be reduced while maintaining sufficient structural strength to withstand the pressures exerted on the carrier, as a result of the additional strength imparted from the arched geometric cut. The deeper arching geometric shape reduces the thickness of steel that the perforating jet must penetrate to exit the carrier which increases the remaining energy for greater penetration and hole size. Increasing the depth of cut of the scallop alone to the same thickness would result in significantly reduced structural strength of the carrier and failure to withstand the external pressures exerted on the carrier. The additional smaller geometric cut utilizes the additional strength created from the rigidity of the geometric cut to counter the effects of the reduced thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a partial side view of the prior art elliptical scallop cut on the outside of the perforating device hollow steel carrier.
[0018] FIG. 2 is a partial, cross sectional view of the prior art elliptical scallop cut along the longitudinal axis of the device of FIG. 1 along line 2 - 2 .
[0019] FIG. 3 is a partial, cross sectional view of the prior art device of FIG. 2 along line 3 - 3 .
[0020] FIG. 4 is a partial side view of the first preferred embodiment of the present invention showing the resulting elliptical shape made by a round bottom cut on the outside of the perforating device hollow steel carrier.
[0021] FIG. 5 is a partial, cross sectional view of the first preferred embodiment of the present invention along the longitudinal axis of the device of FIG. 4 along line 5 - 5 .
[0022] FIG. 6 is a partial, cross sectional view of the first preferred embodiment of the present invention device of FIG. 5 along line 6 - 6 .
[0023] FIG. 7 is a partial side view of the second preferred embodiment of the present invention showing the resulting elliptical shape made from a round flat bottom cut on the outside of the well perforating device hollow steel carrier.
[0024] FIG. 8 is a partial, cross sectional view of the second preferred embodiment of the present invention device along the longitudinal axis of the device of FIG. 7 along the line 8 - 8 .
[0025] FIG. 9 is a partial, cross sectional view of the second preferred embodiment of the present invention device of FIG. 8 along line 9 - 9 .
[0026] FIG. 10 is a partial side view of the third preferred embodiment of the present invention showing the elliptical shape of a standard scallop with an additional longer and narrower geometric cut along the longitudinal axis on the outside of the well perforating device hollow steel carrier.
[0027] FIG. 11 is a partial, cross sectional view of the third preferred embodiment of the present invention device along the longitudinal axis of the device of FIG. 10 along the line 11 - 11 .
[0028] FIG. 12 is a partial, cross sectional view of the third preferred embodiment of the present invention device of FIG. 11 along line 12 - 12 .
DETAILED DESCRIPTION
[0029] In the following description, details of the present invention are given to provide an understanding of the present invention. However, those skilled in the art will know that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments are possible.
[0030] Recesses formed in the outer wall of a body member 10 are to enhance the performance of the shaped charge perforating jets or other explosives. The thinned area allows for less energy to exit the body member 10 and more energy to penetrate the rock formation. The preferred embodiments presented are shaped with geometric cuts to remove more steel, to improve performance, while utilizing the strength of the geometric cut to maximize the remaining strength of the body member 10 to withstand the hydrostatic pressures exerted by the wellbore fluids. One of the preferred embodiments is adding a geometric cut to the industry standard elliptical scallop 12 .
[0031] FIG. 1 is a side view of a typical industry standard prior art scallop 12 cut into the outside of the round tubular body member hollow steel carrier 10 as part of a typical prior art perforating device used to perforate the casing, cement and rock formation in an oil and gas well to allow the reservoir fluids to flow into the well. The perforating device comprises a cylindrical body member 10 , which is sealed to protect the plurality of perforating charges, not shown, from the fluids in the wellbore and from the hydrostatic pressures of those fluids. The body member 10 has a smaller outer diameter than the inner diameter of the casing or tubing in order for the body member 10 to be slidably received within the longitudinal inner diameter of the casing or tubing. The body member 10 outer diameters range from one and three eighths inches to seven inches and are most typically in the two to four inch range.
[0032] There is a prior art scallop 12 cut in the outer wall of the body member 10 where the perforating charge is positioned. The prior art scallop 12 is aligned with the perforating charge such that the perforating jet exits through the prior art scallop 12 to lessen the force needed to exit the body member 10 . Decreasing the force needed to exit the body member 10 increases the remaining force available to penetrate deeper into the rock formation. When the perforating charges are detonated, the perforating jet should exit the body member 10 of the perforating gun at the center of the scallop 12 where the bottom flat section of the scallop has reduced the steel of the body member 10 to its minimum thickness. The minimum thickness of the steel allows for less of the energy from the perforating jet to be used to exit the body member 10 which allows more energy to be available to penetrate into the rock formation. The minimum thickness of the steel is balanced with the need to have sufficient thickness of steel to withstand the hydrostatic pressure exerted on the body member 10 along with providing for thickness variations in the original body member 10 .
[0033] The strength of the tubular hollow steel carrier body member 10 depends primarily upon the thickness and diameter of the carrier. The greater the thickness of the body member 10 provides additional strength. The smaller diameter of the body member 10 also serves to provide additional strength as the tighter arch of the tubular hollow steel carrier body makes the body member able to withstand greater forces. It is this same principle of the arch shape providing additional strength, that allows the present invention to remove more steel where the perforating jet exits the body member 10 while still maintaining sufficient structural integrity to resist the hydrostatic pressures. The additional strength created by the arching geometric cut allows more steel to be removed which in turn allows for greater penetration into the rock formation. The structural dynamics of an arch distributes the load laterally along the curvature of the arch.
[0034] The concept of the present invention and the preferred embodiments all use a geometric cut with an arch. Using an arch in the geometric shape of the cut could allow for many variations. Testing of various shapes on various hollow steel carrier body members has resulted in three preferred embodiments. These three preferred embodiments are not the only possibilities applying the concept of the present invention.
[0035] The first embodiment of the present invention is depicted in a side view in FIG. 4 and in cross sections in FIG. 5 and FIG. 6 . This embodiment is a radius cut scallop 14 . The radius cut scallop 14 is comprised of one continuous curved surface 16 . The elliptical shape of the radius cut scallop 14 is a result of the longitudinal length of the scallop being longer with all of the scallop being a curved surface with no flat area. The embodiment uses the strength of the arch from the radius cut to allow for more steel to be removed with less steel remaining for the perforating jet to penetrate. The strength of the arch provides additional strength to resist the hydrostatic forces of the wellbore fluids. Using the same thickness of steel with a standard scallop would collapse under the hydrostatic forces.
[0036] There are no known attempts to accomplish the result of the present invention. There are however, two patents dealing with a similar shape as the first embodiment of the present invention. Schlumberger is a large manufacturer of perforating guns and has two patents dealing with various geometric shapes of recessed areas for perforations to reduce or control reflection of compression waves generated in response to the perforating jet. These patents, U.S. Pat. Nos. 6,460,463 B1 and 6,523,474 B2, provide for various shapes of recessed areas to reduce compression waves resulting from the explosive charge. The embodiments of these Schlumberger patents are alterations to the standard Schlumberger recessed area, referred to as the prior art in those patents, which is simply a round flat bottom cut with ninety degree angle sides. Schlumberger determined that the geometry of their standard recessed area created these compression waves that cause interference that may adversely affect the performance of the perforating jets. These patents only mention that other types of recess geometries are available, some may have generally elliptical shapes, which is the standard industry elliptical scallop, and that such recess geometries may come at the expense of the body member 10 integrity as the recess may take up to much surface area of the body member 10 or remove too much body member 10 material. The present invention and the three preferred embodiments are all based on standard industry elliptical scallop for tubing guns and has nothing to do with compression waves.
[0037] One of the many embodiments of the Schlumberger patents is similar to the first embodiment of the present invention. Both patents depict and describe an emdodiment that does not have discrete bottom and side surfaces, that instead has a generally arcuate or curvilinear surface that extends around the periphery of the recess. It is further described as the arcuate surface of the recess is generally semi-hemispherical in shape and has a bottom surface portion that is continuous with a side surface portion along an arc. This is all various ways of describing the Sclumberger embodiment with some similarity to the radius cut 14 first embodiment of the present invention. So while these two recessed areas for the perforation have generally simillar shape, they are being utilized for totally different reasons. Schlumberger uses the shape as one of its many variations to possibly reduce the compression waves created from the Schlumberger prior art recessed area. The shape is being used in the first embodiment of the present invention for the reasons stated of using the strength of the arch to allow a deeper cut removing more steel to be removed which absorbs less energy and deeper penetrating of the perforating jet into the rock formation.
[0038] The second embodiment of the present invention is depicted in a side view in FIG. 7 and in cross sectional views in FIG. 8 and FIG. 9 . The second embodiment, the radius with a flat scallop 18 , is similar to the first embodiment in that there is a radius cut with a curved surface 20 , but the second embodiment also has a flat portion 22 at the center of the scallop. The flat area 22 is longitudinal resulting in the elliptical shape. The flat area 22 is small relative to the rest of the radius with a flat scallop 18 . The arched portion of the radius with a flat scallop 18 provides the additional strength to maintain the structural integrity while removing more steel for a deeper penetration.
[0039] The third embodiment of the present invention is depicted in a side view in FIG. 10 and in cross sectional views in FIG. 11 and FIG. 12 . Part of the third embodiment appears as an industry standard elliptical scallop 26 with an additional longitudinal arching cut 28 and is referred to as the double cut scallop 24 . The tightly arched longitudinal arching cut 28 creates a flat area at the center of the scallop 30 . While described as the double cut scallop 24 because of its appearance, it is machined as one single cut. Such tooling to produce this economically has not been available until recently. The cross sectional views of the double cut scallop 24 show how significantly more steel is removed compared to the industry standard elliptical scallop 26 . This third embodiment again uses the strength of the arching cut to maintain structural integrity while removing more steel for deeper penetration.
[0040] Testing has been performed of various geometries including the three embodiments on various sizes of hollow steel carrier body members 10 . The smaller diameter body members 10 have a smaller arch which affords more strength and so more steel can be removed. The larger diameter body members 10 have a larger arch which affords less strength and so less steel can be removed. The first embodiment, radius cut scallop 14 , is the most amount of steel to penetrate and affords the most strength. The second embodiment, radius with a flat scallop 18 , has less steel to penetrate and affords less strength than the first embodiment. The even larger flat portion of the third embodiment, double cut scallop 24 , affords less strength than either the first or second embodiments and is compensated for by the tighter inside arch. For these reasons, the first embodiment, radius cut scallop 14 , is for larger diameter body members 10 of more than four inches. The second embodiment, radius cut with a flat scallop 18 , is for medium diameter body members 10 of two and one half to four inches. The third embodiment, double cut scallop 24 , is for smaller diameter body members 10 of less than two and one half inches.
[0041] The design of the present invention and the three preferred embodiments are much better suited, over the prior art, to accomplish the objectives stated as well as those inherent therein. While the three preferred embodiments of the present invention have been described, numerous changes could be made by those skilled in the art which are encompassed within the spirit of the invention as described.
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The present invention is an improvement in the design of a perforating gun to perforate the casing in oil and gas wells. Perforating guns have a cylindrical body member with explosive charges at specified intervals designed to shoot outwardly through the body member, the well casing, cement sheath, and into the rock formation. There are recessed areas, scallops, on the outer surface of the body member where the perforating jets, formed by the explosive charges, exit the body member. The present invention uses the strength of an arching geometric shape for the recessed area to be able to further reduce the thickness of steel for minimal resistance to the perforating jet. Minimizing the resistance to the perforating jet increases the depth of penetration into the rock formation and increases the hole size.
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This is a continuation of application Ser. No. 439,732, filed Feb. 5, 1974, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates in general to safety seat belt buckles and, more particularly, to a design which provides an optimum combination of design features and parameters to provide a functional combination of high strength, small size, low weight, ease of use and versatility in use together with a reasonable cost to manufacture.
There are a large number of safety seat belt designs which have been used and are being used as well as a large number of designs that have been proposed and are known in the art. It is simple enough to design a buckle to readily meet any one of two given functional criteria as long as other functional criteria are sacrificed. However, as a practical matter there must be a trade-off between such characteristics as low weight and small size on the one hand and structural strength on the other hand. Ease and cost of manufacture is another feature which must be traded off against both weight and size as well as against strength. Other important functional features are ease of manipulation so that the passenger or driver can readily buckle and unbuckle when required. Furthermore, since the use of a seat belt requires some degree of minimum acceptance by the riding public, aesthetic features and simplicity in use as well as weight and size are factors to take into consideration in any given design in order to enhance the likelihood that as large a number of users as possible will in fact use the seat belt rather than try to defeat any system in which the seat belts are used.
Accordingly, the main purpose of this invention is in a seat belt buckle design that provides an optimum combination of parameters that include weight, strength, size, ease of use, reliability, and ease and cost of manufacture.
It is a further purpose of this invention to provide a basic seat belt buckle design which has versatility in that (a) it can be used for a seat belt buckle which either incorporates or omits an electrical switch for an interlock system and (b) it can be used either for a center seat buckle or an outboard seat buckle wherein these two buckles are designed to prevent improper hookup of an outboard seat buckle with a center seat clip and prevent improper hookup of a center seat buckle with an end seat clip. In effect, versatility is another parameter which is part of the optimum combination of parameters to which this invention is addressed.
BRIEF DESCRIPTION OF THE INVENTION
In brief, this invention employs a metal housing within which there is mounted a pushbutton lever, a V-shaped leaf type spring to bias said lever into an upward position, and a single plastic insert for holding an electrical switching arrangement and to provide a crush resistent wall between a plastic cover and the housing. Primarily because of the crush resistent wall on the plastic insert, the cover is designed so that it does not bear or have to resist any significant loading forces. The cover can thus be varied for aesthetic purposes or for the purpose of making sure that the center seat buckle and clip are noncompatible with the outboard seat buckle and clip. The pushbutton lever has sufficient mechanical advantage so that the wearer can readily release the clip and buckle even when there is considerable tension in the webbing to which the clip and buckle are connected. A coil spring loaded rotatable shaft having a radially extending finger serve to make or break the electrical switch connection. The finger is engaged by the leading edge of the clip during buckling and causes the shaft to which it is connected to rotate so that one of the coil spring ends is brought into contact with the electrical circuit to complete the circuit indicating that the buckling has occurred.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing an assembled buckle and an associated clip of a first embodiment of this invention.
FIG. 2 is a perspective view showing an assembled buckle and associated clip of a second embodiment of this invention; the difference between the embodiments shown in FIGS. 1 and 2 being in the buckle cover and in the clip configuration.
FIG. 3 is a perspective view of the buckle of this invention with the cover removed.
FIG. 4 is a plan view of the FIG. 3 buckle in partial cross section with the cover removed and without the push button release lever thereby showing the spring underlying the lever and the electrical connections used to indicate that buckling has been completed.
FIG. 5 is a perspective partial blow-up showing three portions of the buckle in blow-up fashion; the three portions being (a) the cover which is shown in partial cross section, (b) the crush bar member together with the electrical connections carried thereon, and (c) the housing with the release lever assembled thereon and the spring, in invisible lines, beneath the lever.
FIG. 5A is a detailed view, to enlarged scale, of a portion of the side wall of the buckle illustrating the relationship between the lever bars and the side wall opening, as shown in FIG. 5.
FIG. 6 is a perspective blow-up, excluding the cover, of the five remaining major elements of the buckle; namely from top to bottom, the electrical connection arrangement, the crush bar member, the lever, the spring and finally the housing.
FIG. 7 is a perspective blow-up view of the rotatable shaft and biasing spring mounted thereon which spring also operates to provide an electrical contact.
FIG. 8 is a longitudinal cross-section through the buckle in the unbuckled state.
FIG. 9 is a longitudinal cross-section through the buckle showing the condition where the clip has been inserted and thus is the buckled state.
FIG. 10 is a longitudinal cross-section similar to that of FIGS. 8 and 9 showing the release lever depressed and the clip being ejected from the buckle.
FIGS. 11 and 12 represent a first embodiment of the electrical contact arrangement in which the contact is normally open during the unbuckled state; FIG. 11 showing a perspective view of the contact and FIG. 12 showing a cross-sectional view through the rotatable shaft and operative finger attached thereto.
FIGS. 13 and 14 are similar to that of FIGS. 11 and 12 except that they represent a second embodiment of the contact arrangement wherein the electrical contact is normally closed during the unbuckled state.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 illustrate one of the advantages of the basic buckle design of this invention. FIG. 1 shows a buckle 20 and associated clip 21 for an outboard seat while FIG. 2 represents a buckle 22 and associated clip 23 for a center seat. The arrangement shown prevents incorrect buckling of a clip with a buckle for which it is not associated. Yet both buckles use the same basic structure, the most significant difference between the buckle 20 and the buckle 22 being in the covers 24 and 25 respectively. One of the advantages of this invention is that the buckle cover design can be substantially ornamental because it is not load bearing nor does it provide support or positioning for the components of the buckle. Thus, the cover 24, 25 can be designed to provide a new functional feature which is to avoid the improper buckling of dissociated clip and buckle.
Comparing the FIG. 2 arrangement to the FIG. 1 arrangement, the housing 27 of the FIG. 2 buckle is slightly longer than the housing 26 of the FIG. 1 buckle so that the shoulder 28 of the clip 21 will abut against the forward end of the housing 27 and thus prevent latching of the clip 21 in the buckle 22. The FIG. 2 cover 25 has a recessed forward end 29 which mates with a forward projection 30 of a housing 31 on the clip 23. This housing 31 covers the usual friction holding roll (not shown) that is required to permit adjusting the length of the belt strap 32 on the center seat. Since the center seat is not designed with a retractor this older method of adjusting belt 32 length has to be employed and thus the housing 31 exists as a base for providing the additional mating projection 30. Because the shoulder 33 of the clip 23 is further back from the latching opening 34 of the clip 23 than is the case of the FIG. 1 clip, the FIG. 2 clip 23 can proceed further into the buckle housing 27 than can the FIG. 1 clip 21. But because of the projection 30 on the FIG. 2 clip 23, the FIG. 1 buckle cover 24 will prevent the FIG. 2 clip 23 from extending sufficiently far into the FIG. 1 buckle 20 to latch.
The rest of the figures all relate to the same embodiment with a minor exception as to an electrical contact mechanism as shown in FIGS. 13 and 14. A basic terminology usage herein should be defined. As used herein, the forward end of the buckle is considered to be the end having the opening that admits the clip. Thus, the back end of the buckle 20 is the end which is attached to the buckle strap 38. Similarly, the front end of the clip 21 is considered herein to be the end that enters the front end of the buckle 20 while the back portion of the clip 21 is the portion to which the clip strap 39 is connected. The top of the buckle 20 is considered to be the cover 24 while the base or bottom is the opposite surface, which is the main surface 41 of the housing 42. Thus when a first element is described as being above a second element, that means the first element is close to the cover 24 than is the second element.
The buckle 20 is composed of a housing 42 within which there is mounted a manually operated lever 43 and a generally V-shaped leaf spring 44 (best seen in FIG. 6). The leaf spring 44 is positioned between the housing base 41 and the forward portion of the lever 43. The spring 44 biases the lever 43 into its normally up position. The lever 43 can be depressed toward the housing base 41 only so long as user digital pressure is maintained on the pushbutton 45 portion of the lever 43.
The lever 43 has a forward edge 43a, two sidewardly extending ears 43e, a clip engaging latch portion 43c, an opening 43d rearward of the latch portion 43c and the substantially horizontal pushbutton portion 45. The lever ears extend into pieshaped openings 62a in the side wall 62 of the housing 42.
As a further matter of terminology, the term horizontal is used herein to denote substantial parallelism to the base 41 and the term vertical denotes substantial perpendicularity to the base 41.
In addition, a plastic crush bar unit 48 is mounted in the housing 42 rearward of the leaf spring 44. This unit 48 includes a three-sided U-shaped wall 50 positioned around the pushbutton 45 and extending from the housing base 41 to slightly above the plane of the pushbutton 45. This wall 50 will take any loading that may be applied between the cover 24 and the housing 42 thereby providing a crush resistent buckle design. By employing this wall 50 to give the crush resistent parameter, the cover 24 can be designed and is designed without requiring the structural strength that would otherwise be required if the cover 24 had to be relied on to provide the crush resistent parameter. Thus, the alternate cover design shown in FIG. 2 is facilitated.
The unit 48 has three forwardly projecting legs 51, 52 and 53. A small rotatable shaft 54 is mounted on the center leg 52. A finger 55 extends out from this shaft 52. A coil spring 56 is mounted on the shaft 54 and engages the shaft 54 (as shown in FIG. 6) so as to bias the shaft to a rotational position where the finger 55 extends upward (see FIGS. 3 and 8). When so biased, the finger 55 is rotated against an end wall 52a of the center leg 52 thereby preventing further rotation of the shaft 54 and causing the finger 55 to normally project above the wall 52a. When the clip 21 is inserted into the buckle 20, the leading edge of the clip will abut against the forwardly facing side of the finger 55 forcing the finger 55 back thereby rotating the shaft 54 and the coil spring 56 mounted thereon. The two U-shaped electrical connections 57, 58 are positioned so that the connection 57 is in continuous contact with one end 56a of the coil spring 56 (see FIG. 6). The other end 56b of the coil spring 56 is normally in the open position shown in FIG. 12. But, when the finger 55 is moved back causing the shaft 54 and coil 56 to rotate (counterclockwise as seen in FIG. 12), the end 56b rotates down into contact with the second connection element 58 thereby completing an electrical circuit through the buckle 20 from the wire 59 to the wire 60.
As shown in FIGS. 6, 8 and 9, the leaf spring 44 has a base portion 44b which rests against the housing base 41 and two upward and rearward extending arms 44a which bear against the under surface of the lever 43 thereby biasing the lever 43 into its normal upward position. The leaf spring 44 has two upwardly bent side walls 44s which bear against the inner surface of the housing side walls 62 of the housing 42 to position the spring 44 laterally and hold the spring 44 from rattling. Two resilient vertical walls 44c at the back of the leaf spring 44 abut against the crush bar unit 48 and aid in holding snug the parts within the buckle. A tab 44t is bent out from one of the leaf spring side walls 44s to catch into an opening 62b (see FIG. 5A) in the housing 42 side walls 62 and thereby retain the leaf spring 44 against longitudinal movement backward within the housing 42. The opening 62b is an extension of one of the two pie-shaped openings 62a to provide a total opening on one side wall 62 great enough to permit assembling the lever 43 into the housing 42. As shown in FIG. 5A, the spring side walls 44s are stepped to provide a vertical edge 44e. This edge 44e, at least at the opening 62b, holds the lever ear 43e against longitudinal movement back within the opening 62b.
The steel lever 43 includes two sidewardly projecting ears 43e at the front end thereof. These ears fit within the pie-shaped openings 62a of the steel housing side wall 62. The upward limit of rotation of the lever 43 is determined by contact between the ears 43e and the upper edges of the openings 62a. At least nominally, forward movement of the ears 62a is determined by the forward edges of the openings 62a. However, the rearward edge 42a of the J-shaped front section of the housing 42 is positioned sufficiently close (10 to 30 mils in one embodiment) to the forward edge 43a of the lever so as to carry a part of the load on the lever 43 when a clip is locked in and exerts a large forward force on the lever 43. This relationship of housing edge 42b to lever edge 43a tends to minimize bowing of the lever 43 under high loads because as the lever 43 deflects under high loads, the J section 42b takes up the load and distributes the load over the entire front edge 43a of the lever.
The crush bar unit 48 in addition to the three wall crush bar 50 and the three forwardly projecting legs 51, 52, 53, also includes two resilient side walls 64. These side walls 64 are integral with the plastic unit 48 but these side walls 64 have a thickness such that they will flex laterally sufficient to permit snapping of the plastic unit 48 into the metal housing 42 by virtue of engagement between side projection 64a on each side wall 64 and openings 62d on each housing side wall 62. The projection 64a are bevelled on the underside so as to facilitate pushing the unit 48 into the housing 42 and so that the projections 64a can ride down the inner surface of the side walls 62 until they snap into the opening 62b.
This crush bar unit 48 also contains a back member 66 which member 66 includes sections 66a that are somewhat U-shaped in cross section so that the sections 66a engage the rear wall of the opening 41a in the base of the housing 42, through which opening 41a the buckle strap 38 is looped for attachment to the buckle 20. Thus, the buckle strap 38 (see FIG. 8) loops around the plastic section 66a and does not directly impinge on the metal wall for the opening 41a. This provides a degree of protection from abraiding and excess local tension on the strap 38.
An acetyl copolymer resin is used for the plastic crush bar unit 48.
In operation, and with particular reference to FIGS. 8, 9 and 10, the buckle 20 in normal unbuckled state is shown in FIG. 8, the buckle 20 in normal buckled state is shown in FIG. 9 and the buckle while the clip is being unbuckled or unlatched is shown in FIG. 10. When the clip 21 is inserted into the front opening 20a of the buckle 20, it is guided by the J-shaped front end 42b of the housing and is held down by inwardly extending flanges 62c of the front part of the housing side wall 62. Thus, the clip 21 is constrained to contact the rearwardly and slightly upwardly sloping latch portion 43c of the lever 43. The inward progression of the clip 21 forces the lever 43 to pivot down around a line that is approximately at the contact between the ears 43e and the forward edge of the openings 62a in the side wall 62. When the clip 21 has ridden in far enough, the clip opening 68 will be engaged by the rearwardly facing shoulder of the latch portion 43c permitting the lever 43 to snap back up to the position shown in FIG. 9 and thereby positively hold in the clip 21. At the same time, as disclosed above, the forward end of the clip 21 contacts the upwardly extending finger 55 causing it to rotate counterclockwise as seen in the drawings and causing the terminals 58 and 56b to contact thereby completing an electric circuit and providing an indication that the clip 21 is indeed latched into the buckle 20 and thus that the occupant is buckled up. It will be noted that the finger 55 projects up through the opening 43d immediately rearward of the latch portion 43c so that the clip 21 will contact the finger 55 during insertion.
One advantageous feature of the finger 55 design and arrangement shown can best be understood with reference to FIG. 10. On release of the clip 21, the passenger depresses the push button 45 portion of the lever 43 thereby bringing the latch portion 43c below the lever of the clip 21 so that the clip 21 can be pulled out. However, in addition, the finger 55 is biased by the spring 56 to move in a clockwise direction. Thus, as may be seen in FIG. 9, the finger 55 exerts a small upward and backward pressure on the clip 21. This pressure has no effect during the buckled state except perhaps to better seat the clip 21 against the rearwardly facing edge of the latch 43c. However, once the lever 43 and its latch 43c has been moved out of the way, the relatively small pressure exerted by the finger 55 meets no resistance and thus tends to move the clip 21 out of the buckle 20. This not only provides an improved passenger feel for the releasing mechanism, but also aids to assure that the clip 21 does not sit in place and thus is not relatched upon release of the disengaging pressure on the push button 45.
FIGS. 13 and 14 illustrate an embodiment in which the normally open terminals 58 and 56b (as shown in FIGS. 11 and 12) are normally closed terminals 58' and 58b. The buckled-up state is thus indicated by the opening of an electric circuit rather than the closing of a circuit. Otherwise, this FIG. 13 and 14 arrangement is the same as shown in the other FIGS. and the same reference numerals are therefore used.
An advantageous feature of the way in which the lever 43 and spring 44 are mounted in the housing 42 and in which they bear against one another is that these three units 42, 43 and 44 operate as a functional buckle regardless of the condition or even presence of the plastic unit 48 or plastic cover 24. Thus this design enhances safety on collision and extends effective life of the buckle.
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A self-sufficient three-piece structure constituting an open top metal housing within which there is mounted a pushbutton lever and a V-shaped leaf-type spring between lever and base of housing. A single plastic insert providing a crush resistent wall between base of housing and plastic cover also holds an electrical switching arrangement. The electrical switching arrangement includes a rotatable shaft and a radially outward extending finger which is actuated by insertion of the mating clip.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a surveying method.
To maintain or newly construct tracks/roadways, such as, e.g., streets or railroad tracks, it is crucial that the course of a track/roadway is exactly surveyed, compared to a desired course, and afterwards corrections that may be needed are implemented using track construction laying machinery that is suitable for this purpose.
As a matter of principle, when using the corresponding measuring means, it is possible to measure with great precision the course of the track/roadway from outside of the track/roadway in relation to geographic reference points. But these are static measurements for which it is necessary, if larger sections of track/roadway are to be surveyed, that the measurement site next to the track/roadway must, respectively, be newly set up, calibrated and the measurement taken. Measuring processes of this kind are not suited, in particular, for controlling continually operating track construction laying machines whose task it is to correct, if need be, the course of the track/roadway in relation to the preset desired course. Track construction laying machines of this kind depend on an, to the extent that this is possible, continual and current measurements of the current course of the track/roadway directly in the working area of the track construction laying machine in order to allow for these tasks to be completed within the shortest possible amount of time with optimally possible precision.
A method of this kind for the track maintenance of railroads is known, for example, from EP 0 559 850. In this instance, a measuring platform that can be rolled on the tracks is used; it is equipped with optical means that serve to detect position change values of the measuring platform by way of reference points that are arranged next to the tracks. These values are converted to position data and compared to the desired values of a stored survey plan. The deviation between these values presets correction values that can be evaluated by a special track maintenance construction machine in order to be able to correspondingly make corrections to the course of the track. Using a single measurement base, which can preferably be coupled directly ahead of the track maintenance construction machine, it is possible to continually detect and implement the values.
In order to arrive at absolute values for the track maintenance construction machine based on these changes, the position of the measuring platform must be established in absolute terms before the beginning of the measurement with said measuring platform. This is done by way of a separate, static position determination at the beginning of the measurement. Even though the optical measurement achieves very high accuracy, it cannot be implemented under all conditions, due to the requirement for a continuous optical connection between the measuring platform and the reference points. For example, environmental influences such as fog or elements that interrupt and/or disrupt the view, such as construction machinery or workers, may thus lead to measuring errors or may make a measurement impossible altogether.
The object of the present invention consists in providing a measuring method that will allow for a reliable and precise detection of the position change of the measuring platform and thereby of the track course without requiring a continuous connection to the reference points and to allow for continual use of the method also across longer stretches and/or distances while maintaining a high level of precision.
SUMMARY OF THE INVENTION
This object is achieved according to the invention by way of a method for surveying tracks/roadways in relation to a survey plan of the track/roadway, which contains the desired position of the track/roadway in relation to an absolute system of coordinates, provides that the position data of the inertia platform in relation to the system of coordinates are automatically checked and any deviations with regard to the system of coordinates are detected as correction values, and these are used for the correction of the measured data and/or the measured actual position of the measuring platform. To this end, a measuring platform is rolled along the track/roadway which has arranged thereon an inertia platform that is initialized and/or calibrated at the beginning of the measurement and aligned in relation to the system or coordinates; and the inertia platform records, during the travel of the measuring platform, the respective positions of the measuring platform in relation to the system of coordinates.
By using an inertia platform, which is periodically calibrated in relation to the system of coordinates, i.e. its position data is corrected with regard to the system of coordinates, it is possible to continually detect and record with great precision the position of the measuring platform. The advantage of the inertia platform lies in the fact that it provides very precise values virtually irrespective of weather conditions, and that it can be universally used anywhere. Thanks to the periodic position data checks of the inertia platform relative to their effective position in relation to the system of coordinates, it is possible to continually and quickly recognize any deviation of the platform from the actual position and to take these values into account as correction values when calculating the position data.
Preferably, the periodic check of the position data of the inertia platform is done by way of an optical surveying of the position of the measuring platform in relation to the fixed points that are arranged adjacent to the track/roadway. This allows, respectively, for a very precise determination of the actual position of the measuring platform, and any values of the inertia platform deviating from this can be corrected. Since, in contrast to conventional systems, the optical measurement does not have to be effected continually but instead only periodically and at defined sites, this optical measurement is considerably less easily impacted by outside influences, such as e.g. obstacles that hide the view of the fixed points. If need be, it is even possible to forego such a measurement, if such a measurement is not able to deliver precise results; in such a case the measurement, and if need be any correction, is implemented at the next fixed point.
Used, preferably, as inertia platform is a gyrostabilized platform or a laser platform. In this context, the laser platform usually has the higher level of precision and a smaller drift, i.e. a smaller deviation from the actual position after calibration, than the gyrostabilized platforms, which in turn are cheaper to buy and provide a sufficiently high level of precision for tracks/roadways with only minimal directional changes.
Preferably, the measuring platform is additionally equipped with a satellite-supported navigational system; here, the position data of the inertia platform are compared to the position data of this navigational system. If there are any deviations of these position data between each other, corrected position data are calculated and stored. This way, the continual adjustment and/or correction of the position data originating from the inertia platform is even possible between two fixed points, whereby the precision of the method is further improved overall.
Preferably, the position data of the satellite-supported navigational system are also periodically checked in relation to their effective position relative to the system of coordinates and, if deviations have occurred, correspondingly corrected. Moreover, it is possible to correct the position data of the satellite-supported navigational system by including values of a second navigational system that is positioned as defined in relation to the system of coordinates, whereby the precision of the results can be further improved.
Preferably, any deviations of the position data of the inertia platform that are determined at a fixed point are applied linearly to the previously measured points in the sense of a correction. The position values of the measuring platform that were previously detected and stored can be corrected after the fact, if there is a deviation found at a fixed point. Thus, the correction is advantageously applied linearly with regard to the position values relative to the distance of the previous fixed point. This way it is possible, for example, to determine and, if need be, record the actual course of a track/roadway in relation to the system of coordinates and thereby also with regard to the desired course of the survey plan.
Preferably, the measuring platform is connected to reference platforms that can also be rolled along the track/roadway and that follow the course of the track/roadway; the position of the reference platforms can be detected in relation to the measured platform by way of optical means and used to supplement or correct the measured and/or calculated values. Thanks to these additional relative reference points, it is possible, for example, to detect and determine the curve radius of the track/roadway with great precision. Used for this purpose are, preferably, two reference platforms that are sequentially arranged and connected to the measuring platform at a constant, defined distance.
Preferably, the reference platforms are equipped with optical reflectors, and at least one light scanner is used on the measuring platform. The light scanner communicates optically with the reflectors and can very exactly detect the reflectors' relative angle-related deviations, for example in relation of the longitudinal axis of the measuring platform. It is therefore possible to arrive at a very exact determination of, for example, the curve radius of a track/roadway by relying of the known geometrical relations between measuring platform and reference platforms.
Preferably, the method according to the invention is used for measuring railroad tracks. Defined conditions are applicable especially in that area, in particular with regard to the alignment of the measuring platform wherefore the latter is able to detect the course of the mid-line and, by detection of the incline in relation to the horizontal, also the course of the two parallel track lines.
Preferably, the deviations of the raw or corrected position data from the desired position are fed directly as control data to a track construction laying machine that follows the measuring platform or that is directly connected to the measuring platform in order to adjust the track to the desired position. The measuring platform can advantageously be coupled ahead of a track working machine, or it can even be arranged on top thereon and/or integrated therewith and trigger such a machine in order for the course of the track/roadway to be adjusted to the desired course. This process allows for continual and quick track work. This is especially crucial when working with railroad tracks because track work can usually only be conducted during down-times when trains are not operating, and these times are shrinking more and more in view of longer and longer operating times.
An embodiment of the method according to the invention is subsequently described by way of the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a measuring platform for the implementation of the method according to the invention;
FIG. 2 is a schematic view of the course of the measuring points of the method according to the invention while incorporating a satellite-supported navigational system;
FIG. 3 is a schematic view of the course of the measuring points solely on the basis of the detection by the inertia platform;
FIG. 4 is a schematic view of the corrected course of the measuring points according to FIG. 3 based on the determined deviation of the inertia platform;
FIG. 5 is a schematic view of a measuring platform with associated reference platforms for implementing the method according to the invention; and
FIG. 6 is a schematic top view of a measuring apparatus according to FIG. 5 traversing a curved track.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic view of a measuring platform 2 that can be rolled on tracks 1 . Measuring platform 2 comprises a measuring bogie 3 that is equipped with two axles 4 , 5 . Arranged on measuring platform 2 are an inertia platform 6 , an optical scanner 7 and a satellite-supported navigational system 8 .
Inertia platform 6 delivers absolute position data in relation to a system of coordinates whereby first of all an initialization of inertia platform 6 must occur. During the initialization, inertia platform 6 is aligned in a known way based on the known, i.e. measured and/or detected absolute, position of measuring platform 2 . Correspondingly, during the moving action of measuring platform 2 and/or measuring bogie 3 along tracks 1 , inertia platform 6 delivers the respectively current position data in relation to the system of coordinates.
Usable as inertia platforms 6 are commonly known devices that operate either on a mechanical basis with a gyrostabilized platform or that are equipped with elements that are virtually free of wear and tear on the basis of lighting engineering and/or laser technology. Depending on the length of operation since the initialization and of the movements and forces applied upon inertia platform 6 , the position data contain deviations from the effective position of measuring platform 2 . These deviations usually increase with increased length of operation and thereby lead to faulty position-related results. This is the cause for a periodic re-initialization and/or calibration of inertia platform 6 based on known and/or measured position data of the measuring platform in order to ensure sufficiently precise position data.
The calibration can now be done, respectively, automatically in the vicinity of the fixed points 9 , which are preferably arranged near track 1 . For example, these can be exactly measured fixed points 9 that are entered in the survey plan of the tracks, and that are, for example, attached to upright traction pole 10 . The position of measuring bogie 3 and thus of measuring platform 2 can be exactly determined by surveying in relation to such fixed points 9 . Such a survey is preferably done by way of optical scanner 7 that is arranged on measuring platform 2 and/or connected thereto. In an automated state, optical scanners of this kind can deliver very precise measuring results. And based upon these measuring result, it is possible to determine in a way that is known in the art the actual absolute position of measuring bogie 3 and thus of measuring platform 2 in relation to the system of coordinates.
The deviation of the position values that is measured in such a way from the position values supplied by inertia platform 6 directly indicates the effective deviation of inertia platform 6 and can be utilized for the calibration of inertia platform 6 .
In order to be able to effect a correction of the position values delivered by inertia platform 6 already between the two fixed points 9 , the position of measuring platforms 2 is additionally established with the aid of satellite-supported navigational system 8 . This navigational system 8 delivers parallel to inertia platform 6 also absolute position data of measuring platform 2 . A deviation of the position values of inertia platform 6 and of navigational system 8 suggests a deviation of drift of inertia platform 6 . When deviations of this kind occur, it is now possible to achieve a corresponding correction of the position values of inertia platform 6 .
Since even satellite-supported navigational system 8 does not supply any absolutely precise position data, because the latter are dependent on the receiving quality of the signals originating from satellite 11 , deviations are preferably not used at their full value but only as a certain percentage as trend value for the correction of the position data of inertia platform 6 .
FIG. 2 is a schematic depiction of the result of this method of measuring. The desired course S of track 1 according to the survey plan is represented as a perforated line between the two fixed points 9 and 9 ′. The points M reflect the result of the position determination based on travel by measuring bogie 3 on the actual track course. Arrow D indicates the direction of the deviation and/or the drift of inertia platform 6 , which, normally, is not directed parallel in relation to the track course. Starting at point M′, a correction of the position values is now implemented based on the established differences between the position values of inertia platform 6 and satellite-supported navigational system 8 resulting in the depicted course of the position values. Preferably directly next to fixed point 9 ′, the effective position of measuring platform 2 is now determined and a calibration of inertia platform 6 is effected. Since the position values M and/or M′ already underwent a correction, wherefore the deviation from the effective position is minimized, no major deviation in relation to the previous points M′ will be discernable at point M″ at the calibration site.
Consequently, due to this method it is possible to achieve a very good quality of measuring points M, M′ and/or M″; i.e. they reflect this actual course of track 1 with a high level of precision. The method can subsequently be used, for example, in order to create a precise survey plan of the actual position of track 1 . But the data can also be used to trigger a track construction laying machine that is able to change the position of track 1 and that is able to adjust and/or correct the position of the track 1 to match the desired position in accordance to the survey plan.
To improve the precision of the position data of satellite-supported navigational system 8 , it is possible to correct these data based on the measurements by an adjacent, second stationary navigational system 12 that is arranged at a defined position. This correction signal, that results from the difference of the position value determined by the second navigational system 12 and the effective position of second navigational system 12 , can be fed via a receiver 13 of evaluation unit 14 to measuring platform 2 , which is also where all other calculations are done and the determined values are stored and/or recorded.
FIG. 3 shows once more a schematic view of the course of the measured position data and/or of the position data corrected in accordance with the method outlined above between two fixed points 9 and/or 9 ′. Distance A between two sequentially arranged measuring points M 1 and M 2 in relation to desired course S represents the error and/or the deviation of the track location. Distance D between measuring point M n and calibration measuring point M k represents the accumulated deviation and/or drift of inertia platform 6 . If, for example, measuring platform 2 and/or measuring bogie 3 is moved approximately with constant speed in order to record the actual track course, i.e. to do a surveying run, it can be assumed that the deviation and/or drift of inertia platform 6 between two fixed points 9 and/or 9 ′ has been linear. Thus it is possible to correct the position values that are determined between fixed points 9 and/or 9 ′ linearly after the fact in dependence of the distance of first fixed point 9 in correspondence to this deviation, as schematically depicted in FIG. 4 . Position values M that are corrected in this manner provide a very exact image of the actual course of track 1 within the system of coordinates.
FIG. 5 is another embodied example of a measuring bogie 3 for implementing the measuring process according to the invention. In this context, measuring bogie 3 is connected to two additional reference bogies 15 and/or 16 . These reference bogies 15 and/or 16 advantageously have a reference axle 17 and/or 18 that is connected to optical reflectors 19 and/or 20 . Using an optical scanner 21 , it is now possible to automatically and continually measure and/or determine the relative position of reference bogie 15 and/or 16 in relation to measuring bogie 3 .
As can be seen from the schematic top view in FIG. 6 , this information, advantageously angle-related information, can, for example, serve to determine curve radius R of track 1 . Since reference bogies 15 and/or 16 are connected to measuring bogie 3 at a certain known distance, it is possible to easily calculate the radius on the basis of the known geometric conditions.
It is clear to the expert is the field that the method of measuring is not limited for use in connection with railway tracks and/or tracks 1 in particular; instead, it is also suitable for use in connection with streets. In the latter case measuring bogie 3 must be rolled along the mid-line of the street, if need be manually, in order to arrive at the corresponding position values.
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The invention relates to a method for measuring tracks in relation to a measuring plan of the track which contains the actual position of the track, in relation to an absolute coordinate system. A measuring platform ( 2 ) is guided along the track ( 1 ), whereon an inertia platform ( 6 ) is arranged, which is initialised, respectively, calibrated to the beginning of the measurement and is aligned in relation to the coordinate system. The inertia platform ( 6 ) detects the respective positions of the measuring platform ( 2 ) in relation to the coordinate system during the journey of the measuring platform ( 2 ). Positional data of the inertia platform ( 6 ) is periodically examined based on fixed points ( 9; 9 ′) which are arranged in the vicinity of the track and deviations in relation to the coordinate system are corrected by novel calibration, respectively, alignment.
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FIELD OF THE INVENTION
This invention relates to an optical interconnection apparatus which is capable of optical switching, multiplexing, and demultiplexing functions. More particularly, this invention relates to an optical interconnection apparatus that has a wide and substantially flat passband.
BACKGROUND OF THE INVENTION
Optical switching, multiplexing, and demultiplexing have been accomplished in the past by using an interconnection apparatus having a plurality of closely spaced input waveguides communicating with the input of a star coupler. The output of the star coupler communicates with an optical grating comprising a series of optical waveguides, each of the waveguides differing in length with respect to its nearest neighbor by a predetermined fixed amount. The grating is connected to the input of a second star coupler, the outputs of which form the outputs of the switching, multiplexing, and demultiplexing apparatus. An example of such an interconnection apparatus is disclosed in U.S. Pat. Nos. 5,002,350 and 5,136,671.
The geometry of such an apparatus may be such that a plurality of separate and distinct wavelengths each launched into a separate and distinct input port of the apparatus will all combine and appear on a predetermined one of the output ports. In this manner, the apparatus performs a multiplexing function. The same apparatus may also perform a demultiplexing function. In this situation, a plurality of input wavelengths is directed to a predetermined one of the input ports of the apparatus. Each of the input wavelengths is separated from the others and directed to a predetermined one of the output ports of the apparatus. An appropriate selection of input wavelength also permits switching between any selected input port to any selected output port. Accordingly, these devices are referred to as frequency routing devices.
Known frequency routing devices do not efficiently provide a flat passband between a distinct one of the input ports and a distinct one of the output ports. Moreover, it is difficult to selectively choose the center wavelength of the passbands.
It is, therefore, an object of this invention to provide a frequency routing device having a flat passband that is as wide as possible with minimal loss, while at the same time providing grater flexibility in choosing the center wavelength of the passbands.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an example of a conventional optical frequency routing device.
FIG. 2 is a graph showing the transmission coefficients T ik for the routing device of FIG. 1.
FIG. 3 is a graph showing an example of the net transmission coefficient T 0 (X) formed by combining adjacent output waveguides in accordance with this invention.
FIG. 4 is a graph showing the transmission coefficients T 11 and T 12 when the waveguide spacing between the adjacent waveguides to be combined is relatively small.
FIG. 5(a) is a graph showing the net transmission coefficient T 0 (X) when the waveguide spacing is relatively small and FIG. 5(b) is a graph showing the net transmission coefficient T 0 (X) when the waveguide spacing is increased so that a substantially flat passband results.
FIG. 6 shows an example of the frequency routing device in accordance with this invention in which two adjacent output waveguides are combined by a coupler.
FIG. 7 shows a graph of the set of transmission coefficients T 0 (X-(i-1)S) for the frequency routing device shown in FIG. 6.
FIG. 8 shows a graph of the set of transmission coefficients T 0 (X-(i-1)S) for the frequency routing device shown in FIG. 6 when only every third input waveguide is employed.
FIG. 9 is a graph showing an example of a substantially flat net transmission coefficient produced by the routing device in accordance with this invention.
FIG. 10 shows an example of the frequency routing device in accordance with this invention in which two adjacent input waveguides are combined by a coupler.
FIG. 11 is a graph showing an image f(x) appearing on the output free space region of the routing device shown in FIG. 1 and the corresponding mode h(x) for a particular output waveguide.
FIG. 12 is a graph showing an image f 0 (x) appearing on the output free space region of the routing device of this invention for a sufficiently large waveguide spacing.
FIG. 13 is a graph of the transmission coefficient T 0 (x) for a demultiplexer in accordance with this invention when the waveguide spacing is minimized so that the spectral efficiency is maximized.
FIG. 14 shows the demultiplexer producing the behavior illustrated in FIG. 13.
DETAILED DESCRIPTION
FIG. 1 shows the pertinent details of a conventional frequency routing device. The frequency routing device contains a plurality of input waveguides 2 i , i=1, 2, . . . , N connected to a free space region 98. A plurality of output waveguides 30 extends from the free space region 98 and is connected to an optical grating 32. The optical grating 32 comprises a plurality of unequal length waveguides which provides a predetermined amount of path length difference to a corresponding plurality of input waveguides 34 connected to another free space region 46. The free space region 46 is connected to a plurality of output waveguides 4 k , k=1, 2, . . . , N. These frequency routing devices operate as multiplexers and demultiplexers of optical frequencies. For example, if a signal of amplitude A is applied to input waveguide 2 1 then signals of amplitudes AT 11 , AT 12 , . . . AT 1N are produced at the output waveguides where T ik is the value of the transmission coefficient for input waveguide 2 i and output waveguide 4 k . Additional details concerning these routing devices are found in the above-referenced patents.
The typical behavior of the routing device shown in FIG. 1 is illustrated in FIG. 2. This figure shows the set of transmission coefficients T 1k for the routing device for the particular input waveguide 2 1 as a function of wavelength λ. The variation of each transmission coefficient as a function of wavelength is essentially periodic with a period X o . For a symmetric arrangement in which the input and output waveguides are uniformly positioned within the device's field of view (i.e., the Brillouin Zone), X o is given by
X.sub.o =N·S (1)
where N is the total number of input (or output) waveguides and S is the channel spacing, which is defined as the wavelength separation between maximum peaks of adjacent transmission coefficients (see FIG. 2). The wavelength λ 0 is a wavelength that corresponds to a maximum value for one of the transmission coefficients T ik . In FIG. 1, λ 0 corresponds to a maximum of the coefficient T 11 . All other wavelengths of maximum transmission λ ik for the various coefficients T ik essentially differ from λ 0 by multiples of S and therefore are given by the expression
λ.sub.ik =λ.sub.o +(i-k+q·N)S (2)
where the integers i,k =1, . . . , N specify the locations of the input and output waveguides, q is an integer, and λ o is a wavelength of maximum transmission for the waveguides i=k=1. The wavelength λ o will be referred to as the multiplexer center wavelength. The parameter X is defined as follows:
X=λ-[λ.sub.o +(i-k+q·N)S]=λ-λ.sub.ik(3)
The transmission coefficients have essentially identical behavior and, therefore, they are described by the same function T(X). Thus, all the transmission coefficients corresponding to a particular input waveguide yield an array of equally spaced transmission peaks such as shown in FIG. 2. The spacing of adjacent peaks is equal to the channel spacing S.
In a conventional routing device the channel spacing S is chosen to be large enough to ensure negligible crosstalk between different waveguides. Thus, in the vicinity of a particular wavelength of maximum transmission, for a particular coefficient T ik , all other coefficients T ik are negligible. In other words, the various coefficients T ik are typically designed to be essentially non-overlapping, as in FIG. 2.
Generally, in a conventional routing device, energy loss is minimized by insuring a nearly perfect match between each input waveguide and the routing device. In practice, in a symmetric arrangement of the type described in C. Dragone, "An NxN Optical Multiplexer using A Planar Arrangement of Two Star Couplers", IEEE Photonics Technology Letters, Vol. 3, No. 9, September 1991, pp. 812-805, this matching condition is satisfied by using identical input and output waveguides. Then, neglecting losses in the routing device, there will be approximately unity transmission at the wavelengths λ ik . In the following discussion, for the sake of simplicity, losses caused by non-ideal fabrication will be neglected. Accordingly,
T(0)=1
In order to include losses it is sufficient to multiply T(X) by a suitable coefficient b less than unity.
The above-described conventional routing device has an undesirable feature, namely, that the passband has a width W that is typically much smaller than the channel spacing S, as FIG. 2 indicates. The passband width W over which the transmission coefficient variation remains less than 1 db is typically smaller than the channel spacing divided by 3.0. In accordance with this invention, this limitation can be overcome if the routing device shown in FIG. 1 is modified by coupling together pairs of output waveguides (or, alternatively, input waveguides) so as to produce a substantially flat passband. FIG. 6 shows a routing device in which a pair of adjacent output waveguides 4 3 and 4 4 are combined by a Y-branch coupler 6 and FIG. 10 shows a similar arrangement for an adjacent pair of input waveguides.
To provide a routing device with a relatively wide transmission function such as indicated by the curve T o (X) shown in FIG. 3, the channel spacing S between the coupled adjacent waveguides should be reduced so as to cause the corresponding transmission coefficients to overlap. Specifically, if output waveguides k=1 and k=2 (e.g., waveguides 4 1 and 4 2 ) are combined as in FIG. 6, the net transmission coefficient T 0 is given by the sum of the individual, overlapping coefficients T 11 and T 12 . Accordingly, by properly selecting the spacing between the coupled waveguides, the coefficient T 0 exhibits the desired wide passband W.
It should be noted that if two adjacent output (or input) waveguides are coupled with a Y-branch coupler in accordance with this invention, there will be a loss so that the net transmission coefficient T 0 (X) will be less than the sum of the individual transmission coefficients (e.g., T 11 and T 12 for the routing device shown in FIG. 6). Specifically, it can be shown that the net transmission coefficient T(0) is described by the relationship: ##EQU1##
The following discussion will set forth in greater detail the conditions producing a routing device with the desired wide passband behavior shown in FIG. 3. It is well-known that the channel spacing S is linearly related to the waveguide spacing s as follows:
S=cs (5)
where c is a constant that depends on the multiplexer design parameters. When the waveguide spacing s is very small so that the waveguides are strongly coupled, the adjacent transmission coefficients (e.g., T 11 and T 12 for the routing device of FIG. 6) have the behavior illustrated in FIG. 4. At the wavelength corresponding to -S/2 most of the power supplied to the input waveguide is transferred to the output waveguide corresponding to k=1. At the wavelength corresponding to +S/2 most of the power supplied to the input waveguide is transferred to the output waveguide corresponding to k=2. At the intermediate wavelength (i.e., X=0) approximately half of the power is transferred to each of the output waveguides k=1 and 2. The value of each of the transmission coefficients at this intermediate wavelength is approximately T(0)/2. It therefore follows from equation 4 that when the combined waveguides are closely spaced the combination of the two transmission coefficients T 11 and T 12 has the behavior illustrated in FIG. 5(a). In this case T 0 (X) does not exhibit a flat passband but has a maximum value at X=0 and substantially lower values at X=±S/2. However, a substantially flat passband can be obtained by making the waveguide spacing s sufficiently large to produce two distinct transmission maxima separated by a minimum at X=0, as indicated in FIG. 5(b). The ratio between the maximum and minimum transmission values within the passband can be chosen to have any desired value by properly choosing the waveguide spacing s between the waveguides coupled by the Y-branch coupler. For example, the particular behavior illustrated in FIG. 3 is obtained by choosing the waveguide spacing s so that
T(S/2)≃T(0)/2
This equation states that to obtain a substantially flat passband each of the individual transmission coefficients at the intermediate wavelength (X=0) must be approximately one half its maximum value. For this particular waveguide spacing the passband width W is equal to S and it can be shown that the two transmission maxima occur approximately at ##EQU2## and their values are close to 1.05 |T(0)| 2 . Notice, by properly decreasing the spacing so as to cause ##EQU3## a maximally flat passband can be obtained as seen in FIG. 9
The transmission coefficient T 0 (X) shown in FIG. 3 is produced by the routing device shown in FIG. 6 between the input waveguide corresponding to i=1 and the output of the Y-branch coupler 6. The transmission coefficient between all other input waveguides and the Y-branch coupler 6 is obtained by displacing T 0 (X) by an integer multiple of S. Specifically, the set of coefficients T 0 (X-(i-1)S) for all the plurality of input waveguides and the output of the Y-coupler 6 is illustrated in FIG. 7.
For many applications the routing device of this invention should be configured to ensure negligible crosstalk between adjacent waveguides. In other words, the routing device should ideally produce over the entire passband of each transmission coefficient seen in FIG. 7, negligible values for all other coefficients. Clearly, the set of transmission coefficients seen in FIG. 7 do not satisfy this condition. However, this condition can be met by using only every third input waveguide. Since in this case only a fraction of the input waveguides are used, the unused waveguides may be removed and the spacing between the remaining waveguides can be then somewhat reduced without causing substantial crosstalk. FIG. 8 shows an example of the behavior of the routing device of FIG. 6 when only every third input waveguide is used.
A problem with the conventional design of a routing device is that it is difficult to control the fabrication process to within the required accuracy for the center wavelength λ 0 , which is often a fraction of a nanometer. It is thus desirable to design a routing device in which the values of λ 0 can be selectively chosen. For the sake of clarity this problem will be addressed below in terms of a demultiplexer. However, the same considerations apply equally to a multiplexer and a routing device generally. If the demultiplexer must demultiplex a signal composed of N channels centered at the wavelengths,
S.sub.0, S.sub.0 +S, . . . , S.sub.0 +(N-1)S
the demultiplexer must separate the N channels and transmit each of them to a separate output waveguide.
To obtain a properly located center wavelength λ 0 for a demultiplexer such as shown in FIG. 10, several pairs of adjacent input waveguides are coupled by Y-branch couplers. The various pairs are properly spaced apart from one another so as to produce different values for the center wavelength λ 0 for each of the pairs. Moreover, as will be discussed in more detail below, additional values of the center wavelength λ 0 can be produced by interleaving additional output waveguides between the initial set of output waveguides.
As noted earlier, the wavelengths of maximum transmission are determined by the locations of the input and output waveguides on the input and output circles of the two free space regions. In the particular case of the routing device shown in FIG. 1, which consists of a symmetric arrangement of equally spaced input and output waveguides, all wavelengths of maximum transmission are displaced from the center wavelength λ o by multiples of S. Thus, consider N such wavelengths,
α,α+S,α+2S, . . . ,α+(N-1)S (8)
where α=λ o , and let an input signal consisting of N channels centered at these wavelengths be applied to one of the input waveguides, for instance i=1. The routing device will then transmit each wavelength to a different output waveguide. However, the same result will be obtained if the input signal is applied to a different input waveguide, since each of the N transmission coefficients corresponding to any particular input waveguide will produce maximum transmission at one of the above wavelengths. For instance, the coefficients corresponding to the input waveguide i=2 are obtained from those for i=1 by simply applying signal A to waveguide i=2 instead of i=1 and replacing in FIG. 2:
T.sub.11 →T.sub.2N, T.sub.12 →T.sub.21, . . . ,T.sub.1N →T.sub.2,N-1 (9)
Accordingly, the only difference between the transmission coefficients when the signal is applied to i=2 instead of i=1 is a cyclic permutation of the wavelengths of maximum transmission. In either case, the arrangement of FIG. 1 will demultiplex the N channels and transmit them to separate output waveguides.
The value of α for each input waveguide can be changed without affecting the channel spacing S by slightly displacing the location of each input waveguide from the particular location producing α=λ o . As a result, the arrangement of FIG. 1 is now characterized by different values of α
α=α.sub.i (i=1,2,etc.) (10)
for each of the input ports i=1, 2, . . . , N, where α i now differs from λ o because of the i-the waveguide displacement.
The above considerations have shown that it is possible to produce a demultiplexer with a set of distinct values of α by properly displacing the input waveguides. Consider, for instance, a demultiplexer in accordance with this invention such as shown in FIG. 14 having a single pair of adjacent input waveguides 2 i and 2 i+1 connected to a Y-branch coupler 6 and let α=λ o . Let the initial N output waveguides be properly spaced to insure negligible cross-talk between adjacent waveguides. For most applications it is important to minimize the waveguide spacing so as to maximize spectral efficiency, which is determined by the ratio
S/W (11)
where S is the channel spacing and W is the passband width. This arrangement yields the typical behavior shown in FIG. 13, where each transmission coefficient produces negligible transmission at all wavelengths corresponding to the adjacent passbands and the channel spacing has the smallest value that can be chosen without causing substantial crosstalk.
The demultiplexer arrangement of FIG. 14 may be modified to produce additional choices for the value of α. The output waveguide spacing producing the set of coefficients shown in FIG. 13 can be shown to be large enough to allow an additional set of N output waveguides to be included by interleaving the two sets as indicated by the dashed lines shown at the output of the multiplexer seen in FIG. 14. This yields a multiplexer with two sets of output waveguides spaced s/2 apart which provide the following two choices for α:
λ.sub.o, λ.sub.o +S/2 (12)
Additional waveguides are then included at the input of the demultiplexer. For example, N-2 additional input waveguides may be added with a waveguide spacing of S+S/(N-1), as indicated by the dashed lines shown at the input of the multiplexer shown in FIG. 14. The resulting multiplexer has, in addition to the above two choices for α, the following additional choices: ##EQU4## Thus, by properly selecting the input and output waveguides, the wavelength α now can be changed in increments of ##EQU5## assuming that N is even. This enhanced flexibility in design is particularly advantageous because it is generally difficult with current technologies, such as SiOB or InP, to control the center wavelength λ o with the accuracy (i.e., a fraction of a nanometer) that is typically required for long haul and local area networks. As noted earlier, the above technique first discussed for a demultiplexer in which adjacent input waveguides are connected by a Y-branch coupler also clearly applies to a multiplexer in which the adjacent output waveguides are connected by a Y-branch coupler.
Notice that the total number of wavelengths α that can be produced in an interval of width S in the above example is
2(N-1) (15)
For a 4×1 multiplexer, for instance, the total number of wavelengths is 6.
In configuring the demultiplexer in the manner set forth above it was assumed that a single input waveguide (i.e., the waveguide with a value of α closest to the specified value α 0 ) was needed and that the passbands should be spaced an equal distance apart. However, the above considerations apply in general without these restrictions. Moreover, by reversing the direction of transmission, they apply to a multiplexer as well.
The technique described herein substantially increases the passband width by combining two input (or output) waveguides as illustrated in FIGS. 6 and 10. By properly selecting the spacing between the two waveguides the desired value for the passband width can be chosen. Moreover, if the input waveguides width also is properly chosen as discussed below, the desired passband width will be produced with minimal loss at two preselected wavelengths close to the passband edge.
Before discussing the optimal waveguide width for the routing device of this invention, the conditions that optimize the transmission coefficients between two particular waveguides for the conventional routing device shown in FIG. 1 will be presented. The routing device of FIG. 1 can be viewed as an imaging apparatus that transforms the signal illuminating the input circle of the input free space region into a corresponding image f(x) appearing on the output free space region. As indicated in FIG. 11, the location x=d, where d denotes the distance along the output circle corresponding to the center of this image is a function of the wavelength λ. Therefore, the location x=d is in general displaced from the location x=d 1 of the mode h(x) for the particular output waveguide under consideration. The displacement d-d 1 between h(x) and f(x) is essentially a linear function of λ and maximum transmission will be produced at the wavelengths for which d=d 1 . At these wavelengths, the power transmission coefficient will be close to unity, since the routing device losses are small and since the input and output waveguides in FIG. 1 are of essentially the same dimensions and, thus, they essentially produce identical distributions f(x) and h(x). At a wavelength for which d≠d 1 , on the other hand, the displacement will produce a mismatch loss. The variation in the loss as a function of wavelength can be determined by well known methods, by taking into account that the displacement d-d 1 varies linearly with λ in a properly chosen interval corresponding to a period X o . Thus, by calculating the coupling coefficient between the two distributions, the wavelength dependence of the transmission coefficient T(X) can be obtained.
Next consider, instead of the arrangement of FIG. 1, the arrangement of FIG. 10 where a pair of input waveguides are connected by a Y-branch coupler.
If the separation s between the two adjacent waveguides that are coupled together is sufficiently large, then instead of the distribution f(x) the distribution shown in FIG. 12 f 0 (x) results: ##EQU6## where p=s/2, and the coupling coefficient between f o (x) and the output mode h(x) now produces two maxima, approximately for x=d+p and x=d-p. The values of the two maxima (more precisely, the sum of their squares) can be maximized by properly choosing the widths of the two waveguides. The result of this procedure is that the optimum width is obtained when f o (x) approximately matches the distribution
1/2[h(x-p)+h(x+p)] (17)
This will maximize the transmission coefficient at the two wavelengths corresponding to x=d+p and d-p. Moreover, if the spacing s is sufficiently large so that mutual coupling between the two waveguides is small, the above condition will be satisfied by simply choosing h(x)=f(x). Notice that the value of p need not coincide with s/2. Thus, by the above procedure, by properly choosing the value of s one can in general maximize the transmission coefficient at two preselected wavelengths close to the bandpass edges. Accordingly, the desired passband width with maximum efficiency can be obtained by properly choosing the spacing of the two waveguides, and optimizing their width by the above procedure.
As an example, a flat passband characterized by the condition:
T.sub.o (W/2)≠T.sub.o (O) (18)
can be approximately produced by approximating the mode h(x) with a Gaussian distribution. By the above procedure it is determined that T(X) is also Gaussian: ##EQU7## and the parameter υ producing condition (18) is
2υ=0.906W (20)
The corresponding efficiency is given by
0.54369|T(o)|.sup.2 (21)
where T(X) denotes the routing device transmission coefficient that would have been obtained without using this optimization technique but rather by using a single input waveguide with f(x)=h(x). The: above efficiency is not much different from the value
0.5|T(o)|.sup.2 (22)
obtained previously.
An important conclusion implied by the above optimization procedure is that the optimum routing device design producing a flat passband with minimal loss is approximately obtained by combining two output waveguides to produce two displaced replicas of the mode of the input waveguide, as shown by Eq. (1). This is simply the technique described initially in which two input or output waveguides are connected by a Y-branch coupler. The higher efficiency obtained by the above optimization procedure is a consequence of the Gaussian approximation used for h(x).
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We describe a technique for producing a flat passband in a wavelength multiplexer. We obtain this by combining two output waveguides, and by optimizing their parameters so as to produce a maximally flat passband with minimal loss. The optimum parameters are obtained, to a good approximation, by choosing each output waveguide so that its mode approximately matches the input waveguide mode (see page 9 on) and by choosing the spacing of the two waveguides so that the multiplexer transmission coefficient at the edges of the passband is approximately equal to the value at the center of the passband. We also include, in the multiplexer, additional waveguides that allow the center wavelength of the passband to be varied in steps of S/Q, where S is the channel spacing and δ is an integer exceeding the number of channels (multiple control input waveguides). As a result, we obtain a unique arrangement, suitable for realization in integrated form using waveguide arrays. The arrangement is characterized by flat passbands, by high levels of rejection in the stopbands, and it has additional waveguides that allow multiple choices for the wavelengths of the various channels, without affecting the spacing and width of the channels. By properly selected the input and output waveguides,any desired channel wavelength can be selected., with errors less than S/(2δ). This is expected to be an important feature because current technologies cannot control the channel wavelength with the accuracy (of less than a nanometer) that is typically required for long haul and local area networks.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No, 12/482,292, filed Jun. 10, 2009, which is a continuation of U.S. patent application Ser. No. 11/688,368, filed Mar. 20, 2007 which is a divisional of U.S. patent application Ser. No. 09/367,433 filed Jan. 13, 2000, which is a national stage of International Application PCT/US98/02668, filed Feb. 13, 1998, which claims the benefit of U.S. Provisional Application Ser. No. 60/037,779, filed Feb. 14, 1997, each of which is incorporated by reference in its entirety herein, and from which priority is claimed.
TECHNICAL FIELD
[0002] This invention relates to the representation, transmission, processing and display of video and audio-visual information, more particularly of object-based information.
BACKGROUND OF THE INVENTION
[0003] Image and video compression techniques have been developed which, unlike traditional waveform coding, attempt to capture high-level structure of visual content. Such structure is described in terms of constituent “objects” which have immediate visual relevancy, representing familiar physical objects, e.g. a ball, a table, a person, a tune or a spoken phrase. Objects are independently encoded using a compression technique that gives best quality for each object. The compressed objects are sent to a terminal along with composition information which tells the terminal where to position the objects in a scene. The terminal decodes the objects and positions them in the scene as specified by the composition information. In addition to yielding coding gains, object-based representations are beneficial with respect to modularity, reuse of content, ease of manipulation, ease of interaction with individual image components, and integration of natural, camera-captured content with synthetic, computer-generated content.
SUMMARY OF THE INVENTION
[0004] In a preferred architecture, structure or format for information to be processed at an object-based video or audio-visual (AV) terminal, an object-oriented bitstream includes objects, composition information, and scene demarcation information. The bitstream structure allows on-line editing, e.g. cut and paste, insertion/deletion, grouping, and special effects.
[0005] In the preferred architecture, in the interest of ease of editing, AV objects and their composition information are transmitted or accessed on separate logical channels (LCs). The architecture also makes use of “object persistence”, taking advantage of some objects having a lifetime in the decoder beyond their initial presentation time, until a selected expiration time.
BRIEF DESCRIPTION OF THE DRAWING
[0006] FIG. 1 is a functional schematic of an exemplary object-based audio-visual terminal.
[0007] FIG. 2 a is a schematic of an exemplary object-based audio-visual composition packet.
[0008] FIG. 2 b is a schematic of an exemplary object-based audio-visual data packet.
[0009] FIG. 2 c is a schematic of an exemplary compound composition packet.
[0010] FIG. 3 is a schematic of exemplary node and scene description information using composition.
[0011] FIG. 4 is a schematic of exemplary stream-node association information.
[0012] FIG. 5 is a schematic of exemplary node/graph update information using a scene.
[0013] FIG. 6 is a schematic of an exemplary audio-visual terminal design.
[0014] FIG. 7 is a schematic of an exemplary audio-visual system controller in the terminal according to FIG. 6 .
[0015] FIG. 8 is a schematic of exemplary information flow in the controller according to FIG. 7 .
DETAILED DESCRIPTION
[0016] An audio-visual (AV) terminal is a systems component which is instrumental in forming, presenting or displaying audio-visual content. This includes (but is not limited to) end-user terminals with a monitor screen and loudspeakers, as well server and mainframe computer facilities in which audio-visual information is processed. In an AV terminal, desired functionality can be hardware-, firmware- or software-implemented. Information to be processed may be furnished to the terminal from a remote information source via a telecommunications channel, or it may be retrieved from a local archive, for example. An object-oriented audio-visual terminal more specifically receives information in the form of individual objects, to be combined into scenes according to composition information supplied to the terminal.
[0017] FIG. 1 illustrates such a terminal, including a de-multiplexer (DMUX) 1 connected via a logical channel LCO to a system controller or “executive” 2 and via logical channels LC 1 through LCn to a buffer 3 . The executive 2 and the buffer 3 are connected to decoders 4 which in turn are connected to a composer unit 5 . Also, the executive 2 is connected to the composer unit 5 directly, and has an external input for user interaction, for example.
[0018] In the preferred AV architecture, the AV objects and their composition information are transmitted or accessed on separate logical channels. The DMUX receives the Mux2 layer from the lower layers and de-multiplexes it into logical channels. LC 0 carries composition information which is passed on to the executive. The AV objects received on other logical channels are stored in the buffer to be acted upon by the decoders. The executive receives the composition information, which includes the decoding and presentation time stamps, and instructs the decoders and composer accordingly.
[0019] The system handles object composition packets (OCP) and object data packets (ODP). A composition packet contains an object's ID, time stamps and the “composition parameters” for rendering the object. An object data packet contains an object ID, an expiration time stamp in case of persistent objects, and object data.
[0020] Preferably, any external input such as user interaction is converted to OCP and/or ODP before it is presented to the executive. There is no need for headers in a bitstream delivered over a network. However, headers are required when storing an MPEG4 presentation in a file.
[0021] FIGS. 2 a and 2 b illustrate the structure of composition and data packets in further detail. Relevant features are as follows:
[0022] Object ID is composed of object type and object number. The default length of the Object ID is 2 bytes, including ten bits for the object number and 6 for the object type (e.g. text, graphics, MPEG2 VOP, compound object). An extensible code is used to accommodate more than 1023 objects or more than 31 object types. The following convention will be adhered to: a value of 0b111111 in the first six bits of the Object ID corresponds to 31 plus the value of the byte immediately following the ObjectID; a value of 0b11.1111.1111 in the least significant 10 bits of the Object ID corresponds to 1023 plus the value of the two bytes immediately following the Object ID (without counting the object type extension bytes, if present). The following object types are defined:
[0023] Composition Objects (16-bit object IDs)
[0000]
0X0000
scene configuration object
0X0001
node hierarchy specification
0X0002
stream-node association
0X0003
node/scene update
0X0004
compound object
[0024] Object Data (object type, 6 most significant bits)
[0000]
0b00.0010
text
0b00.0011
MPEG2 VOP (rectangular VOP)
[0025] Persistent Objects (PO) are objects that should be saved at the decoder for use at a later time. An expiration time stamp (ETS) gives the life of a PO in milliseconds. A PO is not available to the decoder after ETS runs out. When a PO is to be used at a later time in a scene, only the corresponding composition information needs to be sent to the AV terminal.
[0026] Decoding Time Stamp (DTS) indicates the time an object (access unit) should be decoded by the decoder.
[0027] Presentation Time Stamp (PTS) indicates the time an object (access unit) should be presented by the decoder.
[0028] Lifetime Time Stamp (LTS) gives the duration (in milliseconds) an object should be displayed in a scene. LTS is implicit in some cases, e.g. in a video sequence where a frame is displayed for I/frame-rate or until the next frame is available, whichever is larger. An explicit LTS is used when displaying graphics and text. An AV object should be decoded only once for use during its life time.
[0029] Expiration Time Stamp (ETS) is specified to support the notion of object persistence. An object, after it is presented, is saved at the decoder (cache) until a time given by ETS. Such an object can be used multiple times before ETS runs out. A PO with an expired ETS is no longer available to the decoder.
[0030] Object Time Base (OTB) defines the notion of time of a given AV object encoder. Different objects may belong to different time bases. The AV terminal adapts these time bases to the local one, as specified in the MSDL VM.
[0031] Object Clock Reference (OCR) can be used if necessary to convey the speed of the OTB to the decoder. By this mechanism, OTBs can be recovered/adapted at the AV terminal.
[0032] Composition Parameters are used to compose a scene (place an object in a scene). These include displacement from the upper left corner of the presentation frame, rotation angles, zooming factors, etc.
[0033] Priority indicates the priority of an object for transmission, decoding, and display. MPEG4 supports 32 levels of priority. Lower numbers indicate higher priorities.
[0034] Persistence Indicator (PI) indicates whether an object is persistent.
[0035] Continuation Indicator (CI) indicates the end of an object in the current packet (or continuation).
[0036] Object Grouping facilitates operations to be applied to a set of objects with a single operation. Such a feature can be used to minimize the amount of composition information sent, as well as to support hierarchical scene composition based on independent sub-scenes. The composer manipulates the component objects as a group. The structure of a compound composition packet (CCP) is shown in FIG. 2 c.
[0037] Bitstream Structure includes object composition packets for describing the composition and controlling the presentation of those packets, and object data packets that contain the data for the objects. A scene is composed by a set of composition packets. The bitstream supports representation of scenes as a hierarchy by using compound composition objects (CCP), also known as node hierarchy. A CCP allows combining composition objects to create complex audio-visual scenes.
[0038] Object-Data Packet:
ObjectlD—min (default) 10 bits CI and PI could be combined:
00—begin non-persistent 01—begin persistent 10—continuation 11—end of object
Priority: 5 bits, present only if CI/PI is 0b00 or 0b01 ETS: 30 bits, present if CI/PI is 0b01 For prediction-based video coding, VOP_type is indicated by two bits (00 (I), 01 (P), 10 (B), 11 (PB)), facilitating editing.
[0000]
Object_data_packet{
ObjectID
16 bits + any extensions;
CIPI
2 bits
if (CIPI <= 1){
Priority
5 bits
if (object type is MPEG VOP)
(any prediction based compression)
VOP_type
2 bits
}
if (CIPI == 1)
ETS
28 bits
ObjectData
}
[0048] Object Composition Packet
[0000]
Object_composition_packet{
ObjectID
16 bits + any extensions
OCR_Flag
1 bit
Display_Timers_Flag
1 bit
DTS
30 bits
if (OCR_Flag)
OCR
30 bits
if (Display_Timers_Flag){
PTS
30 bits
LTS
28 bits
}
Composition_parameters;
}
[0049] Composition Parameters are defined in section 2 of MSDL Verification Model, MPEG N1483, Systems Working Draft V2.0, the disclosure of which is incorporated herein by reference.
[0000]
Composition_parameters(
visibility
1 bit
composition_order
5 bits
number_of_motion_sets
2 bits
x_delta_0
12 bits
y_delta_0
12 bits
for (i = 1; i <= number_of_motion_sets; i++){
x_delta_i
12 bits
y_delta_i
12 bits
}
}
[0050] Compound Composition Packet
[0000]
Compound_composition_packet{
ObjectID
16 bits
PTS
30 bits
LTS
28 bits
Composition_parameters
ObjectCount
8 bits
for (i = 0; i < ObjectCount; i++){
Object_composition_packet;
}
}
[0051] Scene Configuration Packet (SCP) is used to change reference scene width, height, to flush the buffer, and other configuration functions. The object type for SCPs is 0b00.0000. This allows for 1024 different configuration packets. The object number 0b00.0000.0000 (object ID 0X0000) is defined for use with flushing the terminal buffers.
[0052] Composition Control for Buffer Management (Object ID 0x0000)
[0053] AV terminal buffers are flushed using Flush_Cache and Scene_Update flags. When using hierarchical scene structure, the current scene graph is flushed and the terminal loads the new scene from the bitstream. Use of flags allows for saving the current scene structure instead of flushing it. These flags are used to update the reference scene width and height whenever a new scene begins. If the Flush_Cache_Flag is set, the cache is flushed, removing the objects (if any). If Scene_Update_Flag is set, there are two possibilities: (i) Flush_Cache-Flag is set, implying that the objects in the cache will no longer be used; (ii) Flush_Cache_Flag is not set, the new scene being introduced (an editing action on the bitstream) splices the current scene and the objects in the scene will be used after the end of the new scene. The ETS of the objects, if any, will be frozen for the duration of the new scene introduced. The beginning of the next scene is indicated by another scene configuration packet.
[0000] Scene_configuration_packet{ ObjectID 16 bits (OXOOOO) Flush_Cache_Flag 1 bit Scene_Update_Flag 1 bit if (Scene_Update_Flag){ ref_scene_width 12 bits ref_scene_height 12 bits } }
Composition Control for Scene Description (Object ID 0x0001)
[0054] A hierarchy of nodes is defined, describing a scene. The scene configuration packets can also be used to define a scene hierarchy that allows for a description of scenes as a hierarchy of AV objects. Each node in such a graph is a grouping of nodes that groups the leaves and/or other nodes of the graph into a compound AV object. Each node (leaf) has a unique ID followed by its parameters as shown in FIG. 3 .
[0000] Composition Control for Stream-Node Mapping (Object ID 0x0002)
[0055] As illustrated by FIG. 4 , table entries associate the elementary object streams in the logical channels to the nodes in a hierarchical scene. The stream IDs are unique, but not the node IDs. This implies that more than one stream can be associated with the same node.
[0000] Composition Control for Scene Updates (Object ID 0x0003)
[0056] FIG. 5 illustrates updating of the nodes in the scene hierarchy, by modifying the specific parameters of the node. The graph itself can be updated by adding/deleting the nodes in the graph. The update type in the packet indicates the type of update to be performed on the graph.
Architectural Embodiment
[0057] The embodiment described below includes an object-based AV bitstream and a terminal architecture. The bitstream design specifies, in a binary format, how AV objects are represented and how they are to be composed. The AV terminal structure specifies how to decode and display the objects in the binary bitstream.
AV Terminal Architecture
[0058] Further to FIG. 1 and with specific reference to FIG. 6 , the input to the de-multiplexer 1 is an object-based bitstream such as an MPEG-4 bitstream, consisting of AV objects and their composition information multiplexed into logical channels (LC). The composition of objects in a scene can be specified as a collection of objects with independent composition specification, or as a hierarchical scene graph. The composition and control information is included in LC 0 . The control information includes control commands for updating scene graphs, reset decoder buffers etc. Logical channels 1 and above contain object date. The system includes a controller (or “executive”) 2 which controls the operation of the AV terminal.
The terminal further includes input buffers 3 , AV object decoders 4 , buffers 4 ′ for decoded data, a composer 5 , a display 6 , and an object cache 7 . The input bitstream may be read from a network connection or from a local storage device such as a DVD, CD-ROM or computer hard disk. LC 0 containing the composition information is fed to the controller. The DMUX stores the objects in LC 1 and above at the location in the buffer specified by the controller. In the case of network delivery, the encoder and the stream server cooperate to ensure that the input object buffers neither overflow nor underflow. The encoded data objects are stored in the input data buffers until read by the decoders at their decoding time, typically given by an associated decoding timestamp. Before writing a data object to the buffer, the DMUX removes the timestamps and other headers from the object data packet and passes them to the controller for signaling of the appropriate decoders and input buffers. The decoders, when signaled by the controller, decode the data in the input buffers and store them in the decoder output buffers. The AV terminal also handles external input such as user interaction.
[0061] In the object cache 7 , objects are stored for use beyond their initial presentation time. Such objects remain in the cache even if the associated node is deleted from the scene graph, but are removed only upon the expiration of an associated time interval called the expiration time stamp. This feature can be used in presentations where an object is used repeatedly over a session. The composition associated with such objects can be updated with appropriate update messages. For example, the logo of the broadcasting station can be downloaded at the beginning of the presentation and the same copy can be used for repeated display throughout a session. Subsequent composition updates can change the position of the logo on the display. Objects that are reused beyond their first presentation time may be called persistent objects.
System Controller(SC)
[0062] The system controller controls decoding and playback of bitstreams on the AV terminal. At startup, from user interaction or by looking for a session at default network address, the SC first initializes the DMUX to read from a local storage device or a network port. The control logic is loaded into the program. RAM at the time of initialization. The instruction decoder reads the instructions from the program and executes them. Execution may involve reading the data from the input buffers (composition or external data), initializing the object timers, loading or updating the object tables to the data RAM, loading object timers, or control signaling.
[0063] FIG. 7 shows the system controller in further detail. The DMUX reads the input bitstream and feeds the composition data on LC 0 to the controller. The composition data begins with the description of the first scene in the AV presentation. This scene can be described as a hierarchical collection of objects using compound composition packets, or as a collection of independent object composition packets. A table that associates the elementary streams with the nodes in the scene description immediately follows the scene description. The controller loads the object IDs (stream IDs) into object list and render list which are maintained in the data RAM. The render list contains the list of objects that are to be rendered on the display device. An object that is disenabled by user interaction is removed from the render list. A node delete command that is sent via a composition control packet causes the deletion of the corresponding object IDs from the object list. The node hierarchy is also maintained in the data RAM and updated whenever a composition update is received.
[0064] The composition decoder reads data from the composition and external data buffer and converts them into a format understood by the instruction decoder. The external input includes user interaction to select objects, disenable and enable objects and certain predefined operations on the objects, During the execution of the program, two lists are formed in the data RAM. The object list, containing a list of objects (object IDs) currently handled by the decoders and a render list, containing the list of active objects in the scene. These lists are updated dynamically as the composition information is received, For example, if a user chooses to hide an object by passing a command via the external input, the object is removed from the render list until specified by the user. This is also how external input is handled by the system. Whenever there is some external interaction, the composition decoder reads the external data buffer and performs the requested operation.
[0065] The SC also maintains timing for each AV object to signal the decoders and decoder buffers of decoding and presentation time. The timing information for the AV objects is specified in terms of its time-base. The terminal uses the system clock to convert an object's time base into system time. For objects that do not need decoding, only presentation timers are necessary. These timers are loaded with the decoding and presentation timestamps for that AV object. The controller obtains the timestamps from the DMUX for each object. When a decoding timer for an object runs out, the appropriate decoder is signaled to read data from the input buffers and to start the decoding process. When a presentation timer runs out, the decoded data for that object is transferred to the frame buffer for display. A dual buffer approach could be used to allow writing to a frame buffer while the contents of the second buffer are displayed on the monitor. The instruction decoder can also reset the DMUX or input buffers by signaling a reset, which initializes them to the default state.
Information Flow in the Controller
[0066] FIG. 8 shows the flow of information in the controller. To keep the figure simple, the operations performed by the instruction decoder are shown in groups. The three groups respectively concern object property modifications, object timing, and signaling.
Object Property Modifications
[0067] These operations manipulate the object IDs, also called elementary stream IDs. When a scene is initially loaded, a scene graph is formed with the object IDs of the objects in the scene. The controller also forms and maintains a list of objects in the scene (object list) and active objects in the object from the render list. Other operations set and update object properties such as composition parameters when the terminal receives a composition packet.
Object Timing
[0068] This group of operations deals with managing object timers for synchronization, presentation, and decoding. An object's timestamp specified in terms of its object time base is converted into system time and the presentation and decoding time of that object are set. These operations also set and reset expiration timestamps for persistent objects.
Signaling
[0069] Signaling operations control the over-all operation of the terminal. Various components of the terminal are set, reset and operated by controller signaling. The controller checks the decoding and presentation times of the objects in the render list and signals the decoders and presentation frame buffers accordingly. It also initializes the DEMUX for reading from a network or a local storage device. At the instigation of the controller, decoders read the data from the input buffers and pass the decoded data to decoder output buffers. The decoded data is moved to the presentation device when signaled by the controller.
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As information to be processed at an object-based video or audio-visual (AV) terminal, an object-oriented bitstream includes objects, composition information, and scene demarcation information. Such bitstream structure allows on-line editing, e.g. cut and paste, insertion/deletion, grouping, and special effects. In the interest of ease of editing, AV objects and their composition information are transmitted or accessed on separate logical channels (LCs). Objects which have a lifetime in the decoder beyond their initial presentation time are cached for reuse until a selected expiration time.
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This is a continuation-in-part of my applications: U.S. Ser. No. 08/253,346 filed 3 Jun. 1994 now abandoned; U.S. Ser. No. 08/162,342 filed 2 Dec. 1993 now U.S. Pat. No. 5,435,274; and U.S. Ser. No. 07/854,938 filed 20 Mar. 1992--the last mentioned application being a continuation-in-part of my then application Ser. No. 07/613,094 filed 15 Nov. 1990, now abandoned.
TECHNICAL FIELD
This invention relates to motor vehicles powered by combustion engines and operable substantially pollution-free on given fuel gas.
BACKGROUND OF THE INVENTION
Fossil fuels, such as coal, petroleum (including diesel oil, kerosene, jet fuel, and gasoline), and even natural gas, are burned for many purposes. Their combustion effluents contain, in addition to the customary carbon dioxide and water, undesirable materials, such as hydrocarbon fragments and derivatives, often in particulate form, carbon monoxide, and gaseous oxides of nitrogen and/or of sulfur transformable to noxious droplet form (acid rain).
Hydrogen, long considered prospectively an ideal fuel because convertible completely to water in air combustion, is unsatisfactory as fuel for internal-combustion engines because it heats the intake valves until pre-ignition flashback occurs, ahead of the combustion chamber--not only deleterious to the engine but also conducive to emission of harmful nitrogen oxides into the atmosphere. See, for example, HYDROGEN STORAGE AND UTILIZATION IN TRANSPORTATION VEHICLES--SUMMARY, published by the U.S. Department of Energy, Alternative Fuels Utilization Program, Office of Transportation Systems in 1988, including citation of numerous other pertinent references.
Many large cities have become badly polluted by the emissions from combustion of fossil fuels. Significant contributors include motor vehicles, lawnmowers, heating systems, manufacturing plants, and electrical generating plants, despite many laws and safeguards for limiting harmful effluents. The increasing smog will become worse at an accelerating rate unless abatement is put into practice. My invention is the first and (so far) only solution to the problem.
SUMMARY OF THE INVENTION
A primary object of the present invention is operation of motor vehicles without pollution of the environment.
Another object of this invention is to fuel combustion in such a way that it is substantially free of harmful emissions.
A further object of the invention is to enable substantially pollution-free operation of internal-combustion engines.
Yet another object of the invention is to enable motor vehicles to provide electrical power useful in their operation.
A still further object of the invention is to render production of electrical energy for use by motor vehicles more environmentally friendly than it customarily is nowadays.
A still further object of this invention is to accomplish the foregoing objects more economically than possible with fossil fuels, preferably taking into account environmental as well as other costs.
In general, the objects of this invention are attained using fuel gas combustible substantially completely to carbon dioxide and water vapor, whether in an internal-combustion engine or otherwise.
More particularly, motor vehicles are fueled according to this invention and thereby enabled to combust the fuel pollution-free and to be driven either directly through engine-produced motive power or indirectly by electricity generated by engine-produced motive power.
In addition, this invention enables vehicles with considerable fuel requirements to produce fuel gas on board--advantageous for sea transport vessels as well as for trans-continental trucks. The fuel gas is liquefiable for convenient storage and air, land, or sea use.
The fuel gas input materials are inexpensive carbon and water. Also required is a source of electrical energy sufficient to strike an underwater arc, which is readily maintained with little energy input because of its negative temperature coefficient of resistance. Once struck, the arc is readily maintained, and requires much less energy input than is subsequently obtainable as output by combustion of the fuel gas evolved via the high-temperature (5°-6000° F.) arc.
Other objects of the present invention, together with means and methods for attaining the various objects, will become apparent from the following description and the accompanying diagrams of preferred embodiments, presented by way of example rather than limitation.
SUMMARY OF THE DRAWINGS
FIG. 1 is a schematic diagram of an exemplary embodiment of the fuel gas evolving apparatus of this invention, including compression and storage equipment, with and without liquefying the fuel gas;
FIG. 2 is a fragmentary side elevation of the carbon arc and vicinity, on an enlarged scale, in the same gas-evolving apparatus;
FIG. 3 is a schematic side elevation of an internal-combustion engine running on stored fuel gas of the invention to produce output motive power to a mechanical transmission or a electrical generator;
FIG. 4 is a schematic block diagram of evolving the fuel gas, compressing and storing it, combusting the fuel to generate electrical power, and feeding back some of the generated power to the input to the arc in which the fuel gas of this invention is being evolved;
FIG. 5 is a schematic side elevation of a truck having its fuel tank refilled with fuel of this invention via a filling station also containing apparatus for evolving and compressing the fuel gas of this invention and for storing the fuel and dispensing it on demand;
FIG. 6 is a schematic side elevation of a tractor and hitched semi-trailer for carrying cargo (not shown) in the major part of its body aft of a bulkhead (vertical broken line) and carrying apparatus (hidden here, see preceding views) for evolving and compressing fuel of this invention within part of its body forward of the bulkhead;
FIG. 7 is a fragmentary schematic view of a driving wheel and vicinity, showing an optional electric motor drive for a FIG. 5 or 6 motor vehicle, in replacement of the conventional drive shaft from engine to a differential, and axle shafts from there to the wheel.
DESCRIPTION OF THE INVENTION
FIG. 1 shows, in schematic side elevation, partly in section, an embodiment of apparatus 10 adapted to evolve, collect, compress, and liquefy fuel gas of this invention. It features, at the left, electrical meter 12 connected to an external source (not shown) of electrical power via pair of leads 11, and connected by pair of leads 13 to welder 14, with heavy-duty electrical output adjustable by setting of arm 15 on dial 16, and connected by pair of heavily insulated leads 17, 19 to respective electrodes 27, 24 in tank 20. The tank is filled with water (shaded) to level 28 near its top.
FIG. 2 shows details of part of the apparatus in tank 20 of FIG. 1 on an enlarged scale, including especially lead 17 connected to graphite block electrode 27, lying on insulating slab 27 on raised floor 26 of the tank, whereas lead 19 connects to the lower end of oblique magazine 24-partly sectioned away to show (shaded) contactor portion 29 of the magazine, fitting closely around carbon rod 25 to assure electrical contact just above its protruding lower end. Cylindrical hood 30, upright on support 31 upstanding from the bottom of tank 20, is open at its submerged bottom end in the water above the nearest approach of the magazine to the block electrode.
FIG. 1 also shows, cylinder 21 (inert flushing gas) with valve 22 connected by tubing 23 to the upper end of magazine 24, which is capable of holding at least several carbon rods and is covered by cap 25 except during loading of the rods. Fuel transport tube 32 connects the top of gas-collecting hood 30 through in-line isolation valve 33 and compression pump 39 to three-way distribution valve 39, which may be closed, open to upper branch line 4, or open to lower branch line 41. The upper branch line leads from the distribution valve to coupling 5 of fuel gas storage container 6 having pressure valve 7 thereon. Successive containers may be connected to the line for filling, and be disconnected therefrom for storage when filled.
Lower branch line 41 from distribution valve 39 leads to the top of condenser 40 inside insulating jacket 45, where it connects to the top end of helical condenser tube 43, whose bottom end connects via outlet tube 49 to (liquid fuel) container 60. The helical tube is surrounded by condenser jacket 42, which has vent tube 41 at its upper end and is supplied at its lower end with coolant from tank 50 (valve not shown) via tube 51 and branch tube 52. Branch tube 53, when its valve 54 is open, feeds coolant around container 60 in insulated box 68, with vent 61 and cover 62, on balance base 69 with scale 65--for weight of the container and its contents.
FIG. 3 shows internal-combustion engine apparatus 70, with cooling radiator at the left. Engine 75 is fed with fuel gas boiling off from container 60 via outlet tube 67 through valve 72 and to the engine intake via tube 74. Air reaches the engine from the atmosphere via adjacent adapter or butterfly valve 73. Drive shaft 76 connects engine motive output to gearbox or electrical generator 77.
It will be understood that motor vehicles, such as automobiles, locomotives, tractors, and trucks, may be operated by application of conventional motive output from a combustion engine to their driving wheels, or alternatively may be operated by application of motive output to electrical generating equipment whose electrical output operates motors mechanically connected to such vehicle drive wheels.
Aircraft and watercraft may be propelled similarly, directly by motive output from a combustion engine or by equivalent electrical driving of propeller or screw means (drive wheel analogues). Not only may ships burn the fuel gas of this invention in the combustion chambers of steam boilers or in formerly diesel-fueled engines, but aircraft also may run on this fuel instead of jet fuel or gasoline.
FIG. 4 shows, in block form, a flow diagram of steps that take place in the practice of this invention. The fuel generation steps predominate in the upper part of the view. The fuel conversion and power generation steps predominate in the lower part of the view.
Sequential steps in the fuel generation part of this invention include (1) TURN ON HIGH CURRENT POWER SUPPLY, (2) START ARC UNDER WATER, (3) FEED CARBON RODS, (4) EVOLVE GASES, (5) COLLECT GASES, (6) FILTER OUT CARBON PARTICLES, (7) COMPRESS FUEL GASES, and (8) STORE COMPRESSED FUEL. The last two mentioned steps are performed upon the evolved fuel gas, presumably a mixture or other aggregation of gases. Accessory composite steps (9) COOL AND FILTER WATER maintain water conditions as desired, especially at the hot underwater arc locus of gas evolution-from which evolved gases bubble up through the intervening water, heating it, and into the overlying hood, to be collected and stored for fuel use as indicated.
Sequential steps in the center of FIG. 4 include arrows and lines from the Store Compressed Fuel step downward to the lower part of the view, and a pair of symmetrically located steps, (16) COMBUST MINORITY OF FUEL (at left) and--at right--(11) COMBUST MAJORITY OF FUEL. Succeeding the latter step are the sequential steps of (12) DRIVE MAJOR GENERATOR, (13) GENERATE EXTERNAL 3.o slashed. AC. A final arrow on the right terminates at (14) EXTERNAL LOADS. To the left from the step (15) COMBUST MINORITY OF FUEL are the sequential steps of (16) DRIVE MINOR GENERATOR and (17) GENERATE INTERNAL AC/DC terminating at (18) INTERNAL LOADS.
FIG. 5 shows, in schematic side elevation, a filling station (at right) providing fuel of this invention to truck 70 (at left). The truck has cab 74 and engine compartment 78 forward, and cargo compartment 77 aft, on flat bed 75 supported via springs on pair of front wheels 71 and two pairs of rear drive wheels 72 connected by suitable means (not shown) to engine 73, whose muffler and exhaust pipe 79 are upright behind the cab. Fuel tank 76 is slung underneath the bed below the cab with fuel line (hidden) to the engine.
Filling station building 101 houses embodiment 100 of apparatus for evolving, collecting, and compressing fuel gas according to this invention, including electric welder 114, water tank 102, electrodes (not noted) circulating pump 103, and water-cooling heat-exchanger 104. Gas-collecting hood 106 is connected in turn to particulate (in-line) filter 107, compressor 108, and storage tank 109. Fuel delivery line 118 connects the stored fuel to metering pump 119, and fuel filling line 120 connects in turn to truck fuel compartment 76.
No attempt is made in FIG. 5 or FIG. 6 to show connection of engine motive output to the drive wheels, as by conventional drive shaft, differential, and axle shaft, or instead--as noted below--by electrical connection, from an added generator run by the engine, to electric motors connected mechanically to the wheels to drive them.
FIG. 6 shows semi-trailer 90 connected at its front end to tractor 80, by hitch 86 on flat bed 85 of the tractor, and supported at its rear end by a double pair of wheels 92. The tractor resembles the front end and undercarriage of the truck of the preceding view in having cab 84 and engine compartment 88 forward on flat bed 85. The bed is supported via springs on pair of front wheels 81 and twin pairs of rear drive wheels 82 connected by means (not shown here) to engine 83, with fuel compartment 86 slung underneath. The trailer, supported at its front end by the tractor, has lateral bulkhead 97 (broken line) dividing it into large rear cargo compartment 98 and small forward on-board fuel-manufacturing compartment 96, containing fuel evolving, collecting, compressing, and storage means of this invention, such as shown to some extent in the filling station, or in modified detail in FIG. 1. Fuel-manufacturing compartment 96, shown at about one-fifth of the trailer length, may be more compact.
FIG. 7 shows electric drive arrangement 110, wherein motor 111 connects by drive belt 115 to drive wheel 112, which otherwise would be driven by conventional mechanical connection from the engine. The motor is a FIG. 4 external load operable by FIG. 3 generator 77.
How to make, store, and use the fuel of the present invention is readily apparent from this description and accompanying diagrams. However, what happens in the electrical arc is not well understood, and need not be understood in order to practice this invention. To the extent that this specification suggests what occurs in or as a consequence of the arc, or interprets decomposition, recombination, or combustion processes, or suggests why the resulting fuel gas has or lacks certain characteristics or certain compositions, that text should be understood as being academic, speculative, or theoretical. In contrast, operational features of this invention, sufficient to enable its practice by persons of at least ordinary skill in the relevant arts, are specified here and are readily understandable.
High-temperature arcing occurs--even under water--when adequate electrical potential (AC or preferably DC) is applied across a pair of electrodes, here preferably composed substantially of graphite. Presumably, pyrolysis ensues, and some surrounding water dissociates into its component hydrogen and oxygen; also some carbon vaporizes. Some of the carbon oxidizes to carbon monoxide, and some of the carbon and/or some of the carbon monoxide oxidizes to carbon dioxide. If the electrodes are less wetted than when immersed in excess water the predominant carbon oxide will be dioxide rather than monoxide. If the electrodes are non-carbonaceous, the essential carbon must be introduced into the arc in rod, particulate, or other suitable form. Presumably, combination of carbon with hydrogen is less likely than with oxygen, whereupon most (if not all) of the hydrogen dissociated from water is present in the form of molecular hydrogen. The gas has (at most) only a faint odor, suggesting minimal organic content, with perhaps trace(s) of ethylenic and/or acetylenic hydrocarbon(s).
The water to be decomposed in the process of this invention is not subject to any unusual requirement. Most water sources prove satisfactory, including brackish or salt--as well as fresh--water, but water polluted with petroleum or the like should be avoided.
The fuel gas of this invention appears to have leak-resistant capability because it diffuses through semi-permeable membranes more slowly than its presumed component compositions do. Comparative testing in balloons of elastomeric material often filled with air or perhaps helium reveal this remarkable property. Whereas a hydrogen-filled balloon will deflate by diffusion of the gas through its wall in a matter of several hours or so, and identical balloons filled with air or carbon oxides deflate likewise in several days or so, an identical balloon filled with the fuel gas of this invention will not deflate fully for at least about several weeks--namely, an order of magnitude (ten times) as long or as slow as air for example, or two orders of magnitude (a hundred times) as long or as slow as hydrogen. Indeed, balloons filled with fuel gas produced by this invention have not fully deflated in a half year--yet another order of magnitude as long (or as slow). This remarkable capability may even compensate to some extent for an incompletely seated valve.
Chemical and physical analyses of this fuel gas have failed to account for its apparent leak-resistant property. Speculation about possible presence of gaseous polymers, fullerenes, etc. has ensued. As already indicated, structural explanations of properties are not essential to production and use of the fuel gas of this invention.
The fuel gas so evolved and collected according to the present invention appears, from physical and chemical analyses, to comprise (by volume) gaseous hydrogen in major amount, as from about four to about seven eighths, carbon monoxide in predominant minor amount, as from about two to about four eighths, and lesser amounts of other gases, such as carbon dioxide, hydrocarbons (or other organics), nitrogen, or oxygen--the latter in concentration insufficient for self-combustion. A representative sample might be about five-tenths hydrogen, three-tenths carbon monoxide, and the rest other gases.
This fuel gas burns evenly with substantially clear flame and no sooting upon adequate access to air (about a half dozen times the fuel volume). It can fuel an internal combustion engine without a carburetor or injection nozzle. Conversion to this gaseous fuel may be facilitated by use of a gas fuel adapter. Suitable adapters are available from Garretson Equipment Co., Inc., Mt. Pleasant, Iowa. Also note Garretson U.S. Pat. Nos. 3,974,851; 4,375,798; 4,829,957.
This fuel gas burns easily and evenly, with adequate access to air (about a half dozen times the fuel volume), and can operate an internal combustion engine without carburetor or injection nozzle. Conversion of gasoline vehicles to this gaseous fuel, however, may be facilitated by use of a gas fuel adapter. Suitable adapters are available from Garretson Equipment Co., Inc., Mt. Pleasant, Iowa. Also note Garretson U.S. Pat. Nos. 3,974,851; 4,375,798; 4,829,957.
The effluent from combustion of the fuel of this invention is substantially entirely carbon dioxide gas and water vapor, as shown by analyses of effluent from lawnmower and automobile engines fueled with it. Hydrocarbon fragments in any form are conspicuous by their absence, as are all particulates, presumably because of the facility of complete combustion of the simple components of the fuel gas. A possibility of hydrocarbon contamination exists from currently used petroleum-based lubricants, or from loosening of carbonized deposits of formerly used lubricants and fuels, especially in old engines.
Oxides of nitrogen, common in combustion products of gases from fossil fuels or of hydrogen alone, are missing (or minimal) because there is no possible source other than air, and the carbon monoxide content effectively cools and evens out combustion in the engine so as to preclude their generation by intake valve overheating, flashback, or other hyperoxidative characteristic of hydrogen combustion.
Carbon monoxide is not found in the effluent, notwithstanding its content in the fuel itself, because carbon monoxide oxidizes so readily to carbon dioxide. Carbon monoxide in automobile exhaust gases results from insufficient combustion of gasoline hydrocarbons.
Indeed, an internal-combustion engine running on this fuel can be located in an occupied room without harming the occupants, as its operation normally reduces pre-existing concentration of ordinary pollutants in the ambient atmosphere (the combustion air source), so such engine operation cleans the air rather than contaminating it. The distinction between gasoline operation of an internal-combustion engine and its operation on the fuel gas of this invention has to be seen and smelled to be believed--and enjoyed. Effluent analysis by competent objective analysts has confirmed the merits of this fuel.
No unusual materials of construction are needed in apparatus of this invention. The reactor need be only a structurally sound tank, such as steel or other metal, and is preferably grounded. The hood to receive the evolved gases may be separate from or combined with the tank. The magazine to hold and dispense carbon rods also may be made of metal, plastic, or ceramic. The magazine may accommodate any convenient number of rods, conveniently loaded at least partly upright, side-by-side on an inside surface slanting down to an exit directly above the desired electrode-bridging location, so as to be fed by gravity, although automatic feed may be adopted if preferred.
Whereas solid graphite is preferred for block electrodes, the rods may be composed mainly or solely of particulate carbon, preferably without added binder. Both are also generally available for use in welding and other high-temperature environments and/or high-pressure environments requiring chemical inertness.
Both water and carbon are also relatively low-cost inputs. Similarly, the power required to decompose water is readily available at reasonable cost in at least most locations.
The electrical potential applied across the underwater arc is preferably DC (direct-current) rather than AC (alternating current). Conventional welding equipment operates from standard line-power AC (usually 3-phase) input, and yields a DC or AC output, as desired. For present purposes a DC output of at least several dozens of volts across the electrodes is preferred. External rectification of AC is readily accomplished, as in welding apparatus, for example. AC to DC conversion without moving parts and with an improved output may be accomplished according to Luce U.S. Pat. No. 4,870,558.
If a conventional power source is objectionable because dependent upon fossil fuels, part of the electrical power output can be applied to maintain the arc, and a small part can even be stored, as in a battery or a large capacitor, to restart the arc at any time. The chemical energy available by burning the fuel is so much greater than the energy required to maintain the arc as to be economical.
Preferred embodiments and variants have been suggested for this invention. Other modifications may be made, as by adding, combining, deleting, or subdividing compositions, parts, or steps, while retaining all or some of the advantages and benefits of the present invention--which itself is defined in the following claims.
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Operation of mechanically or electrically driven vehicles, whether suitable for air, land, or sea transport, substantially pollution-free by operating their internal-combustion engines on a leak-resistant fuel gas derived by pyrolysis of carbon and water.
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FIELD OF THE INVENTION
[0001] The present invention relates to an integrated sensor chip package comprising a substrate having a major surface; a light sensor, the light sensor comprising a plurality of photodetectors on a region of said major surface.
[0002] The present invention further relates to a device including such an integrated sensor chip package.
[0003] The present invention yet further relates to a method of manufacturing such an integrated sensor chip package.
BACKGROUND OF THE INVENTION
[0004] Nowadays, integrated sensors may comprise a plethora of different sensors, such as ambient light (AL) sensors, temperature (T) sensors, gas sensors, relative humidity (RH) sensors, integrated sensor chip analyte detection sensors, and so on.
[0005] Integrated sensors of this kind have a wide range of applications. For example, they can be used in the field of supply chain management to track and monitor the freshness of food and beverages. They can also be used as environmental sensors, for example as part of a heating, ventilation and air conditioning (HVAC) system in an automobile or in a building (e.g. a Smart Building). Additional applications include those in agricultural (e.g. the sensing of environmental conditions in greenhouses) or in medical fields. Their provision in mobile communications devices such as mobile telephones, tablets or laptops can also enable a wide range of further applications that require measurements of local environmental factors.
[0006] The provision of integrated sensor chips of this kind allows devices to be produced that have a small form factor, and which can be manufactured cheaply in large numbers using established semiconductor processing techniques.
[0007] There is a constant desire to diversify the sensor functionality integrated into an integrated sensor chip to add further functionality to an apparatus utilizing the integrated sensor chip. For instance, WO 2009087531 by the present applicant discloses an integrated sensor chip having a light sensor that can detect both the intensity and direction of incident light, e.g. to compensate the output of a display device for ambient lighting conditions to improve the user experience of the display device. To this end, the light sensor comprises a dielectric layer, wherein the dielectric layer is substantially transparent to the incident light as well as a plurality of photo detectors coupled relative to the dielectric layer for detecting the incident light through the dielectric layer. A plurality of stacks of opaque slats embedded within the dielectric layer approximately parallel to an interface between the dielectric layer and the photo detectors is also present to define tapered light apertures between adjacent stacks of opaque slats.
[0008] Such a light sensor requires a relatively complex arrangement of tapered stacks of slats to make the light sensor directionally sensitive. There exists a need to simplify the design of such a light sensor.
SUMMARY OF THE INVENTION
[0009] The present invention seeks to provide an integrated sensor chip package according to the opening paragraph in which sensitivity to the directionality of incident light is provided in a more straightforward manner.
[0010] The present invention further seeks to provide an apparatus including such an integrated sensor chip package.
[0011] The present invention yet further seeks to provide a method of manufacturing such an integrated sensor chip package.
[0012] According to an aspect of the present invention, there is provided an integrated sensor chip package comprising an integrated sensor chip enveloped in a packaging layer, the integrated sensor chip comprising a substrate having a major surface; and a light sensor comprising a plurality of photodetectors on a region of said major surface; the packaging layer comprising an opening exposing said region, the integrated circuit package further comprising a light blocking member over said opening, the light blocking member defining an aperture exposing a first set of photodetectors to light from a first range of directions and exposing a second set of photodetectors to light from a second range of directions, wherein the first range is different to the second range.
[0013] The present invention is based on the insight that a light shielding portion that shades different parts of the light sensor under different angles can be accurately positioned and fitted relative to the package of the integrated sensor chip, thereby providing a straightforward and cost-effective integrated sensor chip including a light sensor that can be used to detect directionality, e.g. the orientation of an apparatus including the integrated sensor chip package.
[0014] In an embodiment, the light blocking member is a plate comprising said aperture. The plate may for instance be a metal plate made of any suitable metal such as aluminium. Such a light blocking member can be placed on the packaging layer in a straightforward manner, thus simplifying the manufacturing process.
[0015] The light blocking member preferably is adhered to the packaging layer for ease of manufacture.
[0016] In an embodiment, the packaging layer comprises a recessed surface portion, said opening being formed in said recessed surface portion, wherein the light blocking member is mounted on said recessed surface portion. This allows for the positioning of the light blocking member in close vicinity to the photodetectors, which allows for more effective angle-dependent shading of the photodetectors and a wide viewing angle of the light sensor.
[0017] The integrated sensor chip may further comprise a fluid sensor such as a gas sensor, wherein the opening further may define a fluidic channel providing fluidic access to the fluid sensor. This obviates the need for a separate access channel to a fluid sensor such as a gas sensor, thereby simplifying the design of such a multi-sensor IC.
[0018] In accordance with another aspect of the present invention, there is provided an apparatus comprising the integrated circuit package according to an embodiment of the present invention. Such an apparatus may for instance be one of a radio frequency identification tag; a mobile communications device; a display device; and a heating, ventilation and air-conditioning (HVAC) system, or any other device that can benefit from the inclusion of the integrated sensor chip package of the present invention.
[0019] In accordance with yet another aspect of the present invention, there is provided a method of manufacturing an integrated sensor chip package, the method comprising providing an integrated sensor comprising a semiconductor substrate having a major surface; providing a light sensor in the integrated sensor chip by forming a plurality of photodetectors on a region of the major surface; packaging the integrated sensor chip in a packaging layer; creating an opening in the packaging layer to expose said region; and placing a light blocking member over said opening, the light blocking member defining an aperture exposing a first set of photodetectors to light from a first range of directions and exposing a second set of photodetectors to light from a second range of directions, wherein the first range is different to the second range. This method thus provides a simple and cost-effective manner of forming a light sensor in a packaged integrated sensor chip that can be used to determine the directionality of the incident light.
[0020] The light blocking member may be fixed to the package layer in any suitable manner. In a particularly suitable embodiment, the step of placing said light blocking member over said opening comprises adhering the light blocking member to the packaging layer. This is a simple and cost-effective manner of fixing the light blocking member to the packaging layer.
[0021] In an embodiment, the method further comprises the step of forming a recessed surface portion in said packaging layer and wherein the step of forming said opening comprises forming said opening in the recessed surface portion; and the step of placing a light blocking member over said opening comprises mounting said light blocking member on said recessed surface portion. This allows for the placement of the light blocking member in close vicinity to the photodetectors, which increases the width of the viewing angle of the light sensor.
[0022] In an embodiment, the step of placing the light blocking member comprises optically aligning the light blocking member with said region. This ensures a highly accurate alignment of the light blocking member with the photodetectors, thus improving the accuracy of the light directional sensor.
[0023] The optically aligning step may comprise aligning the light blocking member with said region using a camera or alternatively may comprise exposing at least some of said photodetectors to a light source through said aperture; measuring the response of the at least some of said photodetectors; and aligning the light blocking member with said region in accordance with said response. The latter embodiment has the further advantage that the testing of the photodetectors may be combined with the alignment of the light blocking member in a single step, thus obviating the need for separate testing of the photodetectors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Embodiments of the invention are described in more detail and by way of non-limiting examples with reference to the accompanying drawings, wherein:
[0025] FIG. 1 schematically depicts a top view of an integrated sensor chip package according to an embodiment of the present invention;
[0026] FIG. 2 schematically depicts a cross section of an integrated sensor chip package according to an embodiment of the present invention;
[0027] FIG. 3 schematically depicts a cross section of an integrated sensor chip package according to another embodiment of the present invention;
[0028] FIG. 4 schematically depicts a top view of an integrated sensor chip package according to another embodiment of the present invention;
[0029] FIG. 5 schematically depicts a top view of an integrated sensor chip package according to yet another embodiment of the present invention;
[0030] FIG. 6 schematically depicts a top view of an integrated sensor chip package according to yet another embodiment of the present invention;
[0031] FIG. 7 schematically depicts an aspect of an integrated sensor chip package manufacturing method according to an embodiment of the present invention; and
[0032] FIG. 8 schematically depicts an aspect of an integrated sensor chip package manufacturing method according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0033] It should be understood that the Figures are merely schematic and are not drawn to scale. It should also be understood that the same reference numerals are used throughout the Figures to indicate the same or similar parts.
[0034] FIG. 1 schematically depicts a top view and FIG. 2 schematically depicts a cross section of an integrated sensor chip package according to an embodiment of the present invention. The integrated sensor chip package comprises a substrate 10 , which may be any suitable substrate, e.g. a semiconductor substrate such as a silicon substrate, a silicon on insulator substrate, a silicon germanium substrate, and so on. The substrate 10 comprises a main surface having a region on which a plurality of photodetectors 12 is formed. In the context of the present application, ‘formed on’ is intended to at least include an embodiment in which the photodetectors 12 are formed on top of the main surface, an embodiment in which the photodetectors 12 are formed partially in the main surface and an embodiment in which the photodetectors 12 are formed embedded in the main surface 10 a , i.e., sharing its photosensitive surface with the main surface of the substrate 10 .
[0035] The photodetectors 12 form part of a light sensor, which may comprise a plurality of groups of photodetectors for determining the intensity and directionality of the incident light. For instance, the light sensor may comprise a grid of photodetectors 12 , in which rows and/or columns of the photodetectors 12 of the grid are arranged to cooperate in the detection of light. FIGS. 1 and 2 schematically depict a 4×4 grid of photodetectors 12 by way of non-limiting example only. Any suitable grid size, e.g. comprising many more photodetectors 12 may be contemplated.
[0036] In FIGS. 1 and 2 , the photodetectors 12 are laterally separated from each other by way of non-limiting example only. It is equally feasible that the areas of the respective photodetectors 12 contact each other. It should be understood that any suitable layout of the photodetectors 12 of the light sensor may be contemplated, e.g. regular or irregular grids, a central photodetector surrounded by peripheral photodetector and so on. It should also be understood that different photodetectors 12 may have different sizes, i.e. different size photosensitive areas. For instance, a light sensor may comprise a central photodetector 12 that is larger than the peripheral photodetectors 12 . Each individual photodetector 12 on the main surface of the substrate 10 may have a photosensitive area of several tens of microns squared, e.g. 100 microns×100 microns, to increase the sensitivity of the photodetector.
[0037] The substrate or sensor chip 10 is typically packaged in a packaging layer 30 comprising an opening 32 to expose the photodetectors 12 on the substrate 10 . Chip packaging is known per se and will not be explained in further detail for the sake of brevity. It should be understood that any suitable chip packaging material, e.g. a resin such as an epoxy resin, premolded packaging, a metal package such as a metal can and so on, may be used for the packaging layer 30 . The opening 32 in the packaging layer 30 may be formed in any suitable manner, e.g. etching, laser cutting, stamping and the like. Alternatively, in case of the packaging layer 30 comprising a resin, the opening 32 may be formed by pressing an insert into the packaging layer 30 during the molding process and removing the insert after curing of the packaging layer 30 .
[0038] The integrated sensor chip package according to embodiments of the present invention further comprises at least one light blocking member 20 placed on the packaging layer 30 . The light blocking member 20 is made of an opaque material such as a metal and is used to prevent exposure of some of the photodetectors 12 a - d to incident light of certain angles of incidence, as is shown in FIG. 2 . In an embodiment, the light blocking member 20 is a metal plate or a plate of another suitable opaque material. The light blocking member 20 defines an aperture 22 through which subsets of the photodetectors 12 may be exposed to incident light depending on the angle of incidence of the light. In FIG. 1 , the aperture 22 has a square shape by way of non-limiting example only. It should be understood that the aperture 22 may have any suitable shape.
[0039] As can be seen in FIGS. 1 and 2 , the light blocking structure 20 at least partially overhangs or shades some of the photodetectors 12 , such that only some of the photodetectors 12 are exposed to light at a certain angle of incidence. This is schematically depicted in FIG. 2 by the dashed lines indicating light passing through the aperture 22 under an angle α such that photodetectors 12 a and 12 c are only partially exposed to the incident light, whilst photodetector 12 b is fully exposed and photodetector 12 d is not exposed at all to incident light of angle α.
[0040] Consequently, when the integrated sensor chip package is exposed to light from a first direction, e.g. having an angle of incidence a, the photodetector 12 b will produce a stronger photo-induced signal than the photodetectors 12 a and 12 c , and photodetector 12 d will produce no more than a negligible signal, e.g. caused by incident scattered light. Different angles of incidence will expose a different subset of the photodetectors 12 to such incident light, such that each angle of incidence can be correlated to a unique signal combination in terms of signal intensity and originating photodetector 12 . These signatures can be identified by a signal processor (not shown) to detect the orientation of the integrated sensor chip package relative to this angle of incidence. Such a signal processor may be provided on the integrated sensor chip or on a separate chip in the package. The intensity of the signals can furthermore be used to derive the intensity of the incident light as is well known per se.
[0041] Because the light blocking member 20 is positioned on the finalized integrated sensor chip package, the light blocking member 20 can be accurately positioned relative to the photodetectors 12 as will be explained in more detail later. It is pointed out that this is an important advantage over prior art arrangements in which the light blocking members were integrated in the chip package as manufacturing tolerances in chip packaging of typically about 100 micron tend to prohibit accurate alignment of the light blocking member 20 with the region of the substrate 10 carrying the photodetectors 12 . Such tolerances for instance cannot be avoided in cavity molding processes, in which the integrated sensor chip is moulded into the packaging layer 30 at elevated temperatures, which introduces a level of uncertainty about the precise position of the integrated sensor chip in the packaging layer 30 .
[0042] The light blocking member 20 may be affixed to the packaging layer 30 in any suitable manner. In an embodiment, the light blocking member 20 is affixed to the packaging layer 30 using an adhesive, i.e. glue.
[0043] FIG. 3 schematically depicts a cross section of another embodiment of an integrated sensor chip package according to the present invention. The integrated sensor chip package of FIG. 3 shares many elements of the integrated sensor chip package of FIG. 1 . Such shared features are identified using the same reference numerals and will not be explained in detail again for the sake of brevity. In FIG. 3 , the surface of the packaging layer 30 in which the opening 32 is formed to expose the photodetectors 12 comprises a recessed surface portion 34 , with the opening 32 being formed the said recessed surface portion 34 . In other words, the surface of the packaging layer 30 in which the opening 32 is formed has a stepped profile. The light blocking member 20 is mounted on the recessed surface portion 34 , e.g. by using an adhesive. This brings the light blocking member 20 in closer vicinity to the region of the substrate 10 carrying the photodetectors 12 , which increases the viewing angle of the light directional sensor. Hence, this embodiment is particularly suitable for providing an integrated sensor chip package comprising a wide-angle light directional sensor.
[0044] As previously explained, ICs can contain a wide variety of sensors. A particularly interesting class of sensors is fluid sensors, e.g. gas or moisture sensors, relative humidity sensors, and so on. Such sensors must be exposed to the environment of the integrated sensor chip package, i.e. the integrated sensor chip package must contain an opening to expose such a fluid sensor to its environment. FIG. 4 schematically depicts a top view of an integrated sensor chip package comprising an opening 32 acting as a fluid channel for a fluid sensor 14 on the IC, e.g. on the main surface of the substrate 10 , on top of the metallization stack of the integrated sensor chip and so on.
[0045] The photodetectors 12 are also exposed by the opening 32 acting as a fluid channel. The light blocking member 20 is located over the opening 32 and may cooperate with the opening 32 to define the fluid channel. The aperture 22 partially exposes the photodetectors 12 as previously explained. The aperture 22 is a circular aperture in FIG. 4 by way of non-limiting example, simply to show that different shapes of apertures 22 may be used for the light blocking member 20 .
[0046] It is noted at this point that the light blocking member may comprise a single aperture 22 or multiple apertures 22 over a single region of photodetectors 12 , as is shown in FIG. 5 . This embodiment can be used to provide a more fine-grained shading pattern over the photodetectors 12 . The multiple apertures 22 may have any suitable shape, e.g. circular, oval, square, oblong shapes and so on. Alternatively, the sensor chip may comprise a substrate 10 comprising a plurality of light-sensitive regions, each region comprising a separate plurality of photodetectors 12 , wherein the light blocking member 20 comprises multiple apertures 22 such that each aperture 22 provides shading to one of said light-sensitive regions. This is shown in FIG. 6 .
[0047] The integrated sensor chip package according to embodiments of the present invention may be integrated in a suitable apparatus. For example, the apparatus may be a Radio Frequency Identification (RFID) tag, a mobile communications device, examples of which include mobile telephones, tablets and laptops. The apparatus alternatively may be a heating, ventilation and air conditioning (HVAC) system. The HVAC system can, for example, be provided in an automobile or in a building (e.g. a Smart Building).
[0048] The apparatus may be a display device, in which case the light sensor of the integrated sensor chip may be used to provide information about the directionality of incident ambient light, which information may be used to adjust e.g. the brightness of (parts of) the image displayed on the display device to compensate for the incident light. Other applications can include use in the field of supply chain management to track and monitor the freshness of food and beverages. Additional applications include those in agricultural (e.g. the sensing of environmental conditions in greenhouses) or in medical fields.
[0049] The integrated sensor chip package according to embodiments of the present invention may be manufactured in any suitable manner. In particular, the manufacturing of an integrated sensor chip comprising a plurality of photodetectors 12 and the packaging of such an integrated sensor chip in a packaging layer 30 , e.g. through a cavity molding process, is well-known per se such that this will not be explained in further detail for the sake of brevity only.
[0050] FIG. 7 schematically depicts an aspect of such a manufacturing step in which the light blocking member 20 is aligned over the opening 32 in the packaging layer with the aid of optical tools, here a camera 50 . The camera 50 is used to identify features on the part of the surface of the substrate 10 that is exposed through the aperture 22 , such as the borders of the underlying photodetectors 12 a - d , some markers of the substrate 10 or combinations thereof, and to provide feedback to a mechanical placement tool (not shown) responsible for the placement of the light blocking member 20 over the opening 32 . This feedback mechanism can be used to accurately align the light blocking member 20 with the photodetectors 12 a - d.
[0051] FIG. 8 schematically depicts an alternative aspect of such a manufacturing step in which the light blocking member 20 is aligned over the opening 32 in the packaging layer with the aid of optical tools, here a light source 60 . In this embodiment, the photodetectors 12 a - d are used to detect the light from the light source 60 , such that the response from the photodetectors 12 a - d is used as the feedback for the mechanical placement tool responsible for aligning the light blocking member 20 with the photodetectors 12 a - d . For instance, the light blocking member 20 can be assumed to be in its intended position when the grid of photodetectors 12 produces a balanced or symmetrical output profile. This embodiment has the further benefit that the photodetectors 12 a - d may be tested at the same time to detect malfunctioning photodetectors 12 a - d.
[0052] An adhesive may be present on the upper surface of the packaging layer 30 , i.e. the surface receiving the light blocking member 20 and/or on the surface of the light blocking member 20 to be adhered to the packaging layer 30 . This adhesive may be developed once the alignment of the light blocking member 20 relative to the photodetectors 12 a - d has been completed, e.g. by drying or curing the adhesive.
[0053] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word “comprising” does not exclude the presence of elements or steps other than those listed in a claim. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. The invention can be implemented by means of hardware comprising several distinct elements. In the device claim enumerating several means, several of these means can be embodied by one and the same item of hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.
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Disclosed is an integrated sensor chip package comprising an integrated sensor chip enveloped in a packaging layer ( 30 ), the integrated circuit comprising a substrate ( 10 ) having a major surface; and a light sensor comprising a plurality of photodetectors ( 12 a - d ) on a region of said major surface; the packaging layer comprising an opening ( 32 ) exposing said region, the integrated sensor chip package further comprising a light blocking member ( 20 ) over said opening, the light blocking member defining an aperture ( 22 ) exposing a first set of photodetectors to light from a first range of directions and exposing a second set of photodetectors to light from a second range of directions, wherein the first range is different to the second range. An apparatus including such an integrated sensor chip package and a method of manufacturing such an integrated sensor chip package are also disclosed.
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This application is a divisional, of application Ser. No. 07/812,830 filed on Dec. 24, 1991, now U.S. Pat. No. 5,416,222 which is a divisional of application Ser. No. 07/449,160 filed on Dec. 12, 1989 and has now matured into U.S. Pat. No. 5,098,912, which is a continuation of application Ser. No. 06/878,023 filed on Jun. 24, 1986, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to compounds having a quite high antimicrobial activity and an excellent pharmacokinetics.
2. Prior Art
Intensive investigations have been done heretofore on antimicrobial compounds. Various pyridonecarboxylic acid derivatives are set forth as antimicrobial compounds in the Claims in the specifications of Japanese Patent Public Disclosure (KOKAI) Nos. 67269/1984 (U.S. Ser. No. 416406) and 214773/1985 (U.S. Ser. No. 581157). It is disclosed therein that compounds of the general formula: ##STR2## wherein X' represents N, CH or C--F, Y' represents a fluorine and R 11 represents an ethyl, 2-fluoroethyl or cyclopropyl are preferred. However, compounds of the above general formula in which the basic substituent Z' which exerts a great influenece on the antimicrobial and physicochemical properties represents a pyrrolidine group disclosed heretofore are only those having a group of the formula: ##STR3## as shown in Example 11 in the specification of J.P. No. 67279/1984 (code No. of the compound: CI-934) and Examples 43 to 47 in the specification of J.P. No. 214773/1985.
However, the actual effect of antimicrobial agents is greatly influenced not only by the antimicrobial activity of the agent, but also by the pharmacokinetics of the agent. In other words, as excellent antimicrobial agent, it is most preferable to use compounds having both strong antimicrobial activity and good pharmacokinetics. It is well-known that the behavior in the human body, i.e., absorbability through the intestinal tract and stability for metabolic disposition depend on physicochemical properties of the compound, in particular, on solubility in water. Namely, if the water-solubility of the compound is extremely low, for example not more than 100 μg/ml, the solubility speed of the compound in the intestinal tract becomes rate-determining, so that the absorption is bad and the compound is easily metabolized when it is absorbed through the intestinal tract.
From thus viewpoint, compound CI-934 has good water-solubility and strong antimicrobial activity against Gram-positive microorganisms, but has a drawback in that its activity against Gram-negative microorganisms is a little weak. On the other hand, the compounds described in examples 44 and 46 of the above J.P. 214773/1985, in which ethyl located on N-1 position of quinoline skeleton is changed to cyclopropyl, have strong antimicrobial activity against Gram-negative microorganisms, but from the extremely low water-solubility thereof it can be assumed that the pharmacokinetics thereof is bad.
SUMMARY OF THE INVENTION
Under such circumstances, the present inventors made various studies and formed that high water solubility can be obtained by selecting compounds of the above formula wherein Z' represents a group of the formula: ##STR4## in which at least one of R 2 and R 3 represents a lower alkyl group and R 11 , X' and Y' represent each a special group from the above-mentioned pyridonecarboxylic acid derivatives, extremely large number of compounds, and in this way there can be obtained compounds having in particular high absorbability through the intestinal tract and stability for metabolic disposition.
It is, therefore, the primary object of the present invention to provide novel compounds having excellent antimicrobial activities against not only Gram-negative and -positive microorganisms but also anaerobes as well as high absorbability through the intestinal tract and stability for metabolic disposition.
Another object of the present invention is to provide a novel process for preparing such compounds.
Another object of the present invention is to provide an excellent antimicrobial agent.
These and other objects of the present invention will be clear from the following description.
In accordance with the present invention, there are provided compounds having the following formula [1]: ##STR5## wherein R 1 , R 2 and R 3 represent each a hydrogen or alkyl group having 1 to 6 carbon atoms (hereinafter referred to as C 1 -C 6 alkyl group), R 2 and R 3 being either the same or different and R 2 and R 3 being not hydrogen at the same time, R 1 may form a methylene chain of the formula: --CH 2 ) n in which n is 2 to 4 together with R 2 or R 3 , or R 2 and R 3 may form together a methylene chain of the formula: --CH 2 ) m in which m is 2 to 5; R 4 represents an ethyl, 2-fluoroethyl, vinyl, isopropyl, isopropenyl or cyclopropyl group; and X represents CH, C--F, C--Cl or N, and salts thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Examples of the lower alkyl groups in the general formula [I] include those having 1 to 6 carbon atoms. Examples of the salts of the compounds of the present invention include salts with inorganic acids and organic acids such as hydrochloric acid, sulfuric acid and methanesulfonic acid or with alkali metals and alkaline earth metals such as sodium and calcium. Further, the compounds of the present invention may be in the form of their hydrates. As a matter of course, stereoisomers and optical isomers (L-, D- and racemic compounds) are included in the compounds of the present invention.
R 1 in the above general formula [I] for the compounds of the present invention is preferably hydrogen or an alkyl group having 1 to 3 carbon atoms. R 2 is preferably hydrogen or an alkyl group having 1 to 3 carbon atoms. R 3 is preferably an alkyl group having 1 to 3 carbon atoms. It is also preferred that R 2 and R 3 form together a methylene chain having 2 to 5 carbon atoms or that R 1 and either R 2 or R 3 form together a methylene chain having 2 to 4 carbon atoms. R 4 is preferably ethyl or cyclopropyl and X is preferably CF or N.
The compounds of the present invention can be synthesized by a process wherein a compound of the general formula [II]: ##STR6## wherein R 4 and X are as defined above is reacted with a pyrrolidine derivative of the general formula [III]: ##STR7## wherein R 1 , R 2 and R 3 are as defined above. This reaction is carried out preferably at a temperature of about 20° to 150° C. in an inert solvent such as acetonitrile, tetrahydrofuran, ethanol, chloroform, dimethyl sulfoxide, dimethylformamide, pyridine, picoline or water.
The pyrrolidine derivative of the above general formula [III] is synthesized by, for example, a process wherein known 1-benzyl-4-carboxy-2-pyrrolidone is treated with thionyl chloride to form an acid chloride, which is then reacted with Meldrum's acid and the resulting product is decarboxylated to obtain 4-acetyl derivative thereof. The ketonic part of the acetyl group is converted into an oxime with hydroxylamine and the product is reduced with lithium aluminum hydride to obtain 3-(1-aminoethyl)-1-benzylpyrrolidine. This product is reacted with 2-[tert-butyloxycarbonyloxyimino]-2-phenyl-acetonitrile (Boc-ON) to form a corresponding tert-butoxycarbonyl (hereinafter referred to as Boc) compound, which is then reduced with palladium/carbon and debenzylated to form 3-(1-tert-butoxycarbonylamino)ethylpyrrolidine. When the Boc compound obtained as above is reduced with lithium aluminum hydride and then with palladium/carbon and debenzylated, 3-(1-methylamino)ethylpyrrolidine is obtained.
In the above-mentioned process for producing the compound of the present invention, the amino group of the pyrrolidine derivative of the general formula [III] may be protected with a group which makes the compound substantially inert to the reaction conditions. Examples of the protective groups include acyl groups such as formyl, acetyl and trifluoroacetyl groups; alkoxycarbonyl groups having 2 to 6 carbon atoms such as ethoxycarbonyl and tert-butoxycarbonyl groups; aryloxycarbonyl groups such as benzyloxycarbonyl, p-methoxybenzyloxycarbonyl and phenoxycarbonyl groups; silyl groups such as trimethylsilyl group; as well as trityl, tetrahydropyranyl, vinyloxycarbonyl, o-nitrophenylsulfenyl, diphenylphosphinyl, p-toluenesulfonyl and benzyl groups. These protective groups can be removed after the reaction, if necessary, by a known process such as hydrolysis with an acid or base.
According to the present invention, at least one of R 2 and R 3 of the general formula [I] is lower alkyl group, so that strong antimicrobial activity of the compounds can be maintained and at the same time the water-solubility thereof can be increased. As a result, there can be provided compounds having particularly high absorbability through the intestinal tract and stability for metabolic disposition, which are superior to the compound CI-934 in terms of antimicrobial activity against Gram-negative microorganisms. Namely, the compounds of the present invention can be predicted to show good pharmacokinetics and to be low in toxicity, so that the compounds are expected to be valuable as pharmaceutical products.
Therefore, the compounds of the present invention can be used widely as antimicrobial agents to be administered to, for example, human and other mammals orally, parenterally or locally. The present invention will be further illustrated by the following non-limitative examples.
EXAMPLES
The carboxylic acid derivatives (M-1) to (M-3) used as the starting materials in the following examples are as follows: ##STR8##
The compounds (M-1) to (M-3) are known ones.
In the following Referential Examples 1 to 23, processes for producing pyrrolidine derivatives to be reacted with the above-mentioned starting compounds will be shown.
Referential Example 1
Synthesis of 1-benzyloxycarbonyl-3-(1-tert-butoxycarbonylaminoethyl)pyrrolidine (P-2): ##STR9##
1.5 g of 3-(tert-butoxycarbonylaminoethyl)pyrrolidine (P-1) obtained in Referential Example 25 and 1.0 g of triethylamine were dissolved in 40 ml of tetrahydrofuran. 1.7 g of benzyloxycarbonyl chloride was added dropwise to the solution under cooling with ice and the obtained mixture was stirred at room temperature for 2 h.
The solvent was distilled off and water was added to the residue. After extraction with ethyl acetate, the organic layer was washed with 10% citric acid solution, saturated sodium hydrogencarbonate solution and saturated aqueous sodium chloride solution successively and then dried. The solvent was distilled off and the residue was subjected to column chromatography with 60 g of silica gel to obtain 1.9 g of the desired comound (p-2) as a colorless, viscous oil from a chloroform/methanol (20: 1) elute.
NMR(CDCl 3 )δ: 1.13, 1.16 (each 1.5H, d, J=7 Hz, about 1:1) 1.44 (9H, s) 1.6˜2.3 (3H, m), 2.9˜3.8 (5H, m), 4.38 (1H, d, J=9 Hz) 5.12 (2H, s) 7.36 (5H, s)
Referential Example 2
Separation of stereoisomers P-2A and P-2B from 1-benzyloxycarbonyl-3-(1-tert-butoxycarbonylaminoethyl)pyrrolidine (P-2) by high performance liquid chromatography (HPLC):
Separation conditions of compound (P-2) by HPLC:
Column: Nucleosil 50-5, 20o×250 mm
solvent: ethyl acetate/n-hexane (3:1)
flow rate: 5.3 ml/min
retention time: 31.0 min (P-2A), 32.2 min (P-2B)
Isomer (p-2A)
IR: 3330, 2970, 1680-1700, 1520
Mass m/e: 349 (M + +1)
NMR(CDCl 3 )δ: 1.13 (3H, d, J=7 Hz), 1.44 (9H, s), 1.7˜2.3 (3H, m), 2.9˜3.9 (5H, m), 4.36 (1H, d, J=9 Hz), 5.12 (2H, s), 7.36 (5H, s)
Isomer (P-2B)
IR: 3330, 2960, 1680˜1670, 1520
Mass m/e: 348 (M + )
NMR(CDCl 3 )δ: 1.16 (3H, d, J=7 Hz), 1.43 (9H, s), 1.6˜2.4 (3H, m), 2.9˜3.9 (5H, m), 4.44 (1H, d, J=9 Hz), 5.12 (2H, s), 7.36 (5H, s)
Referential Example 3
i) Synthesis of stereoisomer (P-3A) of 3-(1-tert-butoxycarbonylaminoethyl)pyrrolidine: ##STR10##
640 mg of 1-benzyloxycarbonyl-3-(1-tert-butoxycarbonylaminoethyl)pyrrolidine isomer (P-2A) and 300 mg of 5% Pd-C (50% wet) were added to 20 ml of ethanol and catalytic reduction was carried out at room temperature under 3 atm. for 3 h. Then, the catalyst was filtered off and ethanol was distilled off to obtain 390 mg of the desired compound (P-3A) in the form of a colorless, viscous oil.
IR: 1700 (shoulder), 1690
NMR (CDCl 3 )δ: 1.14 (3H, d. J=7 Hz) 1.44 (9H, s) 1.5˜2.3 (3H, m) 2.4˜3.3 (4H, m) 3.4˜3.9 (1H, m) 4.56 (1H, d, J=9 Hz),
ii) Synthesis of stereoisomer (P-3B) of 3-(1-tert-butoxycarbonylaminoethyl)pyrrolidine:
An isomer (P-3B) was obtained in the form of a colorless, viscous oil from the isomer P-2B in the same manner as in Referential Example 3-i). IR: 1700 (Shoulder), 1685
IR: 1700 (Shoulder), 1685 NMR(CDCl 3 )δ: 1.17 (3H, d, J=7 Hz) 1.43 (9H, s) 1.7˜2.5 (3H, m) 2.7˜3.4 (4H, m) 3.4˜3.8 (1H, m) 4.83(1H, d, J=9 Hz)
Referential Example 4
i) Synthesis of stereoisomer (P-4B) of 3-(1methylaminoethyl)pyrrolidine: ##STR11##
346 mg of the isomer (P-3B) was dissolved in 20 ml of anhydrous tetrahydrofuran. 500 mg of lithium aluminum hydride (LiAlH4) was added to the solution and the mixture was refluxed for 1.5 h. After cooling 0.5 ml of water, 0.5 ml of 15% NaOH and 1.5 ml of water were added successively to the mixture and the obtained mixture was stirred for additional 30 min. Insoluble matter was filtered off and the filtrate was concentrated to obtain 180 mg of the desired compound (P-4B) in the form of a light yellow oil.
NMR(CDCl 3 )δ: 1.06 (3H, d, J=6 Hz) 2.39 (3H, s)
ii) Synthesis of stereoisomer (P-4A) of 3-(1-methylaminoethyl) pyrrolidine:
An isomer (P-4A) was obtained in the form of an oil from the isomer (P-3A) in the same manner as in Referential Example 4-i).
NMR(CDCl 3 )δ: 1.02 (3H, d, J=6 Hz) 2.39 (3H, s)
Referential Example 5
Synthesis of 3-(1-tert-butoxycarbonylaminopropyl)pyrrolidine (P-5): ##STR12##
The same procedure as in Referential Examples 24 and was repeated except that ethyl malonate was replaced with ethyl methylmalonate to obtain the desired compound (P-5) in the form of a colorless, waxy, unrefined solid.
NMR(CDCl 3 )δ: 0.92 (3H, t, J=8 Hz) 1.42 (9H, s)
Referential Example 6
Synthesis of 2-benzoylamino-2-methylpropionaldehyde (P-6): ##STR13##
32.3 g of pyridium chlorochromate (PCC) was added to 200 ml of dehydrated methylene chloride. 50 ml of a solution of 19.3 g of a known compound in the form of an alcohol in dehydrated methylene chloride was added dropwise thereto under stirring over about 1 h and then the stirring was continued for an additional 20 h. Then, 200 ml of anhydrous ether was added thereto and the mixture was stirred for 30 min. The precipitate thus formed was removed by decantation and the obtained solution was decolored by passing through a Florisil column (15 cm). The solvent was distilled off and the residue was purified by silica gel column chromatography to obtain 11 g of the desired aldehyde (P-6) from a chloroform/methanol (10:1) elute.
NMR(CDCl 3 )δ: 1.56 (3H, s) 6.8 (1H, bs) 7.2˜8.1 (5H, m) 9.4 (1H, s)
Referential Example 7
Synthesis of cis- or trans-ethyl 4-benzoylamino-4-methylpentenoate:
4.0 g of the above-mentioned aldehyde (P-6) was dissolved in 60 ml of dehydrated methylene chloride. 20 ml of a solution of 8.0 g of carboethoxymethylenetriphenylphosphorane [(C 6 H 5 ) 3 P=COOC 2 H 5 ] in dehydrated methylene chloride was added dropwise to the solution and the mixture was stirred at room temperature for 6 h. Then, the solvent was distilled off and the residue was subjected to column chromatography with 600 g of silica gel. After elution with benzene/ethyl acetate (2:1), 0.7 g of the desired compound (P-7) in cis-form and 4.5 g thereof in trans-form were obtained each in the form of a colorless powder.
Trans: NMR(CDCl 3 )δ: 1.34 (3H, t, J=7 Hz) 1.6 (6H, s) 4.24 (2H, q, J=7 Hz) 6.2 (1H, bs) 5.9 (1H, d, J=16.2 Hz) 7.10 (1H, d, J=16.2 Hz) 7.2˜7.9 (5H, m)
Cis: NMR(CDCl 3 )δ: 1.20 (3H, t, J=7 Hz) 1.72 (6H, s) 4.02 (2H, q, J=7 Hz) 5.78 (1H, d, J=12.6 Hz) 6.36 (1H, d, J=12.6 Hz) 7.25˜7.95 (5H, m)
Referential Example 8
Synthesis of ethyl 4-benzoylamino-4-methyl-3-nitromethylpentanoate (P-8): ##STR14##
2.0 g of the trans-olefin (P-7) and 11.5 ml of tetramethylguanidine were added to 110 ml of nitromethane and the mixture was stirred at room temperature for 20 h. Then, the solvent was distilled off and the residue was dissolved in chloroform. The obtained solution was washed with 0.5N hydrochloric acid and then with saturated aqueous sodium chloride solution and dried over anhydrous sodium sulfate.
Chloroform was distilled off and the obtained oily residue was subjected to column chromatography with 250 g of silica gel. After the elution with chloroform/methanol (20:1), 2.4 g of the desired nitromethane adduct (P-8) was obtained in the form of a colorless powder.
NMR(CDCl 3 )δ: 1.25 (3H, t, J=7 Hz) 1.48 and 1.56(each 3H, s) 2.4˜2.8 (2H, m) 4.10 (2H, q, J=7 Hz) 4.4˜5.0 (2H, m) 6.35 (1H, bs) 7.2˜7.9 (5H, m)
The above-mentioned compound can be obtained also from the cis-olefin in a similar manner as described above.
Referential Example 9
Synthesis of 4-(1-benzoylamino-1-methyl)ethyl-2-oxopyrrolidine (P-9): ##STR15##
810 mg of the above-mentioned nitro compound (P-8) was dissolved in 40 ml of anhydrous ethanol. Raney nickel was added to the solution and the catalytic reduction was carried out at ambient temperature under atmospheric pressure for 3 days. The catalyst was filtered off and washed with ethanol three times. The wash solutions were added to the filtrate. The residue was subjected to column chromatography with 60 g of silica gel to obtain 50 mg of a pyrrolidone compound (P-9) in the form of a powder from a chloroform/methanol (10:1) elute.
NMR (CDCl 3 )δ: 1.46 (6H, s), 2.1˜2.6 (2H, m) 2.8˜3.8 (3H, m), 5.96 (1H, bs) 6.16 (1H, bs), 7.2˜8.0 (5H, m)
Referential Example 10
Synthesis of 3-(1-benzylamino-1-methyl)ethylpyrrolidine (P-10): ##STR16##
800 mg of lithium aluminum hydride was added to 20 ml of anhydrous tetrahydrofuran containing 780 mg of the above-mentioned amide compound (P-9). The mixture was refluxed at 80° C. for 6 h. After completion of the reaction, 0.8 ml of water, 0.8 ml of 15% NaOH and 2.4 ml of water were added successively thereto and the mixture was stirred for 30 min. Insoluble matter was removed by filtration and washed with tetrahydrofuran several times. The washing solutions were added to the filtrate and the mixture was concentrated under reduced pressure. The residue was subjected to column chromatography with 60 g of silica gel. After development with n-butanol/acetic acid/water/ethyl acetate (1:1:1:1), the elute was collected and the solvent was distilled off. The obtained residue was dissolved in chloroform, washed with saturated aqueous sodium hydrogencarbonate solution and saturated aqueous sodium chloride solution and dried over anhydrous sodium sulfate. Chloroform was distiled off to obtain 340 mg of the desired compound (P-10).
NMR(CDCl 3 )δ: 1.12 (6H, s), 1.8 (2H, m) 2.3 (1H, m), 2.9 (4H, m) 3.72 (2H, s), 7.28 (5H, m) 7.25˜7.3 (2H, m)
Referential Example 10-1
Synthesis of 3- (1-methyl-1-methylamino) ethylpyrrolidine (P-10-1): ##STR17##
The desired compound (P-10-1) was obtained in the same manner as in Referential Example 10 except that a starting material (P-9-1) having BOC in place of benzoyl in the amide (P-9) was used.
Referential Example 11
Synthesis of 3- (1-amino-1-methyl)ethylpyrrolidine (aqueous solution) (P-11): ##STR18##
200 mg of the above-mentioned amine (P-10), 200 mg of palladium black and 3 ml of 1N-hydrochloric acid were added to 20 ml of methanol and catalytic reduction was carried out at room temperature under atmospheric pressure for 18 h. After completion of the reaction, 2 ml of 1N-hydrochloric acid was added to the reaction mixture and the catalyst was filtered out. The filtrate was distilled off to obtain hydrochloride of the intended compound (P-11). 3 ml of water and 2 ml of 50% NaOH were added thereto and the mixture was distilled under reduced pressure (bath temperature: about 100° C.) and an aqueous solution of the amine (P-11) distilled was collected using acetone/dry ice refrigerant. 3 ml of water was added to the distillation residue and the same procedure as above was repeated twice to obtain an aqueous solution of amine (P-11), which was used in the subsequent reaction step as it was.
Rf value: 0.20 (n-butanol-acetic acid-water-ethylacetate (1:1:1:1))
Referential Example 12
Synthesis of ethyl 1-tert-butoxycarbonylaminocyclopropanecarboxylate (P-12): ##STR19##
5.0 g of known monoethyl 1,1-cyclopropanedicarboxylate, 4.5 ml of triethylamine and 6.9 ml of diphenyl phosphorazidate (DPPA) were added to 80 ml of tert-butyl alcohol and the mixture was refluxed at 90° to 100° C. for 4 h. After distilling the solvent, the residue was dissolved in ethyl acetate and washed with 5% citric acid, saturated aqueous sodium carbonate solution and saturated aqueous sodium chloride solution and then dried. The solvent was distilled off to obtain 5.7 g of the desired compound (P-12) in the form of a light yellow oil.
NMR(CDCl 3 )δ: 1.2(7H, m) 1.44(9H, s) 4.12(2H, q, J=7 Hz) 5.04(1H, bs)
Referential Example 13
Synthesis of 1-tert-butoxycarbonylaminocyclopropanecarboaldehyde (P-13): ##STR20##
7.1 g of the ester compound (P-12) was dissolved in ml of anhydrous n-hexane. 46 ml of diisobutylaluminum hydride (1M solution in n-phexane) was added dropwise to the solution under cooling to -65° C. in argon atmosphere and the mixture was stirred at -60° to -70° C. for 4 h. The temperature was elevated to room temperature and the product was extracted sufficiently with saturated sodium hydrogensulfite solution. The precipitate thus formed was filtered off and the aqueous layer was adjusted to pH 9 with 10% NaOH under cooling with ice. After extraction with ether several times, the ether layer was washed with saturated aqueous sodium chloride solution and dried over magnesium sulfate. Ether was distilled off to obtain 2.6 g of the desired aldehyde (P-13) in the form of a colorless solid.
NMR (CDCl 3 )δ ppm: 1.36 (4H, m), 1.48 (9H, s) , 5.20 (1H, bs), 9.20 (1H, s)
Referential Example 14
Synthesis of ethyl 3- (1-tert-butoxycarbonylaminocyclopropyl)acrylate (P-14): ##STR21##
1.12 g of the starting aldehyde was dissolved in 22 ml of anhydrous methylene chloride. 2.24 g of carbethoxymethylene triphenylphosphorane was added to the solution in argon atmosphere and the mixture was refluxed at 60° C. overnight. The solvent was distilled off and the residue was subjected to the column chromatography with 120 g of silica gel to obtain the desired compound (P-14) in mainly trans-form from the elute obtained with benzene/ethyl acetate (2:1). The product was in the form of a white powder.
NMR(CDCL 3 )δ: 1.30 (3H, t, J=7 Hz), 1.40 (9H, s) 1.0˜1.3 (4H, m) , 4.20 (2H, q, J=7 Hz), 5.0 (1H, bs), 5.80 (1H, d, J=18 Hz), 6.28 (1H, d, J=18 Hz).
Referential Example 15
Synthesis of ethyl 3-(1-tert-butoxycarbonylaminocyclopropyl)-4-nitrobutyrate (P-15): ##STR22##
The starting olefin compound (P-14) was dissolved in 60 ml of nitromethane. 4.5 ml of 1,1,3,3-tetramethylguanidine was added to the solution and the mixture was stirred at room temperature overnight. The solvent was distilled off under reduced pressure and the residue was subjected to column chromatography with 100. g of silica gel to obtain 960 mg of the desired compound (P-15) in the form of a colorless oil.
NMR(CDCl 3 )δ: 0.85˜0.95 (4H, m), 1.30 (3H, t, J=7 Hz), 1.47 (9H, s), 2.25 (1H, m), 2.6 (2H, m), 4.16 (2H, q, J=7 Hz), 4.6 (2H, m), 5.0 (1H, bs)
Referential Example 16
Synthesis of 4-(1-tert-butoxycarbonylaminocyclopropyl) pyrrolidin-2-one (P-16): ##STR23##
960 mg of the nitro compound (P-15) was dissolved in 50 ml of anhydorus ethanol. Raney nickel was added to the solution and catalytic reduction was carried out at room temperature. The catalyst was removed and ethanol was distilled off. The residue was heated to 150° C. for 5 min and then subjected to column chromatography with 80 g of silica gel to obtain 320 mg of ring-closed compound (P-16) from chloroform/methanol (10:1) elute. The product was in the form of a colorless powder.
NMR (CDCl 3 )δ: 0.7˜0.8 (4H, m), 1.38 (9H, s), 2.3 (3H, m), 3.4 (2H, m), 5.0 (1H, bs), 5.8 (1H, bs),
Referential Example 17
Synthesis of 4-(1-aminocyclopropyl)pyrrolidin-2-one trifluoroacetate (P-17): ##STR24##
1.2 ml of trifluoroacetic acid and 0.6 ml of anisole were added to 230 mg of the BOC compound (P-16) under cooling with ice and the mixture was stirred at room temperature for 1 h. Then, ether was added to the reaction mixture and the precipitate thus formed was collected by filtration. After thorough washing with ether, 200 mg of the amine trifluoroacetate (P-17) mentioned above was obtained.
Referential Example 18
Preparation of aqueous solution of 3- (1-aminocyclopropyl)pyrrolidine (P-18): ##STR25##
8 ml of tetrahydrofuran was added to 260 mg of the trifluoroacetate (P-17). Then, 0.5 ml of triethylamine was added to the mixture under cooling with ice to dissolve the compound (P-17) therein. 300 mg of lithium aluminum hydride was added to the solution and the mixture was refluxed overnight. 0.3 ml of water, 0.3 ml of 15% NaOH and 0.9 ml of water were added successively thereto under cooling with ice and the mixture was stirred for 30 min. Insoluble matter was filtered off and then 3 ml of 1N-hydrochloric acid was added to the flitrate. The solvent was distilled off under reduced pressure. 3 ml of water and then 3 ml of 50% NaOH were added to the residue under cooling with ice to obtain an alkaline mixture, which was distilled under reduced pressure (oil bath temperature: about 100° C.) and an aqueous solution of the diamine (P-18) thus distilled was cooled and collected in a dry ice/acetone bath.
The aqueous solution of the compound (P-18) thus obtained was used in the subsequent reaction step as it was.
TLC Rf value: 0.14 (n-butanol-acetic acid-water-ethylacetate (1:1:1:1))
The reaction path in the synthesis of the compounds (P-19) to (P-23) is as follows: ##STR26##
Referential Example 19
Synthesis of (S) -1-tert-butoxycarbonylpyrrolidine-2-methanol (P-19):
4.04 g of (S)-pyrrolidinemethanol and 9.84 g of Boc-ON were dissolved in 100 ml of 75% hydrous dioxane and the solution was stirred for 1 h. Then, the reaction liquid was concentrated, extracted with chloroform, washed with 0.5N-NaOH and saturated aqueous sodium chloride solution and dried over anhydrous sodium sulfate. The solvent was distilled off. The residue was subjected to the column chromatography with 100 g of silica gel and eluted with 2% methanol/chloroform to obtain 8.04 g of a colorless oil (P-19).
Referential Example 20
Synthesis of (S) -1-tert-butoxycarbonylpyrrolidine-2-carboxyaldehyde (P-20):
10 ml of a solution of 8.04 g of the alcohol (P-19) obtained as above in dichloromethane was added to 100 ml of dichloromethane containing 12.9 g of pyridium chlorochromate and the mixture was stirred at room temperature for 2 h. Then, 100 ml of ether was added to the reaction mixture and the mixture was decanted. The residue was washed with 200 ml of chloroform. The wash solution was added to the organic layer and the mixture was passed through a Florisil column to remove chromium compounds. The solvent was distilled off and the residue was purified by column chromatography with 50 g of silica gel and chloroform to obtain 4.76 g (60%) of the aldehyde (P-20) in the form of a yellow oil.
NMR(CDCl 3 )δ: 1.46 (9H, s), 1.70˜2.20 (4H, m), 3.3˜3.6(2H, m), 3.9 4.3(1H, m), 9.4˜9.6 (1H, bs)
Referential Example 21
Synthesis of ethyl trans-3-(1-tert-butoxycarbonyl-2-pyrrolidinyl)acrylate (P-21):
4.76 g of the aldehyde (P-20) obtained as above and 8.32 g of carbethoxymethylenetriphenylphosphorane were added to 100 ml of dichloromethane and the mixture was heated under reflux for three days. The solvent was distilled off and the residue was subjected to column chromatography with 150 g of silica gel and then eluted with benzene/ethyl acetate. (6:1) to obtain 3.83 g of the desired compound (P-21) in the form of a colorless oil.
NMR (CDCl 3 )δ: 1.28 (3H, t, J=7.3 Hz), 1.44 (9H, s), 1.6˜2.2 (4H, m), 3.3˜3.55 (2H, m), 4.19 (2H, q, J=7.3 Hz), 4.3˜4.6 (1H, m), 5.81 (1H, d. d, J=15 Hz), 6.83 (1H, d. d, J=15.6 Hz)
Referential Example 22
Synthesis of ethyl 3- (1-tert-butoxycarbonyl-2-pyrrolidinyl)-4-nitrobutyrate (P-22):
3.83 g of the ester (P-21) obtained as above, 3.28 g of 1,1,3,3-tetramethylguanidine and 20 ml of nitromethane were mixed together and the mixture was stirred at room temperature for 24 h. Nitromethane was distilled off and the residue was subjected to the column chromatography with 75 g of silica gel and eluted with benzene/ethyl acetate (5:1) to obtain 4.5 g of the compound (P-22) in the form of a colorless oil.
Referential Example 23
Synthesis of 4-(1-tert-butoxycarbonyl-2-pyrrolidinyl) pyrrolidin-2-one (P-23):
3.30 g of the nitro compound (P-22) and 1.5 ml of Raney nickel were added to 50 ml of ethanol and the catalytic reduction was carried out for a whole day and night. The catalyst was filtered off and the filtratre was concentrated under reduced pressure. 50 ml of benzene was added to the residue and the mixture was refluxed for a whole day and night. Then, benzene was distilled off under reduced pressure and the residue was subjected to the column chromatography with 50 g of silica gel and eluted with chloroform/methanol (95:5) to obtain 2.13 g of the desired ring-closed compound (P-23) in the form of colorless crystals.
m.p. 140°-143° C. NMR(CDCl 3 )δ: 1.36 (9H, s), 1.5˜2.2(4H, m), 2.0˜2.4 (1H, m), 2.9˜3.6 (4H, m), 3.70˜3.96(1H, m)
Referential Example 24
(1) 4-Acetyl-1-benzyl-2-pyrrolidone:
10 ml of thionyl chloride and 30 ml of dioxane were added to 4.4 g of 1-benzyl-4-carboxy-2-pyrrolidone. The mixture was stirred under heating to 90° to 100° C. for 30 min and then the solvent and excess thionyl chloride were distilled off under reduced pressure to obtain and acid chloride residue.
2.5 g of-magnesium ethoxide and 3.5 g of ethyl malonate were added to 40 ml of anhydrous ether and the mixture was refluxed for 1.5 h to obtain a solution. The solution of the acid chloride in ether prepared as above was added dropwise to this solution under stirring and under cooling with ice. After completion of the addition, the mixture was refluxed for 1 h. An excess amount of dilute sulfuric acid solution was added thereto under cooling with ice to make the solution weakly acidic. It was extracted with ether and dried.
The solvent was distilled off. 10 ml of acetic acid, 45 ml of water and 1 ml of concentrated sulfuric acid were added to the residue and the mixture was refluxed for 5 h. The solvent was distilled off under reduced pressure. The residue was dissolved in chloroform and washed with 10% hydrochloric acid and then with saturated sodium hydrogen carbonate solution and dried. The solvent was distilled off to obtain 3.3 g of the desired compound in the form of an oil.
NMR(CDCl 3 )δ ppm: 2.2 (3H, s) 2.66 (2H, d, J=7.2 Hz) 3.0˜3.6 (3H, m) 4.32, 4.52 (each 1H, d, J=14 Hz, AB-q) 7.29 (5H, s)
(2) 1-Benzyl-4-(l-hydroxyiminoethyl) -2-pyrrolidone:
15 ml of pyridine was added to a mixture of 3.3 g of the compound obtained in the above process (1) and 2.5 g of hydroxylamine hydrochloride and the mixture was heated at 90° C. for 5 h, Water was added to the reaction mixture and then it was made acidic with hydrochloric acid and extracted with dichloromethane. Dichloromethane was distilled off and the obtained residue was subjected to column chromatography with 30 g of silica gel, After elution with methanol/chloroform (1:20), 2.6 g of the desired compound was obtained in the form of a powder.
NMR(CDCl 3 ) δ ppm: 1.8 (3H, s ) 2.62 (2H, d, J=7.2 Hz) 2.9˜3.6 (3H, m) 4.44 (2H, s) 7.28 (5H, s)
Referential Example 25
(1) 3-(1-Aminoethyl) -1-benzylpyrrolidine:
30 ml of anhydrous tetrahydrofuran (THF) was added to 650 mg of 1-benzyl-4-(1-hydroxyiminoethyl)-2-pyrrolidone and 500 mg of lithium aluminum hydride and the obtained mixture was refluxed for 20 h. After the decomposition of lithium aluminum hydride, the precipitate was filtered and washed thoroughly with THF. The wash solution was added to the filtrate. The solvent was distilled off under reduced pressure to obtain 587 mg of the desired compound in the form of a light yellow oil.
NMR(CDCl 3 ) δ ppm: 0.1˜1.1 (3H, 2 pairs of doublet about 1:1, J=7 Hz) 3.55 (2H, s) 7.25 (5H, s)
(2) 3- (1-tert-Butoxycarbonylaminoethyl)-1-benzylpyrrolidine:
580 mg of the compound obtained in the above step (1) and 730 mg of Boc-ON were dissolved in dehydrated THF and the solution was stirred at room temperature for 3 h. After the starting materials were completely disappeared, THF was distilled off. Ethyl acetate was added thereto and the mixture was washed with 0.2N NaOH twice and then with saturated aqueous sodium chloride solution once and dried over anhydrous sodium sulfate. The solvent was distilled off and the residue was subjected to the column chromatography with 30 g of silica gel. After elution with 2% methanol/chloroform, 643 mg of the desired compound was obtained in the form of an oil.
NMR(CDCl 3 ) δ ppm: 1.0˜1.2 (3H, 2 pairs of doublet, J=7 Hz) 1.45 (9H, s) 3.6 (2H, AB-type quartet) 7.3 (5H, S)
(3) 3-[1-(Methylamino)ethyl]-1-benzylpyrrolidine:
642 mg of the compound obtained in the above step (2) and 250 mg of lithium aluminum hydride were added to 10 ml of dehydrated THF and the mixture was refluxed for 2 h. After cooling, 0.25 ml of water, 0.25 ml of 15% aqueous NaOH solution and 0.75 ml of water were added successively thereto and insoluble matter was filtered off. A washer solution of THF (10 ml) was added to the mother liquor and the solvent was distilled off. 448 mg of the desired compound was obtained in the form of a colorless oil.
NMR(CDCl 3 ) δ ppm: 0.9˜1.1 (2H, 2 pairs of doublet, J=7 Hz) 2.35 (3H, s) 3.55 (2H, s) 7.20 (5H, s)
(4) 3-[1-(Methylamino)ethyl]pyrrolidine:
20 ml of ethanol and 500 mg of 5% Pd-C (50% wet) were added to 448 mg of the compound obtained in the above step (3) and reduction was carried out at 40° to 50° C. under 4.3 arm. After seven hours, the catalyst was filtered off and the filtrate was concentrated under reduced pressure to obtain 240 mg of the desired compound in the form of a light yellow oil.
NMR(CDCl 3 ) δ ppm: 0.95˜1.15 (2H, 2 pairs of doublet, J=7 Hz) 2.39 (3H, s)
(5) 3-[1-(tert-Butoxycarbonylamino)ethyl]pyrrolidine:
30 ml of ethanol was added to a mixture of 2.35 g of the compound obtained in the above step (2) and 1.1 g of 5% Pd-C (50% wet) and the reduction was carried out at about 50° C. under 4.3 arm for 4.5 h. The catalyst was removed and then ethanol was distilled off to obtain 1.5 g of the desired compound in the form of a colorless, viscous liquid.
NMR(CDCl 3 ) δ ppm: 1.42 (9H, s) 1.12, 1.15 (each 1.5H, d, J=7 Hz)
Referential Example 26
(12) 4-(1-Aminopropyl)-1-benzyl pyrrolidin-2-one ##STR27##
The oxime compound (11) was -prepared by the same method as set forth in Referential example 25 except that ethyl methylmalonate was used instead of ethyl malonate. 3.0 g of the oxime compound was dissolved in 30 ml of methanol, after which 4 ml of Raney nickel was added thereto to conduct reduction at room temperature for 24 hours. The catalyst was filtered off and the solvent was distilled off. As a result, 2.8 g (100%) of the amine compound (12) was obtained in the form of a light yellow oil.
NMR (CDCl 3 ) δ ppm: 0.91 (3H, t, J=7 Hz) 1.1-1.5 (2H, m), 1.9-2.7 (4H, m) 2.9-3.4 (2H, m), 4.46 (2H, AB-q, J=16 Hz) 7.28 (5H, s)
(13) 1-Benzyl-4-(1-tert-butyloxycarbonylaminopropyl)-pyrrolidin-2-one and HPLC separation (compounds 14-A and 14-B)
3.0 g of the amine compound (12) was dissolved in 20 ml of tetrahydrofuran, after which 3.3 g of Boc compound was added thereto, followed by agitating the mixture at room temperature for a whole day and night. The solvent was distilled off and ethyl acetate was added to the residue. The residue was then washed with 10% citric acid, 0.5N--NaOH solution and a saturated NaCl solution, and thereafter was dried. The residue i.e., viscous oil, was subjected to high performance liquid chromatography (HPLC) to separate steric isomers (14-A) and (14-B).
Separating condition
Column: Nucleosil 50-5 (20o×250 mm)
Solvent: ethyl acetate-tetrahydrofuran (9:1 V/V)
Flow rate: 6.6 ml/min.
Retention time: isomer (14-A): 34 minutes isomer (14-B): 37 minutes
Isomer (14-A) 1.4 g (33%)
m.p. 123°-124°
Elemental analysis calculated for C 19 H 28 N 2 O 3 : Calculation: C 68.65,H 8.49, N 8.43 Found: C 68.84, H 8.51, N 8.37
NMR (CDCl 3 ) δ ppm: 0.90 (3H, t, J=7.5 Hz) 1.1-1.6 (2H, m), 1.40 (9H, s) 2.1-2.6 (3H, m), 2.9-3.7 (3H, m) 4.1-4.4 (1H, m), 4.43 (2H, AB-q, J=16 Hz) 7.28 (5H, s)
Isomer (14-B) 1.4 g (33%)
m.p. 114°-117°
Elemental analysis calculated for C 19 H 28 N 2 O 3 : Calculation: C 68.65,H 8.49, N 8.43 Found: C 68.88, H 8.49, N 8.49
NMR (CDCl 3 ) δ ppm: 0.90 (3H, t, J=7.5 Hz) 1.0-1.6 (2H, m), 1.40 (9H, s) 2.0-2.6 (3H, m) 2.9-3.6 (3H, m) 4.22 (2H, AB-q, J=16 Hz) 4.3-4.5 (1H, m), 7.28 (5H, s)
Isomer (15-B): 4-(1-Aminopropyl)-1-benzylpyrrolidin-2-one
5 ml of trifluoroacetic acid and 1 ml of anisole were added to 1.3 g of Boc compound (14-B) and then the solution was agitated at room temperature for 30 minutes. The solution was concentrated under reduced pressure, after which water was added to the residure, and the residue was washed, adjusted to alkaline side with NaOH, extracted by chloroform, and dried. 800 mg (88%) of amine compound (isomer 15-B) was obtained in the form of colorless oil.
NMR (CDCl 3 ) δ ppm: 0.92 (3H, t, J=7.5 Hz) 1.1-1.5 (2H, m), 1.9-2.7 (4H, m) 2.9-3.5 (2H, m) 4.45 (2H, AB-q, J=16 Hz), 7.28 (5H, s)
Isomer (15-A) can also be obtained by a similar procedure as described above.
Isomer (16-B): 3-(1-Aminopropyl)-1-benzylpyrrolidine
800 mg of the amine compound (15-B) was dissolved in 30 ml of tetrahydrofuran, after which 700 mg of lithium aluminum hydride was added thereto and the mixture was heat refluxed for 4 hours. After cooling, 0.7 ml of water, 0.7 ml of 15% NaOH solution and 2.1 ml of Water were added to the reaction solution in that order, whereafter the reaction mixture was agitated for 30 minutes, insoluble matter was removed therefrom by filtering, and the filtrate was concentrated. As a result, there was obtained 750 mg (100%) of benzylpyrolidine compound (isomer 16-B) in the form of colorless viscous oil.
NMR (CDCl 3 ) δ ppm: 0.92 (3H, t, J=8 Hz) 1.0-1.7 (7H, m), 1.7-2.9 (3H, m), 3.60 (2H, s), 7.30 (5H, s)
Isomer 16-A can also be obtained by a similar procedure as described above.
Isomer 17-B: 1-Benzyl-3-(1-tert-butoxycarbonylaminopropyl) pyrrolidine
750 mg of the benzylpyrrolidine compound (isomer 16-B) was dissolved in 20 ml of tetrahydrofuran, after which 830 mg of Boc-ON compound was added to the solution and the mixture was stirred at room temperature for 1 hour. After the solvent was distilled off, ethyl acetate was added to the residue, and the residue was washed with 0.2N-NaOH solution, with water and dried. The resulting oily product was purified by silica gel chromatography (SiO 2 20 g). As a result, 930 mg (85%) of Boc amine compound (isomer 17-B) was obtained in the form of colorless oil from the fraction eluted with benzene-ethyl acetate (1:1 V/V).
NMR (CDCl 3 ) δ ppm: 0.90 (3H, t, J=8 Hz) 1.1-1.8 (4H, m), 1.44 (9H, s) 1.8-2.7 (5H, m) 3.1-3.5 (1H, m), 3.58 (2H, AB-q, J=14 Hz) 5.1-5.4 (1H, m), 7.30 (5H, s)
Isomer (17-A) can also be obtained in the yield of 77% by a similar procedure as described above.
Isomer (18-B): 3-(1-tert-Butoxycarbonylaminopropyl)pyrrolidine
490 mg of benzylpyridine compound was dissolved in 30 ml of ethanol, after which 1.0 g of 5% Pd-C (50% wet) was added thereto and the mixture was subjected to catalytic reduction for 8 hours at a temperature of 40° to 50° C. under a pressure of 4 atoms. After the catalyst was filtrated off, the solvent was distilled off. As a result, 350 mg (100%) of colorless viscous oil (isomer 18-B) containing small amount of crystal was obtained.
NMR (CDCl 3 ) δ ppm: 0.94 (t, J=7 Hz) 1.44 (s), 1.6-2.2 (m), 2.8-3.8 (m) 4.5-4.8 (m)
Isomer (18-A) can also be obtained by a similar procedure as described above.
EXAMPLE 1
7-[3-(1-tert-Butoxycarbonylaminoethyl) -1-pyrrolidinyl]-1-cyclopropyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid (isomer A: 1-A-1) was synthesized by the following process: ##STR28##
530 mg of 1-cyclopropyltrifluorocarboxylic acid derivatives of formula M-1, 390 mg of an isomer (P-3A) of 3-(1-tert-butoxycarbonylamino-ethyl)pyrrolidine and 190 mg of triethylamine were added to 25 ml of acetonitrile and the mixture was refluxed for 1 h. The solvent was distilled off and water was added to the residue. Insoluble matter was filtered off and the product was washed with acetonitrile and ether successively and dried to obtain 548 mg of the desired compound (1-A-1).
m.p. 195°-198° C.
IR: 1725, 1620
NMRδ: 1.22 (d, J=7 Hz) 1.1˜1.3 (m) 1.46 (9H, s) 1.5˜2.4 (3H, m) 3.4˜4.2 (6H, m) 4.3˜4.6 (1H, m) 7.80 (1H, dd, J=14 Hz, 2 Hz) 8.73 (1H, s)
Elemental analysis calculated for C 24 H 29 F 2 N 3 O 5 Calculation: C 60.37; H 6.12; N 8.80 Found: C 60.10, H 6.06, N 8.76
7-[3-(1-Aminoethyl)-1-pyrrolidinyl]-1-cyclopropyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid (isomer A: 1-A-2) compound of the present invention ##STR29##
12 ml of trifluoroacetic acid and 4.5 ml of anisole were added to 520 mg of the carboxylic acid (1-A-1) obtained in Example 1-1 and then the mixture was stirred at room temperature for 30 min. The solvent was distilled off, water was added to the residue and the mixture was washed with ether. The aqueous layer was adjusted to pH 8.5 with saturated sodium hydrogencarbonate solution and then neutralized to pH 7.0 to 7.2 with concentrated hydrochloric acid. The aqueous-layer was extracted thoroughly with chloroform and dried. Chloroform was distilled off and the resulting solid was recrystallized from concentrated aqueous ammonia/ethanol to obtain 300 mg of the desired carboxylic acid (1-A-2).
m.p. 193°-200° C.
IR: 1815, 1580 (shoulder), 1460
NMR (NaOD) δ: 1.05 (d, J=6 Hz) 0.9˜1.3 (m) 1.4˜1.7 (1H, m) 1.8˜2.3 (2H, m) 2.74 (1H, quintet) 3.2˜3.9 (5H, m) 7.53 (1H, dd, J=15 Hz, 2 Hz) 8.46 (1H, s)
Elemental analysis calculated for C 19 H 21 F 2 N 3 O 3 . 5/4H 2 O Calculation: C 57.06; H 5.92; N 10.51 Found: C 57.35; H 5.81; N 10.42
EXAMPLE 2
7-[3-(1-tert-Butoxycarbonylaminoethyl)-1-pyrrolidinyl]-1-cyclopropyl-6,8-difluoro-1,4-dihydro-4-oxoquinone-3-carboxylic acid (isomer B: 1-B-1) was synthesized as follows: ##STR30##
500 mg of 1-cyclopropyltrifluorocarboxylic acid derivative of formula M-1, 350 mg of an isomer (P-3B) of 3-(1-tert-butoxycarbonylaminoethyl)pyrrolidine and 180 mg of triethylamine were added to 20 ml of acetonitrile and the mixture was refluxed for one hour. The solvent was distilled off and then water was added to the residue. Insoluble matter was filtered off. After washing with acetonitrile and then with ether followed by drying, 428 mg of the desired compound (1-B-1) was obtained.
m.p. 201°-204° C.
IR: 1720, 1620
NMR δ ppm: 1.25 (d, J=7 Hz) 1.1˜1.4 (m) 1.45 (9H, s) 1.5˜2.4 (3H, m) 3.5˜4.2 (6H, m) 4.3˜4.6 (1H, br, d) 7.80 (1H, dd, J=14 Hz, 2 Hz) 8.72 (1H, s)
Elemental analysis calculated for C 24 H 29 F 2 N 3 O 5 . 1/4H 2 O Calculation: C 59.80; H 6.17; N 8.72 Found: C 59.82; H 5.81; N 8.41
7-[3-(1-Aminoethyl)-1-pyrrolidinyl]-1-cyclopropyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid (isomer B: 1-B-2). ##STR31##
10 ml of trifluoroacetic acid and i ml of anisole were added to 410 mg of the carboxylic acid (1-B-1) obtained in Example 2-1 and the mixture was stirred at room temperature for 30 min. The solvent was distilled off and water was added to the residue. After washing with ether, the aqueous layer was adjusted to pH 8.5 with saturated sodium hydrogencarbonate solution, then neutralized to pH 7.0 to 7.2 with concentrated hydrochloric acid and extracted with chloroform. After drying over anhydrous sodium sulfate, chloroform was distilled off and the remaining solid was recrystallized from concentrated ammonia-water/ethanol to obtain 251 mg of the desired compound (1-B-2).
m.p. 213°-215° C.
IR: 1615, 1580, 1460
NMR(NaOD) δ: 1.11 (d, J=6 Hz) 1.3˜1.7 (1H, m) 1.9˜2.2 (2H, m) 2.79 (1H, quintet, J=6 Hz) 3.3˜4.0 (5H, m) 7.57 (1H, dd, J=15 Hz, 2 Hz) 8.47 (1H, s)
Elemental analysis calculated for C 19 H 21 F 2 N 3 O 3 . 1/4H 2 O Calculation: C 59.761 H 5,671 N 11.00 Found: C 59.79; H 5.90; N 11.02
EXAMPLE 3
7-[3-(1-Aminoethyl)-1-pyrrolidinyl]-1-ethyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid (isomer A: 2-A) ##STR32##
The isomer (2-A) was synthesized in a similar manner as described in the synthesis of an isomer (2-B) in Example 4.
m.p. 212°-215° C.
Elemental analysis calculated for C 18 H 21 F 2 N 3 O 3 . 1/4H 2 O Calculation: C 58.45; H 5.86; N 11.36 Found: C 58.40; H 5.71; N 11.41
NMR(NaOD) δ: 1.04 (3H, d, J=7 Hz) 1.36 (3H, t, J=7 Hz) 1.3˜1.6 (1H, m) 1.8˜2.2 (2H, m)
EXAMPLE 4
7-[3-(1-Aminoethyl)-1-pyrrolidinyl]-1-ethyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid (isomer B: 2-B): ##STR33##
160 mg of 1-ethyltrifluorocarboxylic acid derivative of formula M-2, 166 mg of 3-(1-tert-butoxycarbonylaminoethyl)pyrrolidine (P-3B) and 150 mg of triethylamine were added to 10 ml of acetonitrile and the mixture was heated at a bath temperature of 100° to 110° C. under stirring for 3 h. After cooling, the solvent was distilled off under reduced pressure. The residue was washed with water, ethanol and ether successively and then dried. 0.5 ml of anisole and 5 ml of trifluoroacetic acid were added to the solid and the mixture was stirred at room temperature for about 30 min. Then, the solvent was distilled off under reduced pressure. Water was added to the residue and the mixture was washed with chloroform twice. The aqueous layer was made alkaline with saturated sodium hydrogencarbonate solution, neutralized with concentrated hydrochloric acid, extracted with chloroform three times and dried over anhydrous sodium sulfate. The solvent was distilled off under reduced pressure and the obtained residue was recrystallized from concentrated ammonia-water/ethanol to obtain 105 mg of the desired compound (2-B) in the form of fine crystals.
m.p. 212°-217° C. (Decomposition)
Elemental analysis calculated for C 18 H 21 F 2 N 3 O 3 . 3/4H 2 O Calculation: C 57.06; H 5.99; N 11.09 Found: C 57.38; H 6.06; N 11.05
NMR(NaOD)δ: 1.11 (3H, d, J=7 Hz) 1.40 (3H, t, J=7 Hz) 1.4˜1.7 (1H, m) 1.9˜2.2 (2H, m) 2.80 (1H, q, J=7 Hz) 3.4˜3.9 (4H, m) 4.35 (2H, m) 7.63 (1H, dd, J=16 Hz, 2 Hz) 8.32 (1H, s)
EXAMPLE 5
7-[3-(1-Aminoethyl)-1-pyrrolidinyl]-1-cyclopropyl-6-fluoro-1,4-dihydro-4-oxo-1,8-naphthyridine-3-carboxylic acid:
200 mg of naphthyridinecarboxylic acid derivative of formula M-3 and 150 mg of 3-(1-tert-butoxycarbonylaminoethyl)pyrrolidine were added to 5 ml of dimethyl sulfoxide and reaction was carried out at 80° C. for 30 min. Then, the solvent was distilled off under reduced pressure. The residue was subjected to column chromatography with 10 g of silica gel and developed with a lower layer of chloroform/methanol/water (15:3:1). 100 mg of anisole and 3 ml of trifluoroacetic acid were added to the obtained Boc compound and the mixture was stirred at room temperature for 30 min. Trifluoroacetic acid was distilled off. Water was added to the residue to obtain a solution, which was distributed by using hexane twice. The aqueous layer was made alkaline with sodium hydrogencarbonate and adjusted to pH 7.4 with hydrochloric acid. After extraction with chloroform three times followed by drying over anhydrous sodium sulfte, chloroform was distilled off. The obtained residue was recrystallized from ethanol to obtain 90 mg of the desired compound.
m.p. 226°-228° C.
Elemental analysis calculated for C 18 H 21 FN 4 O 3 . 5/4H 2 O Calculation: C 56.33; B 5.76; N 14.83 Found: C 56.46; H 6.19; N 14.63
NMR (NaOD)δ: 0.96 and 1.2 (each 2H, m) 1.12 (3H, d, J=7 Hz) 1.6 and 2.1 (each 1H, m) 3.3 and 3.5 (each 1H, m) 3.6 (1H, m) 3.9 (2H, m) 2.8 (1H, m) 7.76 (1H, d, J=14 Hz) 8.37 (1H, s)
EXAMPLE 6
1-Cyclopropyl-6,8-difluoro-1,4-dihydro-7-[3-(1-methylaminoethyl)-1-pyrrolidinyl]-4-oxoquinoline-3-carboxylic acid (isomer A: 3-A):
This compound was synthesized in a similar manner as described in the synthesis of the isomer (3-B) in Example 7.
m.p. 193°-19720 C.
Elemental analysis calculated for C 20 H 23 F 2 N 3 O 3 . 1/4H 2 O
Calculation: C 60.67; H 5.98; N X0.61 Found: C 60.83; B 5.78; N 10.61
NMR(NaOD) δ: 1.01 (3H, d, J=7 Hz) 0.9˜1.3 (4H, m) 1.4˜1.7 (1H, m) 2.0˜2.2 (2H, m) 2.30 (3H, s) 2.4˜2.6 (1H, m) 3.2˜3.9 (5H, m) 7.53 (1H, dd, J=15 Hz, 2 Hz) 8.46 (1H, s)
EXAMPLE 7
1-Cyclopropyl-6,8-difluoro-1,4-dihydro-7-[3-(1-methylaminoethyl-1-pyrrolidinyl]-4-oxoquinoline-3-carboxylic acid (isomer B: 3-B): ##STR34##
200 mg of compound M-1 was added to 3 ml of dimethyl sulfoxide. The external temperature was elevated to 110° to 120° C. and then 200 mg of 3-(1-methylamino)ethylpyrrolidine (P-4B) was added thereto and the reaction was carried out for an additional 2 h. The solvent was distilled off under reduced pressure and the residue was washed with a small amount of water, ethanol and ether successively and recrystallized from concentrated aqueous ammonia/ethanol to obtain 90 mg of the desired compound (3-B).
m.p. 220°-230° C. (Decomposition)
Elemental analysis calculated for C 20 H 23 F 2 N 3 O 3 . 1/2H 2 O Calculation: C 59.99; H 6.04; N 10.49 Found: C 59.74; H 5.79; N 10.45
NMR(NaOD) δ:1.08(3H, d, J=7 Hz) 0.9˜1.3 (4H, m) 1.4˜1.7 (1H, m) 1.9˜2.3 (2H, m) 2.30 (3H, s) 2.4˜2.7 (1H, m) 3.3˜4.0 (5H, m) 7.55 (1H, dd, J=14 Hz, 2 Hz) 8.46 (1H, s)
EXAMPLE 8
1-Cyclopropyl-6-fluoro-1,4-dihydro-7-[3- (1-methylaminoethyl)-1-pyrrolidinyl]-4-oxo-1,8-naphthyridine-3-carboxylic acid: ##STR35##
150 mg of starting compound M-3 and 200 mg of 3-(1-methylaminoethyl)pyrrolidine were added to 5 ml of dimethyl sulfoxide and the mixture was maintained at 80° C. for 30 min. The solvent was distilled off under reduced pressure and the residue was subjected to column chromatography with 10 g of silica gel. After elution with a lower layer of chloroform/methanol/water (7:3:1) followed by the recrystallization from ethanol/ether, 85 mg of the desired compound was obtained.
m.p. 199°-202° C. (Decomposition)
Elemental analysis calculated for C 19 H 23 FN 4 O 3 . 7/4H 2 O Calculation: C 56.01; H 5.88; N 13.91 Found: C 56.22; H 6.58, N 13.91
NMR (DMSO-d 6 )δ: 0.9˜1.0 and 1.1˜1.2 (each 2H, m) 1.04 and 1.08 (3H, d) 1.6 and 2.2 (2H, m) 2.31 (3H, s) 3.0˜4.0 (5H, m) 7.75 (1H, d, J=14 Hz) 8.35 (1H, s)
EXAMPLE 9
7- [3-(1-Aminopropyl)-1-pyrrolidinyl]-1-cyclopropyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid:
An excess amount of crude 3-(1-tert-butoxycarbonylaminopropyl)pyrrolidine (P-5) and 100 mg of trifluorocarboxylic acid (M-1) were added to 5 ml of dimethyl sulfoxide and the mixture was stirred under heating at a bath temperature of 110° to 120° C. for 30 min. The solvent was distilled off under reduced pressure, whereafter ether was added to the residue and the mixture was stirred and decanted to obtain a precipitate. 2 ml of trifluoroacetic acid and 1 ml of anisole were added to the precipitate and the mixture was stirred at room temperature for 30 min. The solvent was distilled off under reduced pressure. A residue thus obtained was subjected to the column chromatography with 5 g of silica gel. After elution with a lower layer of chloroform/methanol/water (7:3:1), the elute was recrystallized from ethanol/concentrated aqueous ammonia to obtain 37 mg of the desired compound in the form of light yellow crystals.
m.p. 177°-179° C.
Elemental analysis calculated for C 20 H 23 N 3 F 2 O 3 1/4H 2 O Calculation: C 60.67; H 5.98; N 10.61 Found: C 60.33; H 5.70; N 10.68
NMR(DMSO-d 6 ) δ:0.92 (3H, t, J=7 Hz) 1.25 (4H, m) 1.1˜1.3 (1H, m) 1.3˜1.75 (2H; d.m) 2.1 (2H, m) 3.5˜3.95 (4H, m) 4.1 (1H, m) 8.76 (1H, d.d, J=2 Hz, 14 Hz) 8.66 (1H, s)
EXAMPLE 10
7-[3-(1-Aminopropyl)-1-pyrrolindnyl]-1-ethyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid: ##STR36##
54 mg of the desired compound in the form of light yellow, needle-shaped microcrystals was obtained from 100 mg of compound M-2 in a similar manner as described in Example 9.
m.p. 200°-202° C.
Elemental analysis calculated for C 19 H 23 N 3 F 2 O 3 Calculation: C 60.15; H 6.11; N 11.08 Found: C 60.02; H 6.10; N 11.06
NMR(DMSO-d 6 )δ: 0.97 (3H, t, J=7 Hz) 1.43 (3H, t, J=7 Hz) 1.55 (1H, m) 1.70 (2H, m) 2.15 and 2.45 (each 1H, m) 3.17 (1H, m) 3.57˜4.0 (4H, m) 4.58 (2H, q, J=7 Hz) 7.82 (1H, d.d, J=2 Hz, 14 Hz) 8.91 (1H, s)
EXAMPLE 11
7-[3-(1-Amino-1-methyl)ethyl-1-pyrrolidinyl]-1-cyclopropyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid: ##STR37##
4.5 ml of an aqueous solution containing 100 mg (0.35 mmol) of compound M-1 and at least 2 molar ratio, to the compound M-1, of the amine (P-11) was added to 10 ml of dimethyl sulfoxide and the mixture was stirred under heating at a bath temperature of 150° C. for 40 min. After cooling, the precipitated crystals were collected by filtration, washed with water, ethanol and ether successively. The crystals was treated with active carbon and recrystallized from ethanol to obtain 50 mg of the desired compound in the form of a crystalline powder.
m.p. 227°-230° C.
Elemental analysis calculated for C 20 H 23 F 2 N 3 O 3 . 1/2H 2 O Calculation: C 59.99; H 6.04; N 10.50 Found: C 60.02; H 5.98; N 10.47
NMR (NaOD)δ 0.84˜1.32 (8H, m) 1.5˜2.08 (2H, m) 2.20 (1H, m) 3.34˜4.04 (5H, m) 7.57 (1H, d, J=14 Hz) 8.47 (1H, s)
EXAMPLE 12
7- 8 3-(1-amino-1-methyl)ethyl-1-pyrrolidinyl]-1-ethyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid: ##STR38##
187 mg of the desired carboxylic acid was obtained from 173 mg of the compound M-2 in a similar manner as described in Example 11.
m.p. 235°-240° C.
elemental analysis calculated for C 19 H 23 F 2 N 3 O 3 . H 2 O Calculation: C 57.42; H 6.34; N 10.57 Found: C 57.38; H 6.07; N 10.47
NMR(NaOD)δ: 1.12 (6H, s) 1.40 (3H, t, J=8 Hz) 1.70 and 1.96 (each 1H, m) 3.5 and 3.76 (each 2H, m) 4.34 (2H, m) 7.64 (1H, d, J=14 Hz) 8.32 (1H, s)
EXAMPLE 13
7-[3-(1-Amino-1-methyl)ethyl-1-pyrrolidinyl]-1-cyclopropyl-6-difluoro-1,4-dihydro-4-oxo-1,8-naphthyridine-3-carboxylic acid: ##STR39##
42 mg of the desired carboxylic acid was obtained from 70 mg of compound M-3 in a similar manner as described in Example 11.
m.p. 264°-267° C.
Elemental analysis calculated for C 19 H 23 FN 4 O 3 Calculation: C 60.95; H 6.19; N 14.97; Found: C 60.75; H 6.14; N 15.00
NMR (NaOD)δ: 0.96, 1.20 (each 2H×2, m) 1.15 (6H, s) 1.5˜2.15 (2H, m) 2.26 (1H, m) 3.3˜4.06 (5H, m) 7.80 (1H, d, J=14 Hz) 8.37 (1H, s)
EXAMPLE 14
1-Cyclopropyl-6,8-difluoro-1,4-dihydro-7-[3-(1-methyl-1-methylamino)ethyl-1-pyrrolidinyl]-4-oxoquinoline-3-carboxylic acid: ##STR40##
90 mg of compound M-1 and 60 mg of 3-(1-methyl-1-methylamino)ethylpyrrolidine (P-10-1) were added to 5 ml of dimethyl sulfoxide and the reaction was carried out at a bath temperature of 70° for 30 min. Then, the solvent was distilled off under reduced pressure and the residue was subjected to the column chromatography with 10 g of silica gel. After the development with a lower layer of chloroform/methanol/water (7:3:1), the product was recrystallized from ethanol to obtain 55 mg of the desired compound.
m.p. 216°-218° C. (Decomposition)
Elemental analysis calculated for C 21 H 25 F 2 N 3 O 3 . 1/2H 2 O Calculation: C 60.86;H 6.32; N 10.14 Found: C 60.65;H 5.99; N 10.07
NMR(NaOD)δ: 1.0˜1.2 (4H, m) 1.08 (6H, s) 2.24 (3H, s) 3.60 (1H, m) 7.63 (1H, d,d, J=14 Hz. and 2 Hz) 8.48 (1H, s)
EXAMPLE 15
7-[3-(1-Aminocyclopropyl)-1-pyrrolidinyl]-1-cyclopropyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid: ##STR41##
9 ml of an aqueous solution containing 130 mg (0.46 mmol) of the starting compound M-1 and at least two molar ratio, to the compound M-1, of 3-(1-aminocyclopropyl) pyrrolidine (P-18) was added to 20 ml of dimethyl sulfoxide and the mixture was stirred under heating at a bath temperature of 130° to 150° C. for 30 min. After the disappearance of the starting materials was confirmed, the solvent was distilled off under reduced pressure and the residue was subjected to column chromatography with 20 g of silica gel. After the development of the product with a lower layer of chloroform/water/methanol (8:3:1), the product was recrystallized from methanol/chloroform/ether to obtain 52 mg of the desired compound.
m.p. 227°˜230° C.
NMR (NaOD)δ: 0.92˜1.18 (4H×2, m) 1.5 & 2.1 (each 1H, m), 2.52 (1H, m) 3.1˜4.0 (2H×2, m) 3.4 (1H, m) 7.50 (1H, d, J=14 Hz) 8.44 (1H, s)
Elemental analysis calculated for C 20 H 21 F 2 N 3 O 3 . 3/2H 2 O Calculation: C 57.68; H 5.81; N 10.09 Found: C 57.31; H 5.66; N 10.39
EXAMPLE 16
7-[3-(1-aminocyclopropyl)-1-pyrrolidinyl]-1-ethyl-6,8-difluoro-1,4-dihydro-4-oxoquinoline-3-carboxylic acid: ##STR42##
30 mg of the desired carboxylic acid was obtained from mg of compound M-2 in a similar manner as described in Example 15.
m.p. 186°-197° C.
Elemental analysis calculated for C 19 H 21 N 3 F 2 O 3 . H 2 O Calculation: C 57.71; H 5.86; N 10.63 Found: C 57.90; H 5.81; N 10.49
NMR(NaOD)δ: 0.92˜1.18 (4H, m) 1.43 (3H, t, J=7 Hz) 1.60 and 2.15 (2H, m) 2.60 (1H, m) 3.4˜3.9 (4H, m) 4.4 (2H, m) 7.75 (1H, d, J=14 Hz) 8.33 (1H, s)
EXAMPLE 17
1-Cyclopropyl-6,8-difluoro-1,4-dihydro-7-[3-(2S)-pyrrolidinyl)-1-pyrrolidinyl]-4-oxoquinoline-3-carboxylic acid:
508 mg of the Boc compound (P-23), 10 ml of trifluoroacetic acid (TFA) and 1 ml of anisole were mixed together and the mixture was stirred under cooling with ice for 1 h. TFA was distilled off under reduced pressure and then ether was added to the residue. After decantation, 20 ml of tetrahydrofuran was added to the obtained precipitate, i.e., 3-(2S)-pyrrolidinylpyrrolidin-2-one trifluoroacetate (P-24-1). 500 mg of lithium aluminum hydride was added thereto under cooling with ice and the mixture was heated under reflux for 2 h. 2 ml of water was added dropwise thereto under cooling with ice and insoluble matter was filtered off. The filtrate was concentrated to dryness to obtain a colorless oil, i.e., 3-(2S)-pyrrolidinylpyrrolidine (P-24-2). 1 ml of dimethyl sulfoxide and 100 mg of 6,7,8-trifluorocarboxylic acid (M-1) were added to the crude compound (P-24-2) and the mixture was maintained at 120° C. under stirring for 10 min. The solvent was distilled off under reduced pressure. Ethanol was added to the residue and 50 mg of thus formed, yellow crystals were collected by filtration, dissolved in ethanol and aqueous ammonia, treated with active carbon and recrystallized to obtain 18 mg of the desired compound in the form of colorless crystals.
m.p. 284°-287° C.
Elemental analysis calculated for C 21 H 23 N 3 O 2 F 2 . 1/2H 2 O Calculation: C 61.16; H 5.87; N 10.19 Found: C 61.37; H 5.63; N 10.17
NMR (NaOD)δ: 0.90˜1.40 (4H, m) 2.6˜3.0 (1H, m) 7.54 (1H, d, J=14 Hz) 8.46 (1H, s) Others 1.40-2.10 (6H, m), 3.30˜3.90 (6H, m)
EXAMPLE 18
7-[3-(1-Aminoethyl)-1-pyrrolidinyl]-1-1-cyclopropyl-6-fluoro-1,4-dihydro-4-oxo-1,8-naphthylidine-3-carboxylic acid (isomer P-25)
180 mg of isomer P-25 was obtained by the same reaction as set forth in Example 1 except that 400 mg of compound M-3 and 420 mg of amine compound (P-3A) were used.
m.p. 225°-226° C.
Elemental analysis calculated for C 18 H 21 FN 4 O 3 . 3/2H 2 O Calculation: C 55,81; H 6.24; N 14.46 Found: C 56.05; H 6.26; N 14.15
NMR (NaOD) δ (ppm): 0.8-1.2 (4H, m) 1.05 (3H, d, J=6.3 Hz) 7.63 (1H, d, J=13.5 Hz) 8.29 (1H, S)
EXAMPLE 19
Isomer P-26 was obtained by the same procedure as set forth in Example 18.
m.p.: 252°-255° C.
Elemental analysis calculated for C 18 H 21 FN 4 O 3 . H 2 O Calculation: C 57.82; H 6.07; N 14.98 Found: C 57.93; H 6.32; N 14.67
NMR (NaOD) δ (ppm): 0.8-1.2 (4H, m), 1.09 (3H, d, J=6.3 Hz) 7.62 (1H, d, J=13.5 Hz), 8.28 (1H, s)
EXAMPLE 20
Isomer (P-27): 1-ethyl-6,8-difluoro-7-[3-(1-aminopropyl)-1-pyrrolidinyl]-1,4-dihydro-4-oxoquinoline-3-carboxylic acid ##STR43##
200 mg of compound M-2 was suspended in a mixed solution of 20 ml of acetonitrile and 160 mg of triethylamine, after which 190 mg of pyrrolidine compound 18-B was added thereto and the mixture was refluxed for 3 hours. After the solvent was distilled off, water was added to the residue and the insoluble matter was collected by filtration, washed with water, acetonitrile and ether in that order, and dried. The thus obtained colorless crystal was added to a mixed solution of 5 ml of trifluoroacetic acid and 0.5 ml of anisole and the solution was stirred at room temperature for 30 minutes.
After concentration, water was added to the resulting residue. The mixture was washed with chloroform and adjusted to pH 10-11 with 1N sodium hydroxide. After adjusting to pH 7.06 with 10% citric acid, the solution was extracted three times with chloroform. The extract was concentrated to about 3 ml and ether was added thereto. As a result, 127 mg (45%) of isomer (P-27) was obtained in the form of colorless crystal.
m.p.: 211°-215°
Elemental analysis calculated for C 19 H 23 F 2 N 3 O 3 . 1/2H 2 O Calculation: C 58.75, H 6.23, N 10.82 Found: C 58.37, H 5.87, N 10.68
NMR (NaOD) δ ppm: 0.94 (3H, t, J=6 Hz) 1.43 (3H, t, H=6 Hz), 1.2-1.9 (3H, m) 1.9-2.3 (2H, m) 2.5-2.7 (1H, m), 3.4-3.9 (4H, m) 4.2-4.5 (2H, m) 7.70 (1H, dd, J=15 Hz), 8.32 (1H, s)
EXAMPLE 21
Isomer (P-28): 1-Cyclopropyl-6,8-difluoro-7-[3-(1-aminopropyl) -1-pyrrolidinyl]-1,4-dihydro-4-oxoquinoline-3-carboxylic acid ##STR44##
160 mg of isomer (P-28) was obtained by a similar procedure as set forth in Example 20, except that 250 mg of compound M-1 instead of compound M-2 was used and 150 mg of triethyl amine and 250 mg of pyrrolidine compound (18-B) were used.
m.p.: 205°-208°
Elemental analysis calculated for C 20 H 23 F 2 N 3 O 3 . 1/4H 2 O Calculation: C 60.67, H 5.98, N 10.61 Found: C 60.34, H 5.75, N 10.58
NMR (NaOD) δ ppm: 0.94 (3H, t, J=6 Hz), 1.0-1.25 (4H, m) 1.25-1.8 (3H, m) 1.9-2.3 (2H, m) 2.55-2.7 (1H, m), 3.3-4.1 (5H, m) 7.64 (1H, dd, J=15 Hz) 8.48 (1H, s)
EXAMPLE 22
Isomer P-29 was obtained by a similar procedure as set forth in Example 19. ##STR45##
m.p. 166°-168° C.
Elemental analysis calculated for C 20 H 23 F 2 N 3 O 3 . 3/2H 2 O Calculation: C 57.41, H 6.26, N 10.04 Found: C 57.56, H 6.06, N 10.10
NMR (NaOD) δ ppm: 0.93 (3H, t, J=6 Hz) 1.0-1.2 (4H, m) 1.2-1.4 (1H, m), 1.4-1.7 (2H, m) 1.9-2.3 (2H, m) 1.9-2.65 (1H, m), 3.3-4.0 (5H, m) 7.60 (1H, dd, J=15 Hz, 2 Hz), 8.46 (1H, s)
The antimicrobial activities of the compounds of the present invention were determined according to a standard process designated by the Japan Society of Chemotherapy and the minimum growth inhibitory concentrations (MIC) (μg/ml) of the compounds were determined. The results are summarized in the following table. Comparative compounds used were as follows:
(A): Compound in Example 44 in J.P. No. 214773/1985; 1-cyclopropyl-6,8-difluoro-(3-ethylaminomethyl-1-pyrolidinyl)-1,4-dihydro-4-oxoquinoline-3-carboxylic acid.
(B): Compound in Example 46 in J.P. No. 214773/1985; 1-cyclopropyl-6,8-difluoro-(3-methylaminomethyl-1-pyrolidinyl)-1,4-dihydro-4-oxoquinoline-3-carboxylic acid
(C): 1-Ethyl-7-[3-(ethylamino)methyl]-1-pyrolidinyl-6,8-difluoro-1,4-dihydro-4-oxo-3-quinolinecarboxylic acid in Example 11 in J.P. No. 67269/1984.
__________________________________________________________________________ Compound (1-A-2) Compound (1-B-2) A B C of Example 1 of Example 2__________________________________________________________________________E. coli, NIHJ ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Sh. flexneri, 2a5503 ≦0.05 0.10 ≦0.05 ≦0.05 ≦0.05Pr. vulgaris, 3167 0.10 ≦0.05 0.20 0.10 ≦0.05Pr. mirabilis, IF03849 ≦0.05 ≦0.05 0.39 0.10 ≦0.05Ser. marcescens, 13001 0.10 ≦0.05 0.20 0.20 ≦0.05Ps. aeruginosa, 2063 0.39 0.20 0.78 0.78 0.20Ps. aeruginosa, 2128 0.20 0.20 0.39 0.20 ≦0.05Pa. cepacia, IID1340 0.78 1.56 1.56 0.78 0.39Ps. maltophilia, IID1275 0.39 0.20 0.78 0.20 0.10S. aureus, 209P ≦0.05 ≦0.05 0.10 0.10 ≦0.05S. epidermidis, 56500 ≦0.05 ≦0.05 0.39 0.10 ≦0.05Str. pyogenes, G-36 0.10 0.10 0.78 0.10 ≦0.05Str. faecalis, ATCC 19433 0.10 0.10 0.39 0.10 ≦0.05__________________________________________________________________________ Compound of Compound of Compound of Compound of Compound of Example 3 Example 4 Example 5 Example 6 Example 7__________________________________________________________________________E. coli, NIHJ ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Sh. flexneri, 2a5503 ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Pr. vulgaris, 3167 0.20 ≦0.05 ≦0.05 0.10 ≦0.05Pr. mirabilis, IF03849 0.20 0.20 0.39 0.20 ≦0.05Ser. marcescens, 13001 0.20 0.10 0.20 0.20 0.10Ps. aeruginosa, 2063 0.39 0.20 0.78 0.39 0.20Ps. aeruginosa, 2128 0.20 0.10 0.20 0.20 0.10Pa. cepacia, IID1340 1.56 0.78 1.56 0.78 0.78Ps. maltophilia, IID1275 0.78 0.39 0.39 0.20 0.20S. aureus, 209P ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05S. epidermidis, 56500 0.20 ≦0.05 ≦0.05 0.10 ≦0.05Str. pyogenes, G-36 0.39 ≦0.05 0.39 0.20 ≦0.05Str. faecalis, ATCC 19433 0.39 ≦0.05 0.20 0.20 ≦0.05__________________________________________________________________________ Compound of Compound of Compound of Compound of Compound of Example 8 Example 9 Example 10 Example 11 Example 12__________________________________________________________________________E. coli, NIHJ ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Sh. flexneri, 2a5503 ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Pr. vulgaris, 3167 0.10 ≦0.05 0.10 ≦0.05 0.20Pr. mirabilis, IF03849 0.39 0.10 0.20 0.10 0.39Ser. marcescens, 13001 0.39 ≦0.05 0.20 0.10 0.39Ps. aeruginosa, 2063 1.56 0.78 1.56 0.78 1.56Ps. aeruginosa, 2128 0.39 0.20 0.39 0.20 0.39Pa. cepacia, IID1340 1.56 0.39 1.56 0.78 1.56Ps. maltophilia, IID1275 0.78 0.10 0.39 0.10 0.39S. aureus, 209P 0.10 ≦0.05 ≦0.05 ≦0.05 ≦0.05S. epidermidis, 56500 0.20 ≦0.05 0.10 ≦0.05 0.10Str. pyogenes, G-36 0.78 ≦0.05 ≦0.05 ≦0.05 0.10Str. faecalis, ATCC 19433 0.39 0.10 ≦0.05 ≦0.05 0.10__________________________________________________________________________ Compound of Compound of Compound of Compound of Compound of Example 13 Example 14 Example 15 Example 16 Example 17__________________________________________________________________________E. coli, NIHJ ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Sh. flexneri, 2a5503 ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Pr. vulgaris, 3167 0.10 0.20 0.10 0.20 0.10Pr. mirabilis, IF03849 0.39 0.20 0.20 0.39 0.20Ser. marcescens, 13001 0.20 0.39 0.20 0.39 0.10Ps. aeruginosa, 2063 0.39 3.13 0.39 1.56 0.39Ps. aeruginosa, 2128 0.20 0.39 0.20 0.39 0.20Pa. cepacia, IID1340 0.78 1.56 0.39 0.78 0.78Ps. maltophilia, IID1275 0.20 0.39 0.20 0.39 0.39S. aureus, 209P ≦0.05 0.20 ≦0.05 ≦0.05 ≦0.05S. epidermidis, 56500 ≦0.05 0.20 ≦0.05 0.20 0.10Str. pyogenes, G-36 0.10 0.10 ≦0.05 0.20 0.10Str. faecalis, ATCC 19433 0.20 0.10 0.20 0.39 0.10__________________________________________________________________________ Compound of Compound of Compound of Compound of Compound of Example 18 Example 19 Example 20 Example 21 Example 22__________________________________________________________________________E. coli, NIHJ ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Sh. flexneri, 2a5503 ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Pr. vulgaris, 3167 0.10 ≦0.05 ≦0.05 ≦0.05 ≦0.05Pr. mirabilis, IF03849 0.20 0.10 0.10 0.10 0.10Ser. marcescens, 13001 0.20 ≦0.05 0.10 ≦0.05 0.10Ps. aeruginosa, 2063 0.39 0.20 0.39 0.20 0.39Ps. aeruginosa, 2128 0.20 ≦0.05 0.20 0.10 0.20Pa. cepacia, IID1340 0.39 0.39 0.39 0.20 0.20Ps. maltophilia, IID1275 0.20 0.20 0.20 ≦0.05 0.20S. aureus, 209P ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05S. epidermidis, 56500 ≦0.05 ≦0.05 ≦0.05 ≦0.05 ≦0.05Str. pyogenes, G-36 0.39 0.20 ≦0.05 ≦0.05 0.20Str. faecalis, ATCC 19433 0.20 0.10 ≦0.05 ≦0.05 0.20__________________________________________________________________________
WATER-SOLUBILITY AND ACUTE TOXICITY
The water-solubility and acute toxicity of the compounds of the present invention and the comparative compounds, were measured. The results obtained are shown hereunder. The water-solubility was measured by the following method.
(i) Preparation of standard solution
About 400 μg of the sample to be measured was accurately weighed (the weight was defined as W μg), and 01.N NaOH solution was added thereto to bring the whole volume to 50 ml. The UV absorbance of a given amount of the solution was measured and the measured absorbance was defined as A 1 .
(ii) Preparation of sample to be measured
Distilled water was added to the sample to be measured (fine powder) in such amount that the sample was not completely dissolved but suspended, and then the suspension was vigorously agitated at room temperature (between 23° and 26° C.) for 30 minutes. Insoluble matter of the sample was removed therefrom by filtration, after which 3 ml sample of the filtrate (satulated aqueous solution of the sample) was taken. 3 ml of 0.2N NaOH solution was added to the filtrate sample to bring the total volume to 6 ml (i.e. the filtrate was diluted to 50% concentration.) To 1 ml of the resulting solution, 0.1N NaOH solution was further added to bring the total volume to 25 ml (2% concentration). In this connection, degree of dilution was occasionally changed, depending on degree of UV absorbance. The UV absorbance of the given amount of the solution was measured and the resulting absorbance was defined to as A 2 . Where the number of dilution is N, water-solubility (s) is obtained from the following equation: ##EQU1##
__________________________________________________________________________ Compound of the present invention Compound of Compound of Compound of Comparative compound example example example Compound A Compound B Compound C__________________________________________________________________________Water solubility 710 200 2000 40 80 400(μg/ml)Acute toxicity 1/5 0/5 1/5 3/5 2/5 0/5to mouse*__________________________________________________________________________ *200 mg/kg; i.v, (deaths/total number) As is obvious from the above results, the anti-microbial agents of the present invention have high water-solubility as well as low toxicity.
Since not only N-cyclopropyl derivative (example 2, isomer B) but also N 1 -ethyl derivative (example 4), which are 3-(2-aminoethyl) pyrrolidine derivatives, show extremely strong anti-microbial activity against Gram-negative and Gram-positive microorganisms, it can be predicted that analog thereof has naturally strong anti-microbial activity and the analog is also expected to be useful as a pharmaceutical compound.
ABSORPTION AFTER ORAL ADMINISTRATION
The compounds of the present invention and the comparative compound were orally given to rats (one group: 5 rats) at a dose of 20 mg/kg to measure the oral absorption of the compounds. The concentration of the compound in the blood of the rat was measured at 15 minutes, 30 minutes, and 1, 2, 3, 4, and 6 hours after administration.
Serum half lives (T1/2) were calculated as 0.693/K e1 , where K e1 is the elimination rate constant determined by linear regression analysis of the natural logarithm of serum concentration-time data. The area under the serum concentration-versus time curve from zero to 6 h (AUC 0-6 H) was calculated by the trapezoidal method. The results obtained are as follows:
______________________________________ Cmax AUC0-6H (μg/ml.lH) T1/2 (min.) (μg.h/ml)______________________________________Compound of the presentinventionCompound of 2.21 120.6 6.31Example 7Compound of 2.10 135.9 6.43Example 11Compound of 2.14 144.6 7.95Example 13Comparative compound B 1.37 93.0 3.61______________________________________
As is obvious from the above data, the compounds of the present invention are superior to the comparative example in terms of oral absorption.
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This invention provides novel pyridonecarboxylic acid derivatives having a quite high antimicrobial activity. The derivatives have the following formula: ##STR1## wherein R 1 , R 2 and R 3 represent each a hydrogen or C 1-C 6 alkyl group; R 4 represents an ethyl, 2-fluoroethyl, vinyl, isopropyl, isopropenyl or cyclopropyl group; and X represents CH, C--F, C--Cl or N
characterized in that R 2 and R 3 are not hydrogen at the same time.
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RIGHT OF WAY GRADER
[0001] This is a CIP of Ser. No. 09/304,647, filed May 4, 1999, now pending.
BACKGROUND OF THE INVENTION
[0002] This invention relates, in general, to graders, and, in particular, to right of way graders that can be used in conjunction with railroad cars.
[0003] Description of the Prior Art
[0004] In the prior art various types of graders have been proposed. For example, U.S. Pat. No. 3,257,744 to Bohler discloses a blade attached to a railway car and which is movable toward and away from the side of the car by means of a line on a pulley system.
[0005] U.S. Pat. No. 3,445,944 to Speno discloses a side plow which has a blade attached to a railway car and is movable perpendicular to the longitudinal axis of the car.
[0006] U.S. Pat. No. 3,726,347 to Hyman discloses a grader with a wheel that engages a guide member to move the grader perpendicular to the longitudinal axis of the car.
[0007] U.S. Pat. No. 3,815,268 to Yard discloses a ballast box which is attached to a railway car and is moved toward and away from the car by a line on a pulley system and hydraulic cylinders.
[0008] U.S. Pat. No. 4,196,532 to Muller discloses a device for leveling a railroad right of way by means of a blade which is moved by hydraulic cylinders.
[0009] U.S. Pat. No. 5,435,081 to Hannes discloses a grader attached to a railway car by means of a ram which cab be vertically adjusted with respect to the railway car.
SUMMARY OF THE INVENTION
[0010] The present invention is directed to a right of way grader that is attached to a vehicle such as, but not limited to a Kershaw ballast regulator wing. The grader will be attached to the wing so that it can be moved toward and away from the wing, and in addition, the blade attached to the grader can be rotated. The grader will allow the device to extend its reach to an area outside the normal ballast area of a railroad track and to clear away brush and small trees which might impinge upon the ballast area.
[0011] It is an object of the present invention to provide a new and improved grader which can be attached to a railway vehicle to clear brush and small trees from the right of way.
[0012] It is an object of the present invention to provide a new and improved grader which can be adjusted with respect to the railway vehicle, and in addition, it can be moved up and down and can be rotated from side to side.
[0013] It is an object of the present invention to provide a new and improved grader which clears right of way of brush and other debris for a safer work or walking area.
[0014] It is an object of the present invention to provide a new and improved grader which recovers ballast that is too far away for a conventional regulator wing, thereby saving time and money which would be expended in unloading and applying new ballast.
[0015] It is an object of the present invention to provide a new and improved grader which would be useful in clearing snow from the right of way.
[0016] These and other objects and advantages of the present invention will be fully apparent from the following description, when taken in connection with the annexed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a perspective view of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Referring now to the drawings in greater detail, the Figure shows the present invention 1 which can be attached to any type of railway vehicle. The grader of the present invention has a base 2 , 3 which can be attached to a railway vehicle in any conventional manner. The base 2 , 3 has a pair of side flanges 4 which extend from the base 2 , 3 at an angle, and a support member 30 is attached to the ends of the side flanges 4 . The support member 30 has an upper rail 5 and a lower rail 6 . A boom support 18 is designed to fit between the upper and lower rails 5 , 6 so it can slide from one side of the support member 30 toward the other side of the support member 30 .
[0019] The boom support 30 receives an extension arm 20 which is pivotally secured to the boom support 30 by any conventional means such as, but not limited to, a pivot pin 17 , which can be secured through aligned apertures in the boom support 30 and the extension arm 20 . The apertures that receive the pin 17 are not seen in the Figure since they are hidden by other details of the boom support 30 and the extension arm 20 . However, this type of pivoting structure is well known to persons of ordinary skill in the art.
[0020] A first hydraulic cylinder 16 is attached at one end to the boom support 18 , by any conventional means, and the hydraulic cylinder 16 is attached at another end to the extension arm 20 by a bracket 19 . The bracket 19 can be secured to the extension arm 20 by any conventional means. Because of the way the hydraulic cylinder is attached to the boom support 18 and the extension arm 20 , when the conventional hydraulic cylinder arm 31 is extended, it will cause the extension arm 20 to pivot downwardly about the longitudinal axis of the pivot pin 17 . When the hydraulic cylinder arm 31 is retracted, it will cause the extension arm 20 to pivot upwardly about the longitudinal axis of the pivot pin 17 . In this manner, i.e. by extending and retracting the hydraulic cylinder arm 31 , the operator of the present invention 1 can control how close to the ground the blade 26 will be positioned.
[0021] It should be noted that all of the hydraulic cylinders ( 16 , 21 , 24 and 15 ) are conventional cylinders that are controlled by hydraulic oil circuits and valves mounted in the railway vehicle (not shown). In the usual manner with such cylinders, hydraulic oil is supplied to the cylinders from either a separate source or from the hydraulic system of the railway vehicle. The oil is supplied to the cylinders ( 16 , 21 , 24 and 15 ) by means of separate oil lines which are attached to the individual cylinders in any conventional manner. The oil lines are not shown in the Figure for reasons of clarity, however, since the oil lines are conventional and attached in a conventional manner any person of ordinary skill in the art would instantly know how to attach and use the oil lines and cylinders. Therefore, such a showing is unnecessary and if shown would obscure more important details of the present invention.
[0022] The position of the extension arm 20 with respect to the support member 30 is also controlled by a second hydraulic cylinder 15 . The second hydraulic cylinder 15 is connected to a support member side flange 12 by means of a bracket 14 , and the hydraulic cylinder arm 32 of the second hydraulic cylinder is secured to the extension arm 20 in any conventional manner. Therefore, when the extension arm 32 is retracted into the cylinder 15 , the extension arm 20 will move toward the side flange 12 . When the extension arm 32 is extended out of the cylinder 15 , the extension arm 20 will move away from the side flange 12 . In this manner the operator can control the position of the blade 26 with respect to the support member 30 . It should be noted that the second hydraulic extension arm 32 is shown in the Figure to be attached to the extension arm, however, it could instead be attached to the boom support 18 which would result in the same type of operator control.
[0023] Also, it should be noted that the length of the second hydraulic cylinder 15 and arm 32 can be varied to provide more or less movement of the extension arm 20 with respect to the support member 30 . Since the second hydraulic cylinder 15 and arm 32 are mounted at an angle to the extension arm 20 , they will hold the extension arm 20 and the boom support 18 against the support member 30 due to the force vectors created by the second hydraulic cylinder 15 and arm 32 . Since force vectors are a well known engineering concept no further description is necessary or will be given.
[0024] In addition, the support member side flange 12 has a chain 13 attached thereto in any conventional manner. Only a portion of the chain 13 is shown in the Figure, for purposes of clarity, however, it should be noted that the length of the chain would be selected so it can be wrapped around the extension arm 20 and secured thereto in any conventional manner to hold the extension arm while the railway vehicle (not shown) is being moved from one job site to another. This will lessen any strain on the hydraulic system which would normally be used to hold the extension arm in a selected position.
[0025] As shown in the Figure, the lower portion of the support member 30 has a pair of lower side flanges 7 which are pivotally attached to the support member 30 by hinges 33 . The lower side flanges 7 are connected together by a pair of telescoping rods 9 , 10 which are attached to the lower side flanges 7 by brackets 8 . The side flanges 7 can be adjusted by adjusting the length of the telescoping rods 9 , 10 to engage and collect ballast.
[0026] A blade support bracket 22 is attached to the end of the arm 20 by a pivot pin 34 . A third hydraulic cylinder 21 is secured to the extension arm 20 by means of a bracket 19 , and a third hydraulic extension arm 35 is secured to the blade support bracket 22 by a bracket 19 . When the third hydraulic extension arm 35 is extended from the third hydraulic cylinder, this will cause the blade support bracket 22 to pivot about the pivot pin 34 .
[0027] The blade support bracket 22 receives a blade support column 23 . The column 23 is attached to the blade support 25 by any conventional means. The column 23 is inserted through apertures in the bottom and top of the blade support bracket 22 and a pin 36 is passed through apertures in the blade support column 23 to prevent the blade support column from passing back through the apertures in the blade support bracket 22 .
[0028] A fourth hydraulic cylinder 24 is attached at one end to the blade support bracket 22 by any conventional means. A fourth hydraulic extension arm 37 is connected to the blade support 25 by means of a bracket 19 . The blade support 25 has side wings 29 attached at opposite ends of the blade support. The side wings 29 are for creating a box blade and can be removable by any conventional means. Side wings 29 make it possible to evenly distribute fine materials, ballast, mounds of dirt, etc.
[0029] When the fourth hydraulic extension arm 37 is retracted into the fourth hydraulic cylinder 24 , this will cause the blade support 25 to pivot about the vertical axis of the blade support column 23 in a counterclockwise direction. When the fourth hydraulic extension arm 37 is extended from the fourth hydraulic cylinder 24 , this will cause the blade support 25 to pivot about the vertical axis of the blade support column 23 in a clockwise direction. This will give the operator control over the angle of the blade 26 with respect to the extension arm 20 .
[0030] The blade 26 is attached to the blade support 25 by means of threaded fasteners 27 . The blade 26 is double sided so when one side (the side closest to the ground in the Figure) becomes dull, the blade can be removed from the blade support 25 , by removing the threaded fasteners 27 , flipped over and reassembled on the blade support 25 by reinserting the threaded fasteners 27 . This will allow the blade to last longer before it has to be resharpened, thereby prolonging the useful life of the blade. In addition, teeth 28 can be attached to the blade support 25 in order to increase the cutting or scraping power of the blade 26 . The teeth 28 are detachably attached to the blade and can be attached in the down position (the position shown in the Figure) or the teeth can be reversed and put in an up position, i.e. a position where the teeth will not be used, so they will be out of the way when doing normal grading.
[0031] Although the Right of Way Grader and the method of using the same according to the present invention 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.
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A right of way grader that is attached to a Kershaw ballast regulator wing. The grader will be attached to the wing so that it can be moved toward and away from the wing, and in addition, it can be moved up and down and can be rotated from side to side. The grader will allow the device to extend its reach to an area outside the normal ballast area of a railroad track and to clear away brush and small trees which might impinge upon the ballast area. The grader reclaims ballast, drainage, and creates an improved walkway, thus providing a safe working area.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to a polarity switching circuit. More specifically, the present invention relates to a voltage polarity switching circuit, capable of selectively producing positive and negative output voltages whose absolute values are equal to each other, which circuit is suited for fabrication as a semiconductor integrated circuit.
(2) Description of the Prior Art
Positive and negative reference voltages or reference currents having absolute values which are equal to each other are required in a so-called A/D converter for converting analog electric signals of positive and negative polarities into digital codes, and such reference voltages or currents are required in a so-called D/A converter for making the reverse conversion. In order to fabricate the A/D or D/A converter in a small size and with a high accuracy by means of a semiconductor or monolithic IC, however, it is not advantageous from the aspects of both fabrication technique and fabrication economy to incorporate both positive and negative reference voltage sources in the converter. Accordingly, it is usually the practice to incorporate only either the positive or the negative reference voltage source and to combine it with a voltage polarity switching circuit for selectively changing over the polarity of the input voltage, which is the above-mentioned reference source, so as to obtain reference voltages of both positive and negative polarities.
However, since the conventional circuit construction of this kind is affected by the stray capacitance occurring in the integrated circuit, the absolute values of the two positive and negative voltages cannot be made equal to each other, as will be explained later in further detail. To approximate these two voltage values as closely as possible, the charging capacitor must have large electrostatic capacitance and a large area must be secured on a semiconductor substrate to form such a capacitor.
SUMMARY OF THE INVENTION
The present invention is therefore directed to provision of a voltage polarity switching circuit which eliminates the above-mentioned drawback of the conventional circuit, is capable of making the absolute values of the output voltages in both positive and negative directions equal to each other is capable of reducing the capacity of the required charging capacitor, and is thus suited for fabrication as an integrated circuit (IC).
To accomplish the above-mentioned object, the voltage polarity switching circuit in accordance with the present invention comprises a first capacitor, an input terminal for receiving an input voltage to charge said first capacitor, an output terminal for delivering an output voltage, a first switch interposed between one end of said first capacitor and said input terminal, a second switch interposed between the other end of said first capacitor and ground, a third switch interposed between one end of said first capacitor and said output terminal, a fourth switch interposed between one end of said first capacitor and ground, a fifth switch interposed between the other end of said first capacitor and said output terminal, a second capacitor having its one end connected to said output terminal and a sixth switch interposed between the other end of said second capacitor and ground, wherein after said first capacitor is charged by turning on said first, second, fifth and sixth switches with the other switches turned off, said second, third and sixth switches are turned on with the other switches turned off to produce an output voltage of a first polarity at said output terminal, and said fourth and fifth switches are turned on with the other switches turned off to produce an output voltage of a second polarity at said output terminal.
These and other objects and features of the present invention will be apparent from the following detailed description when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prior art block diagram showing an example of an A/D converter as an application example of a voltage polarity switching circuit;
FIG. 2 is a circuit diagram of the heretofore known voltage polarity switching circuit; and
FIG. 3 is a circuit diagram of an example of the voltage polarity switching circuit in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Prior to the explanation of the present invention, an apparatus making practical application of a voltage polarity switching circuit and the conventional circuit construction thereof will be explained with reference to FIGS. 1 and 2.
FIG. 1 shows diagrammatically the construction of a PCM encoder for converting telephone voice signals into digital codes, as an example of the apparatus which makes practical application of the polarity switching circuit.
In the drawing, analog input signals V IN to be encoded in digital code (voice signals in this case) are applied to a voltage comparator 2 through a terminal 1 and are compared with an output voltage from a local D/A converter 3. The result of this comparison is applied to a logic circuit 4. Reference numeral 6 identifies a temperature-stable voltage reference source consisting of a bandgap reference voltage source utilizing the temperature characteristic of the current density at the PN junction of a diode, for example, and reference numeral 7 identifies a polarity switching circuit which changes over the polarity of the output voltage E of the above-mentioned temperature-stable voltage reference source, suitably amplifies the output voltage E and supplies the local D/A converter with positive and negative reference voltages V REF having a value which is in conformity with the maximum value of the analog input signals V IN .
The logic circuit 4 sequentially receives the output signals of the above-mentioned comparator 2 in synchronism with clock pulses provided from a terminal 5 and at the same time, produces output signals T 1 , T 2 , thereby controlling the polarity switching circuit 7 and the local D/A converter 3. For example, while the output voltage of the local D/A converter 3 is made zero at first, the logic circuit receives the output signal of the voltage comparator 2 to determine the polarity of the analog input signal V IN and produces a control signal T 1 in accordance with the result of that determination, thereby to bring the polarity of the output voltage V REF from the polarity switching circuit 7 into conformity with the polarity of the analog input signal V IN . Thereafter, the logic circuit 4 produces the control signal T 2 while referring to the output of the voltage comparator 2 so as to sequentially change the network structure consisting of capacitors or resistance elements forming the local D/A converter and to produce at a terminal 8 a digital value corresponding to the state of the network structure as an A/D-converted value of the above-mentioned analog input signal V IN when the two input voltages of the voltage comparator 2 balance each other.
As a reference voltage supply circuit including the above-mentioned voltage polarity switching circuit 7, there is known a circuit having the circuit construction of FIG. 2 such as disclosed in the Mar. 1, 1979, issue of the magazine "Electronics," at p. 108. This circuit consists of a reference voltage source 6, a charging capacitor C o , six switching elements S 1 -S 6 each consisting of an MOS transistor, for example, and an amplifier (voltage gain G) 10 with high input impedance. When each switching element is opened or closed under the control of an external control signal (such as the output T 1 of the logic circuit of FIG. 1), the circuit operates in three modes, i.e. the charging mode I of the capacitor C o , the non-inverting voltage output mode II and the inverting voltage output mode III. The relationships between these three operation modes and the state of the switches S 1 -S 6 are tabulated in Table 1.
TABLE 1______________________________________ ModeSwitch I II III______________________________________S.sub.1 ON OFF OFFS.sub.2 ON OFF OFFS.sub.3 OFF ON OFFS.sub.4 OFF OFF ONS.sub.5 ON OFF ONS.sub.6 OFF ON OFF______________________________________
When the above-mentioned conventional circuit is fabricated, as an integrated circuit (IC), however, stray capacitance occurs between the respective ends of the capacitor C o and ground and between each node of the amplifier input terminal 11 and ground, as represented by C 1 , C 2 and C 3 in FIG. 2. The stray capacitance causes a difference in the absolute values of the output voltages between the non-inverting voltage output mode II and the inverting voltage output mode III. When this circuit is adapted to an A/D or D/A converter, such as a PCM encoder or a PCM decoder, therefore, it causes the problem of second harmonic distortion in the signal conversion characteristics.
Namely, when the circuit is operated in the charging moe I, at first with the switches S 1 , S 2 and S 5 kept on and the others kept off, not only the capacitor C o but also the stray capacitor C 1 are charged by the output voltage E of the voltage source 6. Since the stray capacitors C 2 and C 3 are grounded via the switches S 2 and S 5 at this time, the terminal 11 goes to ground potential and the output voltage V REF from the amplifier 10 becomes zero Volt.
Next, when the non-inverting voltage output mode II is selected with the switches S 3 and S 6 on and the others off, a part of the charges of capacitors C o and C 1 moves to the stray capacitor C 3 so that the output voltage V REF (+) of the amplifier 10 is represented by the following equation (1); ##EQU1##
On the other hand, when the inverting voltage output mode III is directly selected from the above-mentioned charging mode I, the switches S 4 and S 5 are turned on with the others off whereby the charge of the capacitor C o moves to the stray capacitors C 2 and C 3 and the charge of the stray capacitor C 1 is discharged to ground. Accordingly, the output voltage V REF (-) at this time has a different absolute value from the non-inverting output voltage V REF (+) as represented by the following equation (2); ##EQU2##
If the output of the above-mentioned circuit is as such applied to the reference voltage of the A/D (or D/A) converter, therefore, a second harmonic distortion occurs in the conversion characteristics. The distortion ratio x in this instance is given by the following equation according to the prior art reference (IEEE Trans. on Circuit and Systems, Vol. CAS-25, No. 7, July 1978, p. 427); ##EQU3##
If it is desired to keep the second harmonic distortion ratio x not smaller than 55 dB, about the value required by a voice-PCM encoder, it is necessary that α≦0.008. In the case of the conventional circuit, α is given as follows from the equations (1), (2) and (4) ##EQU4## If C 1 =C 2 =0.5 PF and C 3 =1.5 PF by way of example, the charging capacitor C o must satisfy the relation C o ≧62.5 PF in order to realize the above-mentioned distortion ratio. The capacitor having such a value requires an extremely large chip area when the voltage inversion amplification circuit is constructed by means of a semiconductor IC or monolithic IC, and this markedly deteriorates the economy of the circuit device.
As shown in FIG. 3, the polarity switching circuit in accordance with the present invention, which solves the above-mentioned problem encountered in the prior art, includes a charging capacitor C o , six switching elements S 1 -S 6 and a capacitor C 4 for compensating for the stray capacitors. This circuit is characterized in that one end of the above-mentioned capacitor C 4 is connected to an output terminal 11 (input terminal of an amplification circuit 10) with the other grounded via the switch S 6 . In this arrangement, the charging mode I, the non-inverting voltage output mode II and the inverting voltage output mode III are carried out in accordance with the opening and closing actions of the switches tabulated in Table 2.
TABLE 2______________________________________ ModeSwitch I II III______________________________________S.sub.1 ON OFF OFFS.sub.2 ON ON OFFS.sub.3 OFF ON OFFS.sub.4 OFF OFF ONS.sub.5 ON OFF ONS.sub.6 ON ON OFF______________________________________
In the circuit shown in FIG. 3, C 1 -C 3 represent the stray capacitors added to each node in the same way as in the circuit of FIG. 2.
Next, the operation of the circuit of the present invention will be explained. Initially, in the charging mode I, the switches S 1 , S 2 , S 5 and S 6 are turned on with the others turned off and the output voltage E of the voltage source 6 charges the capacitor C o . Thus, the stray capacity C 1 . At this time, the charges on capacitors C 2 , C 3 and C 4 are all discharged and the output voltage at the terminals 11 and 12 is zero volt.
In the non-inverting voltage output mode II, the switches S 2 , S 3 and S 6 are turned on with the others being turned off. At his time, since the charges on capacitors C 1 and C o move to C 3 and C 4 , the output voltage V REF (+) from the terminal 12 becomes a value expressed by the following equation (5); ##EQU5##
In the inverting voltage output mode III, on the other hand, the switches S 4 and S 5 are turned on with the others off and the charge of the capacitor C o moves to the capacitors C 2 and C 3 so that the output V REF (-) from the terminal 12 is given by; ##EQU6##
When the equations (5) and (6) are substituted for the equation (4), the value α in the circuit of the present invention is expressed by the following equation (7), assuming C o >C 1 ˜C 4 ; ##EQU7##
The second item of the equation (7) always has a positive value with respect to optional values of C o , C 1 , C 3 and C 4 . But in the first item, if the values of C o and C 4 are so set between C o , C 1 , C 2 , C 3 and C 4 as to satisfy the relation ##EQU8## it is possible to make α zero (α=0).
When, for example, the values of the stray capacitors are C 1 =C 2 =0.5 PF and C 3 =1.5 PF, α=0 can be attained by making C 4 =0.7 PF if the capacitor C o =5 PF.
As can be seen from the numeric example, the values of the capacitors C o and C 4 to be used in the circuit of the present invention are extremely small so that these elements can be incorporated in an IC having a small chip size. In accordance with the present invention, further, it is theoretically possible to obtain reference voltages having equal absolute values in both positive and negative directions. For this reason, even if there is considerable variance in the values of C o and C 4 from the design values due to errors during the IC fabrication, the circuit of the present invention provides non-inverting and inverting voltages having by far a higher accuracy when compared with the conventional circuit.
Accordingly, the polarity switching circuit of the present invention per se is suited for the circuit integration (IC). When the present circuit is combined with a reference voltage source and an amplifier, a reference voltage having an optional value both in positive and negative directions can be produced. Thus, the voltage polarity switching circuit of the present invention is very useful for providing an A/D converter or D/A converter having a high level of accuracy as required especially in the field of PCM communication in a remarkably reduced size and in an economical manner.
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In a reference voltage generation circuit consisting of a capacitor, a reference voltage source for generating a predetermined voltage for charging the capacitor and a voltage polarity switching circuit for selectively inverting or not inverting the charged voltage of the capacitor to produce an output voltage at an output terminal, and capable of being fabricated in a semiconductor integrated circuit, the improvement wherein the voltage polarity switching circuit includes a second capacitor for compensating for an error between positive and negative reference voltages due to the stray capacitors.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Pat. app. Ser. No. 09/741,552, filed Dec. 19, 2000, now U.S. Pat. No. 6,543,466, which is a continuation-in-part of U.S. Pat. app. Ser. No. 09/517,391, filed Mar. 2, 2000, now U.S. Pat. No. 6,314,991.
FIELD OF THE INVENTION
The present invention relates to mass flow controllers.
Description of Related Art
Mass flow controllers are known in the art for controlling the specific amount of flow of a fluid, necessary for a particular process, e.g., in semiconductor manufacturing processes, such as chemical vapor deposition or the like. Mass flow controllers are known to be capable of sensing the flow occurring through the controller and modifying or controlling that flow as necessary to achieve the required control of the mass of the fluid delivered to the particular process.
Sensing the flow is a function of the type of fluid utilized and the physical effect used to sense the amount of flow. One typical type of physical effect to sense mass flow is to measure the temperature differential between the upstream and downstream heater/sensor coils exposed to the fluid flow. Other systems may use absolute and/or differential pressure changes, light absorption, or the momentum change (e.g., paddle wheel) to measure the flow.
Modifying or controlling the flow is typically made in response to the sensed flow as it relates to the desired flow by modifying a cross-sectional opening area available to the fluid for flowing. The smaller the area available for flow, the smaller the mass flow, and vice-versa. In the past, this has been accomplished with a typical plunger/diaphragm/orifice system. An orifice provides the variable cross sectional opening area for flow, where the flow control is dictated by the positioning and motion of a plunger/diaphragm or needle stem in the orifice in response to a flow control signal. The flow control signal is generated in response to the measurement of the flow sensor.
A servo control section generates a control signal that drives the positioning of the plunger/diaphragm or needle stem, typically through the use of a solenoid type of driver. The solenoid driver has a ferromagnetic core surrounded by a coil. The plunger/diaphragm, typically made of ferromagnetic material, is held close to the orifice by a spring. The energizing of the coil generates a magnetic field that pulls the plunger/diaphragm away from the orifice while the spring pulls it toward the orifice. The distance between the orifice and the plunger/diaphragm is dependent upon the relative strengths of the magnetic field and the spring. The proportional control valve by its nature is not an open and shut valve. The closer the needle stem or plunger/diaphragm is to the orifice, the more restricted the flow becomes, until the flow is shut off, and the more it is withdrawn the more the flow increases, until it no longer affects the amount of flow.
For precision control, complex and expensive controller circuitry is needed to control the positioning and movement of the needle stem or plunger/diaphragm as the flow is regulated. The valve parts themselves must be manufactured with high precision, and are therefore expensive. In addition, prior art proportional controlled solenoid valve mass flow controllers require the needle stem or plunger/diaphragm to be mounted at right angles to the fluid flow direction. Consequently, the orifice is also mounted at right angles to the fluid flow path, and the fluid has to change direction to go through the orifice, which generates turbulence in the fluid.
Often the mass flow controller, particularly when used in high precision semiconductor manufacturing processes and the like, is part of a tool that has limited space available for the flow controllers, particularly if there are multiple mass flow controllers that are positioned in the immediate area of the actual discharge of the fluid into the tool's process chamber.
There is a need in the art, therefore, for a mass flow controller that is simpler, less expensive, smaller, and easier to manufacture and control.
SUMMARY OF THE INVENTION
The present invention, according to one embodiment, utilizes a closed loop magnetic flux path passing through the body of the controller in the direction of flow from its input to its output to magnetically operate a flexible plunger button valve assembly that is normally spring biased into the shut position. A current generated from a servo control section of a mass flow controller generates magnetic flux to pull the plunger valve assembly away from an orifice and allow more fluid to flow through. By controlling the amount of flux generated, and thereby the positioning of the button valve assembly relative to the orifice, the flow through the orifice can be controlled. Consequently, a large separate proportional control valve section is no longer necessary, which results in a more compact, less expensive and more reliable mass flow controller that is less costly to manufacture and has fewer components than the conventional mass flow controllers discussed above.
The present invention will be more fully understood upon consideration of the detailed description below, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a mass flow controller of the prior art;
FIG. 1B shows magnetic flux path through a mass flow controller of FIG. 1A;
FIG. 2 shows an exploded view of the mass flow controller of FIG. 1A;
FIG. 3A shows a mass flow controller according to one embodiment of the present invention;
3 B- 1 and 3 B- 2 show side and front views, respectively, of a bypass assembly of FIG. 3A according to one embodiment;
FIGS. 3C-1 and 3 C- 2 show side and front views, respectively, of a second embodiment of a bypass assembly;
FIGS. 3D-1 and 3 D- 2 show side and front views, respectively, of a third embodiment of a bypass assembly;
FIGS. 3E-1 and 3 E- 2 show side and front views, respectively, of a fourth embodiment of a bypass assembly;
FIGS. 3F-1 and 3 F- 2 show side and front views, respectively, of a fifth embodiment of a bypass assembly;
FIG. 3G shows a side view of a sixth embodiment of a bypass assembly;
FIG. 3H shows magnetic flux path through a mass flow controller of FIG. 3A;
FIG. 4 shows an exploded view of the mass flow controller of FIG. 3A;
FIG. 5 shows a sectional view of the mass flow controller of FIG. 3A along sectional line A-A′;
FIG. 6A shows a side view of the button assembly and orifice plate shown in FIGS. 3A and 4;
FIG. 6B shows a side view of the button assembly and orifice plate according to another embodiment;
FIGS. 7A and 7B show different configurations of an orifice plate; and
FIG. 7C shows a side view of an orifice plate and button plunger assembly;
FIG. 8 shows an exploded view of a mass flow controller according to another embodiment of the present invention;
FIG. 9 shows magnetic flux path through a mass flow controller according to another embodiment of the present invention;
FIG. 10 shows magnetic flux path through a mass flow controller according to yet another embodiment of the present invention;
FIG. 11 shows a mass flow controller according to another embodiment of the present invention;
FIG. 12 shows the mass flow controller of FIG. 11, rotated 90° about the vertical axis;
FIG. 13 shows the mass flow controller of FIG. 11 with securing screws;
FIG. 14 shows an exploded view of a portion of the mass flow controller of FIG. 11, rotated 90° about the axis perpendicular to the vertical axis;
FIGS. 15 and 16 show a portion of the bypass assembly according to two embodiments of the present invention;
FIG. 17 shows a plunger button assembly according to one embodiment;
FIG. 18 shows an orifice plate according to one embodiment; and
FIG. 19 shows the magnetic flux path through the mass flow controller of FIGS. 11 and 12 .
Use of the same reference symbols in different figures indicates similar or identical items.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1A and 2 show a conventional mass flow controller 10 . FIG. 1A shows an assembled controller 10 , while FIG. 2 shows an exploded view of parts of controller 10 . Mass flow controller 10 has three main sections: a sensor section 20 , a valve section 30 , and a mass controller block section 40 . A fluid input fitting 11 and a fluid output fitting 12 are sealed to respective input and output ends of block section 40 through metal O-rings 13 . Note that other seals are also suitable, such as knife edge, O-ring, C-ring, and flat gasket, made of materials such as metal, polymer, and elastomer. A cover 14 enclosing sensor section 20 and valve section 30 is secured to input and output fittings 11 and 12 by screws 15 .
Gas or fluid enters input fitting 11 through an opening 16 in input fitting 11 . The flow of fluid through mass flow controller 10 is shown in the dark lines in FIG. 1 A. Opening 16 opens into a bypass assembly 17 , which has an input plenum 18 and an output plenum 19 , and which is located within block section 40 . Sensor section 20 is secured to block section 40 via appropriate seals 22 . While a majority of the fluid passes along bypass assembly 17 , a portion of the fluid travels through sensor section 20 along a sensor tube 23 . Bypass assembly 17 restricts the flow of fluid along one of a plurality of channels or grooves formed in the generally cylindrical outer surface of bypass assembly 17 and into output plenum 19 . As is known in the art, this is for the purpose of generating a laminar flow such that a portion of the fluid passing from input plenum 18 into a sensor bypass line 21 and into sensor portion 20 is linearly proportional to the fluid passing from input plenum 18 to output plenum 19 through the plurality of channels or grooves in bypass assembly 17 .
Sensor section 20 typically includes multiple coils 24 wrapped around sensor tube 23 . When fluid flows inside sensor tube 23 from a heated upstream coil to a heated downstream coil that are electrically balanced, thermal energy is transferred from the coils to the flowing fluid. The amount of thermal energy transferred from the coils to the fluid is inversely proportional to the fluid temperature. Thermal energy transfer from the upstream coil and the downstream coil to the fluid is disproportionate because the fluid temperature is different at the upstream coil than at the downstream coil. This difference in heat transfer from the upstream coil and the downstream coil results in a temperature differential between the coils which manifests as a change in the relative resistance of the two coils. This change in resistance is directly proportional to the amount of fluid flowing through sensor tube 23 . Typically, a resistor circuit (not shown), which is coupled to the upstream and downstream coils, is configured to form a balanced bridge network when there is no fluid flow. When the fluid flows, the resistance in the coils changes. The bridge network measures the change of the resistance in the coils and generates a signal corresponding to the flow of fluid through sensor tube 23 .
Fluid from bypass assembly 17 and sensor tube 23 converge and flow into a fluid flow path 25 . Fluid travels along fluid flow path 25 , through valve section 30 , and out through an opening 26 in output fitting 12 . Valve section 30 includes an upper housing 31 enclosing a wound coil assembly 32 of a solenoid valve, which consists of a pole assembly or plug 33 . Pole assembly 33 has a lower housing 34 , which together with upper housing 31 , are secured to block section 40 and sealed with an O-ring 35 or other appropriate seal. A plunger button assembly 37 , having a flat sealing surface 46 , is held in a cavity in lower housing 34 of pole assembly 33 by a plunger button capture ring 36 . Plunger button capture ring 36 , plunger button assembly 37 , and a plunger button assembly pre-tensioning ring 38 are in abutting relation to an orifice plate 39 , which is sealed to block portion 40 by an O-ring 41 or other appropriate seal.
Orifice plate 39 has an opening 42 into which fluid flows from fluid flow path 25 , where the flow of the fluid is controlled by the position of the plunger button assembly 37 , relative to orifice opening 42 . The relative position of plunger button assembly 37 is controlled by magnetic flux generated in core 33 in response to the signal generated from sensor block 20 . Coil 32 is held in place by a top cap 43 and a pole nut 44 . Top cap 43 is sealed with an O-ring 45 . FIG. 1B shows the magnetic flux path of controller 10 . As seen from FIG. 1B, the magnetic flux only travels through valve section 30 to control the position of plunger button assembly 37 , and not through either sensor section 20 , bypass assembly 17 , or block 40 .
FIGS. 3A and 4 show a mass flow controller 300 according to one embodiment of the present invention. FIG. 3A shows an assembled controller 300 , while FIG. 4 shows an exploded view of parts of controller 300 . Mass flow controller 300 includes an input fitting 311 attached to an input magnetic flux plate 312 , typically made of ferromagnetic material, where both input fitting 311 and input magnetic flux plate 312 have an opening 313 through which fluid enters and an output fitting 314 attached to an output magnetic flux plate 315 , typically made of ferromagnetic material, where both output fitting 314 and output magnetic flux plate 315 have an opening 316 through which fluid exits. A mass controller block 320 , typically made of non-ferromagnetic material, is sealed between input magnetic flux plate 312 and output magnetic flux plate 315 by O-rings 321 or other appropriate seals, which can be metal, plated metal, polymeric, or elastomeric material.
Fluid flows through opening 313 into a bypass assembly 317 , typically formed with a ferromagnetic material, via distribution holes 318 . Bypass assembly 317 can be a single part with longitudinal grooves or channels 350 formed directly thereon, or in other embodiments, bypass assembly can be formed from more than one part, as shown in FIG. 3 B. For example, bypass assembly 317 can be formed from an inner core 355 and an outer sleeve 360 having grooves 350 formed along the outer perimeter. Inner core 355 can be of a ferromagnetic material, while outer sleeve 360 can be of a non-magnetic material. In another embodiment, inner core 355 is made of a non-magnetic material, and outer sleeve 360 is made of a ferromagnetic material.
Other embodiments of bypass assembly 317 are shown in FIGS. 3C-1 and 3 C- 2 to 3 F- 1 and 3 F- 2 , and 3 G, where “−1” indicates a side view and “−2” indicates a front view. In each of these embodiments, a bypass assembly 317 includes a ferromagnetic core and pathways along the longitudinal direction of the bypass assembly that allow fluid to flow from one end of the assembly to the other. In FIGS. 3C-1 and 3 C- 2 , ferromagnetic core 355 is surrounded by concentric tubes 361 held in place by ribs 362 . Fluid flows along channels created by concentric tubes 361 and ribs 363 . In FIGS. 3D-1 and 3 D- 2 , ferromagnetic core 355 is surrounded by longitudinal tubes 363 in one or more layers, enclosed by a non-magnetic body 364 . Fluid flows through tubes 363 . In FIGS. 3E-1 and 3 E- 2 , ferromagnetic core 355 is surrounded by one or more laminated sheets 365 having channels 366 , which can be formed by laminating a channeled sheet 367 to a flat sheet 368 . Laminated sheet 365 is then wound around ferromagnetic core 355 . Additional sheets can be wound around an inner sheet to provide multiple channels through which fluid can flow. In FIGS. 3F-1 and 3 F- 2 , ferromagnetic core 355 is surrounded by a porous material 369 , which allows fluid to flow through. In FIG. 3G, core 355 is made of a ferromagnetic porous (sintered) material. Thus, core 355 functions as the path for both the magnetic flux as well as the fluid flow through bypass assembly 317 .
Going back to the embodiment of FIGS. 3B-1 and 3 B- 2 , the fluid flows along longitudinal flow grooves along the outer circumference of bypass assembly 317 . Fluid also flows through distribution holes 318 to a flow sensor input line 319 formed within block 320 . Input line 319 directs the flow to a sensor unit 322 , which is secured to block 320 by screws 323 and two O-rings 324 or other appropriate seals. One O-ring 324 seals the interface between sensor unit 322 and input line 319 of block 320 and second O-ring 324 seals the interface between sensor unit 322 and an output line 325 formed within block 320 . Fluid from output line 325 and bypass assembly 317 travels through a plunger button assembly capture spacer 326 , typically made of ferromagnetic material, a plunger button assembly 327 , (which includes a plunger made of ferromagnetic material, a spring, and a sealing surface), a plunger button pre-tension spacer 328 , an orifice plate 329 typically made of non-magnetic material, and an orifice metal O-ring 330 or other seal, and out through opening 316 in output fitting 314 . Plunger button assembly 327 and orifice plate 329 are shown in greater detail in FIG. 6 A. Plunger button assembly capture spacer 326 secures plunger button assembly 327 , spacer 328 , orifice plate 329 , and O-ring 330 within a cavity in output magnetic flux plate 315 .
In addition, mass flow controller 300 of the present invention includes a magnetic field generating unit 340 . Magnetic field generating unit 340 includes a coil 341 and a core 342 inserted into a cylindrical opening within coil 341 . Core 342 is a cylindrical plug, typically made of a ferromagnetic material, which is inserted into openings in the upper portion of input magnetic flux plate 312 and output magnetic flux plate 315 . Magnetic flux generated by unit 340 is directed down through input magnetic flux plate 312 , to bypass assembly 317 , to plunger button assembly 327 , and back up through output magnetic flux plate 315 . FIG. 3H shows the magnetic flux path of controller 300 . As seen in FIG. 3H, the magnetic flux travels substantially with the fluid flow within the body of controller 300 , i.e., from input magnetic flux plate 312 and through bypass assembly 317 to output magnetic flux plate 315 . This is contrasted with the magnetic flux path of conventional controllers, such as shown in FIG. 1 B.
FIG. 5 is a sectional view of mass flow controller 300 along sectional line A-A′ of FIG. 3 A. FIG. 5 shows that sensor unit 322 is rotated approximately 90° from the orientation of conventional mass flow controller 10 shown in FIGS. 1A and 2. In other words, fluid flowing through sensor unit 322 is orthogonal to the flow direction of the fluid through bypass assembly 317 according to the present invention, whereas the flow directions are parallel with the controller shown in FIGS. 1A and 2. Sensor unit 322 is a conventionally known and used thermal mass flow sensor. The majority of the fluid flows through bypass assembly 317 along flow grooves 350 formed longitudinally on the outer surface of bypass assembly 317 . Some of the fluid flows from distribution holes 318 to flow sensor input line 319 and into a flow sensor tube 344 . Sensor tube 344 has wrapped around its outside a first heater/sensor coil 345 and a second heater/sensor coil 346 , which are connected to terminals 347 .
Passing current through first coil 345 heats the fluid as it passes through sensor tube 344 in the vicinity of first coil 345 . Current is also passed through second coil 346 wrapped around sensor tube 344 in the downstream flow direction of the fluid, i.e., towards output line 325 . As the fluid passes second coil 346 , it gets hotter. However, the amount of heat transferred from coils 345 and 346 to the fluid is different because the fluid temperature is different at coils 345 and 346 . This in turn changes the relative resistance of coils 345 and 346 , which is measured as a voltage differential in an electrical bridge (i.e., a Wheatstone bridge). This voltage differential corresponds to the mass flow amount of fluid passing through sensor tube 344 , and, proportionately, through bypass assembly 317 . Controller unit 300 includes electronic circuitry, not shown, to calculate the mass flow based upon the sensed change in voltage. A servo control section of controller 300 then generates a current signal for magnetic field generating unit 340 , which in turn generates magnetic flux proportional to the signal to move plunger button assembly 327 to control the flow. The servo control system generates current through the coil to generate sufficient magnetic flux until the error signal is minimized or approximately zero. Such systems are conventional and known to those skilled in the art.
FIG. 6A shows, in more detail, plunger button assembly 327 and orifice plate 329 according to one embodiment. Orifice plate 329 is generally flat on both faces, with the face toward button assembly 327 having a frusto-conical portion 600 . Frusto-conical portion 600 has an opening 610 extending through orifice plate 329 such that fluid can flow through orifice plate 329 to opening 316 in output fitting 314 . Plunger button assembly 327 has a smooth flat sealing surface 620 that sits on to frusto-conical portion 600 . Plunger button assembly 327 also has openings 331 located outside sealing surface 620 for fluid to pass through. A spacer 328 (shown in FIG. 4) is positioned between plunger button assembly 327 and orifice plate 329 . Spacer 328 is intended for the purpose of creating an appropriate amount of compression between plunger button assembly 327 and frusto-conical portion 600 by allowing a spring 625 in plunger button assembly 327 to bend to a desired extent by plunger button assembly capture spacer 326 . The thinner the spacer 328 , the greater the bending of spring 625 in plunger button assembly 327 , consequently creating greater compression between plunger button assembly 327 and frusto-conical portion 600 .
Fluid flows through openings 331 around the outer edges of surface 620 as well as around the outer edges of plunger button assembly 327 so that fluid can flow from bypass assembly 317 to opening 610 of orifice plate 329 . The amount of fluid flowing into opening 610 depends on the positioning of plunger button assembly 327 in relation to orifice plate 329 . As the attractive force to plunger button assembly 327 , which is created by the magnetic flux, increases, plunger button assembly 327 is moved away from orifice plate 329 , thereby increasing the amount of fluid flowing into opening 610 . However, as the force decreases, the spring pushes button assembly 327 towards orifice plate 329 , thereby decreasing the fluid flow into opening 610 . The spring force of the spring should be as small as possible, yet sufficient to seal opening 610 to give a zero flow through opening 610 . Zero flow means less than 0.5% of the mass flow controller range.
FIG. 6B shows another embodiment of plunger button assembly 327 in which a magnet 626 is attached to the side of plunger button assembly opposite sealing surface 620 . By changing the flux direction and magnitude through bypass assembly 317 , plunger button assembly 327 can be moved either away from or towards orifice plate 329 , thereby controlling the flow of fluid through orifice plate 329 . For example, if the magnetic flux creates a pole on the end of bypass assembly 317 that is opposite in polarity to magnet 626 , the attractive force between bypass assembly 317 and plunger button assembly 327 (via magnet 626 ) will pull plunger button assembly 327 away from orifice plate 329 , which allows fluid to flow. If the magnetic flux creates a pole that is the same in polarity as magnet 626 , bypass assembly 317 will force plunger button assembly 327 into orifice plate 329 , which will shut off the fluid flow. Thus, depending on the magnitude and direction of the flux and the strength of magnet 626 , a desired fluid flow can be obtained.
In the above described embodiments, opening 610 in orifice plate 329 is a central through hole. However, in other embodiments, opening 610 can be an annular ring of slots 700 (shown in FIG. 7A) or holes 710 (shown in FIG. 7 B), or a combination of both. In these embodiments, the annular ring of holes or slots extend through protruded portions 720 of orifice plate 329 , shown in FIG. 7 C. Plunger button assembly 327 has a central hole 730 or slots (not shown) and sealing surface 740 , which abuts against protruded portions 720 of orifice plate 329 . Without any magnetic flux, protruded portions 720 are sealed against sealing surface 740 , thereby preventing fluid from flowing through the holes or slots in orifice plate 329 . When magnetic flux is generated, plunger button assembly 327 is pulled away from orifice plate 329 to allow fluid flow through orifice plate 329 . Fluid flows through hole 730 of plunger button assembly 327 and holes or slots 750 on the outer edge of sealing surface 740 as well as from the outer perimeter of plunger button assembly 327 to the openings of orifice plate 329 .
The size and number of slots 700 or holes 710 can be chosen to make the mass flow controller for a desired flow rate. For a given flow rate, the area of the slots (FIG. 7A) or holes (FIG. 7B) should be minimized to reduce the back pressure, resulting in less force required (less magnetic flux and therefore less current required) to move plunger button assembly 327 . However, this area must not be minimized to the extent that choking occurs when fluid is attempting to pass through orifice plate 329 . Choking can also occur in the peripheral area of the slots or holes. Therefore, the peripheral area of the slots or holes should be greater than or equal to the cross-sectional area of the slots or holes. Referring to FIGS. 7A-7C, the peripheral area can be defined as the perimeter of the slots or holes times a displacement distance d. Distance d is the maximum distance between plunger button assembly 327 and the end of protruded portions 720 for a given flow rate, as shown in FIG. 7 C.
Therefore, for a given flow rate and cross-sectional area of slots 700 , the peripheral area of the slots can be made equal to or greater than the cross-sectional area of the slots by either increasing the perimeter of the slots or increasing the distance d. Increasing distance d requires more magnetic force to achieve the desired flow rate. On the other hand, increasing the perimeter of the slots, which can be done by increasing the length of the slots and decreasing the width of the slots, allows the peripheral area of the slots to be increased without changing the cross-sectional area of the slots. Consequently, the back pressure is not adversely increased or affected. However, the same effect cannot be realized by using holes instead of slots because increasing the perimeter or circumference of the holes also increases the cross-sectional area of the holes.
FIG. 8 shows another embodiment of the present invention, in which bypass assembly 317 is made of a magneto-restrictive material, instead of a ferromagnetic material described above. The end of bypass assembly 317 facing output magnetic flux plate 315 is secured to a sealing device 800 having holes 805 for fluid to flow through and a sealing area 810 that abuts orifice plate 329 to prevent fluid from flowing through opening 610 in orifice plate 329 . In the normal biased position, sealing device 800 abuts orifice plate 329 when sufficient magnetic flux is generated to seal opening 610 . Magnetic flux travels from input magnetic flux plate 312 toward output magnetic flux plate 315 through bypass assembly 317 and sealing device 800 . When the magnetic flux is reduced, the magneto-restrictive material constricts, which allows fluid to flow through opening 610 in orifice plate 329 . Then, when the magnetic flux is increased, bypass assembly 317 expands until sealing device 800 seals opening 610 . This allows plunger button assembly 327 and plunger button assembly pre-tension spacer 328 of FIG. 4 to be eliminated.
In the above described embodiments, the magnetic flux travels through bypass assembly 317 . In other embodiments, shown in FIGS. 9 and 10, the magnetic flux path travels through the body of the mass flow controller. In FIG. 9, the magnetic flux path (shown as a solid black line) travels through core 342 , along input magnetic flux plate 312 , through mass controller block 320 , which in this embodiment is typically made of a ferromagnetic material, through plunger button assembly 327 and back up through output magnetic flux plate 315 . A magnetic flux separator plate or washer 910 , typically made of a non-magnetic material, is located between mass controller block 320 and output magnetic flux plate 315 so that the magnetic flux travels through plunger button assembly 327 to control the fluid flow through orifice plate 329 . In FIG. 10, coil 341 is wound around mass controller block 320 . Mass controller block 320 , typically made of a ferromagnetic material, encloses bypass assembly 317 . An outer cover 100 , typically made of a ferromagnetic material, encloses coil 341 and block 320 . Similar to FIG. 9, magnetic flux separator plate or washer 910 separates mass controller block 320 from output magnetic flux plate 315 . Accordingly, as shown in FIG. 10, the generated magnetic flux (shown as a solid black line) travels through block 320 to plunger button assembly 327 , up through output magnetic flux plate 315 , along outer cover 100 , and down through input magnetic flux plate 312 . Note that in the embodiments shown in FIGS. 9 and 10, fluid flows through sensor section 20 (FIGS. 1A and 1B) parallel to the flow of fluid through bypass assembly 317 . However, the embodiments shown in FIGS. 9 and 10 are also suitable with sensor unit 322 (FIGS. 3A and 5) that allows fluid to flow perpendicular to the flow of fluid through bypass assembly 317 .
FIGS. 11-19 show an assembled mass flow controller 920 according to another embodiment of the present invention, with FIG. 14 showing an exploded view of parts of mass flow controller 920 , rotated 90°, from FIG. 11 . Referring to FIGS. 11 and 14, mass flow controller 920 has three main sections: a controller block section 921 , a bypass/valve section 922 , and a sensor section 923 . Bypass/valve section 922 with a solenoid core 924 and a solenoid coil 925 are contained within block section 921 . A cover 926 encloses an electronic control printed circuit board (PCB) 927 and sensor section 923 . Mass flow controller 920 is attached and sealed to a surface mount block, such as by screws 928 (FIG. 13) and fluid input/output seals 929 .
Referring to FIG. 11, fluid enters through an input port 930 and flows through a channel 931 into an input plenum 932 located within block 921 , which is typically made of a non-ferromagnetic material. There, the fluid is split, with a majority of the fluid flowing along longitudinal grooves/channels 933 (FIGS. 14-16) formed in the generally cylindrical outer surface of a bypass/valve body 934 , typically made from a ferromagnetic material. In various embodiments, grooves/channels 933 can be formed directly on bypass/valve body 934 (FIG. 14 ), on a sleeve 935 (FIG. 15 ), within a sleeve when the sleeve is a porous material that acts as grooves/channels 933 , or on the inner surface of block 921 (FIG. 16 ). Bypass/valve assembly 922 , which includes bypass/valve body 934 , is attached to block 921 , such as by screws 936 (FIG. 13) and seals 937 and 967 (FIGS. 11 and 14 ). Thus, in bypass/valve assembly 922 within block 921 , the fluid flows from fluid input port 930 to fluid input plenum 932 to an output plenum 938 .
Referring to FIGS. 11-14 and 19 , sensor section 923 is attached to bypass/valve assembly 922 , such as by screws 939 and seals 940 , and can be mounted in any 360° orientation substantially perpendicular to the flux path, as shown in FIG. 19 . Sensor section 923 includes conventionally known and used thermal mass flow sensors. Referring to FIG. 12, the smaller portion of the split fluid flows through channel 941 located within bypass/valve body 934 into a sensor tube 942 and exits from sensor tube 942 into channel 943 located in bypass/valve body 934 and flows through channel 944 located within block 921 , finally meeting the major portion of the split fluid at the output end of the bypass/valve assembly 922 at output plenum 938 . Sensor tube 942 has wrapped around its outside a first heater/sensor coil 945 and connected to terminals 946 .
Passing current through first coil 945 heats the fluid as it passes through sensor tube 942 in the vicinity of first coil 945 . Current is also passed through a second coil 947 wrapped around sensor tube 942 in the downstream flow direction of the fluid, i.e., towards channel 943 . As the fluid passes second coil 947 , it gets hotter. However, the amount of heat transferred from coils 945 and 947 to the fluid is different because the fluid temperature is different at coils 945 and 947 . This in turn changes the relative resistance of coils 945 and 947 , which is measured as a voltage differential in an electrical bridge (e.g., a Wheatstone bridge). This voltage differential corresponds to the mass flow amount of fluid passing through sensor tube 942 , and proportionally through bypass/valve assembly 922 . Mass flow controller 920 includes electronic control PCB 927 to calculate the mass flow based upon the sensed change in voltage.
Bypass/valve assembly 922 contains core 924 , typically made from a ferromagnetic material, surrounded by solenoid coil 925 . One end of core 924 is in intimate contact with a valve pole 948 , typically made from a ferromagnetic material. The other end of core 924 is in intimate contact with a solenoid cap 949 , typically made from a ferromagnetic material. Cap 949 , in turn, is in intimate contact with bypass/valve body 934 . Valve pole 948 is separated from bypass/valve body 934 by a flux isolation ring 950 , typically made from a non-ferromagnetic material.
An electronic servo control section on PCB 927 generates a current signal (depending upon the actual flow and the desired flow) for solenoid coil 925 , which in turn generates magnetic flux proportional to the signal to move a plunger button assembly 951 (shown in greater detail in FIG. 17) to control the flow, as discussed in more detail below. The servo control system generates current through coil 925 to generate sufficient magnetic flux until the error signal (difference between the desired flow and actual flow) is minimized or approximately zero.
An orifice plate 952 , as shown in FIG. 18, typically made of non ferromagnetic material, is generally flat on both faces, with the face towards plunger button assembly 951 having a frusto-conical portion 953 . Frusto-conical portion 953 has an opening 954 extending through orifice plate 952 , such that fluid can flow through orifice plate 952 to a fluid output channel 955 into an output port 956 . Plunger button assembly 951 , as shown in FIG. 17, has a smooth flat sealing surface 957 that sits on to frusto-conical portion 953 . A spring pretension spacer 958 is positioned between plunger button assembly 951 and orifice plate 952 , as shown in FIGS. 11 and 14. Spacer 958 is intended for the purpose of creating an appropriate amount of compression between plunger button assembly 951 and frusto-conical portion 953 by allowing a spring 959 in plunger button assembly 951 to bend to a desired extent by a plunger button capture spacer 960 . The thinner the spacer 958 , the greater the bending of spring 959 in plunger button assembly 951 , consequently creating greater compression between plunger button assembly 951 and frusto-conical portion 953 .
From output plenum 938 , fluid flows through grooves/channels 961 (FIG. 18) formed into orifice plate 952 and into opening 954 . The amount of fluid flowing into opening 954 depends on the positioning of plunger button assembly 951 in relation to orifice plate 952 . As the attractive force to plunger button assembly 951 , which is created by the magnetic flux, increases, plunger button assembly 951 is moved away from orifice plate 952 , thereby increasing the amount of fluid flowing into opening 954 . However, as the force decreases, spring 959 pushes plunger button assembly 951 towards orifice plate 952 , thereby decreasing the fluid flow into opening 954 . The regulated fluid from opening 954 then flows through a fluid output channel 955 and exits from output port 956 .
Although the invention has been described with reference to particular embodiments, the description is only an example of the invention's application and should not be taken as a limitation. For example, the above description describes magnetic flux traveling from the input to the output. However, the magnetic flux can also travel from the output to the input along the direction of the bypass assembly for controlling the fluid flow. The concepts described above can then be modified to open or close the path of the fluid in response to the presence of the magnetic flux. Consequently, various adaptations and combinations of features of the embodiments disclosed are within the scope of the invention as defined by the following claims.
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A mass flow controller has a sensor section that generates an electrical signal, dependent on the measured flow rate. The controller sends a control signal to a magnetic field generating unit, dependent upon the actual flow rate and the desired flow rate, which in response, generates a magnetic flux in the direction of the fluid input to the fluid output through the body of the controller. This means that the magnetic flux is concurrent with the fluid flow within the mass flow controller body. The magnetic flux alters the position of a plunger button assembly, located between the bypass chamber and the fluid output, relative to an orifice plate to control the flow rate to obtain the desired output flow. By incorporating the proportional control valve within the mass flow controller body, the need for a separate and large valve section is eliminated, reducing the size and cost of the controller.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
Macrocyclic esters are obtained by the thermal depolymerization of the corresponding linear polyesters accompanied by ring closure. For such processes, the polyester is heated at an elevated temperature in the presence of a catalyst and the macrocyclic compound formed during the course of the depolymerization is removed from the reaction zone.
2. Description of the Prior Art:
Chlorides, nitrates, carbonates and oxides of magnesium, manganese, iron, cobalt and tin (all in the divalent state) are employed for the depolymerization of linear polyesters in the process of U.S. Pat. No. 2,092,031. In the process of U.S. Pat. No. 4,165,321 Lewis metal salts such as the oxides, hydroxides, halides or carboxylates of Group IIIa, IVa, IVb, Va, VIIb and VIII metals are disclosed to be useful catalysts. Yasakawa et. al. reported the use of lead catalysts (oxide, hydroxide, carbonate, nitrate, borate or organic acid salts) for the preparation of large ring lactones via thermal depolymerization in Chemical Abstracts, Vol. 78 (1973), 158966q and 158968s. Cyclic esters are also obtained via thermal degradation of polyesters using SnCl 2 .2H 2 O in Chemical Abstracts, Vol. 86 (1977), 156163s. In U.S. Pat. Nos. 4,105,672, 4,136,098, and 4,157,330 tin carboxylates and organotin compounds are employed in conjunction with dialkyl-(3,5-di-t-butyl-4-hydroxybenzyl) phosphates to catalyze the reaction. In British patent No. 1,108,720 the formation of cyclic ester anhydrides of alpha-hydroxycarboxylic acids in vacuo by depolymerizing the corresponding linear polymer at 200° -240° C. in the presence of lead (II) stearate is described.
In view of the problems associated with the use of heavy metal catalysts, aluminum oxide has been used to catalyze depolymerizations carried out at atmospheric pressure using superheated steam in Czech patent No. 108,762. The use of metallic aluminum was also reported for the thermal depolymerization of polyesters to form cyclic esters and lactones in Japanese patent No. 36-1375 (1961). Aluminum alcoholates are disclosed for the preparation of large-ring lactones in Japanese patent publication No. 72 25,071.
Mixed-metal catalysts having a carbonic acid radical and based on aluminum and sodium, wherein aluminum is the predominant metal, are also disclosed for the depolymerization of polyesters to produce macrocyclic compounds in Japanese patent disclosure Nos. 1979-103,884 (appln. No. 1978-8,809); 1979-115,390 (appln. No. 1978-22,023); and 1980-120,581 (appln. No. 1979-26,741). The mixed-metal catalysts of these Japanese references all have aluminum:sodium weight ratios greater than about 3.5:1. The catalysts are typically prepared by treating an aqueous mixture of aluminum hydroxide and caustic soda with carbon dioxide. Mixed-metal catalysts comprised of aluminum alkoxides or aluminum carboxylates with an alkali metal or magnesium alkoxide or carboxylate are utilized in the process of U.S. Pat. Nos. 4,393,223 and 4,499,288. Dawsonite, a naturally occurring basic carbonate of sodium and aluminum, is also an effective catalyst for the thermal depolymerization (see U.S. Pat. No. 4,594,434).
A problem common to all of the above-described catalytic thermal depolymerization processes is the viscosity of the reaction mass. As the depolymerization proceeds, the viscosity of the reaction mixture increases due to chain-growth reactions occurring between partially depolymerized fragments and an intractable plastic mass is formed. Stirring becomes extremely difficult and, in some cases, impossible. Mixing is non-existent or, at the very best, highly inefficient. Thus, heat transfer within the highly viscous reaction mass is very poor and localized "hot spots" occur resulting in charring of the reaction mixture and reactor fouling. As a result of these viscosity/heat transfer problems, reaction times are extended, yields are reduced, and undesirable malodorous decomposition products are obtained.
In an effort to overcome these problems, processes have been developed whereby specialized mixing equipment is employed and/or the reaction is conducted in the presence of other compounds. U.S. Pat. Nos. 4,165,321 and 4,218,379, for example, describe processes wherein the reaction is carried out in the presence of a monocarboxylate moiety derived from an aliphatic or aromatic monocarboxylate and wherein agitation is employed which provides top-to-bottom mixing throughout essentially the total volume of the reaction mass in an inverted multiple-blade conical vessel wherein the blades have a helical configuration and are arranged to rotate throughout essentially the entire reaction mass and in close proximity to the interior surface of said conical vessel and in a direction which provides a downward flow within the reaction mixture.
In Japanese patent disclosure No. 1980-120,581 (appln. No. 1979-26,741) the depolymerization and ring formation are carried out in the presence of at least one compound selected from the group consisting of polyoxyalkylene glycols, polyoxyalkylene glycol esters, polyoxyalkylene glycol ethers, monobasic acids, monobasic acid esters, monobasic anhydrides, monovalent alcohols and monovalent alcohol esters. A process is disclosed in Japanese patent No. 73-1972 wherein the depolymerization is carried out in the presence of a paraffin oil. Whereas such processes overcome some of the viscosity/heat transfer problems associated with the reaction, undesirable decomposition products which have objectionable odors result. Such processes are therefore not suitable for the production of macrocyclic compounds intended for critical fragrance applications.
It would be highly desirable therefore if a process were available whereby the viscosity/heat transfer problems associated with these depolymerization reactions were avoided and the formation of undesirable malodorous by-products was minimized or completely eliminated.
SUMMARY OF THE INVENTION
We have now quite unexpectedly discovered that the depolymerization can be advantageously carried out in an olefin polymer. In addition to significantly reducing the viscosity of the reaction mass and thus eliminating problems associated with mixing and heat transfer, other advantages are realized with the present improved process. High yields of the corresponding macrocyclic product are produced at high rates while substantially eliminating reactor fouling and the formation of undesirable malodorous by-products.
For the present improved process, a polyester is heated at a temperature in the range 200° C. to 400° C. and pressure less than about 50 mm Hg in the presence of from 0.01 to 10 weight percent catalyst, based on the polyester, and in the presence of an inert olefin polymer which is a liquid under the operating conditions. The weight ratio of olefin polymer to polyester can range from 100:1 to 1:20. Polyethylene is an especially useful medium for the reaction. Most generally, the depolymerization is carried out at a temperature from 275° C. to 350° C. and pressure from about 10 mm Hg to 0.01 mm Hg using from 0.1 to 5 weight percent catalyst. The process is particularly advantageous for continuous or semi-continuous operation wherein the polyester is continually or incrementally fed to the reactor while continuously removing the macrocyclic ester product. Macrocyclic esters having from 8 to 20 carbon atoms essentially free of undesirable malodors are conveniently obtained by the process of this invention.
DETAILED DESCRIPTION
The present invention relates to an improved process for the depolymerization of linear polyesters accompanied by ring closure to form macrocyclic compounds having from 8 to 20 atoms in the ring. Polyesters employed for the process are obtained by conventional methods known to the art and are derived from conventional dicarboxylic acids, diols and hydroxymonocarboxylic acids. Dicarboxylic acids employed are preferably aliphatic and may be saturated or contain olefinic unsaturation and can be branched or straight-chain. Polyesters derived from aromatic or alicyclic dicarboxylic acids can also be employed, however.
The aliphatic dicarboxylic acids will typically contain from 3 up to about 18 carbon atoms and, more preferably, from about 8 to 14 carbon atoms. Especially useful dicarboxylic acids include, for example, malonic acid, maleic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, azelaic acid, sebacic acid, undecanedioic acid, dodecanedioic acid, brassylic acid, pentadecanedioic acid, and the like. Mixtures of two or more dicarboxylic acids may also be employed. Polyesters derived from C 9-13 saturated aliphatic dicarboxylic acids are especially preferred since macrocyclic compounds produced therefrom exhibit especially desirable fragrance properties and are useful in a wide variety of cosmetic applications.
Diols from which the polyesters are derived are primarily aliphatic diols having from 2 to 12, and more preferably, 2 to 6 carbon atoms. The diols are preferably saturated and can be either straight-chain or branched. Useful diols include ethylene glycol, 1,2- or 1,3-propanediol, 1,2-, 1,3-, or 1,4-butanediol, 1,6-hexanediol, 3-methyl-1,5-pentanediol, 2,3-dimethyl-2,3-butanediol, 1,8-octanediol, 2-ethylhexanediol, 1,10-decanediol, 1,12-dodecanediol, diethylene glycol, triethylene glycol, and the like. Alicyclic diols such as 1,4-cyclohexadimethanol may also be employed. Polyesters derived from ethylene glycol and di-, tri- and tetraethylene glycol are especially advantageous.
Hydroxymonocarboxylic acids from which useful polyesters can be derived include 15-hydroxypentadecanoic acid, 16-hydroxyhexadecanoic acid, 10-oxa-16-hydroxyhexadecanoic acid, 11-oxa-16-hydroxyhexadecanoic acid, 12-oxa-16-hydroxyhexadecanoic acid, 10-thia-16-hydroxyhexadecanoic acid, 11-thia-16-hydroxyhexadecanoic acid, 12-thia-16-hydroxyhexadecanoic acid, and the like.
It is particularly advantageous if the polyesters are terminated with monocarboxylic acid(s) and/or monofunctional alcohol(s) to control the molecular weight and viscosity of the polymer. Polyesters having acid values and hydroxyl values less than about 20 and, more usually, less than 10 are particularly useful. The degree of polymerization of the polyesters will generally be between about 5 and 150 but can be higher, if desired.
Employing polyesters of the above types, it is possible to obtain macrocyclic compounds having from 8 to 20 carbon atoms in the ring. The macrocyclic compounds will conform to the general formulae: ##STR1## where R' is a bivalent aliphatic hydrocarbon radical, which can be branched or straight chain, saturated or contain unsaturation, having from 1 to 16 carbon atoms, R" is a saturated bivalent aliphatic hydrocarbon radical having 2 to 12 carbon atoms and x is an integer from 1 to 4; ##STR2## where R'" is a bivalent aliphatic hydrocarbon radical having from 6 to 18 carbon atoms; or ##STR3## where R", R'" and x are the same as defined above and A is oxygen or sulfur.
Especially useful macrocyclic compounds of the type (I) are those wherein the moiety R' is a saturated aliphatic radical having from 6 to 12 carbon atoms, the aliphatic radical R" has 2 to 6 carbon atoms, and x is 1 or 2. Preferred macrocyclic products of the types (II) and (III) are those wherein R'" is a saturated bivalent aliphatic hydrocarbon radical having from 10 to 14 carbon atoms, the aliphatic radical R" contains from 2 to 6 carbon atoms, A is oxygen, and x is 1 or 2.
Illustrative macrocyclic products which can be conveniently produced by the depolymerization process of this invention include: 3,6,9-tridecamethylene malonate, dodecamethylene malonate, decamethylene malonate, ethylene suberate, ethylene azelate, 3-oxa-pentamethylene azelate, 3-methylpentamethylene sebacate, ethylene undecanedioate, ethylene dodecanedioate, ethylene brassylate, ethylene-alpha-methylbrassylate, ethylene-alpha,alpha-dimethylbrassylate, ethylene-alpha-ethylbrassylate, pentadecanolide, 12-oxa-pentadecanolide, 12-thia-pentadecanolide, hexadecanolide, 10-oxa-hexadecanolide, 11-oxa-hexadecanolide, 11-thia-hexadecanolide, 12-oxa-hexadecanolide and the like. The process of this invention is particularly advantageous for the preparation of ethylene brassylate and ethylene dodecanedioate by the depolymerization of polyethylene brassylate and polyethylene dodecanedioate, respectively.
The macrocyclic products are primarily useful in cosmetic applications. They impart desirable fragrance properties and/or enhance the fragrance characteristics of other compounds combined therewith. For example, they can be used in detergents (heavy duty and regular laundry), soaps (bar soaps, dish soaps and specialty beauty soaps), personal care products (bath oils, shampoos, hair rinses, deodorants, shaving creams and mouthwashes), and as fine fragrance components for perfumes, perfume oils, perfume fixatives, colognes, aftershave lotions and the like.
The present improved process is conducted in an olefin polymer in accordance with conventional procedures known to the art. Details of thermal depolymerizations are well known and in this regard reference may be had to the prior art previously mentioned. The reaction is typically conducted at a temperature in the range 200° C. to 400° C. and, more usually, from 275° C. to 350° C. Subatmospheric pressures are employed to facilitate removal of the macrocyclic product formed. Pressures less than about 50 mm Hg and, more preferably, in the range 0.1 mm Hg to 10 mm Hg are generally employed. A metal catalyst is employed in an amount from 0.01 to 10 weight percent and, more preferably, from 0.1 to 5 weight percent based on the weight of the polyester.
Metal catalysts which can be used include compounds of Group IIa, IIIa, IVa, IVb, Va, VIb, VIIb, and VIII metals (Periodic Table of the Elements, Handbook of Chemistry and Physics, 65th Ed., CRC Press), particularly oxides, hydroxides, halides, and carboxylates of these metals. Oxides, hydroxides, chlorides, and carboxylates of organic acids having from 2 to 20 carbon atoms of magnesium, aluminum, titanium, manganese, iron, cobalt, tin, and lead are particularly useful. Illustrative catalysts of the above types which can be utilized for the depolymerization include but are not limited to aluminum oxide, lead (II) oxide, red lead, lead (II) oxalate, lead (II) stearate, lead (II) palmitate, lead (II) coconoates, cobalt (II) chloride, tin (II) oxide, tin (IV) oxide, tin (II) chloride, tin (II) oxalate, tin (II) stearate, iron (III) chloride, antimony (II) chloride, magnesium oxide, magnesium chloride hexahydrate, manganese (II) chloride tetrahydrate, cobalt (II) chloride hexahydrate, iron (II) chloride tetrahydrate, n-butyl stannoic acid, di-n-butyl tin diacetate, condensed butyl titanate, and the like.
Mixed metal catalysts wherein aluminum is present with an alkali metal or magnesium are particularly effective and especially useful in the present process. Such mixed metal catalysts are disclosed in U.S. Pat. Nos. 4,393,223, 4,499,288, and 4,594,434, details of which are incorporated herein by reference.
For the improved process of this invention, the depolymerization reaction is carried out in an inert olefin polymer which is a liquid under the prevailing operating conditions. Furthermore, the vapor pressure of the polyolefin should be greater than the total pressure of its surroundings, i.e., it should not boil under the operating conditions. This facilitates removal of the macrocyclic ester product formed during the reaction and insures that the product is substantially pure.
Olefin polymers employed for this purpose can be derived from C 2-8 olefins or mixtures thereof. Ethylene homopolymers and copolymers wherein ethylene is the predominant monomer are particularly useful for the process. Polyethylene is particularly advantageous. The weight ratio of the polyolefin to polyester can range from 100:1 to 1:20. In a particularly useful embodiment of the invention, the weight ratio of polyolefin to polyester is in the range 20:1 to 1:12.
The temperature, pressure, amount of catalyst, and ratio of polyolefin to polyester can vary depending on the materials employed, the design of the process equipment, and the method of operation. Whereas the process can be carried out as a batch operation wherein all of the materials are charged to the reactor at the outset, maximum benefit is realized when the depolymerization is conducted on a continuous or semi-continuous basis. With such manner of operation, the polyester is continuously or incrementally fed to the reactor containing all or a major portion of the polyolefin while continuously removing the macrocyclic ester product which is formed. All of the catalyst may be present in the reactor with the polyolefin or all or a portion of the catalyst may be combined with the polyester and fed to the reactor in this manner. Catalyst may also be separately fed to the reactor or metered in solution with the polyolefin, which can be either fresh or recycled polyolefin.
High yields of macrocyclic ester are readily obtained with the improved process of the present invention. The process has the further advantage that the macrocyclic esters thus produced are high quality products, i.e., they are substantially free of undesirable malodorous by-products and catalyst residue, and are readily distilled to yield highly desirable fragrance products suitable for use in the most critical fragrance applications. Moreover, a manageable viscosity is maintained throughout the course of the reaction. This reduces wear and tear on the process equipment (seals, motor, etc.), reduces energy consumption, and permits the reaction to be carried out on a scale larger than was heretofore possible. A further advantage of the present process is the fact that reactor fouling is minimized since the residues formed during the course of the depolymerization remain dispersed within the reaction mixture and do not adhere to the walls of the reactor, stirrer blades, etc. Furthermore, insoluble dispersed residues are removed from the reactor when the polyolefin is discharged. This latter feature is particularly advantageous for continuous operation since, by continuously removing a portion of the polyolefin from the reactor, residues formed during the depolymerization reaction are also removed and prevented from building up within the reactor. Residue buildup within the reactor has heretofore been a problem with depolymerization processes and has prevented true continuous operation. If desired, the residues can be removed from the polyolefin by filtering, decanting, centrifuging, etc. and the polyolefin recycled for further use in the process.
These and other advantages are evident from the following illustrative examples. In these examples all parts and percentages are on a weight basis unless otherwise indicated. The polyethylene brassylate used in the examples was prepared by charging a top-agitated resin kettle fitted with a distillation head and condenser with 109 parts dimethyl brassylate and 30.5 parts polymer grade ethylene glycol. About 2.3 percent methyl esters of a mixture of C 16-22 fatty acids, based on the dimethyl brassylate, was included as a chain terminator. A supported titanium catalyst (0.08 part), prepared from tetraisopropyl titanate and a naturally acidic montmorillonite clay in accordance with the teaching of U.S. Pat. No. 4,032,550, was then added to the reaction mixture under a positive pressure of nitrogen and heating begun. When the temperature of the reaction mixture reached about 180° C. methanol began distilling from the reaction mixture and was collected. After most of the methanol was removed and the temperature increased to about 195° C.-205° C., a vacuum of 2 in Hg was applied and increased slowly to 30 in Hg. Samples were periodically removed from the reactor for analysis and after about 11 hours, when the mixture had an acid value of 0.1 and hydroxyl value of 15.3, heating was terminated. The reaction mixture was cooled to about 180° C. and the vacuum broken with nitrogen. The high molecular weight polyethylene brassylate, viscosity 117 centistokes at 210° C., was filtered to remove the supported titanium catalyst. 2.72 Weight percent of a mixed potassium-aluminum salt KAl (OC 2 H 4 OC 2 H 4 OC 2 H 5 ) 3 (OOC 18 H 35 ) was dissolved in the polyester for use in the depolymerization of the subsequent reactions. A polyester feed based on polyethylene dodecanedioate containing the potassium-aluminum salt at a 2.72 weight percent level was obtained following the above procedure. Similar polyester feeds containing lead stearate and a synthetic Dawsonite obtained in accordance with the process of U.S. Pat. No. 4,238,458 as the depolymerization catalysts were also prepared.
EXAMPLE I
Ethylene brassylate was prepared by depolymerizing the polyethylene brassylate containing the mixed potassium-aluminum salt at a 2.72 weight percent level. The reaction was conducted in polyethylene (1:1 wt. ratio of polyethylene to polyester). For the depolymerization, 70 grams of the polyester was charged to a glass reaction vessel containing 70 grams polyethylene homopolymer (A-C® 617 manufactured by Allied Corporation). The reactor was equipped with a stirrer, thermometer, and short-path adapter connected to a receiving flask with a condenser. The mixture was heated under reduced pressure with agitation to about 250° C. at which point distillate began to collect. Reaction was continued while maintaining the pressure between 0.15 mm Hg and 0.22 mm Hg up to a maximum temperature of 336° C. There was no noticeable thickening of the reaction mixture. Heating was terminated after about 41/2 hours when the distillation rate of ethylene brassylate slowed. 58.4 Grams crude product (83.4% yield) essentially free of malodorous materials and which was readily distilled to obtain a high quality fragrance grade ethylene brassylate was recovered.
To demonstrate the ability to reuse the polyethylene and to operate on a semi-continuous basis, a second 70 gram charge of the polyethylene brassylate feed containing the mixed potassium-aluminum catalyst was made to the reactor after it had been allowed to cool somewhat. Heating was then resumed (pressure 0.11-0.25 mm Hg; temperature max. 331° C.) and 61.3 grams (87.5% yield) ethylene brassylate recovered in approximately 3 hours. Still another 70 gram polyester charge was made to the reactor and 56.0 grams (80% yield) ethylene brassylate recovered from this run after only 79 minutes reaction time. There was no observable difference in the manner in which either of the subsequent reactions proceeded and the recovered product from both of these runs was comparable in quality to that obtained from the first reaction. Similar results were obtained using the polyethylene brassylate containing the Dawsonite catalyst.
EXAMPLES II-IV
Following the general procedure described above, additional depolymerizations were carried out in accordance with the process of this invention using different polyolefin:polyester ratios. The polyethylene (PE) and polyethylene brassylate (PEB) used were the same as employed for Example I. PE:PEB ratios ranged from 2:1 to 9.3:1. Details of the reactions and yields obtained are set forth in Table I. Additional incremental additions of polyester were made as indicated. The yield reported in the table is based on the total amount of polyethylene brassylate charged and total amount of ethylene brassylate recovered for all of the runs for each example.
EXAMPLE V
Following the procedure of Example I, polyethylene dodecanedioate was depolymerized to obtain ethylene dodecanedioate. For the reaction, 75 grams polyethylene dodecanedioate containing 2.72 weight percent of the potassium-aluminum salt and 150 grams polyethylene homopolymer were charged to the reactor and the mixture heated to a maximum temperature of 348° C. at a pressure ranging from 1.1 mm Hg to 1.3 mm Hg. 89.7% Yield ethylene dodecanedioate was recovered in approximately 11/2 hours. There was no noticeable increase in the viscosity of the reaction mixture throughout the course of the reaction. Three additional 75 gram increments of the polyethylene dodecanedioate were charged at approximately 11/2 hour intervals. The total yield of ethylene dodecanedioate obtained was 92.0 percent. The ethylene dodecanedioate was essentially free of malodorous materials and, upon distillation, yielded a high purity product useful for fragrance applications. Inspection of the interior reactor walls and agitator shaft and blades showed them to be virtually residue-free at the conclusion of these runs. Comparable results were obtained using a polyester feed containing lead stearate as the depolymerization catalyst.
When the polyethylene was replaced with polyethylene glycol having an average molecular weight of 3350, undesirable highly colored and malodorous by-products were produced. Similarly, attempts to substitute polyvinyl acetate and oxidized ethylene homopolymer (acid number 30) for the polyethylene were
TABLE I__________________________________________________________________________ Maximum Reaction Ethylene TotalExample No. Charge (Grams) Pressure Temperature Time Brassylate Percent(Run No.) PE PEB (mm Hg) (°C.) (Min.) (Grams) Yield__________________________________________________________________________II(1) 600 300 1.1-2.0 340 180 245 --II(2) -- 296 0.9-1.9 347 180 303 91.9III(1) 400 51.7 0.6-0.9 342 90 43.5 --III(2) -- 54.6 0.7-0.9 341 90 55.9 --III(3) -- 52.7 0.9-1.1 342 90 47.1 92.1IV(1) 125 13.4 0.22-0.30 318 163 10.4 --IV(2) -- 12.5 0.16-0.24 306 178 12.5 88.4__________________________________________________________________________ unsuccessful. The polyvinyl acetate gave a very low yield (21.9%) of crude distillate and the residue remaining in the reactor was extremely gummy. A low yield (27.1%) was also obtained using the oxidized ethylene homopolymer. The viscosity of the reaction mixture increased throughout the depolymerization and ultimately gelled.
EXAMPLE VI
To demonstrate the ability to carry out the process of this invention on a continuous basis, polyethylene dodecanedioate was depolymerized in polyethylene in accordance with the procedure of U.S. Pat. No. 4,165,321. For the reaction, polyethylene dodecanedioate containing the mixed potassium-aluminum catalyst (2.72 wt. %) maintained at 100° C. with agitation was continuously metered from a stainless steel holding tank into a heated stainless steel inverted vertical cone reactor containing 190 pounds polyethylene homopolymer. The reactor was equipped with two conical helicoidal blades whose axis coincided with the cone axes of the bowl and which intermeshed as they were rotated in opposite directions to provide highly efficient top-to-bottom mixing throughout the total volume of the reaction mixture. The blades were positioned to provide maximum blade-to-wall clearance of about 0.25 inch and were rotated at 20 rpm. A high torque motor was used to drive the blades and the load on the motor was constantly monitored. Temperature of the reaction mixture was maintained in the range 342° C. to 343° C. and the pressure was maintained from 3.0 mm Hg to 5.0 mm Hg. Ethylene dodecanedioate was continuously distilled from the reactor and the rate of addition of polyester adjusted to maintain the proper material balance. Ethylene dodecanedioate was obtained at a rate of 36.8 pounds per hour over a 63-hour period during which time the load on the motor remained at a constant 13 percent of the predetermined maximum load limit. The motor is equipped with an automatic shut off in the event the maximum load limit (100%) is reached. Yield of ethylene dodecanedioate was 90.3 percent. The weight ratio of polyethylene to polyethylene dodecanedioate, calculated for the total reaction period, was 1:12. The insoluble residue formed during the course of the depolymerization was dispersed in the polyethylene and the residue was readily and conveniently removed from the reactor by discharging the dispersion.
For comparative purposes and to demonstrate the significant improved results obtained with the process of this invention, the above reaction was repeated except that the polyethylene was omitted. The rate of distillation of the ethylene dodecanedioate was 30.8 pounds per hour over the period of operation (35 hours) and the total yield of ethylene dodecanedioate was only 73.2 percent. At one point during the reaction the load on the motor reached 50 percent indicating a significant increase in the viscosity of the reaction mixture. At the conclusion of the run after the polyester feed was discontinued, it was necessary to continue heating the reactor for about one hour in order to obtain the residue produced during the depolymerization in acceptable granular form so that it could be discharged from the reactor.
EXAMPLE VII
Employing the general procedure and conditions described for Example VI, ethylene brassylate was continuously produced by the depolymerization of polyethylene brassylate. Ethylene brassylate was obtained at a rate of 30.4 pounds per hour and the yield of ethylene brassylate was 82.1%. The load on the motor remained at a constant 12 percent over the entire period of operation.
A series of nine comparative runs were carried out without the polyethylene. The highest distillation rate obtained was 29.1 pounds per hour and the highest yield was 77.6%. The viscosity developed in all of these runs was significantly higher than obtained with the reaction conducted using the polyethylene. In fact, for six of the nine runs the viscosity became so high that the load limit of the agitator motor was reached, i.e., 100% load, and the motor was automatically shut off.
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The catalytic thermal depolymerization of polyesters to produce macrocyclic esters suitable for fragrance applications is carried out using an olefin polymer. High yields of the corresponding macrocyclic ester are produced at high rates while substantially eliminating reactor fouling and the formation of undesirable by-products. The depolymerization is most advantageously conducted using polyethylene.
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[0001] The present invention relates to a fastening device and particularly to a fastening device adapted for use with a wristband.
BACKGROUND OF INVENTION
[0002] Identification bands are commonly used in many applications. For example: collars may be used to identify pets in a veterinary surgery; and wristbands are used for the identification of human patients (particularly new born babies) in hospitals. In the latter case, the band is appropriately positioned and fixed around the patient's wrist as early as possible after arrival at a hospital. Such bands are commonly fastened by a strong adhesive or by a non-releasable stud. This is intended to ensure that the band cannot be easily removed and replaced without providing clear evidence of tampering and that the band cannot be re-used. It is usually necessary to cut the band in order to remove it from the patient when it is no longer required.
[0003] More recently, wristbands have been used in the entertainment industry, particularly at large concerts or sporting events. For example, wristbands may be used to implement non-transferable ticketing, to assist in crowd control, to identify advance payers, to control access to VIP areas and to eliminate lost tickets.
[0004] The use of wristbands for these purposes relies on them being difficult to reproduce and difficult to remove without visible damage. It is also preferable that the wristbands be highly visible and made to a variety of designs, all or which are easy to put on.
[0005] Traditionally, plastic bands formed from a sheet of a plastics material have been used for such purposes. Details are printed on the plastic or placed on inserts sealed in pockets formed in the plastic sheet. However, modern printer technology is now widely available and enables fraudsters to quickly copy such bands. In addition, certain types of plastic sheet material can be warmed and manipulated to facilitate removal of the band without apparent damage, thereby facilitating undetected transfer of the band to another individual.
[0006] An alternative to a plastic band is a woven fabric band with an intricate pattern woven or sewn into it using threads of many different colours. Such bands are much more difficult to copy using commonly available technology and do not generally become more pliable on heating. Accordingly, a fabric wristband with a novel and detailed woven design provides a suitable band for use by the entertainment industry.
[0007] Such bands may be fastened using a compressible metal ring through which the band is threaded. In order to fasten the band, an official compresses the ring using a pair of plier-type hand or bench crushers.
SUMMARY OF INVENTION
[0008] In a first aspect of the invention, there is provided a tamper-evident fastening device suitable for use with a wristband, wherein the device comprises: a casing comprising two separate portions; and a divider which defines two substantially parallel paths of a strap and is adapted to retain two portions of a strap, wherein the two separate portions are positioned on each planar surface of the divider, and wherein the divider and the casing are configured such that they are capable of being connected together via an irreversible lock.
[0009] In a second aspect of the invention, there is provided a fastening device suitable for use with a strap, said device comprising: a casing; a divider disposed within the casing, wherein two substantially parallel paths for receiving first and second end portions of a strap are defined between the divider and the casing; and first and second retaining members arranged on opposite sides of the divider, wherein the first retaining member is arranged to hold a first end portion of the strap so that longitudinal movement of the first end portion is inhibited, and wherein the second retaining member is arranged to hold a second end portion of the strap such that movement of the second end portion in a first longitudinal direction is enabled and movement in a second, opposite longitudinal direction is inhibited.
[0010] In a third aspect of the invention, there is provided a tamper-evident fastening device suitable for use with a wristband, wherein the device comprises: a casing, comprising two separate or hinged parts which are positioned on opposite faces of a divider, and having at least one channel therein having a proximate and a distal portion, said distal portion having a protrusion on one wall of the channel and a recess or step positioned on an opposite wall of the channel; a divider having at least one engagement member adapted for engagement with the channel, said engagement member being adapted to engage the recess or step, and further having a slot therein adapted to engage the protrusion; wherein when the engagement member enters the channel, it is resiliently biased against at least one wall of the proximate part of the channel, and when it traverses the channel to its distal portion, it irreversibly engages with both the step or recess and the protrusion.
[0011] According to the above, there is provided an improved fastening device suitable for use with a strap, which makes the strap easy to put on but difficult to remove or loosen without cutting the strap. In a preferred embodiment, the device is suitable for use with a wristband, preferably a fabric wristband. Fabric wristbands are preferably made from a woven or satin fabric material. They are highly secure and are commonly used for festivals and large events. When the fastening device is used with a wristband, it may be tamper evident and hence provide evidence of tampering.
[0012] The casing of the device is preferably made from moulded plastic material including, but not limited to, polyesters such as PET, nylon, acrylic such as PAN, polyolefins and the like. Other examples include aramid, polyesters, fluoropolymers, polyethers, polyurethanes and polyphenylene sulfides. Nylon is particularly preferred, specific examples being selected from the group consisting of polyhexamethylene adipamide (nylon 66), poly(butyrolactam) (nylon 4), poly(9-aminonoanoic acid) (nylon 9), poly(enantholactam) (nylon 7), poly(capryllactam) (nylon 8), polycaprolactam (nylon 6), poly(p-phenylene terephthalamide), polyhexamethylene sebacamide (nylon 6,10), polyaminoundecanamide (nylon 11), polydodecanolactam (nylon 12), polyhexamethylene isophthalamide, polyhexamethylene terephthalamide, polycaproamide, poly(nonamethylene azelamide (nylon 9,9), poly(decamethylene azelamide) (nylon 10,9), poly(decamethylene sebacamide) (nylon 10,10), and mixtures thereof. Nylon 6 is particularly preferred.
[0013] Preferably, the casing consists of two separate parts which are capable of being connected together by the engagement members on opposing, substantially planar sides of the divider as will be discussed in more detail below.
[0014] The casing may have a hinge for connecting the two separate portions, which is capable of folding or bending along an edge such that the casing is capable of closing over the divider, resulting in the divider being disposed within the casing. In this case, the divider is sandwiched between the two halves or two separate portions of the casing.
[0015] Alternatively, the casing is provided in two separate halves or portions, which engage with the divider, thereby sandwiching the divider between the two halves. This results in the divider being disposed within the casing.
[0016] Preferably the divider has opposite, substantially planar, faces which are brought into face-to-face contact with respective halves or two separate portions of the casing.
[0017] In either of the above alternatives, the divider is held or fixed on one half of the casing. This provides a pathway for housing a first end portion of a strap. Preferably, the end portion of the strap is positioned flush with the end of the casing or does not protrude from the casing when the casing halves are closed. For the hinged embodiment, the hinged half of the casing can then be folded over the opposing side of the divider, thereby providing another pathway for housing a second end portion of the strap. The pathways are substantially the same width as the width of the strap. This enables the prevention of the strap being able to move around freely once they are engaged within the pathways of the device. It also enables the strap being reliably and accurately engaged at predetermined positions by one or more of the retaining members.
[0018] The same process occurs when separate casing portions are used, except that the second half of the casing is brought into engagement with the divider and the first half of the casing.
[0019] Generally speaking, to enable the divider to be fixed to the casing, the divider preferably further comprises at least one engagement member which prevents or restricts the casing from opening once closed. The engagement member is resiliently biased. This means that it is capable of engaging with an opening, providing access to a housing in the casing, by compression of the engagement member. Once the engagement member is positioned within the housing, the resiliently biased portion returns to its resting state, which means that the engagement member cannot be moved back through the opening. Thus, the engagement member is permanently placed within the housing such that an irreversible lock is provided. If a user attempts to open the casing, it would cause breakage of the device, thereby providing evidence of tampering.
[0020] The engagement member may be selected from the group consisting of clips, hooks, barbs, V-shaped members and mixtures thereof, preferably hooks or spikes, most preferably hooks. Preferably, the engagement members of the divider have a hook-like profile. The end of the hook is resiliently biased such that when it is pushed into the channel in the casing, it locates behind the step or in the recess, such that it cannot be withdrawn, as will be described in more detail below.
[0021] The engagement member may also be substantially T-shaped. The T-shaped engagement member may comprise one or, preferably, two resiliently biased members. The resiliently biased members may be positioned on the same side of the horizontal portion of the T-shaped member. However, they are preferably positioned on opposite sides of the T-shaped member. In this embodiment, in use, the horizontal portion of the T-shaped engagement member initially engages with an opening providing access to a housing in the casing. The opening has the same dimensions as the horizontal portion of the T-shaped member, and the resiliently biased members are compressed until they are positioned within the housing, when they return to their resting state such that they cannot be moved back through the opening in the casing, thereby providing an irreversible lock. If a user attempted to open the casing, it would cause breakage of the device, thereby providing evidence of tampering.
[0022] In a preferred embodiment of the invention, the divider comprises six engagement members in total, wherein each planar face comprises three engagement members.
[0023] Alternatively, the divider may comprise eight hooks in total, wherein each planar face comprises four engagement members. More preferably, the divider comprises six engagement members in total, wherein each planar face comprises three engagement members.
[0024] Preferably, the engagement members provide irreversible engagement with the casing. In other words, the engagement member acts as a lock. By irreversible, it is meant that, in normal use, if an attempt is made to open the device, once it is closed, then the device is broken which provides evidence of tampering. In other words, the engagement members are capable of providing evidence of tampering if the casing is forced open.
[0025] When the divider has a planar structure, the one or more engagement members, which prevent the casing from opening once closed, preferably depend from one or more surfaces of the divider. Preferably, said engagement member depends from one or more peripheral edges of the divider. Preferably, said one or more engagement members are upstanding from the plane of the divider, and are preferably substantially perpendicular thereto.
[0026] Preferably, the engagement members are resiliently biased such that they clip or lock into at least one housing(s) which are arranged on or in the casing such that they are capable of engaging the engagement means of the divider and thereby prevent or restrict the casing from opening once closed. An opening(s) is provided to give access to the housing(s). The opening has substantially the same dimensions as the engagement member. Preferably, one or more opening forms a channel, into which an engagement means may be pushed, thereby causing the resilient bias to engage the channel. Preferably, the channel is relatively narrow at the open end (the end which the engagement means initially enters, and hereafter referred to as the proximate end of the channel) and relatively wide at the opposite end of the channel (hereafter referred to as the distal end of the channel). Preferably, there is a step or recess in the channel which delineates the proximate end from the distal end of the channel. Once the engagement member has travelled a predetermined distance within the channel, the engagement member passed into the distal part of the channel. This causes a distal portion (a portion remote from the body of the divider) to spring into the distal part of the channel and become engaged (preferably irreversibly engaged) with the distal portion of the channel, such that it cannot be withdrawn therefrom. Preferably, the engagement member passes over the step or recess in the channel, and the engagement member becomes engaged with the distal part of the channel after the step or recess. This means that it cannot be withdrawn from the channel. The channel described in this paragraph can also be referred to as the housing in the casing.
[0027] The number of housings or channels on the casing is dependent upon the number of engagement members on the divider. Typically, the number of housings or channels on the casing corresponds to the number of engagement members on the divider, i.e., they are equal.
[0028] The engagement members may further comprise a slot configured to engage with a protrusion on the casing. Preferably, the protrusion is positioned within the channel of the casing. Preferably, it is positioned opposite the step or recess (where this embodiment exists).
[0029] The slot is positioned on the portion of the engagement member which is substantially perpendicular to the divider. This provides additional locking and renders the device more difficult to open once closed and hence provides additional tamper-proofing. The slot may be square, rectangular, circular, or any other suitable shape. The protrusion on the casing must have a smaller width than the slot so that it can fully engage into the slot.
[0030] The casing may further comprise a shield which is capable of covering the engagement member once it is engaged with the casing. This not only provides even further tamper-proofing, but also prevents the engagement member, which may have sharp edges, from catching on items of clothing. The shield is preferably tooth-like.
[0031] When the casing is comprised of two separate parts and when the divider has six hooks in total (three on each planar face), each of the two parts of the casing has three openings to engage hooks which are positioned on each planar face of the divider.
[0032] Alternatively, the casing has four openings on its upper and lower face to engage hooks which are positioned on each planar face of the divider. Once the casing is closed, lateral movement of a strap is restricted by virtue of the fact that the pathways defined between the divider and the casing have substantially the same width as the strap.
[0033] The casing may comprise at least one engagement member to prevent the casing from opening. In this embodiment, the casing also comprises at least one housing or channel arranged to engage the engagement member and thereby prevent the casing from opening.
[0034] The engagement member may have a hook like profile (as shown in FIG. 6 ) and the divider is pushed into the channel (or inserted into an opening which provides access to a housing) on the casing. This causes the end of the hook to become resiliently biased against the channel into which it is pushed, until it approaches the distal end of the channel, where is passes the step or recess. At this point, the end of the hook springs past the step or into the recess, and becomes engaged against it, thereby preventing withdrawal from the channel. If tampering takes place, the situation might occur where the engagement members are pressed such that the hook end is forced back over the step or out of the recess. In this case, the shield portions of the casing prevent or restrict access to the engagement members, thereby reducing the likelihood of successful tampering. However, if one of the shields is removed so as to gain access to the engagement members, a further tamper prevention means may be provided. In this embodiment, when the engagement member has been inserted into the channel, the slot provided on the engagement member has been engaged with the protrusion in the channel (again, see FIG. 6 ). This means that even if the engagement member is pressed so as to try to force it out of engagement with the step or recess, back along the channel, this is prevented because of the protrusion engaging the slot. Thus, the more one presses the engagement member, the more the protrusion engages with the slot. This renders the device both tamper evident (because removal of the shield is necessary to attempt the opening of the casings), and very difficult to open without destroying the casings and/or the engagement member.
[0035] More preferably, the engagement member is T-shaped and works in accordance with the definition outlined in the preceding paragraph. Preferably, the T-shaped member comprises at least two hook-like resiliently biased members, wherein each hook is positioned on opposite sides of the T-shaped member.
[0036] Preferably, the divider is planar or at least substantially planar, wherein the divider is substantially planar with respect to the parallel paths which are defined between the divider and the casing. The divider is preferably made from steel, more preferably carbon steel or spring steel.
[0037] The first and second retaining members are preferably arranged on opposite sides of the divider and, in a preferred embodiment, the retaining members are an integral part of the divider and are also made from steel, preferably carbon steel or spring steel.
[0038] The first and second retaining members are preferably independently in the range of 1 to 8 mm in length, preferably at least 2 mm in length.
[0039] The first and second retaining members are preferably independently selected from the group consisting of spears, spikes, barbs or any other shapes capable of retaining, and mixtures thereof. Preferably, the first and second retaining members are barbs or at least resemble barbs. In an even more preferred embodiment, the first and second retaining members have jagged or serrated edges such that they are capable of retaining, preferably wherein said serration comprises at least 2 or 3 barb-like hooks.
[0040] Most preferably, the first and second retaining member is a triangular-shaped spike having an apex for piercing a first and second end portion of a strap. Even more preferably, the first and second retaining member is a plurality of triangular-shaped spikes having an apex for piercing a first and second end portion of a strap, preferably three or four triangular-shaped spikes.
[0041] The second retaining member is preferably resiliently biased towards a predetermined position which is preferably biased away from the plane of the divider. In this embodiment, the second retaining member may be a length which is the same or at least substantially the same as the height of the pathway defined between the casing and the divider. This provides additional assistance in inhibiting the strap from moving in the second, opposite longitudinal direction, i.e., it is possible to pull or move a strap in the first longitudinal direction over the retaining member but once the retaining member extends through the strap, movement in the second, opposite longitudinal direction is inhibited, preferably substantially prevented.
[0042] Alternatively, the second retaining member may have a length which is longer than the height of the pathway defined between the casing and the divider. In this embodiment, the casing comprises a plurality of openings in which the first and second retaining members are engaged when the casing is closed. This encourages a strap to be kept flush within the device such that it cannot be twisted or skewed in any way. The number of openings will correspond to the number of retaining members. For example, preferably, the first and second retaining members are comprised of three or four triangular-shaped spikes. In this case, there will be three or four openings on each portion of the casing.
[0043] Preferably the first retaining member depends from and extends perpendicular or at least substantially perpendicular to the plane of the divider. The first retaining member is arranged to extend through the first end portion of a strap. By “substantially perpendicular”, we include the meaning that the first retaining member may depend from the divider at an angle of substantially 90°, and also any suitable angle which enables a strap to be retained from longitudinal movement in both directions, for example in the range of from greater than 70° to less than 110°, preferably 80° to 100°, more preferably 85° to 95°.
[0044] The second retaining member is arranged to extend through a second end portion of a strap. The second retaining member is arranged to intercept the second end portion of a strap at an acute angle or an angle suitable to enable the strap to move in a first longitudinal direction but retained from movement in a second, opposite direction. For example, the acute angle may be in the range of from less than 70° to greater than 10°, preferably 50° to 20°, more preferably 45° to 30°. This is facilitated by the resiliently biased nature of the second retaining member.
[0045] It is possible that the first retaining member is arranged to intercept the first end portion of a strap at an acute angle or an angle suitable to enable the strap to move in one longitudinal direction, but not in the opposite longitudinal direction, as described above in relation to the second retaining member. In this case, the acute angle may be in the same range as the angle disclosed in relation to the second retaining member, i.e., in the range of from less than 70° to greater than 10°, preferably 50° to 20°, more preferably 45° to 30°. In this embodiment, the first retaining member would also be resiliently biased, like the second retaining member.
[0046] Preferably, in use, the second end portion of the strap can be pressed against the second retaining member. However, the angle of the retaining member to the plane of the strap does not allow the strap to be pierced by the retaining member until the strap is pulled in the second direction. This is akin to the effect of a fishing hook—the hook does not penetrate the fish until the hook is pulled away from the fish. The resiliently biased nature of the second retaining member also facilitates this effect. In this regard, passing the strap over the second retaining member in the first direction enables the second end portion of a strap to be moved. This is preferably the case even where the strap has already been penetrated by the second retaining means. Thus, further pulling of the strap in the first direction merely facilitates tightening of the strap loop. As the strap passes over the second retaining means in the first direction, the retaining means can be biased towards the plane of the divider, thus making passage of the strap easier.
[0047] The fact that the first retaining member is arranged to hold a first end portion of the strap so that longitudinal movement of the first end portion is inhibited, and the second retaining member is arranged to hold a second end portion of the strap such that movement of the second end portion in a first longitudinal direction is enabled and movement in a second, opposite longitudinal direction is inhibited provides many advantages over previous devices that form part of the state of the art.
[0048] For example, one such advantage is that identification means (such as a barcode) or tamper evident means may be applied to the first end portion of the strap, i.e., the portion of the strap that is retained such that movement is inhibited in both longitudinal directions. Since the strap is retained from movement by the first retaining member, the identification or tamper evident means will not become partly or wholly hidden by the fastening device when the wristband/strap is made tighter.
[0049] Barcoded wristbands offer streamlined admission and an increased level of security and eliminate the chance of counterfeiting and re-entry. Event organisers benefit from this since it allows for real time indication of how many people are scanned in or out of an event at any time. The barcode may be applied using a specialist weave of the fabric or by using a sticker.
[0050] The advantage of having two substantially parallel paths for receiving first and second end portions of a strap is that the two end portions of the strap are kept substantially flat and therefore scrunching or folding of the strap is avoided. This enables tidy and efficient application of the strap to the divider, and travel of the strap through the casing. This has the added advantage that when used in combination with a strap comprising identification or tamper evident means, they are not distorted in any way, i.e., the strap is kept flat so that is can be scanned or viewed quickly and efficiently. This means that the time taken to register or scan the identification means, or to view the tamper evident means, is significantly reduced resulting in crowds being controlled more efficiently.
[0051] In one particularly preferred embodiment the device comprises radio enabled technology, preferably a radio-frequency identification (RFID) tag. Generally, the device can then be attached to a person using a strap or wristband. The remote wireless device has an integrated circuit (IC), which includes a memory for storing information (e.g., identification data) and a transponder, as well as an antenna for sending and receiving information to and from a reader. The RFID tag can discretely transmit its identification data to the reader, e.g., through broadcasting or in response to an incoming signal, to expedite an identification process.
[0052] The radio enabled technology (preferably an RFID tag) used in the device of the present invention may be adapted to discontinue operating (i.e., break and/or stop transmitting signals) when an attempt is made to open the closed device. This provides evidence of tampering as a person will be able to scan the tag and immediately establish whether the tag has been broken or not.
[0053] The radio enabled technology (preferably an RFID tag) may be fixed to the device of the present invention by attaching it either to the fabric of the band or to the closure of the band.
[0054] The present invention also provides a wristband comprising a strip of material or strap and a fastening device according to the present invention. Preferably, the strip of material or strap is a woven material, for example, a fabric material, most preferably a high tensile material. The width of the strip of material or strap must be sufficient to allow for the application of a unique design and in a preferred embodiment, the strap is in the range of approximately 10 to 20 mm wide. The unique design may incorporate threads of as many colours as possible to inhibit copying. Threads coloured with ultra violet dye may also be incorporated to provide protection against counterfeiting or the strip of material may be impregnated with a material (such as a magnetic material) which allows easy identification thereof.
[0055] When both the first and second end portions of the strap are retained by the first and second retaining members, a loop is preferably formed which can be made smaller by movement of the second end portion of the strap in the first longitudinal direction. Preferably, once the casing is closed and both the first and second end portions of the strap are retained, the loop cannot be made larger, since movement of the first end portion of the strap is inhibited.
[0056] The second retaining member is preferably arranged such that movement of the strap in the first longitudinal direction causes the second retaining member to pierce the strap, thereby preventing movement in the second longitudinal direction but enabling movement in the first longitudinal direction. When the device is used with a wristband, this means that the loop of the wristband can be made smaller by pulling the second end portion of the strap in the first longitudinal direction. However, since movement in the second, opposite longitudinal direction is inhibited, the wristband cannot be made larger by pulling the second end portion of the strap in the second, opposite longitudinal direction.
[0057] To use the wristband, a wearer slides one of his hands through the loop. Using the forefinger and thumb of the same hand, he can then grip the second end portion of the strap and use his other hand in order to slide the device along the strap to tighten the loop around his wrist. At a concert or sporting event, an official will usually put a wristband on each audience member, thereby ensuring that the loop is tight enough and the wristband cannot be slipped over the hand. In order to remove the wristband, it would then be necessary to cut the strap which provides clear evidence that the wristband has been used and thereby prevents it from being re-used.
[0058] The structure of the present device also reliably enables a smaller length of strap to be used than is presently the case. In this regard, the first end of the strap may be secured in position in the casing. As no longitudinal movement of this end is allowed once the strap has been engaged by the first retaining member, very little excess strap need to extend from the end of the casing. In fact, the first end of the strap may be enclosed when the casing is closed, and does not protrude therefrom. This embodiment will also help to minimise or avoid tampering therewith.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] FIG. 1 shows an example of a divider of the device according to the present invention;
[0060] FIG. 2 shows a side view of the divider of FIG. 1 and the position of the first and second retaining members;
[0061] FIG. 3A shows an example of a divider fixed to a casing and the device is shown in an open position, whereby the first end portion of a strap is retained such that movement is inhibited;
[0062] FIG. 3B shows an example of the device in an open position, whereby the first end portion of the strap is retained such that movement is inhibited and the second end portion a strap is overlaid before closing of the device;
[0063] FIG. 3C shows an example of the device according to the present invention in a closed position and in use with a strap;
[0064] FIG. 4 shows a cross-sectional view of an example of a device of the present invention.
[0065] FIG. 5 shows an exploded view of a device according to the present invention in an open position, viewed from the side;
[0066] FIG. 6 shows an exploded view of the device of FIG. 5 ; and
[0067] FIG. 7 shows an exploded view of a device according to the present invention, having T-shaped engagement members.
DETAILED DESCRIPTION
[0068] The present invention will now be described with reference to the accompanying drawings. A fastening device according to the present invention is depicted in FIGS. 1 to 4 .
[0069] An example of a divider of the present invention is shown in FIG. 1 . The divider 1 shown is planar and one where the first retaining member 4 and the second retaining member 2 are an integral part of the divider 1 . The retaining members are both spikes. Additionally, the divider 1 has a substantially square or rectangular shape. The divider 1 further comprises four engagement members 3 on each planar face of the divider 1 . In the embodiment shown, the engagement members 3 are hooks.
[0070] FIG. 2 shows a side view of the divider according to FIG. 1 . The position of the first retaining member 4 and the second retaining member 2 is depicted in this Figure. For example, it can be seen that the first retaining member 4 is substantially perpendicular to the plane of the divider 1 .
[0071] The second retaining member 2 is shown at an angle of approximately 45° to the plane of the divider 1 . When the second retaining member 2 intersects or pierces a strap 5 , the second retaining member 2 is also at an angle of approximately 45° relative to the plane of the strap 5 .
[0072] In FIG. 2 , the first retaining member 4 and second retaining member 2 are shown as offset to each other. In the embodiment shown, this is purely for manufacturing convenience since this enables the retaining members to be cut from the same piece of steel. The retaining members would be punched out of the same piece of steel and folded into the appropriate positions. Of course, it is not essential that the first and second retaining members are offset to each other. Features 5 a and 5 b are opposite ends of the strap.
[0073] FIGS. 3A to 3C show an example of a fastening device according to the present invention. FIGS. 3A and 3B show the device in an open position and FIG. 3C shows the device in a closed position ready for use in combination with a strap/wristband.
[0074] In this embodiment, the fastening device comprises a plastic moulded casing 6 having a first and second member which are connected via an integrally moulded hinge 9 . The first and second member of the casing 6 can be brought into face-to-face registration with each planar face of the divider 1 such that two substantially parallel pathways are defined between the divider 1 and the casing 6 , wherein each pathway is defined between the casing 9 and one planar face of the divider 1 .
[0075] In FIG. 3A , a first end portion of a strap 5 is placed onto the casing 6 and the divider 1 is connected/fixed to the casing 6 by engagement members 3 and the first retaining member 4 inhibits longitudinal movement of the strap. In this particular embodiment, the engagement member 3 are hooks.
[0076] The casing 6 comprises four openings 7 on each side of the casing 6 , i.e., on each of the first and second members which are connected via the integrally moulded hinge 9 . The purpose of these openings 7 is for engaging the engagement member 3 such that the casing 6 is prevented from opening once closed.
[0077] Before closing the casing 6 to give the embodiment depicted in FIG. 3C , a second end portion of a strap is laid over the face of the divider 1 such that when the casing 6 is closed by folding it about the integrally moulded hinge 9 , the strap forms a loop.
[0078] The fastening device in combination with the strap 5 may then be used as a wristband. To use the wristband, a wearer slides one of his hands through the loop. Using the forefinger and thumb of the same hand, he can then grip the second end portion of the strap and use his other hand in order to slide the device along the strap to tighten the loop around his wrist, thereby making the loop smaller. The loop cannot be made larger.
[0079] FIGS. 3A and 3B also show an embodiment whereby the casing 6 has a plurality of openings 8 in which the second retaining member 2 is engaged/housed when the casing 6 is closed, thereby preventing the strap 5 from being movable in the second longitudinal direction.
[0080] FIG. 4 shows a cross-sectional view of an example of a device according to the present invention.
[0081] In this Figure, the second retaining member 2 can be seen extending through or piercing the strap 5 when the device is closed. It is also shown that the engagement members 3 are hooks, of which four are shown on one face of the divider, but as one can imagine, there are also four hooks on the opposite face of the divider 1 . The casing 6 comprises openings 7 for engaging/housing the hooks which enable the divider 1 to be fixed to the casing 6 . In this embodiment, the hooks are resiliently biased such that the divider 1 clips/locks into the casing 6 and prevents it from opening.
[0082] A fastening device according to the present invention is also depicted in FIGS. 5 and 6 . FIGS. 5 and 6 show an alternative arrangement of the device. This represents a preferred embodiment of the present invention.
[0083] In FIG. 5 , the casing 6 is depicted as two separate parts wherein the divider 1 is positioned between the two separate parts of the casing 6 . The position of the first retaining member 4 and the second retaining member 2 is depicted in this Figure and is the same as that shown in FIG. 2 . For example, it can be seen that the first retaining member 4 is substantially perpendicular to the plane of the divider 1 and the second retaining member 2 is positioned at an acute angle of about 45°.
[0084] FIGS. 5 and 6 also depicts the locking mechanism of the device which provides for irreversible closing of the device such that if an attempt is made to open the device, once closed, the device is broken which provides evidence of tampering.
[0085] The engagement members 3 are shown as hook members. FIG. 6 shows that preferably, there is a total of 6 engagement members 3 on the peripheral edges of the divider 1 . The engagement members 3 also each comprise a slot 12 which is depicted as a square hole in the portion of the engagement member 3 which is substantially perpendicular to the divider 1 . When the engagement member 3 is inserted into an opening in the casing, the slot engages with a protrusion 11 on the casing. The hook portion of the engagement member passes through the channel in the casing and moves into the recess opposite the protrusion. The hook portion of the engagement member 3 is resiliently biased. The divider is made of metal, preferably steel, more preferably spring steel.
[0086] FIGS. 5 and 6 also depict the shields 10 which form part of the casing 6 . When the device is brought into the closed position, the shields 10 fully cover the engagement member 3 in situ (i.e., when the sit in the channel, engaged both with the protrusion and the recess).
[0087] FIG. 7 illustrates a device according to the invention, wherein the engagement members 3 are T-shaped members instead. This represents a particularly preferred embodiment of the present invention. The rest of the device is substantially the same as previously described and, in particular, as depicted in FIGS. 5 and 6 .
[0088] In FIG. 7 , the first and second retaining members 4 , 2 are a plurality of triangular-shaped spikes, in accordance with a preferred aspect of the invention.
[0089] The engagement members 3 in FIG. 7 are substantially T-shaped. The T-shaped engagement member 3 comprises two resiliently biased members, which are positioned on opposite sides of the horizontal portion of the T-shaped member. In use, the horizontal portion of the T-shaped engagement member initially engages with an opening 7 providing access to a housing in the casing. The opening has the same dimensions as the horizontal portion of the T-shaped member, and the resiliently biased members are compressed until they are positioned within the housing, when they return to their resting state such that they cannot be moved back through the opening in the casing, thereby providing an irreversible lock. If a user attempts to open the casing, it would cause breakage of the device, thereby providing evidence of tampering.
[0090] A fastening device according to the present invention is a compact device that may be used in combination with a strap to provide a wristband that has improved properties. An additional advantage of the device according to the present invention is that it can be manufactured more easily than devices that form part of the state of the art and the components fit together to provide a small and compact fastening device.
[0091] A fastening device has been described particularly in the context of wristbands but it can clearly be used for other purposes, such as ankle bands.
[0092] Although one skilled in the art will readily conceive of many alternative embodiments of the invention described above, the present invention includes all such alternatives which fall within the scope of the following claims.
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A tamper-evident fastening device suitable for use with a wristband. The device may include a casing with two separate portions and a divider that defines two substantially parallel paths of a strap and is adapted to retain two portions of a strap. The two separate portions may be positioned on each planar surface of the divider. The divider and the casing may be configured such that they are capable of being connected together via an irreversible lock.
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BACKGROUND OF THE INVENTION
Photometers are generally known for measuring the light permeability of a reagent liquid having a predetermined proportion of a test substance mixed with the reagent liquid. The many uses for such a photometer include a determination of the proportion of hemoglobin in human blood. Prior art photometers for such purposes have been laboratory instruments that were not readily portable and were relatively slow and cumbersome to use. Moreover, the output value from prior art instruments required a calculation to adapt the valve to the particular test, and no direct reading of the output was available.
The invention involves recognition of the need for a portable photometer that can be handheld and operated for quickly and reliably making photometric measurements outside of laboratories. For example, one need for such a portable photometer is to allow doctors to measure the proportion of hemoglobin in human blood quickly and reliably at the scene of an accident or under emergency conditions. The invention aims at a conveniently portable photometer that is simple and easy to operate, accurate and reliable in making measurements, and providing a directly readable display of the test result value from any measurement.
SUMMARY OF THE INVENTION
The inventive portable photometer measures the light permeability of a material for testing and is arranged within a casing sized and shaped for handholding and manipulating. It includes a battery power supply, a lamp in circuit with the power supply, a path for a light beam from the lamp, and a manually operable switch for energizing the lamp. It also includes a conductor plate and an electrically measuring circuit having elements connectable to the conductor plate, with the measuring circuit including at least one light-sensitive element. A wedge filter is movably arranged in the path of the light beam, and a manually movable setting member positions the wedge filter. The measuring circuit also includes an indicator instrument having a pointer cooperating with an index mark for indicating zero compensation of the measuring circuit, which is effected by a manually operable element in the measuring circuit before a test measurement. The casing has an opening for receiving a cuvet containing the material to be tested, so the cuvet is positioned in the path of the light beam, and a viewable scale movable by the setting member with movement of the wedge filter displays a directly readable test result value from adjustment of the wedge filter during a measurement of the material.
The scale and the wedge filter are preferably arranged on the setting member, and viewing windows for the instrument pointer and the scale are preferably arranged on a front face side of the casing, with the lamp switch arranged at an edge side of the casing. The setting member is preferably a disk having a knurled periphery extending outward from the opposite edge side of the casing, and the opening for receiving the cuvet is preferably also in the front face side of the casing and is normally closed by a spring-biased, hinged flap that is movable into the interior of the casing to receive the cuvet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a preferred embodiment of the inventive portable photometer;
FIG. 2 is an end elevation of the photometer of FIG. 1;
FIG. 3 is a transverse cross-sectional view of a battery power supply region of the photometer of FIG. 1; and
FIG. 4 is a partially schematic view of the measuring apparatus and the electrical components of the photometer of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
The illustrated preferred embodiment of the inventive photometer has a relatively flat and oblong casing formed of casing halves 10 and 12 that are preferably screwed together and are preferably formed of thin-walled plastics material. The casing is sized and shaped to be held in one hand, and the instrument is relatively light so that it is readily transportable.
A chamber formed within the casing by partition walls 10a and 12a houses a plurality of batteries 14 forming a battery power supply for the instrument. One or more batteries 14 can be used as desired, and the batteries 14 are preferably oriented axially of the casing at the lower end of the casing as illustrated. The batteries 14 provide a power supply for a lamp 16 which produces an output beam that illuminates a liquid material for a test. A finger-press switch 18 is arranged along an edge side of the casing 12 for energizing the lamp 16, and the switch 18 can be operated by the fingers of a hand holding the casing, as best shown in FIG. 1.
The remainder of the space within the casing houses the rest of the operational elements of the photometer. A setting member 20, preferably formed as a circular rotatable element with a knurled periphery, carries an arcuate wedge filter 22 and is arranged around the lamp 16 for positioning the wedge filter 22 in the path of a light beam from the lamp 16. The beam from the lamp 16 then passes through the wedge filter 22, through a focusing lens 24, and through a cuvet 26 containing a liquid material 28 formed of a reagent liquid with a test substance mixed with the reagent liquid at a predetermined ratio. The light transmitted through the cuvet 26 and the liquid 28 passes through a color filter 30 and impinges on a light-sensitive, photoelectric element 32 which produces a voltage proportional to the incident light intensity. A second photoelectric element 34 is directly exposed to light from the lamp 16 and also produces an electrical voltage.
A measuring and electrical system for the inventive photometer is best shown in FIG. 4 and includes a differential amplifier 36 receiving input from photosensors 32 and 34. An indicator instrument 38 having a pointer 38a is connected to the output of amplifier 36. Power for operating the amplifier 36 and other elements of the measuring circuitry is derived from the battery supply 14 in a generally known way so that circuitry for the power supply has been omitted from FIG. 4 for simplicity's sake. The power supply is arranged for energizing the measuring circuit whenever manual press switch 18 is closed so as to operate the measuring circuit whenever the lamp 16 is energized.
The measuring circuit includes a regulating circuit 40 and a feed circuit 42 interconnected by a switch 44 and arranged in parallel with the differential amplifier 36 to eliminate possible error factors such as a varying voltage from the battery power supply 14, temperature effects, and other sources of error. The regulating circuit 40 and the feed circuit 42, when operated by the switch 44, provide a zero compensation, which is made with the cuvet 26 and its liquid 28 out of the path of the light beam from the lamp 16. The voltages produced by the photoelectric elements 32 and 34 at the two inputs to the differential amplifier 36 are balanced by the regulating circuit 40 and brought to the same value, and the feed circuit 42 insures that the resultant balancing remains stable over a predetermined time delay of a few minutes required for completing a measurement. After the inputs to the amplifier 36 are balanced, the pointer 38a of the indicator instrument 38 registers with a permanent index mark 46 on the casing part 10.
As best shown in FIG. 1, the knurled edge of the setting member 20 projects outward slightly into a recess 10b along the edge side of the casing opposite the press switch 18. This allows the thumb of the hand holding the casing to operate the setting member so that the instrument can be held and operated by one hand. A viewing window 10f near the edge of casing part 10 and next to the recess 10b permits observation of a scale 20s on the front face of the setting member 20, and the scale 20s moves relative to a fixed mark 48 on the casing. The pointer 38a of the instrument 38 is visible in another viewing window 10f also arranged in the front face surface of the casing part 10, and the pointer 38a moves relative to an index mark 46. The switch 44 for the zero compensation of the instrument is preferably a push button accessible on the front face of the casing part 10.
The front face of the casing also has a preferably square access opening 50 for receiving the cuvet 26, which preferably has a square cross section fitting the opening 50. The cuvet 26 can be inserted into the interior of the casing and into the path of the light beam from the lamp 16 for a measurement of the light permeability of the liquid 28 in the cuvet 26. A cover flap 52 is pivotally mounted on a bearing pin 54 and is biased by a spring (not shown) inside of the casing part 10 to swing closed against the interior of the opening 50 to prevent ambient light from entering the instrument. The flap 52 is swung open into the interior of the casing when the cuvet 26 is pushed into the opening 50.
A conductor plate 56 is preferably arranged within the casing to afford connections for elements of the measuring and control system. This facilitates compactness and ease of assembly but is, in itself, a generally known expedient.
In operation, the user holds the inventive photometer in his left hand and moves the setting member 20 with his left thumb until the zero mark 20n on the scale 20s registers with the index mark 48 on the casing. This positions the darkest zone of the wedge filter 22 in the path of the measuring beam from the lamp 16 and provides a base position for checking the zero compensation of the instrument. The user then presses the switch 18 with the fingers of the left hand to energize the lamp 16 and illuminate photocell 32, without the light passing through any cuvet 26; this also illuminates the photocell 34 directly. If the instrument is properly zero compensated, the pointer 38a registers with the index mark 46, and if this does not occur, the user presses the switch 44 with a finger of his right hand so that regulating circuit 40 and the feed circuit 42 automatically effect a zero compensation of the instrument and maintain the zero balance for a predetermined interval that is sufficient to complete the measurement. This moves the pointer 38a back to the index mark 46.
Then the instrument is ready for a test measurement, and the cuvet 26 previously prepared with a test material 28, is inserted, preferably with the right hand, through the opening 50 to bring the cuvet 26 and the test liquid 28 into the path of the light beam from the lamp 16 so that the intensity of the light incident on the photocell 32 is reduced by the test liquid 28. This changes the relationship of the inputs to the amplifier 36 and moves the pointer 38a of the instrument 38 away from the mark 46 to a position such as indicated in broken lines in FIG. 1. The user then moves the setting member 20 with the left thumb to adjust the wedge filter 22 to increase the light from the lamp 16 by an amount sufficient to bring the pointer 38a back to the zero position at mark 46. The adjustment of the wedge filter 22 by the setting member 20 is then related to the light permeability of the liquid 28 in the cuvet 26 and is indicated by the scale 20s. Since the instrument is preferably intended for only one type of photometric measurement, the scale 20s is graduated to display a directly readable test result value for the type of measurement being made. For example, for an instrument intended to measure the proportion of hemoglobin in human blood, the scale 20s is graduated for directly displaying the results in values relating to the hemoglobin test.
The illustrated preferred embodiment of the inventive photometer can be varied considerably within the spirit of the invention. For example, the casing can have different shapes, sizes, and forms, and switches, viewing windows, scales, and the setting member can be arranged in different ways. For example, the setting member can be made as a gear meshing with other gears for positioning a wedge filter or scale, and the setting member need not be a rotatable cylinder or disk, but can be slidable rack meshed with a pinion driving a wedge filter. The inventive instrument can be used for tests other than measuring the proportion of hemoglobin in human blood, and those skilled in the art will understand ways of applying the invention to any photometric measurement facilitated by a portable and handheld instrument. The instrument can also be made for right-handed as well as left-handed operation, and can be adapted to different sizes and shapes of cuvets. Its measuring circuitry can also be arranged in various ways.
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A photometer for measuring the light permeability of a material for testing is made portable for hand-held operation outside a laboratory for measurements such as determining the proportion of hemoglobin in human blood. It includes a battery power supply that energizes a lamp, an opening for receiving a cuvet for a measurement, and a measuring circuit having a light-sensitive element. An indicator instrument in the measuring circuit indicates zero compensation, and a manually movable wedge filter is in the path of the light beam for adjusting the light passing through the cuvet. A manually operable element effects a zero compensation of the measuring circuit before a test is made, and a viewable scale on a setting member carrying the wedge filter directly displays a test result value from adjustment of the wedge filter during measurement of the material.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority to International Patent Application PCT/EP2013/074424, filed on Nov. 21, 2013, and thereby to German Patent Application 10 2012 111 341.6, filed on Nov. 23, 2012 and German Patent Application 20 2012 012 667.9, also filed on Nov. 23, 2012.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] No federal government funds were used in researching or developing this invention.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
SEQUENCE LISTING INCLUDED AND INCORPORATED BY REFERENCE HEREIN
[0004] Not applicable.
BACKGROUND
[0005] 1. Field of the Invention
[0006] The invention relates to an inner seal collar with improved locking mechanism for insertion into pipes, for the purpose of sealing leak points in the same.
[0007] 2. Background of the Invention
[0008] Such internal sealing collars have been known for a long time, and are described by way of example in DE 44 01 318 C2. Using such internal sealing collars, it is possible to repair leakage points in, for example, underground pipes made of concrete or another material, without trenching. For this purpose, the internal sealing collar is inserted into the leaking pipe being repaired, up to the position of the leak. In this process, the internal sealing collar is initially spirally compressed such that it has a smaller diameter than the pipe being sealed. Once the internal sealing collar has been moved into the position of the leak in the pipe being repaired, the internal sealing collar is expanded by means of a mechanical installation device until it has come into very tight contact with the inner wall of the pipe, compressing the seal rings. The internal sealing collar is held in its expanded position by means of an arresting device which has a tensioning pinion which meshes with a toothed bar, and a spring-loading locking pinion which engages with the same.
[0009] EP 0 805 932 B1 suggests an arresting device which is improved over the above. The document discloses an internal sealing collar having an arresting device which enables very small locking steps and therefore ensures a strong, permanent contact with the inner pipe wall following its expansion, providing a strong press force on the sealing organs. The improved arresting device comprises, for this purpose, a slot arranged peripherally around the belt end on the inside, wherein a toothed bar is arranged on each of the two opposing longitudinal edges thereof. Two tensioning pinions are arranged in the slot, each of these engaging with one of the two toothed bars, and also being loaded by one locking pinion which functions as the locking organ. The locking pinion is pressed into the intermediate space between the two tensioning pinions by a tensioning spring.
[0010] An internal sealing collar having such an arresting device is in need of improvement with respect to the force load which can be achieved.
[0011] The aim of the present invention is therefore that of advancing the known internal sealing collars in such a manner that the arresting device can receive greater forces—that is, such that it is more difficult to unlock than previously.
BRIEF SUMMARY OF THE INVENTION
[0012] In a preferred embodiment, an internal sealing collar ( 1 ) for the purpose of insertion into pipes to seal leak points in the same, having a belt ( 2 ) which is compressed circularly and can be expanded, preferably made of sheet steel, the belt parts ( 3 , 4 ) of which preferably overlap in the peripheral direction at least partially, and having an arresting device ( 10 ) which comprises at least two rows of teeth ( 21 , 22 ) which are arranged parallel to each other, wherein one tensioning pinion ( 31 , 32 ) for each of at least two of the rows of teeth ( 21 , 22 ) engages in the same, characterized in that one locking pinion ( 41 , 42 ) each is functionally assigned to the at least two tensioning pinions ( 31 , 32 ), each locking pinion ( 41 , 42 ) pressing against the associated tensioning pinion ( 31 , 32 ) via one spring element ( 51 , 52 ) each, and engaging with the same, and wherein each of the locking pinions ( 41 , 42 ) additionally engages with the associated row of teeth ( 21 , 22 ).
[0013] In another preferred embodiment, an internal sealing collar as described herein, characterized in that, for each of the at least two rows of teeth ( 21 , 22 ), one of the tensioning pinions ( 31 , 32 ) engages in the same.
[0014] In another preferred embodiment, an internal sealing collar as described herein, characterized in that two rows of teeth ( 21 , 22 ) are arranged on opposite longitudinal edges ( 24 , 25 ) of a toothed bar ( 20 ) constructed on the inside belt part ( 2 ).
[0015] In another preferred embodiment, an internal sealing collar as described herein, characterized in that each of the locking pinions ( 41 , 42 ) has a lower tooth count than the associated tensioning pinion ( 31 , 32 ).
[0016] In another preferred embodiment, an internal sealing collar as described herein, characterized in that each of the spring elements ( 51 , 52 ) is a tensioning spring which is fixed by one end thereof, directly or indirectly, to the outside belt part ( 4 ), and on the other end thereof is inserted in an axle region of the associated locking pinion ( 41 , 42 ).
[0017] In another preferred embodiment, an internal sealing collar as described herein, characterized in that the two tensioning pinions ( 31 , 32 ) are each fixed on the outside belt part ( 4 ) via their own axle pin ( 34 , 35 ), and the associated spring elements ( 51 , 52 ) at least partially wind around each of these axle pins ( 34 , 35 ).
[0018] In another preferred embodiment, an internal sealing collar as described herein, characterized in that each of two opposing rows of teeth ( 21 , 22 ) of the toothed bar ( 20 ) belongs to an elongated first recess ( 81 ) and an elongated second recess ( 82 ), respectively, the same running parallel to each other.
[0019] In another preferred embodiment, an internal sealing collar as described herein, characterized in that the two recesses ( 81 , 82 ) are each designed as slots.
[0020] In another preferred embodiment, an internal sealing collar as described herein, characterized in that at least one of the recesses ( 82 ) extends from one row of teeth ( 22 ) of the toothed bar ( 20 ) to an end-face end ( 2 A) of the belt ( 2 ).
[0021] In another preferred embodiment, an internal sealing collar as described herein, characterized in that each of the locking elements and/or locking pinions ( 41 , 42 ) has an overhung mounting.
[0022] In another preferred embodiment, an internal sealing collar as described herein, characterized in that a hold-down plate ( 70 ) is included which is attached on the outside belt part ( 4 ) and overlaps at least one of the two rows of teeth ( 21 , 22 ) with the associated tensioning pinion ( 31 , 32 ) and locking element ( 41 , 42 ).
[0023] In another preferred embodiment, an internal sealing collar as described herein, characterized in that the hold-down plate ( 70 ) comprises a hold-down element ( 74 )—particularly a hold-down bolt—on the side thereof which is functionally assigned to the toothed bar ( 20 ), for the purpose of pressing the toothed bar ( 20 ) toward the outside belt part ( 4 ).
[0024] In another preferred embodiment, an internal sealing collar as described herein, characterized in that the axle pins ( 34 , 35 ) of the two tensioning pinions ( 31 , 32 ) are designed as bolts or rivets, each projecting through corresponding bore holes ( 76 , 77 ) of the hold-down plate ( 70 ).
[0025] In another preferred embodiment, an internal sealing collar as described herein, characterized in that the hold-down plate ( 70 ) overlaps at least a part of the two rows of teeth ( 21 , 22 ), as well as the associated tensioning pinion ( 31 , 32 ) and locking elements ( 41 , 42 ).
[0026] In another preferred embodiment, an internal sealing collar as described herein, characterized in that two hold-down plates ( 70 , 70 A; 70 B, 70 C) are included.
[0027] In another preferred embodiment, an internal sealing collar as described herein, characterized in that each of the two hold-down plates ( 70 ) additionally overlaps a slot which runs parallel to the respective row of teeth ( 21 , 22 ), wherein a fixed bolt sits in said slot.
[0028] In another preferred embodiment, an internal sealing collar as described herein, characterized in that for each of two rows of teeth ( 21 , 22 ), one slot, positioned opposite, is functionally assigned to the same—a bolt ( 92 ) projecting into said slot ( 90 ).
[0029] In another preferred embodiment, an internal sealing collar as described herein, characterized in that an element ( 93 ) which is able to rotate, particularly a rotating disk, is mounted on the bolt ( 92 ) or bolts.
[0030] In another preferred embodiment, an internal sealing collar as described herein, characterized in that a toothed gear ( 94 ) is mounted on the bolt ( 92 ) and meshes with a further row of teeth ( 23 ) arranged in the slot ( 90 ).
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a line drawing evidencing a perspective view, from outside into a part of an internal sealing collar, of the arresting device arranged at this point, according to a first embodiment of an internal sealing collar.
[0032] FIG. 2 shows a view similar to that of FIG. 1 , according to a second embodiment of the internal sealing collar.
[0033] FIG. 3 is a line drawing evidencing an arresting device in FIG. 1 , in a section along the dotted cutaway line in FIG. 1 .
[0034] FIG. 4 is a line drawing evidencing a cutaway view along the cutaway line I-I in FIG. 3 .
[0035] FIG. 5 is a line drawing evidencing a cutaway view of a third embodiment of an internal sealing collar according to the invention, having a relatively wider toothed bar, and two hold-down devices attached to the same.
[0036] FIG. 6 is a line drawing evidencing a cutaway view of an internal sealing collar which is similar to the illustrations in FIGS. 3 and 4 , but according to a fourth embodiment.
[0037] FIG. 7 is a line drawing evidencing a cutaway view of an internal sealing collar which is similar to the illustration in FIGS. 3 and 4 , but according to a fifth embodiment.
[0038] FIG. 8 is a line drawing evidencing a cutaway view of an internal sealing collar according to a sixth embodiment.
[0039] FIG. 9 is a line drawing evidencing a cutaway view of an internal sealing collar according to a seventh embodiment.
[0040] FIG. 10 is a line drawing evidencing a cutaway view of an internal sealing collar according to an eighth embodiment.
[0041] FIG. 11 is a line drawing evidencing a cutaway view of an internal sealing collar according to a ninth embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0042] The invention substantially consists of the provision of two rows of teeth, wherein a different tensioning pinion with an associated locking element engages with each. In this case, each of the locking elements is arranged with the two associated tensioning pinions is designed as a locking pinion. As a result of two rows of teeth being used, and the tensioning pinions assigned to the same, the arresting mechanism is able to receive twice the force via the toothed bar. Each of the two tensioning pinions, and also each of the locking pinions which meshes with the tensioning pinions, engage with the associated row of teeth and mesh with the same.
[0043] In addition, it is advantageous that the locking forces of the tensioning pinion act on the toothed bar, thereby ensuring high static stability of the entire arrangement. Due to the use of a locking pinion which interacts with a tensioning pinion, the configuration achieves half the tooth pitch in comparison with the use of another locking element—such as a detent pin, for example. In this configuration, it is advantageous that the path traveled if the expanded internal sealing collar slips back can only be half of a tooth width.
DETAILED DESCRIPTION OF THE FIGURES
[0044] FIG. 1 shows a perspective view of a part of an internal sealing collar 1 . The observer has a perspective of a compressed belt 2 which is preferably made of sheet steel or the like. In the rolled-up configuration shown, the belt 2 has a belt end and/or belt part 3 on the inside, and a belt end and/or belt part 4 on the outside. So that the belt 2 remains in this rolled-up configuration and its diameter cannot get smaller, a special arresting device 10 is included—and is described in detail further below. The arresting device 10 illustrated in FIG. 1 can be seen in an enlarged illustration and from a top view in the region of FIG. 3 marked by dashed lines.
[0045] An essential feature of the arresting device 10 is a toothed bar 20 with a first row of teeth 21 and a second row of teeth 22 opposite the first. The toothed bar 20 is—as can be seen most clearly in FIG. 1 —molded as a single piece, by its two ends, to the belt part 3 on the inside, as a result of a slot-like first recess 81 being arranged left of the first row of teeth 21 , and a similar recess 82 being arranged right of the second row of teeth 22 . However, the second recess in the embodiment in FIG. 1 has a design which is open toward the open side of the wound-up belt 2 . In contrast, in FIG. 2 , the recess 82 in fact has a similar design to the recess 81 . This means that in the embodiment in FIG. 2 , the recess 82 is also bounded by a wall section 2 A of the belt 2 on the open end face.
[0046] In both embodiments in FIG. 1 and FIG. 2 , the toothed bar 20 is—seen in the peripheral direction of the wound-up belt 2 —an integral component of the belt part 3 on the inside. In this case, the first row of teeth 21 runs along a first longitudinal edge 24 , and the second row of teeth 22 runs along a second longitudinal edge 25 of the toothed bar 20 . The two longitudinal edges 24 , 25 , and therefore the two rows of teeth 21 , 22 , are oriented parallel to each other.
[0047] The toothed bar 20 can, with its two rows of teeth 21 , 22 , have a length which is approximately between an eighth-circle arc and a semi-circle, or somewhat more. However, different lengths can be used. This depends to a critical degree on which outer diameter the internal sealing collar 1 needs to have to be able to seal a corresponding defective pipe.
[0048] As can be seen in FIG. 1 , the slot-like recess 81 illustrated at left is bounded on its right side by the first longitudinal edge 24 , mentioned above, which carries the first row of teeth 21 of the toothed bar 20 . On the opposing side, the recess 81 is bounded by a longitudinal edge 81 a which does not carry any row of teeth. This longitudinal edge 81 a is connected to the first longitudinal edge 24 on its upper and lower ends via transverse edges 81 b and 81 c running at a right angle.
[0049] The right recess 82 comprises the second longitudinal edge 25 of the toothed bar 20 , which carries the second row of teeth 22 . In contrast to the recess 81 , the recess 82 in FIG. 1 is open on its right, wherein the second longitudinal edge 25 , with the second row of teeth 22 , transitions on its upper end and lower end at a right angle into two transverse edges 82 b , 82 c.
[0050] As mentioned above, when the embodiment in FIG. 2 is considered, the right recess 82 has a similar design to the left recess 81 . This means that the second longitudinal edge 25 of the toothed bar 20 , with the second row of teeth 22 arranged on the same, is situated opposite a straight longitudinal edge 82 a which has no row of teeth. As a result, as shown in FIG. 2 , a narrower belt section and/or strut is present which runs parallel to the longitudinal edge 82 a of the belt 2 . This region is marked by the reference number 2 A.
[0051] In each of the two recesses 81 and 82 , two rows of teeth are placed in a particular manner. Specifically, a first tensioning pinion 31 which meshes with the first row of teeth 21 is arranged in the first recess 81 . For this purpose, the first tensioning pinion 31 is mounted on an axle pin 34 which is fixed to the belt part 4 on the outside. This fixture can be achieved by riveting or welding, for example. Other connection means are likewise possible.
[0052] In the embodiment in FIGS. 1 to 3 , the first tensioning pinion has, by way of example, nine teeth which are able to mesh with the first row of teeth 21 when the first tensioning pinion 31 rotates. A first locking pinion 41 is functionally assigned to this first tensioning pinion 31 . This first locking pinion 41 has an overhung mounting. This means that the axis of the locking pinion 41 is not fixed. Rather, this first locking pinion 41 is pressed by a spring element 51 against the first tensioning pinion 31 , such that the first locking pinion 41 is held in engagement with both the tensioning pinion 31 and the first row of teeth 21 . The spring element 51 in the present case is a tensioning spring which winds around the axle pin 34 in a U shape and engages by one end thereof in a central bore hole of the locking pinion 41 . The other end is attached directly or indirectly on the outside belt part 4 .
[0053] In the present embodiment, this other end of the spring element 51 —that is, the tensioning spring—is fixed by a bore hole 71 being made in a hold-down plate 70 , wherein the end of the spring element 51 which is bent at an angle can engage in the same. This hold-down plate 70 has a rectangular design, for example, and overlaps the first row of teeth 21 , as well as the first tensioning pinion 31 , the first locking pinion 41 , and the spring element 51 . The hold-down plate 70 has a fixed connection to the outside belt part 4 . This connection in the embodiment shown is the result of the fact that the axle pin 34 attached to the outside belt end 4 is also fixed to the hold-down plate 70 . As such, the axle pin 34 can be permanently riveted not only to the outside belt end 4 , but also to the hold-down plate 70 . As an alternative, it is also possible for the hold-down plate 70 to be bolted to the outside belt end.
[0054] As can be seen in FIGS. 1 to 3 , a second tensioning pinion 32 with a second locking pinion 42 and a second spring element 52 , in the form of a tensioning spring, is arranged on the second row of teeth 22 in a similar manner. The ends of this second spring element 52 are again inserted into a bore hole of the second spring element 52 , and into a corresponding bore hole 72 of the hold-down plate 70 . The locking element 42 in this case winds around the axle pin 35 around an angle of approximately 180°, wherein the second tensioning pinion 32 can rotate around said axle pin [ 35 ]. This axle pin 35 as well can be designed as a rivet or bolt.
[0055] The hold-down plate 70 serves the purpose of pressing the toothed bar 20 down during the tensioning process. For this purpose, a hold-down element 74 —for example in the form of a plastic knob—can be attached on the side of the hold-down plate 70 which faces the toothed bar 20 . The toothed bar 20 glides along this hold-down element 74 when the internal sealing collar 1 is expanded, and is pressed down. This can be very clearly seen in FIG. 4 , which shows a cutaway view of FIG. 3 along the cutaway line I-I shown in the same figure. It can be seen that the hold-down element 74 sits on the toothed bar 20 .
[0056] In the embodiments presented in FIGS. 1 to 3 , each of the tensioning pinions 31 , 32 has a lower tooth count than the two locking pinions 41 , 42 . This can, but need not necessarily, be the case.
[0057] The functionality of such an arresting device 10 is as follows.
[0058] When the internal sealing collar 1 is installed in a pipe being sealed, the internal sealing collar 1 is initially introduced with a reduced diameter, and therefore in a somewhat rolled-up state, into the pipe being sealed. An assembly dolly is used for this purpose, bringing the internal sealing collar 1 to the necessary point in the pipe being sealed. Once arrived at the point to be sealed, the assembly dolly effects the expansion of the internal sealing collar. To this end, the inside belt part 3 is moved along the direction of arrow P 1 relative to the outside belt part 4 . A direction of movement corresponding to the arrow P 1 is possible because the two locking pinions 41 , 42 with an overhung mounting yield, along the direction of arrow P 2 shown in FIG. 3 , outward and therefore away from each other, thereby allowing the two tensioning pinions 31 , 32 to rotate freely about their axle pins 34 , 35 due to the two rows of teeth 21 , 22 being pushed upward.
[0059] In contrast, a movement against the direction of arrow P 1 is essentially impossible because the arresting device 10 , described above, locks in this case. The two tensioning springs 51 , 52 pull the two locking pinions 41 , 42 in the direction of the tensioning pinions 31 , 32 , and therefore likewise engage with the same, as well as the two rows of teeth 21 , 22 of the toothed bar 20 . A movement of the inner belt part 3 against the direction of arrow P 1 is therefore effectively blocked.
[0060] As a result of the fact that each of the two separate tensioning pinions 31 , 32 on the toothed bar 20 engages with its own locking pinion 41 , 42 , a greater arresting force is reached compared to conventional arresting devices. The high arresting forces are the result of the fact that the arresting device has four toothed gears—that is, the two tensioning pinions 31 , 32 and the associated locking pinions 41 , 42 —all of which engage with the toothed bar 20 in the locking direction.
[0061] Due to the fact that the locking forces of the tensioning pinion 31 and the associated locking pinion 41 , left and right on the toothed bar 20 , act on the tensioning pinion 32 and the associated locking pinion 42 on the right row of teeth 22 , the locking forces of these toothed gears advantageously work against each other, thereby resulting in an increased static stability of the entire arrangement. In contrast to EP 0 805 932 B1, cited in the introduction to the descriptive portion, the locking forces of the two tensioning pinions in the internal sealing collar described therein act away from each other.
[0062] FIG. 5 shows a third embodiment of an internal sealing collar, in the region of the arresting device 10 . In contrast to the embodiments above, the toothed bar 20 in this case is significantly wider, and the hold-down plate has a two-part design. This means that there is not only one hold-down plate which overlaps the entire toothed bar 20 and the associated tensioning pinions 31 , 32 and locking pinions 41 , 42 . Rather, one smaller hold-down plate 70 A is included for each, only overlapping a portion of the toothed bar 20 , and being fixed—by way of example riveted or bolted—to the outside belt part 40 via a bolt 78 . This bolt 78 is positioned, as shown in FIG. 4 , in the recess 81 for the hold-down plate 70 A illustrated at left therein. The hold-down plate 70 B overlaps a left-hand part of the toothed bar 20 , and is fixed—that is, riveted or bolted—to the outside belt part 4 via a bolt 78 . This bolt 78 is positioned, as shown in FIG. 4 , in the recess 81 for the hold-down plate 70 A illustrated at left therein. In addition, each of the regions of the hold-down plates 70 A, 70 B which overlap the intermediate bar 20 is configured with a downward embossment 70 C which extends downward toward the toothed bar 20 and thereby functions as a hold-down device for the toothed bar 20 .
[0063] A similar hold-down plate 70 B overlaps a part of the second row of teeth 22 in a similar manner, as well as the second tensioning pinion 32 found there and the associated second locking pinion 42 . This second hold-down plate 70 B is again fixed—that is, riveted or bolted—to the outside belt part 4 via a bolt 79 . The two hold-down plates 70 A and 70 B illustrated in FIG. 4 are again attached by means of axle pins 34 , 35 to the outside belt end 4 of the internal sealing collar.
[0064] The third embodiment illustrated in FIG. 6 is similar to the embodiment in FIGS. 1 to 3 . However, in the regions A and B, two identical arresting devices 10 arranged parallel to each other are configured in the embodiment. The reference numbers used above are used again in FIG. 6 , but doubled.
[0065] A further embodiment of an internal sealing collar is shown in detail in FIG. 7 . The illustration corresponds to the embodiment in FIG. 6 , with one difference. The difference is that a slot and/or gap 100 is included between the two toothed bars 20 , extending from the one end of the two toothed bars 20 to the other end of the toothed bars, and projecting further to the end of the outside belt part 3 . This gap and/or slot 100 makes it possible to compensate for a twisting of the internal sealing collar when the same is tensioned. The gap and/or slot 100 in this case has a design with a width such that the corresponding parts of the inside belt end 3 do not overlap when the internal sealing collar is twisted.
[0066] Finally, it is noted that the toothed gears illustrated—that is, the two tensioning pinions 31 , 32 and the associated locking pinions 41 , 42 —can have different tooth counts. In addition, these toothed gears can also have designs with different heights and/or different thicknesses. However, a configuration wherein these toothed gears are identical in both tooth count and thickness is also within the scope of the invention.
[0067] At least the toothed gears consist advantageously of steel—preferably V4A steel—or titanium. Titanium has the advantage of being resistant to acid. The hold-down plates 70 can also be manufactured from these materials.
[0068] Finally, it is noted that the internal sealing collar can be entirely surrounded, on its outer side, by a tube made of rubber-elastic material. In addition, it is also possible that the internal sealing collar 1 is connected, on the outer side, with rubber elastic sealing strips. This increases the sealing effect of the internal sealing collar 1 when the same is placed on the pipe being sealed.
[0069] A sixth embodiment of an internal sealing collar according to the present invention is shown by way of example in FIG. 8 , in the region of the arresting mechanism. The reference numbers used above continue to indicate the same parts. The arresting mechanism in this case includes two toothed bars which are arranged in mirror image to each other along a center line X, positioned respectively to the left and right of a slot 90 , 91 —in the top view in FIG. 8 of the left part of the arresting mechanism—the slot 91 is positioned closer to the left edge of the belt 20 , while the slot 90 is arranged closer to the center line X, and runs parallel to this center line X. The slot 91 has a straight contour toward the left belt end, and comprises a row of teeth 21 on its side which faces the center line X. The tensioning pinion 31 and the locking pinion 41 engage with this row of teeth 21 in the manner described above. The locking pinion 41 also meshes with the tensioning pinion 31 . The spring element is again indicated with the reference number 51 . The right slot 90 has a straight contour toward the center line X, and comprises a row of teeth 23 which faces the row of teeth 21 . A bolt 92 is positioned in the slot 90 , wherein a toothed gear and/or pinion 94 is mounted on the same in a manner allowing rotation. This toothed gear 94 meshes with the row of teeth 23 . A hold-down element 70 A overlaps the slot 90 , 91 in the manner illustrated in FIG. 8 in the region of the tensioning pinion 31 , locking pinion 41 , and toothed gear 94 configured at that position. The hold-down element 70 A again establishes a fixed connection between a bolt 78 and the belt 2 .
[0070] In a similar manner, a further arresting mechanism is positioned in a mirror image on the right side of the center line X. The two slots 90 , 91 comprise rows of teeth 22 , 24 which face each other. A bolt 92 engages in the left slot in FIG. 8 , wherein a toothed gear is mounted on the same in a manner allowing rotation, and engages with the row of teeth 24 . A tensioning pinion 32 and a locking pinion 42 are mounted in the manner described above in the slot 91 illustrated at far-right, wherein the locking pinion 42 is pressed against the tensioning pinion 32 via the spring element 52 . A hold-down element 70 B overlaps the slot 90 , 91 in a similar manner to the hold-down element 70 A, in the region of the toothed gears and/or pinions mentioned above. The hold-down element 70 B is fixed to the belt 2 via a bolt 79 .
[0071] The embodiment illustrated in FIG. 9 is very similar to the embodiment in FIG. 8 . However, the toothed gears and pinions are arranged in the slots 90 , 91 in opposite configurations to each other. This means that in FIG. 9 , in the slot 90 illustrated at left—that is, the slot which is closest to the left belt end—a bolt 92 projects into the slot 90 , wherein a toothed gear 94 is mounted on the same in a manner allowing rotation. This toothed gear 94 meshes with the row of teeth 23 . A slot 91 is positioned to the right thereof, with a row of teeth 21 which the tensioning pinion 31 and the locking pinion 41 engage with. A similar arrangement of tensioning pinion 32 , locking pinion 42 , spring element 52 , and bolt 92 is found on the right side of the center line X in FIG. 9 , placed in mirror image.
[0072] The embodiments in FIG. 10 and FIG. 11 are similar to the embodiments in FIG. 8 and FIG. 9 . The only difference is that in this case there is no row of teeth constructed in the slots 90 . Rather, only one bolt 92 projects into these slots, wherein a disk 93 which is capable of rotation is preferably mounted on the same. This rotating disk 93 is supported in the slot 90 on one edge.
LIST OF REFERENCE NUMBERS
[0000]
1 internal sealing collar
2 belt
2 A end-face belt
3 inside belt part, belt end
4 outside belt part, belt end
10 arresting device
20 toothed bar
21 first row of teeth
22 second row of teeth
24 first longitudinal edge
25 second longitudinal edge
31 first tensioning pinion
32 second tensioning pinion
41 first locking element
42 second locking element
43 bore hole
44 bore hole
34 axle pin
35 axle pin
51 first spring element
52 second spring element
70 hold-down plate
70 A hold-down plate
70 B hold-down plate
70 C downward embossment
71 bore hole
72 bore hole
74 hold-down element
78 bolt
79 bolt
81 first recess
81 a straight longitudinal edge
82 second recess
82 b transverse edge
82 c transverse edge
90 slot
91 slot
92 bolt+
93 disk, rotating element
94 toothed gear
100 gap on inside belt end 3
A first region
B second region
P 1 arrow
P 2 arrow
2 A edge
I-I cutaway line
X center line
[0121] The references recited herein are incorporated herein in their entirety, particularly as they relate to teaching the level of ordinary skill in this art and for any disclosure necessary for the commoner understanding of the subject matter of the claimed invention. It will be clear to a person of ordinary skill in the art that the above embodiments may be altered or that insubstantial changes may be made without departing from the scope of the invention. Accordingly, the scope of the invention is determined by the scope of the following claims and their equitable equivalents.
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The invention is an inner seal collar for inserting into pipes in order to seal leakage points in said pipes, comprising an expandable strip which is bent into the shape of a ring and which is preferably made of steel sheet, parts of said strip at least partly overlapping in the circumferential direction, and comprising a locking device which has at least two parallel rows of teeth, wherein a separate clamping pinion engages into at least two of the rows of teeth. The invention comprises a separate blocking pinion paired with each of the at least two clamping pinions, said blocking pinion pushing against the corresponding clamping pinion via a respective spring element and being engaged with said clamping pinion, and each of the blocking pinions is also engaged with the corresponding row of teeth.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method of controlling operation of an injection molding system for producing a desired product such as a compact disk (CD), a digital video disk (DVD), or the like, wherein the product is molded by an injection molding machine and is further processed in the following or subsequent step or steps. More particularly, the present invention is concerned with such a method of controlling operation of an injection molding system, which method permits the injection molding system to resume its operation in a short time, with a minimized loss of manufacture, when the subsequent step or steps is/are troubled.
2. Description of the Related Art
There is known an injection molding system in which a desired product is molded by an injection molding machine and is then processed in the subsequent step or steps. In this conventional molding system, the injection molding machine is arranged to be held in its normal operation mode so as to continue its injection molding operation, even where the subsequent step(s) is/are unavailable for processing the molded products. There is also known another injection molding system in which a plurality of injection molding machines produce components of a desired product, respectively, and these components are transported to the subsequent common step(s) so as to be assembled into the desired product. In this conventional molding system, each of the injection molding machines is also arranged to be held in its normal operation mode so as to continue its injection molding operation, even in the case where the plurality of injection molding machines are not simultaneously started so that the molded components cannot be assembled in the subsequent step(s).
In order to solve the above-described problems, it can be envisioned a method of once stopping the injection molding machine. However, this method is not practical, since the method causes undesirable decrease in temperature of a mold of the injection molding machine and accordingly causes variation of temperature of a mass of molten or plasticized resin material stored in a heating cylinder of the injection molding machine, thereby requiring a relatively long interval before resuming the injection molding operation of the injection molding machine. This means that the injection molding machine of the conventional injection molding systems is necessarily required to be held in its normal operating condition, even if the subsequent or other step(s) becomes unavailable. In this condition, an injection molding system for producing a CD, for example, may produce a stack of a larger number of molded disk substrates to be processed in the subsequent step(s), requiring a separate storage of these molded disk substrate and a re-execution of only the subsequent step(s) with respect to these stored molded disk substrates. Thus, the conventional injection molding system for producing the CD suffers from extremely low production efficiency.
Further, in a conventional injection molding system for producing a DVD or the like, for example, two injection molding machines produce respective component disks which are transferred to the subsequent common step(s) to provide a bonded composite disk used as the DVD. In this case, the two injection molding machines are required to substantially simultaneously produce the component disks to be bonded together into the bonded composite disk. If this requirement is not satisfied, the resultant bonded composite disk may suffer from occurrence of defects such as bending or buckling thereon. When one of the two injection molding machines does not operate due to a delay in its starting operation, or a stop of its operation, the other injection molding machine is still held in its normal operation mode so as to produce the component disks. Thus, the component disks molded by the other injection molding machine cannot be utilized for producing the bonded composite disks, until the operation of the one injection molding machine is started or resumed, resulting in undesirable disposal of these molded component disks.
SUMMARY OF THE INVENTION
The present invention has been developed in view of the circumstances described above. It is therefore an object of the present invention to provide a method of controlling operation of an injection molding system, which method permits an improved production efficiency of the injection molding system and allows an injection molding device to resume its operation in a short time, when the subsequent step or steps is/are malfunctioned.
The above-indicated object of the present invention may be achieved according to a principle of this invention which provides a method of controlling operation of injection molding device including at least one injection molding device successively executes an injection molding operation thereof so as to successively produce a molded product, at least one takeout device successively takes out the molded product from the corresponding injection molding device so as to successively transfer the molded product to a subsequent-step part adapted to further process the molded product, and a monitoring device adapted to detect an abnormal operation in the subsequent-step part and generate an abnormal signal upon detection of the abnormal operation, the method comprising the steps of: changing an operation mode of the at least one takeout device so as to transfer the molded disk to a part which is separate from the subsequent-step part, upon generation of the abnormal signal by the monitoring device; and extending a cycle time of the injection molding operation of the at least one injection molding device, upon generation of the abnormal signal by the monitoring device.
Preferably, the extension of the cycle time is executed by controlling a cooling time and/or an intermediate time after a completion of the product-takeout action and before an initiation of the mold closing action, by a suitable timer.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features, advantages and technical and industrial significance of the present invention will be better understood by reading the following detailed description of the presently preferred embodiment of the invention, when considered in connection with the accompanying drawings, in which:
FIG. 1 is a block diagram schematically showing one example of an injection molding system utilized upon executing a method of controlling operation of the injection molding system according to the present invention;
FIG. 2 is a flow chart illustrating a routine for operating an injection molding device according to selective one of a normal operation mode and a cycle-time extension mode, and for stopping the operation of the injection molding device; and
FIG. 3 is a time chart illustrating an operation condition of the injection molding machine in the cycle-time extension mode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, there is schematically shown an injection molding system including an injection molding device 1 , a takeout device 3 , a subsequent-step part 4 , a stock part 7 as a part. The injection molding device 1 may be constituted by a known injection molding device having an injection device and a mold clamping device. As well known in the art, the mold claming device is adapted to clamp a mold consisting of a pair of mold halves which are brought into contact with each other to define therebetween a mold cavity whose configuration is corresponding to that of a desired product, while the injection device is adapted to heat and melt a suitable resin material therein. The injection device is operable to injection-the molten resin into the mold cavity of the mold clamped by the mold claming device. The injection molding device 1 is operated according to a time chart of FIG. 3 so as to produce a desired product 5 . It is noted that the injection molding device 1 may be constituted by a single injection molding device, or alternatively by a plurality of injection molding devices.
The takeout device 3 is adapted to take out the molded product 2 from the injection molding device 1 , and then transfer the molded product 2 to the subsequent-step part 4 . Various kinds of known takeout devices may be usable as the takeout device 3 . For instance, an arm-type or a shoot-type takeout device is employable. More specifically described, the arm-type takeout device includes a working arm which is movable, after the mold is opened, in the vicinity of the molded product 2 held by one mold half, so as to suction the molded product 2 by applying a vacuum force to the molded product 2 . The working arm is then moved to a desired portion while holding the molded product 2 by the vacuum force, so as to transfer the molded product 2 to the desired portion. The shoot-type takeout device includes a shoot member which is adapted to receive the molded product 2 ejected and dropped from the opened mold, and then to carry the molded product 2 to the desired portion.
In the subsequent-step part 4 , the molded product 2 is further processed by known treatments such as vapor deposition, application of a protective layer and printing (which will be described later). The subsequent-step part 4 is provided with a monitoring device (not shown) which is adapted to detect an abnormal operation in the subsequent-step part 4 , and generates an abnormal signal 6 upon detection of the abnormal operation. The abnormal signal 6 is applied to the takeout device 3 . In the present embodiment, the operation of the takeout device 3 is controlled, such that the takeout device 3 changes its operation mode from a normal operation mode in which the molded product 2 is transferred to the subsequent-step part 4 to an abnormal operation mode in which the molded product 2 is transferred to the stock part 7 , when the abnormal signal 6 is applied to the takeout device 3 . The abnormal signal 6 is also applied to the injection molding device 1 . Upon application of the abnormal signal 6 , the injection molding device 1 is controlled to change its operation modes from a normal operation mode to a cycle-time extension mode or an automatically stopping mode, according to the control flow of FIG. 2 .
The subsequent-step part 4 is presented in order to apply further required treatments to the molded product 2 in order to finalize the molded product 2 as a desired product 5 . When the injection molding system is arranged to produce a CD, a disk substrate molded by the injection molding device 1 is further processed in the subsequent-step part 4 such that a reflector film made of pure aluminum is formed by vapor deposition on one of opposite major surfaces of the disk substrate on which the information in the form of pits has been reproduced, and then a protective film made of a synthetic resin material is formed on the formed reflector film. When the injection molding system is arranged to produce a DVD, the subsequent-step part 4 includes not only the step for forming the reflector film on the surface of each of two component disks separately molded by two injection molding devices 1 , but also steps for bonding the component disks to each other at respective surfaces on which the reflector films are formed, and for printing a desired design on one or both of opposite major surfaces of a bonded composite disk. In order to improve production efficiency, the production line of the injection molding system is arranged such that the subsequent-step part 4 successively processes the molded product 2 successively transferred from the injection molding device 1 , leading to no accumulation of the molded product 2 in the production line. For ensuring no accumulation of the molded product 2 in the production line, a method of controlling the operation of the injection molding system according to the present embodiment is arranged, such that the monitoring device of the subsequent-step part 4 generates the abnormal signal 6 upon detecting of the abnormal operation or malfunction in the subsequent-step part 4 which causes inability of the subsequent-step part 4 for processing the molded product 2 . The generated abnormal signal 6 is transmitted to the takeout device 3 and the injection molding device 1 . Upon receiving the abnormal signal 6 from the monitoring device, the takeout device 3 changes its operation mode from the normal operation mode to the abnormal operation mode so as to transfer the molded product 2 to the stock part 7 , so that unnecessary transportation of the molded product 2 to the subsequent-step part 4 is effectively avoided. The injection molding device 1 changes its operation mode, upon receiving the abnormal signal 6 from the monitoring device, from the normal operation mode to the cycle-time extension mode, whereby the injection molding device 1 can be operated with an extended cycle time. In this respect, the cycle time may be extended within a predetermined range so that adverse effects of the extension of the cycle time upon resuming the injection molding operation of the injection molding device 1 is minimized.
Referring next to FIG. 2, there will be described in detail the operation of the injection molding device 1 which is sequentially controlled according to a flow chart of FIG. 2, by utilizing a suitable control device (not shown) such as a programmable logic controller (PLC) including a sequencer, for example. The control device includes a micro processing unit (MPU), a read only memory (ROM), a random access memory (RAM), and an input and output (I/ 0 ) port. It is noted that one operation cycle of the injection molding device 1 is started from a mold closing action, as is apparent from a time chart of FIG. 3 . That is, an initiation signal is generated when the molded product 2 is taken out from the mold half by the takeout device 3 . Once the current operation cycle is started, the control flow goes to Step S 1 at which the MPU of the control device determines whether the initiation signal is detected. If an affirmative decision (YES) is obtained at Step S 1 , the control flow goes to Step S 2 to allow the injection molding device 1 to initiate its operation according to the normal operation mode. If a negative decision (NO) is obtained in Step S 1 , the control flow goes back to recommence Step S 1 . Step S 2 is followed by Step S 3 at which the MPU judges whether the abnormal signal 6 is generated in the subsequent-step part 4 . If a negative decision (NO) is obtained at Step S 3 , namely if the abnormal signal 6 is not generated, the control flow goes to Step S 4 to allow the injection molding device 1 to execute a current injection molding cycle according to the normal operation mode. Step S 4 is followed by Step S 5 to initialize (e.g., initialize to zero) a counter number (n) variable of an abnormal counter for counting the number of execution of the injection molding according to the cycle-time extension mode.
On the other hand, if an affirmative decision (YES) is obtained at Step S 3 , namely if the abnormal signal 6 is generated in the subsequent-step part 4 , the control flow goes to Step S 6 at which the operation mode of the injection molding device 1 automatically changes from the normal operation mode to the cycle-time extension mode which is previously stored in the RAM of the control device. Step S 6 is followed by Step S 7 to allow the injection molding device 1 to execute the current injection molding cycle according to the cycle-time extension mode. The process flow goes to Step S 8 at which the counter number (n) variable of the abnormal counter is increased by one. It is noted that the counter number (n) variable of the abnormal counter is increased by one every injection molding cycle according to the cycle-time extension mode.
Step S 8 is followed by Step S 9 at which verification is made regarding whether the value of the current counter number (n) variable is made equal to a predetermined value stored in the RAM of the control device. If the affirmative decision (YES) is obtained in Step S 9 , the control flow goes to Step S 10 to automatically stop the operation of the injection molding device 1 . The provision of Step S 10 is effective to prevent unnecessary production of a larger number of disks to be disposed, when a relatively long time is needed for eliminating or repairing defects in the subsequent-step part 4 . If the defects in the subsequent-step part 4 are eliminated, the abnormal signal 6 is canceled, so that the injection molding device 1 and the takeout device 3 are both continuously operated according to the respective normal operation modes.
Referring next to FIG. 3, there will be described in detail the operation of the injection molding device 1 according to the cycle-time extension mode. Upon generation of the initiation signal, there is initiated a series of injection molding operations such as a mold closing action, a nozzle forwarding action, a mold clamping action, injection action, a cooling time, a mold opening action, a product takeout, and the like. As shown in FIG. 3, the mold closing action in the mold clamping device and the nozzle forwarding action in the injection device are simultaneously initiated. In the mold clamping device, the subsequent actions, i.e., the mold clamping action, the injection action, the cooling time, the mold opening action, the product takeout are successively executed. Depending on molding conditions, the injection device needs to execute its injection molding operation with its nozzle portion held in communication with a sprue leading to the cavity of the mold, without executing a reciprocal motion of the injection device in a direction toward and away from the mold. In FIG. 3, hatched arrows (a), (b), (c), (d) indicate timers or time counters which are available for the cycle-time extension mode, while a non-hatched arrow (e) indicates a timer or a time counter which is available when the injection device is reciprocally moved. That is, the timer (e) functions as a delay time counter for measuring a predetermined delay time (e.g., a fixed timer for 0.5 seconds) after the injection device has reached to its fully advanced position and before the initiation of the injection action, so that the injection action of the injection device is initiated when the delay time has passed. The presence of the delay time counter (e) is effective to assure a fully engagement between the nozzle portion of the injection device and the sprue leading to the mold cavity of the mold. These timers (a)-(e) are effectively constituted by utilizing functions of the control device (PLC).
The timer (a) as a first timer is arranged to initiate a measurement of a predetermined delay time after the completion of the injection action. When the timer (a) has measured the predetermined delay time, then a cooling timer initiates a measurement of a predetermined cooling time. The provision of the timer (a) leads to a substantially extended cooling time, resulting in an extension in the cycle time. In this embodiment, the timer (a) is arranged in and controlled by the control device, while predetermined values of the delay timer is stored in the RAM of the control device. While the timer (a) is constructed independently of the cooling timer in this embodiment, the timer (a) may otherwise be embodied by utilizing the cooling timer. In this case, the predetermined cooling time of the cooling timer may be extended by an appropriate delay time. Alternatively, the cooling time of the cooling timer may be arranged to be variable depending on the appropriate delay time.
The timer (b) as a second timer is arranged to initiate a measurement of a predetermined delay time after the completion of the product takeout action by the takeout device 3 . When the timer (b) has measured the predetermined delay time, then the next injection molding cycle is started by the initiation of the mold closing action. The provision of the timer (b) leads to a substantially extended intermediate time after the completion of the current molding cycle and before the initiation of the next molding cycle, resulting in an extension in the cycle time. In this embodiment, the timer (b) is arranged in and controlled by the control device, while predetermined values of the delay time is stored in the RAM of the control device. While the timer (b) is constructed independently of a conventional intermediate timer for measuring a predetermined intermediate time after the completion of the mold opening action before the mold closing action, in this embodiment, the timer (b) may otherwise be embodied by utilizing the intermediate timer. In this case, the predetermined intermediate time of the intermediate timer may be extended by an appropriate delay time. Alternatively, the intermediate time of the intermediate timer may be arranged to be variable depending on the appropriate delay time.
In general, an injection molding system arranged for producing a DVD or a CD-R is required to increase temperatures of the mold and nozzle portion to a relatively high level, in comparison with an injection molding system arranged for producing a CD. Owing to the high temperatures of the mold and nozzle portion, an extension of a cooling time only by about 15 seconds does not provide significant adverse effects on the successive injection molding condition. For the above reasons, the injection molding operation according to the cycle-time extension mode can be operated in a cycle time of about 18 seconds, while the injection molding operation according to the normal operation mode is operated in a cycle time of 4-5 seconds. Thus, the number of the disposed disks produced in the injection molding according to the cycle-time extension mode can be reduced to not greater than one-thirds of the number of the disposed disks produced in the injection molding operation according to the normal operation mode. Meanwhile, the above-mentioned need for the high-temperatures of the mold and nozzle portion may possibly restrict the extension of the intermediate time. Namely, the extension of the intermediate time leads to a larger amount of heat radiation from the mold cavity, since the mold is opened during the intermediate time. This may possibly cause a significant adverse effect on the following injection molding cycle, and an increase in possibility of drawing of the molten resin out of the nozzle portion, when the injection device is moved away from the mold. Thus, it is desirable in the injection molding system arranged for producing the DVD or CD-R not to employ the cycle-time extension mode in which the intermediate time is extended.
On the other hand, the injection molding system arranged for producing a CD is generally operated to execute an injection molding operation with relatively-low mold and nozzle temperatures and with a relatively short cycle time. Due to this characteristics of the injection molding system for producing the CD, an amount of extension of the cooling time is substantially limited to as much as 8 seconds, while the intermediate time can be extended for about 5 seconds. In the injection molding system arranged for producing the CD, both of the cooling and intermediate times can be utilized for the cycle-time extension mode, thereby permitting a cycle time of about 16 seconds in its cycle-time extension mode, although the injection molding operation according to the normal operation mode requires a cycle time of 3.5-4.0 seconds. Thus, the number of the disposed disks produced in the injection molding operation according to the cycle-time extension mode can be reduced to not greater than one-fourth of the number of the disposed disks produced in the injection molding operation according to the normal operation mode.
When the injection molding system for producing the CD is operated according to the cycle-time extension mode in which the intermediate time is extended, the molten resin in the nozzle portion may possibly flow into and solidify within the sprue of the mold, if the nozzle portion of the injection device is held in communication with the sprue of the mold, resulting in undesirable closing of the sprue. To avoid this drawback, the cycle-time extension mode of the injection molding system for producing the CD is desirably further arranged such that the timer (c) as a third timer is initiate to measure a predetermined time after the completion of the mold opening action, during which the injection device is retracted in the direction away from the mold, and that the timer (d) as a fourth timer is also initiated at the same time when the timer (c) is initiated, so as to measure a predetermined time during which the screw of the injection device is retracted in the direction away from the nozzle portion of the injection device, thereby preventing drawing of the molten resin out of the nozzle. In this respect, the timers (c), (d) are constituted independently of each other and independently of the timer (b) so that an amount of retraction of the nozzle portion and an amount of retraction of the screw are respectively determined independently of each other and independently of the intermediate time determined by the timer (b).
As is apparent from the aforementioned description, an injection molding system arranged for producing a disk product such as a CD in which the subsequent-step part is required to finalize the molded product, is effectively controlled by the present controlling method so that the number of overproduced or unnecessary products to be disposed is significantly decreased, even when the injection molding device is required to continuously execute its injection molding operation under malfunction of the subsequent-step part. Further, the injection molding system for producing the CD is effectively controlled by the present controlling method so that the injection molding system is capable of resuming its injection molding operation in a short time. The present method also effectively controls an operation of another injection molding system arranged for producing a disk product such as a DVD in which two injection molding devices respectively produce component disks which are transferred to the subsequent-step part so as to be bonded together to be provided as a bonded composite disk. More specifically described, if one of the two injection molding devices is malfunctioned due to a retard of its startup operation or a stop of its operation, the other injection molding device can be controllable to be operated in a cycle-time extension mode. Therefore, the present method can decrease the number of unusable disk components to be disposed, which disk components are produced by the other injection molding device until the one injection molding device becomes available for molding the component disk.
While the present invention has been described in detail in its presently preferred embodiment by reference to the accompanying drawings, for illustrative purpose only, it is to be understood that the invention is not limited to the details of the illustrated embodiment, but may be otherwise embodied with various other changes, modifications and improvements, which may occur to those skilled in the art, in the light of the foregoing teachings, without departing from the spirit and scope of the invention defined in the subsequent claims.
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A method of controlling operation of an injection molding system in which at least one injection molding device successively executes an injection molding operation thereof so as to successively produce the molded product, and at least one takeout device successively takes out the molded product from the corresponding injection molding device so as to successively transfer the molded product to a subsequent-step part in which the molded product is further processed, while a monitoring device is arranged for detecting an abnormal operation in the subsequent-step part and generating an abnormal signal upon detection of the abnormal signal, the method comprising the steps of: changing an operation mode of the at least one of takeout device so as to transfer the molded disk to another part which is separate from the subsequent-step part, upon generation of the abnormal signal by the monitoring device; and extending a cycle time of the injection molding operation of the at least one injection molding device upon generation of the abnormal signal by the monitoring device.
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BACKGROUND OF THE INVENTION
[0001] The present invention is related to a D.C.-A.C. converting circuit applicable to electronic parts such as electroluminescent cells. During the conversion of the electronic parts from low voltage D.C. to high voltage A.C., the circuit of the present invention is able to overcome the inherent voltage barrier problem and effectively enhance output voltage.
[0002] Various electroluminescent cells (EL) have been developed and widely used in various fields. However, the D.C.-A.C. converting circuit for driving the electroluminescent cell is still not optimal and needs to be improved. A prior technology discloses a circuit structure (as shown in FIG. 1) for driving the electroluminescent cell. The circuit is a full-wave A.C. boosting circuit. The left side of the phantom line is boosting part, while the right side of the phantom line is a switch part forming alternate current. A high voltage signal is formed at point H. However, when passing through the switch part, due to the inherent voltage barrier problem of the electronic parts, the highvoltage at point Hwill about 10˜30% decay. As a result, the efficiency will be discounted. With respect to the above problem, it is found by the applicant that in fact, the “on/off” of the transistor (electronic switch) is activated by the signal of the controlling end. The speed of the electronic switch is an important factor of the efficiency of boosting. When turning from “on” to “off”, the shorter the activation time is, the higher the high voltage signal energized by the inductance is, that is, the better the efficiency is. In general control, in the case that the signal A is high potential, Q 1 is powered on, while in the case that the signal A is low potential, Q 1 is cut off. However, the existence of parasitic capacity in Q 1 and the operation rate of Q 1 itself limit the output thereof. By means of speeding the cutoff of Q 1 , the output of Q 1 will be effectively enhanced. This measure is applicable to half-wave structure as shown in FIG. 2 and to full-wave boosting structure as shown in FIGS. 1 and 3 to effectively enhance output voltage.
[0003] The above-identified prior technology discloses a circuit structure for driving the electroluminescent cell as shown in FIG. 3. U.S. Pat. No. 650,228 discloses a circuit structure for driving the electroluminescent cell as shown in FIG. 4. FIG. 5 shows a part for controlling signal waveform. According to the aforesaid concept, in the case that the controlling signals A, B are modified into the pattern as shown in FIG. 6, the efficiency will be about 20˜30% increased.
SUMMARY OF THE INVENTION
[0004] It is therefore a primary object of the present invention to provide a D.C.-A.C. converting circuit capable of increasing boosting efficiency.
[0005] It is a further object of the present invention to provide the above D.C.-A.C. converting circuit capable of reducing the noise caused by the electronic switch.
[0006] The present invention can be best understood through the following description and accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a circuit diagram of a conventional full-wave boosting circuit (Prior Art);
[0008] [0008]FIG. 2 is a circuit diagram of a conventional half-wave boosting circuit (Prior Art);
[0009] [0009]FIG. 3 is a circuit diagram of another type of conventional full-wave boosting circuit, showing the switch part thereof (Prior Art);
[0010] [0010]FIG. 4 is a circuit diagram of still another conventional full-wave boosting circuit (Prior Art);
[0011] [0011]FIG. 5 is a diagram of a waveform of the controlling signal according to FIG. 3;
[0012] [0012]FIG. 6 is a diagram of another waveform of the controlling signal according to FIG. 3;
[0013] [0013]FIG. 7 is a circuit diagram of a preferred application of the present invention;
[0014] [0014]FIG. 8 is a diagram of a waveform of the controlling signal according to FIG. 7;
[0015] [0015]FIG. 9 is a circuit diagram of another preferred application of the present invention;
[0016] [0016]FIG. 10 is a diagram of a waveform of the controlling signal according to FIG. 9;
[0017] [0017]FIG. 11 is a diagram of a conventional waveform of the high voltage A.C. signal of a loading;
[0018] [0018]FIG. 12 is a diagram of another waveform of the high voltage A.C. signal for driving a loading of the present invention;
[0019] [0019]FIG. 13 is a diagram of still another waveform of the high voltage A.C. signal for driving a loading of the present invention;
[0020] [0020]FIG. 14 is a circuit diagram of still another preferred application of the present invention;
[0021] [0021]FIG. 15 is a diagram of the controlling signal and output waveform according to FIG. 14;
[0022] [0022]FIG. 16 is a diagram of a modified waveform applying the structure of FIG. 2;
[0023] [0023]FIG. 17 is a diagram of another modified waveform applying the structure of FIG. 2;
[0024] [0024]FIG. 18 is a circuit diagram of still another preferred application of the present invention;
[0025] [0025]FIG. 19 is a circuit diagram of a conventional controlling circuit;
[0026] [0026]FIG. 20 is a diagram of still another waveform of the high voltage A.C. signal for driving a loading of the present invention;
[0027] [0027]FIG. 21 is a diagram of a modified waveform applying the structure of FIG. 8;
[0028] [0028]FIG. 22 is a diagram of a modified waveform applying the structure of FIG. 10;
[0029] [0029]FIG. 23 is a diagram of still another waveform of the high voltage A.C. signal for driving a loading of the present invention;
[0030] [0030]FIG. 24 is a circuit diagram of still another preferred application of the present invention;
[0031] [0031]FIG. 25 is a diagram of the switch circuit of a conventional full-wave boosting circuit; and
[0032] [0032]FIG. 26 is a diagram of a waveform of the controlling signal according to FIG. 25.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Please refer to FIG. 7. The capacitive loading D.C.-A.C. converting circuit capable of increasing boosting efficiency and reducing noise of the present invention includes several transistors Q 1 ˜Q 5 , several diodes D 1 ˜D 2 and several cooperative electronic parts such as inductors and capacitors. Each of the left and right halves of the capacitive loading has a set of boosting circuit. When the left half works, the transistor Q 4 is turned on, while Q 5 is cut off and Q 1 is turned on, while Q 3 is cut off. After a period of time, the point H 1 of the controlling signal B of Q 2 (also referring to FIG. 8) will be boosted to a high voltage state. At this time, the transistor Q 2 will stop operating. Q 1 is cut off, while Q 3 is turned on. The point H 1 discharges through Q 3 and is instantaneously lowered from high voltage to a nearly zero potential. Thereafter, the transistor Q 4 is cut off, while Q 6 is turned on and Q 5 operates according to signal E. Further after a period of time, point H 2 also reaches a high potential. Then Q 4 is turned on, while Q 6 is cut off and Q 5 stops operating. The point H 2 discharges and is lowered from high potential to a nearly zero potential. Accordingly, repeatedly, high voltage is sequentially generated at two ends of the capacitive loading to form a high voltage A.C. signal. This structure is advantageous in that the electronic switch in the phantom line frame of FIG. 1 is replaced with D 1 , D 2 so that the signal added to the load will be more efficient.
[0034] [0034]FIG. 9 shows another preferred embodiment of the circuit of the present invention, in which when Q 3 , Q 4 are cut off, Q 1 is turned on and Q 2 operates according to the controlling signal B of FIG. 10. After a period of time, point H reaches a high voltage point and Q 1 , Q 2 are cut off, while Q 4 is turned on and Q 3 operates according to controlling signal C. The point H first discharges through D 3 , L 2 , Q 4 to a nearly zero potential. Then, due to the negative voltage boosting of L 2 and Q 3 , after a period of time, point H reaches a high negative voltage. At this time, Q 3 , Q 4 are cut off, while Q 1 is turned on and Q 2 operates. After point H is recharged from high negative voltage to zero potential, point H is further charged to high positive voltage. According to such cycle, a continuous high voltage A.C. signal is formed as shown in FIG. 10.
[0035] In the above circuit structure, D 1 and D 4 are mainly used to prevent the transistors from breaking. With respect to D 4 , when Q 1 , Q 2 operate and Q 3 , Q 4 are cut off, point H will have a high positive voltage signal and point K is also a high positive voltage signal. At this time, Q 4 is in off state. Q 4 is an NPN type transistor so that the collector C of Q 4 can bear the high positive voltage to a certain extent without breaking. However, Q 3 is a PNP type transistor so that the collector C of Q 3 cannot bear the high positive voltage. Therefore, a diode D 4 is added to prevent Q 3 from breaking and thus avoid failure of high voltage. Similarly, D 1 is added, for Q 2 cannot bear high negative voltage. In addition, the measures of FIGS. 7 and 9 can be used in cooperation with the aforesaid measure for changing the level of the controlling signal into negative voltage or positive voltage greater than VDD so as to more effectively increase the whole efficiency.
[0036] All the above circuit structures can boost low voltage D.C. signal into high voltage A.C. signal. However, there is still a problem existing in such circuit structures, that is, interference problem. In general, such driving structure is co-used with other IC or electronic parts. The boosting operation will lead to a high-frequency interference signal or even audible noise. In order to solve this problem, the above three circuit structures are further modified. FIG. 11 shows a driving high voltage A.C. signal of a loading. Such high voltage A.C. signal is achievable from the above three circuit structures. The circled part of FIG. 11 is the part which most often causes interference signal. The optimal waveform is sinusoidal wave. However, for achieving the optimal sinusoidal wave, a more complicated circuit structure is necessary. This is not desired. Therefore, the waveform of FIG. 11 can be simplified into the alternative waveform as shown in FIGS. 12 or 13 .
[0037] The conventional circuit structure of FIG. 1 can be such modified that only two resistors and two transistors are added as shown in FIG. 14 to achieve the waveform of FIG. 12. FIG. 15 shows the controlling signal and output waveform thereof.
[0038] Furthermore, in FIG. 2, the R can be achieved by limiting the current when starting to discharge. The waveform is as shown in FIG. 16. The value of the Rwill determine the slope of the H. This concept is better than that when the value of the R is zero ( instantaneous discharge of capacitive loading ). However, it is still not optimal. The even better measure is to let R zero. By means of the signal B of FIG. 2 or the signals B and C of FIG. 14, which control and energize the transistors in cooperation with the change of bandwidth of signal A, the effect as shown in FIG. 17 can be achieved. Due to the change of bandwidth of Ad, the position Ha will become more smooth. The position Ib controls the magnitude of the discharged current to obtain the waveform of Hb. Accordingly, the waveform of h can be nearer to the sinusoidal wave. Therefore, the interference and noise of the capacitive loading such as electroluminescent cell can be reduced.
[0039] Furthermore, FIG. 18 shows a more idealistic measure for directly changing the current of the controlling signal and achieving the object without adding any extra part. When C=“H” ( high potential ) and E=“H”, H 2 is equal to grounding, while when B=“L” (low potential) and D=“L”, after a period of time, H 1 will be charged to high voltage. At this time, A stops sending signal and theoretically point H 1 will remain in a high voltage state. At this time, D sends in a stable constant small current and Q 8 is in a high impedance energized state. H 1 slowly discharges through Q 8 to obtain the waveform as shown in FIG. 12. Reversely, H 2 is the same. Certainly, there are many measures for controlling the constant current. FIG. 19 shows an ordinary application in which Q 8 or Q 9 of FIG. 18 is controlled to discharge via constant current. Moreover, if the controlled current during the discharge is not constant and is slowly increased along with the time or the controlled current discharged through Q 8 or Q 9 is increased along with the time, the optimal waveform as shown in FIG. 13 can be achieved.
[0040] [0040]FIG. 20 is a diagram of the rectified controlling signal for reducing the interference of the circuit structure, in which T 1 means that signal B is a constant small current and Q 2 is in a high impedance energized state, while T 2 means that signal A is a constant small current and Q 1 is also in a high impedance energized state.
[0041] By means of the above rectifying measure, the signal waveform of FIG. 8 is further modified into the pattern of FIG. 21, in which T 1 means that Q 3 of FIG. 7 is in a high impedance energized state, while T 2 means that Q 4 of FIG. 7 is in a high impedance energized state. FIG. 10 is modified into the signal waveform of FIG. 22 capable of reducing noise, in which T 1 means that Q 4 of FIG. 9 is in a high impedance energized state, while T 2 means that Q 1 of FIG. 9 is in a high impedance energized state. The boosting controlling signal is further changed to make the output waveform nearer to the sinusoidal wave as shown in FIG. 23.
[0042] In addition, as shown in FIG. 24, the present invention can be extensively applied to a field necessitating multiple EL to achieve independent control. For example, both the inner and outer panels of a mobile phone need backlight. The low voltage D.C. boosting block is referred to FIG. 1 and the switch structure is as shown in FIG. 25. When SW* 1 and SW* 2 are in energized state in reverse direction and the SWC* serves as the common point of all the signals, SW 11 to SWC 1 is in reverse direction or in the same direction and SW 21 to SWC 1 is in reverse direction or in the same direction. Accordingly, SWC 1 , SWC 2 , SW 11 and SW 12 will form a full-bridge switch. That is, when SWC 1 and SW 12 are energized, SWC 2 and SW 11 are cut off. Reversely, when SWC 1 and SW 12 are cut off, SWC 2 and SW 11 are energized. Accordingly, alternately, the voltage applied to EL 1 will be in a continuous high voltage A.C. pattern. When cutting off EL 1 , the SWC 1 and SW 11 and SWC 2 and SW 12 are adjusted to be in the same direction. Accordingly, a continuous high voltage A.C. signal cycle is formed as shown in FIG. 10. By means of the above measure, multiple EL can be independently controlled and the noise is reduced.
[0043] The above embodiments are only used to illustrate the present invention, not intended to limit the scope thereof. Many modifications of the above embodiments can be made without departing from the spirit of the present invention.
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D.C.-A.C. converting circuit capable of increasing boosting efficiency and reducing noise, including a boosting section composed of serially connected transistors, inductors and capacitors and an A.C. electronic switch part composed of several transistors (electronic switches such as MOSFET, gate throttle, etc.) and capacitors. When the signal for controlling the operation of the transistors is boosted from low potential to high potential, the operation of the transistors is speeded. When cut off, the signal is formed with a negative voltage level pattern, whereby the transistors can be more quickly cut off. The electronic switch part of the circuit is replaceable with several serially connected diodes to also achieve the voltage for increasing boosting efficiency. During discharge, a measure for controlling the current of the circuit is added so as to reduce the noise produced during boosting procedure.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is related to U.S. Patent Application No. 60/478,835, filed Jun. 17, 2003, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to high-pI materials and hydrolytically stable, high-pI hydrogel and/or membrane compositions made from these materials. Additionally, this invention relates to the use of hydrolytically stable, high-pI hydrogel and/or membrane compositions in analytical and preparative-scale isoelectric focusing separation and/or isoelectric trapping separation of ampholytic compounds.
BACKGROUND OF THE INVENTION
[0003] Electrophoretic techniques and isoelectric focusing (IEF) techniques in particular, remain key technologies for the separation of ampholytic components. IEF is a widely used technique that may be performed on either an analytical or a preparative scale. For example, IEF may be used in clinical diagnosis, biotechnology, pharmaceutical and food industries. Furthermore, IEF may be used alone or may be used in combination with other analytical or preparative techniques.
[0004] In IEF, ampholytic components are separated with the help of an electric field in a pH gradient wherein the pH increases from a lower pH value at the anode to a higher pH value at the cathode. (For a monograph on IEF, see, e.g., P. G. Righetti, Isoelectric focusing: theory, methodology and applications, Elsevier Biomedical, Amsterdam, 1983, which is herein incorporated by reference). Since the net charge of an ampholytic component is zero in its isoelectric state, the electrophoretic migration velocity of an ampholytic component is zero whenever the pH of its environment becomes equal to its isoelectric point (pI) value. Thus, ampholytic components with different pI values stop migrating at different points in a pH gradient.
[0005] Relatively stable continuous pH gradients can be created by several means. For example, mixtures of carrier ampholytes (compounds that have adequate buffering ability and conductivity in the vicinity of their pI value) may be used. Alternatively, appropriate amounts of suitable weak acids and weak bases or weak acids and strong bases or strong acids and weak bases may be bound, in a spatially controlled manner, into an ion-permeable matrix, such as a cross-linked polyacrylamide gel. The bound acids and bases provide a preformed and stabilized the pH gradient which may then be used for immobilized pH gradient IEF (IPGIEF). (For a monograph on IPGIEF, see, e.g., P. G. Righetti, Immobilized pH gradients: theory and methodology, Elsevier, Amsterdam, 1990, which is herein incorporated by reference).
[0006] Ampholytic sample components can also be separated from each other by isoelectric trapping (IET) utilizing isoelectric membrane-based multicompartmental electrolyzers (e.g., Faupel et al., U.S. Pat. No. 5,082,548, which is incorporated herein by reference) wherein at the end of an IET separation process, ampholytic sample components are obtained in their isoelectric state.
[0007] Despite the versatility of IEF and IET technologies, the present methods are not particularly suitable for separation or processing of compounds having very high isoelectric points, because the separation media presently employed are not particularly stable at extreme pH values. Thus, there is a need in the art for hydrolytically stable, high-pI hydrogel and/or membrane compositions for the separation of compounds having very high pI values. As will become apparent from the following detailed description, the present invention provides hydrolytically stable, high-pI hydrogel and/or membrane compositions to meet this and other needs.
SUMMARY OF THE INVENTION
[0008] The invention provides a hydrolytically stable isoelectric hydrogel material having a pI value in the range of 11.5<pI<14, that is comprised of an isoelectric compound having a pI value in the range of 11.5<pI<14. The pI of the isoelectric compound and thus, the pI of the hydrolytically stable isoelectric hydrogel material, is conferred by the pI value of the isoelectric compound. The hydrolytically stable isoelectric hydrogel material may further comprise a hydrolytically stable hydrophilic polymer and a cross-linker. The invention also provides a hydrolytically stable isoelectric membrane that comprises the hydrolytically stable isoelectric hydrogel material, and methods for preparing a hydrolytically stable isoelectric membrane.
[0009] Thus, in a first aspect, the present invention provides a hydrolytically stable isoelectric hydrogel material having a pI value in the range of 11.5<pI<14 (e.g., between 11.5, 12, 12.5, 13, 13.5, and 14), wherein the hydrolytically stable isoelectric hydrogel material comprises an isoelectric compound having a pI value in the range of 11.5<pI<14, wherein the pI is established by a substantially permanently cationic group and two hydroxyl groups with pK a values in the range of 11.5<pK a <14. The hydrolytically stable isoelectric hydrogel material also comprises an additional reactive group, and the pI value of the isoelectric hydrogel is conferred by the pI value of the isoelectric compound. In another aspect, the hydrolytically stable isoelectric hydrogel material may further comprise a hydrolytically stable hydrophilic polymer comprised of two or more reactive groups that are substantially free of ionic functional groups, together with a cross-linker substantially free of ionic functional groups that comprises two groups able to react with both the isoelectric compound and the hydrolytically stable polymer without altering the pI value of the isoelectric compound by more than about 1 pH unit. In one aspect, the pI value of the isoelectric hydrogel is changed by changing identity of the isoelectric compound.
[0010] In another aspect, the isoelectric compound comprising the isoelectric hydrogel material is present at a concentration that is equal to or higher than necessary to create an aqueous solution of the isoelectric compound having pH equal to the pI value of the isoelectric compound.
[0011] In another aspect, the isoelectric compound is a native or derivatized carbohydrate or polyhydroxy compound, the permanently cationic functional group is a quaternary ammonium group, the additional reactive group of the isoelectric compound is a hydroxyl group, the hydrolytically stable hydrophilic polymer is an oligosaccharide or a synthetic polymer containing multiple hydroxyl groups, and the cross-linker has two or more reactive groups selected from the group consisting of an aldehyde, epoxy, halo, alkylsulfonyl, and arylsulfonyl groups.
[0012] In another aspect, the native or derivatized carbohydrate or polyhydroxy compound comprising the isoelectric compound is selected from the group consisting of native or derivatized monosaccharides, native or derivatized disaccharides, native or derivatized trisaccharides, native or derivatized oligosaccharides, native or derivatized polysaccharides, native or derivatized cyclodextrins, native or derivatized maltodextrins, native or derivatized amyloses, native or derivatized dextrans, native or derivatized starches, native or derivatized celluloses, and native or derivatized guar gums, the quaternary ammonium group comprising the cationic functional group comprises one or more substituents selected from the group consisting of methyl, ethyl, propyl, butyl, higher alkyl, hydroxymethyl, hydroxyethyl, hydroxypropyl, hydroxybutyl, higher hydroxyalkyl, saturated ring systems, and unsaturated ring systems (e.g. aryl, heteroaryl, cycloalkyl, heterocycloalkyl), the hydrolytically stable hydrophilic polymer is selected from the group consisting of hydroxymethyl cellulose, hydroxyethyl cellulose, and poly(vinyl alcohol), and the cross-linker is selected from the group consisting of glutaraldehyde, glycerol-1,3-diglycidyl ether, bis-(2-bromoethylene)-ethyleneglycol, and bis(2-tosylethylene)-ethyleneglycol.
[0013] In another aspect the isoelectric compound is a glycidyl alkylammonium derivative such as a glycidyl trimethylammonium derivative of beta-cyclodextrin, the hydrolytically stable hydrophilic polymer is poly(vinyl alcohol), and (c) the cross-linking agent is glycerol-1,3-diglycidyl ether.
[0014] The invention also provides a hydrolytically stable isoelectric membrane having a pI value in the range of 11.5<pI<14 comprising a hydrolytically stable isoelectric hydrogel supported on a hydrolytically stable, porous, inert or reactive substrate.
[0015] In one aspect the hydrolytically stable isoelectric hydrogel membrane the porous substrate comprising the membrane is selected from the group consisting of poly(vinyl alcohol), partially or fully hydrolyzed poly(epihalohydrin), partially or fully hydrolyzed poly(epihalohydrin-co-ethylene oxide), poly(vinyl sulfone), and poly(ether-ether ketone).
[0016] The invention also provides, hydrolytically stable hydrophilic isoelectric hydrogel material having a pI value in the range of 11.5<pI<14 comprising a precursor comprising a hydroxyl group with a pKa value in the range of 11.5<pKa<14 and an additional reactive group, a derivatizing agent comprising a permanently cationic functional group and an additional reactive group, wherein the derivatizing agent is structurally different from the precursor, and wherein the pI value of the isoelectric hydrogel is conferred by the concentration of the derivatizing agent and the precursor and the pKa value of the hydroxyl group of the precursor. In a related aspect, the hydrolytically stable hydrophilic isoelectric hydrogel material may further comprise a hydrolytically stable hydrophilic polymer having two or more reactive groups that is substantially free of ionic functional groups, wherein the hydrophilic polymer agent is structurally different from the precursor and the derivatizing agent, and a cross-linker substantially free of ionic functional groups and having two groups able to react with both the precursor and the hydrolytically stable hydrophillic polymer, wherein the cross-linker is structurally different from both the precursor, the derivatizing agent and the polymer.
[0017] In another related aspect, the invention provides a hydrolytically stable hydrophilic isoelectric hydrogel material wherein the precursor is a native or derivatized carbohydrate or polyhydroxy compound, the derivatizing agent comprises a quaternary ammonium group, the reactive group of the derivatizing agent is selected from the group consisting of hydroxyl, aldehyde, epoxy, halo, alkylsulfonyl, and arylsulfonyl groups, the hydrolytically stable hydrophilic polymer is an oligosaccharide or a synthetic polymer containing multiple hydroxyl groups, and the cross-linker has two or more reactive groups selected from the group consisting of aldehyde, epoxy, halo, alkylsulfonyl, and arylsulfonyl groups.
[0018] In another related aspect the invention provides a hydrolytically stable hydrophilic isoelectric hydrogel material wherein the precursor is selected from the group consisting of native or derivatized monosaccharides, native or derivatized disaccharides, native or derivatized trisaccharides, native or derivatized oligosaccharides, native or derivatized polysaccharides, native or derivatized cyclodextrins, native or derivatized maltodextrins, native or derivatized amyloses, native or derivatized dextrins, native or derivatized starches, native or derivatized celluloses, and native or derivatized guar gums, the quaternary ammonium group of the derivatizing agent contains one or more substituents selected from the group consisting of methyl, ethyl, propyl, butyl, higher alkyl, hydroxymethyl, hydroxyethyl, hydroxypropyl, hydroxybutyl, higher hydroxyalkyl groups, saturated ring systems, and unsaturated ring systems, the cross-linker is selected from the group consisting of glutaraldehyde, glycerol-1,3-diglycidyl ether, bis-(2-bromoethylene)-ethyleneglycol, and bis(2-tosylethylene)-ethyleneglycol and the hydrolytically stable polymer is selected from the group consisting of hydroxyethyl cellulose, hydroxymethyl cellulose, and poly(vinyl alcohol).
[0019] In a related aspect, the precursor is beta-cyclodextrin, the derivatizing agent is glycidyl-trimethylammonium chloride, the cross-linker is glycerol-1,3-diglycidyl ether, and the hydrolytically stable hydrophilic polymer is poly(vinyl alcohol). In a specific embodiment the precursor is poly(vinylalcohol), and the cross-linker is glycerol-1,3-diglycidyl ether and the derivatizing agent is glycidyl-trimethylammonium chloride.
[0020] The invention also provides a hydrolytically stable isoelectric membrane having a pI in the range of 11.5<pI<14 comprised of a hydrolytically stable isoelectric hydrogel having a pI in the 11.5<pI<14, supported on a hydrolytically stable, porous, inert or reactive substrate. In one embodiment, the material of the porous substrate is selected from the group consisting of poly(vinyl alcohol), partially or fully hydrolyzed poly(epihalohydrin), partially or fully hydrolyzed poly(epihalohydrin-co-ethylene oxide), poly(vinyl sulfone), and poly(ether-ether ketone).
[0021] The invention further provides a method of forming a hydrolytically stable isoelectric membrane having a pI value in the range of 11.5<pI<14, comprising the steps of (a) selecting a carbohydrate-based or polyhydroxy compound-based isoelectric material having a pI value in the 11.5<pI<14 range, (b) reacting the isoelectric material at a concentration sufficiently high to set the pH of its aqueous solution equal to its pI value, with a cross-linker substantially free of ionic functional groups that is structurally different from the isoelectric material, thereby forming an isoelectric hydrogel having a pI value in the range of 11.5<pI<14 on a hydrolytically stable substrate. In a related embodiment the isoelectric material which is at a concentration sufficiently high to set the pH of its aqueous solution equal to its pI value, is reacted with: (i) a cross-linker substantially free of ionic functional groups, and (ii) a hydrophilic polymer substantially free of ionic functional groups that is structurally different from the isoelectric material and the cross-linker.
[0022] In another aspect the invention provides a method of forming a hydrolytically stable isoelectric membrane having a pI value in the 11.5<pI<14 range, comprising the steps of (a) selecting a carbohydrate-based or polyhydroxy compound-based precursor having a hydroxyl group with a pKa value in the range of 11.5<pKa<14 and having an additional reactive group, (b) selecting a derivatizing agent having a substantially permanently cationic functional group and an additional reactive group, wherein the derivatizing agent is structurally different from the precursor, (c) selecting a concentration of the precursor and the derivatizing agent to establish a desired pI value, (d) selecting a cross-linker having two or more reactive groups, wherein the cross-linker being substantially free of ionic functional groups and structurally different from both the precursor and the derivatizing agent, (e) reacting the precursor, and the derivatizing agent with the cross-linker, thereby forming an isoelectric hydrogel having a pI value in the range of 11.5<pI<14 on a hydrolytically stable substrate. In another embodiment the method of forming a hydrolytically stable isoelectric membrane having a pI value in the 11.5<pI<14 range may further comprise the steps of (f) selecting a hydrolytically stable, hydrophilic polymer having at least two reactive groups that is substantially free of ionic functional groups and structurally different from both the precursor, the derivatizing agent and the cross-linker; and (g) reacting the hydrolytically stable, hydrophilic polymer, with the precursor, the derivatizing agent and the cross-linker.
[0023] Finally the invention provides for the use of hydrolytically stable isoelectric materials and membranes comprising hydrolytically stable isoelectric material for an isoelectric trapping separation of an ampholytic compound.
[0024] Throughout this specification, unless the context requires otherwise, the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
[0025] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of the invention.
[0026] Other objects, advantages and embodiments of the invention will be apparent from the detailed description of the invention that follows.
DETAILED DESCRIPTION OF THE INVENTION
[0000] Definitions
[0027] Unless defined otherwise, all technical and scientific terms used herein generally have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Generally, the nomenclature used herein and the laboratory procedures described below are those well known and commonly employed in the art.
[0028] Reactive group, of a “functional group” as used herein refers to groups including, but not limited to, olefins, acetylenes, alcohols, phenols, ethers, oxides, halides, aldehydes, ketones, carboxylic acids, esters, amides, cyanates, isocyanates, thiocyanates, isothiocyanates, amines, hydrazines, hydrazones, hydrazides, diazo, diazonium, nitro, nitriles, mercaptans, sulfides, disulfides, sulfoxides, sulfones, sulfonic acids, sulfinic acids, acetals, ketals, anhydrides, sulfates, sulfenic acids isonitriles, amidines, imides, imidates, nitrones, hydroxylamines, oximes, hydroxamic acids thiohydroxamic acids, allenes, ortho esters, sulfites, enamines, ynamines, ureas, pseudoureas, semicarbazides, carbodiimides, carbamates, imines, azides, azo compounds, azoxy compounds, and nitroso compounds. Exemplary functional groups include, but are not limited to hydroxyl, aldehyde, epoxy, halo, alkylsulfonyl, and arylsulfonyl groups and the like. Methods to prepare each of these functional groups are well known in the art and their application to or modification for a particular purpose is within the ability of one of skill in the art (see, for example, Sandier and Karo, eds. O RGANIC F UNCTIONAL GROUP PREPARATIONS , Academic Press, San Diego, 1989).
[0029] The term “alkyl,” by itself or as part of another substituent, means, unless otherwise stated, a straight or branched chain, or cyclic hydrocarbon radical, or combination thereof, which may be fully saturated, mono- or polyunsaturated and can include di- and multivalent radicals, having the number of carbon atoms designated (i.e. C 1 -C 10 means one to ten carbons). Examples of saturated hydrocarbon radicals include, but are not limited to, groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, isobutyl, sec-butyl, cyclohexyl, (cyclohexyl)methyl, cyclopropylmethyl, homologs and isomers of, for example, n-pentyl, n-hexyl, n-heptyl, n-octyl, and the like. An unsaturated alkyl group is one having one or more double bonds or triple bonds. Examples of unsaturated alkyl groups include, but are not limited to, vinyl, 2-propenyl, crotyl, 2-isopentenyl, 2-(butadienyl), 2,4-pentadienyl, 3-(1,4-pentadienyl), ethynyl, 1- and 3-propynyl, 3-butynyl, and the higher homologs and isomers. The term “alkyl,” unless otherwise noted, is also meant to include those derivatives of alkyl defined in more detail below, such as “heteroalkyl.” Alkyl groups, which are limited to hydrocarbon groups are termed “homoalkyl”.
[0030] The term “heteroalkyl,” by itself or in combination with another term, means, unless otherwise stated, a stable straight or branched chain, or cyclic hydrocarbon radical, or combinations thereof, consisting of the stated number of carbon atoms and at least one heteroatom selected from the group consisting of O, N, Si and S, and wherein the nitrogen and sulfur atoms may optionally be oxidized and the nitrogen heteroatom may optionally be quaternized. The heteroatom(s) O, N and S and Si may be placed at any interior position of the heteroalkyl group or at the position at which the alkyl group is attached to the remainder of the molecule. Examples include, but are not limited to, —CH 2 —CH 2 —O—CH 3 , —CH 2 —CH 2 —NH—CH 3 , —CH 2 —CH 2 —N(CH 3 )—CH 3 , —CH 2 —S—CH 2 —CH 3 , —CH 2 —CH 2 ,—S(O)—CH 3 , —CH 2 —CH 2 —S(O) 2 —CH 3 , —CH═CH—O—CH 3 , —Si(CH 3 ) 3 , —CH 2 —CH═N—OCH 3 ,and —CH═CH—N (CH 3 )—CH 3 . Up to two heteroatoms may be consecutive, such as, for example, —CH 2 —NH—OCH 3 and —CH 2 —O—Si(CH 3 ) 3 . Similarly, the term “heteroalkylene” by itself or as part of another substituent means a divalent radical derived from heteroalkyl, as exemplified, but not limited by, —CH 2 —CH 2 —S—CH 2 —CH 2 — and —CH 2 —S—CH 2 —CH 2 —NH—CH 2 —. For heteroalkylene groups, heteroatoms can also occupy either or both of the chain termini (e.g., alkyleneoxy, alkylenedioxy, alkyleneamino, alkylenediamino, and the like). Still further, for alkylene and heteroalkylene linking groups, no orientation of the linking group is implied by the direction in which the formula of the linking group is written. For example, the formula —C(O) 2 R′—represents both —C(O) 2 R′—and —R′C(O) 2 —.
[0031] The term “aryl” means, unless otherwise stated, a polyunsaturated, aromatic, hydrocarbon substituent, which can be a single ring or multiple rings (preferably from 1 to 3 rings), which are fused together or linked covalently. The term “heteroaryl” refers to aryl groups (or rings) that contain from one to four heteroatoms selected from N, O, and S, wherein the nitrogen and sulfur atoms are optionally oxidized, and the nitrogen atom(s) are optionally quaternized. A heteroaryl group can be attached to the remainder of the molecule through a heteroatom. Non-limiting examples of aryl and heteroaryl groups include phenyl, 1-naphthyl, 2-naphthyl, 4-biphenyl, 1-pyrrolyl, 2-pyrrolyl, 3-pyrrolyl, 3-pyrazolyl, 2-imidazolyl, 4-imidazolyl, pyrazinyl, 2-oxazolyl, 4-oxazolyl, 2-phenyl-4-oxazolyl, 5-oxazolyl, 3-isoxazolyl, 4-isoxazolyl, 5-isoxazolyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, 2-furyl, 3-furyl, 2-thienyl, 3-thienyl, 2-pyridyl, 3-pyridyl, 4-pyridyl, 2-pyrimidyl, 4-pyrimidyl, 5-benzothiazolyl, purinyl, 2-benzimidazolyl, 5-indolyl, 1-isoquinolyl, 5-isoquinolyl, 2-quinoxalinyl, 5-quinoxalinyl, 3-quinolyl, and 6-quinolyl. Substituents for each of the above noted aryl and heteroaryl ring systems are selected from the group of acceptable substituents described below.
[0032] For brevity, the term “aryl” when used in combination with other terms (e.g., aryloxy, arylthioxy, arylalkyl) includes both aryl and heteroaryl rings as defined above. Thus, the term “arylalkyl” is meant to include those radicals in which an aryl group is attached to an alkyl group (e.g., benzyl, phenethyl, pyridylmethyl and the like) including those alkyl groups in which a carbon atom (e.g., a methylene group) has been replaced by, for example, an oxygen atom (e.g., phenoxymethyl, 2-pyridyloxymethyl, 3-(1-naphthyloxy)propyl, and the like).
[0033] Each of the above terms (e.g., “alkyl,” “heteroalkyl,” “aryl” and “heteroaryl”) are meant to include both substituted and unsubstituted forms of the indicated radical. Preferred substituents for each type of radical are provided below.
[0034] Substituents for the alkyl and heteroalkyl radicals (including those groups often referred to as alkylene, alkenyl, heteroalkylene, heteroalkenyl, alkynyl, cycloalkyl, heterocycloalkyl, cycloalkenyl, and heterocycloalkenyl) can be one or more of a variety of groups selected from, but not limited to: —OR′, ═O, ═NR′, ═N—OR′, —NR′R″, —SR′, -halogen, —SiR′R″R′″, —OC(O)R′, —C(O)R′, —CO 2 R′, —CONR′R″, —OC(O)NR′R″, —NR″C(O)R′, —NR′—C(O)NR″R′″, —NR″C(O) 2 R′, —NR—C(NR′R″R′″)═NR″″, —NR—C(NR′R″)═NR′″, —S(O)R′, —S(O) 2 R′, —S(O) 2 NR′R″, —NRSO 2 R′, —CN and —NO 2 in a number ranging from zero to (2m′+1), where m′ is the total number of carbon atoms in such radical. R′, R″, R′″ and R″″ each preferably independently refer to hydrogen, substituted or unsubstituted heteroalkyl, substituted or unsubstituted aryl, e.g., aryl substituted with 1-3 halogens, substituted or unsubstituted alkyl, alkoxy or thioalkoxy groups, or arylalkyl groups. When a compound of the invention includes more than one R group, for example, each of the R groups is independently selected as are each R′, R″, R′″ and R″″ groups when more than one of these groups is present. When R′ and R″ are attached to the same nitrogen atom, they can be combined with the nitrogen atom to form a 5-, 6-, or 7-membered ring. For example, —NR′R″ is meant to include, but not be limited to, 1-pyrrolidinyl and 4-morpholinyl. From the above discussion of substituents, one of skill in the art will understand that the term “alkyl” is meant to include groups including carbon atoms bound to groups other than hydrogen groups, such as haloalkyl (e.g., —CF 3 and —CH 2 CF 3 ) and acyl (e.g., —C(O)CH 3 , —C(O)CF 3 , —C(O)CH 2 OCH 3 , and the like).
[0035] Similar to the substituents described for the alkyl radical, substituents for the aryl and heteroaryl groups are varied and are selected from, for example: halogen, —OR′, ═O, ═NR′, ═N—OR′, —NR′R″, —SR′, -halogen, —SiR′R″R′″, —OC(O)R′, —C(O)R′, —CO 2 R′, —CONR′R″, —OC(O)NR′R″, —NR″C(O)R′, —NR′—C(O)NR″R′″, —NR″C(O) 2 R′, —NR—C(NR′R″R′″)═NR″″, —NR—C(NR′R″)═NR′″, —S(O)R′, —S(O) 2 R′, —S(O) 2 NR′R″, —NRSO 2 R′, —CN and —NO 2 , —R′, —N 3 , —CH(Ph) 2 , fluoro(C 1 -C 4 )alkoxy, and fluoro(C 1 -C 4 )alkyl, in a number ranging from zero to the total number of open valences on the aromatic ring system; and where R′, R″, R′″ and R″″ are preferably independently selected from hydrogen, (C 1 -C 8 )alkyl and heteroalkyl, unsubstituted aryl and heteroaryl, (unsubstituted aryl)-(C 1 -C 4 )alkyl, and (unsubstituted aryl)oxy-(C 1 -C 4 )alkyl. When a compound of the invention includes more than one R group, for example, each of the R groups is independently selected as are each R′, R″, R′″ and R″″ groups when more than one of these groups is present.
[0036] The expression “having a pI value in the range of 11.5<pI<14” or “a pI value in the 11.5<pI<14 range” refers to an isoelectric point value in a range that at its lower extreme encompasses pI values of 11.5, 12, 12.5, 13, or 13.5, and at its higher extreme encompasses pI values ranging between 12, 12.5, 13, 13.5, or 14. Similarly, the expression “a pKa value in the range of 11.5<pI<14” and its equivalents, refers to pKa values in a range that at the lower extreme encompass pKa values of 11.5, 12, 12.5,13, or 13.5, and at the higher extreme encompass pKa values of 12, 12.5, 13, 13.5, or 14.
[0037] The term “isoelectric point” refers to the point at which a molecule or compound, which can exist in forms bearing either negative and/or positive charges, is electrically balanced, such that the net charge on the molecule or compound is zero. Thus, an isoelectric hydrogel material, or an isoelectric membrane is an entity that is electrically neutral or uncharged under specified conditions.
[0038] The term “ionic functional group” refers to refers to functional group that is capable of being ionized, such that the functional group may become either positively or negatively charged upon ionization.
[0039] The term “cationic functional group” refers to an ionic functional group, as defined above, that bears a positive charge under a given set of conditions. The phrase “permanently cationic functional group” refers to a molecule or compound that exists under defined conditions as a positively charged molecule at least more than about 90% of the time, preferably at least more than about 91%, 92%, 93%, 94% of the time, or more preferably at least more than about 95%, 96%, 97%, 98% or 99% of the time. An exemplary “permanently cationic functional group” is a quaternary ammonium group.
[0040] The phrase “substantially free of ionic groups” refers to a molecule that is at least more than about 90% free of ionic functional groups, preferably at least more than about 91%, 92%, 93%, 94% free of ionic functional groups, or more preferably at least more than about 95%, 96%, 97%, 98% or 99% free of ionic functional groups and most preferably is 100% free of ionic functional groups.
[0000] Introduction
[0041] In membrane-mediated isoelectric focusing and isoelectric trapping separations isoelectric hydrogels and/or membranes may serve either as ion-permeable separative barriers or ion-permeable cathodic electrode compartment barriers. Isoelectric hydrogels and/or membranes can play multiple roles to effect or aid the desired separations through buffering and/or sieving ability and/or through the prevention of convective mixing. Typically, the ion-permeable barriers, hydrogels and/or membranes are prepared from acrylamide and/or acrylamido weak and/or strong electrolyte derivatives by polymerization of suitable monomers, modifiers and crosslinkers.
[0042] Though acrylamide-based ion-permeable barriers, hydrogels and/or membranes have many outstanding and desirable characteristics, neither the monomers, nor the polymers are hydrolytically stable at above about pH 10.5. Hydrolysis of the amide bond creates weak acid functional groups in the polyacrylamide-based matrix which, upon dissociation, act as immobilized negative charges in the gel matrix, which create electroosmotic flow and/or bind certain analytes, both of which are often detrimental to the separation.
[0043] In addition to the limited hydrolytic stability of the acrylamide-based hydrogels and/or membranes in high pH environments, the formation of pI>10.5 isoelectric hydrogels and/or membranes is hindered by the lack of suitable acrylamido weak base derivatives with pK b values between 2 and 4.
[0044] Since it is often desirable to utilize hydrogels and/or membranes that have pI values above 10.5, there is clearly a need in the art for hydrolytically stable, high-pI hydrogel and/or membrane compositions.
[0045] Fortunately, molecular configurations that result in isoelectric substances with a high pI value have been discovered, and are provided by the present invention. Such isoelectric materials can be used to create hydrolytically stable hydrogel materials that can further be used to create hydrolytically stable isoelectric membranes. Thus, the invention provides hydrolytically stable, high-pI hydrogel and/or membrane compositions for the separation of ampholytic compounds.
[0000] Chemistry of High pI Isoelectric Materials
[0046] The pK a values of the secondary alcohol groups of certain carbohydrates and polyhydroxy compounds lie in the 10.5<pK a range (e.g., 10.55, 10.6, 11, 11.5, 12, 12.5, 13, 13.5, 14), while the pK a values of the primary alcohol groups are typically in the pK a >13 range. For example, the pKa values a few common carbohydrates are as follows (Bruggink, C., AVH Association—7 th Symposium—Reims, March 2000 3-9; Masuda, T., et al., J. Chromatogr A., 961 (1) 89-96; Lee, Y-H. and Lin, T., Electrophoresis, 17, 333-340; Rong, D. and D'Souza, V., Tetrahedron Letters, 31 (30) 4275-4278, all incorporated herein by reference):
Compound pK a Maltose 11.94 Lactose 11.98 Fructose 12.03 Mannose 12.08 Xylose 12.15 Glucose 12.28 Galactose 12.39 Dulcitol 13.43 Sorbitol 13.60 α-Methyl glucoside 13.71 1,3-dimethoxy glycerol 13.68 γ-cyclodextrin 12.05 (secondary OH) β-cyclodextrin 12.20 (secondary OH) α-cyclodextrin 12.33 (secondary OH)
[0047] It has now been discovered that an isoelectric substance with a high pI value can be created from a molecules containing any of the following combinations: (i) at least one secondary OH group with a 11.5<pK a <14 (e.g., with a pKa of between about 11.5, 12, 12.5, 13, 13.5 and 14) and an amine group with a 1<pK b <4 (e.g., with a pKb of between 1, 1.5, 2, 2.5, 3, 3.5, and 4); (ii) at least two secondary OH groups with pK a values in the 11.5<pK a <14 range and one strongly basic functional group (such as a quaternary ammonium group); or (iii) at least one secondary OH group with a pK a value in the 11.5<pK a <14 range and one such primary OH group with a pK a value in the 13<pK a range (e.g., with a pKa of about 13, 13.5, or 14) and one permanently cationic functional group (such as a quaternary ammonium group). After obtaining such an isoelectric material, the material can be used to produce a hydrogel and/or membrane by crosslinking it with any suitable bifunctional or polyfunctional agent or by grafting it onto any suitable crosslinkable or crosslinked substrate.
[0048] Secondary alcohols of many oligo- and polysaccharides including, but not restricted to, cyclodextrins, maltodextrins, amyloses, starches, dextrans, celluloses, luteoses, curdlans, guar gums, agaroses, etc., have the same desired property as the molecules described above (secondary OH groups with pK a values in the 10.5<pK a <14 range, primary OH groups in the 13<pK a range). These oligomers and/or polymers can be modified with suitable amine or quaternary ammonium functional groups to create high pI isoelectric materials which can be converted, e.g., by crosslinking, into suitable hydrogels and/or membranes.
[0049] Secondary alcohol groups of many oligomeric and polymeric materials including, but not restricted to, poly(vinylalcohol) and its derivatives, partially or fully hydrolyzed poly(epihalohydrine)s and their derivatives, partially or fully hydrolyzed poly(epihalohydrine-co-ethylene oxide)s and their derivatives polymers formed from polyhydroxy compounds and di-, oligo- or polyepoxides also have the same desired property (secondary OH groups with pK a values in the 10.5<pK a <14 range and primary OH groups with pK a values in the 13<pK a range) that makes them suitable for use in synthesizing an isoelectric substance with a high pI value. These oligomers and/or polymers can be modified with suitable amino or quaternary ammonium functional groups to create high-pI isoelectric materials which can be converted, e.g., by crosslinking, into suitable hydrogels and/or membranes.
[0050] The hydrophilic, polymeric nature of such hydrogels and/or membranes reduces the magnitude of electroosmotic flow through such hydrogels and/or membranes, which is very desirable for electrophoretic separations.
[0051] By varying the connection of the OH group-containing material and/or the type and/or the concentration of the crosslinking agent and the cationic functional group, the present invention can produce high-pI isoelectric hydrogels and/or membranes that can also act as sieving matrices in electrophoretic separations, similar to the way acrylamide-based gels do.
[0052] It will be appreciated that many additional tasks can be solved utilizing the hydrolytically stable, high-pI isoelectric hydrogel and/or compositions of the present invention without departing from the essence of this disclosure.
[0000] Apparatus Suitable for Use of High pI Isoelectric Materials
[0053] A membrane-based electrophoresis apparatus particularly suitable for isoelectric focussing or isoelectric trapping has been developed by The Texas A&M University System and Gradipore Limited (WO 02/24314, which is incorporated herein by reference). The apparatus, termed herein as “the Twinflow unit” comprises (a) a first electrolyte reservoir and a second electrolyte reservoir; (b) a first sample reservoir and a second sample reservoir; (c) a separation unit having a first electrolyte chamber in fluid connection with the first electrolyte reservoir, a second electrolyte chamber in fluid connection with the second electrolyte reservoir, a first sample chamber positioned between the first electrolyte chamber and the second electrolyte chamber, a second sample chamber positioned adjacent to the first sample chamber and between the first electrolyte chamber and the second electrolyte chamber, the first sample chamber being in fluid connection with the first sample reservoir, and the second sample chamber being in fluid connection with the second sample reservoir; (d) a first ion-permeable barrier positioned between the first sample chamber and the second sample chamber, the first ion-permeable barrier prevents substantial convective mixing of contents of the first and second sample chambers; (e) a second ion-permeable barrier positioned between the first electrolyte chamber and the first sample chamber, the second ion-permeable barrier prevents substantial convective mixing of contents of the first electrolyte chamber and the first sample chamber; (f) a third ion-permeable barrier positioned between the second sample chamber and the second electrolyte chamber, the third ion-permeable barrier prevents substantial convective mixing of contents of the second electrolyte chamber and the second sample chamber; (g) electrodes positioned in the first and second electrolyte chambers; (h) means for supplying electrolyte from the first electrolyte reservoir to the first electrolyte chamber, and from the second electrolyte reservoir to the second electrolyte chamber; and (i) means for supplying sample or liquid from at least the first sample reservoir to the first sample chamber, or from the second sample reservoir to the second sample chamber.
[0054] In use, a sample to be treated is placed in the first and/or second sample reservoirs and provided to, or circulated through, the first and/or second chambers. Electrolyte is placed in the first and second electrolyte reservoirs and passed to, or circulated through, the respective first and second electrolyte chambers without causing substantial mixing between the electrolyte in the two electrolyte reservoirs. Electrolyte or other liquid can be placed in first and/or second sample reservoirs if required. An electric potential is applied to the electrodes wherein one or more components in the first and/or second sample chamber are caused to move through a diffusion barrier to the second and/or first sample chamber, or to the first and/or second reservoir chambers. Treated sample or product can be collected in the second and/or first sample reservoir.
EXAMPLES
[0055] Various hydrogels were prepared at temperatures ranging from room temperature to about 80° C. and reaction times varying from a few minutes to several days. Higher temperatures were used in order for the reaction to proceed at a reasonable rate. It has been found, however, that the actual reaction temperature and time of reaction incubation are not particularly critical to develop various hydrogels according to the present invention. It will be appreciated that as temperatures are elevated, the rate of reaction will increase and incubation times will be shorter. Accordingly, one of skill in the art will be able to choose appropriate reaction conditions and the determine how long the reaction needs to proceed. The following examples are meant to illustrate, but not limit the invention.
Example 1
[0056] Weigh a 100 ml beaker. Place the weighed 100 ml beaker and two 230×190 ×6 mm, clean glass plates into a drying oven at 80° C. Cut a 160×200 mm piece of a Grade BFN 3 Papylon PVA paper (Sansho Co., Ltd, The 2nd Kitahama Building 1-29, Kitaham-Higashi, Chuoh-Ku, Osaka, Japan). Fit a 250 ml, two-neck, round bottom flask with a condenser and a nitrogen purge line. Place a 1″ football-shaped stir bar into the flask. Purge the system with nitrogen gas. Circulate ice-water through the condenser.
[0057] Place the flask into a heating mantle. Add 60 ml deionized water to the flask. Add 6.58 g (0.1645 mol) NaOH to the flask. Stir and heat the solution to a boil. Add 12 g (0.2727 mol secondary OH group equivalent) 99% hydrolyzed poly(vinylalcohol), average molecular weight 89,000-98,000 (PVA) to the flask. Maintain a nitrogen atmosphere over the reaction mixture, continue stirring and heating until PVA is completely dissolved. Turn off the heating mantle. Add 1.8 g (0.012 mol) glycidyl trimethylammonium chloride (Q) to the reaction mixture and stir until Q is dissolved.
[0058] Take the hot, bottom glass plate from the oven and place it onto a layer of paper towels. Take the hot, 100 ml beaker from the oven and weigh into it a 60 g aliquot of the hot, viscous reaction mixture. Quickly add to it 4.5 ml (4.916 g, 0.024 mol) glycerol diglycidyl ether and mix it well (manually) with a spatula. Pour half of the beaker's content onto the hot, bottom glass plate and quickly distribute the mixture over the plate by tilting it around. Lower the BFN 3 PVA substrate onto the reaction mixture and saturate the substrate with the reaction mixture.
[0059] Take the hot, cover glass plate from the oven, pour the second half of the reaction mixture from the beaker onto it and quickly distribute the mixture over the plate by tilting it. Lower the coated face of the cover plate onto the BFN 3 PVA substrate and press the plate to evenly distribute the reaction mixture over the entire surface of the BFN 3 PVA substrate. Place two 16×16×2″ cement patio paving stones onto the glass plates to compress them and squeeze out the excess reaction mixture.
[0060] Two hours later, remove the stones from the glass plates. Let the glass plate mold stand undisturbed at room temperature for 38 hours (total curing time 40 hours).
[0061] Fill a 16×12×6″ polypropylene tub with deionized water. Using a razor blade, cut along all four edges of the glass plate mold to remove the solidified, spilled-out reaction mixture. Lower the mold into the deionized water in the tub. Gently pull the glass plates apart under the water. The membrane should slip off easily from the glass plates. Gently slosh around the membrane in the water for about five minutes. Replace the water, slosh around the membrane for another five minutes. Repeat the procedure at least five times. Test the pH of the last wash water, it should be neutral. The salvage edge of the membrane should be clear, transparent, the surface of the membrane strong, even and slippery.
[0062] Store the membrane in deionized water in the fridge until used. The membrane will swell to a final thickness of about 0.4 to 0.7 mm. Using a pair of scissors, cut the membrane to size to fit the separation cartridge of the Twinflow unit. Punch inlet and outlet holes into the membrane and assemble the cartridge. Leak test the Twinflow unit, then commence the separation. After use, rinse the membrane and dispose it as solid waste.
[0063] The new compositions permit the preparation of hydrolytically and mechanically stable, high-pI hydrogels and/or membranes that were not available prior to this invention.
[0064] Numerous other hydrophilic, hydrolytically stable, high-pI compositions can be created along the synthetic lines described above, and these are expected to work just as well as the examples described below.
[0065] Hydrolytically stable high-pI hydrogels and/or membranes as outlined above has been experimentally demonstrated as follows.
Example 1.1
[0066] High-pI, clear hydrogels were prepared by crosslinking trimethylammonio-β-cyclodextrin with epichlorohydrin in the presence of NaOH, at 80° C.
Example 1.2
[0067] High-pI, clear hydrogels were prepared by crosslinking trimethylammonio-β-cyclodextrin with glycerol diglycidyl ether in the presence of NaOH, at 80° C.
Example 1.3
[0068] High-pI, clear hydrogels were prepared by crosslinking trimethylammonio-β-cyclodextrin and poly(vinylalcohol) with glycerol diglycidyl ether in the presence of NaOH, at 80° C.
Example 1.4
[0069] High-pI, clear hydrogels were prepared by crosslinking β-cyclodextrin and poly(vinylalcohol) with glycerol diglycidyl ether in the presence of glycidyl trimethylammonium chloride and NaOH, at 80° C.
Example 1.5
[0070] High-pI isoelectric membranes were prepared by casting, in a glass mold, an 80° C. reaction mixture of glycidyl trimethylammonium chloride, β-cyclodextrin, poly(vinylalcohol), glycerol diglycidyl ether and NaOH over a Papylon Grade 3 poly(vinylalcohol) substrate and reacting the mixture at 60° C. for 40 hours.
Example 1.6
[0071] High-pI isoelectric membranes prepared in Example 1.5 above were tested in the Twinflow unit described above. The membranes were used in a single separation compartment configuration, as the cathodic membrane. The anodic membrane was a pI=3 polyacrylamide isoelectric membrane (Gradipore Limited, Australia). The anolyte was 50 mM benzenesulfonic acid (BSH), the catholyte 50 mM benzyltrimethylammonium hydroxyde (BzOH)and 950 mM NaOH, the separation compartment contained tyramine (Tyr, approximate pI=10), histidine (His, pI=7.5) and meta-aminobenzoic acid (MABA, approximate pI=3.9) as analytes. Leak-free seal was achieved, and MABA, His and Tyr were trapped for the duration of the 180 min run. Neither BSH, nor BzOH invaded the separation compartment. When the run was repeated with a 50 mM benzyltrimethylammonium hydroxyde solution as the catholyte, Tyr was lost to the cathode compartment within 15 min indicating that the pI value of the high-pI membrane was greater than 12.7.
Example 1.7
[0072] High-pI, clear hydrogels were prepared by reacting trimethylammonio-guar gum with glycidyl trimethylammonium chloride and crosslinking it with glycerol diglycidyl ether in the presence of NaOH, at 80° C.
Example 1.8
[0073] High-pI, clear hydrogels were prepared by reacting glycidyl trimethylammonium chloride with poly(vinylalcohol), and crosslinking it with glycerol diglycidyl ether, in the presence of NaOH, at 80° C.
Example 1.9
[0074] High-pI isoelectric membranes were prepared by casting, in a glass mold, an 80° C. reaction mixture of glycidyl trimethylammonium chloride, poly(vinylalcohol), glycerol diglycidyl ether and NaOH over a Papylon Grade 3 poly(vinylalcohol) substrate and reacting the mixture at 60° C. for 24 hours.
Example 1.10
[0075] The high-pI isoelectric membranes prepared in Example 1.9 above were successfully tested in the Twinflow unit, in single separation compartment configuration, as the cathodic membrane. The separation compartment contained Tyr (pI=10), His (pI=7.5) and MABA (pI=3.9) as analytes. Leak-free seal was achieved and MABA, His and Tyr were trapped for the duration of the 180 min run. When the run was repeated with a pH 12 NaOH solution as the catholyte, Tyr was lost to the cathode compartment, within 15 min, indicating that the pI value of the high pI membrane was greater than 12.
Example 1.11
[0076] High-pI isoelectric membranes were prepared by casting, in a glass mold, an 80° C. reaction mixture of glycidyl trimethylammonium chloride, poly(vinylalcohol), glycerol diglycidyl ether and NaOH over a Papylon Grade 3 poly(vinylalcohol) substrate and reacting the mixture at room temperature for 40 hours.
Example 1.12
[0077] The high-pI isoelectric membranes prepared in Example 1.11 above were successfully tested in the Twinflow unit, in single separation compartment configuration, as the cathodic membrane. The separation compartment contained Tyr (pI=10), His (pI=7.5) and MABA (pI=3.9) as analytes. Leak-free seal was achieved and MABA, His and Tyr were trapped for the duration of the 180 min run.
Example 1.13
[0078] High-pI isoelectric membranes were prepared by casting, in a glass mold, an 80° C. reaction mixture of glycidyl trimethylammonium chloride, poly(vinylalcohol), glycerol diglycidyl ether and NaOH over a Papylon Grade 4 poly(vinylalcohol) substrate and reacting the mixture at room temperature for 40 hours.
[0079] High-pI isoelectric membranes prepared in Example 1.13 above were successfully tested in the Twinflow unit, in single separation compartment configuration, as the cathodic membrane. The separation compartment contained Tyr (pI=10) and MABA (pI=3.9) as analytes. Leak-free seal was achieved and both MABA and Tyr were trapped for the duration of the 180 min run.
Example 1.15
[0080] High-pI isoelectric membranes were prepared by casting, in a glass mold, an 80° C. reaction mixture of glycidyl trimethylammonium chloride, poly(vinylalcohol), glycerol diglycidyl ether and NaOH over a Papylon Grade 2 poly(vinylalcohol) substrate and reacting the mixture at room temperature for 40 hours.
Example 1.16
[0081] High-pI isoelectric membranes prepared in Example 1.15 above were successfully tested in the Twinflow unit, in single separation compartment configuration, as the cathodic membrane. The separation compartment contained Tyr (pI=10), His (pI=7.5) and MABA (pI=3.9) as analytes. Leak-free seal was achieved and both MABA and Tyr were trapped for the duration of the 180 min run.
Example 1.17
[0082] High-pI isoelectric membranes prepared in Example 1.15 and Example 1.16 above were tested in the Twinflow unit, in single separation compartment configuration, as the cathodic membranes. The separation compartment contained a recombinant thyroid-stimulating hormone (rTSH) preparation in a growth medium with a conductivity of 5000 μS. Desalting of the sample was successfully completed to a residual conductivity of about 800 μS, and neither albumin, nor rTSH was lost indicating that the high-pI isoelectric membranes functioned properly as cathodic isoelectric membranes.
Example 1.18
[0083] High-pI isoelectric membranes prepared according to Example 1.11 and Example 1.15 above were successfully tested as cathodic membranes in over 10 isoelectric trapping (IET) separations using the Twinflow unit. Each time, when the NaOH concentration in the catholyte was 200 mM or higher, and the IET current was sufficiently high, the membranes behaved satisfactorily.
[0084] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly disclosed. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
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The invention provides a hydrolytically stable isoelectric hydrogel material having a pi value in the range of 11.5<pI<14, that is comprised of an isoelectric compound having a pI value in the range of 11.5<pI<14. The pI of the isoelectric compound and thus, the pI of the hydrolytically stable isoelectric hydrogel material, is conferred by the pI value of the isoelectric compound. The hydrolytically stable isoelectric hydrogel material may further comprise a hydrolytically stable hydrophilic polymer and a cross-linker. The invention also provides a hydrolytically stable isoelectric membrane that comprises the hydrolytically stable isoelectric hydrogel material, and methods for preparing a hydrolytically stable isoelectric membrane.
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FIELD OF THE INVENTION
[0001] This invention relates to web services composition, particularly in a constrained data flow environment.
BACKGROUND
[0002] Web services are self-contained, self-describing, modular applications that can be published, located and invoked across the Internet. They encapsulate information, software or other resources, and make them available over a network via standard interfaces and protocols. They typically are based on industry standard technologies of WSDL (to describe), UDDI (to advertise and syndicate) and SOAP (to communicate). Web services enable users to connect different components within and across organizational boundaries in a platform and language independent manner. New and complex applications can be created by aggregating the functionality provided by existing web services, referred to as service composition, and the aggregated web service is known as composite web service. The constituent web services involved in a service composition are known as component web services. Web service composition enables businesses to interact with each other and process and transfer data to realize complex operations. Furthermore, new business opportunities can be realized by utilizing the existing services provided by other businesses to create a composite service.
[0003] Composite web services may be developed using a specification language such as Business Process Execution Language for Web Services (BPEL4WS), or Web Services Choreography Interface (WSCI), or Business Process Modeling Language (BPML) and executed by an engine such as IBM's WebSphere™ Business Integration Process Choreographer, and IBM's Business Process Execution Language for Web Services Java Run Time (BPWS4J). Typically, a composite web service specification is executed by a single coordinator node. The coordinator node receives the client requests, makes the required data transformations and invokes the component web services according to the specification of composite service. This mode of execution is referred to as centralized orchestration. However, in certain scenarios businesses might want to impose restrictions on access to the data they provide or the source from which they can accept data. Centralized orchestration can lead to violation of these data constraints as the central coordinator has access to the output data of all the component web services and all the component web services receive data from central coordinator only.
[0004] Alternatively, fully decentralized orchestration might be used, where the original BPEL4WS is partitioned into as many partitions as the number of component web service and each partition resides with the component web service it invokes. The required data transformations are made by these partitions themselves. While a fully decentralized orchestration can overcome many data flow constraints, this approach has certain limitations. Not all the business providing web services may have engines to execute BPEL4WS process. Some of the businesses which have this capability may not allow BPEL4WS processes written by others to execute on their servers. Further, certain data flow constraints can not be met with any of the fully decentralized topologies possible. A fully decentralization approach is described in Chafle et al., “Orchestrating Composite Web Services Under Data Flow Constraints”, in proceedings of the 3 rd IEEE International Conference on Web Services, 2005.
[0005] Under common data flow constraints neither centralized nor fully decentralized orchestrations of composite web services are practicable. Therefore, the invention provides an improved method and system for composition of web services.
SUMMARY
[0006] A partially decentralized composition of web services is performed by distributing the coordination responsibility of the component web services, performed at run time by the original centralized composite web service software, to multiple web services. The original software is divided into multiple code partitions and placed among different web services. These code partitions invoke one or more component web services and perform the required data transformation applicable to enable calling and the return of data from the web services. An advantage is that the partitions need not be co-located with the web service it invokes (as against fully decentralized composition) and a therefore the partition(s) may invoke more than one component web service. Also, data transformation is not restricted to domain(s) producing or consuming the data and can be performed by any web service that is eligible to access the data. The web services containing the code partitions that invoke more than one web services and perform the required data transformation are converted into new coordinator nodes. To satisfy any data flow constraints, the data is sent from producer to consumer along a path restricted to the nodes eligible to access this data. The code performing the required data transformation is located on the nodes in this path and may span across multiple nodes.
DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic block diagram of an example decentralization method.
[0008] FIG. 2 is a schematic block diagram of an example customer request servicing method
[0009] FIG. 3 is an example topology generated by an embodiment of the invention.
[0010] FIG. 4 is a schematic block diagram showing a runtime infrastructure.
[0011] FIG. 5 is a block flow diagram of implementing a constraint reinforcer.
[0012] FIG. 6 is a schematic block diagram of tools used to generate partitions.
[0013] FIG. 7 is a state diagram of a decentralizer.
DETAILED DESCRIPTION
Overview
[0014] In the known centralized orchestration approach discussed above, complete BPEL4WS flow resides at the coordinating node which executes it and coordinates the execution of all other component web services. In fully decentralized orchestration approach discussed above, there are no coordinating nodes, there are N number (N is number of component web services involved) of BPEL4WS partitions and all the BPEL4WS code partitions are co-located with the component web service they invoke.
[0015] In contrast, in an example embodiment of the present invention, multiple web service domains take up the run time responsibility of coordinating two or more component web services. In other words, the number of code partitions may vary between 1 to N (where N is number of component web services involved), and number of coordinating nodes may be zero or more.
[0016] Although BPEL4WS is presented as the preferred embodiment hereinafter, it is to be understood that the invention is not limited to any particular web service composition language, and applies to web services composition in general.
Workflow
[0017] FIG. 1 shows a process flow 10 , in which an original centralized BPEL4WS code 12 residing on a coordination node is broken into multiple BPEL4WS partitions in the step 14 . Partitioning of the BPEL4WS code occurs at the time of service installation on a computing infrastructure or whenever associated overarching service composition policies change.
[0018] The partitioning generates a set of web services node topologies which meet predetermined data flow and deployment-related constraints, discussed below. The decentralization may lead to many topologies, involving a client interface node, one or more coordination nodes, one or more non-coordinator nodes (usually dependent upon a coordinator node), and one or more component web services. The component web services can depend directly on the receiving node, from a coordination node, or from a non-coordination node. A partition node (node containing BPEL4WS partition, it can be a coordination node or non-coordination node) operates to receive and transform input data (which can include the client request and data returned from a component web service that has already been executed). The partition node then calls any dependent component web services and receives the outputs form those web services. The partition node then transforms such received data and calls any dependent coordination or non-coordination nodes, else returns the results to a higher node in the topology.
[0019] In step 16 , one of the topologies from the many topologies that are generated is chosen. If more than one topology is generated, then policies/constraints such as ‘topology leading to minimum response time’ or ‘topology having minimum number of hops’ can be used to choose one topology thereof. All partitions of the selected topology are then deployed at their respective system locations in step 18 , resulting in a partially decentralized topology. The decentralization takes place at the time of service installation or whenever policies change.
[0020] Referring now to the process flow 20 in FIG. 2 , when a request 22 , for example a customer request, is received by the composite web service, the request is executed by the partially decentralized topology generated by the process flow 10 of FIG. 1 , where, in step 24 , the component web services are invoked by their respective controlling coordination node according to the specification of the original composite web service. These coordination nodes may or may not be collocated with the component web services that they invoke.
Web Services Example
[0021] Consider a Telecom Service Provider (telco) intending to provide a location-based service to the subscribers where subscribers can get a schedule of movies being screened at movie theaters in a radius of 5 miles from where the subscriber is located. There exists a Yellow Pages service provider incorporating web service that can provide a list of movie theaters and required contact information of the movie theatres in a radius of 5 miles from the subscriber's location. Also, the movie theaters deploy web services that provide movie schedules.
[0022] The telco develops a composite web service, that makes use of the web services provided by the Yellow Pages service provider and web services of the movie theaters, to provide a location based movie schedule service to subscribers. Without any data flow constraints, the telco can create composite web service(s) using centralized orchestration. The composite web service(s) deployed at the telco asks the Yellow Pages service provider to fetch a list of movie theaters located within a radius of 5 miles of the subscriber. The composite web service(s) requests all the movie theaters fetched by the Yellow Pages service for the movie schedules, and returns the consolidated schedule to the subscriber.
[0023] However, in a real world scenario, there may be constraints on data sharing. The example scenario discussed above has following data flow constraints:
1. The yellow pages service provider may not send the list of movie theaters to the telco. This is because telco may cache this information and once cached subsequently not access the yellow pages service provider for each invocation thus depriving the yellow pages service provider of repeated revenue. 2. The movie theaters may not send their schedule directly to the subscribers. Sending information directly to the subscribers requires that subscriber information is disclosed to the public, for example the movie theaters. Exposure of customer information is a sensitive privacy issue, and telcos may not be willing to disclose such sensitive information.
[0026] Besides the data flow constraints, the following deployment constraints of runtime infrastructure also exist.
3. Some movie theaters do not have infrastructure to execute BPEL4WS processes. 4. Some movie theatres, may have the capability to execute BPEL4WS processes, but may not allow BPEL4WS processes written by third parties to be executed on their servers.
[0029] With these constraints in place, centralized orchestration of the composite service is not possible as it violates constraint 1. Alternatively, a fully decentralized orchestration approach can be used to overcome such data flow constraints. In one such fully decentralized topology the yellow pages service provider calls the movie theaters on behalf of the telco and the movie theaters send their schedule directly to the telco. The issue with this topology is that the telco does not know how many movie theaters were contacted and thus how many responses the telco needs to wait for to complete the response for the request. Therefore, this is not a valid topology. In another possible fully decentralized topology, the movie theaters may send their schedule directly to the customer. This requires sensitive customer information related to the subscribers to be disclosed to the movie theaters which violates the data flow constraint 2 and hence prohibits the use of this topology.
[0030] Besides the data flow constraints discussed above, the fully decentralized topologies cannot meet the deployment constraints mentioned in items 3 and 4 above as any decentralized topology would require the movie theaters to run a partition of BPEL4WS process written by the telco.
[0031] In one embodiment shown in FIG. 3 , the BPEL4WS code is formed into two partitions 37 , 40 , taking into consideration the data flow constraints and deployment constraints, and the partitions are deployed over the web services topology 30 at two component services nodes: a Telco Service Provider's site 36 and a Yellow Pages Service Provider's Domain site 38 . The Telco Service Provider's site 36 acts as a coordination node. The Yellow Pages Service provider's site 38 acts as a non-coordination node.
[0032] On receiving a request 34 from the client Telco subscriber 32 (i.e., a client node), the partition 37 within the Telco Service Provider's site 36 contacts the partition 40 (within the Domain site 38 ), which is configured to retrieve the list of movie theatres from a Yellow Pages web service 42 . The list retrieved is used to contact the movie theatres 44 , collate the results as a response, and returns the results to the partition 37 . Thus, it becomes feasible for the partition 37 to compose the response for the web service request 34 even in the presence of the data flow and deployment constraints discussed above.
[0033] A partially decentralized orchestration system (such as the example system 30 of FIG. 3 ) consists of a runtime infrastructure and an optional set of automation tools.
Runtime Infrastructure
[0034] FIG. 4 shows a representative architecture of a runtime infrastructure 50 . This infrastructure 50 consists of: one composite web service runtime environment (node 52 ), at least one component web service runtime engine with partition (node 70 , node 90 ), and zero or more component web service runtime engines without partition 110 .
[0035] Composite Web Service Node: The node 52 is a client interface node. The BPEL4WS partition, residing in the BPEL4WS engine 54 at this node 52 , is configured to receive any client requests (e.g., the block 24 in FIG. 2 ), and starts execution of the composite service. The node 52 also includes a deployment manager 58 , a monitoring agent 60 and a status monitor 62 , the function of which will be described below.
[0036] Component Web Service Node (with BPEL4WS partition): The nodes 70 , 90 are component web service nodes with BPEL4WS partition (and thus examples of coordination nodes), which invoke the local web service, may also invoke web services in other domains (e.g., the web service of node 110 ) and may also perform the required data transformation. In terms of coordination responsibility, the component web service nodes with BPEL4WS partition can be further categorised as coordination nodes and non-coordination nodes. Node 90 invokes local web service as well as web services in other domains (web service of node 110 ), the node has to coordinate the invocation and execution of multiple web services and is thus termed as coordination node. Node 70 on the other hand invokes only the local web service, no coordination among multiple web services is involved and thus the node is termed as non-coordination node. The nodes 70 , 90 include a partition deployer 76 , 96 , a constraint reinforcer 78 , 98 , a BPEL4WS Engine 72 , 92 , a monitoring agent 80 , 100 and the component web service 74 , 94 . The data flow constraints are stored in the database (DB) 102 .
[0037] Component Web Service Runtime Node (without BPEL4WS partition): The node 110 does not contain any BPEL4WS partition related to the composite web service (and thus an example of a non-coordination node). That is, it may be a node that does not have a BPEL4WS engine or it may not allow BPEL4WS partitions for this composite web service. The node 110 includes a monitoring agent 112 and the component web service 114 . The data flow constraints are stored in the database (DB) 116 .
[0038] The status monitor 62 receives status information (i.e., as shown by the dashed arrowheaded lines) from the monitoring agent 60 of its own node 52 , and from the monitoring agents 80 , 100 , 112 of the other nodes 70 , 90 , 110 .
[0039] The deployment manager 58 receives the topology (i.e., a set of BPEL4WS flows, 56 ) selected for deployment from a topology selector 150 (shown in FIG. 6 ), and sends (i.e., shown by the solid arrowheaded lines) the partitions of that topology for deployment to the partition deployers 76 , 96 of the corresponding component web service nodes 70 , 90 .
[0040] The partition deployer 76 , 96 has two main functions: constraint checking and verification, and deployment. The partition deployer 76 , 96 verifies that the BPEL4WS partitions are allowed to be deployed at the respective node 70 , 90 , and the partitions are allowed from this composite web service runtime environment 52 and authenticity of the composite web service runtime environment 52 . The partition deployer 76 , 96 further verifies whether the partition submitted for deployment at the respective node 70 , 90 satisfies all applicable data flow constraints. Constraint checking and verification is essential because the partition is generated by an external entity and after deployment the partition executes within the domain as a trusted piece of code and has full access to unencrypted output data of the component web service if encryption is being used.
[0041] The partition deployer 76 , 96 accepts the incoming BPEL4WS partition form the deployment manager 58 and passes the partition to the constraint reinforcer 78 , 98 to generate the additional set of constraints. In cases where encryption is being utilized, the constraint reinforcer 78 , 98 will also be utilized to add additional security policies to the existing security policies so that any confidential data that is flowing out of that node in the form of newly created message types is also encrypted. The partition is then passed through a constraint checker (not shown, but a part of the partition deployer 76 , 96 ) that checks that the partition adheres to all the data flow constraints. After constraint checking and verification, the partition is then deployed on to the BPEL4WS engine 72 , 92 .
[0042] The goal of the constraint reinforcer 78 , 98 is to ensure that the data flow constraints are applied to any new message types that are generated as a result of data transformations being applied to a message type that was part of the original constraints. This new set of constraints will be similar to the ones that already exist for the original message type differing only in the name of the message type and message fields.
[0043] The constraint reinforcer 78 , 98 uses the Data Dependence Graph (DDG) to trace the transformation of the output data of the component web service. For each partition, the constraint reinforcer 78 , 98 searches for all invokes/replies in that partition. For each invoke/reply the constraint enforcer 78 , 98 extracts the input message type. The constraint reinforcer 78 , 98 uses the DDG to trace back to the origin of this input message type. The constraint reinforcer 78 , 98 then searches for all the constraints in the constraints database 82 , 102 that have this original message type as part of the tuple (see below). For all such constraints, the constrain enforcer 78 , 98 generates a new set of constraints essentially similar to the original ones but with the original message type and message field names replaced by the newly generated message type and message field names.
[0044] FIG. 5 is a flow diagram showing an algorithm 120 implementing the constraint reinforcer 78 , 98 as a flow diagram. The process flow begins at step 122 with a partition under evaluation at the constraint reinforcer 78 , 98 . At step 124 , the first invoke/reply is picked. At step 126 , the input message is identified. At step 128 , a DDG is used to trace back to the source message for elements of this input message. The first source message is picked at step 130 . The rules for this message type are found at step 132 . At step 134 , the rules corresponding for the input message type are generated based on rules found at step 132 . These rules are essentially similar to rules found at step 132 , but the message type and message field names are corresponding to the input message. At this point, at step 136 , it is determined whether there are any further source messages. If yes, then at step 138 , the next source message is picked and the process is repeated from step 132 . If no, then at step 140 it is determined whether there are any more invoke/reply requests to be processed. If yes, then at step 142 , the next invoke/reply request is picked and the process flow returns to step 126 . If no, then in step 144 the process has completed.
[0045] Constraints are expressed as a 3-tuple of <source, destination, MessageType>. Both the source and the destination are expressed in terms of a domain name. MessageType is the input message type that a particular port type expects. Constraints fall under the “Allowed” and “Not Allowed” categories. “Allowed” constraints are those where either a source can send data to given set of destinations, or where a destination can accept data from the given set of sources. “Not allowed” constraints are those where either a source cannot send data to a given set of destinations or where a destination cannot receive data from given set of sources. The source and destinations can also be expressed in terms of domain name sets e.g. *.co.jp for all companies located in Japan.
[0046] In the movie theater example described above, the data flow constraints for the Yellow Pages Service Provider 42 can be expressed as follows:
[0000]
<Allowed>
<Source>X Yellow Pages</Source>
<Destination>* Movie Theater</Destination>
<MessageType>*</MessageType>
</Allowed>
<NotAllowed>
<Source>X Yellow Pages</Source>
<Destination>*</Destination>
<MesssageType>MovieTheaterList</MessageType>
<NotAllowed>
[0047] The “Allowed” and “NotAllowed” constraints can appear in any relative order in the Rules schema with the condition that more specific constraints appear first followed by the less specific ones.
Automation Tools
[0048] FIG. 6 shows tools used for automatically generating BPEL4WS partitions from centralized BPEL4WS code, namely a topology selector 150 and a decentralizer 152 . The tools draw on the stored data flow constraints and deployment constraints 154 and the BPEL4WS specification 156 . The BPEL4WS flows 158 generated by these tools 150 , 152 are fed to the deployment manager 58 of runtime infrastructure 50 .
[0049] Decentralizer: The decentralizer 152 partitions the composite web service specification using program analysis techniques taking data flow constraints and deployment related constraints into account. The partitions are composite web service specifications themselves that execute at distributed locations and can be invoked remotely. The decentralizer 152 also generates the WSDL descriptors for each of these partitions. The WSDL descriptors permit them to be deployed and invoked in the same way as any standard web service.
[0050] An algorithm to create decentralized topologies from a given composite BPEL4WS specification will now be described with reference to the state diagram 170 of FIG. 7 . In FIG. 7 the boxes represent (intermediate) output and the arrowheaded lines represent procedural steps. All activities are divided into three categories—receive, pick and reply are classified as Fixed Nodes, invoke is classified as Partially Fixed Node and all the other activities are classified as Portable Nodes.
[0051] A Program Dependence Graph (PDG) based code partitioning algorithm designed for multiprocessor execution can be used to implement the state diagram 170 . Such an algorithm creates independently schedulable tasks at the granularity of partitions of a PDG. To reduce overhead, such algorithms try to merge several PDG nodes to create a larger partition, possibly sacrificing parallelism.
[0052] A Threaded Control Flow Graph (TCFG) representation 172 of the composite web service is created. The data dependencies (not shown) are added to this TCFG 172 to get a first PDG 176 . For BPEL4WS flows, special handling related to flow and sequence activities are performed. From the control dependence point of view, all the activities inside one leg of the flow activity are dependent on the flow activity, which is in turn dependent on its container activity (e.g., flow or sequence). All the legs of the flow activity have no control dependence among them except for the explicit link constructs. Further, flow activity does not have any data dependence, and the removal of this flow activity from the PDG 172 makes no difference to composition of web services. Similarly, the purpose of sequence activity is to provide a container for other activities and it does not have any real data or control dependency, and therefore all the sequence activities can also be removed from the PDG with out any loss of information. This PDG 176 is further modified to ensure that all the data dependent edges (other than loop-carried dependencies and across TCFG-level edges) are from the left to right direction. These modifications are done by reordering the activities. In this state, the PDG may have data dependent edges across various hierarchical levels of the PDG. These across TCFG-level edges are now broken into at most three different data dependence edges as follows:
1. Taking two nodes between which the across-level data dependent edge exists: node A and node B, and the edge is from node A to node B. Now, a common ancestor of the two nodes, a node C is found. 2. If the common ancestor happens to be one of the two nodes, the edge is not broken. 3 . If the common ancestor happens to be immediate parent of any of the two nodes, the edge is broken into two edges. If node C is immediate parent of node A, then a node D is found such that node D is ancestor of node B and sibling of node A. Now, the node A→node B edge is broken into node A→node D and node D→node B edges. Similarly, if node C is immediate parent of node B, then node D is found such that it is ancestor of node A and sibling of node B. 4. In all the other cases, node D and node E which are immediate children of node C but ancestor of node A and node B respectively are found. Now, the node A→node B edge is broken into node A→node D, node D→node E and node E→node B edges.
[0056] A PDG-based code partitioning algorithm 178 first breaks the PDG 176 into independently executable program sections, which in this case are individual BPEL4WS activities, and then tries to merge them to create manageable number of partitions. Consequently, the problem of code partitioning in this case is actually merging individual activities together to create partitions, which are semantically similar to the input BPEL4WS specification 174 .
[0057] For this purpose, starting at the bottom of the Program Dependence Tree, the sibling nodes that have the same control dependence condition are identified and those nodes are merged. Two sibling nodes in the PDG 176 that have the same control dependence relationship between them if the reversal of flow order of these two nodes does not violate any other dependency. Once all the nodes at one level are merged, this algorithm is applied recursively to the higher levels of the tree till the root node is reached. The result is the partitioned output BPEL4WS specification 182 . An informal description of the algorithm is as follows:
1. Locate a control node, N c in the PDG and all child nodes associated with the control node are leaf nodes. For all the nodes that have the same control dependence condition on N c repeat steps 2 through 6. Continue the process till all the control nodes have been processed. 2. For the control node N c , divide all its children into two sets P and F, where P consists of all the Portable Nodes and F consists of all the other nodes. For each node in P, chose a node in F and merge the portable node P with the node from F. If all the merging combinations are exhausted, go to step 9. 3. Move all the portable nodes next to the node with which they are to be merged and arrange them in a linear order such that all the data dependent edges among the nodes merged together are from the left to right direction. If no such ordering is feasible, discard the merging and go back to step 2. 4. Arrange all the groups (where one group consists of a node from F along with its merged nodes) such that all the data dependent edges among the groups are from the left to right direction. If no such ordering is feasible, discard the merging and go back to step 2. 5. Treat N c as a leaf node. 6. Repeat step 1 to 5 for all the levels of the PDG, thereby creating one topology with partitions which are either groups of Fixed Nodes along with their merged nodes or groups of Partially Fixed Nodes which were merged with themselves in step 2 along with their merged nodes. 7. Merge all Partially Portable Nodes in F with their merged Portable Nodes with some node in F including itself. When a node is merged with itself this means it will be co-located with the web service it invokes. 8. The nodes which were merged with themselves in step 8 are given the constraints of the web services they invoke and the Fixed Nodes are given the constraints of the composite web service. It can be verified that the topology identified in step 2 to 7 does not violate any data flow constraint and deployment related constraints. If any of the constraints are violated, it is discarded, otherwise code for that topology is generated. 9. Steps 7 to 8 are repeated for all the possible mergers of nodes in P with nodes in F and all the Partially Portable Nodes in F.
[0067] Topology Selector: The topology selector 150 ranks the topologies generated by the decentralizer 152 according to some given criteria such as “minimum response time” or “maximum throughput” or “minimum data transfer”. The best topology as ranked by the topology selector 150 is chosen for deployment. The topology selector 150 receives all the topologies generated by the decentralizer 152 as its input. It also takes one or more appropriate criterion to rank the topologies.
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A partially decentralized composition of web services is performed by distributing the coordination responsibility of the component web services, originally performed at run time by the centralized execution language code, to multiple web service domains. The original software is divided into multiple code partitions and placed among different web service domains. These code partitions invoke one or more component web services and perform the required data transformation applicable to enable calling and returning data from the web services. The partitions may invoke more than one web service. The web service domains containing the code partitions that invoke more than one web services and perform the required data transformation become new coordinator nodes. In constrained data flow environments, to satisfy any data flow constraints, the data is sent from producer to consumer along a path restricted to the nodes eligible to access this data. The code performing the required data transformation is located on the nodes in this path and may span across multiple nodes.
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FIELD OF THE INVENTION
The invention relates to diaphragm and chamber devices, e.g., those used in balancing flow to and from a dialyzer in a dialysate supply machine.
BACKGROUND OF THE INVENTION
One type of balancing chamber used in dialysate supply machines has rigid outer walls and a diaphragm that divides the chamber into two regions so that as one region is being filled with fresh dialysate the other is discharged of an equal amount of spent dialysate as the diaphragm moves toward one of the rigid walls. When all of the spent dialysate has been discharged from the spent dialysate region, the valves at inlets and outlets to the regions are switched, and the spent dialysate side is filled, as the fresh dialysate side discharges, and the diaphragm moves toward the other wall, until all fresh dialysate has been discharged, and so on.
It is desirable to accurately sense when the diaphragm approaches a wall so that the valves to the chamber switch from one mode to the other at the proper time. Schal U.S. Pat. No. 4,530,759, which is hereby incorporated by reference, discloses sensing when a diaphragm has reached a wall by sensing when a pump supplying dialysate to a region is drawing a sharply increasing electrical current. Flowrate sensors, pressure sensors, and contact switches have been suggested as other mechanisms to sense the end of a stroke in similar applications in Papanek et al. U.S. Pat. No. 4,366,061 (col. 9, lines 40-47); Pinkerton U.S. Pat. No. 4,178,240 (col. 3, lines 18-24) and Schal U.S. Pat. No. 4,267,040 (col. 6, lines 29-47).
SUMMARY OF THE INVENTION
It has been discovered that the position of a diaphragm between walls of a chamber can be accurately sensed by providing a magnet that is carried by and movable with the diaphragm and a magnet position sensor that is carried by a side wall of the chamber.
In preferred embodiments, the magnet position sensor provides an output signal the magnitude of which varies as the distance between the magnet and sensor varies; there are valved inlets and outlets to the chamber regions on opposite sides of the diaphragm, and the valves are controlled in response to signals from the magnet position sensor; there are magnet position sensors carried by both walls; and the balance chamber is connected in parallel with an identical balance chamber. Because the diaphragm need not bottom out, long life of the diaphragm is promoted, and there are no large pressure spikes. There also are very repeatable switching points, as there are no contact elements that could perform unrepeatably after wear.
Other advantages and features of the invention will be apparent from the claims and from the following description of the preferred embodiment thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawings will be described first.
Drawings
FIG. 1 is a vertical sectional view showing a balance chamber according to the invention.
FIG. 2 is a diagrammatic exploded perspective view of part of the FIG. 1 chamber.
FIG. 3 is a diagram showing the valves and the electronics controlling the FIG. 1 chamber.
STRUCTURE
Referring to FIG. 1, there is shown balance chamber 10 including diaphragm 12, rigid walls 14, 16, peripheral clamp 18, and magnetic position sensors 17, 19.
Diaphragm 12 is symmetrical about horizontal axis 20 and includes generally flat flexible rubber sheet 22 and magnet 24. Sheet 22 is made of ethylene propylene elastomer (available from Bellofram Corp. under the trade designation 270-968) and includes peripheral sealing bead 26 (0.150" in axial direction and 0.060" thick in radial direction), center portion 28, including 0.06±0.02" thick layers 30, 32 on the front and back of magnet 24, and 0.030" thick intermediate corrugated portion 34, including eight annular corrugations 36. The overall thickness of corrugated portion 36 (i.e., the distance along an axis parallel to axis 20) is 0.180"; the dimension of each corrugation along an axis perpendicular to axis 20 is 0.186", and the radius of curvature of each corrugated portion 36 is about 0.105", making the shape of each corrugation 36 in cross-section slightly less than a half circle.
Magnet 24 is 0.49±0.01" in diameter, is 0.19±0.01" thick, and is made of ceramic material (barrium or strontium ferrite, Grade 5, oriented and sintered, available from Magnetic Sales and Manufacturing Co., Culver City, Calif.), and molded within flexible sheet 22 in a demagnetized condition (to avoid attracting dirt during manufacture), and magnetized thereafter, having a north pole at one face and a south pole at the other.
Rigid wall 14 has inlet 38 and outlet 40 for fresh dialysate, and rigid wall 16 similarly has inlet 42 and outlet 44 for spent dialysate. Variable volume region 46 between wall 14 and diaphragm 12 is a fresh dialysate region, and variable volume region 48 between diaphragm 12 and wall 16 is a spent dialysate region. Near the peripheries of walls 14, 16 are annular recesses 50 for receiving peripheral sealing bead 26. Rigid walls 14, 16 define recessed regions 52, 54 for receiving center portion 28 of diaphragm 12.
Referring to FIGS. 1 and 2, cavities 56, 58, outside and adjacent to recessed regions 52, 54, receive hall effect sensors 17, 19 (FIG. 2), used to sense the position along travel axis 20 of magnet 24. Sensors 17, 19 include circuit boards 51 secured against stops 53 in the ends of recessed regions 52, 54, by overhanging washers 57 and screws 55, which are screwed into screw holes 59. Magnetic position sensors 17, 19 are available from Honeywell, Micro Switch Div., under the trade designation 91SS12-2.
Chamber 10 is connected in parallel with an identical chamber and connected so that one is filling with fresh dialysate and discharging spent dialysate while the other is discharging fresh dialysate and filling with spent dialysate and vice versa.
Referring to FIG. 3, the electronic control circuitry for chamber 10 is shown. Sensors 17, 19 are connected to analog-to-digital converter 60, in turn connected to electronic controller 62. Controller 62 is connected to provide control signals to two-position (open-closed) solenoid valves 64, 66, 68, 70, controlling flow through fresh dialysate inlet 38, fresh dialysate outlet 40, spent dialysate inlet 42 and spent dialysate outlet 44 respectively.
Operation
Balance chamber 10 is used connected in parallel with an identical balance chamber in a dialysate supply machine. Inlet 38 is connected to a source of fresh dialysate; outlet 40 is connected to a dialyzer; inlet 42 is connected to receive spent dialysate from a dialyzer, and outlet 44 is connected to a drain. Valves to inlets 38, 42 and outlets 40, 44 are controlled so that one balance chamber is receiving, in its region 46, fresh dialysate from a source and discharging spent dialysate from its region 48 to a drain (valves 64, 70 to inlet 38 and outlet 44 being open, valves 66, 68 to outlet 40 and inlet 42 being closed, diaphragm 12 moving to the right) while the other balance chamber is providing fresh dialysate from its region 46 to the dialyzer and receiving spent dialysate in its region 48 from the dialyzer (valves 66, 68 to outlet 40 and inlet 42 being open, valves 64, 70 to inlet 38 and outlet 44 being closed, diaphragm 12 moving to the left).
Travel of diaphragm 12 from one rigid wall to the other is sensed by hall effect sensors 17, 19 in cavities 56, 58. As diaphragm 12 approaches a wall 14 or 16, magnet 24 approaches either sensor 17 or 19 and moves away from the other. Assuming diaphragm 12 is moving to the right (valves 64, 70 open, valves 66, 68 closed), as the magnetic south pole of magnet 24 approaches sensor 19, its output voltage increases as the distance decreases. When microcomputer 62 senses that the output voltage has reached a preset voltage selected so that diaphragm 12 has not bottomed out, it sends control signals to close solenoid valves 64, 70 and open solenoid valves 66, 68 at the same time that the second balance chamber (not shown) is switched the other way. Diaphragm 12 is now moved toward wall 14 by fluid entering inlet 42 and fluid leaving outlet 66. As the magnetic north pole of magnet 24 approaches sensor 17, its output voltage decreases as the distance decreases. When the voltage reaches a preset voltage level, the valves are switched again, and so on.
Balance chamber 10 has long life, as wear on diaphragm 16 is reduced, as it does not bottom out during operation. Also large pressure spikes can be avoided, since one can avoid having the diaphragm bottom out, and the switching points are very repeatable, as the sensors are very accurate and are not subject to wear, as contact switches are. Because of corrugations 36, diaphragm 12 remains symmetrical about axis 20 as it travels along axis 20 in a rolling fashion so that the front and back (north and south) faces of magnet 24 maintain their perpendicular orientation to axis 20, avoiding distortions in the signals of the hall effect sensors sensing magnet position.
Other Embodiments
Other embodiments of the invention are within the scope of the following claims.
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A diaphragm and chamber device including chamber means for defining a chamber having fixed position walls on opposite sides, a diaphragm in the chamber and sealably mounted between the walls to define first and second regions therein on opposite sides of the diaphragm, the diaphragm being movable in the chamber so as to change the volume of the two regions as the diaphragm moves toward either the wall, a magnet carried by the diaphragm and movable therewith, and a magnet position sensor carried by a the wall and sensing the location of the magnet and thus the diaphragm.
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BACKGROUND
[0001] The present invention relates generally to integrated circuit heat dissipation devices, and, more particularly, to an anisotropic heat spreading apparatus and method for semiconductor devices.
[0002] The semiconductor industry has seen tremendous technological advances in recent years that have permitted dramatic increases in circuit density and complexity, as well as equally dramatic decreases in power consumption and package sizes. Present semiconductor technology now permits single-chip microprocessors with many millions of transistors, operating at speeds of tens (or even hundreds) of MIPS (millions of instructions per second), to be packaged in relatively small, air-cooled semiconductor device packages. Because integrated circuit devices, microprocessors and other related components are designed with increased capabilities and increased speed, additional heat is generated from these components.
[0003] As packaged units and integrated circuit die sizes shrink, the amount of heat energy given off by a component for a given unit of surface area is also on the rise. The majority of the heat generated by a component, such as a microprocessor for example, must be removed from the component in order to keep the component at an acceptable or target operating temperature. If the heat generated is not removed from the component, the heat produced can drive the temperature of the component to levels that result in early failure of the component. In some instances, the full capability of certain components cannot be realized since the heat the component generates at the full capability would result in failure of the component.
[0004] An integrated circuit has a front side and a backside. The front side of the integrated circuit includes leads for inputs, outputs and power to the integrated circuit. Leads include many forms, including pins and balls in a ball grid array. The leads of an integrated circuit are attached to pads on another device such as a printed circuit board. For example, an integrated circuit that includes a die having a microprocessor therein has a front side that is attached to the pads on a motherboard, substrate or leadframe. In contrast, a heat sink is attached to the backside of the integrated circuit, extending away from the printed circuit board to which the integrated circuit is mounted. Accordingly, a major portion of the heat generated is generally extracted from the backside of the integrated circuit with the die therein.
[0005] There is a practical limitation on the amount of heat that can be extracted from the backside of the integrated circuit die, as a result of the thermal resistance of the thermal interface materials (such as any thermal grease, adhesives or solders) used between the backside of the integrated circuit die and the heat sink. Typically, heat sinks are formed from materials such as copper or aluminum and have a limited ability to conduct heat. Relatively large fin structures are also provided to increase the amount of heat removed via conduction. Fans are also provided to move air over the fin structures to aid in the removal of heat. Increasing the size of the fin structure increases the volume of the heat sink, and generally also increases the stack height of the heat sink. In many electronic devices, the overall size of the heat sink is generally limited by volume constraints of the housing. For example, in some mobile products such as laptop computers and ultra-mobile computers, small stack heights are required.
[0006] The use of aluminum and copper heat sinks with fin structures are now therefore approaching their practical limits for removal of heat from a high performance integrated circuit, such as the integrated circuits that include dies for microprocessors. When heat is not effectively dissipated, the dies develop “hot spots” (i.e., areas of localized overheating). Unfortunately, the current cost performance lids do not adequately solve this heat dissipation/distribution problem. Moreover, the existing lid materials are isotropic, in that they provide singular heat flow characteristics derived from the intrinsic homogeneous properties of the lid material. In some instances, traditional aluminum and copper heat sinks have been replaced with sinks incorporating exotic materials (e.g., diamond particles) therein. However, diamond heat sinks are difficult to manufacture, in addition to being expensive. In particular, one aspect of diamond heat sink formation is that one major surface of the heat sink must be ground smooth in order to provide a good thermal connection at a thermal interface. The grinding or smoothing of diamond is also time consuming.
[0007] In view of the above, it would be desirable to be able to provide a heat spreading apparatus and methodology for semiconductor devices in a manner that is both efficient and cost effective.
SUMMARY
[0008] The foregoing discussed drawbacks and deficiencies of the prior art are overcome or alleviated by a heat spreading apparatus for use in cooling of semiconductor devices. In an exemplary embodiment, the heat spreading apparatus includes a frame having a plurality of individual cells formed therein, each of the cells configured for filling with a material of selected thermal conductivity therein. The selected thermal conductivity of material within a given one of the cells corresponds to a thermal profile of the semiconductor device to be cooled.
[0009] In another embodiment, a method for forming a heat spreading apparatus for semiconductor includes extruding a frame material to form a plurality of individual cells, filling a first group of the individual cells with one or more high thermal conductivity materials, and filling at least a second plurality of the individual cells with one or more materials of lower thermal conductivity than in the first plurality of cells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Referring to the exemplary drawings wherein like elements are numbered alike in the several Figures:
[0011] FIG. 1 is a top, cross sectional view of the structure of a heat spreading apparatus, in accordance with an embodiment of the invention;
[0012] FIG. 2 illustrates one specific example of the heat spreading apparatus of FIG. 1 , following the fill of the individual cells with various thermal spreading materials;
[0013] FIG. 3 illustrates an alternative embodiment of the fill pattern of the heat spreading apparatus;
[0014] FIG. 4 illustrates another alternative embodiment of the fill pattern of the heat spreading apparatus;
[0015] FIG. 5 illustrates still another alternative embodiment of the fill pattern of the heat spreading apparatus;
[0016] FIGS. 6-8 illustrate partial, side cross sectional views of various additional embodiments of the heat spreading apparatus;
[0017] FIG. 9 is a flow diagram illustrating a method for forming a heat spreading apparatus, in accordance with a further embodiment of the invention; and
[0018] FIG. 10 is a flow diagram illustrating an alternative embodiment of the method shown in FIG. 9 .
DETAILED DESCRIPTION
[0019] Disclosed herein is a cost/performance heat spreading apparatus and method that provides tailored thermal conduction properties of selective areas of the apparatus to correspond to determined hot spots on a chip. Briefly stated, the heat spreading apparatus incorporates anisotropic properties to address the varying heat transfer requirements of a semiconductor chip, while a web (e.g., honeycomb) of high strength material included in the heat spreading apparatus provides the skeleton thereof with sufficient strength to be used in mechanically loaded applications, such as land grid array (LGA) applications.
[0020] Moreover, the present solution allows high thermal conductivity (T c ) materials, such as diamond particles in a polymer matrix, to specifically contact the hot spots of a chip, while higher strength, less thermally conductive materials may be used to fill the honeycomb cells where the desired heat transfer is less significant. By specifically tailoring the material that each of the honeycomb cells are filled with, more expensive, high heat transfer materials can be provided only where desired in specific locations, thus saving the cost of fabricating a lid entirely with more expensive materials (such as diamond, for example).
[0021] Referring now to FIG. 1 , there is shown a top, cross sectional view of the structure of a heat spreading apparatus 100 , in accordance with an embodiment of the invention. As is shown, the heat spreading apparatus 100 includes a web of individual cells 102 that may be filled with materials of various thermal properties. In the embodiment depicted, the web is shown a “honeycomb-like” design of individual hexagonal cells. However, other shapes and designs of cell configurations are also contemplated including, but not limited to, packed arrangements such as circular type cell shapes (e.g., circle, oval, elliptical, etc.) and polygonal type cell shapes having three or more sides, as well as cells of varying sizes. Exemplary materials that may be used to form the sidewall, top and bottom surfaces of the cells 102 include, but are not limited to, metals (e.g., aluminum, copper), thermoplastics and plated materials. The web can further be extruded, molded, machined and the like, depending on the particular material or materials used in forming the same. It should be further noted that in the exemplary embodiment of FIG. 1 , the thickness of the cell walls are not necessarily to scale, and are exaggerated for illustrative purposes.
[0022] FIG. 2 illustrates one specific example of the heat spreading apparatus 100 of FIG. 1 , following the fill of the individual cells 102 with various thermal spreading materials used therein. In the example depicted, a first group of cells 102 has a first fill material 104 a formed therein, a second group of cells 102 has a second fill material 104 b formed therein, a third group of cells 102 has a third fill material 104 c formed therein, and a fourth group of cells 102 has a fourth fill material 104 d formed therein. Further, in the example depicted, the chip (not shown) to which the heat spreading apparatus 100 is to be attached is determined to have the hottest spots in the center thereof, with the cooling requirements being decreased in a generally rectangular pattern away from the center. Accordingly, for an economical yet effective heat transfer apparatus 100 , the first cell material 104 a (darkest shading) may be a high T c , higher cost material such as diamond, silicon carbide or aluminum silicon carbide, for example. For the cells corresponding to somewhat cooler spots on the chip, the second and third cell materials 104 b , 104 c (intermediate shadings) may be medium cost, medium T c materials. Finally, for the peripheral areas of apparatus 100 corresponding to the coolest spots on the chip, the fourth cell material 104 d (lightest shading) may be a low cost, low T c material.
[0023] FIG. 3 illustrates an alternative embodiment of the heat spreading apparatus 100 , wherein the pattern of cell fill materials varies in a circularly outward pattern, again with the higher T c /cost fill material 104 a being located in the centermost cells. In FIG. 4 , a “sunburst” pattern of high T c fill material 104 a is defined within the heat spreading apparatus 100 . Again, several different patterns of differing fill materials are contemplated, depending on a specific thermal profile and mechanical needs of the chip to which the apparatus 100 is intended to be attached. FIG. 5 illustrates still an alternative embodiment of the heat spreading apparatus 100 , having cell patterns of both different fill materials and different shapes. For example, the heat spreading apparatus 100 can have cells 102 of a first size and shape (such as small hexagonal or circular cells), as well as cells 106 of a second size and shape (such as larger rectangular cells). Thus configured, the heat spreading apparatus 100 can optimize thermal spreading, strength of the structure (for retention hardware forces where applicable), and heat dissipation of specific chip hot spots.
[0024] As indicated above, the individual cells 102 of the heat spreading apparatus 100 may be filled with a variety of different materials to create anisotropic thermal conduction properties across the entire structure in the z (as well as the planar x-y) directions. To this end, thermoplastics and thermosets may be compounded with industrial diamond particles, graphite, liquid metals, water or phase change materials. In essence, the cells 102 may be filled (either fully or partially) with any material that provides the desired thermal and mechanical properties in the chip location specified.
[0025] FIGS. 6-8 illustrate partial, side cross sectional views of various additional embodiments of the heat spreading apparatus 100 . For instance, in FIG. 6 , it can be seen that the higher T c fill materials 104 a are used in the center cells, while the intermediate and lower T c fill materials 104 c , 104 d are used in the middle and outer perimeter cells, respectively. As is further illustrated, the heat spreading apparatus 100 may include a top surface 108 and a bottom surface 110 for providing an enhanced thermal interface to a heat sink and chip, as well as to encapsulate the filler material(s) used within the cells. FIG. 7 once again illustrates that the cells may have different shapes and/or sizes with respect to one another. As further shown in FIG. 8 , one or more of the cells may be partially filled with a thermal liquid (e.g., water) so as to effectively act as a vapor chamber and/or “heat pipe.”
[0026] FIGS. 9 and 10 illustrate exemplary heat spreader formation processes, in accordance with a further embodiment of the invention. In the embodiment of FIGS. 9 ( a ) and 9 ( b ), the exemplary process 900 is illustrated for a simple 5-cell spreader structure having a center cell bordered by the other four cells. However, it will be appreciated that this example is simplified for illustrative purposes only, and that the process is applicable to a heat spreading device having a greater number of individual cells, such as those described above. In this particular embodiment, the heat spreading device is created by infiltrating a mold filled with thermally conductive particles, with different regions of the spreader having different fill materials, wherein the fill materials are initially separated by a frame. The frame (or cell walls) is “consumable” in this embodiment, meaning that they are absorbed into the other spreader materials during fabrication. FIG. 9 ( a ) is a process flow diagram, while FIG. 9 ( b ) illustrates the simplified cell structure of the heat spreading apparatus.
[0027] As particularly shown in block 902 of FIG. 9 ( a ), the frame is extruded (e.g., using a material such as silver) and placed into a mold for infiltration of the individual cells. The center cell (or cells) is filled with a high T c material, such as high-grade diamond particles, as shown in block 904 . In contrast, the border cells are filled with a lower T c material, such as silicon carbide, as shown in block 906 . Then, the filled mold and source of bulk frame material (e.g., silver) is placed within a suitable heating apparatus, as shown in block 908 . In block 910 , the assembly is reflowed to as to infiltrate the particles within the mold. Additionally, with this particular embodiment, the frame walls are melted so as to form an amalgam with the fill materials. However, the tailored thermal profile of the apparatus is still preserved. Next, the assembly is cooled and removed from the mold, as shown in block 912 , and any flash may be removed from the assembly by machining and/or surface finishing, as shown in block 914 .
[0028] Finally, FIG. 10 ( a ) illustrates an alternative process flow diagram 1000 similar to that of FIG. 9 ( a ), only with the cell wall structure being maintained following cell material infiltration. In block 1002 , the frame is extruded (e.g., using a material such as copper). The frame may also be chrome plated before being placed into a mold for infiltration of the individual cells. The center cell (or cells) is filled with a high T c material, such as high-grade diamond particles, as shown in block 1004 . In contrast, the border cells are filled with a lower T c material, such as low-grade diamond particles, as shown in block 1006 . Then, the filled mold and source of bulk frame material (e.g., copper) is placed within a suitable heating apparatus, as shown in block 1008 . In block 1010 , the assembly is reflowed to as to infiltrate the particles within the mold. Again, in this particular embodiment, the frame walls are not melted during the reflow. Next, the assembly is cooled and removed from the mold, as shown in block 1012 , and any flash may be removed from the assembly by machining and/or surface finishing, as shown in block 1014 .
[0029] While the invention has been described with reference to a preferred embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A heat spreading apparatus for use in cooling of semiconductor devices includes a frame having a plurality of individual cells formed therein, each of the cells configured for filling with a material of selected thermal conductivity therein. The selected thermal conductivity of material within a given one of the cells corresponds to a thermal profile of the semiconductor device to be cooled.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is related to and claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application 60/088,754, filed Jun. 10, 1998.
BACKGROUND OF INVENTION
This invention pertains to hermetically sealed, positive displacement compressors for compressing refrigerant in refrigeration systems such as air conditioners, refrigerators and the like. In particular, the invention describes a rotary compressor mechanism of the type which includes a cylinder block having a cylindrical cavity, a bearing assembly and a motor assembly driving a roller piston disposed in the cylindrical cavity. More particularly, the cylinder block includes a vane slot extending completely axially through the cylinder block to accommodate a reciprocating vane therein and the vane being urged against the roller piston.
Rotary compressors are well known in the art, as exemplified by U.S. Pat. No. 4,889,475 which is assigned to assignee of the present application. Generally, the tolerances between the reciprocating vane and the slot sidewalls defining the vane slot of the cylinder block must be tightly controlled in order to optimize compressor efficiency. Proper vane clearances are necessary to allow free reciprocation of the vane in its slot and to allow sealing against discharge pressure gas blow-by therebetween. Maintaining these clearances in previous compressors often requires precision vane and/or slot machining, or select fitting of the individual vanes and cylinder blocks. A disadvantage arising from precision machining of the slot and/or vane is the associated cost of precision machining a pair of sidewalls defining the vane slot and vane. Always existent with precision machining is the immense cost associated with the act of “scrapping a part” when one of the final operations is spoiled due to a myriad of possible and easily made mistakes. A structure and method for easily providing uniform clearances between the vanes and their slots without resorting to costly and time consuming machining operations or select fitting is needed.
Generally, rotary compressor assembly entails first, laboriously preparing the vane and vane slot for an introduction of the vane into the vane slot, and second, the vane is introduced into the vane slot. A disadvantage, already mentioned hereinabove, is that laboriously preparing components, through precision machining and the like, has an increased cost associated therewith. Therefore, if components, such as the vane and vane slot, required less labor and the precise relationship required between the vane and vane slot were sustained through an inventive method of assembly, this inventive method would be highly desirous.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages of the prior art described above by providing a rotary compressor assembly as herein described.
The present invention rotary compressor assembly is hermetically sealed and comprises a housing, a cylinder block and a bearing assembly disposed within the housing. The cylinder block and the bearing assembly define a cylindrical cavity which has a roller piston disposed therein. The rotary compressor assembly includes a motor drivingly coupled to the roller piston.
The present invention rotary compressor assembly also includes the cylinder block having a vane slot extending completely axially through the cylinder block and extending radially from an outside perimeter surface of the cylinder block to the cylindrical cavity. At least a portion of the vane slot is defined by a pair of substantially parallel sidewalls and a vane is disposed in and guided by the vane slot and is urged against said roller piston. The cylinder block, of the present invention rotary compressor assembly, is in a state of circumferentially oriented stress and is fixed in that state of stress.
The present invention also includes a method to assemble a rotary compressor assembly which include steps, one step being, spreading apart the sidewalls of the vane slot in the cylinder block. Another step includes inserting into the spread apart slot a gauge vane of thickness greater than the thickness of a reciprocating vane. Yet another step includes releasing the block to cause the slot sidewalls to engage the gauge vane. Remaining steps include fixing the cylinder block to hold the sidewalls substantially parallel, removing the gauge vane from the slot, and inserting the reciprocating vane in the slot, whereby a clearance is maintained between the reciprocating vane and slot sidewalls.
The present invention also provides yet another method to assemble a rotary compressor assembly which includes steps, one being, inserting into the vane slot in the cylinder block the gauge vane of thickness greater than a thickness of the reciprocating vane. Another step includes closing together sidewalls of the vane slot in the cylinder block to cause the slot sidewalls to engage the gauge vane with the cylinder block. Also included are the steps of fixing the cylinder block to hold the sidewalls substantially parallel, removing the gauge vane from the slot, and inserting the reciprocating vane in the slot, whereby a clearance is maintained between the reciprocating vane and slot sidewalls.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of the embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a sectional side view of one embodiment of a compressor assembly according to the present invention, also showing the cross-over tube fluidly connecting the two discharge chambers and the compressor assembly discharge tube;
FIG. 2 is an enlarged fragmentary sectional side view of the rear portion of the compressor assembly shown in FIG. 1;
FIG. 3 is a sectional rear view of the compressor assembly shown in FIG. 2, taken along line 3 — 3 thereof;
FIG. 4 is a sectional front view of the compressor assembly shown in FIG. 2, taken along line 4 — 4 thereof;
FIG. 5 is a front view of the front main bearing of the compressor assembly shown in FIG. 1, including the outline of the cylinder block location on the axial main bearing surface;
FIG. 6 is a rear view of the main bearing shown in FIG. 5;
FIG. 7 is a rear view of the rear main bearing of the compressor assembly shown in FIG. 1, including the outline of the cylinder block location on the axial main bearing surface;
FIG. 8 is a front view of the main bearing shown in FIG. 7;
FIG. 9 is sectional side view of each of the main bearings shown in FIGS. 5 and 7, along lines 9 — 9 thereof;
FIG. 10 is a fragmentary sectional side view of each of the main bearings shown in FIGS. 6 and 8, along lines 10 — 10 thereof;
FIG. 11 is a front view of the common front and rear cylinder block of the compressor assembly shown in FIG. 1;
FIG. 12 is a front view of the front outboard bearing of the compressor assembly shown in FIG. 1;
FIG. 13 is a sectional side view of the outboard bearing of FIG. 12, along line 13 — 13 thereof;
FIG. 14 is a rear view of the rear outboard bearing of the compressor assembly shown in FIG. 1;
FIG. 15 is a sectional side view of the outboard bearing of FIG. 14, along line 15 — 15 thereof;
FIG. 16A is a partial sectional side view of the shaft of the compressor assembly shown in FIG. 1;
FIG. 16B is an enlarged sectional rear view of the shaft shown in FIG. 16A, along line 16 B— 16 B thereof;
FIG. 16C is an enlarged sectional front view of the shaft shown in FIG. 16A, along line 16 C— 16 C thereof;
FIG. 17A is an enlarged sectional side view of an eccentric of the compressor assembly shown in FIG. 1;
FIG. 17B is a sectional end view of the eccentric shown in FIG. 17A, along line 17 B— 17 B thereof;
FIG. 18 is a sectional side view of a second embodiment of a compressor assembly according to the present invention, also showing the cross-over tube fluidly connecting the two discharge chambers and the compressor assembly discharge tube;
FIG. 19 is an enlarged fragmentary sectional side view of the bottom portion of the compressor assembly shown in FIG. 18;
FIG. 20 is a sectional plan view of the compressor assembly shown in FIG. 19, taken along line 20 — 20 thereof;
FIG. 21 is a top view of the common upper and lower cylinder block of the compressor assembly shown in FIG. 18;
FIG. 22 a bottom view of the lower outboard bearing of the compressor assembly shown in FIG. 18;
FIG. 23 is a sectional side view of the outboard bearing of FIG. 22, along line 23 — 23 thereof;
FIG. 24 is a sectional side view of the third embodiment of a compressor assembly according to the present invention, also showing the cross-over tube fluidly connecting the two discharge chambers and the compressor assembly discharge tube;
FIG. 25 is an enlarged fragmentary sectional side view of the front portion of the compressor assembly shown in FIG. 24;
FIG. 26 is a sectional rear view of the compressor assembly shown in FIG. 25, taken along line 26 — 26 thereof;
FIG. 27 is a sectional front view of the compressor assembly shown in FIG. 25, taken along line 27 — 27 thereof;
FIG. 28 is a fragmentary perspective of a common cylinder block of the compressor assembly shown in FIG. 24, including the reed valve assembly and extended vane;
FIG. 29 is a front view of the front main bearing of the compressor assembly shown in FIG. 24, including the outline of the cylinder block location on the axial main bearing surface;
FIG. 30 is a rear view of the main bearing shown in FIG. 29;
FIG. 31 is a rear view of the rear main bearing of the compressor assembly shown in FIG. 24, including the outline of the cylinder block location on the axial main bearing surface;
FIG. 32 is a front view of the main bearing shown in FIG. 31;
FIG. 33 is sectional side view of each of the main bearings shown in FIGS. 30 and 32, along lines 33 — 33 thereof;
FIG. 34 is a front view of the common front and rear cylinder block of the compressor assembly shown in FIG. 24;
FIG. 35 is a sectional bottom view of the cylinder block of FIG. 34, along line 35 — 35 thereof;
FIG. 36 is a front view of the front outboard bearing of the compressor assembly shown in FIG. 24;
FIG. 37 is a sectional side view of the outboard bearing of FIG. 36, along line 37 — 37 thereof;
FIG. 38 is a sectional side view of the outboard bearing of FIG. 36, along line 38 — 38 thereof;
FIG. 39 is an exploded view of the pump assembly and rear outboard bearing of the present invention shown in FIG. 24;
FIG. 40 is a partial sectional side view of the shaft of the compressor assembly shown in FIG. 1;
FIG. 41 is an enlarged sectional rear view of the shaft shown in FIG. 40, along line 41 — 41 thereof;
FIG. 42 is an enlarged sectional front view of the shaft shown in FIG. 40, along line 42 — 42 thereof;
FIG. 43 is a front perspective view of an eccentric of the compressor assembly as shown in FIG. 24;
FIG. 44 is a sectional side view of the eccentric shown in FIG. 43, along line 44 — 44 thereof;
FIG. 45 is a sectional end view of the eccentric shown in FIG. 44, along line 45 — 45 thereof;
FIG. 46 is a sectional side view of a fourth embodiment of a compressor assembly according to the present invention, also showing the cross-over tube fluidly connecting the two discharge chambers and the compressor assembly discharge tube;
FIG. 47 is a sectional side view of a fifth embodiment of a compressor assembly according to the present invention, showing the suction tube fluidly connecting a discharge of one of the compressor mechanisms to a suction port of the remaining compressor mechanism and the compressor assembly discharge tube;
FIG. 48 is a sectional rear view of the compressor assembly shown in FIG. 47, taken along line 48 — 48 thereof;
FIG. 49 is a sectional rear view of the compressor assembly shown in FIG. 47, taken along line 49 — 49 thereof;
FIG. 50 is a simplified model of the common cylinder blocks of the compressor assemblies shown in FIGS. 1, 18 , 24 and 46 - 47 , showing an inwardly tapered vane slot;
FIG. 51 is the model cylinder block of FIG. 51, showing a gauge vane therein, outward forces applied thereto and a state of circumferentially oriented tensile stress;
FIG. 52 is the model cylinder block of FIG. 51, showing an operable vane slot of width “S” and the state of circumferentially oriented tensile stress preserved therein;
FIG. 53 is a simplified model of the common cylinder blocks of the compressor assemblies shown in FIG. 1, 18 , 24 and 46 - 47 , and an alternative to the model cylinder block of FIG. 51, showing an outwardly tapered vane slot;
FIG. 54 is the model cylinder block of FIG. 53, showing a gauge vane therein, inward forces applied thereto and a state of circumferentially oriented compressive stress; and
FIG. 55 is the model cylinder block of FIG. 53, showing an operable vane slot of width “S” and the state of circumferentially oriented compressive stress preserved therein.
Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplifications set out herein illustrate embodiments of the invention in alternative forms, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments disclosed below are not intended to be exhaustive or limit the invention to the precise form disclosed in the following detailed description.
Referring to FIG. 1, there is shown twin rotary compressor assembly 10 , a first embodiment according to the present invention. Compressor assembly 10 comprises housing 12 which is itself comprised of first housing portion 14 , second, cylindrical housing portion 16 and third housing portion 18 , first and third housing portions 14 and 18 being somewhat cup shaped, second housing portion 16 interposed between housing portions 14 and 18 . Compressor assembly 10 further comprises front and rear main bearings 20 , 22 , respectively, which comprise, within housing portions 14 and 18 , respective front and rear compressor mechanisms 24 and 26 . As will be discussed further below, front main bearing 20 and rear main bearing 22 are mirror images of each other. Each of main bearings 20 , 22 may be machined from a common casting or, alternatively, from a common sintered powder metal form. Main bearings 20 and 22 are respectively provided, at their peripheries, with annular, oppositely facing control surfaces 28 and 29 . Control surfaces 28 and 29 lie in parallel planes which are perpendicular to the central axis of each main bearing. The forwardly and rearwardly facing axial surfaces of cylindrical second housing portion 16 are each provided with axial counterbore 30 concentric about the central axis of housing portion 16 and which provides annular shoulders 31 against which axial surfaces 28 , 29 abut. Shoulders 31 lie in parallel planes which are perpendicular to the central axis of cylindrical housing portion 16 and provide control surfaces for proper axial spacing and radial alignment of main bearings 20 , 22 , and ensure they fit squarely within housing portion 16 . Proper placement of main bearings 20 , 22 allows the shaft supported thereby to be properly journaled and assures proper clearances are provided between the moving components which comprise front and rear compressor mechanisms 24 , 26 . The mating axial ends of housing portions 14 , 16 and 18 are joined at the outer radial periphery of respective main bearings 20 , 22 , to which they are sealably attached, as by welding. Welding each of housing portions 14 , 16 and 18 to the main bearings separates housing 12 into three distinct internal chambers separated by the main bearings. Front chamber 32 is generally defined by inside surface 33 of housing portion 14 and forward facing axial surface 34 of main bearing 20 . Similarly, rear chamber 36 is defined by inside surface 37 of third housing portion 18 and rearward facing axial surface 38 of rear main bearing 22 . As will be discussed further below, chambers 32 and 36 contain refrigerant gas at discharge pressure, and are also referred to hereinafter as front and rear discharge chambers, respectively. Intermediate main bearings 20 and 22 and generally defined by inside cylindrical surface 39 of center housing portion 16 and surfaces 40 and 42 of front and rear main bearings 20 and 22 , respectively, is chamber 44 . Chamber 44 , as will be discussed further below, contains refrigerant gas at suction pressure, and is hereinafter referred to as suction chamber 44 . Within suction chamber 44 is disposed motor assembly 46 comprising stator 48 in surrounding relationship with rotor 50 . Shaft 52 extends through the center of rotor 50 , and is attached thereto to be driven by rotor 50 when motor assembly 46 is energized through terminals 54 , which electrically communicate the motor with an external source of power. Providing the motor in the suction chamber provides a cooler operating environment for it, promoting its efficient operation and prevents its overheating. Further, placement of the motor assembly in the relatively cool environment of the suction chamber provides for easier identification of an internal motor over-temperature condition vis-a-vis compressors having motors exposed to discharge pressure, for the temperature protection device (not shown) attached to the stator windings, which interrupts electrical current to the motor when it becomes overheated, need not be calibrated to operate in relatively narrow temperature difference ranges between discharge gas temperatures to which the motor is ordinarily exposed and the motor over-temperature point.
Shaft 52 comprises large diameter central portion 56 , which extends through rotor 50 , and forwardly and rearwardly extending small diameter portions 58 and 60 , respectively, adjacent portion 56 . At the juncture of shaft portion 56 with shaft portions 58 and 60 , shaft 52 is provided with annular groove 57 in which may be disposed oil seal 59 which may be made of a material such as Teflon® or Ryton® and past which some leakage is permissible. Annular shoulder 62 is formed on the axial surface of shaft large diameter portion 56 , at its juncture with groove 57 . Thrust washer 64 is disposed about small diameter shaft portion 60 , with its forwardly and rearwardly facing axial surfaces abutting shaft shoulder 62 and forward facing axial surface 66 of hub portion 68 of rear main bearing 22 . Motor assembly 46 is arranged such that the windings of stator 48 and rotor 50 are axially offset by distance δ. Upon energization of stator 48 , rotor 50 not only rotates but is also urged rearward as it attempts to axially align its windings with those of the stator. Rotor 50 thus exerts a rearward axial force on shaft 52 which is transferred through shoulder 62 to thrust bearing 64 and opposed by main bearing 22 . In this way, axial surfaces of the eccentrics and adjacent bearings are not brought into abutment and caused to carry an axial load. Small diameter shaft portions 58 and 60 are respectively journaled in main bearing journals 70 and 72 , which extend through main bearing hub portions 74 and 68 .
Front compressor mechanism 24 and rear compressor 26 are each provided with cylinder block 76 . Cylinder block 76 comprises outer peripheral surface 78 and inner cylindrical cavity 80 . Cylindrical cavity 80 extends through the width of cylinder block 76 between its forward and rearwardly facing parallel axial surfaces 82 and 84 , respectively. In front compressor mechanism 24 , cylinder block rearward surface 84 abuts forwardly facing axial surface 34 of main bearing 20 . Similarly, in rear compressor mechanism 26 , cylinder block forward surface 82 abuts rearwardly facing main bearing axial surface 38 . Thus it can be seen that cylinder blocks 76 are similarly oriented about shaft 52 in front and rear compressor mechanisms 24 , 26 .
In front compressor mechanism 24 , forward cylinder block surface 82 abuts rearwardly facing axial surface 86 of front outboard bearing 88 . Outboard bearing 88 , frontmost cylinder block 76 and front main bearing 20 are attached by a plurality of bolts 90 extending through bolt holes 92 , 94 and 96 , with bolts 90 threadedly engaging main bearing bolt holes 96 . In rear compressor mechanism 26 , rearward cylinder block surface 84 abuts forwardly facing axial surface 98 of rear outboard bearing 100 . As described above, a plurality of bolts 90 attaches outboard bearing 100 , rearmost cylinder block 76 and rear main bearing 22 , extending through bolt holes 102 , 94 and 104 provided therein, threadedly engaging main bearing bolt holes 104 . Small diameter shaft portions 58 and 60 extend through outboard bearings 88 and 100 , and are supported in respective journals 106 and 108 provided therein. As will be discussed further below, front outboard bearing 88 and rear outboard bearing 100 are mirror images of one another, and may be machined together or on common tooling from identical castings or sintered powder metal forms.
Shaft 52 is provided with axial bore 110 which extends completely through its length. At its rearmost end, bore 110 is provided with impeller-type pump assembly 112 of a type commonly used in the art. Pump assembly 112 draws liquid lubricant from the lowermost portion of rear discharge chamber 36 , which serves as a sump, through vertical lubricant draw conduit or tube 114 , which extends downwardly from pump assembly 112 . The lowermost portion of front discharge chamber 32 also contains a quantity of liquid lubricant, also referred to as oil, as may that of suction chamber 44 . Pump assembly 112 provides oil through bore 110 to rear compressor mechanism 26 and to front compressor mechanism 24 for lubrication thereof, as will be discussed further below.
Discharge chambers 32 and 36 are in fluid communication with one another by means of external cross-over discharge conduit in the form of a tube 115 which extends axially along the outside of compressor housing 12 and, referring to FIGS. 3 and 4, extends into discharge chambers 32 and 36 to the extent that its open ends 116 are disposed above the normal height of a pool of liquid lubricant having surface level 118 . Cross-over tube 115 , as initially shown in FIG. 1 and various Figures thereafter, is an uninterrupted conduit, however, a sweat fitting or other like sealing fitting may disrupt the continuity to ease in the assembly process of the compressor assembly. Discharge pressure gas from front discharge chamber 32 is provided through cross-over tube 115 to discharge chamber 36 , wherein it joins the discharge pressure gas exhausted from rear compressor assembly 26 and is discharged from compressor assembly 10 through discharge conduit or tube 120 , which extends into the upper portion of rear discharge chamber 36 . Each pool of liquid lubricant having level 118 is maintained at approximately equal heights in both discharge chambers 32 and 36 by excess lubricant being redistributed between the two discharge chamber sumps via cross-over tube 115 as level 118 rises above the height of tube end opening 116 (FIG. 3 ).
Referring again to FIG. 1, it can be seen that each compressor mechanism 24 and 26 is provided with eccentric 122 mounted on respective small diameter shaft portion 58 , 60 and disposed in cavity 80 of each cylinder block 76 . Each eccentric 122 is mounted about the axis of shaft 52 180° apart from the other to ensure proper balance. Further, counterweight 123 may be provided at opposite axial ends of rotor 50 , 180° apart, to aid in balancing compressor assembly 10 . Referring now to FIG. 4, which illustrates rear compressor mechanism 26 but which may be analogously applied to understand the structure of front compressor mechanism 24 , it can be seen that eccentric 122 is disposed about shaft portion 60 and is fixed for rotation therewith by means of set screw 124 threadedly engaged in hole 126 provided in the eccentric. Terminal point 128 of set screw 124 is received in countersink 130 provided in the surface of shaft portion 60 . With reference to FIGS. 2 and 4, it is shown that cylindrical roller piston 132 is provided about eccentric 122 , inside surface 133 of roller piston 132 in sliding contact with outer peripheral surface 134 of eccentric 122 . Further, it can be seen from FIGS. 1 and 2 that the forwardly and rearwardly facing axial surfaces of roller piston 132 are closely adjacent to the axial surfaces of the main and outboard bearings, with a maximum axial clearance preferably of about 0.0007 inch between the piston/bearing interfaces. In the known manner of operation of rotary compressors, roller piston 132 rotates on the cylindrical surface of cavity 80 in an epicyclic manner. Outer cylindrical surface 135 of roller piston 132 is in sliding contact with tip 136 of vane 138 . Vane 138 is provided in each compressor mechanism 24 , 26 , and is urged into sliding engagement with roller piston surfaces 135 by means of springs 142 which encircle depending vane posts 144 and abuts vane surfaces 146 adjacent thereto. The opposite ends of springs 142 are retained by brackets 148 which are attached to surfaces 34 and 38 of main bearings 20 and 22 by means of rivets 150 provided in holes 152 and 154 .
Referring to FIGS. 2 and 4, it can be seen that vane 138 has opposite, parallel planar sides 156 and 158 , and opposite, parallel edges 160 and 162 . Edges 160 , 162 are in sliding engagement with the respective adjacent axial main and outboard bearing surfaces.
Suction gases enter compressor assembly 10 through suction conduit or tube 164 (FIGS. 1, 3 ), which extends into suction chamber 44 . The outlet of suction tube 164 is covered by filter 165 in which debris carried by refrigerant returning to the compressor assembly may be captured. Filter 165 may be a wire cloth or finely meshed screen which may be spot welded over or press-fitted into the end of tube 164 . Filter 165 may be 100 mesh wire screen, comprising 100 interwoven wires of 0.007 inch diameter per inch, which would only allow particles smaller than approximately 0.003 inch to pass through to chamber 44 . Because the suction gases returning the compressor assembly are directed through suction tube 164 into chamber 44 , which provides a relatively large expansion volume, a refrigerant system incorporating the inventive compressor would not ordinarily require an in-line suction muffler external to the compressor assembly.
Suction chamber 44 will contain a quantity of lubricant carried with refrigerant returning to compressor 10 , and as shown in FIG. 1 and 2, lubricant level 166 is substantially lower than lubricant levels 118 in discharge chambers 32 and 36 . Referring to FIGS. 5-8, and 10 , it can be seen that front and rear main bearings 20 , 22 are provided with suction ports 168 , 170 , respectively, which extend axially therethrough (FIG. 10 ). Normally, suction chamber lubricant level 166 is below suction ports 168 , 170 but may be above lubricant inlet bores 172 , 174 , provided in respective main bearing surfaces 40 , 42 . Bores 172 , 174 extend axially from respective surfaces 40 , 42 into web portion 175 of the main bearings, in which they terminate without projecting through to axial surfaces 34 , 38 thereof. Referring to FIG. 10, radial conduits 176 , 178 are provided in the peripheral edges of main bearings 20 , 22 to fluidly connect lubricant intake bores 172 , 174 with suction ports 168 , 170 . The peripheral openings of conduits 176 , 178 are sealed upon assembly and welding of housing portions 14 , 18 to main bearings 20 , 22 .
Suction ports 168 , 170 communicate with suction port 180 in cylinder block 76 which can be seen in FIGS. 4 and 11. Like cylindrical cavity 80 , suction port 180 extends axially between the surfaces 82 and 84 of cylinder block 76 , and communicates directly with cavity 80 through suction inlet 182 . As suction gas flows from suction chamber 44 into suction port 180 through ports 168 , 170 , it may aspirate oil from chamber 44 through lubricant intake apertures 172 , 174 and bores 176 , 178 into suction port 180 , if level 166 is above the height of apertures 172 , 174 , thus scavenging oil from the suction chamber. This scavenged oil is carried by the refrigerant into cavity 80 , which comprises the compression chamber of compressor mechanisms 24 , 26 , and delivered therethrough to discharge chambers 32 , 36 .
In cylinder block 76 , adjacent suction inlet 182 is a vertically oriented channel or vane slot 184 which extends the width of the cylinder block between surface 82 and surface 84 and has generally parallel side walls 186 , 188 (FIG. 11 ). Vane 138 is disposed in vane slot 184 and vertically reciprocates therein as its tip 136 follows outside surface 135 of roller piston 132 , with one of vane surfaces 156 , 158 adjacent vane slot sidewall 186 , the opposite vane surface adjacent vane slot sidewall 188 . Vane 138 may be a sintered powder metal part, the tolerances between its opposite planar surfaces 156 , 158 and its opposite edges 160 , 162 closely controlled. Cylinder block 76 may be manufactured from individually cast blanks which have been machined or they may be sintered powder metal parts. Alternatively, an axially elongate “loaf” of uniform cross section may be produced by casting, powder metal techniques or extrusion, which is then sawed into individual cylinder blocks of appropriate thickness and machined.
An “off the shelf” cylinder block, including an inwardly tapered vane slot (FIG. 50 ), has a vane slot width less than the vane and requires a force being exerted, proximate to the vane slot walls, to force them apart to receive the vane. In order to provide proper clearances between vane slot sidewalls 186 a and 188 a and the adjacent vane surfaces 156 , 158 , a process of assembling a rotary compressor according to the present invention includes the steps of: forcing apart vane slot walls 186 a and 188 a slightly; providing a dummy vane or gauge vane (FIGS. 51 and 54) having generally the same shape as vane 138 except being about 0.0020 inch thicker between its opposite planar surfaces in vane slot 184 a ; allowing vane slot walls 186 a , 188 a to resiliently come into contact with the planar sides of the gauge vane; assembling the main bearing, cylinder block and outboard bearing together about the shaft/eccentric/piston assembly; placing and torquing bolts 90 to appropriate levels to compress cylinder block 76 a between the bearings, thereby establishing sufficient frictional contact between the abutting axial surfaces of the bearings and the cylinder block to hold vane slot walls 186 a , 188 a at their current spacing; and removing the gauge vane and substituting therefor vane 138 , which will have approximately 0.0020 inch clearance between one of its planar sides 156 , 158 and its adjacent vane slot sidewall.
An alternative to the inwardly tapered vane slotted cylinder block, as hereinabove described, is an “off the shelf” cylinder block including an outwardly tapered vane slot (FIG. 53 ), having a vane slot width greater than the vane and requiring a force being exerted, proximate to the vane slot walls, to force them together to support the vane. A method of decreasing the width of vane slot 184 b to provide a suitable clearance between the vane 138 and vane slot 184 b may be employed. In order to provide proper clearances between vane slot sidewalls 186 b and 188 b and the adjacent vane surfaces 156 , 158 , a process of assembling a rotary compressor according to the present invention includes the steps of: providing the gauge vane having generally the same shape as vane 138 except being about 0.0020 inch thicker between its opposite planar surfaces in vane slot 184 b ; decreasing the width of the vane slot 184 b by forcing the vane slot walls 186 b and 188 b slightly together to frictionally hold the gauge vane therebetween; applying an inward force to the vane slot walls 186 b , 188 b to come into contact with the planar sides of the gauge vane; assembling the main bearing, cylinder block and outboard bearing together about the shaft/eccentric/piston assembly; placing and torquing bolts 90 to appropriate levels to compress cylinder block 76 b between the bearings, thereby establishing sufficient frictional contact between the abutting axial surfaces of the bearings and the cylinder block to hold vane slot walls 186 b , 188 b at their current spacing; and removing the gauge vane and substituting therefor vane 138 , which will have approximately 0.0020 inch clearance between one of its planar sides 156 , 158 and its adjacent vane slot sidewall.
Referring now to FIGS. 50-55, model cylinder blocks are disclosed, functionally appertaining to all the cylinder blocks disclosed herein, however, simplified to aid in the explanation of the relationship between the vane slot and the cylinder block of the present invention compressor assembly. Referring now to FIG. 50, shown is a model cylinder block 76 a having a cylindrical cavity 80 a defined by a cylinder wall 81 a . Also shown is tapered vane slot 184 a cut all the way through the cylinder wall 81 a and extending to an outer periphery 78 a of the model cylinder block 76 a . The taper in tapered slot 184 a has been exaggerated for clarity. Vane slot 184 a is defined by a pair of vane slot sidewalls 186 a and 188 a , respectively, and further includes a first vane slot opening 189 a , proximate to the outer periphery 78 a of the model cylinder block 76 a , and a second vane slot opening 191 a , which is proximate to the cylinder wall 81 a within the cylindrical cavity 80 a . FIG. 50 shows tapered vane slot 184 a having the first vane slot opening 189 a , which is relatively narrower than the second vane slot opening 191 a , for reasons further described below.
FIG. 51 discloses the insertion of a gauge vane showing the model cylinder block 76 a of FIG. 50, having a pair of equal and opposing forces 193 imparted on extended portions 185 a of the cylinder block to elastically spread apart the vane slot sidewalls 186 a and 188 a , respectively. A gauge vane 138 g has been inserted between the vane slot sidewalls 186 a , 188 a and is shown holding the vane slot sidewalls 186 a , 188 a apart, and substantially parallel. The gauge vane 138 g has first and second ends 139 and 140 , respectively, wherein the first end 139 of gauge vane 138 g has a tapered contour so that the gauge vane may be forcefully wedged into the first vane slot opening 189 , which acts similar to forces 193 spreading apart the vane slot sidewalls 186 a , 188 a , to fit the vane therebetween. With the gauge vane 138 g in place and having vane slot sidewalls 186 a and 188 a , respectively, in contact with the gauge vane 138 g , a state of stress develops in cylinder block portions 197 a and is represented by arrows 195 . The state of stress 195 is circumferentially oriented about the cylinder block 76 a and is disposed within cylinder block portions 197 a , which are located immediately adjacent cylinder wall 81 a , and continue circumferentially about the cylinder block 76 a . The state of stress 195 is tensile in nature and circumferentially orients therealong a substantial portion of cylinder block portions 197 a . State of stress 195 is caused by the spreading apart of vane slot sidewalls 186 a and 188 a , respectively, and once created, the cylinder block 76 a is secured by bolting or the like to an adjoining bearing or bearings, to preserve the stresses within cylinder block portions 197 a . Thus, once the gauge vane 138 g is removed the state of stress 195 remains preserved therein, as hereinafter described.
Referring to FIG. 52, the model cylinder block 76 a is shown having preserved the circumferentially oriented stress, as shown by arrows 195 , however, the gauge vane 138 g has been removed and replaced by vane 138 . FIG. 52 shows, albeit exaggeratedly, a vane slot width “S” being preserved, with gauge vane 138 g removed, and the state of circumferentially oriented stress 195 remaining preserved therein. The vane 138 , having a width or thickness “T”, is freely reciprocatable within vane slot width “S”, the width between “S” and “T” defines a clearance. In order for vane 138 to reciprocate within vane slot width “S” the clearance must be suitable, however, an excessive clearance leads to premature vane wear, and additionally, inefficient compressor mechanism operation due to refrigerant gas blow-by through the clearance.
Referring now to FIGS. 53-55, similar to FIGS. 50-52, a simplified cylinder block is shown, however the cylinder block has a closeable vane slot. Referring now to FIG. 53, shown is a model cylinder block 76 b having a cylindrical cavity 80 b defined by a cylinder wall 81 b . Tapered vane slot 184 b is cut all the way through the cylinder wall 81 b and extends to an outer periphery 78 b of the model cylinder block 76 b . The taper in tapered slot 184 b has been exaggerated for clarity. Vane slot 184 b is defined by a pair of vane slot sidewalls 186 b and 188 b , respectively and further includes a first vane slot opening 189 b , proximate to the outer periphery 78 b of the model cylinder block 76 b , and a second vane slot opening 191 b , which is proximate to the cylinder wall 81 b within the cylindrical cavity 80 b . FIG. 53 shows tapered vane slot 184 b , having the first vane slot opening 189 b , which is relatively broader than the second vane slot opening 191 b , for reasons further described below.
FIG. 54 represents the gauge vane insertion or vane slot setting step of the inventive method, showing the model cylinder block 76 b of FIG. 53, having a pair of equal and opposing forces 199 imparted on extended portions 185 b of the cylinder block 76 b elastically closing together the vane slot sidewalls 186 b and 188 b , respectively. A gauge vane 138 g has been inserted between the vane slot sidewalls 186 b , 188 b and is shown contacting vane slot sidewalls 186 b , 188 b to provide a substantially parallel slot. Gauge vane 138 g used on cylinder block 76 a , may also be utilized on cylinder block 76 b in providing a standard in which to set the vane slot. With the gauge vane 138 g in place and having vane slot sidewalls 186 b and 188 b , respectively, in contact with the gauge vane 138 g , a circumferentially oriented state of stress 201 develops in cylinder block portions 197 b , which are located immediately adjacent cylinder wall 81 b . The cylinder block portions 197 b are circumferentially continuous about the cylinder wall 81 b . The circumferentially oriented state of stress 201 is compressive in nature, for a substantial portion of cylinder block portions 197 b about the cylinder wall 81 b . State of stress 201 is caused by the closing together of vane slot sidewalls 186 b and 188 b , respectively, and once the stress 201 is created, the cylinder block 76 is thereafter secured by bolting or the like to an adjoining bearing or bearings, to preserve the stresses within the cylinder block portions 197 b . Thus, subsequent to the gauge vane 138 g being removed the state of stress 201 is preserved therein, as hereinafter described.
Referring to FIG. 55, the model cylinder block 76 b is shown having the gauge vane 138 removed and the gauge vane width “S” preserved. Also preserved is the circumferentially oriented compression stress 201 . FIG. 55 shows the vane 138 g in the vane slot 184 . The vane 138 b having a width or thickness “T” is freely reciprocatable within vane slot width “S” and the width between “S” and “T” defines a clearance. In order for vane 138 to reciprocate within vane slot width “S” the clearance must be suitable, however, an excessive clearance leads to excessive vane wear and malfunction. Also an excessive clearance coincides with inefficient compressor operation due to refrigerant gas blow-by through the clearance.
As mentioned above, during the step of increasing the width “S” of the vane slot 184 a , cylinder block portions 197 a develop a state of circumferentially oriented tensile stress 195 , which is preserved once the cylinder block 76 a is clamped between outboard bearings 88 , 100 and main bearings 20 , 22 . In contrast, during the step of decreasing the width “S” of the vane slot 184 b , cylinder block portions 197 b develop a state of circumferentially oriented compressive stress 201 , which is preserved once the cylinder block is clamped between outboard bearings 88 , 100 and main bearings 20 , 22 . Generally, pre-stressing portions of the cylinder block 76 , as hereinabove explained, results in offsetting dynamic forces imparted on the cylinder block 76 by the rotating roller piston 132 , to enhance wear resistence and longevity of the cylinder block 76 . Furthermore, the tapered vane slotted cylinder block requires fewer machining operations and costly machining operations may be avoided.
Referring now to FIGS. 1, 2 and 4 , and more specifically the liquid lubrication of the vane and vane slot, each liquid lubricant pool having surface level 118 in discharge chambers 32 , 36 is of sufficient height to immerse vane 138 in the pool of lubricant. Immersion of vane 138 in the lubricant seals the clearance between vane 138 , the sidewalls of vane slot 184 and the adjacent axial bearing surfaces against refrigerant blow-by from the compression chamber, as well as lubricates the vane surfaces.
Referring again to FIG. 4, it can be seen that cylindrical discharge opening 190 is provided in the cylindrical wall of cavity 80 adjacent vane slot 184 , on the opposite side thereof from inlet opening 182 . By providing cylindrical discharge opening 190 in the wall of cavity 80 adjacent vane slot 184 , rather than in the axial surface of the outboard bearing, an outlet port of unchanging area is provided for discharge gases to be exhausted from the compression chamber throughout the compression cycle, regardless of the roller piston position. Adjacent and downstream of cylindrical discharge opening 190 is frustoconical valve seat 192 on which the mating frustoconical surface of head 194 of poppet 196 seals. Poppet head 194 is urged into sealing contact with surface 192 by compression spring 198 disposed about poppet shaft 200 . One end of spring 198 abuts the underside of poppet head 194 ; its opposite end abuts disc 202 , which is cushioned by neoprene cushion 204 and disposed in pocket 206 of poppet retainer 208 . Retainer 208 limits the radial travel of poppet 196 away from seat 192 to about ⅛ inch, the terminal end of poppet shaft 200 opposite head 194 abutting disc 202 at the furthest extent of poppet travel. Neoprene cushion 204 softens the impact of the poppet shaft end against disc 202 , thereby quieting the operation of the compressor. Poppet 196 prevents previously exhausted discharge pressure gases from reentering the compression chamber, where they would otherwise be recompressed, undermining the efficiency of the compressor. Poppet 196 is preferably made of a durable yet lightweight material, for example a plastic such as Vespel™, as may retainer 208 . Disc 202 may be plastic or metal.
Retainer 208 is provided in radially extending cylinder block bore 210 and maintained in position therein by means of pin 212 extending through a pair of holes 214 provided on opposite axial sides of bore 210 . Pin 212 is prevented from moving axially within holes 214 by its ends abutting the adjacent axial surfaces of the main and outboard bearings. Discharge gases compressed in the compression chamber urge poppet 196 off its seat 192 against the force of spring 198 and flow past poppet head 194 into discharge cavity 216 provided in cylinder block 76 . Poppet 196 is urged by spring 198 back into sealing engagement with seat 192 once the discharge pressure gas has exited the compression chamber through opening 190 , preventing the expelled gas from flowing back into the compression chamber.
Discharge cavity 216 extends axially between cylinder block surfaces 82 , 84 , and is defined by cavity surface 217 and the adjacent axial surfaces of the main and outboard bearings. Cavity 216 serves to attenuate gas-borne noises and pressure pulses arising from operation of the compressor. As shown in FIG. 4, discharge gases exit cavity 216 by means of discharge port 218 provided in outboard bearing 100 (and through corresponding port 220 in front outboard bearing 88 , FIG. 12 ). Discharge gases expelled from cylinder block discharge cavity 216 through discharge ports 218 , 220 enter respective discharge chambers 32 and 36 . Those of ordinary skill in the art will appreciate that discharge chambers 32 and 36 serve as mufflers as well, attenuating gas-borne noises and pressure pulses before discharge pressure refrigerant exits compressor assembly 10 through discharge conduit or tube 120 . Furthermore, each compressor mechanism 24 , 26 , respectively, draws refrigerant gases from the suction chamber 44 and discharges the compressed gases into the discharge chambers 32 , 36 respectively, to further attenuate sources of fluid borne noise and vibration which would be otherwise carried by suction conduits, discharge conduits and the like, rigidly connecting the housing to the compressor mechanisms.
As shown in FIGS. 13 and 15, outboard bearings 88 and 100 are provided with conduits 222 and 224 which respectively extend from inlets 226 , 228 to outlets 230 , 232 . Inlets 226 and 228 are provided proximate the terminal ends of shaft 52 in respective bearing hub portions 234 , 236 ; outlets 230 , 232 open onto respective axial surfaces 86 , 98 into regions of the compression chambers which are at a pressure intermediate suction and discharge pressure (FIG. 4 ). The outboard axial surfaces of roller pistons 132 cover and block outlets 230 , 232 as the roller pistons reach orientations about the cylindrical surfaces of cavities 80 normally corresponding to pressures at and above which oil, which is approximately at discharge pressure, may be forced to reversibly flow backwards through conduits 222 , 224 . Referring to FIG. 1, it can be seen that front outboard bearing hub portion 234 is provided with oil diverter cap 238 , which may be made of sheet metal. Cap 238 directs oil received from shaft bore 110 and directs it towards inlet 226 of conduit 222 . Through conduit 222 oil is provided to the compression chamber of the front compressor mechanism, lubricating exposed surfaces therein. Similarly, hub 236 of rear outboard bearing 100 is provided with cap 240 enclosing a portion of pump 112 and which may also be made of sheet metal. Cap 240 is provided with an central aperture through which lubricant draw conduit or tube 114 is fitted. Cap 240 directs lubricant received from lubricant tube 114 upstream of pump 112 through inlet 228 of conduit 224 .
FIGS. 16A through 16C detail the shaft 52 . As seen in FIG. 16B and 16C, at the point of respective small diameter shaft portions 60 and 58 about which eccentrics 122 are attached thereto. FIG. 16B shows that shaft portion 60 is provided with crossbore 242 which extends through the diameter of shaft portion 60 intersecting axial bore 110 . FIG. 16C shows that shaft portion 58 is provided with similar crossbore 244 . Referring now to FIGS. 17A and 17B, there is shown cross-sectional views of eccentric 122 , which as discussed above is attached to the shaft 52 at countersinks 130 provided in shaft portions 58 and 60 . Eccentric 122 is provided with axial bore 246 having centerline 248 offset and parallel to axis 250 of shaft 52 (FIG. 16 A). Eccentric 122 is provided with crossbore 252 which extends through eccentric bore 246 to a second axial bore 254 extending between the axial surfaces of the eccentric. With eccentric 122 assembled to shaft portions 58 , 60 , eccentric crossbore 252 is brought into alignment with shaft crossbores 244 and 242 . Because one end of crossbore 252 opens to outside surface 134 of the eccentric, oil provided through bore 110 to aligned bores 242 , 252 and 244 , 252 lubricates the interfacing cylindrical surfaces 133 and 134 between roller piston 132 and eccentric 122 . The opposite end of crossbore 252 extends into axial eccentric bore 254 , providing oil received from shaft bore 110 axially into the forward and rear spaces provided between the eccentric axial surfaces and the adjacent axial surfaces of the main and outboard bearings, these spaces inside surface 133 of roller piston 132 ; during normal compressor operation, these spaces are filled with oil.
Referring now to FIG. 18, there is shown compressor assembly 10 ′, a second embodiment according to the present invention. Compressor 10 ′ is for the most part identical with compressor assembly 10 , except is adapted to be vertically oriented. Thus with respect to the preceding discussion, the forward compressor mechanism 24 is, in this second embodiment, referred to as upper compressor mechanism 24 ′. Similarly, with respect to the preceding discussion, rear compressor mechanism 26 is now lower compressor mechanism 26 ′. All previously discussed components of compressor assembly 10 are configured and carried over into compressor assembly 10 ′ in the same way except as distinguished hereinbelow.
Compressor assembly 10 ′, being vertically oriented, has a pair of pools of liquid lubricant having levels 118 ′ in each of its discharge chambers 32 , 36 . The level of lubricant or oil 118 ′ in upper discharge chamber 32 is, in normal operation of compressor assembly 10 ′, above axial surface 86 of upper outboard bearing 88 ′. Thus vane 138 of upper compressor mechanism 24 ′ is, as described with respect to front and rear compressor mechanisms 24 , 26 of compressor assembly 10 , immersed in oil. Oil may initially collect in the lower portion of suction chamber 44 , as shown in FIG. 18 having level 166 ′, however, the oil eventually aspirates through the suction port 170 (FIGS. 7 and 8 ), and commonly exhibits a negligible level therein. As described above, oil will be scavenged from chamber 44 through aperture 174 in lower main bearing 22 . Aperture 172 of upper main bearing 20 will draw suction pressure gas into port 168 instead of oil. As best seen in FIG. 19, oil draw tube 114 ′ extends downwardly from cap 240 to provide access to the oil in the lower portion of chamber 36 . Compressor assembly 10 ′ employs the same lubrication methods as described above, with the exception that, because vane 138 of lower compressor mechanism 26 ′ cannot be immersed in oil, additional lubrication providing means is provided. Referring to FIG. 21, there is shown cylinder block 76 ′ which is identical to cylinder block 76 with the exception that sidewalls 186 , 188 of vane slot 184 are provided with scallops 256 , 258 , respectively. These scallops have the shape of a circle segment and, as will be described further below, allow oil to be provided adjacent the planar sides of vane 138 in lower compressor mechanism 26 . Referring to FIG. 22, it is seen that lower outboard bearing 100 ′ is provided with an axially directed through bore 260 of size matching the circle which would be defined by scallops 256 and 258 in cylinder block 76 ′. Into bore 260 is press fitted second oil draw conduit or tube 262 which extends from the location approximate surface 98 of outboard bearing 100 ′ downwardly into the oil contained in the lower portion of chamber 36 . During operation of compressor assembly 10 ′, as vane 138 reciprocates in compressor mechanism 26 ′, the oil in chamber 36 , which is under discharge pressure, is drawn through oil draw tube 262 into scallops 256 , 258 , sealing the gap between vane slot sidewalls 186 , 188 and planar sides 156 , 158 of the vane. Thus, it can be seen that oil forced or drawn upward through tube 262 lubricates and seals vane 138 in vane slot 184 . Upper compressor mechanism 24 ′ may utilize a common cylinder block 76 ′. Upper outboard bearing 88 ′, may be provided with bore 264 corresponding to bore 262 in lower outboard bearing 100 ′ to, perhaps, better facilitate machining operations. If upper outboard bearing 88 ′ is provided in compressor assembly 10 ′ instead of outboard bearing 88 , bore 264 would be plugged to prevent the ingress of discharge pressure gasses from chamber 32 into scallops 256 , 258 . Bore 264 would be plugged with plug 266 (FIG. 18 ).
Referring to FIG. 24, a third embodiment of the twin rotary compressor assembly 10 ″ is shown and is similar to the first embodiment compressor assembly 10 except as identified hereinbelow. Refrigerant gases, at suction pressure, flow into tube 164 ″ through filter 165 ″ and into suction chamber 44 . Chamber 44 , as in the first embodiment, is the suction chamber wherein the motor assembly 46 is immersed in relatively cool refrigerant gases. Following introduction into suction chamber 44 , refrigerant then flows through identical suction mufflers 268 , fastened to front and rear main bearings 20 ″, 22 ″ respectively, as shown. Suction mufflers 268 are thin metallic or plastic discs, overlaying axial surface 40 ″ of the front bearing 20 ″ and surface 42 ″ of the rear bearing 22 .″ Suction mufflers 268 have collar portions 270 , which are slightly larger in diameter than hubs 68 ″ and 74 ″ to allow refrigerant gases to pass therebetween. Each suction muffler 268 , acts to slow down the refrigerant gases entering each compressor mechanism to alleviate and attenuate noise otherwise manifested by free flowing refrigerant gases. Similar to the operations of the first embodiment compressor assembly 10 , as previously described above, compressor assembly 10 ″ compresses refrigerant in compressor assemblies 24 ″ and 26 ″ and discharges the compressed gases into front discharge chamber 32 and rear discharge chamber 36 through front and rear outboard bearings 88 ″ and 100 ″, respectively. The discharge gases carrying fluid-borne noise are muffled by first housing portion 14 ″ and second housing portion 18 ″. Discharge gases within chamber 32 , as well as discharge gases from chamber 36 , communicate via external cross-over tube 115 ″. The merged discharge gases are then dispersed through the discharge tube 120 ″ exiting the housing 12 ″ of the compressor assembly 10 ″.
The compressor assembly 10 ″ supports shaft 52 ″ at two locations, namely, a front portion 282 and a rear portion 280 . At the front portion 282 of the shaft 52 ″, the supporting structure includes the front main bearing 20 ″ wherein the front main bearing 20 ″ includes a bushing 272 which contacts the large diameter portion 56 ″ of the front portion 282 of the shaft 52 ″. Likewise, at the rear portion 280 of the shaft 52 ″, the rear main bearing 22 ″ supports the shaft 52 ″ through rear bushing 274 . The shaft 52 ″ freely rotates within the front and rear bearings, however, endwise movement of the shaft 52 ″ is restrained by common cover plate 288 . Cover plates 288 mount to the front outboard bearing 88 ″ and the rear outboard bearing 100 ″, each secured by a pair of screws 292 , to restrain endwise movement of the shaft 52 ″.
Referring now to FIG. 25, orientation of shaft 52 ″, eccentric 122 ″ and roller piston 132 , and additionally, lubrication thereof, will now be discussed. The crossbore 252 ″ in eccentric 122 ″ aligns with the crossbore 244 ″ in the front portion 282 of the shaft 52 ″ to allow oil to flow to the roller piston 132 . Oil travels through bore 286 , down the centerline of the shaft 52 ″, entering crossbore 244 ″ and crossbore 252 ″ of eccentric 122 ″ to coat the inner surface 133 of the roller piston 132 . Eccentric 122 ″ includes a pair of reliefs 294 along the outer surface 134 ″ of the eccentric 122 ″ in order to increase oil flow to the inner surface 133 of the roller piston 132 as well as a pair of axial faces 295 of the eccentric 122 ″. Also shown is outboard bearing 88 ″ having an oil passageway 298 , well below oil level 118 so that vane 138 ″ reciprocating between vane slot surfaces 296 are well saturated in oil to prevent refrigerant gas blow-by.
Referring to FIG. 26, the outboard bearing 88 ″ includes a raised portion 234 ″, the discharge port 220 ″, and the oil passageway 298 . The raised portion 234 ″ of the outboard bearing 88 ″ also includes threaded holes 300 to fasten cover plates 288 thereto. Oil passage 298 in outboard bearing 88 ″ is shown well below oil level 118 allowing oil to enter passageway 298 and generally saturate vane 138 ″ and vane slot 184 ″ in oil. Discharge port 220 ″ is shown well above oil level 118 so that under normal operation of the front compressor mechanism 24 ″ oil does not create a back pressure and refrigerant gases may freely exit discharge port 220 ″.
Referring to FIG. 27, within the front compressor mechanism 24 ″ is shown the roller piston 132 , the eccentric 122 ″ and the shaft 52 ″ wherein the eccentric 122 ″ is pinned to the shaft 52 ″. The rear compressor mechanism 26 ″ involves an identical configuration in that the eccentric 122 ″ is thereby pinned to the shaft 52 ″. Momentarily referring to FIG. 42, there is seen a groove 306 in the shaft 52 ″ receiving a pin 302 (FIG. 27) and further, as shown in FIGS. 43-45 there is a groove 34 in the eccentric 122 ″ that receives the pin 302 , thereby securing the eccentric 122 ″ to the shaft 52 ″.
Referring again to FIG. 27, and more specifically the area about vane 138 ″, vane 138 ″ is shown in vane slot 184 ″ and held in contact with the roller piston 132 by biasing member or spring 142 ″. Spring 142 ″ is restrained within a spring cavity 308 by a cover 310 and cover 310 is secured by screw 312 . Screw 312 is threaded into hole 314 which is within cylinder block 76 ″. Scallops 256 ″ and 258 ″ can be seen disrupting spring cavity 308 as scallops 256 ″ and 258 ″ are continuous along the width of cylinder block 76 ″. Cylinder block 76 ″ includes an inner wall 313 defining a portion of the discharge cavity 216 ″ wherein a reed valve 318 and retainer 320 are secured. Reed valve 318 and retainer 320 operate by allowing compressed discharge gases to escape the cylindrical cavity 80 , and in addition, to keep discharge gas from flowing back into the cylindrical cavity 80 . The reed valve 318 and the retainer 320 are secured to the cylinder block 76 ″ by way of a pair of threaded fasteners 322 .
Referring to FIG. 28, the retainer 320 and the corresponding reed valve 318 include three individual fingers which correspond with three discharge openings 316 (FIG. 35 ). The retainer 320 has a first end 323 which is secured by fasteners 322 and a second end 325 including the three fingers extending therefrom. The three fingers of the retainer 320 overlay the three discharge openings 316 . Corresponding reed valve is sandwiched between the retainer 320 and inner wall 323 . Each finger of the retainer is held away from the inner wall 313 and acts as a stop for each corresponding finger of the reed valve 318 . Pressure within the cylindrical cavity 80 increases until the fingers of the reed valve are displaced and cylinder pressure is alleviated. The fingers of the reed valve 318 return to their original position overlaying the inner wall 313 when cylinder chamber pressure is sufficiently decreased. The retainer 320 may be made of a metallic material or a suitable rigid, high temperature plastic. The reed valve 318 may be made of a metallic material or a suitable high temperature polymer. Also shown in FIG. 28 are a pair of bolt holes 324 which receive bolts 336 to fasten cylinder block 76 ″ to the front main bearing 20 ″ and the rear main bearing 22 ″.
Referring now to FIG. 29, outboard bearing 20 ″ includes control surface 28 ″ which serves as a partition to separate discharge chamber 32 from suction chamber 44 . Main bearing 20 ″ includes the pair of holes 326 that receive the bolts 336 (not shown) to fasten the cylinder block 76 ″ to control surface 28 ″ of the main bearing 20 ″. The main bearing 20 ″ also includes three threaded holes 331 which receive three threaded fasteners or bolts 90 (not shown) to secure not only the cylinder block 76 ″ but the outboard bearing as well. Suction port 168 ″ is a continuous hole through bearing 20 ″ and aligns with the suction portion of cylinder block 76 ″.
Referring now to FIG. 30, the side opposing control surface 28 ″ of main bearing 20 ″ is shown including a well portion 328 and several raised portions thereon. Three distinct and equally radially displaced raised portions 330 include threaded holes 331 which receive bolts 90 (not shown) to clamp the cylinder block 76 ″ between the front main bearing 20 ″ and the front outboard bearing 88 ″ (not shown). A pair of raised portions 332 include a first set of threaded holes 324 to receive bolts 326 in mounting the cylinder block 76 ″ to the front main bearing 20 ″. A second set of threaded holes 335 are included in raised portions 332 and receive screws 334 (not shown) to hold the suction muffler 268 thereagainst. The final raised portion 338 also includes threaded hole 335 to secure the suction muffler 268 in a third location to the front main bearing 20 ″. The front main bearing 20 ″ also includes suction port 168 ″ aligning with the suction port 180 ″ of the cylinder block 76 ″ and bushing 272 , within the center portion of front main bearing 20 ″ and supporting shaft 52 ″.
Referring to FIG. 31 and front main bearing 20 ″ in FIG. 29, rear main bearing 22 ″ is a mirror image of 20 ″. Rear main bearing 22 ″ includes a control surface 29 ″ which encloses discharge chamber 36 and separates discharge chamber 36 from suction chamber 44 . Rear main bearing 22 ″ includes a pair of threaded holes 326 to secure cylinder block 76 ″, and in addition, three threaded holes 331 which fasten the rear outboard bearing 100 ″ to the rear main bearing 22 ″ sandwiching the cylinder block 76 ″ therebetween. The rear main bearing 22 ″ also includes a hole therethrough 170 ″ aligned within suction port 180 ″ of cylinder block 76 ″ to allow suction gases within chamber 44 to enter cylinder block 76 ″ in the rear compressor mechanism 26 ″. Referring now to FIG. 32, the rear main bearing 22 ″ is a mirror image of front main bearing 20 ″, as shown in FIG. 30, and its ‘structure’ and operation is similar thereto. Referring now to FIG. 33, rear main bearing 22 ″ includes through holes 331 to receive bolts 90 (not shown) fastening rear outboard bearing 100 ″ to rear main bearing 22 ″. A second hole 335 is shown, which does not continue through the width of the rear main bearing 22 ″. A portion of hole 335 is threaded to receive a fastener 334 to secure the suction muffler 268 to the axial surface 42 ″ of rear main bearing 22 ″.
Referring now to FIG. 34, a common cylinder block 76 ″ of the third embodiment is shown. The vane slot 184 ″ includes an upper portion 340 and a lower portion 342 . The upper portion 340 of the vane slot 184 ″ includes the surfaces 186 ″ and 188 ″ contacting the vane 138 ″, whereas during compressor assembly 10 ″ operation, the lower portion 342 of the vane slot 184 ″ does not contact vane 138 ″. The upper portion 340 of the vane slot 184 ″ is separated from the lower portion 342 by scallops 256 ″ and 258 ″, respectively. Cylinder block 76 ″ includes holes 94 which facilitate outboard bearing bolts 90 (not shown) and additionally, holes 324 to facilitate cylinder block screws 334 (not shown).
Referring to FIG. 35, cylinder block 76 ″ includes the inner wall 313 partially defining the discharge cavity 216 ″ which accommodates the retainer 320 and reed valve 318 . More specifically, a pair of holes 344 include threads which receive a pair of screws 322 (FIG. 28) to secure the retainer 320 and reed valve 318 . Also, within inner wall 313 are three discharge openings 316 which fluidly connect discharge cavity 216 ″ to cylindrical cavity 80 . Discharge openings 316 in inner wall 313 are overlayed by the three fingers of the reed valve 318 (FIG. 28 ). Cylinder block 76 ″ also includes a spring cavity having a suitable depth to receive an adequate sized spring, such as spring 142 ″ (FIG. 27 ), however leaving enough cylinder block material to form an adequately supportive vane slot for the vane 138 ″.
Referring to FIGS. 36-38, there is shown the front outboard bearing 88 ″ and more specifically the oil conduit 224 ″ contained therein. FIG. 37 displays oil conduit 224 ″ having a conduit inlet 226 ″ at chamfer 346 extending diagonally through the width of the outboard bearing 88 ″, and exiting at conduit outlet 230 ″ of the axial surface 86 ″. Conduit outlet 230 ″ is positioned within an interior portion of the cylindrical cavity 80 to expose front portion 282 of shaft 52 ″ to a lower pressure than rear portion 280 of shaft 52 ″. This pressure difference acts to draw oil from rear portion 280 of shaft 52 ″ to front portion of shaft 52 ″ through bores 284 and 286 , respectively (FIG. 24 ). This “rear to front” migration of oil through shaft 52 ″ ensures oil is introduced into cylindrical cavities 80 for proper lubrication of the roller piston 132 ″ and surfaces defining the cylindrical cavity 80 . FIG. 38 displays the pair of holes 300 which threadably receive screws 292 to secure cover plate 282 in restraining endwise movement of shaft 52 ″.
Referring to FIG. 39, rear outboard bearing 100 ″ is shown with the oil pump assembly 112 ″. Rear outboard bearing 100 ″ includes two through holes: the oil passageway 298 and discharge port 218 ″. Referring now to FIGS. 40-42, shaft 52 ″ includes the front portion 282 and the rear portion 280 coinciding with the front and rear ends of the compressor assembly 10 ″. A center portion of the shaft includes a surface 56 ″ which is in rotational contact with the front bushing 276 and the rear bushing 278 . On shaft 52 ″ are a pair of O-ring grooves 276 and 278 , respectively, which receive O-rings (not shown). O-ring grooves 276 and 278 , respectively, serve to separate the suction chamber pressure within suction chamber 44 from the discharge chamber pressure in front chamber 32 and rear discharge chamber pressure in rear chamber 36 . Shaft 52 ″ includes a large diameter inner bore 286 and a somewhat smaller bore 284 extending through the rear portion 280 of the shaft 52 ″. Cross bore 242 ″ allows oil, being drawn from the rear portion 280 of the shaft, into eccentric 122 ″, similarly, cross bore 244 ″ allows oil being drawn from the rear portion 280 of the shaft 52 ″ and into eccentric 122 ″ positioned at the front portion 282 of the shaft 52 ″.
Referring to FIG. 41, crossbore 242 ″ is shown intersecting through bore 284 to facilitate the migration of oil into eccentric 122 ″. Also shown is surface 60 ″ including a disruption thereon in the form of a pin groove 350 . Referring to FIG. 42, the front portion 282 of the shaft 52 ″ includes outer surface 56 ″, front small diameter portion 58 ″ and pin groove 306 thereon. Crossbore 244 ″ intersects inner bore 286 to welcome oil migration into the eccentric 122 ″ attached thereto (not shown).
Referring now to FIGS. 43-45, eccentric 122 ″ includes a pair of reliefs 294 and inner bore 246 ″ formed continuously through and a pin groove 304 therealong. During operation of the compressor 10 ″, oil moves through passageway 252 ″ towards the outer surface 134 ″ of eccentric 122 ″ coating the outer surface 134 ″ as well as the inner surface 133 of the roller piston 132 . The pair of reliefs 294 facilitate optimum lubrication of axial faces 295 of the eccentric 122 ″.
Referring now to FIG. 46, a fourth embodiment of the compressor assembly 10 ′″ of the present invention is shown and is similar in many aspects to the third embodiment 10 ″, however, vertically oriented. The compressor assembly 10 ′″ includes a lower compressor mechanism 26 ′″ having an oil suction tube 262 ″ sealably fitting into an oil passageway 353 in lower outboard bearing 100 ″ to draw from oil level 118 ″ and lubricate the vane 138 ′″. Also included in this particular embodiment is an elbowed pump intake conduit in the form of a tube 354 within the oil pump assembly 112 ′″ to draw oil vertically and into the lower portion 280 of the shaft 52 ′″. The oil level in the upper discharge chamber, nearing the discharge port, becomes an undesirous source of backpressure if such level exceeds the discharge port, however, nonetheless depicted to set forth that the reed valve 318 (FIG. 28 ), within the cylinder block, may suffice as an oil barrier to block excessive amounts of oil attempting to enter the cylindrical cavity via the discharge port.
Referring to FIG. 47, yet another embodiment, the fifth embodiment of the present invention compressor assembly 10 ″″, discloses a cascaded compressor assembly, or series configuration, such that general operation can be described as follows: a first compressor mechanism 24 ″″ compresses refrigerant gas to an intermediate pressure stage and discharges such pressurized gas to a second compressor 26 ″″, via an suction tube 356 , wherein the final discharge pressure is obtained. More specifically, refrigerant gas is introduced at a suction pressure within suction chamber 44 and thereafter is suctioned into front compressor 24 ″″, exclusively. The gas at suction pressure is then compressed to an intermediate pressure and dispersed within discharge chamber 32 . Thereafter, the refrigerant gas at intermediate suction pressure and within discharge chamber 32 is extended through suction tube 356 . Suction tube 356 is in exclusive communication with an suction port 358 located on an axial surface 359 of the outboard bearing 100 ″″ of the rear compressor mechanism 26 ″″. The intermediate stage refrigerant gas, supplied to compressor 26 ″″ by suction tube 356 , is further compressed and discharged into discharge chamber 36 . The discharged refrigerant, at the secondary or maximum pressure, within chamber 36 exits the compressor housing 12 ″″ through discharge tube 120 ″″.
Referring to FIG. 48, the rear outboard bearing 100 ″″ has an suction port 358 , sealably receiving the suction tube 356 , the oil passageway 298 ″″ and the discharge port 218 ″″. Once again, oil level 118 ″″ substantially covers the vane 138 ″″ and vane slot 134 ″″ (see also FIG. 47 ). However, it can be seen care is taken to avoid oil level to reach discharge port 218 ″″. Suction port 358 seals around suction tube 356 therefore an oil level 118 ″″ substantially thereover the suction port 358 will not hinder operation of the compressor assembly 10 ″″ whatsoever. Referring to FIG. 49, main bearing 22 ″″ has control surface 29 ″″ with cylinder block 76 ″″ attached thereto. However, in contrast to the previously hereinabove described compressor assembly embodiments, compressor assembly 10 ″″ includes the main bearing 22 ″″ which does not fluidly communicate with the suction chamber 44 .
While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of this disclosure. Therefore, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. For example, aspects of the present invention may be applied to single cylinder rotary compressors. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.
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A hermetic rotary compressor assembly having a housing, a cylinder block and a bearing assembly within the housing. The cylinder block and the bearing assembly define a cylindrical cavity which has a roller piston disposed therein. The rotary compressor assembly includes a motor drivingly coupled to the roller piston and the cylinder block has a vane slot extending completely axially through and extending radially from an outside perimeter surface of the cylinder block to the cylindrical cavity. At least a portion of the vane slot is defined by a pair of substantially parallel sidewalls and a vane is disposed in and guided by the vane slot and is urged against said roller piston. The cylinder block is fixed in a state of circumferentially oriented stress. A method to assemble the rotary compressor includes spreading apart the sidewalls of the vane slot in the cylinder block, inserting into the spread apart slot a gauge vane of thickness greater than the thickness of a reciprocating vane, releasing the block to cause the slot sidewalls to engage the gauge vane, fixing the cylinder block to hold the engaged sidewalls, removing the gauge vane from the slot, and inserting the reciprocating vane in the slot, whereby a clearance is maintained between the reciprocating vane and slot sidewalls. Another method includes closing together sidewalls of the vane slot to engage the gauge vane, fixing the cylinder block to hold the engaged sidewalls, removing the gauge vane from the slot, and inserting the reciprocating vane in the slot.
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TECHNICAL FIELD
[0001] Embodiments of the invention relate to controlling temperature and humidity in a greenhouse.
BACKGROUND
[0002] Air temperature and relative humidity of an environment in which plants grow affect plant growth and health by affecting photosynthesis and transpiration. Photosynthesis is a process by which plants convert carbon dioxide and water to organic compounds needed for plant growth and metabolism. Transpiration is a process by which plants draw water and nutrients required for plant growth and metabolism from soil into their roots and transport the water and nutrients to their leaves and other plant organs.
[0003] Photosynthesis and transpiration are temperature and relative humidity dependent. Relative humidity, is a ratio equal to an amount of water contained in the atmosphere per unit volume of air divided by a maximum amount of water a unit volume of the air can contain before the water begins to condense out of the air. Water condenses out of air when the air's relative humidity is equal to 100%. Photosynthesis generally increases with increase in temperature. Transpiration is affected by a rate at which water drawn in from the soil and transported to plant leaves and organs evaporates from surfaces of the leaves and organs and increases with increase in rate of evaporation. Evaporation of water from plant surfaces also aids a plant in dissipating heat and regulating plant body temperature. Rate of evaporation and therefore transpiration, and a plants ability to cool itself, generally decreases with increasing relative humidity.
[0004] Plants adapted to different natural environments, for example, desert plants such as cactuses and tropical plants such as orchids, thrive in different temperature and relative humidity ranges. If they are subjected to temperatures and relative humidities outside of the ranges for which they are adapted, they generally do not do well, and may become diseased. Relative humidity in an environment in which a plant grows that is greater than a maximum for which the plant is adapted can result in a reduction in rate of evaporation to such an extent that concomitant reduction in plant transpiration, and the plant's ability to dissipate heat and regulate its body temperature, damages plant metabolism and health. High relative humidity also tends to result in condensation of water droplets on surfaces of plants when ambient temperature in the environment decreases during the diurnal cycle. The condensed moisture promotes germination of fungal pathogen spores, such as Botrytis and powdery mildew, on the plant surfaces that can damage or kill the plants.
[0005] Because of the sensitivity of plants to temperature and RH, artificial environments, such as provided by greenhouses, in which plants are commercially grown, must generally be monitored and controlled to maintain air temperature and humidity within desired ranges. For many greenhouse environments in which leafy plants and vegetables are grown, it is advantageous for temperature to be maintained in a range from about 18° C. to about 22° C. and relative humidity in a range from about 75% to about 82%.
[0006] In the closed environment of a greenhouse, RH tends to increase as a result of plant transpiration and evaporation of water from the soil and can be difficult to control. Typically, relative humidity in a greenhouse is controlled using a longstanding conventional procedure, in which hot humid air in the greenhouse is periodically vented to the outside environment and replaced with cooler air drawn into the greenhouse from the outside. The indrawn cool air is heated to bring its temperature within a desired range of greenhouse air temperatures. Heating the indrawn cool air also reduces its relative humidity. The capacity of air to hold water increases and its RH decreases with increasing air temperature. Relative humidity of indrawn cool air, even if it is 100% (i.e. at which relative humidity water begins to condense out of the air) may be reduced substantially by increasing that air's temperature. For example relative humidity of outside air at a temperature of 18° C. and 100% relative humidity is decreased to a relative humidity of 50% by heating to a temperature of 25° C.
[0007] Whereas the longstanding conventional procedure for controlling relative humidity by periodically venting hot humid greenhouse air and replacing it with cooler air drawn into the greenhouse from the outside and heated is generally effective, it exposes greenhouse plants to relatively large fluctuations in air temperature. The procedure also consumes relatively large amounts of energy and is therefore expensive.
[0008] By way of example, air temperature in a greenhouse using conventional humidity control systems may fluctuate from a low temperature equal to about an outside air temperature, for example, 10° C., to a maximum temperature of about 22° C. Relative humidity of the inside air may suffer a range from about 70% to about 100%. During a diurnal cycle for which outside relative humidity of outside air fluctuates between about 60% to about 70% and temperature of outside air between about 12° C. and 16° C. a conventional system may consume more than about 2,000 kWh (kilowatt hours) of energy.
SUMMARY
[0009] An embodiment of the invention relates to providing a greenhouse environment control (GECO) system for controlling temperature and relative humidity in a greenhouse by periodically venting warm humid air in the greenhouse and replacing it with air drawn in from the outside that is heated by heat extracted from the vented warm humid air. Between periods when warm humid air is vented, the GECO system generates and heats a moderate flow of outside air into the greenhouse. The process is relatively energy efficient and characterized by relatively moderate fluctuations in greenhouse air temperature that results from exchanging greenhouse inside air with air from the outside.
[0010] In accordance with an embodiment of the invention, the GECO system comprises an air circulation and heat exchange system and a controller that controls the circulation and heat exchange system selectively to operate in a “flush” mode or in a “maintenance” mode. The circulation and heat exchange system comprises a first “vent” heat exchanger that is coupled by a refrigerant fluid and a refrigerant flow system to a second, “intake” heat exchanger. The vent heat exchanger comprises a vent fan system selectively controllable to drive warm moist air from inside the greenhouse to outside the greenhouse or to drive air from outside to inside the greenhouse, through a relatively long air flow path in a large efficient “vent” radiator. The intake heat exchanger comprises an intake fan system controllable to draw relatively cold air from outside the greenhouse to inside the greenhouse through a relatively long air flow path in a large and efficient “intake” radiator.
[0011] In the flush mode, the GECO controller controls the vent fan system to drive hot humid air from the greenhouse through the vent radiator to the outside, and the intake fan system to draw air from the outside into the greenhouse through the intake radiator to replace the vented air. The vent radiator extracts heat from the vented air to heat the refrigerant fluid and cool the vented air. The refrigerant flow system transports the refrigerant heated by heat extracted by the vent radiator from the vented air to the intake radiator. The intake radiator heats air drawn into the greenhouse by the intake fan system and cools the refrigerant. After heat is removed from the refrigerant to heat the intake air, the cooled refrigerant is recycled by the refrigerant flow system to the vent radiator where it is heated again and recycled back to the intake radiator. Optionally, the vent heat exchanger cools venting air to a temperature substantially equal to an ambient temperature of the outside air and the intake radiator heats drawn in air to a desired greenhouse temperature.
[0012] In the maintenance mode the GECO system operates to maintain temperature and RH in the greenhouse within desired ranges by generating a relatively slow and steady influx of heated outside air into the greenhouse. To generate the influx, the GECO controller controls both the intake and venting fan systems to draw outside air into the greenhouse and heat the drawn in air to a desired greenhouse temperature. The rate of influx is determined to create an air pressure inside the greenhouse that is slightly greater than atmospheric pressure, and a resultant leakage of air out from the greenhouse equal to the rate of influx. Optionally, air leakage out of a greenhouse having a floor area of about 1,000 m 2 (square meter) and height of about 3 m is greater than or equal to about 2,500 m 3 /hr (cubic meters per hour). Optionally, the air leakage is less than about 3,500 m 3 /hr. In an embodiment of the invention the air leakage may be equal to about 3,000 m 3 /hr (cubic meters per hour). Optionally, the desired greenhouse temperature is equal to about 22° C. To provide heat for heating the drawn in outside air, the controller couples the refrigerant flow system to a heat source.
[0013] By controlling durations and frequency of switching between flushing and temperature maintenance modes of operation in accordance with an embodiment of the invention, the GECO system provides substantial savings in amounts of energy required to control temperature and RH in a greenhouse and reduces amplitude of fluctuations in temperature and RH of air in the greenhouse.
[0014] An embodiment of the invention relates to providing a system, hereinafter a water agitator (WAGIT), that operates to clean surfaces of leaves and plant parts of moisture that may have accumulated on the surfaces. The system comprises a source of acoustic energy controllable to transmit sound waves which generate vibrations in the leaves and plant parts that agitate and shake water droplets from their surfaces. In an embodiment of the invention, the acoustic source is tunable to transmit acoustic waves at resonant vibration frequencies of plant leaves.
[0015] There is therefore provided in accordance with an embodiment of the invention, apparatus for controlling an environment in a greenhouse, the apparatus comprising: first and second heat exchangers, each comprising a radiator and a fan system for driving air through the radiator; a first refrigerant circulation system that circulates a refrigerant fluid between and through the radiators; a heater controllable to heat the refrigerant; a controller that controls the apparatus to operate selectively in a maintenance mode or a flush mode, wherein in the maintenance mode the heater heats the refrigerant and the first and second fan systems drive air from outside to inside the greenhouse and through the radiators to acquire heat from the refrigerant, and in the flush mode the first fan system vents air from inside to outside the greenhouse through its respective radiator to deposit heat in the refrigerant and the second fan system drives air from outside to inside the greenhouse and through its respective radiator to acquire the heat deposited in the refrigerant. Optionally the apparatus comprises a third heat exchanger controllable to heat air inside the greenhouse. Optionally, the third heat exchanger comprises a radiator, a second refrigerant flow system that streams a refrigerant through the radiator, a heater that heats the refrigerant in the second refrigerant flow system and a fan system that drives air inside the greenhouse through the radiator to acquire heat from the refrigerant and remain in the greenhouse.
[0016] Optionally the apparatus comprises a fluid flow control valve controllable to connect the first and second refrigerant flow systems so that heated refrigerant from the second refrigerant flow system can flow into the first refrigerant flow system. Optionally, in the maintenance mode, the controller controls the fluid control valve to connect the first and second refrigerant flow systems.
[0017] In an embodiment of the invention, in the maintenance mode, the controller controls the third heat exchanger to substantially refrain from heating air inside the greenhouse.
[0018] In an embodiment of the invention, the controller controls the third heat exchanger to heat air inside the greenhouse when temperature of the inside air drops below a predetermined minimum air temperature.
[0019] In an embodiment of the invention, in the maintenance mode the controller controls the fan systems of the first and second heat exchangers to draw air from outside to inside the green house at an average flow rate that is substantially proportional to a volume of the greenhouse. Optionally, the flow rate is greater than about 2,500 m 3 /hr (cubic meters per hour) per 3,000 m 3 of greenhouse volume. Additionally or alternatively, the flow rate is less than about 3,500 m 3 /hr per 3,000 m 3 of greenhouse volume. Optionally, the flow rate is equal to about 3,000 m 3 /hr per 3,000 m 3 of greenhouse volume.
[0020] In an embodiment of the invention, the controller controls the apparatus to operate in a flush mode if relative humidity in the greenhouse is greater than a predetermined minimum relative humidity.
[0021] In an embodiment of the invention, the controller switches operation of the apparatus between flush and maintenance modes at regular intervals. Optionally, duration of a period of operation in the flush mode is the same for a plurality of consecutive periods of operation in the flush mode. Optionally, the flush mode periods are repeated at a repetition frequency greater than about 0.8 per hour. Additionally or alternatively, the repetition frequency is less than about 1.2 per hour. In an embodiment of the invention, the repetition frequency is equal to about 1 per hour.
[0022] In an embodiment of the invention, periods of operation in the flush mode have duration less than or equal to about 10 minutes. In an embodiment of the invention, periods of operation in the flush mode duration greater than or equal to about 5 minutes. In an embodiment of the invention, periods of operation in the flush mode have duration equal to about 6 minutes. In an embodiment of the invention, the controller initiates periods of operation in the maintenance mode substantially at times at which periods of operation in the flush mode end.
[0023] There is further provided in accordance with an embodiment of the invention, a method of controlling an environment in a greenhouse, the method comprising: periodically, during first periods, venting air from inside to outside the greenhouse while drawing air from outside to inside the greenhouse and heating drawn in air with heat extracted from the vented air; and during second periods between the first periods, drawing in air from outside to inside the greenhouse and heating the air as it is drawn in.
[0024] Optionally the method comprises initiating first periods when the relative humidity becomes greater than a predetermined relative humidity. Alternatively or additionally the method comprises switching between first and second periods at regular intervals. Optionally the method comprises determining a same duration for a plurality of consecutive first periods.
[0025] In an embodiment of the invention the method comprises initiating second periods substantially at times when first periods end.
[0026] In an embodiment of the invention, an average flow rate at which air is drawn in from outside to inside the green house during the second periods is substantially proportional to the greenhouse volume. Optionally, the flow rate is greater than about 2,500 m 3 /hr per 3,000 m 3 of greenhouse volume. Additionally or alternatively, the flow rate is less than about 3,500 m 3 /hr per 3,000 m 3 of greenhouse volume. Optionally, the flow rate is equal to about 3,000 m 3 /hr per 3,000 m 3 of greenhouse volume.
[0027] In an embodiment of the invention, first periods have duration less than or equal to about 10 minutes. In an embodiment of the invention, first periods have duration greater than or equal to about 5 minutes. In an embodiment of the invention, first periods have duration equal to about 6 minutes.
[0028] There is further provided in accordance with an embodiment of the invention, a method of removing water droplets from surfaces of plants growing in a greenhouse, the method comprising: providing an acoustic generator configured to generate acoustic waves in the greenhouse; and operating the acoustic generator to transmit sound waves that are incident on, and generate vibrations in, surfaces of the plants that cause water droplets on the surfaces to roll or be shaken off the surfaces. Optionally, the sound waves are characterized by a frequency that is substantially equal to a resonant frequency of vibration of the plant surfaces. Additionally or alternatively, the sound waves are characterized by a frequency that is substantially equal to a resonant frequency of vibration of the water droplets.
[0029] In the discussion unless otherwise stated, adjectives such as “substantially” and “about” modifying a condition or relationship characteristic of a feature or features of an embodiment of the invention, are understood to mean that the condition or characteristic is defined to within tolerances that are acceptable for operation of the embodiment for an application for which it is intended.
[0030] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF FIGURES
[0031] Non-limiting examples of embodiments of the invention are described below with reference to figures attached hereto that are listed following this paragraph. Identical structures, elements or parts that appear in more than one figure are generally labeled with a same numeral in all the figures in which they appear. Dimensions of components and features shown in the figures are chosen for convenience and clarity of presentation and are not necessarily shown to scale.
[0032] FIG. 1A schematically shows a conventional environment control system operating to maintain temperature and relative humidity in a greenhouse;
[0033] FIG. 1B shows a flow chart descriptive of operation of the conventional environment control system shown in FIG. 1A ;
[0034] FIG. 1C and 1D show graphs of relative humidity and temperature respectively of air in a greenhouse environment controlled by the conventional environment control system shown in FIG. 1A ; and
[0035] FIG. 2A schematically shows a GECO greenhouse environment control system operating to maintain temperature and relative humidity in a greenhouse, in accordance with an embodiment of the invention;
[0036] FIG. 2B shows a flow chart descriptive of operation of the GECO system shown in FIG. 2A , in accordance with an embodiment of the invention;
[0037] FIGS. 2C and 2D show graphs of relative humidity and temperature respectively of air in a greenhouse environment controlled by the GECO system shown in FIG. 2A , in accordance with an embodiment of the invention; and
[0038] FIG. 3 schematically shows operation of a WAGIT moisture removal system operating to remove moisture from a leaf in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0039] In the following detailed description, components and operation of a conventional greenhouse environment control system are described and discussed with reference to FIGS. 1A and 1B . FIGS. 1C and 1D show graphs of relative humidity and temperature of air in a greenhouse environment controlled by conventional environment control system such as that shown in FIG. 1A . Components and operation of a GECO environment control system in accordance with an embodiment of the invention are described and discussed with reference to FIGS. 2A and 2B . FIGS. 2C and 2D show graphs of relative humidity and temperature of air in a greenhouse environment controlled by a GECO system in accordance with an embodiment of the invention such as the GECO system shown in FIG. 1A . Operation of a WAGIT system for accelerating removal of water from plant surfaces is discussed with reference to FIG. 3 .
[0040] FIG. 1A schematically shows a greenhouse 20 having windows 22 and exhaust fans 24 mounted respectively in opposite walls 26 and 28 of the green house. Greenhouse 20 comprises a conventional environment control system 30 for controlling temperature and RH in the greenhouse. The environment control system comprises an “inside” heat exchanger 40 for heating air inside greenhouse 20 to a desired temperature, manifold flow sleeves 60 for distributing the heated air to different regions in the greenhouse and sensors 31 and 32 for monitoring temperature and RH respectively of air inside the greenhouse. A controller 33 controls the environment control system, windows 22 and exhaust fans 24 of greenhouse 20 responsive to measurements of temperature and RH provided by sensors 31 and 32 .
[0041] Heat exchanger 40 comprises a radiator 42 and a refrigerant flow system comprising a refrigerant heater 41 and a refrigerant pump (not shown) that streams heated refrigerant, generally water, into and out of the radiator. The refrigerant flow system is connected to radiator 42 by inlet and outlet pipes 43 and 44 respectively. Heat exchanger 40 optionally comprises two blowers 46 controllable to drive air in the greenhouse through radiator 42 , where the air is heated to a desired temperature by the refrigerant streaming through the radiator. Heated refrigerant enters radiator 42 via inlet pipe 43 and after heating greenhouse air blown through the radiator by blowers 46 , the refrigerant is cooled and leaves the radiator via outlet pipe 44 to return to the refrigerant flow system and heater 41 where it is reheated and returned to again flow through the radiator. It is noted that in FIG. 1A and figures that follow, heater 41 is schematically shown located in greenhouse 20 and close to heat exchanger 40 . Heater 41 does not of course have to be located inside greenhouse 20 , and in practice the heater is generally located outside the greenhouse, and often far from the green house.
[0042] Air blown through and heated in radiator 42 flows out of heat exchanger 40 and, optionally, into manifold flow sleeves 60 through coupling sleeves 62 . The manifold sleeves are typically made of plastic sheeting and/or fabric, and are inflated by the heated air that enters them from the heat exchanger. Sleeves 60 are formed having holes (not shown) through which heated air from heat exchanger 40 flowing in the sleeves flows out of the sleeves to mix with air in the greenhouse to maintain a desired greenhouse air temperature and relative humidity. Arrows 64 schematically represent air flowing out of sleeves 62 . Whereas in FIG. 1A heated air exiting heat exchanger 40 is directed into manifold sleeves 60 for dispersion into the greenhouse volume, in some greenhouses heated air is dispersed differently. For example, in some greenhouses heated air from a heat exchanger flows directly from the heat exchanger into the greenhouse volume. By way of another example, in some greenhouses heated water is streamed through a network of pipes on the greenhouse floor to heat the air inside the greenhouse.
[0043] Controller 33 optionally controls environment control system 30 to control temperature and relative humidity in greenhouse 20 by periodically replacing hot humid air inside the greenhouse with air drawn in from the outside and heated, in accordance with a conventional exemplary algorithm schematically represented by a flow diagram 100 shown in FIG. 1B . The numeral 100 is used to refer to the flow diagram and to the algorithm which it represents.
[0044] Generally, a greenhouse environment control system, such as environment control system 30 , is off during the day in climates for which there is sufficient solar energy incident on the greenhouse to maintain greenhouse air temperature above a desired minimum. In flow diagram 100 it is assumed that initially, as shown in a block 102 of the flow diagram, that controller 33 controls heat exchanger 40 to be off and therefore environment control system 30 to refrain from heating air in greenhouse 20 .
[0045] In a block 104 , controller 33 optionally acquires a measurement “T” of air temperature in greenhouse 20 from temperature sensor 31 . In a decision block 106 the controller determines if the measured temperature T is less than a predetermined desirable minimum temperature “T Min ”. Whereas T Min is dependent upon a type of plants grown in greenhouse 20 , for many plants T Min is advantageously equal to about 20° C. If, in decision block 106 , controller 33 determines that T is less than T Min , as generally might occur towards nightfall, the controller optionally proceeds to a block 108 and turns on heat exchanger 40 to heat air in greenhouse 20 to a temperature above T Min . Turning on the heat exchanger generally involves turning on blowers 46 and the refrigerant flow system to stream hot refrigerant through radiator 42 ( FIG. 1A ). Thereafter, controller 33 optionally proceeds to a block 110 .
[0046] If instead of finding in decision block 106 that T is less than T Min as assumed in the preceding paragraph the controller 33 finds that T is greater than or equal to T Min the controller skips block 108 and proceeds to block 110 .
[0047] In a block 110 , whether or not controller 33 skips block 108 , the controller acquires a measurement “RH” of relative humidity of the air in greenhouse 20 from humidity sensor 32 and in a block 112 , the controller compares RH to a given desired maximum, “RH Max ”. In a decision block 112 the controller also, optionally, determines whether at a time at which RH is acquired in block 110 , an elapsed time since air in the greenhouse was last replaced by heated air from the outside is greater than an optionally predetermined time interval “τ”. If in decision block 112 RH is less than RH Max , or the elapsed time is less than τ, controller 33 skips a block 114 discussed below, and advances to a block 116 .
[0048] In block 116 the controller acquires a temperature measurement T, and in a decision block 118 determines whether T>T Min . If T is greater than T Min the controller returns to block 102 and turns off heat exchanger 40 . On the other hand, if T≦T Min , controller 33 returns to block 110 , acquires measurement new RH, and in block determines if the new RH is greater than RH Max .
[0049] If in decision block 112 controller 33 determines that RH is greater than RH Max and the elapsed time is greater than τ, controller 33 proceeds to block 114 to replace overly humid air in greenhouse 20 with outside air to reduce humidity in the greenhouse. To accomplish the replacement, the controller opens windows 22 and controls fans 24 to vent air from inside greenhouse 20 and draw air in from the outside through open windows 22 to replace the vented air.
[0050] In block 116 , after replacement of air in greenhouse 20 , controller 33 acquires a temperature measurement T, and in decision block 118 , if T>T Min the controller returns to block 102 and turns off heat exchanger 40 . On the other hand, if T<T Min , controller 33 continues to heat air (block 108 ) in greenhouse 20 and returns to block 110 .
[0051] Generally air drawn in from outside greenhouse 20 to replace air inside the greenhouse is relatively cold, and typically has a temperature that is substantially less than T Min . As a result, immediately after replacing air inside greenhouse 20 with outside air, temperature of air in greenhouse 20 is less than T Min . For a period after air replacement therefore, from decision block 118 controller 33 generally repeatedly returns to block 110 to cycle through blocks 110 - 118 , heating air in greenhouse 20 until the controller determines in decision block 118 that temperature of air in the greenhouse is greater than the desired minimum T Min .
[0052] For many greenhouse environments RH Max is advantageously equal to about 85%. Time interval τ is determined to prevent cold air from outside greenhouse 20 being drawn in to replace greenhouse air so frequently that a rate at which cold air drawn into greenhouse 20 must be heated to maintain a desired greenhouse temperature exceeds a capacity of the heat exchanger to heat the drawn in air.
[0053] FIGS. 1C and 1D show graphs 201 and 202 of relative humidity and temperature respectively of air inside and outside of greenhouse 20 having an environment control system 30 operating in accordance with an algorithm similar to algorithm 100 . In graphs 201 and 202 solid curves 211 and 212 show relative humidity and temperature respectively for air inside greenhouse 20 as a function of time for a period of two days. Time in hours is shown along the graphs' abscissas. Dotted curves 214 and 215 show relative humidity and temperature respectively for air outside greenhouse 20 as a function of time for the same two day period. The curves in graphs 201 and 202 were experimentally determined for a greenhouse, hereinafter also referred to as a 3 m×1,000 m 2 greenhouse, having height equal to about 3 m and floor space equal to about 1,000 m 2 . Heat exchanger 40 when turned on provided 290 kW of energy to heat air streaming at 14,000 m 3 /hr (cubic meters/hr) through radiator 42 . On the average, for each diurnal cycle the heat exchanger operated for about seven hours. In consequence, conventional environment control system 30 consumed about 2,030 kWh (kilowatt hours) of energy during each diurnal cycle.
[0054] From the graphs it is seen that both relative humidity and temperature of air in greenhouse 20 cyclically fluctuate with relatively large amplitudes in cadence with the repeated replacement of hot humid greenhouse inside air with cold, relatively low humidity outside air. Temperature fluctuates with amplitude of about 7° C. between about 14° C. and about 21° C. and relative humidity fluctuates with an amplitude of about 20% between about 75% and 95%.
[0055] FIG. 2A schematically shows a greenhouse 320 comprising a greenhouse environment control system 330 , that is a GECO system 330 , also referred to as GECO 330 , used to control the environment in the greenhouse, in accordance with an embodiment of the invention.
[0056] GECO system 330 optionally comprises components, such as an inside heat exchanger 40 and vent fans 24 comprised in environment control system 30 , and in addition comprises an air circulation and heat exchange system 340 , hereinafter also referred to as a climate control system (CCS) 340 , in accordance with an embodiment of the invention.
[0057] CCS 340 optionally comprises a controller 342 and a vent heat exchanger 350 coupled by a refrigerant fluid flow system 360 to an intake heat exchanger 370 . Vent heat exchanger 350 comprises a vent radiator 352 and vent fan system 354 . The vent fan system is selectively controllable to drive warm moist air from inside the greenhouse to outside the greenhouse or to drive air from outside to inside the greenhouse, through a relatively long air flow path in a large efficient “vent” radiator 352 . Airflow arrows 355 pointing from vent heat exchanger 350 towards the outside of greenhouse 320 and airflow arrows 356 pointing from the vent heat exchanger towards the inside of the greenhouse, schematically represent the selectable directions in which vent fan system 354 can drive air. Intake heat exchanger 370 comprises an intake fan system 374 controllable to draw relatively cold air from outside the greenhouse in a direction indicated by airflow arrows 371 to inside the greenhouse through a relatively long air flow path in a large and efficient “intake” radiator 372 .
[0058] Fluid flow control system 360 comprises refrigerant circulation pipes 362 that connect intake radiator 372 with vent radiator 352 and a refrigerant pump 364 controllable to pump refrigerant in the circulation pipes between the vent and intake radiators. Circulation pipes 362 are connected by a fluid flow control valve 366 to inlet pipe 43 through which hot refrigerant from refrigerant heater 41 is introduced into radiator 42 . The circulation pipes are optionally connected by a T joint 367 to outlet pipe 44 through which relatively cold refrigerant leaves radiator 42 . Controller 342 controls heat exchanger 40 , and controls flow valve 366 , pump 364 , vent and intake heat exchangers 350 and 370 to selectively operate CCS in a flush mode or a maintenance mode.
[0059] In the flush mode, controller 342 controls vent fan system 354 to drive air from inside greenhouse 320 in a direction indicated by airflow arrows 350 to outside of the greenhouse and intake fan system 374 to drive air from outside the greenhouse to inside the greenhouse in a direction indicated by airflow arrows 371 . In the flush mode the controller closes flow valve 366 and operates refrigerant pump 364 to circulate refrigerant from vent radiator 352 to intake radiator 372 .
[0060] Hot humid air driven by vent fan system 354 through vent radiator 352 in the direction of airflow arrows 355 is cooled in passing through the vent radiator and heats refrigerant fluid in the radiator. Pump 364 pumps heated refrigerant from the vent radiator to intake radiator 372 where it is cooled in heating air driven by intake fan system 374 through the intake radiator. In the flush mode CCS 340 replaces hot humid air vented by vent heat exchanger 350 from inside greenhouse 320 with cold air drawn into the greenhouse by intake heat exchanger 370 and heats the indrawn air with heat that the vent heat exchanger extracts from the vented air. In an embodiment of the invention, heat extracted from the vented air is sufficient to heat indrawn air to a temperature substantially equal to a desired greenhouse air temperature.
[0061] In the maintenance mode, controller 342 controls vent fan system 354 to drive air from outside greenhouse 320 to inside the greenhouse in a direction of airflow arrows 356 and intake fan system to drive air from outside to inside in a direction of airflow arrows 371 . The controller also opens flow valve 366 to connect circulation pipes 362 to inlet pipe 43 so that refrigerant fluid in the inlet pipe heated by heater 41 that heats refrigerant fluid for heat exchanger 40 can enter circulation pipes 362 . Controller 342 operates pump 364 to circulate the heated refrigerant fluid entering the pipes from inlet pipe 43 through radiators 352 and 372 to heat air drawn in from the outside by vent and intake fan systems 354 and 374 . The controller controls a flow rate at which the indrawn and heated air enters greenhouse 320 so that air pressure in the greenhouse is slightly greater than atmospheric pressure and heated air from outside flows into the greenhouse at a moderate rate and replaces air inside the greenhouse.
[0062] In an embodiment of the invention, controller 342 controls switching between flushing and maintenance modes of CCS 340 , and durations of the modes, to maintain a relatively steady response to changes in temperature and relatively humidity of air in greenhouse 320 . Cycling of CCS 340 between flushing and maintenance modes obviates the periodic greenhouse air replacements that characterize operation of conventional greenhouse environment control systems and provides relatively efficient control of greenhouse temperature and relative humidity. FIG. 2B shows a flow diagram 400 of an exemplary algorithm, also referenced by numeral 400 , that describes operation of GECO 330 in controlling temperature and humidity in greenhouse 320 , in accordance with an embodiment of the invention.
[0063] In flow diagram 400 it is assumed that, as in flow diagram 100 ( FIG. 1B ), initially, GECO 330 is in a quiescent state, in which radiators 42 , 352 or 372 are not operating to heat air in or being drawn into greenhouse 320 . Accordingly, a block 402 of the flow diagram shows that /greenhouse heating is off. In a block 404 controller 342 receives a measurement “T” of temperature in greenhouse 320 from temperature sensor 31 and a measurement “RH” of relative humidity of air in the greenhouse from humidity sensor 32 . In a decision block 406 , if T is greater than a desired minimum temperature T Min for example, 20° C., controller 342 returns to block 402 . If however, T is less than or equal to T Min , in a block 408 the controller turns inside heat exchanger 40 on, and in a block 410 turns CCS 340 ( FIG. 2A ) on in the flush mode. In the flush mode as noted above, heat exchanger 350 is turned on to vent air from inside greenhouse 320 and extract heat from the vented air and heat exchanger 370 is turned on to draw air into the greenhouse from the outside and heat the drawn in air with the heat extracted from the vented air. In a block 412 controller 342 acquires another measurement T of temperature and another measurement RH of relative humidity.
[0064] In a decision block 414 controller 342 determines whether T is less than or equal to T Min . If T≦T Min , the controller leaves inside heat exchanger 40 on and CCS 340 in the flush mode, and returns to block 412 , to acquire further measurements of T and RH and in decision block 414 to compare T to T Min . If on the other hand, in decision block 414 the controller determines that T>T Min , the controller continues to a decision block 416 and determines whether RH<RH Max . If RH is greater than or equal to RH Max , the controller optionally turns off inside heat exchanger 40 in a block 418 and returns to block 412 to again cycle through to block 418 leaving inside heat exchanger 40 off, until in decision block 416 controller 342 determines that a measurement RH is less than RH Max . Upon determining that RH is less than RH Max controller 342 proceeds to a block 420 and switches CCS 340 to the maintenance mode.
[0065] In a block 422 controller 342 acquires measurements of T and RH and in a block 424 determines whether T≦T Min . If T less than or equal to T Min , the controller returns to block 408 to turn on inside heat exchanger 40 , turn on CCS 340 in the flush mode, and cycle through blocks in flow diagram 400 to block 424 . If in decision block 424 T>T Min , in a block 426 controller 342 determines whether temperature T is greater than a maximum desirable temperature T Max . If T is greater than T Max the controller returns to block 402 and shuts down heating of air inside greenhouse 320 . Optionally, T Max is a temperature equal to about 22° C. If on the other hand, T is less than or equal to T Max , the controller proceeds to a decision block 428 to determine whether RH<RH Max . If RH is less than RH Max , the controller leaves CCS 340 in the maintenance mode and returns to block 422 . If on the other hand RH is greater than or equal to RH Max , the controller returns to block 410 and switches CCS 340 to operation in the flush mode.
[0066] Operation of GECO system 330 in accordance with an algorithm, such as algorithm 400 reduces magnitude of fluctuations in greenhouse temperature and relative humidity, and results in substantial savings in costs and amounts of energy required to control temperature and relative humidity in a greenhouse. FIGS. 2C and 2D show graphs 501 and 502 of relative humidity and temperature respectively of air inside and outside of greenhouse 320 controlled by a GECO system similar to GECO system 330 operating in accordance with an algorithm similar to algorithm 400 .
[0067] In graphs 501 and 502 solid curves 511 and 512 respectively show relative humidity and temperature respectively for air inside greenhouse 320 as a function of time for a period of two days. Time in hours is shown along the graphs' abscissas. Dotted curves 514 and 515 show relative humidity and temperature respectively for air outside greenhouse 20 as a function of time for the same two day period.
[0068] The curves in graphs 501 and 502 , as were the curves in graphs 201 and 202 ( FIGS. 1C and 1D ), were experimentally determined for a 3 m×1,000 m 2 greenhouse. Vent and intake radiators 352 and 372 had a length in a direction of air flow through the radiators equal to about 100 cm and a cross section perpendicular to the air flow equal to about 60 cm×60 cm. Each radiator comprised in its 100 cm×60 cm×60 cm volume, an array of 16 sets of 16 rows each of ⅝ inch copper pipe. Fan systems 354 and 374 were capable of streaming 1,500 m 3 /h (cubic meters of air per hour) through their respective associated radiators. Heat exchangers 350 and 370 were capable of extracting heat from heated water flowing through their copper pipes, or introducing heat into cooled water flowing in the pipes at rate of about 10 kW. Heat exchangers 350 and 370 were turned on for about 7 hours during each diurnal cycle. Whereas, when turned on, heat exchanger 40 in GECO system 330 , operated at an energy consumption of about 290 kW, during each diurnal cycle it was turned on for about three and a third hours. An overall average energy consumption of GECO system 330 per diurnal cycle was about 1030 kWh.
[0069] From graphs 501 and 502 it is seen that neither the relative humidity, curve 511 , and temperature of air, curve 512 , in greenhouse 320 exhibit the large cyclical changes exhibited by relative humidity and temperature controlled by conventional environment control system 30 in greenhouse 20 ( FIG. 1A ). Temperature in greenhouse 320 fluctuates with amplitude of about 2° C. between about 20° C. and about 22° C., and relative humidity in the greenhouse fluctuates with an amplitude of about 8% between about 80% and about 87%. Not only does GECO system 330 provide substantially improved control of temperature and relative humidity in a greenhouse but it does it with substantially reduced energy consumption compared to a conventional greenhouse environment control system.
[0070] For example, as noted above, for external conditions of temperature and relative humidity of outside air indicated by curve 215 in graph 202 and curve 214 in graph 201 respectively, conventional greenhouse environment control system 30 may consume about 2,030 kWh of energy per diurnal cycle to control air in greenhouse 20 with proficiency represented by curves 212 and 211 in the graphs. A GECO system in accordance with an embodiment of the invention similar to GECO system 330 on the other hand, for conditions of relative humidity and temperature of outside air indicated by curve 514 in graph 501 and curve 515 in graph 502 respectively, may control humidity and temperature for greenhouse 320 with substantially improved proficiency exhibited by curves 511 and 512 in the graphs at an energy cost of 1,030 kWh per diurnal cycle. Whereas the conditions of temperature and relatively humidity of outside air under which GECO system 330 operates to control temperature and relative humidity of air in greenhouse 330 are substantially more demanding than the conditions of temperature and relative humidity of outside air under which conventional environment control system 30 operates, the GECO system operates at an average power consumption that is about half that at which the conventional system operates.
[0071] It is noted that the energy consumption and flow rates referred to above for GECO system 330 that controls an environment for a 3 m×1,000 m 2 greenhouse and provides performance substantially as shown in graphs 501 and 502 , scale substantially linearly with greenhouse size. For example, a GECO system in accordance with an embodiment of the used to control the environment in a 3 m×2,000 m 2 greenhouse may be configured to consume twice the energy and provide twice the flow rates provided by a GECO system that controls the environment in a 3 m×1,000 m 2 greenhouse.
[0072] In some embodiments of the invention, controller 342 controls GECO 330 to switch between flush and maintenance modes at optionally predetermined regular intervals. For example, a GECO system similar to GECO 330 in accordance with an embodiment of the invention may operate in flush and maintenance modes for about six and about fifty four minutes respectively every hour can maintain a greenhouse temperature between about 20° C. and about 22° C., and relative humidity between about 80% and about 87%, for outside air and relative humidites for which graphs 501 and 502 were obtained.
[0073] To provide added protection for plants against disease encouraged or promoted by water condensation on plant leaves and body parts, a greenhouse may comprise a WAGIT in accordance with an embodiment of the invention that operates to sonically clean surfaces of leaves and plant parts of moisture that may have accumulated on the surfaces.
[0074] FIG. 3 schematically shows a WAGIT 600 operating to remove water droplets 650 condensed on a plant leaf 652 , in accordance with an embodiment of the invention. WAGIT 600 optionally comprises an acoustic transducer 602 , such as a piezoelectric crystal, driven by a power source 604 to generate acoustic waves, schematically represented by dashed arcs 610 that propagate to leaf 652 . When sonic waves 610 are incident on leaf 652 they generate large amplitude vibrations, represented by dashed silhouettes 654 , in the leaf that shake water droplets 650 off the leaf. The removal of the water droplets is schematically indicated by arrows 656 .
[0075] In an embodiment of the invention, power source 604 drives transducer 602 to generate waves 610 at a frequency substantially coincident with a resonant frequency of leaf 652 . As a result, acoustic waves 610 generate relatively large vibrations in leaf 652 that are relatively efficient in shaking droplets 650 off the leaf. Optionally, power source 604 drives acoustic transducer 602 to generate acoustic waves at a resonant frequency of water droplets 650 , which generate relatively large vibrations in the bodies of the droplets. The vibrations cause the droplet to “roll” off leaf 652 .
[0076] In the description and claims of the present application, each of the verbs, “comprise” “include” and “have”, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of components, elements or parts of the subject or subjects of the verb.
[0077] Descriptions of embodiments of the invention in the present application are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments utilize only some of the features or possible combinations of the features. Variations of embodiments of the invention that are described, and embodiments of the invention comprising different combinations of features noted in the described embodiments, will occur to persons of the art. The scope of the invention is limited only by the claims.
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Apparatus for controlling an environment in a green-house, the apparatus comprising: first and second heat exchangers, each comprising a radiator and a fan system for driving air through the radiator; a first refrigerant circulation system that circulates a refrigerant fluid between and through the radiators; a heater controllable to heat the refrigerant; a controller that controls the apparatus to operate selectively in a maintenance mode or a flush mode, wherein in the maintenance mode the heater heats the refrigerant and the first and second fan systems drive air from outside to inside the greenhouse and through the radiators to acquire heat from the refrigerant, and in the flush mode the first fan system vents air from inside to outside the greenhouse through its respective radiator to deposit heat in the refrigerant and the second fan system drives air from outside to inside the greenhouse and through its respective radiator to acquire the heat deposited in the refrigerant.
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FIELD OF THE INVENTION
The invention relates to a vibration isolation member and more particularly the invention relates to a vibration isolation member that provides substantially equal dynamic stiffness in radial and axial directions and comprises an outer member with an inner periphery, an inner member with an outer periphery and a resilient member joining the inner and outer members wherein the dimensions of the inner and outer peripheries provide for an interference therebetween in the event of a failure of the elastomer.
BACKGROUND OF THE INVENTION
Vibration isolation members are frequently used in aircraft interior applications to reduce the vibration and noise exposure to delicate and sensitive instrumentation and also to passengers in the aircraft cabin. In aircraft applications the vibration isolation members must provide the requisite vibration reduction with a minimum size and weight vibration isolation member.
One means for effectively reducing such exposure to noise and vibration is to use a vibration isolation member that has iso-elastic stiffness properties. A vibration member that is iso-elastic has equal stiffness in the axial and radial directions. Iso-elastic stiffness permits the vibration isolator to provide dependable performance in any orientation and maximize vibration reduction for a given installation. A vibration isolation member that does not provide such iso-elastic stiffness properties will transmit vibration more efficiently in one or more directions, compared to an iso-elastic vibration member having the same minimum stiffness.
Additionally, it is desirable to include a mount fail-safe feature that prevents the mount from separating in the event the mount fails under loading. Several prior art mounts provide fail safe features that function in a single axial direction however, such prior art mounts typically do not have two fail safe paths. Moreover, in vibration isolation members that comprise iso-elastic members, the members frequently do not have a fail-safe or interference path that is defined by the components that comprise the mount. Rather the fail-safe feature is produced by adding washers or other discrete mechanical members to the member. The additional components required to provide a fail safe feature in an iso-elastic vibration isolation member add weight and increase the volume required to house the member in the aircraft.
The foregoing illustrates limitations known to exist in present devices and methods. Thus, it is apparent that it would be advantageous to provide a vibration isolator that provides iso-elastic stiffness in combination with fail safe feature and thereby solves one or more of the shortcomings of present isolation devices and methods. Accordingly, a suitable vibration isolation member is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention this is accomplished by providing a vibration isolation member that provides iso-elastic stiffness and at least one fail-safe feature.
More specifically the vibration isolation member of the present invention comprises an inner member comprising an outer periphery having a first dimension; an outer member comprising a base and a shroud that extends away from the base, the shroud adapted to overlay the inner member, said shroud defining an inner periphery having a second dimension, the second dimension being less than the first dimension; and a resilient member constrained between the shroud and the inner member, whereby the vibration isolation member provides iso-elastic stiffness and an interference between the inner and outer members in the event of a failure of the resilient member.
The inner member is unitary and is comprised of a stem and a seat where the seat includes a first surface, a second surface spaced from the first surface and a third surface that joins the first and second surfaces. The third surface is oriented at an angle relative to the first surface. The seat has a frustoconical configuration.
The outer member shroud may comprise a single segment or may comprise a first segment, a second segment and a third segment, the second segment joining the first and third segments. The outer member first segment is oriented substantially axially, the third segment is oriented substantially radially and the second segment is oriented at an angle relative to the first and second segments. The third surface of the seat is substantially parallel to the second segment of the shroud.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the vibration isolation member of the present invention.
FIG. 2 is a top view of the vibration isolation member of FIG. 1 .
FIG. 3 is a longitudinal sectional view taken along line 3 - 3 of FIG. 2 .
FIG. 4 is a longitudinal sectional view like the sectional view of FIG. 3 illustrating a second embodiment vibration isolation member of the present invention.
FIG. 5 is a longitudinal sectional view like the sectional view of FIG. 3 illustrating third embodiment vibration isolation member of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning to the drawing Figures wherein like parts are referred to by the same numbers in the Figures, the first embodiment vibration isolation member 10 of the present invention is disclosed in FIGS. 1 , 2 and 3 .
Generally, vibration isolation member 10 comprises an inner member 12 , an outer member 14 and a resilient member 16 that joins the inner and outer members. The resilient member is constrained between the inner and outer members. The inner and outer members 12 and 14 are relatively rigid. The vibration isolation member 10 is made from a conventional molding process well known to those skilled in the art and during the molding process the resilient member is bonded to the inner and outer members. The resilient member 16 may be comprised of any suitable material however for purposes of the preferred embodiment of the invention the resilient member is comprised of a silicone or a synthetic rubber.
As shown in the sectional view of FIG. 3 , the isolator is adapted to be connected between a support structure 18 such as an aircraft frame for example, and a suspended body 20 which may be an interior aircraft instrument or trim panel. The isolator 10 of the present invention reduces the transmission of vibratory disturbances, which may be in the form of acoustic noise, between the support structure 18 and the suspended body 20 . The isolator also limits heat transfer between body 20 and structure 18 . Also shown in FIG. 3 , the isolation member is joined to the suspended body 20 by conventional fastener 22 that extends between the body 20 and inner member 12 ; and is joined to the support structure 18 by fasteners 24 a , 24 b that extend through the outer member 14 . The fasteners may be comprised of any suitable fastener well known to those skilled in the art including, but not limited to screws or quick-connect fasteners. By these connections, the outer member 14 remains substantially stationary during use and the inner member 12 may be displaced in radial and axial directions represented by respective directional arrows 25 and 26 .
The relatively rigid inner member 12 is unitary and comprises an axially extending cylindrical stem 30 and frustoconical seat 32 . As shown in FIG. 3 , the seat includes first and second faces 34 and 36 joined by angled surface 38 that extends outwardly from face 34 to face 36 . The surface 38 may extend at any suitable angle, Θ relative to face 34 . For purposes of describing the preferred embodiment of the invention, the angle may be about 55°. The stem is made integral with the seat 32 at face 34 and the free end of the stem extends outwardly from the opening in the outer member 14 defined by inner periphery 62 . Faces 34 and 36 are circular, planar members that join the surface 38 at respective outer edges. The inner member includes an axially extending bore 40 that extends through the stem and seat and is adapted to receive fastener 22 previously described above. The seat defines an outer periphery 42 that comprises a diameter, D′. The extent of the inner member outer periphery 42 is also represented in dashed font in FIG. 2 . As shown in FIG. 3 , when the member 10 is installed the seat is located proximate the support member 18 . Additionally, as shown in FIG. 3 , the surface 36 is located a distance away from the support structure 18 to allow for displacement of inner member 12 when the isolation member 10 experiences a vibratory disturbance.
The relatively rigid outer member 14 is unitary and comprises a substantially planar flange or base 50 with bores 52 a and 52 b that are adapted to receive fasteners 24 a and 24 b as described hereinabove. The base 50 is made integral with an annular shroud 54 that overlays seat 32 . The shroud comprises a first segment 56 that extends in the axial direction defined by arrow 26 , a second segment 58 that extends substantially parallel to surface 38 , and a third segment 60 that extends in the radial direction defined by arrow 25 . The second segment 58 joins the first and third segments 56 and 60 . See FIG. 3 . Although the second segment is shown at an orientation that is substantially parallel to surface 38 it should be understood that although such a parallel configuration is preferred the second segment could be oriented at any relative angle and do not have to be parallel.
Third segment 60 terminates at inner periphery 62 that defines diameter, D″. As shown in FIGS. 2 and 3 , the outer periphery 42 has a diameter D′ that has a greater radial dimension than inner periphery 62 diameter, D″. In the event that resilient section fails, and the seat is displaced axially toward panel 20 , an interference or fail-safe load path would be created between the seat and the segment 60 preventing further displacement of seat outward from the outer member. Thus the inner member would be captured by the outer member. As shown most clearly in the sectional view of FIG. 3 , to ensure that the desired interference is produced between the seat and shroud, the inner periphery 62 must terminate radially inwardly from the outer periphery 42 .
During molding, resilient member 16 is bonded to the surface 38 and also to the inner surface of second segment 58 . Additionally, the molding process produces relatively thin skin segments bonded along the inner surface of third segment 60 and inner periphery 62 , stem 30 and surface 34 , outer periphery 42 and along portions of the inner surfaces of flange 50 and first segment 56 . Apart from the skins, the main portion of the resilient member 16 has a substantially trapezoidal cross section.
The vibration isolation member 10 of the present invention provides iso-elastic stiffness. The term “iso-elastic” means that the isolation member 10 has substantially the same stiffness in the axial and radial directions for any applied load. Because the resilient member 16 is constrained between the inner member 12 and outer member 14 the resilient member 16 experiences combined shear loads and loads in either tension or compression regardless of the direction and magnitude of the load applied to the vibration isolation member 10 .
The vibration isolation member 10 of the present invention provides a double fail safe feature that captures the inner member and maintains it in the chamber 80 defined by the outer member and the support structure 18 . Failure of the elastomer member 16 or failure of the bonds between member 16 and either inner member 12 or outer member 14 will not permit the inner member to relocate outside of the outer member. The inner member is captured by either the structural panel 18 or by the interference between the seat and segment 60 as described hereinabove. Therefore, in order for the inner member seat to become displaced from the chamber 80 , failure of the inner member, outer member fasteners or structural member must occur in addition to the resilient member failure. Additionally, in the event the resilient member 16 fails the seat will not be displaced out of chamber 80 . The suspended body 20 will engage the rigid outer member while the seat will interfere with the inner member. Additionally, the structural member will impede additional axial displacement of the seat towards member 20 . In this way, the mount of the present invention provides double fail-safe feature in combination with its iso-elastic stiffness.
A second preferred embodiment vibration isolation member 70 is shown in FIG. 4 . The alternate embodiment mount 70 includes relatively rigid inner member 72 comprises stem 30 and seat 32 which defines angled surface 38 . The stem 30 , seat 32 and surface 38 as well as the other components and features are the same as those described hereinabove in conjunction with first embodiment vibration isolation member 10 . In the second embodiment mount 70 , the stem 30 and seat 32 may be made directly integral. The inner member 72 does not include surface 34 joining the stem and seat. The second embodiment member 70 includes the double fail-safe feature and also includes an iso-elastic stiffness.
A third preferred embodiment vibration isolation member 75 is illustrated in FIG. 5 . The alternate embodiment mount 75 includes relatively rigid outer member 76 with shroud 78 . As shown in FIG. 5 , the shroud member is comprised of a hollow cone with a wall comprised of a single angled segment, that terminates at an inner periphery 62 . As described in conjunction with first embodiment isolation member 10 , the inner periphery 62 has a diameter D″ that is less than the diameter D′ of the outer periphery 42 of the seat 32 . The other components and features of member 75 are the same as those described hereinabove in conjunction with first embodiment vibration isolation member 10 . The third embodiment member 70 includes the double fail-safe feature and also includes an isoelastic stiffness.
It should be understood the use of outer member 76 and inner member 72 are not limited to the isolation members shown in their respective embodiments but rather, outer member 76 may be combined with inner member 72 if desired.
While I have illustrated and described a preferred embodiment of my invention, it is understood that this is capable of modification, and I therefore do not wish to be limited to the precise details set forth, but desire to avail myself of such changes and alterations as fall within the purview of the following claims.
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A vibration isolation member comprising an inner member comprising an outer periphery having a first dimension; an outer member comprising a base and a shroud that extends away from the base, the shroud adapted to overlay the inner member, said shroud defining an inner periphery having a second dimension, the second dimension being less than the first dimension; and a resilient member constrained between the shroud and the inner member, whereby the vibration isolation member provides iso-elastic dynamic stiffness and an interference between the inner and outer members in the event of a failure of the resilient member.
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[0001] This application claims priority under 35 U.S.C. §119(e) from, and claims the benefit of, U.S. Provisional Application No. 61/138,792, filed Dec. 18, 2008, which is by this reference incorporated in its entirety as a part hereof for all purposes.
TECHNICAL FIELD
[0002] This invention relates to the manufacture of diaminopyridines and related compounds, and to the industrial use thereof for the synthesis of other useful materials.
BACKGROUND
[0003] The compound 2,6-diaminopyridine (“DAP”), which is represented by the structural formula shown below:
[0000]
[0004] is a useful starting material for preparing monomers for rigid rod polymers such as those described in WO 94/25506, as well as for the preparation of dyes, metal ligands, medicines and pesticides.
[0005] It is known to prepare DAP by means of the Chichibabin amination reaction, in which pyridine is reacted with sodium amide in an organic solvent. This is a complicated reaction, however, and handling the sodium amide and isolating the desired product from this complex mixture are difficult operations to perform on a commercial scale.
[0006] The synthesis of 2,6-diaminopyridine and related compounds from glutaronitriles or glutarimidines may be described as proceeding via a dehydrogenative aromatization reaction. A batch process for the preparation of 2,6-diaminopyridine and related compounds from glutaronitriles and related compounds by contacting an acyclic dinitrile compound with a chemical oxidant and/or a dehydrogenation catalyst in liquid ammonia neat or in a mixture of ammonia and a polar, aprotic solvent, and heating the reaction mixture in a closed vessel, is described in U.S. application Ser. No. 12/519,592, filed Jun. 17, 2009 (previously published as WO 2008/82509 and published as U.S. Patent Publication No. 20/______), which is by this reference incorporated in its entirety as a part hereof for all purpose.
[0007] A batch process for the preparation of 2,6-diaminopyridine and related compounds from glutarimidines and related compounds by contacting a glutarimidine with a chemical oxidant and/or a dehydrogenation catalyst in liquid ammonia neat or in a mixture of ammonia and a polar, aprotic solvent, and heating the reaction mixture in a closed vessel, is described in U.S. application Ser. No. 12/516,005, filed May 22, 2009 (previously published as WO 2008/82500 and published as U.S. Patent Publication No. 20/______), which is by this reference incorporated in its entirety as a part hereof for all purpose.
[0008] A continuous gas-phase process for the preparation of 2,6-diaminopyridine and related compounds from glutaronitriles and related compounds by contacting an acyclic dinitrile compound in the form of a gas with a dehydrogenation catalyst and heating in the presence of ammonia gas or a mixture of ammonia gas and a carrier gas, is described in U.S. patent application Ser. No. 12/169,152 (filed 8 Jul. 2008 and published as U.S. Patent Publication No. 20/______), which is by this reference incorporated in its entirety as a part hereof for all purpose.
[0009] Despite these existing processes to make aminopyridines, a need remains for a process for the continuous liquid-phase preparation of aminopyridines, and in particular DAP and related compounds. This would allow the reaction to be run at lower temperatures and/or higher pressure which may increase the productivity of the process.
SUMMARY
[0010] The inventions disclosed herein include processes for the preparation of diaminopyridines and related compounds, processes for the preparation of products into which diaminopyridines and related compounds can be converted, and the products obtained and obtainable by such processes.
[0011] Features of certain of the processes of this invention are described herein in the context of one or more specific embodiments that combine various such features together. The scope of the invention is not, however, limited by the description of only certain features within any specific embodiment, and the invention also includes (1) a subcombination of fewer than all of the features of any described embodiment, which subcombination may be characterized by the absence of the features omitted to form the subcombination; (2) each of the features, individually, included within the combination of any described embodiment; and (3) other combinations of features formed by grouping only selected features taken from two or more described embodiments, optionally together with other features as disclosed elsewhere herein. Some of the specific embodiments of the processes hereof are as follows:
[0012] In one embodiment hereof, this invention provides a continuous process for the synthesis of a compound as represented by the structure of the following
[0013] Formula (I)
[0000]
[0000] by (a) providing a compound as represented by the structure of the following Formula (II)
[0000]
[0000] in the form of a liquid; (b) providing an ammonia component selected from the group consisting of: neat liquid ammonia, a mixture of liquid ammonia and a solvent, and ammonia gas; (c) heating a heterogeneous dehydrogenation catalyst; and (d) contacting the Formula II compound and the ammonia component in the presence of the catalyst to produce a Formula (I) product; wherein R 1 and R 2 are each independently selected from H and a hydrocarbyl group.
[0014] In another embodiment hereof, this invention provides a process for preparing a Formula (I) compound, as described above, that further includes a step of subjecting the Formula (I) compound to a reaction (including a multi-step reaction) to prepare therefrom a compound (such as that useful as a monomer), oligomer or polymer.
[0015] An advantageous feature of the processes hereof is that they are conducted in the liquid phase in a continuous manner, thereby resulting in a significant decrease in overall reaction time in a liquid phase process and enabling component recycle without isolation. For example, the process may be carried out at low temperatures, e.g. a temperature of about 160° C., at short reaction times. Such features combine to produce an economically favorable process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Various features and/or embodiments of this invention are illustrated in a drawing as described below. These features and/or embodiments are representative only, and the selection of these features and/or embodiments for inclusion in the drawing should not be interpreted as an indication that subject matter not included in the drawing is not suitable for practicing the invention, or that subject matter not included in the drawing is excluded from the scope of the appended claims and equivalents thereof.
[0017] FIG. 1 is a schematic representation of a reactor as may be used in a process hereof.
DETAILED DESCRIPTION
[0018] In a process as described herein, there is provided a continuous process for the liquid-phase preparation of 2,6-diaminopyridine and related compounds from glutaronitrile and related compounds.
[0019] In one embodiment of the processes hereof, a diaminopyridine compound [as represented by the structure of Formula (I) as shown below] may be synthesized from an acyclic dinitrile compound [as represented by the structure of Formula (II) as shown below] by providing the acyclic dinitrile compound in the form of a liquid; providing an ammonia component selected from the group consisting of: neat liquid ammonia, a mixture of liquid ammonia and a solvent and ammonia gas; heating a dehydrogenation catalyst; and contacting the dinitrile compound and the ammonia component in the presence of the heated catalyst to produce the desired diaminopyridine [Formula (I)] product.
[0000]
[0020] In Formulae (I) and (II), R 1 and R 2 are each independently selected from H, and a hydrocarbyl group. Examples of hydrocarbyl groups suitable for use in R 1 or R 2 include without limitation
[0021] a C 1 ˜C 12 , C 1 ˜C 8 , C 1 ˜C 6 , or C 1 ˜C 4 , straight-chain or branched, saturated or unsaturated, substituted or unsubstituted, aliphatic hydrocarbyl group; and
[0022] a C 3 ˜C 12 , C 3 ˜C 8 , or C 3 ˜C 6 , cyclic, saturated or unsaturated, substituted or unsubstituted, aliphatic hydrocarbyl group.
[0023] An unsubstituted hydrocarbyl group as described above contains no atoms other than carbon and hydrogen. In a substituted hydrocarbyl group,
[0024] one or more heteroatoms selected from O, N, S and P may optionally be substituted for any one or more of the in-chain (i.e. non-terminal) or in-ring carbon atoms, provided that each heteroatom is separated from the next closest heteroatom by at least one and preferably two carbon atoms, and that no carbon atom is bonded to more than one heteroatom; and/or
[0025] one or more halogen atoms may optionally be bonded to a terminal carbon atom.
[0026] In addition, however, a substituted C 3 ˜C 12 cyclic hydrocarbyl group may contain one or more C 1 ˜C 8 , or C 1 ˜C 4 , straight-chain or branched, saturated or unsaturated, aliphatic hydrocarbyl groups bonded to a carbon atom in the ring structure, such group itself optionally being substituted with one or more heteroatoms selected from O, N, S and P, and/or containing one or more halogen atoms, subject to the conditions set forth above.
[0027] A C 1 ˜C 12 straight-chain or branched, saturated or unsaturated, substituted or unsubstituted, aliphatic hydrocarbyl group suitable for use herein may include, for example, a methyl, ethyl, n-propyl, i-propyl, n-butyl, sec-butyl, tert-butyl, n-pentyl, n-hexyl, n-octyl, trimethylpentyl, allyl and/or propargyl group. An unsaturated aliphatic group may include one or more double bonds, such as in a dienyl or terpenyl structure, or a triple bond such as in an acetylenyl structure. A C 3 ˜C 12 cyclic, saturated or unsaturated, substituted or unsubstituted, aliphatic hydrocarbyl group suitable for use herein may include, for example, an alicyclic functional group containing in its structure, as a skeleton, cyclohexane, cyclooctane, norbornane, norbornene, perhydro-anthracene, adamantane, or tricyclo-[5.2.1.0 2.6 ]- decane groups. Preferably, one or both of R 1 and R 2 are H.
[0028] When R 1 and R 2 are both H, the acyclic dinitrile is glutaronitrile (“GN”) and the Formula (I) compound is 2,6-diaminopyridine (“DAP”), as represented by the structures of the formulae shown in the following reaction scheme:
[0000]
[0029] Various compounds of Formula (II), for use as a starting material herein, may be synthesized by processes known in the art, or are available commercially from suppliers such as Alfa Aesar (Ward Hill, Mass.), City Chemical (West Haven, Conn.), Fisher Scientific (Fairlawn, N.J.), Sigma-Aldrich (St. Louis, Mo.) or Stanford Materials (Aliso Viejo, Calif.).
[0030] In the processes hereof, a Formula (II) acyclic dinitrile compound in the form of a liquid is contacted with an ammonia component selected from the group consisting of: neat liquid ammonia, a mixture of liquid ammonia and a solvent and ammonia gas.
[0031] The reaction is conducted in the liquid phase, i.e. the reaction temperature and pressure are selected to ensure a liquid state for the Formula (II) compound-rich phase by operating at a temperature less than the boiling point of the particular Formula (II) compound utilized in the reaction under the chosen reaction conditions. For example, the boiling point of the Formula (II) compound when it is glutaronitrile (i.e. R 1 and R 2 are both H) is 286° C. at atmospheric pressure (1 atm, 0.101 MPa), 319° C. at 2 atm (0.203 MPa), 370° C. at 5 atm (0.507 MPa), 392° C. at 7 atm (0.709 MPa), and 417° C. at 10 atm (1.01 MPa) [as described in Design Institute for Physical Properties (DIPPR®) 2004]. Therefore at, for example, 2 atm (0.203 MPa) pressure, the selected reaction temperature would be below 319° C. to maintain the glutaronitrile-rich phase as a liquid.
[0032] In a process hereof, a Formula (II) compound in the form of a liquid is contacted with an ammonia component in the presence of a heterogeneous dehydrogenation catalyst. A catalyst suitable for use in a process hereof is a substance that increases the rate of approach to equilibrium of the reaction without itself being substantially consumed in the reaction. A dehydrogenation catalyst suitable for use herein typically contains at least one metal, or metal salt, wherein the metal for use in the catalyst is selected, for example, from elements of Groups IVA, VA, VIA, VIIA, VIII, IB and/or IIB of the Periodic Table [as such groups are described, for example, in the periodic table in a reference such as Advanced Inorganic Chemistry by Cotton and Wilkinson, Interscience, New York, 2nd Ed. (1966)]. A particular metal, for use by itself or in a metal salt, may be selected from Group VIII elements such as iron, cobalt and nickel; and/or from the platinum group of metals including ruthenium, rhodium, palladium, osmium, iridium and platinum. The platinum group of metals and their salts are preferred, more preferably platinum and palladium and their salts. Sponge metal catalysts may also be used, including without limitation Raney® iron, Raney® nickel, Raney® cobalt (Raney is a registered trademark of W.R. Grace and Company, Columbia Md. USA) and equivalent sponge metal catalysts.
[0033] In a heterogeneous catalyst, a metal or metal salt of the desired elements may be deposited on any support with a sufficiently high surface area. A heterogeneous catalyst may thus be distinguished from a homogeneous catalyst, which is not supported, in the sense that a homogeneous catalyst and the reactants reside in the same phase, which is uniform, and the catalyst is molecularly dispersed with the reactants in that phase.
[0034] The support for a heterogeneous catalyst as used herein may be amorphous or may possess a crystalline structure, or may contain both amorphous and crystalline portions. The support may be a solid metal oxide or solid non-metal oxide, each with surface —OH groups. Examples of such metal oxides are those from tri- and tetravalent metals, which may be a transition or non-transition metal or any rare earth such as alumina, titania, cobaltic oxide, zirconia, ceria, molybdenum oxide and tungsten oxide. An example of a typical non-metal oxide is silica. The support may also be a zeolite or zeotype material having a structure made up of tetrahedra joined together through oxygen atoms to produce an extended network with channels of molecular dimensions. The zeolite/zeotype materials typically have SiOH and/or AlOH groups on the external or internal surfaces. The support may also be activated carbon, coke or charcoal. Preferably, the support is at least one of alumina, silica, silicalite, ceria, titania, or carbon, more preferably alumina, silica or carbon.
[0035] In one embodiment of the processes hereof, the reaction is conducted by injecting a Formula (II) dinitrile compound in liquid form, and liquid ammonia neat or in a mixture of liquid ammonia and a solvent, as reactants in liquid form into a reactor that is loaded with the desired catalyst. The Formula (II) dinitrile compound may be supplied neat or in a solution. Suitable solvents for the Formula (II) dinitrile compound include without limitation ethanol, 1,4-dioxane, tetrahydrofuran and acetone. Mixed solvents can be used. Ethanol is preferred as a solvent for the Formula (II) dinitrile compound. Where the ammonia component is a mixture of liquid ammonia and a solvent, suitable solvents for that purpose include without limitation 1,4-dioxane, tetrahydrofuran, acetone, acetonitrile, dimethylformamide and pyridine. Mixed solvents can also be used, such as 1,4-dioxane plus pyridine.
[0036] In a further embodiment of the processes hereof, the ammonia component is in the form of a gas. Ammonia, as anhydrous ammonia, has a boiling point of about −33° C., and is therefore available as a gas at ambient temperatures, and may be used as such for injection into the reactor.
[0037] The reactions hereof are conducted in the liquid phase, i.e. the reaction temperature and pressure are selected to ensure a liquid state for the Formula (II) compound-rich phase by operating at a temperature less than the boiling point of the particular Formula (II) compound utilized in the reaction under the chosen reaction conditions. The reaction can be conducted in the liquid phase at a temperature that may suitably be about 125° C. or more, or about 150° C. or more, and yet about 300° C. or less, or about 200° C. or less, or about 175° C. or less; or that may be in the range of from about 125° C. to about 300° C., in the range of from about 125° C. to about 200° C., or in the range of from about 150° C. to about 175° C. The reaction temperature referred to here is the temperature that has been provided for the catalyst in the catalyst zone of the reactor. A temperature in these ranges is provided by heating the various portions of the reactor from a source external thereto, in particular a heating element designed to surround and heat the catalyst zone of the reactor, and thus the catalyst itself. The selected temperature thus exists in the catalyst zone of the reactor upon the occasion when the Formula (II) dinitrile compound and the ammonia component are contacted in the presence of the catalyst.
[0038] The reaction may be run at ambient pressure, or at a pressure of up to about 75 atm or up to about 150 atm (up to about 7.6 MPa or up to about 15.2 MPa), or at a pressure in the range of about 1 to about 10 atm (about 0.10 to about 1.0 MPa), or at a pressure in the range of about 1 to about 2 atm (about 0.10 to about 0.20 MPa). The reaction may be run for a length of time of a minute or less, or for a length of time of about 5 to about 10 seconds, or of about 1 to about 2 seconds, or of less than one second. In all cases, however, the reaction is carried out at a temperature and pressure and for a time that is sufficient to obtain liquid-phase production of a Formula (I) diaminopyridine reaction product.
[0039] In various embodiments, the amount of ammonia fed to the reactor may be about 1 molar equivalent or more, or about 10 molar equivalents or more, or about 25 molar equivalents or more, and yet about 700 molar equivalents or less, about 400 molar equivalents or less, or about 300 molar equivalents or less; or may be in the range of from about 1 molar equivalent to about 700 molar equivalents, or in the range of from about 10 molar equivalents to 400 molar equivalents, or in the range of from about 25 molar equivalents to 300 molar equivalents, per molar equivalent of Formula (II) dinitrile compound that is fed in. In yet other embodiments, a diaminopyridine compound may be produced at a concentration in the range of from about 1 to about 400 molar equivalents per molar equivalent of the Formula (II) dinitrile compound used in the reaction.
[0040] Reactors suitable for use in the processes hereof include fixed-bed reactors, and pipe, tubular or other plug-flow reactors and the like in which the catalyst particles are held in place and do not move with respect to a fixed residence frame; or fluidized bed reactors. Reactants may be flowed into and through reactors such as these on a continuous basis to give a corresponding continuous flow of product at the downstream end of the reactor. These and other suitable reactors are more particularly described, for example, in Fogler, Elements of Chemical Reaction Engineering, 2nd Edition, Prentice-Hall Inc. (1992). One example of a continuous, fixed-bed, liquid-phase reactor as used in an embodiment of the processes hereof is shown in FIG. 1 . In a reactor such as shown in FIG. 1 , in-flow lines for the ammonia component ( 1 ) and dinitrile feed ( 2 ) are heat traced to keep reactants at a suitable temperature, and the temperature of the catalyst zone ( 3 ) is controlled by a separate heating element at that location. The diaminopyridine product is collected from the reactor effluent ( 4 ).
[0041] A compound of Formula (I) (a “Pyridine Product”), after being produced for example in the manner as described above, may, as desired, be isolated and recovered. The Pyridine Product may also, however, be subjected with or without recovery from the reaction mixture to further steps to convert it to another product such as another compound (such as a type useful, for example, as a monomer), or an oligomer or a polymer. Another embodiment of a process hereof thus provides a process for converting a Pyridine Product, through a reaction (including a multi-step reaction), into another compound, or into an oligomer or a polymer. A Pyridine Product may be made by a process such as described above, and then converted, for example, by being subjected to a polymerization reaction to prepare an oligomer or polymer therefrom, such as those having amide functionality, imide functionality, or urea functionality, or a pyridobisimidazole-2,6-diyl(2,5-dihydroxy-p-phenylene) polymer.
[0042] A Pyridine Product such as a diaminopyridine may be converted into a polyamide oligomer or polymer by reaction with a diacid (or diacid halide) in a process in which, for example, the polymerization takes place in solution in an organic compound that is liquid under the conditions of the reaction, is a solvent for both the diacid(halide) and the diaminopyridine, and has a swelling or partial salvation action on the polymeric product. The reaction may be effected at moderate temperatures, e.g. under 100° C., and is preferably effected in the presence of an acid acceptor that is also soluble in the chosen solvent. Suitable solvents include methyl ethyl ketone, acetonitrile, N,N-dimethylacetamide dimethyl formamide containing 5% lithium chloride, and N-methyl pyrrolidone containing a quaternary ammonium chloride such as methyl tri-n-butyl ammonium chloride or methyl-tri-n-propyl ammonium chloride. Combination of the reactant components causes generation of considerable heat and the agitation, also, results in generation of heat energy. For that reason, the solvent system and other materials are cooled at all times during the process when cooling is necessary to maintain the desired temperature. Processes similar to the foregoing are described in U.S. Pat. No. 3,554,966; U.S. Pat. No. 4,737,571; and CA 2,355,316.
[0043] A Pyridine Product such as a diaminopyridine may also be converted into a polyamide oligomer or polymer by reaction with a diacid (or diacid halide) in a process in which, for example, a solution of the diaminopyridine in a solvent may be contacted in the presence of an acid acceptor with a solution of a diacid or diacid halide, such as a diacid chloride, in a second solvent that is immiscible with the first to effect polymerization at the interface of the two phases. The diaminopyridine may, for example, be dissolved or dispersed in a water containing base with the base being used in sufficient quantities to neutralize the acid generated during polymerization. Sodium hydroxide may be used as the acid acceptor. Preferred solvents for the diacid(halide) are tetrachloroethylene, methylenechloride, naphtha and chloroform. The solvent for the diacid(halide) should be a relative non-solvent for the amide reaction product, and be relatively immiscible in the amine solvent. A preferred threshold of immiscibility is as follows: an organic solvent should be soluble in the amine solvent not more than between 0.01 weight percent and 1.0 weight percent. The diaminopyridine, base and water are added together and vigorously stirred. High shearing action of the stirrer is important. The solution of acid chloride is added to the aqueous slurry. Contacting is generally carried out at from 0° C. to 60° C., for example, for from about 1 second to 10 minutes, and preferably from 5 seconds to 5 minutes at room temperature. Polymerization occurs rapidly. Processes similar to the foregoing are described in U.S. Pat. No. 3,554,966 and U.S. Pat. No. 5,693,227.
[0044] A Pyridine Product such as a diaminopyridine may also be converted into a polyimide oligomer or polymer by reaction with a tetraacid (or halide derivative thereof) or a dianhydride in a process in which each reagent (typically in equimolar amounts) is dissolved in a common solvent, and the mixture is heated to a temperature in the range of 100˜250° C. until the product has a viscosity in the range of 0.1˜2 dL/g. Suitable acids or anhydrides include benzhydrol 3,3′,4,4′-tetracarboxylic acid, 1,4-bis(2,3-dicarboxyphenoxy) benzene dianhydride, and 3,3′,4,4′-benzophenone tetracarboxylic acid dianhydride. Suitable solvents include cresol, xylenol, diethyleneglycol diether, gamma-butyrolactone and tetramethylenesulfone. Alternatively, a polyamide-acid product may be recovered from the reaction mixture and advanced to a polyimide by heating with a dehydrating agent such as a mixture of acetic anhydride and beta picoline. Processes similar to the foregoing are described in U.S. Pat. No. 4,153,783; U.S. Pat. No. 4,736,015; and U.S. Pat. No. 5,061,784.
[0045] A Pyridine Product such as a diaminopyridine may also be converted into a polyurea oligomer or polymer by reaction with a polyisocyanate, representative examples of which include toluene diisocyanate; methylene bis (phenyl isocyanates); hexamethylene diisocyanates; phenylene diisocyanates. The reaction may be run in solution, such as by dissolving both reagents in a mixture of tetramethylene sulfone and chloroform with vigorous stirring at ambient temperature. The product can be worked up by separation with water, or acetone and water, and then dried in a vacuum oven. Processes similar to the foregoing are described in U.S. Pat. No. 4,451,642 and Kumar, Macromolecules 17, 2463 (1984). The polyurea forming reaction may also be run under interfacial conditions, such as by dissolving the diaminopyridine in an aqueous liquid, usually with an acid acceptor or a buffer. The polyisocyanate is dissolved in an organic liquid such as benzene, toluene or cyclohexane. The polymer product forms at the interface of the two phases upon vigorous stirring. Processes similar to the foregoing are described in U.S. Pat. No. 4,110,412 and Millich and Carraher, Interfacial Syntheses, Vol. 2, Dekker, New York, 1977. A diaminopyridine may also be converted into a polyurea by reaction with phosgene, such as in an interfacial process as described in U.S. Pat. No. 2,816,879.
[0046] A Pyridine Product such as a tetraaminopyridine may be converted to a pyridobisimidazole-2,6-diyl(2,5-dihydroxy-p-phenylene) polymer by polymerizing a 2,5-dihydroxyterephthalic acid with the trihydrochloride-monohydrate of tetraaminopyridine in strong polyphosphoric acid under slow heating above 100° C. up to about 180° C. under reduced pressure, followed by precipitation in water, as disclosed in U.S. Pat. No. 5,674,969 (which is incorporated in its entirety as a part hereof for all purposes); or by mixing the monomers at a temperature from about 50° C. to about 110° C., and then 145° C. to form an oligomer, and then reacting the oligomer at a temperature of about 160° C. to about 250° C. as disclosed in U.S. Patent Publication 2006/0287475 (which is incorporated in its entirety as a part hereof for all purposes). The pyridobisimidazole-2,6-diyl(2,5-dihydroxy-p-phenylene) polymer so produced may be, for example, a poly(1,4-(2,5-dihydroxy) phenylene-2,6-pyrido[2, 3-d: 5,6-d′]bisimidazole) polymer, or a poly[(1,4-dihydrodiimidazo[4,5-b:4′,5′-e]pyridine-2,6-diyl) (2,5-dihydroxy-1,4-phenylene)] polymer. The pyridobisimidazole portion thereof may, however, be replaced by any one or more of a benzobisimidazole, benzobisthiazole, benzobisoxazole, pyridobisthiazole and a pyridobisoxazole; and the 2,5-dihydroxy-p-phenylene portion thereof may be replaced by the derivative of one or more of isophthalic acid, terephthalic acid, 2,5-pyridine dicarboxylic acid, 2,6-naphthalene dicarboxylic acid, 4,4′-diphenyl dicarboxylic acid, 2,6-quinoline dicarboxylic acid, and 2,6-bis(4-carboxyphenyl)pyridobisimidazole.
EXAMPLES
[0047] The advantageous attributes and effects of the processes hereof may be seen in a series of examples (Examples 1 and 2), as described below. The embodiments of these processes on which the examples are based are representative only, and the selection of those embodiments to illustrate the invention does not indicate that conditions, regimes, steps, techniques, configurations, protocols, materials or reactants not described in these examples are not suitable for practicing these processes, or that subject matter not described in these examples is excluded from the scope of the appended claims and equivalents thereof.
[0048] Materials.
[0049] The following materials were used in the examples. Commercial reagents, such as glutaronitrile (99%), ethanol (99.5%), and 2,6-diaminopyridine (98%), were obtained from Aldrich Chemical Company (Milwaukee, Wis., USA), and used as received unless otherwise noted. Palladium (0.5 weight percent on alumina as 1/16-inch round beads) catalyst was obtained from Engelhard Corporation (now BASF Catalysts LLC, Florham Park, N.J., USA), and used as received unless otherwise noted. Anhydrous ammonia (99.99%) was obtained from MG Industries (Malvern, Pa., USA) and used as received.
[0050] Methods
[0051] In these examples, the following protocol was used (except as noted in the description of a particular example): the reactions were carried out in a custom fixed-bed liquid phase reactor fabricated from ⅜-inch (0.95-cm) 316 S.S. tubing (numerical references below being to FIG. 1 ). The reactor was operated under continuous flow of mixtures of anhydrous ammonia ( 1 ) and organic reactants. The organic reactants were optionally dissolved in a solvent, such as ethanol, and were metered as a liquid by a syringe pump (Isco Model 100 DM) ( 2 ) and heated to reaction temperature by passing the liquid feed through a heated injector and combining it with the heated ammonia gas. The ammonia was metered with a mass flow controller (Brooks Model 5850E). The inlet lines and liquid injector were heat traced with electrical heating tape to pre-heat the reactor feeds prior to contacting the catalyst reaction zone ( 3 ). The reactor and catalyst reaction zone were heated with an electrical tube furnace. The reactor effluent was passed through a chiller and then a syringe needle into vented and chilled sample vials where the liquid products were collected ( 4 ), and unreacted ammonia was vented to a fume hood containing the entire apparatus. A circulating bath was used to chill these sample recovery vials.
[0052] The meaning of abbreviations as used in the examples is as follows: “bp” means boiling point, “cm” means centimeter(s), “DAP” means 2,6-diaminopyridine, “g” means gram(s), “GN” means glutaronitrile, “LDL” means lower-detection limit, “min” means minute(s), “mL” means milliliter(s), “MHz” means megahertz, “NMR” means nuclear magnetic resonance spectroscopy, “mol” means mole, “mmol” means millimole(s), “μmol” means micromole(s), “Pd/Al 2 O 3 ” means palladium on alumina catalyst, “scc” means standard cubic centimeter (cubic centimeters at standard conditions of temperature and pressure), “temp” means temperature, and “TLC” means thin-layer chromatography.
[0053] In Examples 1-2, qualitative evidence for DAP formation was determined by TLC (silica gel 60 F 254 plates, 2.5 cm×7.5 cm) and/or 1 H NMR spectral analysis, with comparison of crude product mixtures with authentic material as specified. For TLC, the LDL was confirmed to be less than 1 μmol/mL. Percent conversion was estimated based on 1 H NMR spectral integration, recorded at 500 MHz unless otherwise specified, of 2,6-diaminopyridine (DAP) produced in the reaction. The temperature reported is the temperature at the catalyst zone of the reactor.
Examples 1-2
[0054] These examples demonstrate qualitative fixed-bed liquid-phase conversion of GN to DAP.
[0055] The reactor zone was charged with 2 g catalyst and pre-heated to approximately 160° C. The reactor inlet lines were pre-heated to approximately 160° C. Once the temperatures had equilibrated, anhydrous ammonia flow was set at 1000 scc ammonia per min. A solution of glutaronitrile (bp 285-287° C.) (25.0 g, 265.62 mmol) in ethanol (75.0 g, 1.63 mol) was loaded into the syringe pump and fed to the reaction zone at flow rates and reactor temperatures per those indicated in Table 1. Following reaction at the specified condition, DAP was detected by TLC and/or 1 H NMR analysis in each example.
Table 1.
[0056]
[0057] Where a range of numerical values is recited herein, the range includes the endpoints thereof and all the individual integers and fractions within the range, and also includes each of the narrower ranges therein formed by all the various possible combinations of those endpoints and internal integers and fractions to form subgroups of the larger group of values within the stated range to the same extent as if each of those narrower ranges was explicitly recited. Where a range of numerical values is stated herein as being greater than a stated value, the range is nevertheless finite and is bounded on its upper end by a value that is operable within the context of the invention as described herein. Where a range of numerical values is stated herein as being less than a stated value, the range is nevertheless bounded on its lower end by a non-zero value.
[0058] In this specification, unless explicitly stated otherwise or indicated to the contrary by the context of usage, where an embodiment of the subject matter hereof is stated or described as comprising, including, containing, having, being composed of or being constituted by or of certain features or elements, one or more features or elements in addition to those explicitly stated or described may be present in the embodiment. An alternative embodiment of the subject matter hereof, however, may be stated or described as consisting essentially of certain features or elements, in which embodiment features or elements that would materially alter the principle of operation or the distinguishing characteristics of the embodiment are not present therein. A further alternative embodiment of the subject matter hereof may be stated or described as consisting of certain features or elements, in which embodiment, or in insubstantial variations thereof, only the features or elements specifically stated or described are present.
[0059] In this specification, unless explicitly stated otherwise or indicated to the contrary by the context of usage,
(a) amounts, sizes, ranges, formulations, parameters, and other quantities and characteristics recited herein, particularly when modified by the term “about”, may but need not be exact, and may also be approximate and/or larger or smaller (as desired) than stated, reflecting tolerances, conversion factors, rounding off, measurement error and the like, as well as the inclusion within a stated value of those values outside it that have, within the context of this invention, functional and/or operable equivalence to the stated value; (b) all numerical quantities of parts, percentage or ratio are given as parts, percentage or ratio by weight; (c) use of the indefinite article “a” or “an” with respect to a statement or description of the presence of an element or feature of this invention, does not limit the presence of the element or feature to one in number; and (d) the words “include”, “includes” and “including” are to be read and interpreted as if they were followed by the phrase “without limitation” if in fact that is not the case.
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A liquid-phase, continuous process is provided for the manufacture of 2,6-diaminopyridine and related compounds from glutaronitriles, which are used industrially as compounds and as components in the synthesis of a variety of useful materials. The synthesis proceeds by means of a dehydrogenative aromatization process.
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FIELD OF THE INVENTION
The present invention relates to rechargeable flashlights, their use and operation.
BACKGROUND OF THE INVENTION
Rechargeable flashlights have been known for a considerable time. Disclosed in U.S. Pat. No. 5,847,540 is a rechargeable flashlight having a plug unit supported in the flashlight housing for rotation between a non-charging position, in which blades of the plug unit are retracted into the housing, and a charging position in which the blades are projecting from the housing for insertion into an AC outlet. The plug unit cooperates with a switch unit in the housing for connecting a rechargeable battery to a bulb circuit and disconnecting the battery from a charging and indicating circuit when the plug unit is in the non-charging position. The switch unit also disconnects the battery from the bulb circuit and connects the battery to the charging circuit and indicating circuit when the plug unit is in the charging position. This document teaches that the plug unit can be rotated into and out of the body of the flashlight while remaining connected thereto.
Another flashlight is disclosed in U.S. Pat. No. 4,515,790 which has a rechargeable power pack or cartridge which discloses a plug structure for use with standard electricity sockets or supply outlets, whereas the power cartridge also has a shape which allows the plug structure to be utilised for example with a cigarette lighter outlet of a motor vehicle so that the user has the option of recharging from either electricity supply outlets or from a cigarette lighter outlet of a motor vehicle or a boat. The battery is removed from the flashlight as it is a part of the power pack for recharging purposes. The construction thus can result in the separation of the power pack from the flashlight during the recharging process, which will decrease the ready to use state of the flashlight by comparison to the flashlight disclosed in U.S. Pat. No. 5,847,540.
The applicant does not concede that the prior art discussed above forms part of the common general knowledge in the art of the skilled addressee that the priority date of this application.
SUMMARY OF THE INVENTION
The present invention provides a flashlight having: a body with a light means at one end, a battery, and a circuit therebetween, so that when said circuit is closed said light means will generate light; recharging terminals for recharging said battery and an adaptor having electrical connectors for connecting the adaptor to a power supply; structural connection means on said body and/or said adaptor to releasably connect said body and said adaptor; and electrical connection means on both said body and said adaptor to releasably electrically connect said terminals and said adaptor; said recharging terminals being able to be received in said adaptor and said electrical connectors being able to be received in said body when said adaptor is not in use for recharging.
The adaptor and the body have said structural connection means disconnected in order for said electrical connection means to electrically connect said terminals and said adaptor.
The structural connection means can include a female portion on one of said body or said adaptor, with the other having a male portion. The female portion or said male portion when present on said body has said electrical connectors extending therefrom. The female portion or the male portion of said adaptor has said electrical connectors extending therefrom.
The female portion or male portion said body can include cavities to receive said electrical connectors.
The female portion or male portion of said adaptor can include cavities to receive said terminals.
The adaptor can be shaped so that when said structural connection means connect said body and said adaptor, said adaptor is of a shape which substantially matches the shape of said body in the vicinity of said adaptor.
The adaptor can be shaped so that when said structural connection means connects said body and said adaptor is the rear part of the body.
The adaptor can include a socket to receive said recharging terminals.
When said electrical connectors are in a power supply socket with a vertically oriented front face, said adaptor can have an upper face into which said rechargeable terminals are inserted, the upper face being at an angle to the horizontal so that a line normal to the upper face extends away from the adaptor on a divergent path away from the vertical.
The body can have a female portion and said adaptor can have a male portion.
The male portion can be of a shape and or size to fit between said recharging terminals.
The adaptor can include a hinged cover to overlay said electrical connection means on said adaptor.
The hinged cover can act to limit movement of said flashlight on said adaptor when they are electrically connected.
The adaptor can have a first position relative to the body to enable recharging of the battery in which the recharging terminals are received in the adaptor, and another, second position relative to the body, for when the adaptor is not in use for recharging the battery, in which the electrical connectors are received in the body.
The present invention also provides a flashlight having a body with a light means at one end, a battery, and a circuit therebetween, so that when said circuit is closed said light means will generate light; said light means including a frusto-conical reflector having a central axis and a reflective surface projecting towards the axis, the reflective surface being straight when viewed in a cross-section of the reflector taken through the axis, a white light LED emitting a conical light output and a double convex lens portion, said double convex lens portion being located away from said LED so that the outside diameter of said double convex lens portion will be struck by a circle of light from said LED which is of substantially the same diameter.
Around said double convex lens portion can be a straight sided lens. The straight sided lens and said double convex lens portion can be integrally formed in a single lens member.
A flashlight as claimed in claim 28 wherein said light means produces a beam emitted from said flashlight which has four bands of differing light intensity.
Preferably there is a circular centre and at least three annular bands of light there around.
The circular centre preferably has the highest light intensity relative to said annular bands. The first band adjacent to said circular centre preferably has the lowest light intensity relative to said annular bands. The second band adjacent said first band preferably has a light intensity less than said circular centre but greater than said first band. The third band adjacent said second band can have a light intensity less than said second band but greater than said first band.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention, will be described by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 illustrates a perspective view of a rechargeable flashlight;
FIG. 2 illustrates a rear perspective view of the flashlight of FIG. 1 with the rear adaptor removed;
FIG. 3 illustrates a front perspective view of the rear adaptor of the flashlight of FIG. 1 .
FIG. 4 illustrates the flashlight of FIG. 1 mounted on the adaptor and positioned in an electricity socket; FIG. 5 illustrates an adaptor similar to FIG. 3 with a cover in the open position.
FIGS. 6 and 7 illustrate perspective views of shutter members;
FIG. 8 illustrates the shutter member of FIG. 6 assembled into an adaptor;
FIG. 9 illustrates a perspective view of a flashlight body's end having three pins.
FIG. 10 is a side elevation of FIG. 9 ;
FIG. 11 is a plan view of FIG. 9 ;
FIG. 12 is a cross section through the forward end of the flashlight of FIG. 1 ; and
FIG. 13 is a schematic representation of the light output of the lens assembly of FIG. 12 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
Illustrated in FIG. 1 is a flashlight 10 which has a body 12 with a lens assembly 14 at its forward end. At the top of the body 12 is a three position switch 16 and a red LED 18 positioned behind the switch 16 .
At the rear of the body 12 is located an adaptor 20 . Illustrated in FIG. 3 the adaptor 20 has two electrical connectors 22 and 24 for insertion into a wall socket. The format of the electrical connectors 22 and 24 are to suit the spacing and shape required for European wall sockets and it will be understood that the shape and spacing of these can be varied according to requirements in various countries around the world.
The connectors 22 and 24 extend away from a hexagonally shaped male portion 26 which has cut aways 28 and 30 on opposite sides leading to a recess 32 shown on the right side with a similar recess which is not visible on the left. (A left recess is visible in FIG. 5 and is labelled with the numeral 73 .) The right side 34 of the adaptor 20 as illustrated in figure 3 will become the upper surface of the adaptor 20 when the adaptor 20 is in use in a wall socket as illustrated in FIG. 4 .
The side 34 has a rotating cover 36 which covers and protects the sockets 38 and 39 in the adaptor 20 . In FIG. 5 the cover 36 is rotated to the open position.
As can be seen from FIGS. 1 and 3 , the shape of the adaptor 20 with the cover 36 closed, complements and finishes the rear of the flashlight body 12 . The lines and starting point of the outward surfaces of the front 45 of the adaptor 20 , blend with the lines and finishing point of the outward surfaces of the rear 40 of the flashlight body 12 .
The rear 40 of the flashlight body 12 has a cavity 42 , which has a complementary shaped hexagonal recess 43 to receive the hexagonal male portion 26 of the adaptor 20 . The recess 43 receives the male portion 26 therein whilst the cavities 32 (and 73 ) at the sides of the hexagonal male portion 26 receive therein recharging terminals 44 and 46 which are of a generally cylindrical shape, and which project outwardly from the cavity 42 . The hexagonal male portion 26 has shallow recesses 51 so that complementary shaped protrusions 53 on the cavity 42 can sit therein to lock the adaptor 20 and body 12 together, until sufficient force is applied to separate the two components.
While the above discussion and FIGS. 1 , 2 , 3 and 4 utilise a recess 43 and male portion 26 which are generally hexagonal in shape, this hexagonal shape is only a preferment. As can be seen from FIG. 5 , a different shaped male portion 26 A is used.
As can be seen from FIG. 4 , the side 34 , when in situ in a wall socket is upwardly facing. It will also be noted from the side elevation of FIG. 4 , that an imaginary line 48 , which is normal or perpendicular to the side 34 , divergently extends away from the adaptor 20 , at an angle 59 from the vertical 57 represented by the wall 50 , to which the socket 47 is attached.
This angle 59 also has the same magnitude as the angle 61 which is the angle between the side 34 and the horizontal 63 , as shown in FIG. 4 .
The angles 59 and 61 are approximately 8° but can be in the range of 5° to 30°. This angle allows the flashlight body, to rest on the adaptor 20 in an equilibrium condition due to the flashlight body 12 having a contoured forward end whereby the lighting means and lens assembly 14 are oriented at an angle to the longitudinal axis of the rest of the flashlight body 12 . The cover 36 also opens outwardly to an angle of similar magnitude as angle 59 , so as to provide support to the rear end 40 of the flashlight body 12 , by engaging the face 33 , which is located on the top (when the flashlight is in the orientation of FIG. 1 ) of the body 12 . This helps to keep the flashlight 10 in position on the adaptor 20 and limits the movement which may separate the flashlight 10 from the adaptor 20 . The movement is thus limited to a side to side movement, generally parallel to the wall 50 in which the power socket is located, and not toward or away from the wall 50 .
Once the adaptor 20 , is located in a power socket 71 which is then switched on, then the rechargeable batteries in the flashlight 10 will be recharged.
During recharging the LED will switch on intermittently. Once full recharging has occurred, the LED will be lighted continuously.
Once recharging has occurred, the flashlight can be simply taken off the adaptor 20 , and is useable without the adaptor 20 being reconnected to the rear of the flashlight.
However, for aesthetic purposes the adaptor 20 can be reconnected to the rear 40 of the body 12 .
The two position switch 16 has an intermediate off position and a first on position which lights the lamp means with a low level current. The second on position will light the lamp means with a relatively high level current.
The lamp means is preferably provided by means of 1 or more LEDs.
By using LED's the flashlight will have a relatively long run time before the rechargeable batteries are drained.
Alternatively other type of lamp means can be utilised.
As can be seen in FIG. 2 , the flashlight 10 has the two terminals 44 and 46 extending away from the rear thereof. The terminals 44 and 46 are mounted in and extend away from a plug member which is assembled, captured and held by the rear end of the flashlight 10 when it is assembled. However, in another embodiment, an alternative plug member 400 as illustrated in FIG. 9 to 11 can be utilised for assembly into, capture and holding by the rear end of the flashlight 10 . The plug 400 includes the terminals 44 and 46 , as well as an additional central pin 120 . The pin 120 will prevent a terminal 44 or 46 from being inserted into an aperture 38 or 39 in such a manner that would otherwise have had the other terminal 46 or 44 exposed on the outside of the adaptor 20 . The pin 120 performs this preventative task because unless the terminals 44 and 46 and pin 120 are aligned with apertures 38 and 39 and a third aperture 41 (see FIG. 5 ) then the terminals 44 and 46 will not individually be able to enter the adaptor 20 .
Other means to prevent improper use can be provided such as shutters 100 and 130 in FIGS. 6 and 7 , which will now be described.
Illustrated in FIG. 6 is a shutter member 100 for use with a flashlight having a plug 400 of FIGS. 9 to 11 . The shutter 100 has two angled faces 102 and 104 at its ends. The angle on the faces 102 and 104 is approximately 45° to the base of the shutter 100 . Between the angled faces 102 and 104 is a bight 106 . The faces 102 and 104 will be engaged by terminals 44 and 46 on the flashlight 10 , whereas the bight 106 can receive central third pin 120 . Behind the bight 106 is a three sided recess 108 which has a central face 110 . The face 110 and recess 108 receives the end of a compression spring 114 (see FIG. 8 ) and provides a bearing surface for the end of the spring 114 to push against.
The shutter member 100 can be made of injection moulded plastic and located or assembled in the adaptor 20 as illustrated in FIG. 8 so that the faces 102 and 104 overlie the contacts (no illustrated) which will be engaged by terminals 44 and 46 . The shutter system 100 can be utilised with a flashlight similar to that of FIG. 2 having only two terminals ( 44 and 46 ) but it is thought to be best used with a flashlight having three pins: namely terminals 44 and 46 and central pin 120 (see FIGS. 9 , 10 and 11 ).
The terminals 44 and 46 will pass through apertures 38 and 39 in the adaptor 20 while pin 120 will pass through a central aperture 41 (see FIG. 5 where it is indicated in dashed linework). The terminals 44 and 46 will engage the surfaces 102 and 104 respectively to thereby push the shutter 100 in a rearward direction 112 against the bias of the spring 114 which is illustrated in FIG. 8 . As the shutter 100 moves in the direction of arrow 112 further pushing of the rear of the flashlight 10 towards the adaptor 20 will mean that the shutter 100 will move completely out of the way of the terminals 44 and 46 allowing the terminals 44 and 46 ultimately push past the shutter 100 so as to engage the contacts located below the shutter 100 . As the terminals 44 and 46 are moving inward, the pin 120 will simultaneously pass through the central aperture 41 and into the bight 106 which will not interfere with the movement of the shutter 100 in the direction of 112 .
When the terminals 44 and 46 push past the shutter 100 and engage the contacts below the shutter 100 the recharging process can begin once the adaptor 20 is inserted into a power socket, which can then be switched on.
Illustrated in FIG. 7 is another shutter 130 which has only a central angled face 132 (being at an angle of approximately 45° to the base of the shutter 130 ) and flat faces 134 and 136 on either side thereof. The shutter 130 operates in much the same manner as the shutter 100 except that the shutter 130 will move in the direction of arrow 112 only when the central pin 120 engages the angled face 132 . Thus should the pin 120 fracture or otherwise break the terminals 44 and 46 will not cause the shutter 130 to move in the direction 112 , as they will perpendicularly engage the flat faces 134 and 136 , thereby preventing access to the contacts below the shutter 130 . Contrasted with this the shutter 100 of FIG. 6 will continue to perform even if the central pin 120 were not present, as the shutter 100 will still move in the rearward direction 112 . Thus the shutter 130 is inherently better in operation than the shutter 100 .
The central pin 120 if utilised with a shutter 100 serves the purpose of preventing the terminal 44 or 46 from being placed into one of the apertures 38 or 39 with the other terminal 46 or 44 being left in an exposed condition outside of the adaptor 20 . However, in an embodiment which utilises the shutter 130 , the central pin 120 has the additional purpose of moving the shutter 130 to its open condition allowing the terminals 44 and 46 to gain access to the contacts located underneath the shutter.
Illustrated in FIG. 12 is a cross section through the reflector and lens assembly 14 of flashlight 10 of FIG. 1 . As can be seen from FIG. 12 flashlight 10 has a lens assembly 14 which consists of a conical reflector 200 in which is centrally positioned a white LED 202 . The lens assembly 14 also includes a lens 204 which has a double convex central lens portion 206 (which can also be seen in FIG. 1 ) surrounded by an annular straight sided lens portion 208 . The lens 206 is positioned at a suitable distance from the LED 202 so that when the cone angle 210 of the LED 202 is taken into consideration, the outside diameter of the double convex lens portion 206 is positioned away from the LED 202 so that it will be struck by the cone of light 212 when the cone has a diameter of substantially the same dimension as the diameter of the lens 204 . The annular straight sided portion 208 of the lens 204 will transmit the light from LED 202 which is reflected off the walls 214 of conical reflector 200 . This will produce the effect of a concentrated central beam with a less bright halo concentrically arranged around the centre of the central beam.
It has also been noticed that this reflector and lens assembly 14 will produce a series of concentric rings as illustrated in FIG. 13 , whereby the centre portion 300 is the brightest with at least three annular bands 301 , 302 and 303 around the centre 300 . The first annular band 301 is a relatively dark ring (darker than the outer two annular bands 302 and 303 and the centre portion 300 ). The second annular band 302 is brighter than the third annular band 303 , but is of less intensity than the centre portion 300 . This effect has been found to produce a useful light output even though only relatively little power is being consumed from the power source.
The bands 301 , 302 and 303 are illustrated as being homogenous, however, in practice the bands 301 , 302 and 303 may be interspersed with flecks of light or possibly thin lines of light.
Due to the power plug requirements of some countries, the adaptor used may need to be of a shape and size which will not permit the adaptor to be attached, when not in use, to the rear of the flashlight. Thus such an adaptor can be stored separately from the flashlight, with an end cap being provided to cover the terminals 44 and 46 at the rear of the flashlight, when recharging is not required. While some of the features of the adaptor 20 would not be required on such an adaptor, such an adaptor can include the shutter systems described above to attempt to prevent misuse.
It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.
The foregoing describes embodiments of the present invention and modifications, obvious to those skilled in the art can be made thereto, without departing from the scope of the present invention.
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The present invention provides a flashlight having a body with a light means at one end, a battery, and a circuit therebetween, so that when said circuit is closed said light means will generate light; recharging terminals for recharging said battery and an adaptor having electrical connectors for connecting to a power supply; structural connection means on said body and or said adaptor to releasably connect said body and said adaptor; and electrical connection means on both said body and said adaptor to releasably electrically connect said terminals and said adaptor.
The present invention also provides a flashlight having a body with a light means at one end, a battery, and a circuit therebetween, so that when said circuit is closed said light means will generate light; said light means including a conical reflector, a white light LED emitting a conical light output and a double convex lens portion, said double convex lens portion being located away from said LED so that the outside diameter of said double convex lens portion will a circle of light from said LED which is of substantially the same diameter.
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RELATED APPLICATION
[0001] This application claims priority to related U.S. Provisional Application No. 61/987,859, bearing the same title and filed May 2, 2014. The application in its entirety is expressly incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to radio-protective apparatus and more particularly to an x-ray protection cabin for use by medical professionals and others likely to be exposed to ionizing radiation of the X-ray type and the like.
[0004] 2. Prior Art
[0005] As disclosed in the Magram U.S. Pat. No. 5,185,778, modern operating rooms often include a table on which a patient lies during an operating procedure, and diagnostic equipment in the form of an x-ray source and an x-ray detector, is located on a gantry with the patient and operating table between the x-ray source and detector. The gantry is rotatable about a horizontal axis so that a surgeon viewing a display responsive to the detector is provided with real time display of the tissue being operated on. During the procedure, the patient is irradiated by x-rays for prolonged intervals and is either moved relative to the source of x-rays by providing the table with motors and a linkage that move the table and patient relative to the platform, or held in a fixed position by holding the table in situ relative to the platform.
[0006] During the operation the surgeon and one or more assistants standing next to the operating table are constantly exposed to x-rays back-scattered from the patient and/or table unless adequate shielding is provided. It is well known that the accumulated effect of the back-scattered radiation over many years of conducting surgical procedures may have deleterious effects on the health of the surgeon and assistant(s), and may induce cancer.
[0007] To reduce the x-ray exposure to the surgeon and assistant(s) while the x-ray source is irradiating a patient, they usually wear leaded eyeglasses, a lead thyroid covering and a lead apron which covers the chest, abdomen and thighs but leaves uncovered the arms, hands, legs below the knees and head. However it is known that such radiation protection is only partially effective in blocking radiation and leaves substantial parts of the body uncovered, and that amount of back-scattered x-ray radiation incident on the surgeon and assistant(s) can be substantial enough to cause radiation damage to the surgeon and assistant(s) when they are exposed over a prolonged time period.
[0008] In some instances lead shield panels that are transparent to optical energy but substantially opaque to x-rays are provided for the surgeon and assistant(s) to stand behind. Such shield panels are typically unitary structures fixedly mounted on caster supported frames to allow a degree of freedom of movement. The panels are usually made of lead glass having sufficient thickness to substantially attenuate the back-scattered x-rays and thereby provide at least some protection for the surgeon and assistants. However the panels often do not enable the surgeon and/or assistants easy access to the patient during the operating procedure. Consequently, if access to the patient is necessary during the procedure and while the patient is being x-rayed, there is a substantial likelihood that sensitive body portions of the surgeon and/or assistant(s) will be irradiated with undesirable doses of back-scattered x-ray radiation.
[0009] In a subsequently issued U.S. Pat. No. 7,465,947, Magram discloses a shielding apparatus wherein back-scattered x-rays incident on a surgeon or assistant working with a patient on an operating table can be reduced by upper and lower x-ray shield panels mounted so they can be turned relative to each other about a common vertical axis. The panels are thick enough and have proximate horizontal edges close enough to each other to substantially attenuate back-scattered x-rays incident on front faces of the panels when the panels are aligned. The panels are individually pivotal about a vertical axis to form an opening enabling the user's hand(s) and forearm(s) to extend through. A hinge connects the upper and lower panels to a third panel. In a second embodiment, the upper and lower panels are moved up and down together, while the lower panel remains aligned with a fixed fourth panel for protecting the user's legs.
[0010] In U.S. Pat. No. 7,112,811, Lemer discloses a caster mounted protective screen assembly including a patient facing front wall fixedly connected to a lateral wall running perpendicular, or essentially perpendicular, to the front wall. The walls include transparent panels extending over at least a part of the height thereof. The upper part of the front wall is inclined slightly forwards, forming an overhang which permits the user to approach the working region, and further includes two holes for permitting passage of the user's arms into the working region. In an embodiment, a protective drape or curtain is pivotally connected to the rearmost extremity of the lateral wall to provide a degree of shielding of the user's back. However, no protection is provided on the fourth side of the apparatus.
[0011] While such attempts to address the problems associated with the exposure of surgeons and assistants to radiation during radiological surgery and diagnosis, there remains a need for an improved x-ray screening apparatus which is more convenient to use, which offers better visibility of the surgeon's work region, and which provides better protection of surgeons and assistants from exposure to scattered x-ray radiation.
[0012] Accordingly, it is an object of the present invention to provide a new and improved method of and apparatus for shielding surgeons and/or assistants from scattered x-ray radiation during surgery while x-rays are being used for diagnostic purposes.
[0013] Another object of the present invention is to provide a new and improved apparatus for shielding critical body parts of surgeons and/or assistants during an operating procedure that is accompanied by patient exposure to diagnostic x-ray radiation.
[0014] Another object of the present invention is to provide a new and improved shielding apparatus having features which enable relatively easy access to the patient.
[0015] Still another object of the present invention is to provide on the one hand better visibility of the user's work region, and on the other hand greater comfort while positioned behind the screen within the framework of his intervention.
[0016] Yet another object is to provide better working conditions for surgeons, medical technitions and assistants during the conduct of radiologic procedures, without requiring the wearing of heavy protective clothing, and which thus enables conduct of the intervention with greater accuracy, higher efficiency, and a greater degree of safety.
[0017] A further object of the present invention is to provide a new and improved shielding apparatus for use in an operating room environment including x-ray diagnostic equipment, wherein the shielding arrangement includes a movable that is relatively easily moved, despite the substantial weight and density of its shielding components.
[0018] A still further object of the present invention is to provide a new and improved shielding apparatus for use in an operating room environment including x-ray diagnostic equipment, wherein the leaded rubber used for radiation protection is encased in a fabric so that the user has no direct contact with the lead; an added safety feature.
SUMMARY OF THE INVENTION
[0019] Briefly, a presently preferred embodiment of the present invention provides a movable radiologically protective enclosure for a physician, assistant or medical technician working in close proximity to a source of radiologic energy. The embodiment includes a lower assembly for enclosing and shielding the lower torso and legs of the user, and for adjustably supporting an upper assembly designed to enclose and shield the upper torso, head and arms of the user as well as allow improved visual and functional access to patient and/or radiologic equipment. To counter balance the weight of the upper assembly, a suitable gas spring, or the like, may be used.
[0020] The lower assembly includes a wheeled lower structural framework, preferably made of rectangular tube stock or the like, for supporting frontal and partial lateral radiologic shield components as well as a pair of pivotally mounted radiologic shielding and enclosing components associated with opposite sides of the frontal and lateral shield components. The enclosure components are designed to be rotatable between open and at least substantially closed positions to allow user ingress and egress to and from the enclosure.
[0021] The upper assembly also includes a structural framework similarly adapted to carry radiologic shielding including flexible, frontal and partial lateral radiologic shielding components including protective draping material, or the like, for shielding the upper torso of the user. The upper shielding is provided with frontal portals that are sleeved with flexible protective material to allow the user to protectively extend his or her hands and arms through the sleeves and into the patient region. The sleeves are detachable and re-attachable via snap buttons, Velcro fasteners, or any other suitable means. As in the lower assembly, the rearmost sides of the upper assembly are pivotally connected to open and at least substantially close as required for user ingress and egress.
[0022] The upper structural framework is also adapted to support a radiologically protective, at least partially transparent dome or cap component, preferably made of lead glass or clear lead plastic material, into which the user's head will extend to provide a full range of visibility. In one embodiment, this component is pivotally attached to the frontal portion of the supporting upper framework and is linked to the supporting frame with adjustable supports so that it can be selectively tilted forward to accommodate the user's visual needs and comfort. To counter balance the weight of the cap or dome, a suitable gas spring, or the like, may be used.
[0023] Advantageously, an X-ray radiation impervious skirt is hung from the lower perimeter of the dome or cap to block any radiation that might have a tendency to pass under the back portion of the dome or cap when it is in the tilted forward disposition. Moreover, all of the drapes, skirt pieces, strips and shielding linings are preferably made of fabric-encased lead impregnated rubber material or the like.
[0024] The upper structural framework of the upper assembly is advantageously connected to the lower structural framework in a manner so as to allow vertical relative movement therebetween to accommodate different user heights as well as to allow retraction of the upper unit into the lower assembly for storage space conservation when the apparatus is not in use. The relative movement may be advantageously facilitated by the use of frictionless slides, telescoping tubular members or other suitable means. In addition, gas springs, or functionally similar counter-balancing means, may be used to assist in the raising and lowering of the upper assembly relative to the lower assembly.
[0025] Also, to facilitate the selective positioning of the upper assembly relative to the lower assembly, a suitable jack or screw mechanism, or the like, may be advantageously used to lift and lower the upper assembly to an intended height position relative to the lower assembly, and a pawl and ratchet mechanism, or the like, may be used to lock the upper assembly in place.
BRIEF DESCRIPTION OF THE SEVERAL FIGURES OF THE DRAWING
[0026] FIG. 1 is a side elevational view of an embodiment of the present invention;
[0027] FIG. 2 is a front elevational view of the embodiment of FIG. 1 ;
[0028] FIG. 3 is a rear elevational view of the embodiment of FIG. 1 ;
[0029] FIG. 4 is a side elevational view showing structural details of the lower sub-assembly of the embodiment of FIG. 1 ;
[0030] FIG. 5 is a front elevational view showing structural details of the lower assembly of the embodiment of FIG. 1 ;
[0031] FIG. 6 is a rear elevational view showing structural details of the lower assembly of the embodiment of FIG. 1 ;
[0032] FIG. 7 is a cross sectional view taken along the line 7 - 7 in FIG. 4 ;
[0033] FIG. 8 is an enlarged view of the portion of FIG. 7 indicated by the arrow 8 ;
[0034] FIG. 9 is a side elevational view showing structural details of the lower structural assembly of the embodiment of FIG. 1 ;
[0035] FIG. 10 is a rear elevational view showing structural details of the upper structural assembly of the embodiment of FIG. 1 ;
[0036] FIG. 11 is a cross sectional view taken along the line 11 - 11 in FIG. 9 ;
[0037] FIG. 12 is a cross section taken through the base ring of the dome unit depicted in the embodiment of FIG. 1 ;
[0038] FIG. 13 is an enlarged view of the portion of FIG. 12 indicated by the arrow 13 in FIG. 12 ;
[0039] FIG. 14 is a side elevational view showing structural details of the mating of the upper structural assembly of FIG. 10 to the lower structural assembly of FIG. 9 ;
[0040] FIG. 15 is a rear elevational view showing structural details of the mated assembly of FIG. 14 ;
[0041] FIGS. 16 and 17 are respectively side and rear elevations showing the fully assembled embodiment of FIG. 1 with the dome tilted forward, all radialogically protective elements installed on the surer-structure of the apparatus, and the upper assembly lowered to its lowermost position;
[0042] FIG. 18 is a stylized partial top down view taken in the plane suggested by the line 18 - 18 of FIG. 14 ;
[0043] FIG. 19 is a cross section taken along the line 19 - 19 of FIG. 16 ;
[0044] FIG. 20 is an enlarged diagram showing details of the area 20 in FIG. 19 ;
[0045] FIG. 21 is a side elevational view showing the structural assembly of an alternative embodiment of the present invention;
[0046] FIG. 22 is a side elevational view showing structural details of the lower sub-assembly of the embodiment of FIG. 21 ;
[0047] FIG. 23 is a top plan view of the lower sub-assembly shown in FIG. 22 ;
[0048] FIG. 24 is a front elevational view of the lower sub-assembly shown in FIG. 22 ;
[0049] FIG. 25 is a side elevational view showing structural details of the upper sub-assembly of the embodiment of FIG. 21 ;
[0050] FIG. 26 is a top plan view of the upper sub-assembly shown in FIG. 26 ;
[0051] FIG. 27 is a front elevational view of the upper sub-assembly shown in FIGS. 25 and 26 ;
[0052] FIG. 28 is a side elevational view showing structural details of the attachment of the curved hinged bar included in the upper sub-assembly of the embodiment of FIG. 21 ;
[0053] FIG. 29 is a top plan view of the curved horizontal member of the upperframe sub-assembly shown in FIG. 26 showing structural details of the attachment of the curved hinged side bars included in the upper frame sub-assembly of the embodiment of FIG. 21 ;
[0054] FIG. 30 is a top plan view showing the trapezoidally configured cube shaped cap attached to the C-shaped upper structure of the embodiment shown in FIG. 21 ; and
[0055] FIG. 31 is an elevational view showing the trapezoidally configured cube shaped cap attached to the C-shaped upper structure of the embodiment shown in FIG. 21 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0056] Referring now to FIGS. 1-3 of the drawing, an embodiment of the present invention, generally referred to as an X-shield cabin, is shown at 10 and includes a lower sub-assembly unit 12 for enclosing and shielding the lower torso and legs of a user, and for supporting an upper sub-assembly unit 14 designed to envelope and shield the upper torso and arms of the user as well as allow functional access to patients and/or radiologic equipment. A transparent dome 16 , or the like, made of leaded glass or clear lead plastic material is attached to a C-shaped upper horizontal frame member 32 of the upper sub-assembly 14 by a front hinge 33 . For the convenience of the user, the dome 16 may be selectively tilted forward (as depicted in FIG. 16 ) about hinge 33 and held in place by slotted curved support links 44 affixed to the base ring or rim 41 of the dome assembly and matching locking thumb screws 44 affixed to frame member 32 and disposed on opposite sides of the dome.
[0057] The structural components of the lower sub-assembly unit 12 are best depicted in FIGS. 4-8 and include a lower supporting framework provided by a C-shaped horizontal base member 18 and three hollow, vertically extending column members 19 welded thereto. As will be illustrated below in FIGS. 14 and 15 , the hollow columns 19 telescopically receive corresponding vertical guide rods 56 of the upper frame sub-assembly and allow the upper unit to be selectively raised and lowered relative to the lower unit to accommodate different user height requirements. The lower portions of the side columns 19 also have ratchets 26 affixed to their rearwardly facing sides. The lower framework is advantageously mounted on three wheels including a front caster 20 and two fixed position side wheels 21 affixed to the C-shaped horizontal frame member 18 to allow mobility of the cabin within the hospital environs.
[0058] The lower framework is also preferably made of rectangular tube stock and supports a frontal and partial lateral radiologic shield component 22 as well as a pair of rearwardly disposed radiologic shield and enclosure components 24 respectively associated with each side of the frontal and lateral shield component 22 . These lower front and rear enclosure components are preferrably rigid and covered with a lead impregnated rubber lining.
[0059] Each rearwardly extending component 24 is hingedly connected by one or more hinges 26 to a vertical column member 19 ( FIGS. 3 , 4 and 8 ), and are designed to be rotatable between open and at least substantially closed positions to partially envelope the back side of the user when in use, and yet allow convenient ingress and egress to and from the cabin. The rearmost extremities of the panels 24 are at least partially supported by legs 28 , the lower ends of which have rubber or soft plastic pads 29 affixed thereto to serve as frictional stops tending to resist unwanted movement of the cabin.
[0060] As best shown in FIGS. 9-11 , the upper unit and sub-assembly 14 includes an upper structural framework comprised of the C-shaped horizontal member 32 ( FIG. 11 ) and three sets of vertically depending columns and guide members preferably welded to the underside of member 32 . The columns 54 overlap the rachets, provide rigidity for the sub-assembly and carry the spring loaded pawls 50 (not shown, but see FIG. 1 ) attached at apertures 58 provided proximate the lower extremities of the columns. The guide rods 56 telescopically mate with the columns 19 of the lower sub-assembly as described above. The pawls engage the teeth of the ratchets to allow selective positioning of the upper sub-assembly.
[0061] The upper sub-assembly provides support for the dome 16 and may include a curved plastic panel wrapped about the upper frontal port of the frame. In such case, two or more apertures would typically be provided therein defining portals though which the user may extend his arms. As illustrated in several figures of the drawing, the upper framework is adapted to carry radiologic shielding including flexible, protective draping material, or the like, both inside and outside the plastic panel for shielding the upper torso of the user. The frontal portion of any upper shielding is also provided with frontal portals that are aligned with the hardware portals and are sleeved with flexible protective material to allow the user to protectively extend his or her hands and arms through the frontal portion of the protective shielding and into the work region. The sleeves are usually detachable and re-attachable via snap buttons, Velcro or any other suitable means. The exterior draping material has holes through which the sleeves extend. As in the lower assembly, the rearmost sides of the upper assembly are pivotally connected to open and at least substantially close as required for user ingress and egress.
[0062] Referring specifically to FIGS. 14 and 15 , illustrations are provided showing how the upper structural framework of the upper unit is advantageously connected to the lower structural framework by the telescopic entry of the guide rods 56 into the upper ends of the open columns 19 at 57 and 59 in a manner so as to conveniently allow vertical relative movement there between to accommodate different user heights as well as to allow retraction of at least a portion of the upper unit into the lower unit for storage space conservation when the apparatus is not in use. The relative movement may be advantageously facilitated by the use of frictionless slides, telescoping tubular members or other suitable means. In addition, gas springs 70 , or functionally similar counter-balancing means, may be used to assist in the raising and lowering of the upper assembly relative to the lower assembly. Also, to facilitate the selective positioning of the upper assembly relative to the lower assembly, a suitable jack or screw mechanism, or the like, may be used to lift and lower the upper assembly to an intended height position relative to the lower assembly, and as illustrated, the pawl and ratchet mechanism, or the like, may be used to lock the assembly in place once it is adjusted.
[0063] As mentioned above and further illustrated below in FIGS. 16 and 17 , the upper structural framework is also adapted to support the radiologically protective, at least partially transparent dome or cap component 16 , preferably made of lead glass or clear lead plastic material, into which the user's head will extend. In the present embodiment, this component is pivotally attached to the frontal portion of the supporting upper framework and linked to the supporting frame with adjustable supports so that it can be tilted forward to accommodate the user's visual comfort. To counter balance the weight of the cap or dome, a suitable gas spring, or the like, may be used.
[0064] Advantageously, and as illustrated in FIGS. 12 and 13 , as well as in FIGS. 16 and 17 , an X-ray radiation impervious skirt comprised of multiple segments 64 of suitable material is hung from the lower perimeter of the dome or cap to block any radiation that might have a tendency to pass under the back portion of the dome or cap when it is in the tilted forward disposition. In the illustrations of FIGS. 12 and 13 , it will be noted that the upper edges of the radiation impervious material are suitably affixed to an interior dome edge ring 62 disposed inside the dome edge and in alignment with the dome edge circumscribing ring 41 . Note also that all of the material junctions, for example, at the hinged junctions of the rear drape supporting arms 38 to the ends of the C-shaped frame member 32 , as shown in FIGS. 19 and 20 , are also overlapped by other pieces of the drape material to insure that no scattered radiation is allowed to leak through. All of the drapes, skirt pieces, strips and shielding linings are preferably made of fabric-encased lead impregnated rubber material or the like.
[0065] In FIGS. 21-31 details of the underlying superstructure of an alternative embodiment of the present invention are illustrated at 100 . In this embodiment, a generally C-shaped horizontal base member 102 is combined with three centrally located (relative to the center part of the :“C”), parallel and vertically extending hollow column members 104 , 106 and 108 (see FIGS. 23 and 24 in particular) to provide a base frame assembly 111 . The hollow column members form slides, and a ratchet 110 is affixed to the rear side of the center column 106 .
[0066] A corresponding but truncated C-shaped upper horizontal member 112 is combined with three vertically extending parallel rods 114 , 116 and 118 that are respectively adapted to telescopically mate with the three column members 104 , 106 and 108 , and form a top frame assembly 120 that in addition includes a pair of rearwardly extending curved drape support bars 122 which are hingedly attached at 124 to the truncated arms 126 of the top horizontal member 112 . In addition, three vertical frame members 128 , 130 and 132 extend downwardly from member 112 in spaced apart parallel relationship to the rods 114 , 116 and 118 . A spring loaded pawl 140 is carried by the centermost vertical frame member 130 proximate its lower end to engage the ratchet 110 .
[0067] Lying above and hingedly attached at to the upper member 112 is a generally C-shaped partial upper enclosure structure 142 that is selectively secured in an upwardly rotated position relative to the horizontal plane of top frame member 112 by a slotted bracket 144 and thumb screw 146 .
[0068] Secured to the top of and rotatable therewith is a transparent cap 148 for receiving the head of a user. Not shown are a generally C-shaped upper drape open at the back and represented by the dashed lines 150 . This radilogically protective drape is suspended from the top rim 152 of the upper enclosure structure 142 . A second lower drape, open at the back and represented by the dashed lines 156 is suspended from the support arms 122 of the upper framework structure.
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A movable and radiologically protective enclosure for a physician or medical technician working in close proximity to a source of radiologic energy. The embodiments include a lower assembly for enclosing and radiologically shielding the lower torso and legs of the user, and for supporting an upper assembly designed to enclose and radiologically shield the upper torso and arms of the user. A transparent radiologically impervious dome or the like is carried by the upper assembly to receive and protect the head of the user as well as allow visual and functional access to patients and/or radiologic equipment Means are provided for allowing the upper assembly to be vertically adjusted in position and to angularly tilt the torso and/or head protecting components. Protective sleeves are also provided at frontal ports for allowing the user to protectedly reach into the work area.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/964,669, filed on Aug. 14, 2007, which is hereby incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to systems and methods for targeting advertisements to users based on data derived from social networking websites. More particularly, the present invention relates to using data endemic to social networking websites to more efficiently present advertisements and other content to users across the Internet.
BACKGROUND OF THE INVENTION
[0003] Social networking websites, such as MySpace, Friendster, Facebook, and Linkedin, have grown enormously over the past few years. It has been generally reported by industry analysts that as much as forty percent of a consumer's time on the Internet is spent surfing social networking webpages and/or webpages generally characterized by the core content having been created by other consumers rather than employees of the website being visited. A member of a social networking website establishes an account and creates relationships with other accounts, thereby connecting the members in a network. When a member connects with other members by proffering or accepting invitations to link their pages, those members are broadcasting their own social network. In addition to generating these links of association, members of these social network websites provide descriptive personal profiles that include their likes, their dislikes, demographic information, etc. These personal profiles and links to other members create a social network.
[0004] The traditional methods for targeting online advertisements generally presupposed that the consumer's visit to a given website(s) revealed his or her interest and therefore the kinds of advertisements that they should be shown. For example, visitors to “www.flyfishing.com” could be assumed to be interested in equipment, clothing and books known to be of interest to fishing enthusiasts. The first generation of Internet advertising companies spent an enormous amount of time and energy creating taxonomies that mapped individual web sites such as www.flyfishing.com with categories known to be of interest to advertisers such as travel, sports, education, etc. Many companies, such as Doubleclick Inc., placed “cookies” on the computers of consumers and used these cookies to target advertisements to consumers based on the interest(s) that had been evidenced by a consumers visits to a catalogued site.
[0005] For a time, this system provided a more efficient way to target consumers for advertisers. Especially in the early years of the Internet when consumers spent the vast majority of their time viewing content produced by the employees of major portals, such as Yahoo! or AOL (formerly America Online, Inc.), it was easy for the creators of advertising technology to state with confidence that a visitor to AOL's “small business” section was a current or would-be entrepreneur who would respond at high rates to advertisements for products, such as franchising opportunities and small business credit cards. However, as consumers began spending an ever increasing percentage of their time on the Internet at social networking websites (and other websites having user-generated content) that defy easy categorization, marketers are increasingly challenged to discern which advertisements can most profitably be shown to which consumers. Whereas in the past, online advertising companies could package consumers for sale to advertisers based on what websites (e.g., sports, travel, beauty, small business, etc.) those consumers visited. It has been currently reported that twenty percent of online consumer page views can be readily catalogued in this manner and that as much as eighty percent of all Internet page views occur on social networking, user generated content and other pages that defy ready characterization into an existing Internet advertising interest segment.
[0006] This problem in matching advertisements and consumers has become more acute as the exploding popularity of social networking sites has increased the number of advertisement impressions seen at these sites. It has been reported that social networking websites, such as MySpace, display over one billion advertisements per day. However, a majority of these displayed advertisements are often disregarded by consumers or members of the social networking websites. Even though these social networking websites possess an enormous amount of information on each member and present a number of advertisements per day, advertisers and social networking websites have done little to leverage this wealth of information.
[0007] Thus, it would be desirable to provide an advertisement application that leverages the rich, but unused data available from social networking webpages.
SUMMARY OF THE INVENTION
[0008] In accordance with the present invention, systems and methods for facilitating the transmission of advertisements to users are provided.
[0009] Generally speaking, the application uses data endemic to social networking websites (e.g., relationship information and visitation information) to provide advertisements and other suitable content to the user of a social network website and the members of the user's micronetwork or micro-affinity group.
[0010] It should be noted that the application uses relationship information, visitation information, and/or any other suitable information to create micronetworks or micro-affinity groups. Advertisements and/or other suitable content are provided to these micronetworks or micro-affinity groups. The application does not group the user and some members of the micronetwork based on common attributes (e.g., members in the same zip code, members having the same age, etc.).
[0011] It should also be noted that the application generally does not analyze user profiles on social networking websites or obtain attribute data on a particular user or users in order to provide advertisements or media content to that particular user. This may, for example, protect the privacy of users. More particularly, the application generally does not associate data obtained from a user of a social networking website with that particular user. For example, in response to a user selecting an advertisement on the social networking website relating to hybrid automobiles, the application may determine whether to transmit that advertisement (or similar advertisements) to one or more of the members within the user's micronetwork or micro-affinity group. In another example, in response to a user visiting a website relating to hybrid automobiles, the application may determine whether to transmit that advertisement (or similar advertisements) to one or more members of the social networking website that the user has visited. In yet another example, in response to a user visiting a website relating to hybrid automobiles, the application may associate advertisements relating to hybrid automobiles with the micronetwork or micronetworks of which the user is a member. In yet another example, application does not store information (e.g., name, email address, etc.) such that it can be linked to an individual user.
[0012] Even further, in response to a member visiting the social networking page associated with the user, the application associates the member with the user's micronetwork or micro-affinity group. The associations between the user and one or more micronetworks or micro-affinity groups are not transparent to the user. For example, in order to protect the privacy of users, the application generally does not reveal to the user, members of the user's micronetworks or micro-affinity groups, and/or members of the social networking website the different micronetworks associated with each of them. In another example, by creating micronetworks or micro-affinity groups, the application does not collect any private information relating to the user or the members of the social networking website. The application creates micronetworks and provides media (e.g., advertisements, content, etc.) to members of those micronetworks.
[0013] In some embodiments, the interactive advertisement application presents a user at a user computer with a publicly accessible website that includes user-generated social networking content over the Internet. The user is authorized to access features and receive the user-generated social networking content associated with the publicly accessible website upon inputting user information. In response to receiving user information from the user, the application displays a webpage associated with the user.
[0014] At least one advertisement is displayed on the webpage, where the at least one advertisement embeds an object (e.g., a cookie, a web bug, etc.) in the user computer. The object is used to obtain a unique identifier associated with the user. The object is also used to construct a micronetwork of the members associated with the user, where the object obtains the unique identifier from each member that visits the webpage and the unique identifier from each member that establishes a relationship with the user. In addition, the object monitors information relating to the user (e.g., actions executed by the user). Based on the information monitored by the object, the application retargets advertisements for transmission to the user and the micronetwork associated with the user.
[0015] The application transmits at least one retargeted advertisement to the user and the micronetwork associated with the user, where the at least one retargeted advertisement is transmitted using the unique identifier associated with the user and the unique identifier associated with each member of the micronetwork.
[0016] Thus, there has been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
[0017] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0018] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0019] These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and description matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Various objects, features, and advantages of the present invention can be more fully appreciated with reference to the following detailed description of the invention when considered in connection with the following drawing, in which like reference numerals identify like elements.
[0021] FIG. 1 is a simplified flowchart illustrating the transmission of advertisements to the user and one or more members of the social networking website using an embedded object in accordance with some embodiments of the present invention.
[0022] FIG. 2 is an illustrative diagram showing micronetworks or micro-affinity groups that may be generated in accordance with some embodiments of the present invention.
[0023] FIG. 3 is a simplified flowchart illustrating the transmission of advertisements to the user and one or more members of the social networking website based on a monitored response rate in accordance with some embodiments of the present invention.
[0024] FIG. 4 is a schematic diagram of an illustrative system on which an interactive advertising application may be implemented in accordance with some embodiments of the present invention.
[0025] FIG. 5 is a schematic diagram of an illustrative user computer and server as provided, for example, in FIG. 4 in accordance with some embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] In accordance with the present invention, an interactive advertising application (sometimes referred to herein as “the application”) is provided. The application uses data (e.g., relationship data, visitation data, e-commerce activity data, etc.) from social network websites or other sources of user-generated content to target advertisements (e.g., a static advertisement, a rotating advertisement, a video advertisement, an audio advertisement, etc.) or any other suitable media content to users.
[0027] Generally speaking, the application uses relationship information and visitation information to provide advertisements to the user of a social network website and the members of the user's micronetwork or micro-affinity group. It should be noted that, in some embodiments, the advertisements may be provided to the user of the social networking website and a particular degree of the user's micronetwork (e.g., the first degree micronetwork, the second degree micronetwork, etc.).
[0028] As used herein, a “micronetwork” (sometimes referred to herein as a “micro-affinity group”) generally includes a subset of users who, through their behavior as evidenced on social networking websites, are more likely to share interests and consumer preferences. For example, a micronetwork may include members with a user's social network that share a particular interest. In another example, a micronetwork may include users that have visited the user's page on the social networking website.
[0029] It should be noted that the application uses relationship information, visitation information, and/or any other suitable information to create micronetworks or micro-affinity groups. Advertisements and/or other suitable content are provided to these micronetworks or micro-affinity groups. The application does not group the user and some members of the micronetwork based on common attributes (e.g., members in the same zip code, members having the same age, etc.).
[0030] It should also be noted that the application generally does not analyze user profiles on social networking websites or obtain attribute data on a particular user or users in order to provide advertisements or media content to that particular user. This may, for example, protect the privacy of users. More particularly, the application generally does not associate data obtained from a user of a social networking website with that particular user. For example, in response to a user selecting an advertisement on the social networking website relating to hybrid automobiles, the application may determine whether to transmit that advertisement (or similar advertisements) to one or more of the members within the user's micronetwork or micro-affinity group. In another example, in response to a user visiting a website relating to hybrid automobiles, the application may determine whether to transmit that advertisement (or similar advertisements) to one or more members of the social networking website that the user has visited. In yet another example, in response to a user visiting a website relating to hybrid automobiles, the application may associate advertisements relating to hybrid automobiles with the micronetwork or micronetworks of which the user is a member. In yet another example, application does not store information (e.g., name, email address, etc.) such that it can be linked to an individual user.
[0031] Even further, in response to a member visiting the social networking page associated with the user, the application associates the member with the user's micronetwork or micro-affinity group. The associations between the user and one or more micronetworks or micro-affinity groups are not transparent to the user. For example, in order to protect the privacy of users, the application generally does not reveal to the user, members of the user's micronetworks or micro-affinity groups, and/or members of the social networking website the different micronetworks associated with each of them. In another example, by creating micronetworks or micro-affinity groups, the application does not collect any private information relating to the user or the members of the social networking website. The application creates micronetworks and provides media (e.g., advertisements, content, etc.) to members of those micronetworks.
[0032] In some embodiments, the application may use data, such as relationship and visitation data, which includes information from other users within the user's social network, to create a micronetwork or micro-affinity group of members. The micronetwork may be, for example, based on the visitation data of a user's page on a social networking website (e.g., the members that visit the user's page, the number of times a member visits the user's page, the number of times a member selects an advertisements while visiting the user's page, the period of time or frequency that a member is visited, etc.), the visitation data in relation to whom a user visits (e.g., the member's page that the user visits, the number of times the user visits another member's page), etc. In another example, the micronetwork may be based on relationship data of a user's page on a social networking website.
[0033] In accordance with the present invention, a user of a social networking website, such as MySpace, Friendster, or Facebook, is presented with an advertisement while accessing the pages of the social networking website. The advertisement allows a cookie (sometimes referred to as a “web bug” or “pixel tag”) to be embedded in the user's computer. The cookie monitors and records the user's actions—e.g., visits to other member's social networking webpages, visits to other websites, visits to the user's social networking webpage by other members (using a friendID or other identifier embedded in the URL), etc. Based on this monitored information from the cookie, the application creates a micronetwork of members.
[0034] The user's first degree micronetwork may include, for example, the members that visit the user's page and the members that the user visits. Similarly, the user's second degree micronetwork may include the members of the first degree micronetwork associated with each member of the user's first degree micronetwork. For example, if user_zero visits ten members of the social networking website with a high degree of frequency and those ten members each visit ten other members frequently, user_zero's first degree micronetwork includes the ten members frequently visited by user_zero and user_zero's second degree micronetwork includes one hundred members or each member's first degree micronetwork of the user_zero's first degree micronetwork.
[0035] As used herein, the application may use cookies or web bugs that are embedded in a web page to monitor the activity of the user at a social networking website or on other websites. For example, the application may generate cookies when a web browser operating on the user's computer views an advertisement on a social networking website. In some embodiments, a cookie may be one or more text files that contain a string of alphanumeric characters. In some embodiments, cookies may be pieces of data that are unable to perform any operation by themselves. Alternatively, each cookie may be a graphic (e.g., a 1×1 pixel GIF image, a web beacon, a tracking bug, a pixel tag, a clear gif, etc.) on a webpage that is designed to monitor who is reading the webpage and the user's activity on the webpage.
[0036] It should be noted that the cookie or web bug is generally transparent to the user. When a web browser is used by the user to view the social networking website, the web browser transmits a request to a server to deliver or download content from one or more servers. The request generally includes, for example, the IP address of the user's computer, the time the content was requested, the type of web browser that made the request (e.g., Microsoft Internet Explorer, Netscape Navigator, Mozilla Firefox, etc.), and the existence of cookies previously set by the server. The server may store this information and associate it with a unique identifier.
[0037] Alternatively, micronetworks may also be created by placing tracking beacons in high volumes of advertisements flows. These tracking beacons record content into a database, such as the URLs of the content pages that the user views. Using neural networks or other approaches for analyzing the data stored in the database, the user may be assigned to a particular micronetwork. In yet another embodiment, micronetworks may be created by using traffic logs maintained by large user-generated content websites. These traffic logs may be used to clusters users into micronetworks.
[0038] It should be noted that, in some embodiments, third party advertisement servers may access visitation data captured by these cookies or web bugs. For example, when browsing a website, the browser sends a request to a web server that includes the IP address of the user's computer, the time the content was requested, the type of web browser that made the request, and the existence of cookies previously set by the server. The server may store this information and associate it with a unique identifier. The information collected using the cookie may be transmitted to a third party advertisement server. In some embodiments, the cookie may be associated with a particular third party advertisement server. For example, the server may place multiple cookies on a user's computer, where each cookie corresponds to a particular third party advertisement server. The collected data is transmitted to each third party advertisement server.
[0039] In addition to creating a micronetwork, the application uses the cookie to monitor the websites and web pages visited by the user outside of or external to the social networking website. For example, in response to the user visiting a particular website, such as Orbitz.com, the cookie communicates to the application that the user is visiting a travel website. In response, the cookie may inform the application that the user has visited a travel website and the application may provide the user and members in the user's micronetwork with travel-related advertisements. Alternatively, the cookie may transmit such information to an advertisement server. The advertisement server may then transmit a travel-related advertisement that is provided to the first degree micronetwork and second degree micronetwork on the social networking website. Again, the second degree micronetwork or second degree orbit may include the members of the first degree micronetwork associated with each member of the user's first degree micronetwork. For example, person 0 's micronetwork has seven people (persons 1 through 7 ) and each person has seven members in their associated micronetwork. Then, the second degree micronetwork or orbit has forty-nine additional members (persons 8 through 56 ).
[0040] These advertisements may be served to the micronetworks until a given response rate is no longer attained.
[0041] Again, it should be noted that the application uses relationship data, visitation data, and/or other suitable data to create micronetworks. The application does not group the user and members of the social networking website based on common attributes (e.g., members in the same zip code, members having the same age, etc.). The application does not analyze user profiles on social networking websites or obtain attribute data on a particular user or users in order to provide advertisements or media content to that particular user. This may, for example, protect the privacy of users. Accordingly, the application generally does not associate private data obtained from a user of a social networking website with that particular user.
[0042] As the application does not collect private information relating to the user or the members of the social networking website, the application does not communicate private information (e.g., information acquired by monitoring the user or particular social networking members) to the user or members in the micronetwork associated with the user. The application does not serve or provide advertisements to each member based on individual needs. For example, the application does not provide fly fishing advertisements in response to the embedded web bug monitoring that the user has accessed a fly fishing website. Instead, the application determines that one or more members in the micronetwork have accessed a website relating to Caribbean cruises and transmits a targeted advertisement to at least a portion of the micronetwork.
[0043] In response to a member visiting the social networking page associated with the user, the application associates the member with the user's micronetwork or micro-affinity group. The associations between the user and one or more micronetworks or micro-affinity groups are not transparent to the user. For example, in order to protect the privacy of users, the application generally does not reveal to the user, members of the user's micronetworks or micro-affinity groups, and/or members of the social networking website the different micronetworks associated with each of them. In another example, by creating micronetworks or micro-affinity groups, the application does not collect any private information relating to the user or the members of the social networking website. The application creates micronetworks and provides media (e.g., advertisements, content, etc.) to members of those micronetworks.
[0044] It should also be noted that, as these advertisements are served to particular micronetworks, additional web bugs and new web bugs are placed and new relationship and visitation data is received, which is continually used by the application to update the micronetworks and the advertisements that are served to the micronetworks.
[0045] It should also be noted that, in some embodiments, the application may extract URL links to other member pages listed as friends from the user's page on the social networking website. For example, the application may extract and store URL links to other pages (containing their associated user profiles and user information).
[0046] The following figures and their accompanying descriptions provide detailed examples of the implementation of the systems and methods of the present invention.
[0047] As shown in FIG. 1 , the application may receive an indication that the user has logged into a social networking website (e.g., myspace.com, facebook.com, etc.) (step 10 ). For example, the application may receive a notification from the server running the social networking website that the user has logged into the social networking website. In another example, the application may receive a request from the server running the social networking website that the user has logged into the social networking website and requests that one or more advertisements be transmitted to the server for providing to the user. In response, the application may provide the server of the social networking website or may directly provide the web browser of the user with one or more advertisements (e.g., targeted advertisements from a particular advertisement group) (step 120 ).
[0048] The application may obtain an identifier associated with the user of the social networking website (step 130 ). For example, in response to receiving a request from the server running the social networking website for advertisements, the application may obtain a unique identifier from the request or from the web browser of the user. The unique identifier may be embedded in the URL of the page. For example, the application obtains friend identifier “111111” from the URL http://friends.myspace.com/index.cfm?fuseaction=user.viewfriends&friendID=111111. In another example, the friend identifier “111111” may be retrieved from the request sent by the web browser of the user.
[0049] Along with the one or more advertisements for the user, the application may transmit an object, such as a web bug or a cookie, to the web browser of the user of the social networking website (step 140 ). The object may, for example, monitor the interactions of the user with other members of the social networking website (e.g., the friends or other members that the user has an established relationship, the members that visit the user's page on the social networking website, the members that the user frequently visits, etc.). For example, the object may record the members' pages that the user frequently accesses and the members that frequently access the user's page. The object may be associated with the friend identifier, where the friend identifier acts as a unique tracking token. The server may also store any information obtained on the user (e.g., the members of the social networking websites that the user interacts with, the pages visited, the pages of other websites visited by the user, the unique identifiers associated with the members of the social networking website that the user interacts with, etc.) to create and dynamically update the user's micronetworks.
[0050] As shown in FIG. 2 , the object and the friend identifier may be used to determine the user's micronetworks. For example, a micronetwork may include members with a user's social network that share a particular interest (e.g., a “foreign travel” micronetwork 250 and a “foreign films” micronetwork 260 for user “Amanda” 210 ). Each user in the “foreign travel” micronetwork may have visited the “foreign travel” page or links on the webpage of user “Amanda.” In another example, a micronetwork may include users that have visited the user's page on the social networking website. In yet another example, the micronetwork may be, for example, based on the visitation data of a user's page on a social networking website (e.g., the members that visit the user's page, the number of times a member visits the user's page, the number of times a member selects an advertisements while visiting the user's page, the period of time or frequency that a member is visited, etc.), the visitation data in relation to whom a user visits (e.g., the member's page that the user visits, the number of times the user visits another member's page), etc. In another example, the micronetwork may be based on relationship data of a user's page on a social networking website.
[0051] In some embodiments, the object may also monitor the user's activity across multiple websites. For example, the object may record page requests from the user (e.g., jetblue.com, flyfishing.com, etc.). In another example, the object may record the amount of time the user spends on a website (e.g., 2 minutes on friendster.com, 15 minutes on cnn.com, etc.).
[0052] Referring back to FIG. 1 , the application may use the collected data from the embedded object to provide the user of the social networking website and the user's micronetwork with targeted advertisements (step 150 ). For example, in response to the embedded object indicating that the user of the social networking website has frequently visited three members, the application may provide the user and those three members (the user's micronetwork) with the same set of advertisements. The set of advertisements may be targeted to relate to subject matter of one of the websites that the user has visited according to the embedded object.
[0053] As described previously, it should be noted that the application does not communicate private information (e.g., information acquired by monitoring the user or the user's micronetwork) to the user or members in the micronetwork associated with the user. The application does not serve or provide advertisements to each member based on individual needs. Rather, the application determines that one or more members in the micronetwork have accessed a website relating to Caribbean cruises and transmits one or more targeted advertisement to the user and at least a portion of the micronetwork associated with the user.
[0054] Alternatively, the application may transmit the collected data from the embedded object to one or more third party advertisement servers. Each third party advertisement server may provide the user of the social networking website and the user's micronetwork with targeted advertisements. In some embodiments, the application may analyze the collected data from the embedded object and request that the third party advertisement server transmit particular targeted advertisements. In other embodiments, the application may transmit the collected data for analysis by the third party advertisement server.
[0055] In some embodiments, the application may retarget the one or more advertisements that are transmitted to the user and the recently interacted members. For example, the set of advertisements may be automatically updated to relate to the subject matter of one or more websites that the user has recently visited.
[0056] In some embodiments, the application may monitor the behavior of the user and the members within the user's social network to gauge the effectiveness of the selected advertisements.
[0057] The application may provide the user of the social network and one or more of the micronetwork corresponding to the user with one or more advertisements. As described in FIG. 1 , the application may provide the user and members of the user's micronetwork with a set of advertisements. In another example, the application may provide the user and the user's first degree micronetwork and second degree micronetwork with a set of advertisements.
[0058] In another example, using the embedded object, the embedded object may monitor the interactions of the user of the social networking website with one or more websites (e.g., flyfishing.com). In response, the application may determine that the user is interested in particular topics, such as fishing, fly fishing, fishing trips, fishing equipment, etc. The application may send advertisements relating to one or more of the topics to the user and one or more members of the user's micronetwork.
[0059] The application may monitor the interactions of the user and the member within the user's micronetwork with the selected advertisements (step 310 ). Based on monitoring the interactions, the application may determine the number of members interacting with each of the advertisements. In some embodiments, each advertisements may have specific requirements attached to the advertisement (e.g., advertisement A is shown until less than 25% of members click on the advertisement, advertisement B is shown until less than 10% of members scroll over the advertisement, etc.). Advertisements that are not selected are less likely to be selected for display to the user and the members within the user's social network, while advertisements that have a high click through rate are more likely to be selected for display.
[0060] The application may continue to provide the user and one or more members of the user's micronetwork with the selected advertisements until the monitored response rate is less than a predetermined response rate (step 320 ). For example, the application may continue to provide the advertisements to the micronetwork until a particular lift over average is no longer achieved.
[0061] In some embodiments, the application may use feedback information from the user of the social network website and the members of the micronetwork to determine the advertisements to deliver to the user's micronetwork. For example, the application may provide the user with ten advertisements while the user accesses different webpages on the social networking website. The application monitors the user's interactions with the advertisements (e.g., plays with a gaming application associated with the advertisement, clicks on the advertisement, scrolls over the advertisement, watches the media content associated with the advertisement, etc.). Based on monitoring the user's interactions with the advertisements, the application may provide one or more of the same advertisements to the user's first degree micronetwork and/or second degree micronetwork. For example, the application determines that the user clicks on an advertisement directed to fly fishing. In response to the user selecting that advertisement, the same advertisement directed to fly fishing may be provided to the user's first degree micronetwork. Alternatively, multiple advertisements directed to fly fishing may be provided to the user and the user's first degree micronetwork.
[0062] In some embodiments, the application may use feedback information from the user of the social network website to determine the advertisements to deliver to the user as the user uses the Internet. The embedded object (e.g., a cookie) along with the visitation data allows the application to provide relevant advertisements through the websites the user visits based on the actions of the user or the user's micronetwork while using the Internet. The application monitors the user's interactions with the advertisements (e.g., plays with a gaming application associated with the advertisement, clicks on the advertisement, scrolls over the advertisement, watches the media content associated with the advertisement, etc.). Based on monitoring the user's interactions with the advertisements, the application may provide one or more of the same advertisements to the user's first degree micronetwork and/or second degree micronetwork while those users are accessing websites on the Internet. For example, the application determines that the user clicks on an advertisement directed to fly fishing. In response to the user selecting that advertisement, the same advertisement directed to fly fishing may be provided to the user's first degree micronetwork while the members of that first degree micronetwork are accessing one or more websites (e.g., Google.com, NYTimes.com, etc.) on the Internet.
[0063] Alternatively, the application may monitor advertisements on one or more websites, receive information from one or more third party advertisement networks or advertisement servers, and/or receive information from one or more web servers. For example, when the user visits the webpage of a merchant (e.g., Orvis), the webpage may include pixel tags from third party advertisement networks (e.g., advertisement servers that are affiliated with the webpage). These pixel tags or other embedded objects record that the user's computer has visited the merchant's webpage and provide other information to the advertisement server (e.g., the particular page accessed by the user, the amount of time spent on a particular page, information on the user's computer, information from the user's web browser, etc.). Using the information from the advertisement server, the application may provide or instruct the advertisement server to provide the user and the members within the user's micronetwork with advertisements on other webpages to bring the user and the members back to the merchant's website. Alternatively, the application may use the information from the advertisement server to provide the user and the members within the user's micronetwork with advertisements relating to the subject matter of the merchant's website.
[0064] In some embodiments, the application may monitor the behavior of the user and the members within the user's social network to gauge the effectiveness of the selected advertisements. For example, the application may continue to provide the user and the user's micronetwork with the selected advertisements until a particular lift over average is no longer achieved. The application may monitor the interactions of the user and the member within the user's micronetwork with the selected advertisements. Based on monitoring the interactions, the application may determine the number of members interacting with each of the advertisements. In some embodiments, each advertisements may have specific requirements attached to the advertisement (e.g., advertisement A is shown until less than 25% of members click on the advertisement, advertisement B is shown until less than 10% of members scroll over the advertisement, etc.). Advertisements that are not selected are less likely to be selected for display to the user and the members within the user's micronetwork, while advertisements that have a high click through rate are more likely to be selected for display.
[0065] Alternatively, the application may continue to provide the user with the selected advertisements until a predetermined time has elapsed.
[0066] It should be noted that each user has a micronetwork and the micronetwork may continually change. As a user changes (e.g., different interests, new interests, different members, new friends, etc.), the application may accommodate to the changes by rotating or adjusting the micronetwork associated with the user.
[0067] FIG. 4 is a generalized schematic diagram of a system 400 on which an interactive advertisement application may be implemented in accordance with some embodiments of the present invention. As illustrated, system 400 may include one or more user computers 402 . User computers 402 may be local to each other or remote from each other. User computers 402 are connected by one or more communications links 404 to a communications network 406 that is linked via a communications link 408 to a server 410 .
[0068] System 400 may include one or more servers 410 . Server 410 may be any suitable server for providing access to the application, such as a processor, a computer, a data processing device, or a combination of such devices. Communications network 406 may be any suitable computer network including the Internet, an intranet, a wide-area network (“WAN”), a local-area network (“LAN”), a wireless network, a digital subscriber line (“DSL”) network, a frame relay network, an asynchronous transfer mode (“ATM”) network, a virtual private network (“VPN”), or any combination of any of such networks. Communications links 404 and 408 may be any communications links suitable for communicating data between user computers 402 and server 410 , such as network links, dial-up links, wireless links, hard-wired links, any other suitable communications links, or a combination of such links. User computers 402 enable a user to access features of the application. User computers 402 may be personal computers, laptop computers, mainframe computers, dumb terminals, data displays, Internet browsers, personal digital assistants (“PDAs”), two-way pagers, wireless terminals, portable telephones, any other suitable access device, or any combination of such devices. User computers 402 and server 410 may be located at any suitable location. In one embodiment, user computers 402 and server 410 may be located within an organization. Alternatively, user computers 402 and server 410 may be distributed between multiple organizations.
[0069] The server and one of the user computers, which are depicted in FIG. 4 , are illustrated in more detail in FIG. 5 . Referring to FIG. 5 , user computer 402 may include processor 502 , display 504 , input device 506 , and memory 508 , which may be interconnected. In a preferred embodiment, memory 508 contains a storage device for storing a computer program for controlling processor 502 .
[0070] Processor 502 uses the computer program to present on display 504 the application and the data received through communications link 404 and commands and values transmitted by a user of user computer 402 . It should also be noted that data received through communications link 404 or any other communications links may be received from any suitable source, such as a social networking website (e.g., www.myspace.com) or any other suitable source. Input device 506 may be a computer keyboard, a cursor-controller, dial, switchbank, lever, or any other suitable input device as would be used by a designer of input systems or process control systems.
[0071] Server 410 may include processor 520 , display 522 , input device 524 , and memory 526 , which may be interconnected. In a preferred embodiment, memory 526 contains a storage device for storing data received through communications link 408 or through other links, and also receives commands and values transmitted by one or more users. The storage device further contains a server program for controlling processor 520 .
[0072] In some embodiments, the application may include an application program interface (not shown), or alternatively, the application may be resident in the memory of user computer 402 or server 410 . In another suitable embodiment, the only distribution to user computer 402 may be a graphical user interface (“GUI”) which allows a user to interact with the application resident at, for example, server 410 .
[0073] In one particular embodiment, the application may include client-side software, hardware, or both. For example, the application may encompass one or more Web-pages or Web-page portions (e.g., via any suitable encoding, such as HyperText Markup Language (“HTML”), Dynamic HyperText Markup Language (“DHTML”), Extensible Markup Language (“XML”), JavaServer Pages (“JSP”), Active Server Pages (“ASP”), Cold Fusion, or any other suitable approaches).
[0074] In one particular embodiment, the application may be integrated with a social networking website. For example, the application may display advertisements on the social networking website when the user browses through various pages of the website (e.g., the myspace.com website). In response to the user viewing various pages on the website, the application may select another advertisement to be displayed on a portion of each page of the website.
[0075] It should be noted that the application may use cookies to match the user profiles to the author's computer. As advertisements are served on the pages of a social networking website, it may be initially unclear whether the person viewing a profile is the author of a page or a visitor. By using profile page visit frequency and session identifiers, the application stores this information in cookies. Within these cookies, the application sets the best current estimate of the user's unique identifier.
[0076] In some embodiments, at the time of an advertisement request, a packet of data is transmitted to the advertisement server (e.g., a server connected to the social networking website, a server controlled by the advertiser, a server controlled by the application, etc.). The packet may include, for example, cookie information containing the unique identifier. The unique identifier may be looked up in the database and a targeted advertisement may be selected and provided to the user of the social networking website.
[0077] Although the application is described herein as being implemented on a user computer and/or server, this is only illustrative. The application may be implemented on any suitable platform (e.g., a personal computer (“PC”), a mainframe computer, a dumb terminal, a data display, a two-way pager, a wireless terminal, a portable telephone, a portable computer, a palmtop computer, an H/PC, an automobile PC, a laptop computer, a cellular phone, a personal digital assistant (“PDA”), a combined cellular phone and PDA, etc.) to provide such features.
[0078] It will also be understood that the detailed description herein may be presented in terms of program procedures executed on a computer or network of computers. These procedural descriptions and representations are the means used by those skilled in the art to most effectively convey the substance of their work to others skilled in the art.
[0079] A procedure is here, and generally, conceived to be a self-consistent sequence of steps leading to a desired result. These steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared and otherwise manipulated. It proves convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. It should be noted, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities.
[0080] Further, the manipulations performed are often referred to in terms, such as adding or comparing, which are commonly associated with mental operations performed by a human operator. No such capability of a human operator is necessary, or desirable in most cases, in any of the operations described herein which form part of the present invention; the operations are machine operations. Useful machines for performing the operation of the present invention include general purpose digital computers or similar devices.
[0081] The present invention also relates to apparatus for performing these operations. This apparatus may be specially constructed for the required purpose or it may comprise a general purpose computer as selectively activated or reconfigured by a computer program stored in the computer. The procedures presented herein are not inherently related to a particular computer or other apparatus. Various general purpose machines may be used with programs written in accordance with the teachings herein, or it may prove more convenient to construct more specialized apparatus to perform the required method steps. The required structure for a variety of these machines will appear from the description given.
[0082] The system according to the invention may include a general purpose computer, or a specially programmed special purpose computer. The user may interact with the system via e.g., a personal computer or over PDA, e.g., the Internet, an Intranet, etc. Either of these may be implemented as a distributed computer system rather than a single computer. Similarly, the communications link may be a dedicated link, a modem over a POTS line, the Internet and/or any other method of communicating between computers and/or users. Moreover, the processing could be controlled by a software program on one or more computer systems or processors, or could even be partially or wholly implemented in hardware.
[0083] Although a single computer may be used, the system according to one or more embodiments of the invention is optionally suitably equipped with a multitude or combination of processors or storage devices. For example, the computer may be replaced by, or combined with, any suitable processing system operative in accordance with the concepts of embodiments of the present invention, including sophisticated calculators, hand held, laptop/notebook, mini, mainframe and super computers, as well as processing system network combinations of the same. Further, portions of the system may be provided in any appropriate electronic format, including, for example, provided over a communication line as electronic signals, provided on CD and/or DVD, provided on optical disk memory, etc.
[0084] Any presently available or future developed computer software language and/or hardware components can be employed in such embodiments of the present invention. For example, at least some of the functionality mentioned above could be implemented using Visual Basic, C, C++ or any assembly language appropriate in view of the processor being used. It could also be written in an object oriented and/or interpretive environment such as Java and transported to multiple destinations to various users.
[0085] Accordingly, an interactive advertisement application is provided.
[0086] It is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0087] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0088] Although the present invention has been described and illustrated in the foregoing exemplary embodiments, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the details of implementation of the invention may be made without departing from the spirit and scope of the invention.
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Systems and methods for targeting online advertisements using data derived from social networks are provided. In accordance with some embodiments, the method comprises: presenting a user at a user computer with a publicly accessible website that includes user-generated social networking content over the Internet, wherein the user is authorized to access features and the user-generated social networking content associated with the publicly accessible website upon inputting user information; in response to receiving user information from the user, displaying a webpage associated with the user; displaying at least one advertisement on the webpage, wherein the at least one advertisement embeds an object in the user computer and wherein the object is used to obtain a unique identifier associated with the user; using the object to construct a micronetwork of the members associated with the user, wherein the object obtains the unique identifier from each member that visits the webpage and the unique identifier from each member that establishes a relationship with the user; using the object to monitor information relating to the user, wherein the information includes actions executed by the user; retargeting advertisements for transmission to the user and the micronetwork based on information monitored by the object; and transmitting at least one retargeted advertisement to the user and the micronetwork associated with the user, wherein the at least one retargeted advertisement is transmitted using the unique identifier associated with the user and the unique identifier associated with each member of the micronetwork.
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FIELD OF THE INVENTION
[0001] The present inventive method relates to a pharmaceutical sedation formulation for quickly and safely rendering a subject intoxicated, incapacitated, and/or immobilized within a short period after administration. The formulation also allows for the safe approach and subduing of a subject within a short period of time after dosing, and continues to render the subject safe for handling and/or transport for hours, without harm to or death of the subject. The formulation may include at least one cannabinoid from or derived from plants of the Cannabaceae sensu stricto family, and more specifically plants of the C. Cannabis L. genera.
[0002] In the beginning God made heaven and earth . . . . Then God said, “Behold, I have given you every seed-bearing herb that sows seed on the face of all the earth, and every tree whose fruit yields seed; to you it shall be for food. I also give every green plant as food for all the wild animals of the earth, for all the birds of heaven, and for everything that creeps on the earth in which is the breath of life.” It was so. Then God saw everything He had made, and indeed, it was very good. So evening and morning were the sixth day. Book of Genesis, Chap 1:1, 29-31 , The Orthodox Study Bible: Ancient Christianity Speaks to Today's World , Thomas Nelson Publishing, 2008, USA.
[0003] “ . . . the greatest service which can be rendered to any country is to add a useful plant to its culture; especially a bread grain, next in value to bread, is oil.”, Thomas Jefferson, 3rd President of the United States of America, Memorandum of Services to My Country , 1800, USA.
[0004] “Damn it Charles, no damn good will ever come of this cannabis crap! Plus, it's illegal!” Excited utterance of Frank G. Ankner, father and grandfather of instant co-inventors, 1978, Lake Worth, Fla. USA.
[0005] Since antiquity, the Cannabaceae sensu stricto (“s.s.”) family of plants have had a wide variety of innovative uses, with some varieties being used for and as food, spice, and ceremonial purposes as early as 8000 B.C.E. Modern uses of the Cannabaceae s.s. family include; varieties being cultivated for plant fiber used in almost innumerable products, varieties being cultivated containing flavonoid and aromatic substances used in the production of beer and in fragrances, varieties being cultivated for human and animal consumption, varieties being cultivated for oil as illumination and lubrication, and being cultivated for oil as bio-fuel replacements for fossil-fuel, and varieties cultivated which contain powerful antimicrobial substances used as sanitizers, antibiotics, and being researched as anti-cancer agents.
[0006] Many cultural anthropologists and ethnobotanists hold that C. cannabis L. varieties are among the first plants cultivated by humanity. Modernly, C. cannabis L. varieties are cultivated and utilized extensively and world-wide. Stems, branches, and leaves are used for plant fiber and as biofuel; sprouts and seeds as food-stocks; seeds for inexpensive lubrication and illumination oil, and also as biofuel; flowers for aromatic, recreational, ritual, sacramental, and medicinal purposes; and flowers and roots for medicinal and pharmaceutical formulations.
[0007] Recently, substances in some C. cannabis L. varieties have been used to effectively eradicate both MRSA and ORSA bacterium (Methicillin-Resistant Staphylococcus aureus and Oxacillin-Resistant Staphylococcus aureus ), occurring both in and ex vivo. MRSA and ORSA are both extremely virulent, antibiotic resistant strains of bacterium which sicken millions and cause hundreds of thousands of deaths per-year world-wide; particularly in industrialized nations. Research continues into using C. cannabis L. variety substances as and in sanitizers and antibiotics which kill pathogens like MRSA and ORSA, and other drug resistant pathogens.
[0008] It is well known in the fields of non-lethal and less-than-lethal weapons that humanely rendering a subject (either human or animal) “compliant to commands”, “safe to approach and subdue”, and/or to render a subject unconscious or unresponsive within a short period of time—would save lives in many critical and life-threatening situations. Further, if a subject remains incapacitated or immobilized for a long period of time, minutes to hours, taking the subject into lawful custody or containment would be safer for both the subduer as well as the subdued. Providing an effective, instantaneous or near-instantaneous, non-lethal or less-than-lethal, option or method for subduing an already intoxicated, psychotic, extremely agitated, violent or nonviolent recipient or offender would a true God-send. Both goals of military a civilian law enforcement personal is keeping the peace and saving lives. Both goals may be better accomplished via the instant inventive cannabinoid formulation and associated delivery means.
[0009] Known non-lethal or less-than-lethal weapons and techniques include but are not limited to: so-called “Taser” guns, rubber, wax, or plastic bullets, “bean-bag” bullets, airfoil projectiles, tear-gas, mace, pepper-spray, and the like, or other psychochemical warfare agent or method. Although never developed into an effective weapons system, psychochemical warfare theory and research, along with overlapping mind control drug research, was secretly pursued in the mid-20th century by the U.S. Military and Central Intelligence Agency in the context of the Cold War. These research programs were ended when they came to light and generated controversy in the 1970s. The degree to which the Soviet Union developed or deployed similar agents during the same period remains largely unknown. This course of human events during that time hindered cannabis, cannabis -derived, or synthetic-cannabinoids from being developed into safe and effective non-lethal sedatives and non-lethal psychochemical weapons. In the 1970s, with the U.S. categorizing cannabis as a Schedule 1 Controlled Substance, touting cannabis as an effective and safe sedation or psychochemical warfare agent would have been prohibitive to then public policy and law. Possibly, executive governmental agencies, legislatures, law enforcement, and civilian defenders, and medical science are now amenable to just such an effective method to counter the ever changing and ever present threats to life and limb in today's world in a humane and non-lethal manner.
[0010] In the fields of veterinary science, zoology, zoo keeping, animal control, and in many related fields of endeavor, so-called “tranquilizing” apparatus, formulations, and methods are well known.
[0011] Advantageously, a humane cannabinoid formulation may be used as and for quickly and safely sedating a subject within a short period of time, thus making subduing, and if required, containing the subject safer for all involved.
[0012] Additionally, and depending upon the cannabinoid formulation, a human or animal may be quickly incapacitated or immobilized at a distance. The purpose of or for incapacitating or immobilizing a human or animal may be many and varied. It is contemplated that the fields of medicine, veterinary medicine and science, military combat, law enforcement, corrections, emergency response, mass casualty response, and similar fields of endeavor may benefit from cannabinoid formulations, or a cannabinoid being added to or administered with known sedative formulations for medical, scientific, and industrial purposes. Other cannabinoid formulations may be also used for scientific and industrial sedative use improvement and purposes.
[0013] Cannabinoids were first discovered in the 1940s when cannabidol (herein “CBD”) and cannabinol (“CBN”) were identified. The structure of tetrahydrocannabinol (“THC”) was not identified designated until 1964.
[0014] Due to molecular similarity and ease of synthetic conversion, CBD was originally believed to be a natural precursor to THC. However, it is now known that CBD and THC are produced independently in the cannabis plant from the precursor cannabigerol (“CBG”).
[0015] At present, at least 85 different cannabinoids have been isolated and identified from cannabis plants. Cannabinoids are a class of diverse chemical compounds that among other actions, act on cannabinoid receptors in cells that repress neurotransmitter release in the brains of humans and animals. Ligands have at least one donor atom with an electron pair used to form covalent bonds with the central atom. Ligands for these receptor proteins include endo-cannabinoids (produced naturally in the body), phyto-cannabinoids (found in cannabis and some other plants), and synthetic-cannabinoids (those manufactured artificially).
[0016] The most notable cannabinoid is the phyto-cannabinoid tetrahydrocannabinol (herein “THC”) which is thought to be the primary psychoactive component of cannabis . Cannabidiol (herein “CBD”) and cannabinol (herein “CBN”) are other major cannabinoids of C. Cannabis L plants. It is believed there are yet unknown cannabinoids to be isolated from cannabis which may exhibit varied effects and affects on and in humans and animals.
[0017] Cannabis , and other cannabinoid producing plants, can exhibit wide variation in the quantity and type of cannabinoids they produce. The mixture of cannabinoids produced by a plant is typically known as the plant's cannabinoid “profile” or “presentation”. Selective breeding has been used to influence plant genetics and modify the cannabinoid presentation. For example, strains that are used as fiber (commonly called hemp) are bred such that they are low in psychoactive chemicals like THC. Strains used in medicine are often bred for high CBD content, and strains used for recreational purposes are usually bred for high THC content, or for a specific desired cannabinoid balance or profile.
[0018] Quantitative analysis of a plant's cannabinoid profile is often determined by gas chromatography, or more reliably gas chromatography combined with mass spectrometry. Liquid chromatography techniques are also possible, and unlike gas chromatography methods can differentiate between the acid and neutral forms of a cannabinoid. There have been systematic attempts to monitor the cannabinoid profile of cannabis over time, but their accuracy has been impeded by prohibitive controlled substance classification status of the cannabis plant in many countries.
[0019] Before the 1980s, it was speculated that cannabinoids produced their physiological and psychoactive effects via nonspecific interaction with cell membranes, instead of interacting with specific cell membrane-bound receptors. Discovery of the first cannabinoid receptors in the 1980s resolved the debate. Cannabinoid receptors are common in animals, and have been found in mammals, birds, fish, and reptiles. At present, there are two known types of cannabinoid receptors; CB1 and CB2—with scientific evidence mounting of more cannabinoid receptors yet to be identified.
[0020] CB1 receptors are found primarily in the brain, and more specifically in the basal ganglia and limbic system including the hippocampus. CB1 receptors are also found in the cerebellum. The human brain has more cannabinoid receptors, both CB1 and CB2, than any other G protein-coupled receptor (“GPCR”) type. Both human male and female reproductive systems also include CB1 receptors.
[0021] Advantageously however, CB1 receptors are absent in the medulla oblongata, the part of the brain stem responsible for autonomic respiratory and cardiovascular function. This is highly advantageous when cannabinoids are used for and as sedative and anesthetic formulations. Affecting or depressing autonomic respiratory and/or cardiovascular function has long been a limiting disadvantage of known sedative and anesthetic formulations. Fortunately, unless introduced at extremely toxic levels, CB1 agonist cannabinoids primarily leave autonomic respiratory and cardiovascular functions in humans and animals unaffected, due to the lack of CB1 receptors in the brain stem medulla oblongata.
[0022] CB2 receptors are predominantly found in the immune system, and in immune-derived cells of humans and animals—with the greatest density being in the spleen. While found only in the peripheral nervous system, some studies indicate that CB2 is expressed by a subpopulation of microglia in the human cerebellum. CB2 receptors appear to be responsible for the known anti-inflammatory and possibly other therapeutic affects and effects of cannabis.
[0023] Cannabis -derived phyto-cannabinoids are primarily concentrated in viscous resin produced in structures known as “glandular trichomes” of the cannabis plant. All cannabinoid classes are thought to be derived from CBG type compounds and differ mainly in the way this precursor is cyclized. Classical cannabinoids are derived from their respective 2-carboxylic acids (2-COOH) by decarboxylation (catalyzed by heat, light, or alkaline conditions). These include but are not limited to CBG (Cannabigerol), CBC (Cannabichromene), CBL (Cannabicyclol), CBV (Cannabivarin), THCV (Tetrahydrocannabivarin), CBDV (Cannabidivarin), CBCV (Cannabichromevarin), CBGV (Cannabigerovarin), and CBGM (Cannabigerol monomethyl ether).
[0024] THC is the primary psychoactive component of the cannabis plant. Delta-9-tetrahydrocannabinol and delta-8-tetrahydrocannabinol mimic the action of anandamide (“AEA”), a neurotransmitter produced naturally in the body of humans and animals. These two cannabinoids produce the classic psychoactive affects and effects associated with cannabis by binding to CB1 receptors in the brain. THC appears to act as an analgesic to ease moderate-to-severe pain, and act as a neuroprotective while also offering the potential to reduce neuroinflammation and to stimulate neurogenesis. THC seems to have approximately equal affinity for CB1 and CB2 receptors.
[0025] CBD is not psychoactive and at first was thought to not affect the psychoactivity of THC. However, recent evidence shows that cannabis users prone to psychosis while using a high THC to CBD ratio cannabis had fewer and less extreme psychotic-like symptoms using high CBD to THC ratio cannabis . Some research suggests that the antipsychotic affects of CBD potentially represent a novel mechanism in the treatment of schizophrenia and other affective disorders. CBD has little affinity for CB1 and CB2 receptors, but acts as an indirect antagonist of cannabinoid agonists. Recently, CBD was found to be an antagonist at the putative new cannabinoid receptor GPR55, a GPCR expressed in the caudate nucleus and putamen of the brain. CBD appears to relieve convulsion, inflammation, anxiety, and nausea, and has a greater affinity for the CB2 receptor than for the CB1, although the overall affinity to both is weak. CBD shares a precursor with THC and is the main cannabinoid in low-THC cannabis strains. CBD also apparently plays a role in preventing the short-term memory loss associated with THC in mammals. CBD has also been shown to act as a 5-HT1A receptor agonist. Some beneficial effects observed from 5-HT1A receptor activation are decreased aggression, increased sociability, decreased impulsivity, inhibition of drug-seeking behavior, facilitation of sex drive and arousal, inhibition of penile erection, decreased food intake, prolonged REM sleep latency, and reversal of opioid-induced respiratory depression.
[0026] Researchers at California Pacific Medical Center have discovered CBD's ability to “turn off” the activity of ID1, a gene responsible for metastasis in breast and other types of cancers, including aggressive triple negative breast cancer.
[0027] CBN is primarily a product of THC degradation, and there is usually little CBN in living or freshly harvested cannabis . CBN content increases as THC degrades in storage and with exposure to light and air. CBN is only mildly psychoactive, and its affinity to the CB2 receptor is higher than to the CB1.
[0028] Many ethnobotanists, organic chemists, biochemists, and medical professionals consider THC, CBD, and CBN to be the “big three” of cannabinoids and cannabis , and of which's ratio primarily effects the profile or presentation of a specific cannabis variety.
[0029] Cannabigerol (“CBG”) is non-psychotomimetic but still impacts the overall effects and affects of cannabis . CBG acts as a α2-adrenergic receptor agonist, 5-HT1A receptor antagonist, CB1 receptor antagonist, and also binds to the CB2 receptor.
[0030] Tetrahydrocannabivarin (“THCV”) is prevalent in certain central Asian and southern African strains of cannabis . It is an antagonist of THC at CB1 receptors and attenuates the psychoactive effects of THC. The psychoactive effects of THCV in cannabis and cannabis formulations are not yet well characterized. Unlike THC, CBD, and cannabichromene (“CBC”), THCV doesn't begin as cannabigerolic acid (“CBGA”). Instead of combining with olivetolic acid to create CBGA, geranyl pyrophosphate joins with divarinolic acid, which has two less carbon atoms. The result is cannabigerovarin acid (“CBGVA”). Once CBGVA is created, the process continues as it would for THC. CBGVA is broken down to tetrahydrocannabivarin carboxylic acid (“THCVA”).
[0031] Cannabidivarin (“CBDV”) usually comprises a minor part the cannabis cannabinoid profile. Enhanced levels of CBDV have been reported in feral cannabis plants of the northwest Himalayas and in hashish from Nepal. GW Pharmaceuticals is actively developing a CBDV based formulation due to CBDV's demonstrated neurochemical pathway for previously observed antiepileptic and anticonvulsive affects.
[0032] Cannabichromene (“CBC’) is non-psychoactive, does not affect the psychoactivity of THC, and is more common in tropical cannabis varieties. CBC exhibits anti-inflammatory and analgesic properties. Evidence suggests that CBC may play a role in anti-inflammatory and anti-viral effects, and may contribute to the overall analgesic effects of cannabis . One study in 2010 showed that CBC along with CBD and THC has antidepressant affects. Another study showed that CBC helps promote neurogenesis.
[0033] Cannabinoid production in cannabis starts when an enzyme causes geranyl pyrophosphate and olivetolic acid combine and form CBGA. Next, CBGA is independently converted to either CBG, THCA, CBDA or CBCA by four separate synthase, FAD-dependent dehydrogenase enzymes. There is no evidence for enzymatic conversion of CBDA or CBD to THCA or THC. For the propyl homologues (THCVA, CBDVA and CBCVA), there is an analogous pathway that is based on CBGVA from divarinolic acid instead of olivetolic acid.
[0034] Each of the cannabinoids above may be in different forms depending on the position of the double bond in the alicyclic carbon ring. There is potential for confusion because there are different numbering systems used to describe the position of this double bond. Under the dibenzopyran numbering system widely used today, the major form of THC is called Δ9-THC, while the minor form is called Δ8-THC. Under an alternate terpene numbering system, these same compounds are labeled Δ1-THC and Δ6-THC, respectively. Accordingly, herewithin tetrahydrocannabinol and/or “THC” shall be defined to include the delta-9-tetrahydrocannabinol, delta-8-tetrahydrocannabinol, delta-1-tetrahydrocannabinol, and delta-6-tetrahydrocannabinol designations.
[0035] Most classical cannabinoids are twenty-one-carbon compounds. However, some do not follow this rule primarily because of variation in the length of the side-chain attached to the aromatic ring. In THC, CBD, and CBN, this side-chain is a pentyl (five-carbon) chain. In the most common homologue, the pentyl chain is replaced with a propyl (three-carbon) chain. Cannabinoids with the propyl side-chain are named using the suffix varin, and are designated, for example, THCV, CBDV, or CBNV.
[0036] Phyto-cannabinoids are known to occur in several plant species besides cannabis . These include but are not limited to echinacea purpurea, echinacea angustifolia, echinacea pallida, acmella oleracea, helichrysum umbraculigerum , and radula marginata . The best-known cannabinoids that are not derived from cannabis are the lipophilic alkamides (alkylamides) from the echinacea species, most notably the cis/trans isomers dodeca-2E, 4E, 8Z, 10E/Z-tetraenoic-acid-isobutylamide. At least 25 different alkylamides have been identified, and some have shown affinities to CB2 receptors. In echinacea species, cannabinoids are found throughout the plant structure but are most concentrated in the roots and flowers. Yangonin found in the kava plant is a ligand to the CB1 receptor. Tea ( camellia sinensis ) catechins also have an affinity for human cannabinoid receptors. A widespread dietary cannabinoid, beta-caryophyllene, a component from the essential oil of cannabis and other medicinal plants, has also been identified as a selective agonist of peripheral CB2 receptors in vivo. Black truffles also contain anandamide.
[0037] Most phyto-cannabinoids are nearly insoluble in water, but are soluble in lipids, alcohols, and other non-polar organic solvents.
[0038] Cannabinoids can be administered by many methods typically including but not limited to smoking, vaporizing, ingestion, transdermal sorption, sublingual sorption, or other mucosa sorption. Once in the body, most cannabinoids are metabolized in the liver, especially by cytochrome P450 mixed-function oxidases, mainly CYP 2C9. Thus, supplementing the inventive formulation with CYP 2C9 inhibitors may lead to extended or enhanced intoxication, incapacitation, or immobilization.
[0039] Cannabinoids can be separated from cannabis or other plants by extraction with organic solvents. Hydrocarbons and alcohols are often used as solvents. However, these solvents are extremely flammable and many are toxic. Butane may also be used, which evaporates extremely quickly. Supercritical solvent extraction with carbon dioxide is an alternative technique. Although this process requires high pressures, there is minimal risk of fire or toxicity, solvent removal is simple and efficient, and extract quality can be well controlled. Once extracted, cannabinoid blends can be separated into individual components using wiped film vacuum distillation or other distillation techniques. However, to produce high-purity cannabinoids, chemical synthesis or semi-synthesis is generally required.
[0040] Endo-cannabinoids are substances produced from within the body that activate cannabinoid receptors. After discovery of the first cannabinoid receptor in 1988, scientists began searching for an endogenous ligand for the receptor.
[0041] Endo-cannabinoids serve as intercellular “lipid messengers”, signaling molecules that are released from one cell and activating the cannabinoid receptors present on other nearby cells. Although in this intercellular signaling role they are similar to the well-known monoamine neurotransmitters, such as acetylcholine and dopamine, endo-cannabinoids differ in numerous ways. For example, endo-cannabinoids are used in retrograde signaling between neurons. Furthermore, endo-cannabinoids are lipophilic molecules that are not very soluble in water. They are not stored in vesicles, and exist as integral constituents of the membrane bilayers that make up cells. Endo-cannabinoids are believed to be synthesized “on-demand” rather than made and stored for later use. The mechanisms and enzymes underlying the biosynthesis of endo-cannabinoids remain elusive and continue to be an area of active research.
[0042] Conventional neurotransmitters are released from a “presynaptic” cell and activate appropriate receptors on a “postsynaptic” cell, where presynaptic and postsynaptic designate the sending and receiving sides of a synapse, respectively. Endo-cannabinoids, on the other hand, are described as retrograde transmitters because they most commonly travel “backward” against the usual synaptic transmitter flow. They are, in effect, released from the postsynaptic cell and act on the presynaptic cell, where the target receptors are densely concentrated on axonal terminals in the zones from which conventional neurotransmitters are released. Activation of cannabinoid receptors temporarily reduces the amount of conventional neurotransmitter released. This endo-cannabinoid mediated system permits the postsynaptic cell to control its own incoming synaptic traffic. The ultimate effect on the endo-cannabinoid-releasing cell depends on the nature of the conventional transmitter being controlled. For instance, when the release of the inhibitory transmitter GABA is reduced, the net effect is an increase in the excitability of the endo-cannabinoid-releasing cell. On the converse, when release of the excitatory neurotransmitter glutamate is reduced, the net effect is a decrease in the excitability of the endo-cannabinoid releasing cell.
[0043] Endo-cannabinoids are hydrophobic molecules, they cannot travel unaided for long distances in the aqueous medium surrounding the cells from which they are released, and therefore act locally on nearby target cells. Hence, although emanating diffusely from their source cells, they have much more restricted spheres of influence than do hormones which can affect cells throughout the body.
[0044] In 1992 the first such endo-cannabinoid compound was identified as arachidonoylethanolamine, and named anandamide (“AEA”). AEA is derived from arachidonic acid and has a pharmacology similar to THC, although its chemical structure is different. AEA has an affinity for CB1 receptors and to a lesser extent CB2, where it acts as a partial agonist. AEA is about as potent as THC at the CB1 receptor, and is found in nearly all tissues in a wide range of animals. AEA has also been found in plants, including small amounts in cocoa beans. Two analogs of AEA, 7, 10, 13, and 16-docosatetraenoylethanolamide and homo-γ-linolenoylethanolamine, have similar pharmacology. All of these are members of a family of signaling lipids called N-acylethanolamines, which also includes the noncannabimimetic palmitoylethanolamide and oleoylethanolamide, which possess anti-inflammatory and orexigenic effects, respectively. Many N-acylethanolamines have also been identified in certain other plant seeds and in mollusks.
[0045] Another endo-cannabinoid, 2-arachidonoylglycerol (“2-AG”), binds to both the CB1 and CB2 receptors with similar affinity, acting as a full agonist at both. 2-AG is present at significantly higher concentrations in the brain than AEA, causing some controversy whether 2-AG rather than AEA is chiefly responsible for endo-cannabinoid signaling in vivo. In particular, one in vitro study suggests that 2-AG is capable of stimulating higher G-protein activation than AEA, although the physiological implications of this finding are not yet known.
[0046] Discovered in 2000, N-arachidonoyl dopamine (“NADA”) preferentially binds to the CB1 receptor. Like AEA, NADA is also an agonist for the vanilloid receptor subtype 1 (TRPV1), a member of the vanilloid receptor family. Outside the food industry, vanilloids which act at TRPV1 are used in so-called “pepper-spray” and/or other mace formulations.
[0047] In 2001, a fourth, ether type endo-cannabinoid, 2-arachidonyl glyceryl ether (“noladin ether”), was isolated from porcine brain. Prior to this discovery, noladin ether had been synthesized as a stable analog of 2-AG; indeed, some controversy remains over 2-AGs classification as an endo-cannabinoid, as another group failed to detect the substance at “any appreciable amount” in the brains of several different mammalian species. Noladin ether binds to the CB1 receptor and causes sedation, hypothermia, intestinal immobility, mild reduced sensitivity to pain in mice, and binds weakly to the CB2.
[0048] A fifth endo-cannabinoid, virodhamine, or O-arachidonoyl-ethanolamine (“OAE”), was discovered in 2002. Although it is a full agonist at CB2 and a partial agonist at CB1, it behaves as a CB1 antagonist in vivo. In rats, OAE was found to be present at comparable or slightly lower concentrations than AEA in the brain, but peripherally in two-to-nine fold higher concentrations.
[0049] Recent evidence has highlighted lysophosphatidylinositol (“LPI”) as the endogenous ligand to novel endocannabinoid receptor GPR55, making it a strong contender as the sixth endo-cannabinoid.
[0050] Historically, laboratory synthesis of cannabinoids were often based on the structure of herbal or phyto-cannabinoids, and a large number of analogs have been produced and tested. Synthetic-cannabinoids are particularly useful in experiments to determine the relationship between the structure and activity of cannabinoid compounds, by making systematic and incremental modifications of cannabinoid molecules. When synthetic-cannabinoids are used recreationally, they present significant health dangers to users. In the period of 2012 through 2014, over 10,000 contacts to poison control centers in the United States were related to use or abuse of synthetic-cannabinoids.
[0051] Medications containing natural or synthetic cannabinoids or cannabinoid analogs include: Dronabinol (Marinol), which is Δ9-THC used as an appetite stimulant, anti-emetic, and analgesic; Nabilone (Cesamet, Canemes), a synthetic cannabinoid and an analog of Marinol; Rimonabant (SR141716), a selective CB1 receptor inverse agonist once used as an anti-obesity drug under the proprietary name Acomplia, and was also used for smoking cessation; CP-55940, produced in 1974 as a synthetic cannabinoid receptor agonist many times more potent than the phyto-cannabinoid THC; Dimethylheptylpyran (DMHP), an analog of phyto-cannabinoid THC; HU-210, about 100 times as potent as phyto-cannabinoid THC; HU-331, a potential anti-cancer drug derived from CBD that specifically inhibits topoisomerase II; SR144528, a CB2 receptor antagonist; WIN 55,212-2, a potent cannabinoid receptor agonist; JWH-133, a potent selective CB2 receptor agonist; Levonantradol (Nantrodolum), an anti-emetic and analgesic, but not currently in use in medicine; and AM-2201, a potent cannabinoid receptor agonist.
[0052] What is desired therefore is a method of humanely incapacitating or immobilizing a human or animal by providing a formulation including a cannabinoid which renders a recipient incapacitated or immobilized within a short period of time after dosing.
[0053] What is further desired is a delivery means which doses the recipient with the inventive formulation resulting in a tetrahydrocannabinol blood level of above at least approximately 1-250 milligrams per milliliter of whole blood for incapacitation, or at least approximately 250-500 milligrams per milliliter of whole blood immobilization, and below a dosage which causes irreparable harm to or the death of the recipient.
[0054] What is additionally desired is a method of providing a delivery means to induce an incapacitating or immobilizing dose of the inventive formulation at a distance.
[0055] Further desired is a method of providing cannabinoid formulation wherein the formulation includes at least one antipsychotic or neroleptic such as but not limited to butyrophenones, phenothiazines, thioxanthenes, co-called atypical antipsychotics, and so-called second-generation antipsychotics to prevent or mitigate the violent psychosis of a formulation recipient.
[0056] What is also desired is a method of providing an inventive formulation which induces a lethal cannabinoid blood level in a recipient which causes the death of the recipient within a humane period of time after formulation administration.
SUMMARY OF THE INVENTION
[0057] It is therefore an object of the present invention to provide a method of humanely incapacitating a human or animal comprising providing a formulation including a cannabinoid which renders a recipient incapacitated within a short period of time after dosing, and providing a delivery means which doses the recipient with the formulation resulting in a tetrahydrocannabinol blood level of above at least approximately one-to-fifty milligrams per milliliter of whole blood (1-50 mg/ml) and below a dosage which causes irreparable harm to or death of the recipient.
[0058] Another objective of the present invention is to provide a method of humanely incapacitating a human or animal comprising, providing a formulation including a cannabinoid which renders within a short period of time a recipient incapacitated after administration of the formulation to the recipient, providing a delivery means which doses the recipient with the formulation inducing a tetrahydrocannabinol blood level of above at least approximately one-to-fifty milligrams per milliliter of whole blood (1-50 mg/ml) and below a dosage which causes irreparable harm to or death of the recipient, and wherein the formulation continues to render the recipient incapacitated for a long period of time without irreparable harm to or death of the recipient.
[0059] It is further an object of the present invention to provide a method of humanely immobilizing a human or animal comprising, providing a formulation including a cannabinoid which renders a recipient immobilized within a short period of time after dosing, providing a delivery means which doses the recipient with the formulation inducing a tetrahydrocannabinol blood level of above at least approximately two-hundred-and fifty and five-hundred and milligrams per milliliter of whole blood (250-500 mg/ml) and below a dosage which causes irreparable harm to or death of the recipient, and wherein the formulation continues to render the recipient immobile for a long period of time after dosing without irreparable harm to or death of the recipient.
[0060] It is yet another objective of the present invention to provide a method of humanely incapacitating or immobilizing a human or animal comprising, providing a formulation including a cannabinoid and a delivery means capable of dosing the recipient with the inventive formulation at a distance which renders a recipient incapacitated or immobilized within a short period of time after dosing, and wherein the recipient remains incapacitated or immobilized for a long period of time without causing irreparable harm to or the death of the recipient.
[0061] It is yet another objective of the present invention to provide a method of humanely incapacitating or immobilizing a human or animal comprising, providing a formulation including a cannabinoid and a delivery means capable of dosing the recipient with the inventive formulation at a distance which renders a recipient incapacitated or immobilized within a short period of time after dosing, and wherein the recipient remains incapacitated or immobilized for a long period of time without causing irreparable harm to or the death of the recipient.
[0062] Yet further, it is an objective of the present invention to provide a method of humanely incapacitating a human or animal comprising, providing a formulation including a cannabinoid which renders a recipient incapacitated within a short period of time after dosing, providing a delivery means which doses the recipient with the formulation resulting in a tetrahydrocannabinol blood level of above at least approximately one-to-fifty milligrams per milliliter of whole blood (1-50 mg/ml) and below a dosage which causes irreparable harm to or the death of the recipient, wherein the formulation includes at least one antipsychotic from the group consisting of antipsychotic or neuroleptic formulations including but not limited to butyrophenones, phenothiazines, thioxanthenes, atypical antipsychotics, second-generation antipsychotics, and combinations thereof.
[0063] Still further, an object of the present invention is to provide a method of humanely causing the death of a recipient comprising, providing a formulation wherein the formulation induces a lethal cannabinoid blood level in the recipient which causes the death of the recipient within a humane period of time after formulation introduction to the recipient.
DETAILED DESCRIPTION OF THE INVENTION
[0064] The inventive method provides a formulation delivery means configured for dosing a subject at a distance. The delivery means may include a dart-pistol or dart-rifle including a hypodermic dart containing the inventive cannabinoid or cannabinoid based formulation. Both the dart-pistol and hypodermic dart may be any known so-called “dart-gun” system which is capable of dosing a recipient with the inventive formulation at a distance. It is contemplated that the inventive formulation may be primarily a cannabinoid based formulation. However, cannabinoids may be added to known sedative formulations to improve their safety and/or performance. Many and varied cannabinoid formulations may be innovated.
[0065] In an exemplary embodiment of the inventive formulation, an incapacitating dosage of tetrahydrocannabinol may be added to known effective dosage of propofol (diprivan). For healthy adults 55 years or younger, a general intravenous anesthetic infusion of diprivan is 40 mg every 10 seconds until induction onset. For general anesthetic use, a typical dose of diprivan is 2.0-2.5 mg per kilogram of recipient body weight, with a maximum dosage of 250 mg. However, delivery of diprivan at a distance makes it extremely difficult to guarantee an intravenous injection. Therefore, an intermuscular injection of approximately 150-250 mg of diprivan may be required to ensure almost instantaneous recipient incapacitation. By adding an appropriate dose of tetrahydrocannabinol to result in approximately one-to-fifty milligrams per milliliter of whole blood (1-50 mg/ml) of tetrahydrocannabinol, to the diprivan; once dosed, the recipient will be almost instantaneously incapacitated by the diprivan, within seconds, while the tetrahydrocannabinol dose will still further sedate the recipient for approximately another four-to-six hours, without depression of the body's autonomic functions.
[0066] If it is unnecessary to “immediately”, or to “near-immediately”, incapacitate a recipient, the inventive formulation may strictly consist of cannabinoids such as tetrahydrocannabinol. During instant inventor experimentation, an intermuscular injection of 5.0 mg of tetrahydrocannabinol rendered an overall healthy 50 year old, 100 kg male, fully incapacitated within 10-30 seconds, with its effects lasting approximately four-to-six hours.
[0067] The lethality of intravenous dosing of tetrahydrocannabinol in humans is typically unknown. As detailed in Marihuana, A Signal of Misunderstanding , a report delivered to the United States Congress by Raymond P. Shafer on Mar. 22, 1972 (herein incorporated by reference in its entirety), in laboratory animals, a dosage that caused death in 50% of subjects (“LD50”) was in units of mg of tetrahydrocannabinol per kg of body weight. In mice and rats, an LD50 tetrahydrocannabinol dose is 28.6 mg per 42.47 kg of body weight. A dosage of approximately 1000 mg of tetrahydrocannabinol per kg of body weight is known to be the lowest intravenous dosage which causes death in laboratory animals. The typical lethal oral dosage of tetrahydrocannabinol is between approximately 225-450 mg per kg of body weight in laboratory animals.
[0068] Using intravenous administration, the acute one dose LD50 for tetrahydrocannabinol was 100 mg/kg in dogs and 15.6-62.5 mg/kg in monkeys depending on concentration of the solution. The minimal lethal intravenous dose for dogs, also depending upon concentration, was 25-99 mg/kg, and for monkeys 3.9-15.5 mg/kg.
[0069] In contrast to the delayed death observed in rats after oral administration, lethality in rats, dogs, and monkeys after intravenous injection occurred within minutes. When sublethal amounts were injected, central nervous system depression with concomitant behavioral changes similar to those observed after oral doses were observed. However, their onset was more rapid and the intensity of affect more severe with anesthesia, with convulsions noted after injection. Monkeys and dogs that survived the intravenous injection of concomitant recovered completely within five to nine days.
[0070] The only consistent pathological changes noted were in animals which succumb. Pulmonary changes including hemorrhage, edema, emphysema, and generalized congestion were found—and death resulted from respiratory arrest and subsequent cardiac failure. The investigators presumed one mechanism possibly accounting for these findings was due to the concentration of the tetrahydrocannabinol solution and its insolubility in water. Presumably when these highly concentrated solutions mixed with blood, the tetrahydrocannabinol precipitated out of solution. The precipitated foreign material then formed aggregates (or emboli) that were filtered out in the lung capillaries causing a physical blockage of pulmonary blood flow.
[0071] Subsequently, intravenous studies were repeated using tetrahydrocannabinol emulsified in a sesame oil, polysorbate 80, or saline vehicle at 15 mg/ml or 40 mg/ml. The emulsions were administered at a uniform rate of 2 ml/15 sec. Doses administered were 1, 4, 16, 64, 92,128, 192 and 256 mg/kg. All monkeys injected with 92 mg/kg or less survived and completely recovered from all effects within two to four days. An analogous intravenous dosage for a 100 kg human would be 9,200 mg (9.2 g) of near-pure tetrahydrocannabinol. All monkeys injected with 128 mg/kg or more succumb within thirty minutes for all but one subject, which took one-hundred-and-eighty minutes to expire. An analogous lethal intravenous dosage for a 100 kg human would be 12,800 mg (12.8 g) of near-pure tetrahydrocannabinol.
[0072] Histopathological changes found in the lungs of the deceased monkeys were like those described after the previous intravenous experiment. All monkeys that died exhibited severe respiratory depression and bradycardia within five minutes after injection. Respiratory arrest and subsequent cardiac failure occurred within minutes. Behavioral changes preceding death were salivation, prostration, coma, and tremors.
[0073] Behavioral and physiological changes described clinically in the surviving monkeys followed a consistent developmental sequence and were roughly dose related in severity and duration. Onset was fifteen minutes following injection and duration was up to forty-eight hours. Huddled posture and lethargy were the most persistent changes. Constipation, anorexia, and weight loss were noted. Hypothermia, bradycardia, and decreased respiratory rate generally were maximal two-to-six hours post injection. Tremors with motion but not at rest were believed to be caused by peripheral muscle inadequacy.
[0074] In summary, enormous intravenous doses of tetrahydrocannabinol, and all tetrahydrocannabinol and concentrated cannabis extracts ingested orally were unable to produce death or organ pathology in large mammals, but did produce fatalities in smaller rodents due to profound central nervous system depression.
[0075] The nonlethal oral consumption of 3 g/kg of tetrahydrocannabinol by a dog and monkey would be comparable to a 154-pound human eating approximately forty-six pounds, 21 kg, of one-percent THC cannabis , or ten-pounds of five-percent hashish, at one time. In addition, 92 mg/kg tetrahydrocannabinol intravenously produced no fatalities in monkeys. These doses would be comparable to a 154-pound human smoking at one time almost three pounds (1.28 kg) of one-percent THC cannabis, 250,000 times the usual smoked dose, and over a million times the minimal effective dose assuming fifty-percent destruction of the tetrahydrocannabinol by combustion.
[0076] Thus, evidence from animal studies and human case reports appears to indicate that the ratio of lethal-dose to effective-dose of tetrahydrocannabinol is quite large; and much more favorable than that of many other common psychoactive agents including alcohol and barbiturates. This effective-to-lethal tetrahydrocannabinol dosage ratio may be exploited for medical, scientific, and industrial purposes.
[0077] Relatedly, known antipsychotic compounds may be included in the inventive cannabinoid formulation to prevent or mitigate quick onset and/or violent psychotic reactions to the inventive cannabinoids, especially tetrahydrocannabinol. Such known antipsychotic or neroleptic formulations include but are not limited to butyrophenones, phenothiazines, thioxanthenes, so-called atypical antipsychotics, and so-called second-generation antipsychotics.
[0078] The inventive method provides another apparatus or delivery means adapted for dosing a recipient with the inventive formulation at a distance. The delivery means may be a common paint-ball pistol or rifle. Utilizing the inventive formulation with the associated paint-balls (ammunition), a vaporizing or misting inventive formulation may be used. As the “paint-balls” burst on the front torso of a recipient, the resulting “cannabinoid cloud” soon to envelop the recipients face and head will render the recipient incapacitated. The same apparatus or delivery means may be used for animals.
[0079] Many and varied apparatus or inventive formulation delivery means types and techniques may be provided, such as but not limited to, non-lethal or less-than-lethal weapons such as hypodermic syringes, darts, blowpipes, dart-pistols, dart-rifles, jab-sticks, dart-arrows, slingshots, mace, mace guns, paint-ball guns, flash-bag grenades, stun-shock grenades, gas canisters, deployable gas canisters, and combinations thereof.
[0080] Additionally, many and varied lethal weapons using modified ammunition and the inventive formulation may be used, such as but not limited to, single-shot, semi-automatic, or fully-automatic revolvers, pistols, shotguns, scatterguns, rifles, grenade launchers, rocket launchers, mortars, light artillery, heavy artillery, missile launchers, and combinations thereof.
[0081] Correspondingly, water-borne, air-borne, and space-borne systems may also be used to effectively deliver the inventive formulation to a recipient.
[0082] While not wishing to be bound by any one theory or combination of theories, it is believed that, the combination, ratio, delivery means, method, or technique, dosage, dosage timing, dosage sequence, and in combination with other known sedatives; cannabinoids, and specifically THC, CBD, and CBN, may be exploited for industrial, scientific, and medical use.
[0083] Accordingly, this invention is not to be limited by the embodiments as described, since these are given by way of example only and not by way of limitation.
[0084] Having thus described several embodiments for practicing the inventive method, its advantages and objectives can be easily understood. Variations from the description above may and can be made by one skilled in the art without departing from the scope of the invention, which is to be determined from and by the following claims.
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A method of humanely incapacitating or immobilizing a human or animal by providing a formulation including a cannabinoid rendering a recipient incapacitated or immobilized within a short period of time, and a delivery means which doses the recipient with the formulation resulting in a tetrahydrocannabinol blood level of above at least approximately 1-250 milligrams per milliliter of whole blood for incapacitation, or at least approximately 250-500 milligrams per milliliter of whole blood immobilization, and below a dosage which causes irreparable harm to or the death of the recipient. Providing a delivery means to induce an incapacitating or immobilizing dose at a distance. Providing a formulation including an antipsychotic to prevent or mitigate any violent psychosis of the recipient. Providing a formulation which induces a lethal cannabinoid blood level in the recipient which causes the death of the recipient within a humane period of time after formulation administration.
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TECHNICAL FIELD
[0001] The present disclosure relates to the field of polymer resin, and in particular to an ultra-high molecular weight polyethylene resin and its application in fiber spinning industry.
TECHNICAL BACKGROUND
[0002] Ultra-high molecular weight polyethylene fiber is the third generation high performance fiber emerged in the early 1990s. The relative molecular weight of ultra-high molecular weight polyethylene fiber is over 1 million, the molecular shape thereof is linear straight chain structure, and the degree of orientation thereof approaches 100%. Due to excellent mechanical properties and outstanding comprehensive performances of the ultra-high molecular weight polyethylene fibers, the application potential thereof is huge. Ultra-high molecular weight polyethylene fibers are applicable to both military use and civil use, and are widely used in various aspects, such as bulletproof products, explosion proof equipment, high strength cable and sports equipment, etc.
[0003] Ultra-high molecular weight polyethylene fibers are made by processing ultra-high molecular weight polyethylene resin. At present, ultra-high molecular weight polyethylene resin is mainly prepared by Ziegler low-pressure slurry process, i.e., the process of polymerizing ethylene at certain temperature and pressure and producing products with different molecular weights, using β-TiCl 3 /Al(C 2 H 5 ) 2 Cl or TiCl 4 /Al(C 2 H 5 ) 2 Cl as main catalyst, triethyl aluminum as co-catalyst, and saturated hydrocarbon at the temperature of 60 to 120° C. as dispersion medium.
[0004] Patent literature CN1033703 provides a method for preparing ultra-high molecular weight polyethylene, which can regulate the molecular weight of the ultra-high molecular weight polyethylene. According to the patent, ultra-high molecular weight polyethylene resin having good particle-size distribution and molecular weight that can be adjusted within a range from 0.6 to 6.1 million can be prepared under the temperature of 65 to 85° C., using MgCl 2 and ZnCl 2 composite supported titanium catalyst. According to this invention, the molecular weight of the product can be adjusted by regulating the Zn/Ti molar ratio. The catalyst used therein is a composite supported catalyst. The resin prepared through polymerization according to this patent is not used in fibers. The resin particle has smooth surface, and comprises no porous and gyms-like structure.
[0005] Patent literature CN1999809336 relates to a method for producing high-strength polyethylene fibers, wherein a polymerization mixture comprising from 99 to 50 parts by weight of (A) and from 1 to 50 parts by weight of (B), where (A) is high molecular weight polymer comprising mainly ethylene component and having a weight average molecular weight to number average molecular weight ratio (Mw/Mn) of no greater than 4 and an intrinsic viscosity η of no less than 5 dl/g, and (B) is an ultrahigh molecular weight polymer having an intrinsic viscosity at least 1.2 times that of high molecular weight polymer (A), is dissolved in solvent to a concentration of from 5% by weight to 80% by weight, then spun and drawn. The method according to this patent can efficiently manufacture high-strength polyethylene fibers having an intrinsic viscosity η of no less than 5 dl/g, a strength of no less than 20 g/d and an elasticity modulus of no less than 500 g/d. According to this patent, a mixture of two ethylene polymers having different intrinsic viscosities is used. For fibers made from the mixture, uniformity and stable performance can hardly be achieved, and the mechanical performances thereof are lower than those of ultra-high molecular weight polyethylene fibers.
[0006] Patent literature EP277750 provides an ultra-high molecular weight polyethylene resin for producing ultra-high strength fibers, having an intrinsic viscosity 11 in a range of 5 to 30 dl/g and a particle size in a range of 1 to 300 μm. Patent literature JP 2007297763 provides a method for producing high-strength polyethylene fibers, using high molecular weight polyethylene resin having an intrinsic viscosity greater than 8 dl/g. Patent literature CN 101421444 provides a spinning method for high strength polyethylene fibers that are difficult to obtain by conventional gel spinning methods. The high molecular weight polyethylene resin according to this patent has an intrinsic viscosity greater than 8 dl/g. When the polymer dope for spinning is prepared, ethanol compound, in which the resin is insoluble, is added. The mixture of decalin, poor solvent and ethanol compound is used as solvent, in which the polymer swells and dissolves. Thus, after spinning, high strength fibers can be obtained. Currently, during the production of fibers, ultra-high molecular weight polyethylene resin with relatively low intrinsic viscosity, i.e., relatively low molecular weight, is mainly used, which would significantly reduce the mechanical properties of the final fiber product.
[0007] At present, gel spinning process is mainly used for the production of ultra-high molecular weight polyethylene fibers. Gel spinning process requires the use of a specific solvent before the melt spinning and drawing, so that the entire or partial molecular chain of the ultra-high molecular weight polyethylene can be disentangled, thereby uniform solution can be formed. Therefore, the solubility of ultra-high molecular weight polyethylene particles in the solvent is critical, which determines the production efficiency and property of the fiber product to a large extent.
[0008] However, the solubility of ultra-high molecular weight polyethylene becomes poorer and poorer as the molecular weight thereof increases, and thus the production efficiency and the property of the fiber product would become poorer in the spinning process. On the other hand, although when the ultra-high molecular weight polyethylene has low molecular weight the solubility thereof would certainly increase, the tensile strength of the fiber product made therefrom would be far from satisfactory. The ultra-high molecular weight polyethylene in the prior art cannot have both good solubility and high molecular weight, and be spun into fiber with high stretching strength at the same time.
SUMMARY OF THE INVENTION
[0009] The objective of the present disclosure is to provide a use of ultra-high molecular weight polyethylene resin in fiber spinning, and to solve the problems that ultra-high molecular weight polyethylene resin at present is difficult to dissolve during fiber spinning, and has low strength, and that the fiber manufactured from the ultra-high molecular weight polyethylene resin is unstable in performance.
[0010] The present disclosure relates to an ultra-high molecular weight polyethylene resin, wherein the polyethylene resin has a viscosity average molecular weight in a range from 2 to 7 million, a volume average particle size in a range from 100 to 350 μm, a particle-size distribution in a range from 1.0 to 2.1, a tensile breaking stress in a range from 30 to 60 MPa, a bulk density of resin in a range from 0.10 to 0.50 g/cm 3 , and an initial crystallinity in a range from 60.5 to 90%.
[0011] The decalin absorption amount of the ultra-high molecular weight polyethylene resin according to the present disclosure is in a range from 2 to 50 g per 100 g of ultra-high molecular weight polyethylene resin, and the white oil absorption amount of the ultra-high molecular weight polyethylene resin is in a range from 5 to 60 g per 100 g of ultra-high molecular weight polyethylene resin.
[0012] In preferred embodiments of the present disclosure: the initial crystallinity of the ultra-high molecular weight polyethylene resin is preferably in a range from 63 to 85%; an infiltration time of resin particles in solvent decalin is in a range from 0.5 to 11 min, preferably in a range from 1 to 8 min; the viscosity average molecular weight of the ultra-high molecular weight polyethylene resin is in a range from 2.5 to 6 million, preferably in a range from 3.5 to 5.5 million; the average particle size of the ultra-high molecular weight polyethylene resin is preferably in a range from 150 to 250 μm; the particle-size distribution of the ultra-high molecular weight polyethylene resin is in a range from 1.2 to 2.0, preferably in a range from 1.4 to 1.9; the bulk density of the ultra-high molecular weight polyethylene resin is in a range from 0.20 to 0.45 g/cm 3 , preferably in a range from 0.20 to 0.35 g/cm 3 ; and the tensile breaking stress of the ultra-high molecular weight polyethylene resin is in a range from 32 to 60 MPa, preferably in a range from 35 to 60 MPa. Good tensile breaking stress can well facilitate the thermal drawing of fibers.
[0013] The initial crystallinity according to the present disclosure refers to the crystallinity directly determined in a process, in which nascent state polymer particles generated in the reactor haven't been through a thermal process, and the thermal history is not eliminated. It represents the extent of entanglement of the nascent state ultra-high molecular weight polyethylene resin particles. In addition, the solubility of ultra-high molecular weight polyethylene in solvent is related to the extent of entanglement of the macromolecules thereof. The more entangled the ultra-high molecular weight polyethylene macromolecules, the lower the initial crystallinity of the resin particles, and the poorer solubility of the resin particles in the solvent. On the contrary, the less entangled, the higher the initial crystallinity of the resin particles, and the better solubility of the resin particles in the solvent. Therefore, the ultra-high molecular weight polyethylene resin with higher initial crystallinity also has better solubility.
[0014] The initial crystallinity of the ultra-high molecular weight polyethylene resin according to the present disclosure is in a range from 60.5 to 90%, which can effectively shorten the time of dissolution. If the initial crystallinity is lower than 60.5%, the extent of entanglement is high, and thus the solubility is poor. In this case, it is difficult for the resin to be made into fibers. If the initial crystallinity is higher than 90%, the production cost is high and the process is complex. In this case, the production is difficult to be implemented.
[0015] The decalin absorption amount of the ultra-high molecular weight polyethylene resin according to the present disclosure is in a range from 2 to 50 g per 100 g of ultra-high molecular weight polyethylene resin, and the white oil absorption amount of the ultra-high molecular weight polyethylene resin is in a range from 5 to 60 g per 100 g of ultra-high molecular weight polyethylene resin.
[0016] In dry spinning process, the ultra-high molecular weight polyethylene resin is infiltrated in decalin at first. If the ultra-high molecular weight polyethylene resin can fully absorb dacalin, the solubility thereof during spinning can be better, which can facilitate the spinning. In this case, the fibers obtained can have higher strength and better uniformity. If each 100 g ultra-high molecular weight polyethylene resin absorbs less than 2 g of decalin, the resin cannot be sufficiently dissolved, and thus the spinning effect would hardly be satisfactory. If each 100 g ultra-high molecular weight polyethylene resin absorbs more than 50 g of decalin, the process would be difficult to be implemented and industrially uneconomical. In wet spinning process, mineral oil is used as solvent. If each 100 g ultra-high molecular weight polyethylene resin absorbs less than 5 g white oil, the resin cannot be sufficiently dissolved, and thus the spinning effect would hardly be satisfactory. If each 100 g ultra-high molecular weight polyethylene resin absorbs more than 60 g white oil, the process would be difficult to be implemented and industrially uneconomical.
[0017] The ultra-high molecular weight polyethylene resin particles according to the present disclosure comprise porous and gyms-like structures. Due to the wide and deep cracks on the surfaces of the particles, the solvent can rapidly penetrate into the particles during spinning and accelerate the dissolution of the particles. In this case, the infiltration time of the resin particles in solvent decalin according to the present disclosure, which is in a range from 0.5 to 11 min, and preferably in a range from 1 to 8 min, is shorter as compared with the prior art. The infiltration time is also an indicator for evaluating the solubility of the ultra-high molecular weight polyethylene resin. If the infiltration time is shorter than 0.5 min, it means that the resin is easily soluble in solvent and usually has small molecular weight, and thus the fibers made from the resin would have low strength. If the infiltration time is longer than 11 min, it means that the resin is difficult to dissolve. In this case, deficit points are easily formed and decollation would easily occur during the manufacturing of fibers.
[0018] The molecular weight of the ultra-high molecular weight polyethylene resin is in a range from 2 to 7 million, preferably in a range from 2.5 to 6 million, and more preferably in a range from 3.5 to 5.5 million. If the molecular weight is overly high, such as higher than 7 million, because the polymer is difficult to dissolve in the solvent and the dissolution time is too long, the processing of the fibers would be highly difficult. If the molecular weight is too low, such as lower than 2 million, the problems of decollation and lowered fiber strength would occur, and the fiber product prepared can hardly be satisfactory.
[0019] The process of fiber preparation is complex, and requires highly of the particle morphology of the ultra-high molecular weight polyethylene resin. The particle morphology, particle size, and the particle-size distribution of the ultra-high molecular weight polyethylene resin will affect the dissolving rate of the resin particles in the solvent, thereby influencing the production efficiency, and even the product performance. During fiber production, if there are large particles in the resin, which might only swell instead of dissolving when most particles have sufficiently dissolved, the large particles would become deficit points during spinning. The particle morphology of a sample can be analyzed through photomicrography technology (see FIGS. 1-4 of the present disclosure). The resin according to the present disclosure is characterized by uniform particles, with modest average particle size being in a range from 100 to 350 μm, preferably in a range from 150 to 250 μm, as well as narrow distribution, with the average particle-size distribution being in a range from 1.0 to 2.1, preferably in a range from 1.2 to 2.0, and more preferably in a range from 1.4 to 1.9. In this case, homogeneous dissolution of the resin in the spinning solvent can be facilitated. If the average particle size is larger than 350 μm, the time for dissolution would be greatly increased. If the average particle size is smaller than 100 μm, the operative difficulty for resin production would be significantly increased due to relatively large number of fine particles in the resin. When the particle-size distribution is smaller than 1.0, the process required for resin production would be harsh, and the difficulty of production would increase. When the particle-size distribution is larger than 2.1, the time of dissolution of the resin in the solvent would be inconsistent, thereby the uniformity of the spinning solvent would be influenced, the spinning process would be unstable, and decollation would easily occur.
[0020] Good tensile breaking stress can well facilitate the thermal drawing of fibers. The tensile breaking stress of the ultra-high molecular weight polyethylene resin according to the present disclosure is in a range from 32 to 60 MPa. If the tensile breaking stress is lower than 32 MPa, the strength of the fibers would be reduced, and if the tensile breaking stress is higher than 60 MPa, filamentation is difficult to be carried out during the multistage drawing phase in the spinning process.
[0021] The ultra-high molecular weight polyethylene resin according to the present disclosure has a bulk density that can be adjusted in a broad range, which is from 0.10 to 0.50 g/cm 3 . If the bulk density is lower than 0.10 g/cm 3 , the resin would be too loose for the packaging and material feeding during production. If the bulk density is higher than 0.50 g/cm 3 , the resin would be too compact, and thus the infusion of solvent therein will be influenced.
[0022] The present disclosure further provides a method for preparing an ultra-high molecular weight polyethylene resin. In the presence of a main catalyst and a co-catalyst, ethylene is homopolymerized through a slurry polymerization process, thereby obtaining the ultra-high molecular weight polyethylene resin. Specifically, the method for preparing the ultra-high molecular weight polyethylene resin is as follows.
[0023] (1) Preparation of Main Catalyst
[0024] In inert atmosphere, magnesium halide is dispersed in an inert solvent. Alcohol is added for reaction, thereby forming magnesium halide-alcohol adduct solution or dispersoid. Subsequently, alkyl aluminum halide is added to react with the magnesium halide-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. A titanium compound is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled, and catalyst for preparing the ultra-high molecular weight polyethylene is obtained.
[0025] (2) Preparation of Ultra-High Molecular Weight Polyethylene
[0026] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, co-catalyst and main catalyst are added in sequence, and the temperature in the reactor is raised to a certain polymerization temperature. Vinyl monomer is injected into the reactor, and the pressure in the reactor is raised to certain polymerization pressure. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for a period of time, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0027] In the reaction, the co-catalyst can be one or more aluminum alkyls. The ratio of the main catalyst to the co-catalyst is selected so that Al/Ti molar ratio thereof is in a range of 30˜1000:1.
[0028] In step (1), the general formula for the Ti compound is Ti(OR 3 ) n X 4-n , wherein R 3 is an alkyl comprising 1 to 6 carbon atoms, X is halogen, preferably chlorine or bromine, and more preferably chlorine, and n is an integer selected from 0 to 4.
[0029] In step (1), the Ti loading reaction should be controlled under the temperature in a range from 0 to 130° C. for 10 min to 5 hr.
[0030] In step (2), the solvent for the polymerization is selected from aliphatic hydrocarbon compound or aromatic hydrocarbon compound comprising 5 to 15 carbon atoms, such as pentane, hexane, heptanes, octane, nonane, decane, 6# solvent oil, 120# solvent oil, methylbenzene, or xylene, wherein the solvent is preferably selected from hexane, heptanes, or 6# solvent oil, and more preferably 6# solvent oil.
[0031] In step (2), the co-catalyst can be one or more aluminum alkyls, such as trimethyl aluminum, triethyl aluminum, triisopropyl aluminum, triisobutyl aluminum, tri-n-hexylaluminum, diethylaluminum chloride, dibutylaluminum chloride, dibutylaluminum bromide, or other similar compounds. Preferably, the co-catalyst is triethyl aluminum. The co-catalyst can be one type of aluminum alkyl, or a combination of multiple aluminum alkyls.
[0032] The present disclosure further relates to the application of an ultra-high molecular weight polyethylene resin as raw material in the processing of polyethylene fibers.
[0033] The fibers obtained through spinning, using the ultra-high molecular weight polyethylene resin according to the present disclosure as raw material, have high tensile strength of 800 cN/dtex or more.
[0034] The main catalyst should be used in combination with the co-catalyst aluminum alkyls. The ratio of main catalyst to co-catalyst can be controlled in a range of Al/Ti molar ratio of 30˜1000:1, preferably in a range of 50˜400:1.
[0035] In step (2), the reaction temperature is in a range from 30 to 100° C., preferably in a range from 50 to 85° C.
[0036] In step (2) the reaction pressure is in a range from 0.1 to 1.6 MPa, preferably in a range from 0.4 to 0.8 MPa.
[0037] In step (2), the time of polymerization reaction is in a range from 0.5 to 10 hr, preferably in a range from 1 to 8 hr.
[0038] In step (2), the speed of stirring during the polymerization is in a range from 60 to 500 rpm. For a reactor with relatively small volume, stirring speed can be higher. However, for a reactor having a volume of more than 1 m 3 , the stirring speed should be lower.
[0039] The stirring paddle used in the present disclosure can be either a grid stirrer or an anchor stirrer. In order to enhance the cooling effect of the reactor, circulating water can also be fed into the paddle.
[0040] The catalyst according to the present disclosure can be fed to the reactor in a form of dry powder. Alternatively, the catalyst can be premixed with the polymerization solvent and then fed to the reactor.
[0041] As compared with the prior art, the present disclosure had the following advantages.
[0042] (1) The ultra-high molecular weight polyethylene resin according to the present disclosure has a relatively high initial crystallinity, which is in a range from 60.5 to 90%, a volume average particle size in a range from 100 to 350 nm, a molecular weight in a range from 2 to 7 million, a tensile breaking stress in a range from 30 to 60 MPa, and a bulk density of resin in a range from 0.10 to 0.50 g/cm 3 . The resin particles comprise porous and gyms-like structures. The decalin absorption amount of the resin is in a range from 2 to 50 g per 100 g of ultra-high molecular weight polyethylene resin, and the white oil absorption amount of the resin is in a range from 5 to 60 g per 100 g of ultra-high molecular weight polyethylene resin. The infiltration time of resin particles in solvent decalin is in a range from 0.5 to 11 min.
[0043] (2) The ultra-high molecular weight polyethylene resin is characterized by being excellent in fiber spinning performance, rapid in swelling and dissolution, and stable in spinning and thermal stretching processes. The fibers prepared have characteristics of high modulus and high strength, wherein the modulus ≧25 cN/dtex, and the strength ≧800 cN/dtex.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0044] The accompanying drawings, which constitute a part of the description, are provided for further understanding the technical solution of the present disclosure and that of the prior art. The accompanying drawings describing the examples of the present disclosure are used to explain the technical solution of the present disclosure together with the examples, they should not be construed as limitations thereto. In the drawings:
[0045] FIG. 1 shows a scanning electron micrograph of ultra-high molecular weight polyethylene resin particles prepared according to example 1 of the present disclosure,
[0046] FIG. 2 shows a scanning electron micrograph of ultra-high molecular weight polyethylene resin particles prepared according to example 3 of the present disclosure,
[0047] FIG. 3 shows a scanning electron micrograph of ultra-high molecular weight polyethylene resin particles prepared according to example 5 of the present disclosure, and
[0048] FIG. 4 shows a scanning electron micrograph of ultra-high molecular weight polyethylene resin particles prepared according to comparison example 1.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0049] The present disclosure will be explained in details with reference to the embodiments and the accompanying drawings, whereby it can be fully understood how to solve the technical problem by the technical means according to the present disclosure and achieve the technical effects thereof, and thus the technical solution according to the present disclosure can be implemented. It is important to note that as long as there is no structural conflict, all the technical features mentioned in all the embodiments may be combined together in any manner, and the technical solutions obtained in this manner all fall within the scope of the present disclosure.
[0050] The method and conditions for testing the characteristics and properties described in the present disclosure are as follows.
[0051] 1) A bulk density is measured with a BMY-1 apparent density tester under GB/T 1636-2008 standard.
[0052] 2) Measurement of molecular weight is carried out through viscometric method under the temperature of 135° C., with decalin as the solvent. The time for the polyethylene solution to flow out is measured with an Ubbelohde viscometer, and then an intrinsic viscosity η of the polymer is calculated. According to the following equation:
[0000] M γ =5.37×10 4 ×[η] 1.37
[0053] M γ obtained is the molecular weight of the polymer.
[0054] 3) A particle size and a particle-size distribution of the resin are obtained by processing micrographs taken by an optical microscope with a computer system.
[0055] 4) Measurement of a tensile breaking stress: a compression molded sample is prepared according to GB/T 21461.2 standard, and the sample is tested at a stretching velocity of 50 mm/min.
[0056] 5) Electron microscope: the morphology of the polymer resin is observed with an EVO18 scanning electron microscope produced by British ZEISS company, and the sample surface is processed through metal spraying.
[0057] 6) Measurement of an initial crystallinity: the initial crystallinity X i of the resin is calculated according to the following equation:
[0000]
X
i
=
Δ
H
f
293
×
100
%
[0058] In the above equation, ΔH f is the melting enthalpy of the polymer, with J·g −1 being the unit. The melting enthalpy is tested through a method under GB/T 19466.3-2004 standard using a DSC 2910 produced by TA company, USA, and the value of melting enthalpy obtained from the first scanning is selected.
[0059] 293 is the value of the melting enthalpy when the crystallinity of the polyethylene is 100%, the unit thereof being J·g −1 .
[0060] 7) The measurement of absorption amount of solvent is as follows.
(a) A centrifuge tube with absorbent cotton is used. The bottom of the centrifuge tube is a conical glass tube with a hole having a diameter of about 0.8 mm. (100±2) mg absorbent cotton is weighed in the centrifuge tube and gently pushed to the bottom thereof. The weight of the absorbent cotton and the centrifuge tube is measured to the accuracy of 0.1 mg. Subsequently, about 1 g sample is weighed in the centrifuge tube to the accuracy of 0.1 mg. 2 ml solvent (white oil or decalin) is added into the centrifuge tube with burette. And then the centrifuge tube is placed still for 10 min. (b) Put the centrifuge tube into a sleeve, and then the sleeve is placed into a positioning hole in a rotor of a centrifuge. It should be noted that the sleeve should be placed in a well balanced position. (c) The centrifuge is started. The centrifugal acceleration at the bottom of the sample is (11,000-13,000) m/s 2 , and the rotation lasts for 60 min. After the centrifuge is static, the centrifuge tube is taken out and wiped off of residual solvent on the exterior wall. Afterwards, the centrifuge tube is weighed to the accuracy of 0.1 mg. (d) Before running the test, blank sample test with no resin therein should be conducted according to the above steps. (e) At room temperature, the grams Xs of the solvent absorbed by 100 g resin is calculated according to the following equation:
[0000]
X
s
=
(
m
3
-
m
0
)
-
m
2
m
2
-
m
1
×
100
[0066] In the above equation:
m 0 is the mass of the solvent absorbed by the absorbent cotton in the blank test, the unit being g, m 1 is the mass of the centrifuge tube together with the absorbent cotton, the unit being g, m 2 is the mass of the centrifuge tube with the absorbent cotton and the resin sample, the unit being g, and m 3 is the mass of the solvent absorbed by the centrifuge tube having absorbent cotton and the resin sample after centrifugation, the unit being g.
[0071] 8) Measurement method of the infiltration rate is as follows. 1 g ultra-high molecular weight polyethylene resin is taken and put into a 50 ml volumertric flask. Decalin solvent is added into the flask to the scale mark thereof. Subsequently, the flask is closed with a glass stopper and placed into 120° C. oil bath. In the meantime, a stopwatch is started and the time for the components in the solvent to disappear visually is recorded.
[0072] 9) The resin according to the present disclosure can be manufactured into ultra-high molecular weight polyethylene fibers through dry process or wet process. Typical manufacturing process is as follows. Ultra-high molecular weight polyethylene resin is dissolved in decalin, and is extruded through a twin screw extruder, and is subsequently spun with a round single hole spinneret. The same process can be applied to various samples. The highest spinning temperature is 260 to 280° C. The gel fibers of the sample obtained are sufficiently extracted in an extraction agent, and then tensioned and dried. The dry gel fibers are used in the next step, i.e., ultra thermal drawing. Three-level drawing technology is adopted, with the temperatures of the three levels respectively being 80° C. for the first level, 100° C. for the second level, and 120° C. for the third level.
Example 1
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0073] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
[0074] (2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin.
[0075] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 1.5 mg main catalyst prepared according to the above steps are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0076] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I, and the scanning electron micrograph of the resin particles is as shown in FIG. 1 .
(3) Spinning Test is Conducted on the Polymer Resin Through the Following Process
[0077] Ultra-high molecular weight polyethylene resin is dissolved in decalin. Subsequently, the ultra-high molecular weight polyethylene resin is extruded through a twin screw extruder and spun with a round single hole spinneret. The same process can be applied to various samples. The highest spinning temperature is 260 to 280° C. The gel fibers of the sample obtained are sufficiently extracted in the extraction agent, and then tensioned and dried. The dry gel fibers are used in the next step, i.e., ultra thermal drawing. Three-level drawing technology is adopted, with the temperatures of the three levels respectively being 80° C. for the first level, 100° C. for the second level, and 120° C. for the third level. The spinning performances are as shown in Table II.
Example 2
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0078] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled, and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0079] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 1.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 55° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0080] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 3
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0081] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled, and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0082] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 1.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 65° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0083] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I, and the scanning electron micrograph of the resin particles is as shown in FIG. 2 .
(3) Spinning Test is Conducted on the Polymer Resin Through the Following Process
[0084] Ultra-high molecular weight polyethylene resin is dissolved in decalin. Subsequently, the ultra-high molecular weight polyethylene resin is extruded through a twin screw extruder and spun with a round single hole spinneret. The same process can be applied to various samples. The highest spinning temperature is 260 to 280° C. The gel fibers of the sample obtained are sufficiently extracted in the extraction agent, and then tensioned and dried. The dry gel fibers are used in the next step, i.e., ultra thermal drawing. Three-level drawing technology is adopted, with the temperatures of the three levels respectively being 80° C. for the first level, 100° C. for the second level, and 120° C. for the third level. The spinning performance is as shown in Table II.
Example 4
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0085] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0086] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 1.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 72° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0087] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
(3) Spinning Test is Conducted on the Polymer Resin Through the Following Process
[0088] Ultra-high molecular weight polyethylene resin is dissolved in decalin Subsequently, the ultra-high molecular weight polyethylene resin is extruded through a twin screw extruder and spun with a round single hole spinneret. The same process can be applied to various samples. The highest spinning temperature is 260 to 280° C. The gel fibers of the sample obtained are sufficiently extracted in the extraction agent, and then tensioned and dried. The dry gel fibers are used in the next step, i.e., ultra thermal drawing. Three-level drawing technology is adopted, with the temperatures of the three levels respectively being 80° C. for the first level, 100° C. for the second level, and 120° C. for the third level. The spinning performances are as shown in Table II.
Example 5
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0089] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0090] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 1.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.4 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0091] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I, and the scanning electron micrograph of the resin particles is as shown in FIG. 3 .
Example 6
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0092] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0093] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 1.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.8 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0094] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 7
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0095] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0096] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 1.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 1.0 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0097] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 8
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0098] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0099] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 0.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0100] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 9
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0101] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0102] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 1.0 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0103] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 10
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0104] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0105] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 2.0 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0106] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 11
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0107] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0108] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 2.5 mg said main catalyst added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0109] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 12
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0110] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0111] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 3 ml co-catalyst triethyl aluminum and 1.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0112] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 13
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0113] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0114] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 5 ml co-catalyst triethyl aluminum and 1.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. N the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0115] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 14
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0116] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0117] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 1.5 mg said main catalyst are added in sequence. The stirring speed is 210 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 2 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0118] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Example 15
(1) Preparation of Ultra-High Molecular Weight Polyethylene Catalyst
[0119] In inert atmosphere, 1 g magnesium chloride is dispersed in n-hexane. N-butanol is added for reaction at 70° C., thereby forming magnesium chloride-alcohol adduct solution or dispersoid. Subsequently, aluminum diethyl monochloride is added to react with the magnesium chloride-alcohol adduct, forming an intermediate product. The intermediate product is treated with ultrasound in an ultrasonic device. Titanium tetrachloride is added for a Ti loading reaction. Afterwards, said Ti loading reaction mixture is treated with ultrasound in the ultrasonic device. Finally, solid particles are recycled and the ultra-high molecular weight polyethylene catalyst is obtained.
(2) Preparation of the Ultra-High Molecular Weight Polyethylene Resin
[0120] After nitrogen purging in a polymerization reactor, solvent is added therein, and stirring is started. Then, 4 ml co-catalyst triethyl aluminum and 0.5 mg said main catalyst are added in sequence. The stirring speed is 300 rpm, and the polymerization temperature is raised to 60° C. Vinyl monomer is injected into the reactor. The pressure in the reactor is raised to 0.6 MPa. In the meantime, the pressure and temperature in the reactor are maintained constant. After the reaction proceeds for 1 hr, resin particles generated suspend in the solvent, thereby forming polymer slurry in the solvent. Finally, after the solvent is removed from the polymer slurry, the ultra-high molecular weight polyethylene resin required is obtained.
[0121] The properties of the ultra-high molecular weight polyethylene resin obtained are as shown in Table I.
Comparison example 1
[0122] A commercially available ultra-high molecular weight polyethylene resin A is used for a spinning test. The molecular weight of resin A is 1.85 million. The spinning process is the same as that described in example 1. The properties of the resin, which are obtained through the test method according to the present disclosure, are as shown in Table I, and the spinning performance thereof is as shown in Table II. The scanning electron micrograph of the resin of the present comparison example is as shown in FIG. 4 .
[0123] As shown in FIG. 1 , as compared with comparison example 1, the resin particles in example 1, example 3 and example 5 are characterized by uniform particle morphology and containing less large particles and fine particles therein. There are plenty of cracks and gyms-like structures on the resin particles, in which case, it is easy for the solvent to infiltrate into the particles, thereby the swelling and dissolving time of the particles can be significantly shortened.
Comparison Example 2
[0124] A commercially available ultra-high molecular weight polyethylene resin B is used for a spinning test. The molecular weight of resin B is 2.77 million. The spinning process is the same as that described in example 1. The properties of the resin, which are obtained through the test method according to the present disclosure, are as shown in Table I, and the spinning performance thereof is as shown in Table II.
Comparison Example 3
[0125] A commercially available ultra-high molecular weight polyethylene resin C is used for spinning test. The molecular weight of resin C is 3.59 million. The spinning process is the same as that described in example 1. The properties of the resin, which are obtained through the test method according to the present disclosure, are as shown in Table I, and the spinning performance thereof is as shown in Table II.
Comparison Example 4
[0126] A commercially available ultra-high molecular weight polyethylene resin D is used for a spinning test. The molecular weight of resin D is 4.33 million. The spinning process is the same as that described in example 1. The properties of the resin, which are obtained through the test method according to the present disclosure, are as shown in Table I, and the spinning performance thereof is as shown in Table II.
[0127] Table I shows the properties of the ultra-high molecular weight polyethylene resin in the examples and those in the comparison examples.
[0000]
TABLE I
Intial
Average
Infiltration
Molecular
Solvent absorption amount
Bulk
Tensile
crystallinity
particle size
Particle size
time
weight
g
density
breaking stress
%
μm
distribution
Min
10 4
Decalin
White oil
g/cm 3
MPa
Example 1
69.4
177
1.69
9
550
16.42
20.57
0.27
36.7
Example 2
72.1
183
1.78
8
623
21.75
23.45
0.26
37.3
Example 3
67.3
185
1.74
10
434
14.38
17.12
0.29
35.8
Example 4
63.6
182
1.84
9
303
15.72
17.99
0.31
34.9
Example 5
68.7
168
1.79
10
535
13.88
15.72
0.27
36.2
Example 6
69.3
175
1.65
9
568
16.01
19.01
0.28
35.9
Example 7
68.2
190
1.75
9
520
16.59
18.93
0.27
36.5
Example 8
69.1
187
1.81
10
379
12.11
14.87
0.30
36.7
Example 9
68.7
174
1.84
11
499
9.57
14.22
0.29
36.1
Example 10
69.5
193
1.73
9
425
17.54
20.14
0.25
35.9
Example 11
67.9
175
1.69
9
378
16.89
19.43
0.23
36.8
Example 12
68.3
183
1.88
10
520
15.34
19.67
0.25
36.2
Example 13
69.1
186
1.82
8
407
19.56
23.79
0.29
35.9
Example 14
67.4
180
1.77
9
504
16.29
18.89
0.28
36.2
Example 15
68.8
179
1.79
9
517
15.03
18.04
0.26
36.7
Comparison
57.8
226
2.17
12
185
4.11
9.31
0.29
30.1
example 1
Comparison
58.3
205
2.14
12
277
3.95
7.04
0.39
31.7
example 2
Comparison
57.9
221
2.23
12
359
4.07
8.50
0.41
32.5
example 3
Comparison
59.0
209
2.19
13
433
3.77
6.92
0.40
32.7
example 4
[0128] Table II shows the spinning performance of fibers in the examples and in the comparison examples.
[0000]
TABLE II
Tensile
Fine-
breaking
ness
stress
Modulus
Elongation
Sample
dtex
cN/dtex
cN/dtex
at break %
Example 1
First level
18
14.2
450.7
4.79
drawing
Second level
13
24.7
869.3
3.62
drawing
Third level
11
28.0
1084.7
3.39
drawing
Example 3
First level
20
13.9
398.9
4.71
drawing
Second level
16
23.5
780.4
4.03
drawing
Third level
13
26.4
937.6
3.86
drawing
Example 4
First level
22
13.0
392.3
4.16
drawing
Second level
17
21.7
682.4
3.89
drawing
Third level
15
25.0
870.8
3.25
drawing
Comparison
First level
28
10.8
280.8
3.75
example 1
drawing
Second level
26
15.4
378.5
3.56
drawing
Third level
23
18.7
502.4
3.24
drawing
Comparison
First level
25
12.4
331.2
3.84
example 2
drawing
Second level
22
16.7
450.1
3.67
drawing
Third level
18
19.5
606.8
3.41
drawing
Comparison
First level
23
13.9
370.3
3.92
example 3
drawing
Second level
20
17.3
580.1
3.78
drawing
Third level
16
20.6
795.4
3.56
drawing
Comparison
First level
19
14.4
399.2
4.01
example 4
drawing
Second level
16
18.6
645.6
3.84
drawing
Third level
14
22.1
858.9
3.66
drawing
[0129] According to Table I and Table II, as compared with the comparison examples, the resin according to any example of the present disclosure has relatively high initial crystallinity, proper average particle size, relatively narrow particle-size distribution, and controllable molecular weight. In the meantime, the tensile breaking stress of the resin is significantly improved, and the solvent absorption amount thereof is increased. As a result, in the fiber spinning process, the resin can dissolve rapidly, and the fibers obtained have higher strength and higher modulus.
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Disclosed are an ultra-high molecular weight polyethylene resin for fiber and a preparation method thereof. The initial crystallinity of the resin is 60.5 to 90%, the volume average particle size is between 100 and 350 μm, the particle-size distribution is 1.0-2.1, the molecular weight is 2-7 million, the tensile breaking stress is 30 to 60 MPa, the bulk density of the resin is 0.10 to 0.50 g/cm 3 , the infiltration time in the solvent decalin is 0.5 to 11 min, the decalin absorption amount of the resin is 2 to 50 g of decalin per 100 g of ultra-high molecular weight polyethylene resin, and the white oil absorption amount is 5 to 60 g of decalin per 100 g of ultra-high molecular weight polyethylene resin. The ethylene homopolymerization is performed using a slurry polymerization process in the presence of a main catalyst and a co-catalyst.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a submission under 35 U.S.C. §371 of International Application No. PCT/EP2011/005618, filed Nov. 9, 2011, which claims priority to German Application No. 10 2010 051 048.3, filed Nov. 11, 2010, the disclosures of which are hereby expressly incorporated by reference herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to an interchangeable holder system and a construction machine comprising such an interchangeable holder system.
BACKGROUND OF THE INVENTION
[0003] A typical field of application for generic interchangeable holder systems is their use in machines for preparing ground surfaces, more particularly in the field of road and way construction. These are frequently machines having a driven working drum which is mounted for rotation about a horizontal axis and on which a large number of ground preparation tools, more particularly cutters or chisels and more specifically round shaft chisels, are disposed. The entire block consisting of the working drum and the large number of ground preparation tools is also referred to below as the milling rotor. Such machines include, for example, so-called stabilizers, recyclers or road cutters, more particularly cold cutters. Under working conditions, the holders containing the cutting tools are exposed to high loads and to extremely high wear, caused, on the one hand by the broken ground material in the drum housing and, on the other hand, depending on the embodiment, by the round shaft chisel rotating, for example, in the chisel holder. The wear occurs, inter alia, particularly in the region of the bore accommodating the chisel shaft in the chisel holder and in the region of the contact surface of a possibly present wearing disk. Moreover, the chisel holder is worn out or destroyed in the case of fracture, loss, or wear of the chisel. In order to make it possible to replace the worn or broken components of the chisel holder easily and quickly, the use of so-called interchangeable holder systems has become established.
[0004] The essential components of such an interchangeable holder system are a basic module and an interchangeable holder connected to the basic module and comprising a cutting tool. More specifically, the interchangeable holder may be integrally united with the cutting tool or alternatively comprise a suitable tool head, which is configured to accommodate a ground preparation tool, for example a chisel, more particularly a round shaft chisel. The basic module is rigidly attached to the cylindrical external surface of the milling drum, which is usually mounted on horizontal bearings extending at right angles to the direction of travel of an appropriate construction machine, for example by fixed welding of the basic module to the drum body. Thus the basic module is the link between the interchangeable holder system and the drum body. The basic module also serves to provide bearings for the interchangeable holder or is configured to accommodate the interchangeable holder and provide bearings therefor. Frequently, there is provided for this purpose an interchangeable holder head in the basic module, which head may be in the form of an insertion bore in the basic module, for example. The interchangeable holder may be reversibly mounted on the basic module and comprises for this purpose, for example, a suitable journal, which is pushed into the insertion bore for the purpose of mounting the interchangeable holder on the basic module. The interchangeable holder is then fixed in position on the basic module by means of a suitable securing device comprising, for example, threads, or bores for locking pins and/or screw bolts, etc. The interchangeable holder may further be at least partially conical in shape and is pushed, for mounting purposes, into an insertion bore provided in the basic module.
[0005] The cutting tool in the interchangeable holder may, on the one hand, be integrally united with the interchangeable holder, for example in the form of a cutter. On the other hand, the interchangeable holder may be configured for accommodation of an independent cutting tool and for providing bearings therefor. This is frequently the case, for example, when a chisel, especially a round shaft chisel, is used. An appropriate tool head is then provided on the interchangeable holder, for example a cylindrical chisel head in the form of a slot for round shaft chisels. Round shaft chisels are frequently mounted in the interchangeable holder for rotation about their cylinder axis and are secured against axial displacement by suitable locking means, as for example a locking sleeve.
[0006] The advantage of such an interchangeable holder system lies basically in the fact that in the case of a defective ground preparation tool and/or an interchangeable holder, it is possible to selectively replace the tool and/or the interchangeable holder without it being necessary, for this purpose, to elaborately break the fixed connection between the basic module and the drum body and then re-establish it.
[0007] Although generic interchangeable holder systems have basically proved to be successful, there is still room for improvement. For example, the known interchangeable holder systems are frequently of an extremely bulky nature, due, for example, to the method of supporting the interchangeable holder on the basic module. Particularly those embodiments in which the interchangeable holder is placed in position in an appropriate insertion bore in the basic module at least partially by means of, for example, one or more studs or the like, both the interchangeable holder and, more particularly, the basic module must be comparatively broad and heavy in order to satisfy stability requirements. On account of the massive construction, more particularly the overhanging holder width, increased power requirements must be satisfied during transportation of the material or during mixing operations. Thus, a correspondingly high driving power must be available when the machine is in action, which is inevitably accompanied by increased acquisition and operating costs. Furthermore, the separation of the interchangeable holder from the holder is frequently hampered by this system. More particularly, in a corrosive environment, such as prevails, for example, when certain binding agents are to be incorporated in the subsurface, corrosion frequently takes place to additionally bond the interchangeable holder to the holder. This is particularly problematic in the region of pin-and-socket connectors between the interchangeable holder and the holder. Moreover, the production of the hitherto known interchangeable holder systems is comparatively cost-intensive, since broad fitment tolerances exist, particularly between the basic module and the interchangeable holder, which make an extensive manufacturing process necessary. Finally, the joint between the basic module and the interchangeable holder is frequently difficult to access, so that here again there is room for improvement.
SUMMARY OF THE INVENTION
[0008] It is thus an object of the present invention to provide an interchangeable holder system which facilitates the exchange of the interchangeable holder on the basic module and at the same time increases the resistance values thereof and improves handling thereof.
[0009] The interchangeable holder system of the present invention comprises a basic module and an interchangeable holder that is equipped with a cutting tool and is capable of being attached to the basic module. The designation “equipped with a cutting tool” relates, on the one hand, to those embodiments in which the cutting tool is integrally united with the interchangeable holder and, on the other hand, to those embodiments in which the cutting tool is held by the interchangeable holder as a discrete part. The latter comprises both embodiments in which the cutting tool is rigidly connected to the interchangeable holder and variants in which the cutting tool is configured so as to replaceably mounted in the interchangeable holder, more particularly as a round shaft chisel. The basic module comprises a forward contact surface and a rearward contact surface situated below the level of the forward contact surface. The terms “forward” and “rearward” relate more particularly to a longitudinal axis of the cutting tool, oriented in the machine direction of the cutting tool. In the case of a round shaft chisel, the longitudinal axis of the cutting tool is thus the shaft axis extending from the rearward end of the chisel towards the tip of the chisel. The longitudinal axis of the cutting tool extends in general with reference to a plane at right angles to the rotation axis of the milling rotor generally in the region between a radial plane extending through the rotation axis “a” of a milling rotor equipped with the interchangeable holder system of the present invention and the direction of action of the force applied by the ground material to be prepared and acting tangentially at the cutting periphery of the milling rotor on the tip of the cutting tool. The terms “forward” and “rearward” are to be understood, in particular, in terms of the mounting direction of the interchangeable holder on the basic module, the forward contact surface on the basic module being at a higher level than the rearward contact surface. The two contact surfaces are separated from each other by a stopping step in the form of a stop wedge. The stop wedge in the present instance consists more particularly of two contact surfaces set at an angle to each other so as to approach each other, these being of a protruding or receding configuration with regard to the adjacent surface. The pointing direction of the wedge is that direction in which the distance between the contact surfaces diminishes. The interchangeable holder is configured for at least partial contact with the basic module at the forward contact surface and at the rearward contact surface across the stopping step. The interchangeable holder system of the present invention finally comprises a securing device, by means of which the interchangeable holder bearing on the basic module can be fixed in position on the basic module.
[0010] A fundamental aspect of the present invention resides first in the fact that the interchangeable holder no longer needs to be pushed into the basic module in order to attach it to the basic module, for example by means of a journal or by way of its base body inserted into an appropriate reception hole, but rather can be attached flat against the basic module. For this purpose there are present on the basic module the said forward contact surface and the said rearward contact surface, both of which simultaneously serve as a contact surface or a bearing surface for the interchangeable holder on the basic module. The terms “forward” and “rearward” refer to a reference perpendicular standing vertically on one of the two surfaces, the “rearward” contact surface being at a receded level relative to the “forward” contact surface, at least in the region of the stopping step, as viewed along this reference perpendicular. As regarded in the machine direction (i.e., that direction in which the cutting tool is moved by the rotating milling rotor during the milling operation), the forward contact surface is at least partially, and more particularly completely, in advance of the rearward contact surface. The forward contact surface and the rearward contact surface are thus two surfaces, whose levels relative to each other are offset in the machine direction of the interchangeable holder system disposed on a milling rotor, said offset from each other being formed by the stopping step, that is to say, taken as a whole, a step is formed between them. The “forward” contact surface is that surface which at least in the region of the stopping step is at a higher level along the machine direction and the “rearward” contact surface is correspondingly that surface which at a receded level relative to the forward contact surface along the machine direction at least in the region of the stopping step, that is, in the transition region between the forward contact surface and the rearward contact surface, more particularly as regarded in the axial direction of the cutting tool. The machine direction of the interchangeable holder system is that direction in which it is moved by a milling rotor during the milling operation. Said movement is usually a movement of rotation, that is to say, the machine direction is in each case a tangential directional vector. If, for example, a round shaft chisel is used as cutting tool, the machine direction is typically inclined relatively to the axial direction of the round shaft chisel or the round shaft chisel head in the interchangeable holder as a tangent starting from the tip of the chisel and directed in the direction of rotation to the cutting periphery of the milling rotor.
[0011] The forward contact surface and the rearward contact surface are relevant to the stopping step extending between said two contact surfaces. The stopping step is such that element which connects the forward contact surface to the rearward contact surface. The stopping step comprises a top edge extending in the longitudinal direction and merging into the forward contact surface, and a bottom edge extending in the longitudinal direction and merging into the rearward contact surface. Between these two edges there is usually present a wall in the form of a step, which is preferably in the form of a flat plane at least in certain regions thereof or is segmented to form a plurality of flat plane elements. However, it is of course also possible to design the wall in the form of a step in the longitudinal direction of the top edge and/or the bottom edge as a curved element, for example so as to be convex or concave or wavy, etc. Furthermore, the wall in the form of a step or stopping step is tilted or inclined relatively to the forward contact surface and/or the rearward contact surface, an arrangement in which the wall in the form of a step is perpendicular to the adjacent forward contact surface and/or the adjacent rearward contact surface in each case, or an arrangement in which the said wall at least partially represents an undercut relatively to the forward contact surface, i.e., is at an angle to the forward contact surface of less than 90°, has proved to be preferable.
[0012] In practical usage, it is important in a generic interchangeable holder system that the correct alignment of the interchangeable holder relative to the basic module be reliably ensured during assembly. Another important factor is that the position of the interchangeable holder should remain perfectly stable in spite of the considerable forces that act on the interchangeable holder system under working conditions, in order to ensure flawless functioning of an appropriately equipped milling rotor. The term “working conditions” means the practical employment of the interchangeable holder system in carrying out milling operations, usually with a milling rotor. According to one embodiment of the present invention, this is achieved, on the one hand, by the specific design of the counter contact surface on the interchangeable holder for achieving contact with the forward contact surface and the rearward contact surface across the stopping step and, on the other hand, by the design of the stopping step as a stop wedge and by the presence of a securing device.
[0013] Thus the interchangeable holder firstly comprises counter contact surfaces, which are provided for the purpose of making contact with, or of bearing flat against, the forward contact surface and the rearward contact surface on the basic module. Once the interchangeable holder has been mounted on the basic module, the interchangeable holder will bear, with a first contact surface, against the forward contact surface of the basic module and, with a second contact surface, against the rearward contact surface of the basic module. In other words, the interchangeable holder thus likewise comprises a forward contact surface (i.e., a contact surface that protrudes towards the basic module) and a rearward contact surface situated at a receded level relative to its forward contact surface (in the direction towards the interchangeable holder), which contact surfaces are separated from each other at different levels by a step, such that the interchangeable holder can bear flat against the forward contact surface and the rearward contact surface on the basic module when mounted on the basic module. In the mounted state, the forward contact surface (i.e., that protruding towards the basic module) of the interchangeable holder bears against the rearward contact surface of the basic module and vice versa. Due to the fact that the interchangeable holder is thus configured to bear against the basic module across the stopping step in the form of a stop wedge, there results, firstly, a type of anti-twist stop on the basic module with respect to the interchangeable holder. On account of the stopping step present in the region of contact between the interchangeable holder and the basic module, the interchangeable holder cannot be freely rotated with respect to the basic module in a plane parallel to the rearward or forward contact surfaces, but is hindered from doing so by the stopping step. The stopping step present in the basic module and bridged by the interchangeable holder in the stopping region or contact area between the basic module and the interchangeable holder thus contributes substantially to the positional stabilization of the interchangeable holder on the basic module. In other respects, the region of contact between the two contact surfaces and the stopping step between the basic module and the interchangeable holder is free from protruding elements, such as slide-in elements, for example journals, a bearing cone, etc., and is thus in its overall design completely flat such that the interchangeable holder need not be partially pushed into an insertion bore in the basic module, but can be mounted flat thereon.
[0014] Another contribution to the mounting of the interchangeable holder on the basic module is afforded by the wedge-shaped design of the stopping step on the basic module and the appropriate mating surface on the interchangeable holder. In addition, the interchangeable holder is provided with a stopping step in the form of a stop wedge which comes to bear against the stopping step in the basic module. Thus the stopping step in the form of a stop wedge on the basic module is wedge-like engaged by a counter region of the interchangeable holder, which counter region is likewise in the form of a stop wedge and comes to bear against this region. In this way, any shift of the interchangeable holder in the pointing direction of the wedge, that is, in the direction in which the tip of the wedge points in each case, is totally excluded. The stop wedge on the basic module (and respectively also on the mating surface of the interchangeable holder) is characterized, firstly, in that it has a wedge-shaped profile in the plane of the forward contact surface and/or the rearward contact surface. Thus the connecting region between the forward contact surface and the rearward contact surface is, for example, substantially V-shaped or C-shaped or has at least two wedge flanks that approach one another. The wedge flanks of the stop wedge or the two side walls of the stop wedge are in other words disposed relatively to each other in such a manner that the distance separating each other increases in one direction (in the direction pointing away from the tip of the wedge). The stop wedge for this purpose may, for example, be rounded off or curved so as to obtain, for example, a convex or concave profile. However, it has proved to be very advantageous to use the design of the stop wedge comprising plane and linear flanks. The term “flank” designates in each case a continuously extending, more particularly at least substantially plane, wedge-shaped surface or wall of the stop wedge formed by the stopping step. Plane and linear flanks are considerably more suitable for the purpose of counteracting rotation of the interchangeable holder relatively to the holder or basic module in the following manner described in detail by way of example and for the purpose of establishing a positive interlock. At least the top edge and/or the bottom edge thus preferably comprises two flank segments, which in the plane of the corresponding forward contact surface and/or rearward contact surface are configured or arranged such that they approach one another. There may, of course, be present a plurality of wedge segments disposed side-by-side such that the stopping step comprises an overall serrated profile, for example. The segments are preferably identical as regards their step height and their respective edge length. However, the edges of the two segments extend in different directions in space and the distance between them increases in the direction contrary to the pointing direction of the wedge, such that they form, say, a “V” or “C” relatively to each other in the plane of the forward contact surface and/or in the plane of the rearward contact surface. The stop wedge may be further configured in such a manner that the wedge flanks directly intersect in the region of the tip of the stop wedge. Alternatively, however, an opening may be present in the region of the tip of the stop wedge, so that the extensions of the longitudinal edges of the wedge flanks intersect at the tip of the wedge. Thus the two segments form, in other words, a contact wedge on the basic module, which contact wedge is preferably configured so as to positively accommodate a corresponding counter wedge on the interchangeable holder. This arrangement makes it possible to achieve a particularly efficient anti-twist stop on the interchangeable holder relative to the basic module. To this end, the contact wedge on the basic module may be configured to protrude from the basic module in the direction of the interchangeable holder to engage in an appropriate recess in the wedge on the interchangeable holder. However, it is preferable to provide a wedge-like protrusion on the interchangeable holder and to provide the requisite opening in the basic module for the purpose of accommodating, or bearing against, the wedge-like protrusion. Both the wedge-like protrusion and the opening in the wedge are included in the term “stop wedge”. The wedge-like protrusion and the opening in the wedge are further configured relatively to each other in such a manner that the forces acting on the interchangeable holder when the cutting tool is subjected to a work load are directed at least partially against the stopping step in the basic holder such that the interchangeable holder is, for example, “pressed” into the stopping step under working conditions. This is particularly successful due to the fact that the forward contact surface of the basic module extends, with respect to the bottom region of the basic module (the connecting region for the cylindrical drum of the milling rotor), at least in the region of the stopping step, at least partially above the rearward contact surface and thus forms a hindrance to displacement caused by the transverse force acting on the interchangeable holder, that is to say, forms a cross force absorber.
[0015] Finally, another element of the interchangeable holder system of the present invention is the provision of a securing device. The securing device serves the purpose of fixing or holding the interchangeable holder in position on the basic module after it has been placed flat on the basic module or mounted thereon. Such securing devices are known per se in the prior art and may, for example, be based on suitable screwing methods, bracing methods, bolting methods, etc. Basically, it is possible to resort to prior methods known to the person skilled in the art for the purpose of achieving the securing device for locking the basic module to the interchangeable holder. However, it is ideal when the securing device comprises at least one mounting screw that can be used for the purpose of fixing the interchangeable holder to the basic module. For this purpose, such a locating screw is guided, for example, through an appropriate through bore extending through the basic module such that it meets the interchangeable holder, in which a corresponding female thread is present. The integration of the female thread in the interchangeable holder has the further advantage that, when the interchangeable holder is replaced, not only is the interchangeable holder but also the female thread renewed and thus a reliable and heavy-duty engagement of the locating screw is ensured. According to one embodiment, the design of the securing device of the present invention stabilizes the installation of the interchangeable holder on the basic module in the manner described above. The design of the stopping step as a stop wedge as proposed by the present invention makes it possible, in a preferred embodiment, to also relieve the securing device from transverse forces and thrust forces occurring between the interchangeable holder and the basic module, since these forces are transferred between the two components substantially via the wedge-shaped stopping step. Preferably, the securing device is further configured in such a manner that it is inclined relatively to the forward contact surface and to the rearward contact surface on the basic module such that when the securing device is tightened, the interchangeable holder with its region of contact is drawn into the thrust wedge on the basic module, particularly when this is undercut. This arrangement, in conjunction with the flat region of contact between the interchangeable holder and the basic module, has the further advantage that dismantling is facilitated. First of all, the securing device can be more easily released, since it is subjected to less load on account of the wedge-shaped design of the stopping step. At the same time, the interchangeable holder can then be readily released from the basic module, even if the interchangeable holder adheres to the basic module on account of corrosion. If desired, any adhesion forces present may then be overcome, for example, by means of hammer blows applied to the interchangeable holder in the direction contrary to that in which the wedge of the stopping step points.
[0016] In all, the interchangeable holder system of the present invention thus makes it possible to place the interchangeable holder on the basic module without it being necessary for the basic module to accommodate or receive, for this purpose, a (plug-in) part of the interchangeable holder in a bearing-type bore in the basic module (or vice versa). Rather, there exists between the basic module and the interchangeable holder an exclusively stepped flat region of contact in the surface, which in each case extends to the edge of the basic holder and the interchangeable holder and ensures secure seating of the interchangeable holder on the basic module. The interchangeable holder system can therefore be substantially narrower than the known interchangeable holder systems, as a result of which there is a considerable saving of material and weight. At the same time, the disassembly of the interchangeable holder is particularly facilitated, since this can be achieved simply by knocking the interchangeable holder out of the wedge-shaped stopping step. Moreover, there is no need to carry out the usually cost-intensive and time-consuming production of elaborate and extensive of regions involving fitting tolerances between the interchangeable holder and the basic module, since the contacting structures consisting of the “forward” and “rearward” contact surfaces in the basic module (and, as mentioned above, in the interchangeable holder), as proposed by the present invention, can be achieved in a comparatively simple manner.
[0017] It is basically possible for the interchangeable holder to only partially bear against the forward contact surface and the rearward contact surface on the basic module and for the stopping step to contact only certain regions or certain spots thereon. In view of the facilitated assembly and, in particular, of the secure positioning of the interchangeable holder on the basic module, it is, however, preferred that the interchangeable holder, for the purpose of achieving a flat contact across the entire basic module, be configured so as to complement the forward contact surface, the rearward contact surface and the stopping step of the basic module such that it bears flush against the forward contact surface and the rearward contact surface and against the stopping step across the entire contact surface. The interchangeable holder is thus positively configured with respect to the basic module in the region of contact. On the basic module, substantially the entire region consisting of the forward contact surface, the rearward contact surface, and the stopping step is thus formed as a common continuous region of contact, via which the interchangeable holder bears against the basic module as a continuous entity and preferably exclusively in the mounted state on the basic module. Thus in other words, the interchangeable holder is in its region of contact configured as the negative of the region of contact on the basic module. This relates, however, only to the design of the contact surfaces and ignores, for example, the presence of maintenance holes and reception holes for tools adapted to prepare ground surfaces, etc. Essential to this embodiment is the fact that the basic module and the interchangeable holder can be placed together in the region of the forward and rearward regions of contact and in the region of the stopping step substantially with no gap formed therebetween in the mounted state, on account of the mutually positively configured regions of contact.
[0018] And more particularly, from the manufacturing point of view, it is advantageous when the forward contact surface and the rearward contact surface of the basic module (and accordingly also those of the interchangeable holder) are in each case perfectly plane. Thus each of the contact surfaces lies, in these embodiments, in a plane and are not curved, serrated, wavy, or otherwise three-dimensionally shaped, although this is basically possible but not preferred. Furthermore, the plane of the forward contact surface and/or of the rearward contact surface is preferably configured in the interchangeable holder system in such a manner that it is cut so as to be inclined to the direction of force absorption of the ground preparation tool. The direction of force absorption of the ground preparation tool is the direction in which the force exerted by the surface to be prepared acts, under working conditions, against the ground preparation tool. When a round shaft chisel is used, the said direction is usually the direction of the force acting tangentially against the tip of the chisel at the cutting periphery of the rotating milling rotor contrary to the direction of rotation of the milling rotor. Thus the direction of force absorption is contrary to the machine direction.
[0019] It is further possible for the forward contact surface and the rearward contact surface to be at an angle to each other so as to intersect when appropriately extended. However, it is preferred that the plane in which the forward contact surface lies be parallel to the plane in which the rearward contact surface lies. This facilitates the fabrication of the interchangeable holder system of the present invention. Moreover, it is possible, in this embodiment, for both the forward contact surface and the rearward contact surface to be disposed obliquely to the direction of force absorption, in order to obtain ideal force transmission results and thus an interchangeable holder system with particularly satisfactory load-bearing properties.
[0020] The stopping step is, as mentioned above, the coupling element between the forward contact surface and the rearward contact surface in the basic module. Preferred design options for the stopping step are revealed, within the scope of the present invention, for example, in the design of the stopping step in the transition region to the forward contact surface and/or in the transition region to the rearward contact surface. Thus it is possible, for example, to provide the stopping step with a rounded shape in a plane at right angles to the longitudinal extent of the stopping step. For this purpose, the edge region or marginal region between the stopping step and the forward contact surface and/or the rearward contact surface may, for example, be rounded. However, in order to obtain ideal positional stabilization and power transmission between the basic module and the interchangeable holder, the edge is preferably tapered or beveled. Thus two straight lines of the respective portions of the surface meet towards the respective edge in the plane at right angles to the longitudinal extent of the edge. It is preferred that these lines be at right angles to each other or form an acute angle.
[0021] Another design option for the stopping step resides in their specific arrangement on the basic module. For example, the wedged shape of the stopping step may be in the form of a continuous element having two wedge flanks or stop limit surfaces that converge in the region of the tip of the wedge. In practical usage of the interchangeable holder system of the present invention, it has been found, however, to be advantageous to provide the stopping step in segmented form. The term “segmented” should be understood, in particular, to mean that the stopping step does not extend continuously across its entire area between the forward and rearward regions of contact, but comprises at least two segments. The segmentation may be based on different angular positions of the flanks of the stop wedge with respect to the forward contact surface and the rearward contact surface, on the one hand, and/or on different lengths of each flank. Furthermore, at least one flank of the stopping step in the form of a stop wedge may be interrupted, for example, by a bore. Finally, for example, the region of the tip between the two flanks, i.e., the region in which the two flanks of the stop wedge meet in the pointing direction of the wedge, may comprise an opening. Thus, in this embodiment, the stopping step in the form of a stop wedge comprises two contact surfaces that are spaced at an angle to each other. It is essential for the design of the stopping step in wedge form that it should comprise at least two wedge-shaped surfaces, against which the interchangeable holder with its corresponding wedge-shaped counter region can hit in addition to the forward contact surface and the rearward contact surface, so that displacement thereof in the pointing direction of the wedge (the direction in which the tip of the wedge points) is hindered.
[0022] Even though the angular position of the two legs or flanks of the stop wedge can be basically varied over a broad range, the longitudinal edges of the two segments of the stop wedge are preferably at an angle to each other ranging from 120° to 30°, more particularly from 100° to 50°, and very particularly from 80° to 60°. It is not necessary, as already stated above, for the two wedge flanks or legs to be directly adjacent to each other. The angles stated above apply likewise to legs that are spaced apart from each other. The appropriate angles formed by the legs are then determined by the extensions of the legs along their longitudinal edges.
[0023] In order to obtain as uniform an anti-twist stop as possible in both directions of rotation of the interchangeable holder with respect to the basic module, the stopping step in the form of a stop wedge is preferably configured mirror-symmetrically on the basic module. The flanks of the stop wedge are therefore preferably configured in the same manner. The same applies to the segmented form of the stopping step. The at least two segments are thus likewise preferably configured in the same manner and are ideally mirror-symmetrical to each other.
[0024] Furthermore, the stopping step may vary in the manner stated above alternatively or additionally to the above preferred developments regarding the arrangement of the wall in the form of a step or the flanks of the stop wedge of the stopping step relative to the forward contact surface and/or the rearward contact surface. In addition to the course of the respective edge relative to the forward contact surface or to the rearward contact surface in the respective plane of the contact surfaces, the cross-sectional profile of the stopping step, that is to say, the design of the stopping step in a plane at right angles to the wall in the form of a step, may be differently configured. On the one hand, is it again possible to shape the wall in the form of a step adjoining the upper contact surface and/or the receded contact surface so as to be rounded, while basically preference is given to an angular design, as stated above. Regarding the respective angle between the wall in the form of a step and the forward contact surface or the rearward contact surface, optimum results have been obtained using in each case a right-angled or perpendicular arrangement, since such an arrangement is favorable for fabrication and at the same time produces, in the mounted state, reliable results regarding the positional stability of the interchangeable holder with respect to the basic module. Alternatively, however, it is possible to configure the wall in the form of a step such that it is tilted or inclined with respect to the forward contact surface and/or to the rearward contact surface, more particularly in such a way that the forward contact surface protrudes above the rearward contact surface in the region of the stopping step or forms a type of overhang (which will, in the mounted state, be rearwardly engaged by the interchangeable holder ideally configured so as to have a suitably complementary shape). In this way, the profile of the stopping step in the vertical cross-sectional plane likewise affords a type of retaining wedge, with the result that this interchangeable holder system is capable of carrying an even greater load.
[0025] It will be appreciated that, according to the present invention, all of the design alternatives for the basic module relating to the forward contact surface and the rearward contact surface and to the stopping step also apply to the design of the region of contact on the interchangeable holder, preferably as regards the complementary configuration of the contact surfaces and the stopping step. For the sake of clarification, it is not intended to repeat all of the embodiment variants for the interchangeable holder.
[0026] In a particularly preferred embodiment of the present invention, the interchangeable holder system is further provided with a relieving device between the interchangeable holder and the basic module, which relieving device is configured in such a manner that, when the interchangeable holder system is heavily loaded, for example by the occurrence of increased thrust forces on the cutting tool, it will provide for additional force absorption from the interchangeable holder into the basic module. More specifically, the basic module may for this purpose comprise, for example, a supporting projection and the interchangeable holder a relief ledge. It is essential for this embodiment that the basic module comprises a supporting projection in addition to the wedge-shaped stopping step of the present invention. The supporting projection is configured in such a manner that the interchangeable holder, when subjected to a heavy load, i.e., more particularly, when it starts to show slight deformation, can be additionally supported by said supporting projection. More particularly, any thrust forces acting on the interchangeable holder can be absorbed in this way in a very satisfactory manner and transferred to the basic module, with the result that the overall load-bearing capacity of the interchangeable holder system can be enhanced. For this purpose, the supporting projection is, for example, in the form of a projection that can be at least partially surroundingly or rearwardly engaged by the interchangeable holder. The interchangeable holder may for this purpose comprise, for example, a suitable relief ledge in the form of a hook-like projection provided on the interchangeable holder and configured such that it can at least partially surroundingly engage the supporting projection. The supporting projection and the relief ledge can be basically designed in such a manner that they bear against each other in the mounted state of the interchangeable holder on the basic module such that force transmission from the relief ledge to the supporting projection can take place even under small loads. It is preferred, however, that in the mounted state the relief ledge and the supporting projection be separated from each other by a small gap. When the interchangeable holder is now subjected to an excessive load to the point at which partial deformation of the interchangeable holder takes place, this gap will be closed as a result of the deformation and the relief ledge will come to bear, ideally flatly, against the supporting projection. From this moment on, continued loading will cause an additional partial force absorption to occur via the supporting projection of the basic module, such that the interchangeable holder is totally relieved. Thus the relief ledge and the supporting projection in the interchangeable holder system are again preferably designed in such a way that the counter-force caused to act under working conditions on the interchangeable holder system by the ground being prepared presses the relief ledge against the supporting projection. As regards the stopping step in the form of a stop wedge, this means that the supporting projection is preferably disposed upstream of the stop wedge, as regarded in the direction of thrust, i.e., in the direction in which, under working conditions, typically thrust forces are exerted on the interchangeable holder system. Furthermore, the stop wedge preferably points in the direction in which the thrust forces act on the interchangeable holder system. In this way, forces acting on the interchangeable holder will be absorbed by the basic module in an optimal manner.
[0027] The supporting projection and the relief ledge may vary in design, but it is preferred that, at least in the loaded condition, there is basically a positive engagement of the relief ledge on the supporting projection across the entire region of contact between these two elements. Thus the region of contact on the relief ledge is ideally designed so as to be complementary to the region of contact of the supporting projection. For this purpose, both the relief ledge and the supporting projection are configured, for example, such that each is flat and ideally extends at right angles to the machine direction of the interchangeable holder system. However, in addition to plane embodiments, curved variants are also possible. It is however more particularly possible to configure the respective stopping regions on the supporting projection and on the basic module, such that they are segmented, as stated above for the stop wedge, and, more particularly, are likewise wedge-shaped, and it is here again self-evident that in addition to embodiments comprising linear or plane segments use may also be made of curved or mirrored convex or concave segments. It is of very great advantage in this respect when the wedge of the wedge-shaped stopping region between the supporting projection and the base ledge points in the direction of the stop wedge between the forward contact surface and the rearward contact surface and ideally in the same direction as this stop wedge. It is also preferred that the supporting projection, as regarded in the cross-section of the interchangeable holder system, be configured so as to extend from the marginal area of the receded contact surface of the basic module, more particularly approximately in the machine direction of the cutting tool, to form a rearwardly directed hook-like element and thus, in particular, does not protrude above the receded contact surface.
[0028] The basic module and/or the interchangeable holder are also preferably formed as forged or cast parts.
[0029] Moreover, a material-guiding region is preferably present on the basic module and/or on the interchangeable holder in the region directed in the machine direction, which material-guiding region serves as an improved guiding means for the milled material and/or the material to be mixed and as a wear pad. More specifically this can be, for example, one or preferably two wedge-shaped surfaces downwardly sloping to the sides of the basic module or interchangeable holder, which sloping surfaces are ideally center-symmetrical to each other. This region is also preferably domed away from the basic module to form a boss, and it is basically also possible to provide a boss-like design not comprising appropriate wedge-shaped surfaces. This boss contributes to the formation of a region of wear or a wear pad on the interchangeable holder that enables a considerable extension of the operating life of the interchangeable holder to be achieved. Furthermore, the boss preferably extends in the machine direction of the interchangeable holder system and may additionally overlap a portion of the basic module on at least one side of the region of contact between the interchangeable holder and the basic module in order to protect the basic module more efficiently from wear.
[0030] During operation, is it frequently necessary for the region of the cutting tool to be accessible from the rear, as regarded in the machine direction of the interchangeable holder system. This is the case, for example, when a cutting tool held in the interchangeable holder, for example a round shaft chisel, is to be selectively replaced without dismantling the interchangeable holder from the basic module. To this end, the interchangeable holder is frequently provided with an access opening, through which the rear part the cutting tool accommodated by the interchangeable holder is accessible. This may be necessary, for example, for the purpose of ejecting the cutting tool from the interchangeable holder. More specifically, it might be the end of a chisel shaft, for example. According to the present invention, provision is therefore made, in a preferred embodiment, for an opening to be present in the basic module, which is configured in such a manner that it allows access from the outside of the interchangeable holder system to the cutting tool, more particularly to the rear end of the cutting tool, in the interchangeable holder. Although it is basically also possible to provide a suitable opening in the interchangeable holder itself, it is better, for stability reasons, to make the interchangeable holder as massive as possible in the region of the respective holding means for a cutting tool, for example for a substantially hollow cylindrically shaped holder for a round shaft chisel, and to configure the holder so as to surroundingly accommodate the tool. In order, nevertheless, to provide access to the rear end of the cutting tool, it is therefore preferable to provide suitable means of access in the basic module. It is particularly favorable when the opening in the basic module merges into the forward region of contact and/or the rearward region of contact or is, in other words, a partial cut-out in the forward and/or rearward regions of contact. With regard to the basic module, the opening is in this case therefore a notch, more particularly a notch that is open towards the rear end of the interchangeable holder system, and is not a hole-like opening, which arrangement, in particular, considerably facilitates the production flow. Moreover, cleaning of the recess is facilitated. Alternatively or additionally, it is preferable when the cutting tool is held alone by the interchangeable holder. Mounting of a round shaft chisel thus takes place, in this embodiment, exclusively on the interchangeable holder and not additionally on the basic module. This simplifies the design of the basic module.
[0031] Another aspect of the present invention relates to the provision of a construction machine for the preparation of ground surfaces, more particularly to a cold milling machine, stabilizer or recycler, comprising a milling rotor, on which there is disposed at least one interchangeable holder system as defined in any one of the previous claims. The interchangeable holder system of the present invention enables, in particular, the resistance to transportation and mixing to be reduced. This means that equal operation results can be achieved at lower driving power requirements, which makes it possible to use driving units that have lower drive requirements and are thus less expensive in terms of acquisition and operating costs, or to increase the performance for a given driving power. It will also be appreciated that the present invention also extends to a basic module and an interchangeable holder as such and to their use in an interchangeable holder system having the above features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The present invention is explained in greater detail below with reference to two exemplary embodiments. In the drawings:
[0033] FIG. 1 is a perspective oblique view of an interchangeable holder system according to one embodiment as viewed obliquely from the front;
[0034] FIG. 2 is a perspective oblique view of the interchangeable holder system shown in FIG. 1 , as viewed obliquely from the rear;
[0035] FIG. 3 is a longitudinal cross-section taken in the machine direction through the interchangeable holder system as shown in FIGS. 1 and 2 ;
[0036] FIG. 4 is an exploded oblique view of the interchangeable holder system as shown in FIGS. 1 to 3 , as viewed at the same angle as in FIG. 2 ;
[0037] FIG. 5 is a perspective oblique view of the basic module as shown in FIGS. 1 to 4 , as viewed obliquely from the front;
[0038] FIG. 6 is a perspective forward view of the basic module as shown in FIG. 5 ;
[0039] FIG. 7 is a perspective rearward view of the interchangeable holder as shown in FIGS. 1 to 4 ;
[0040] FIG. 8 is a perspective rearward view of the interchangeable holder as shown in FIG. 6 ;
[0041] FIG. 9 is an enlarged detail of the region of contact between the interchangeable holder and the basic module;
[0042] FIG. 10 is an alternative embodiment of the interchangeable holder comprising a convex stop wedge and a wedge-shaped relief ledge;
[0043] FIG. 11 shows a further alternative embodiment of the interchangeable holder comprising a concave stop wedge and a wedge-shaped relief ledge;
[0044] FIG. 12 shows a further embodiment of the basic module comprising a wedge-shaped supporting projection; and
[0045] FIG. 13 shows a further embodiment of an interchangeable holder comprising an integrated cutting tool.
DETAILED DESCRIPTION OF THE INVENTION
[0046] Identically constructed components or components of identical function are designated in the following figures by identical reference signs.
[0047] FIG. 1 shows an interchangeable holder system 1 in the mounted state. FIGS. 2 to 4 illustrate alternative views of the interchangeable holder system 1 as shown in FIG. 1 , while the following FIGS. 5 to 9 show individual views or enlarged details of this embodiment. In FIGS. 10 to 13 there are shown alternative design variants in detail.
[0048] The basic structure of the interchangeable holder system will first be described in greater detail in an overview of FIGS. 1 to 4 . The elements of the interchangeable holder system 1 according to one embodiment are a basic module 2 , an interchangeable holder 3 located in the forward region of the basic module 2 and comprising a cutting tool 4 . The basic module 2 has a bottom region 5 , by means of which it is attached to a working drum 6 (only partially visible in FIG. 3 ) of a milling rotor (not completely visible in the figures). The interchangeable holder system 1 can be assembled by first of all attaching the basic module 2 via its bottom region 5 to the external surface of the working drum 6 , for example by welding. In the present exemplary embodiment, the external surface of the working drum 6 is cylindrical in shape, but it is also basically possible to use a non-cylindrical drum body. The interchangeable holder 3 can be mounted on the basic module 2 in the manner described below in detail. The interchangeable holder 3 finally comprises the cutting tool 4 , which may, on the one hand, be an independent component located on the interchangeable holder 3 , and is more specifically, for example, a round shaft chisel, as shown in FIGS. 1 to 4 . On the other hand, however, the cutting tool may alternatively be integrally united with the interchangeable holder 3 , as illustrated, for example, by the exemplary embodiment of the interchangeable holder 3 shown in FIG. 13 . The cutting tool 4 shown in FIG. 13 is more specifically a cutter 40 formed on the interchangeable holder. The longitudinal axis A 3 of these embodiments is defined more particularly by a\perpendicular extending from the cutting edge to the contact surface between the interchangeable holder and the basic module. Under working conditions, the working drum 6 is caused to rotate by a suitable driving system, such that the cutting tool 4 comes into contact with the surface of the ground to be prepared in the machine direction “a”, which it then mills, mixes, and crunches, etc., in an appropriate manner.
[0049] Another important element of the interchangeable holder system 1 , is a securing device 7 comprising, in the present embodiment, a screw-threaded bolt 8 , a through hole 9 in the basic module 2 , and an insertion bore 10 having a female thread in the interchangeable holder 3 . In FIGS. 1 and 2 this is indicated only by the head of the screw-threaded bolt 8 of the securing device 7 being visible in the form of a hexagon head, by way of example. Of course, a plurality of bolted joints and/or other alternative fastening mechanisms may be employed. The significance of the design of the securing device 7 resides in the fact that it makes it possible to fix the interchangeable holder 3 in its position on the basic module 2 as attached thereto. The individual assembly steps for the interchangeable holder system 1 are indicated, for example, in FIG. 4 , in which the order of assembly of the individual elements of the interchangeable holder system 1 is first of all indicated by the arrows b, c and d. In order to finally fix the interchangeable holder 3 to the basic module 2 , the screw-threaded bolt 8 engaging the female thread of the insertion bore 10 must be tightened in the direction of the arrow e.
[0050] One feature of the interchangeable holder system 1 resides in its comparatively narrow design as compared with its axial width B (width of the interchangeable holder system in the direction of the rotation axis of the working drum 6 ) which is made possible by the specific design of the connecting region between the basic module 2 and the interchangeable holder 3 . Details on the structure of this connecting region are illustrated with regard to the basic module 2 especially in FIGS. 5 and 6 , and with regard to the interchangeable holder 3 especially in FIGS. 7 and 8 . The fundamental aspect of the present invention resides in the fact that for the purpose of mounting the interchangeable holder 3 on the basic module 2 , it is laid flat on the basic module, is positionally stabilized by the wedge-shaped stopping step, and is then fixed in position by means of the securing device 7 . For this purpose, the contact region or bearing region 11 between the basic module 2 and the interchangeable holder 3 is formed in the manner described below.
[0051] According to one embodiment, elements of the contact area 11 on the basic module 2 are a forward contact surface 12 , a rearward contact surface 13 and the stopping step 14 in the form of a stop wedge AK (in the dashed circle). The terms “forward” and “rearward” refer to the relative positions of the contact surfaces 12 and 13 in relation to a reference perpendicular S standing on said contact surfaces 12 and 13 respectively in the region of the stopping step. The rearward contact surface 13 is thus at a receded level relative to the forward contact surface 12 , as regarded in the direction towards the basic module 1 . Under working conditions, the force applied to the interchangeable holder system 1 as a result of the resistance of the ground material being prepared acts in the direction F a . While the drum is rotated, this force acts, with regard to the cutting periphery SK of the interchangeable holder system 1 , tangentially against the region of the tip of the cutting tool 4 and can, with reference to the exemplary embodiment illustrated in FIGS. 1 to 4 , be divided into an axial force F x effective in the axial direction A 3 of the chisel shaft and a transverse force F q acting on the cutting tool 4 at right angles thereto in the plane of rotation of the milling rotor. The transverse forces F q act in a direction parallel to the forward contact surface and the rearward contact surface. Specifically, the cutting periphery SK is the cutting line or processing line along which the cutting tool 4 will pass when the drum is rotated. With reference to the specific embodiment shown in FIGS. 1 to 8 , the terms “forward” and “rearward” also refer to the axial direction or longitudinal axis A 3 of the chisel 4 , as regarded in the direction towards the tip of the chisel. Thus the “forward” contact surface 12 is situated ahead of the rearward contact surface 13 as regarded in the direction towards the tip of the chisel. The contact surfaces 12 and 13 are in each case of a plane configuration and extend in each case to the marginal regions of the basic module 2 . The contact surfaces 12 and 13 thus form the termination of the basic module 2 as regarded in the direction of the interchangeable holder 3 . The contact surface 12 lies in the plane 15 and the contact surface 13 in the plane 16 . The two planes 15 and 16 are parallel to each other and are spaced from each other by the distance AH along the perpendicular S (and in the present exemplary embodiment also along the longitudinal axis A 3 of the cutting tool, more specifically the round shaft chisel 4 ). Alternatively, the planes 15 and 16 of the contact surfaces 12 and 13 may also be at an angle to each other and not parallel to each other. It is important the two planes 15 and 16 be at an angle to the perpendicular S or to the longitudinal axis A 3 of the chisel 4 , at least in the region of the stopping step 14 . It is also important that the forward contact surface 12 be disposed above the lower contact surface 13 on the basic module 2 with respect to a radial plane A 5 (and vice versa on the interchangeable holder 3 ). The radial plane A 5 relates to the rotation axis of the milling rotor or to a perpendicular standing on the external surface of the milling rotor. Thus the forward contact surface 12 is further removed from the milling drum or from the bottom region 5 of the basic module 2 than the lower contact surface 13 , such that the interchangeable holder, as described in greater detail below, will be pressed into the basic module 2 and not pushed away therefrom under working conditions. Furthermore, the forward contact surface 12 is segmented and comprises two surface segments 12 a and 12 b , which, though spatially separated from each other by the opening 17 in the basic module 2 , both still lie in the plane 15 . However, the contact surface 13 is in the form of a continuous surface in the plane 16 .
[0052] The two contact surfaces 12 and 13 are interconnected via the stopping step 14 . Thus the stopping step 14 comprises the area of the contact region of the basic module 2 relative to the interchangeable holder 3 , which is situated between the contact surface 12 or the surface segments 12 a and 12 b and the contact surface 13 . The transition between the stopping step 14 and the rearward contact surface 13 is formed by the side edges 18 a and 18 b of the stopping step 14 and the transition relative to the forward contact surface 12 is formed by the side edges 19 a and 19 b ( FIG. 6 ). The stopping step 14 is thus likewise segmented and comprises the two walls in the form of a steps or surface segments 14 a and 14 b (also referred to below as wedge flanks or stepped segments. Each of the two surface segments 14 a and 14 b is likewise plane and lies independently in a plane, the two planes of the surface segments 14 a and 14 b intersecting in the plane 15 of the forward contact surface and in the plane 16 of the rearward contact surface at a wedge angle α, as illustrated in detail in FIG. 6 by the extension I of the side edge 19 a and the extension II of the side edge 19 b . The two surface segments 14 a and 14 b of the stopping step 14 are thus, in this exemplary embodiment, configured as a “V” relatively to each other and together form a wedge-shaped receiver or a thrust wedge, as illustrated in detail by the extensions I and II of the two side edges 19 a and 19 b in FIG. 6 . This wedge pointing away from the bottom region 5 of the basic module 2 serves to secure the position of the interchangeable holder 3 in the manner described below. The tip of the wedge formed by the two surface segments 14 a and 14 b is replaced by the opening 17 . Instead of a flat design of the surface segments 14 a and 14 b it is also possible to form these regions as profiled or curved regions or regions provided with other surface segments, etc.
[0053] The regions of the interchangeable holder 3 that are opposed to its forward contact surface 12 and its rearward contact surface 13 respectively beyond the stopping step 14 are configured for flat contact with the basic module and have a structure that is complementary to the basic module 2 in this region. In addition, the interchangeable holder 3 is thus provided with two contact surfaces 20 and 21 facing the region of contact of the basic module 2 , the contact surface 20 being situated at a receded level relative to the contact surface 21 in relation to the main body of the interchangeable holder 3 . The plane of the contact surface 20 and the plane of the contact surface 21 are parallel to each other and are likewise spaced by a distance AH, relative to a perpendicular standing on one of the two planes ( FIG. 9 ). Alternatively, the contact surfaces 20 and 21 may be non-parallel, i.e., at an angle to each other. The decisive requisite is that the contact surfaces 20 and 21 of the interchangeable holder 3 can, in the mounted state of the interchangeable holder system 1 , rest against the contact surfaces 12 and 13 of the basic module 2 . Both contact surfaces 20 and 21 are in the form of continuous surfaces, but it is basically equally possible for the region of contact of the interchangeable holder 3 to include segmented contact surfaces. As in the case of the basic module 2 , the two contact surfaces 20 and 21 of the interchangeable holder 3 are also interconnected via a wedge-shaped stopping step 22 , the stopping step being multipartite or segmented and comprising the two surface segments 22 a and 22 b (also referred to below as wedge flanks). The transition between the rearward contact surface 20 and the stopping step 22 is formed by the side edge 23 (comprising the segments 23 a and 23 b ) and the transition between the stopping step 22 and the forward contact surface 21 is formed by the side edge 24 (comprising the segments 24 a and 24 b ). In addition, the surface segments 22 a and 22 b of the stopping step 22 are at an angle α to each other (indicated in FIG. 8 by the extensions III and IV of the side edges 24 a and 24 b ), such that the stopping step 22 is configured as a whole to the effect that it forms a V-shaped wedge projecting towards the basic module 2 (but in the present embodiment forming a wedge-like protrusion in contrast to the wedged-shaped recess in the basic module 2 ) having wedge flanks 22 a and 22 b . In this respect, the (receiving) wedge formed on the basic module 2 is complementary, more particularly as regards height and angular position of the two stepped segments 14 a and 14 b , to the (projecting) wedge formed on the interchangeable holder 3 by the step-shaped segments 22 a and 22 b.
[0054] It is essential according to one aspect for the stop wedge AK of the present embodiments that the distance between the two opposing wedge flanks 22 a and 22 b (or the wedge flanks 14 a and 14 b on the basic module 2 configured to be complementary to said wedge flanks), to be at least partially broadened away from the tip of the wedge KS (indicated, for example, in FIGS. 6 and 9 as dashed extensions of the side edges 19 a / 19 b and/or 24 a / 24 b ). In addition to the design of the stop wedge AK having plane flanks, as shown, for example in FIGS. 5 to 8 , alternative designs of the stop wedge AK are possible. FIGS. 10 and 11 show in each case a stop wedge AK in the interchangeable holder 3 having, for example, curved wedge flanks 22 a and 22 b . For example, the two wedge flanks 22 a and 22 b in the exemplary embodiment as shown in FIG. 10 are curved towards each other towards the tip of the wedge (convex variant) and in the exemplary embodiment as shown in FIG. 11 are curved away from each other towards the tip of the wedge (concave variant). It is obvious that in these embodiments the interchangeable holder 3 of the appropriate basic module (not visible in the figures) must be complementary thereto or provided with a suitably curved stop wedge.
[0055] The adaptation of the region of contact on the basic module 2 to the design of the region of contact on the interchangeable holder 3 is further revealed by the enlarged detail shown in FIG. 9 , which shows a portion of a side view of the interchangeable holder system 1 as shown in FIGS. 1 and 2 , wherein the angle of view in FIG. 1 is indicated by the arrow f. The vertical misalignment AH between the forward contact surface 12 and the rearward contact surface 13 on the basic module 2 corresponds to the vertical misalignment AH present between the forward contact surface 21 and the rearward contact surface 20 on the interchangeable holder 3 . Moreover, the planes 15 and 16 on the basic module 2 and the plane in which the rearward contact surface 20 and the forward contact surface 21 of the interchangeable holder 3 each lie are all parallel to each other. Alternatively, the non-superposed contact surfaces may be non-parallel to each other, i.e., at an angle to each other, in the mounted state. Thus the design of the basic module 2 in the region illustrated in FIG. 9 on an enlarged scale, taken from the region of contact, is a negative impression of the region of contact of the interchangeable holder 3 , based on the design of the surfaces bearing against each other, and vice versa. When the interchangeable holder 3 is mounted on the basic module 2 in its holding position (for example as shown in FIGS. 1 to 3 ), the forward contact surface 12 of the basic module 2 will bear flat against the rearward contact surface 20 of the interchangeable holder 3 , the rearward contact surface 13 of the basic module 2 will bear against the forward contact surface 21 of the interchangeable holder 3 , and the stopping step 14 will bear against the stopping step 22 , such that there is a continued positive fit between the basic module 2 and the interchangeable holder 3 across this entire region of contact.
[0056] More particularly, FIG. 9 further illustrates the angular position of the rearward contact surface 13 and the forward contact surface 12 relative to the stopping step 14 in the basic module 2 and the rearward contact surface 20 and the forward contact surface 21 relative to the stopping step 22 in the interchangeable holder 3 , which, in the present exemplary embodiment, in each case is formed by a right angle or is equal, in the respective component, to 90° (β 1 and β 3 ) and/or 270° (β 2 and β 4 ). It is however also possible to vary this angle, in order, for example, to acquire an inclined position of the stopping step or of the individual segments of the respective stopping step, such that the interchangeable holder will, for example by means of its stopping step 22 , which in the present exemplary embodiment is in the form of a wedge-like protrusion, partially engage the wedge receiving means of the stopping step 14 of the basic module 2 from behind, which wedge receiving means is likewise inclined in a complementary manner. For this purpose it is basically also possible for the contact surfaces 12 and 13 on the basic module 2 or the contact surfaces 20 and 21 on the interchangeable holder 3 to be non-parallel.
[0057] Another variant, which is not illustrated in the present figures, consists in disposing the wedge-like protrusion on the basic module 2 and the wedge receiving means on the interchangeable holder 3 or in swapping the regions of contact between the interchangeable holder 3 and the basic module 2 as shown in the figures. The essential prerequisite is that the basic module 2 and the interchangeable holder 3 together form a wedge-type bearing having the stated properties.
[0058] The design of the contact surfaces 12 , 13 , 20 , and 21 and of the stopping steps 14 and 22 makes it possible for the interchangeable holder 3 to bear flat against the basic module 2 . For the purpose of fixing the interchangeable holder 3 to the basic module 2 , there is provided a securing device 7 , which makes it possible to finally tighten the interchangeable holder 3 against the basic module 2 . To this end, the longitudinal axis A 1 of the screw-threaded bolt 8 extends in the longitudinal cross-sectional plane as shown in FIG. 3 obliquely to the reference perpendicular S and obliquely to the longitudinal axis A 3 or rotation axis of the round shaft chisel (=cutting tool 4 ) bearing-mounted in the insertion bore 32 in the interchangeable holder 3 (A 3 is, in the present exemplary embodiment, parallel to the reference perpendicular S, or the rotation axis/longitudinal axis A 3 is likewise at right angles to the forward contact surface and the rearward contact surface 12 , 13 , 20 , and 21 between the basic module 2 and the interchangeable holder 3 ). By this means the interchangeable holder 3 will, during its assembly on the basic module 2 and during tightening of the screw-threaded bolt 8 , be drawn into the wedge-shaped stopping step or drawn via its own stop wedge AK into the complementary stop wedge AK on the basic module 2 until it bears against the stop limit surfaces 12 and 13 and against the stopping step 14 , by which means the assembly, in particular, is facilitated and a positive interlock is obtained. Another essential feature is that the female thread engaged by the screw-threaded bolt 8 in the interchangeable holder 3 is disposed in the interchangeable holder 3 . With each replacement of the interchangeable holder 3 there is at the same time a renewal of a part of the securing device 7 in the interchangeable holder system 1 , more specifically the female thread, so that perfect functioning of the screw-threaded bolt 8 is ensured.
[0059] Another essential feature of the interchangeable holder system 1 resides in the fact that the cutting tool 4 bearing-mounted in the interchangeable holder 3 of the mounted interchangeable holder system 1 can be accessed from the rear (as regarded along the longitudinal axis and the working tip of the round shaft chisel) by an ejecting tool 25 (purely phantomly illustrated in FIG. 3 ) and can be pressed forwardly out of the insertion bore 32 of the interchangeable holder 3 . Said access is made possible, on the one hand, by means of an insertion bore 32 for the cutting tool extending through the interchangeable holder 3 and, on the other hand, by means of the generously dimensioned opening 17 , with regard to its spatial dimensions, on the basic module 2 , which opening 17 leads towards the interchangeable holder 3 to merge with the insertion bore for the cutting tool in the interchangeable holder 3 .
[0060] On account of the presence of the stopping steps 14 and 22 bearing against each other in the basic module 2 and in the interchangeable holder 3 respectively, an anti-twist lock is achieved between the interchangeable holder 3 and the basic module 2 and thus likewise between the interchangeable holder 3 and the working drum 6 supporting the interchangeable holder system 1 . This positive effect is greatly enhanced by the fact that the stopping steps 14 and 22 are in each case in the form of wedges, such that the two wedge-shaped elements, in the assembled state of the interchangeable holder system 1 , interengage or bear against each other. By this means, not only is the anti-rotatory effect of the stopping steps 14 and 22 enhanced, but also at the same time the assurance of exact positioning of the interchangeable holder 3 with respect to the basic module 2 is improved.
[0061] Another essential feature of the exemplary embodiment illustrated in the figures is the presence of a relieving or supporting device 29 , comprising a supporting projection 27 on the basic module 2 and a base ledge 28 on the interchangeable holder 3 . The supporting device 29 makes it possible to achieve a reduction of the load on the interchangeable holder 3 , and more particularly on the securing device 7 , when the interchangeable holder system 1 is heavily loaded, i.e., to achieve overload protection. The supporting device is to this end configured such that the interchangeable holder 3 , when heavily loaded, comes to bear, with its base ledge 28 , flat against the supporting projection 27 on the basic module 2 , by which means additional force absorption is rendered possible over the region of the supporting device 29 . For this purpose, the supporting projection 27 and the base ledge 28 have supporting surfaces facing each other, which in the loaded condition come to bear against each other. In the less loaded mounted state of the interchangeable holder system 1 , there is, in the present exemplary embodiment, thus a narrow gap between these supporting surfaces. The hook-like shaped base ledge 28 engages, for this purpose, in the undercut formed by the supporting projection 27 . The contact surface on the supporting projection 27 extends in the cross-section of the interchangeable holder 3 ( FIG. 3 ) along the axis A 2 , which more particularly extends obliquely to the direction of action of the applied force F a and obliquely to the axis A 1 . The essential point of this arrangement is, furthermore, that the supporting device 29 of the interchangeable holder 3 is additionally stabilized in its assembled position with respect to the basic module 2 when heavily loaded and at the same time relieves the securing device 7 (more specifically the mounting screw 8 ). The supporting device 29 is further configured such that the interchangeable holder 3 is drawn up via its base ledge 28 against the underside of the supporting projection 27 when the screw-threaded bolt 8 is tightened.
[0062] The supporting projection 27 extends with its contact surface along the axis A 4 ( FIG. 5 ) linearly across the entire width B of the basic module 2 and merges via a linear edge 33 into the rearward contact surface 13 . The axis A 4 thus lies in the plane 16 . In the region in which the base ledge 28 bears against the supporting projection 27 , it is configured in a complementary manner and comprises two plane surfaces disposed at an angle to each other. It is, however, also possible to configure the stop limit surfaces of the supporting device 29 with a profile. Thus it has proved to be advantageous when, for example, the contact surface of the supporting device 29 is provided with a profile in the form of a roof or wedge such as the surfaces 27 a and 27 b and/or 28 a and 28 b disposed at an angle γ relative to each other, as shown, for example, in FIGS. 10 and 11 for the interchangeable holder 3 and in FIG. 12 for the basic module 2 , to give an improved torque support. The tip of the wedge points in the direction of the stop wedge AK. Of course, alternative designs of the stopping region may be provided, as for example a plurality of roof-shaped profiles and/or a plurality of supporting devices 29 between the basic module 2 and the interchangeable holder 3 , etc.
[0063] The interchangeable holder 3 finally also comprises an attrition bulge protruding in the machine direction “a”, i.e., a domed attrition region 30 having two material guiding surfaces 30 a and 30 b sloping to the side and to the rear. The camber of the attrition region 30 extends from the interchangeable holder 3 parallel to the longitudinal axis A 3 of the chisel 4 to across the plane in which a wearing disk VS is disposed between the chisel 4 and the region of contact of the chisel 4 in the axial direction A 3 on the interchangeable holder 3 . This plane is at right angles to the cutting plane in FIG. 3 . The interchangeable holder 3 in its entirety together with the attrition region 30 covers the region of contact with the basic module 2 and more particularly protects the basic module 2 from attrition. Basically, this effect of the interchangeable holder 3 may be enhanced when the basic module 2 has an overlapping configuration. Directly below the round shaft chisel 4 annularly overlapping the interchangeable holder 3 in the axial direction A 3 , there is present another attrition region 31 on the interchangeable holder 3 , on which the wearing disk VS rests.
[0064] While the present invention has been illustrated by description of various embodiments and while those embodiments have been described in considerable detail, it is not the intention of Applicant to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will readily appear to those skilled in the art. The present invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicants' invention.
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The present invention relates to an interchangeable holder system comprising a basic module and an interchangeable holder for the accommodation of a cutting tool, which interchangeable holder is capable of being attached to the basic module, for the purpose of preparing ground surfaces, and to a construction machine, more particularly a stabilizer, a recycler, or a cold milling machine, comprising a milling device comprising such an interchangeable holder system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Patent Application Ser. No. 62/102,279, filed 12 Jan. 2015; and U.S. Provisional Patent Application Ser. No. 62/059,212, filed 3 Oct. 2014, which are hereby incorporated herein by reference and priority of each is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates to continuous batch washers or tunnel washers. More particularly, the present invention relates to an improved method of washing textiles or fabric articles (e.g., clothing, linen) in a continuous batch multiple module tunnel washer wherein the textiles are moved sequentially from one module to the next module. A counter flowing rinse is boosted (e.g., using pumps) to elevate and/or maintain a selected flow rate or flow pressure head. Even more particularly, the present invention relates to a method and apparatus for washing fabric articles in a continuous batch tunnel washer using an improved flow arrangement wherein the pressure head is boosted at selected modules of the multiple modules of the continuous batch tunnel washer using one or more booster pumps that maintain substantially constant pressure of the rinse liquid that is counter flowed. Multiple dual use modules can be employed which provide faster rinsing with high velocity counterflow, more through put with less water usage by recycling water. After a final module, fabric articles can be transferred to a liquid extraction device (e.g., press or centrifuge) that removes excess water.
[0006] 2. General Background of the Invention
[0007] Currently, washing in a commercial environment is generally conducted with a continuous batch tunnel washer. Such continuous batch tunnel washers are known (e.g., U.S. Pat. No. 5,454,237) and are commercially available (www.milnor.com). Continuous batch washers have multiple sectors, zones, stages, or modules including pre-wash, wash, rinse and finishing zone.
[0008] Commercial continuous batch washing machines in some cases utilize a constant counterflow of liquor. Such machines are followed by a centrifugal extractor or mechanical press for removing most of the liquor from the goods before the goods are dried. Some machines carry the liquor with the goods throughout the particular zone or zones.
[0009] When a counterflow is used in the prior art, there is counterflow during the entire time that the fabric articles or textiles are in the main wash module zone. This practice dilutes the washing chemical and reduces its effectiveness.
[0010] A final rinse with a continuous batch washer has been performed using a centrifugal extractor or mechanical press. In prior art systems, if a centrifugal extractor is used, it is typically necessary to rotate the extractor at a first low speed that is designed to remove soil laden water before a final extract.
[0011] Patents have issued that are directed to batch washers or tunnel washers. The following table provides examples of such patented tunnel washers, each listed patent of the following table being hereby incorporated herein by reference.
[0000]
TABLE
PATENT NO.
TITLE
ISSUE DATE
4,236,393
Continuous tunnel batch washer
2 Dec. 1980
4,485,509
Continuous batch type washing
4 Dec. 1984
machine and method for operating
same
4,522,046
Continuous batch laundry system
11 Jun. 1985
5,211,039
Continuous batch type washing
18 May 1993
machine
5,454,237
Continuous batch type washing
3 Oct. 1995
machine
US20110296626
Continuous batch tunnel washer
8 Dec. 2011
and method
WO2011/153398
Continuous batch tunnel washer
8 Dec. 2011
and method
WO 2015/095179
Floor Mat And Particulate Laden
25 Jun. 2015
Material Washing Apparatus And
Method
US 2015/0167221
Floor Mat And Particulate Laden
18 Jun. 2015
Material Washing Apparatus And
Method
8,689,463
Clothes Dryer Apparatus With
8 Apr. 2014
Improved Lint Removal System
WO 2014/031757
Washer Extractor Apparatus And
27 Feb. 2014
Method
US 2014/0053344
Washer Extractor Apparatus And
27 Feb. 2014
Method
US 2014/0053343
Continuous Batch Tunnel Washer
27 Feb. 2014
And Method
WO 2014/031625
Continuous Batch Tunnel Washer
27 Feb. 2014
And Method
US 2013/0291314
Continuous Batch Tunnel Washer
7 Nov. 2013
And Method
US 2013/0213244
Laundry Press Apparatus And
22 Aug. 2013
Method
8,370,981
Integrated Continuous Batch
12 Feb. 2013
Tunnel Washer
8,365,435
Laundry Press Apparatus And
5 Feb. 2013
Method
WO 2013/016103
Laundry Press Apparatus And
31 Jan. 2013
Method
US 2013/0025151
Laundry Press Apparatus And
31 Jan. 2013
Method
8,336,144
Continuous Batch Tunnel Washer
25 Dec. 2012
And Method
US 2012/0304487
Clothes Dryer Apparatus With
6 Dec. 2012
Improved Lint Removal System
8,166,670
Clothes Dryer Apparatus With
1 May 2012
Improved Lint Removal System
US 2012/0023680
Integrated Continuous Batch
2 Feb. 2012
Tunnel Washer
WO 2012/009360
Modulated Air Flow Clothes Dryer
19 Jan. 2012
And Method
US 2011/0283557
Modulated Air Flow Clothes Dryer
24 Nov. 2011
And Method
US 2011/0225741
Continuous Batch Tunnel Washer
22 Sep. 2011
And Method
WO 2011/109371
Washer Extractor And Method
9 Sep. 2011
US 2011/0209292
Washer Extractor And Method
1 Sep. 2011
7,971,302
Integrated Continuous Batch
5 Jul. 2011
Tunnel Washer
US 2010/0313440
Laundry Press Apparatus And
16 Dec. 2010
Method
WO 2010/144715
Laundry Press Apparatus And
16 Dec. 2010
Method
WO 2010/124076
Continuous Batch Tunnel Washer
28 Oct. 2010
And Method
WO 2009/129362
Continuous Batch Tunnel Washer
22 Oct. 2009
And Method
US 2009/0260161
Integrated Continuous Batch
22 Oct. 2009
Tunnel Washer
US 2009/0260162
Continuous Batch Tunnel Washer
22 Oct. 2009
And Method
US 2009/0255145
Clothes Dryer Apparatus With
15 Oct. 2009
Improved Lint Removal System
CN 1553973
Continuous Tunnel Batch Washer
8 Dec. 2004
Apparatus
EP 1425455
Continuous Tunnel Batch Washer
9 Jun. 2004
Apparatus
US 2003/0110815
Continuous Tunnel Batch Washer
19 Jun. 2003
Apparatus
WO 2003/016608
Continuous Tunnel Batch Washer
27 Feb. 2003
Apparatus
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention provides an improved method of washing fabric articles in a continuous batch tunnel washer. Embodiments of the method include providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid.
[0013] Embodiments of the method of the present invention provide a counterflow (or counter flow) of liquid in the washer interior during rinsing including some interrupted counterflow. The counterflow is along a path that is generally opposite the direction of travel of the fabric articles. Booster pumps can be placed at intervals to increase the pressure and/or velocity of counter flowing rinse water. For example, in a twelve (12) module continuous batch washer there can be booster pumps placed at the fourth and eighth modules.
[0014] At a final module, the fabric articles are transferred via the discharge to a water extraction device or extractor (e.g., press or centrifuge). The extractor is used to remove excess water from the fabric articles after they have been discharged from the continuous batch tunnel washer.
[0015] For the greatest part of each cycle, processing without counterflow creates standing baths so that chemicals are allowed to do their job without being diluted. Then, for a very short portion of each cycle, high-velocity counterflow is applied, thus providing the first part of the required dilution effect. A second stage of dilution ensures the goods move into far cleaner water every time. Dedicated rinse modules are not required, meaning more production from fewer modules.
[0016] The counterflow is stopped for about the first 65-75% of each transfer cycle. The entire amount of counterflow water is then pumped at a very fast rate in the final 25-35% of the time remaining. The pumps are preferably high-volume, variable speed inverter-driven so that both flow rate and duration of the counter-flowing water can be fully varied based on goods being processed. The high speed flow gives better rinsing action and uses far less water.
[0017] Washers of the present invention achieve very low fresh water consumption. For light soil linen, the water consumption is about 0.3 gallons per pound (2.5 liters per kilogram) of linen processed. For most heavy soil linen, the expected water consumption is about 0.5 gallons per pound (4 liters per kilogram).
[0018] The method and apparatus of the present invention saves water with these features:
[0019] 1) Interrupted Counterflow—Water only flows for rinsing which is about the last 25-35% of each cycle;
[0020] 2) Controlled Flow—Water is delivered by high-volume inverter pumps with vigorous flow that removes suspended soil and uses chemistry faster, with less water;
[0021] 3) Dual-Use Modules—Each module is used for both standing bath washing and counterflow rinsing; and
4) Full Water Availability—Fresh water and recycled press water are collected in a single tank mounted within the washer frame (e.g., under the load scoop). No external tanks are required.
[0023] The present invention is able to achieve maximum chemical performance with standing bath washing and high-velocity counterflow rinsing. High-speed water recirculation within the first module allows fast sluicing and wet-down, causing the chemistry to instantly penetrate the soiled linen.
[0024] After the transfer of the goods, the counterflow is interrupted creating a standing bath with no water flow so that chemistry is not diluted. Chemicals work at full concentration from the start of each bath. Chemicals work faster because of the large cylinder volume and fast intermixing with the goods.
[0025] Programmable high-volume pumps create a vigorous flow to remove exhausted chemistry and suspended soil effectively. Fixed partitions between each module prevent chemical mixing and leakage. No seals are required between modules.
[0026] Flow is paused at the start of each cycle to create standing baths without dilution so that chemicals work faster. Counterflow water is pumped at high volume for the very last portion of the cycle. Vigorous flow removes contaminants from fabric articles or linen much more quickly, thus reducing overall cleaning time. All wash modules are used for two functions: 1) standing bath and 2) high-speed counterflow for faster, better rinsing. Because of the dual-use modules, fewer modules are required. Rinsing occurs immediately after chemical action in each wash module. No separate rinse modules are required. Water and chemistry recirculate at high-velocity within the first module. Goods are sluiced faster and more completely into the machine. Wet-down of the fabric articles to be washed is almost instantaneous. Chemistry penetrates the fabric articles or linen instantly which is important for protein stains. The first module can thus be a working module.
[0027] The present invention requires fewer modules because of faster rinsing with high-velocity counterflow, more throughput with dual-use modules, and less water usage by recycling water.
[0028] The present invention includes a method of washing fabric articles in a continuous batch tunnel washer. The method includes providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules, and a volume of liquid. The fabric articles are moved from the intake to the modules and then to the discharge in sequence. In the step of moving the fabric articles, multiple of the modules define a dual use zone having dual use modules that function as both wash modules and rinse modules and adding a washing chemical to the volume of liquid in the dual use zone. After a selected time period, a rinsing liquid counterflows in the dual use zone along a flow path that is generally opposite the direction of travel of the fabric articles. During the step of counter flowing, pressure of the counter flowing rinsing liquid can be boosted with a pump at one or more positions spaced in between the intake and the discharge.
[0029] In the step of boosting pressure, multiple booster pumps can be provided, each pump boosting counter flowing rinsing liquid flow rate at a different one of the modules.
[0030] During the step of counter flowing, the counter flow can be at a flow rate of between about 20 and 300 gallons (76-1,136 liters) per minute.
[0031] In one embodiment, during the step of counter flowing, the counter flow is at a flow rate of between about 25 and 220 gallons (95-833 liters) per minute. In one embodiment, during the step of counter flowing, the counter flow is at a flow rate of between about 35 and 105 gallons (132-397 liters) per minute.
[0032] In one embodiment, the booster pumps are spaced apart by more than one module. In one embodiment, the booster pump discharges liquid into a module that is a dual use module wherein textile articles are both washed and rinsed.
[0033] In one embodiment, the booster pumps each discharge liquid into a module that is a dual use module wherein textile articles are both washed and rinsed.
[0034] In one embodiment, liquid flow in the dual use module is substantially halted for a time period that is less than about five minutes.
[0035] In one embodiment, liquid flow in the dual use zone is substantially halted for a time period that is less than about three minutes.
[0036] In one embodiment, liquid flow in the dual use zone is substantially halted for a time period that is less than about two minutes.
[0037] In one embodiment, liquid flow in the dual use zone is substantially halted for a time period that is between about twenty and one hundred twenty (20-120) seconds.
[0038] In one embodiment, a volume of liquid in a plurality of the modules is heated to a temperature of between about 100 and 190 degrees Fahrenheit (38-88 degrees Celsius).
[0039] In one embodiment, the counter flow during the step of counter flowing extends through multiple of the modules.
[0040] In one embodiment, the dual use zone includes multiple modules.
[0041] In one embodiment, each booster pump discharges counter flowing fluid into a module that is not a module closest to the discharge.
[0042] The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior, wherein multiple of the modules define a dual use zone having modules that each function as both wash and rinse modules, moving the fabric articles from the intake to the discharge, adding a washing chemical to the dual use zone wherein modules in the dual use zone wash the fabric articles with a combination of water and said washing chemical, after a selected time interval and after the step of adding a washing chemical, counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in the step of moving the articles, and counter flowing water through the modules of said dual use zone to effect a rinse of the fabric articles.
[0043] In one embodiment, the present invention further comprises boosting the flow rate in the step of counter flowing so that it is maintained at a desired value.
[0044] In one embodiment, multiple booster pumps are employed in order to boost the flow rate.
[0045] In one embodiment, there are a plurality of modules in between the booster pumps.
[0046] The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, a plurality of modules that segment the interior, and wherein a plurality of said modules define a dual use zone, moving the fabric articles from the intake to the discharge and through the modules in sequence, the fabric articles traversing the dual use zone during the step of moving the fabric articles from the intake to the discharge, adding a washing chemical to the dual use zone, and rinsing the fabric articles in the dual use zone by counter flowing liquid in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in prior steps.
[0047] In one embodiment, the present invention further comprises extracting excess fluid from the fabric articles after the step of rinsing the fabric articles.
[0048] In one embodiment, there is substantially no counterflow during the step of adding a washing chemical to the dual use zone and for a time period after this step.
[0049] In one embodiment, the time period is less than about five minutes.
[0050] The present invention includes a method of washing fabric articles in a continuous batch tunnel washer, comprising the steps of providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior, the interior including at least one dual use zone that includes multiple of said modules that each function as both a wash module and a rinse module, moving the fabric articles and a volume of liquid in a first direction of travel from the intake to the discharge and through the dual use zone, washing the fabric articles with a chemical bath in the dual use zone, and rinsing the fabric articles by counter flowing a rinse liquid in the dual use zone along a second flow path that is generally opposite the first direction of travel of the fabric articles in the step of moving the fabric articles.
[0051] In one embodiment, the present invention further comprises the step of boosting the flow pressure head of the counter flowing liquid in the step of rinsing the fabric articles by counter flowing at one or more modules.
[0052] In one embodiment, in the step of rinsing the fabric articles by counter flowing, the counter flow has a duration of between about 2 and 6 minutes.
[0053] In one embodiment, the counter flow is at a flow rate of between about 20 and 300 gallons (76-1,136 liters) per minute.
[0054] In one embodiment, the counter flow is at a flow rate of between about 25 and 220 gallons (95-833 liters) per minute.
[0055] In one embodiment, the counter flow is at a flow rate of between about 35 and 105 gallons (132-397 liters) per minute.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0056] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0057] FIG. 1 is a schematic diagram showing a first embodiment of the apparatus of the present invention;
[0058] FIG. 2 is a schematic diagram showing a second embodiment of the apparatus of the present invention; and
[0059] FIG. 3 is a schematic diagram showing a third embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0060] FIG. 1 shows a schematic diagram of the textile washing apparatus of the present invention, designated generally by the numeral 10 . Textile washing apparatus 10 provides a tunnel washer 11 having an inlet end portion 12 and an outlet end portion 13 . In FIG. 1 , tunnel washer 11 provides a number of modules 14 - 25 . The plurality of modules 14 - 25 can include modules which can be dual use modules in that the dual use modules function as both main wash and rinse modules. The total number of modules 14 - 25 can be more or less than the number of modules shown in FIGS. 1-2 .
[0061] Inlet end portion 12 can provide a hopper 26 that enables the intake of textiles or fabric articles to be washed. Such fabric articles, textiles, and goods to be washed can include clothing, linens, towels, and the like. An water extractor device 30 can be positioned next to the outlet end portion 13 of tunnel washer 11 . Flow lines are provided for adding water and/or chemicals (e.g., cleaning chemicals, detergent, etc.) to tunnel washer 11 .
[0062] When the fabric articles, goods and/or linens are initially transferred into modules 14 - 25 , an interrupted counterflow for a part of the batch transfer time is used. By using this interrupted counterflow for part (e.g., between about fifty and ninety percent (50-90%), preferably about seventy-five percent (75%)) of the batch transfer time, each module 14 - 25 performs as a separate batch. Batch transfer time can be defined as the time that the fabric articles/linens remain in a module before transfer to the next successive module.
[0063] By halting counterflow when some of the modules are functioning as main wash modules, this creates essentially a standing bath for the washing process and allows the cleaning chemicals to perform their function fully without any dilution from a counterflow of fluid within the tunnel washer 11 . Counterflow returns for the last part (e.g., last 25%) of the transfer time and is pumped at a higher rate (e.g., between about three hundred and four hundred percent (300%-400%)) of the normal rate. This higher rate is thus higher than the flow rate of prior art machines using full time counterflow. For example, prior art machines with full time counterflow typically employ a flow rate of between about ten and thirty (10-30) gallons (38-114 liters) per minute and create a full rinsing hydraulic head. The present invention eliminates the need to have additional modules dedicated to the function of rinsing and finishing as required in the prior art, thus saving cost and floor space.
[0064] FIGS. 1 and 2 show first and second embodiments of the apparatus of the present invention illustrated generally by the numerals 10 ( FIG. 1 ) and 10 A ( FIG. 2 ). FIGS. 1-2 also illustrate embodiments of the method of washing fabric articles in a continuous batch tunnel washer. Textile washing apparatus 10 , 10 A each provide tunnel washer 11 or 11 A having inlet end portion 12 and outlet end portion 13 . Tunnel washer 11 interior 31 is divided into sections or modules. These modules can include modules 14 - 25 ( FIG. 1 ). These modules can include additional modules or fewer modules such as modules 14 - 21 of FIG. 2 .
[0065] In FIG. 1 , water extracting device 30 (e.g., press or centrifuge) is positioned next to discharge 27 . The extraction device 30 is used to remove excess water or extracted water from the fabric articles after they have been discharged from the tunnel washer 11 and placed within the extractor 30 . Extraction devices 30 are commercially available. An extraction device 30 could be used with the embodiments of FIG. 1 or 2 .
[0066] The modules 14 - 25 in FIG. 1 or the modules 14 - 21 of FIG. 2 can include dual use modules. If a module is a dual use module, it is used for both standing bath washing and counterflow rinsing. The modules 14 - 25 can thus include pre-wash modules, main wash modules, and rinse modules, with some modules being dual wash modules. For example, modules 14 - 24 can be dual use modules in FIG. 1 . Modules 14 - 20 can be dual use modules in FIG. 2 .
[0067] When functioning as a main wash or standing bath, counterflow via lines 28 , 36 can be slowed or halted for a time. Then, counterflow resumes during rinsing. In FIG. 1 , a fresh water storage tank 29 can provide fresh water via flow line 38 . Module 25 can be injected with a selected sour solution and/or a selected finishing solution that is delivered via inflow line 32 . Flow line 32 transmits the sour solution and/or finishing solution from tank 37 to module 25 . Finishing solutions can be any desired or known finishing solution, for example a starch solution or an antimold agent.
[0068] An extracted water tank 33 can be positioned to receive extracted water from an extraction device 30 . Flow line 34 is a flow line that transfers water from extraction device 30 to tank 33 . Water contained in tank 33 can be recycled via flow lines 35 or 36 . A sour or finishing solution can be injected at module 25 via inflow tank 37 . Fresh water can be added to tank 33 via freshwater inflow line 38 . Flow line 35 is a recirculation line having pump 39 that transfers extracted water from tank 33 to hopper 26 . Another recirculation flow line is flow line 36 . The flow line 36 transfers extracted water from tank 33 to flow line 28 and then to interior 31 of tunnel washer 11 , beginning at module 24 and then by counterflow to modules 23 , 22 , 21 , 20 , 19 , 18 , 17 , 16 , 15 in sequence. For the continuous batch washing apparatus 10 of FIG. 1 , twelve modules are shown as an example. The modules 14 , 25 can have a temperature of around 40 degrees Celsius. The modules 15 , 16 can have a temperature of around 70 degrees Celsius. The module 19 can have a temperature of around 50 degrees Celsius.
[0069] In the example of FIG. 1 , each of the modules 14 - 24 can be dual use modules. In FIG. 1 , each of the modules 14 - 24 could thus be part of both a wash function and then a rinse function. In FIG. 1 , rinse liquid counterflows via flow line 28 to module 24 , then to module 23 , then to module 22 .
[0070] The flow lines 35 and 36 can be provided with pumps in order to boost pressure in those flow lines. Pump 39 is provided in flow line 35 for transmitting water to hopper 26 via flow line 35 . Pump 40 is provided in flow line 36 for transmitting water to tank 37 or flow line 28 for counterflow rinsing.
[0071] The flow line 36 splits at tee fitting 47 into flow line 28 and flow line 32 . The flow line 32 is a flow line that carries re-circulated extracted water from tank 33 to tank 37 . Inflow tank 37 can be used to supply sour or finishing chemicals via flow line 32 to the final module 25 , which can be a finish module.
[0072] Flow line 28 is a re-circulation flow line that enters module 24 and then flows water in counterflow to modules 23 , 22 in sequence. A booster pump 41 receives flow from flow line 28 . The booster pump 41 then discharges its flow via flow line 43 to module 21 . Flow then transfers from module 21 to module 20 then to module 19 and then to module 18 where it transfers via flow line 43 to booster pump 42 . Booster pump 42 then discharges its counter flowing rinsing fluid via flow line 44 to module 17 and then to module 16 and then to module 15 . At module 15 , the rinsing fluid can be discharged via discharge valve 45 . A discharge valve 46 can also be provided for module 14 . The booster pumps 41 , 42 ensure that counter flowing rinsing fluid is maintained at a selected flow rate, flow volume and flow pressure. The booster pumps 41 , 42 ensure that a desired pressure head is maintained.
[0073] In the example of Table 1 below, a batch size can be between about fifty (50) and three hundred (300) pounds (23-136 kg) of fabric articles, lines or textiles. Total water consumption could be about 0.62 gallons per pound (5.1 liters/kg) of cotton textile fabric articles. Total water consumption could be about 0.64 gallons per pound (5.3 liters/kg) for poly cotton fabric articles.
[0074] FIG. 2 shows a second or alternate embodiment of the apparatus of the present invention, designated generally by the numeral 10 A. Textile washing apparatus 10 A in FIG. 2 is an eight module machine, providing modules 14 , 15 , 16 , 17 , 18 , 19 , 20 , and 21 . As with the preferred embodiment of FIG. 1 , the textile washing apparatus 10 A provides a tunnel washer 11 A having an inlet end portion 12 and an outlet end portion 13 . The outlet end portion 13 can provide a water extraction device 30 , not shown in FIG. 2 for purposes of clarity.
[0075] Inlet end portion 12 provides hopper 26 for enabling fabric articles such as linen articles to be added to the interior 31 of tunnel washer 11 A. A discharge 27 receives effluent from the last or final module 21 where it enters an extractor 30 (not shown). Fluid is then discharged via flow line 51 for collection and extracted water tank 33 . Pump 50 receives flow from extracted water tank 33 . Pump 50 then transfers fluids from extracted water tank 33 to pulse flow tank 54 . A valve 53 can be provided in flow line 52 . Pump 55 can be a variable speed pump that transfers fluid from pulse flow tank 54 to flow line 70 and then to module 20 . Flow line 70 can be provided with valve 71 and flow meter 72 . Line 70 discharges at flow line discharge 73 into module 20 .
[0076] Pump 56 transmits fluid from pulse flow tank 54 to flow line 67 and then to final module 21 . The flow line 67 can be provided with a tee fitting 87 . Flow line 67 discharges at flow line discharge 69 into module 21 . Flow line 67 can be provided with valve 68 . Flow line 86 communicates with flow line 67 at tee fitting 87 . Flow line 86 can be provided with valve 88 and flow meter 89 . The flow line 86 discharges into hopper 26 as shown in FIG. 2 .
[0077] Pulse flow tank 54 can receive make up water from flow line 57 . Flow line 57 can be valved with valve 58 to receive influent water from a user's water supply. Flow line 57 can be provided with flow meter 59 . Flow line 57 can also be provided with a back flow preventer or check valve 60 .
[0078] Pump 62 can be a variable speed pump. Pump 62 receives flow from module 18 through suction line 61 . Pump 62 then transmits fluid through flow line 63 to module 17 at flow line discharge 66 . Flow line 63 can be provided with valve 64 and flow meter 65 .
[0079] A number of chemical injectors or chemical inlets 74 - 82 can be provided for transmitting a selected chemical into a selected module of the modules 14 - 21 . Examples are shown in FIG. 2 . Module 14 has a chemical inlet 74 for adding or injecting alkali. Module 14 is also provided with a chemical inlet 75 for adding or injecting detergent. Similarly, chemical inlets 74 and 75 are provided on module 15 . Module 16 is provided with chemical inlet 76 and 77 which enables injection or addition of peracetic acid and peroxide respectively. Modules 17 and 18 can be fitted with chemical inlets 78 for the addition or injection of bleach. Modules 19 and 20 are fitted with chemical inlet 79 that can be used to inject any selected chemical. Module 21 is a final module that can receive finishing chemicals such as a sour, softener, and bacteriostat. The chemical inlet 80 designates sour injection. The chemical inlet 81 designates softener injection. The chemical inlet 82 can be for injecting a bacteriostat. Multiple steam inlets 83 can be provided as shown in FIG. 2 . In FIG. 2 , a steam inlet 83 is provided for each of the modules 14 - 21 .
[0080] Flow line 84 receives flow from module 14 . Pump 90 then pumps flow received from flow line 84 into flow line 85 which then discharges into hopper 26 as shown in FIG. 2 . A flush zone is thus created in hopper 26 by water entering the hopper 26 from flow line 85 as well as water entering hopper 26 from flow line 86 as shown in FIG. 2 . The effect of these flow lines 85 , 86 is to transform the hopper 26 and first module 14 into a process area where fabric articles, linen or fabrics are quickly wetted and initially cleaned. A flow line 91 can be provided for counterflow of one module (e.g. module 20 ) to the previous module (e.g. module 19 ). Flow lines 91 can be provided for each module 15 , 16 , 17 , 18 , 19 , 20 as seen in FIG. 2 .
[0081] Table 1 show examples of water flow rates (in gallons per minute and liters per minute) for light soil and heavy soil for either embodiment ( FIG. 1 or FIG. 2 ). Water flow time (examples) are shown in seconds. Exemplary weights (linen) are shown in pounds and in kilograms. Fresh water consumption is shown for light soil linen in gallons per pound (e.g., 0.1-0.8 gallons per pound) and liters per kilogram (e.g., 1.7-6.7 liters per kilogram for heavy soil linen).
[0000]
TABLE 1
Water Volumes
Linen Classification
Light Soil
Heavy Soil
GPM
LPM
GPM
LPM
Water
Minimum
25
95
50
190
Flow Rate
Middle
105
398
120
455
Maximum
220
833
220
833
Seconds
Seconds
Water
Minimum
10
10
Flow Time
Middle
30
30
Maximum
360
360
Pounds
KG
Pounds
KG
Linen
Minimum
50
23
50
23
Weight
Middle
110
50
110
50
Maximum
300
137
300
137
Gal/Lb
L/Kg
Gal/Lb
L/Kg
Fresh
Minimum
0.1
0.8
0.2
1.7
Water
Middle
0.3
2.5
0.4
3.3
Consumption
Maximum
0.8
6.7
0.8
6.7
[0082] FIG. 3 shows a third embodiment of the apparatus of the present invention designated generally by the numeral 10 B. In FIG. 3 , there can be seen a tunnel washer 11 B having an inlet end portion 12 and an outlet or discharge end portion 13 . The tunnel washer 11 B has an intake hopper 26 . The tunnel washer 11 B can have a plurality of modules such as eight modules shown in FIG. 3 and referenced by the numerals 14 , 15 , 16 , 17 , 18 , 19 , 20 , and 21 .
[0083] Fresh water tank 92 can be positioned next to reuse water tank 94 . Another tank that is provided is an extracted water tank 93 that receives water from an extractor 140 (e.g., press or centrifuge). Extractor 140 can be used to remove water from fabric articles, linen, or clothing or other items to be cleaned and after discharge from final module 21 . Such extractors are commercially available and well-known in the art. Pump 96 discharges fluid from extracted water tank 93 into flow line 97 . The flow line 97 can be provided with a valve 98 . The flow line 97 discharges into reuse tank 94 as shown.
[0084] Flow line 99 is a discharge flow that discharges fluid from reuse tank 94 . Flow line 99 can have valve 139 . Flow line 100 is a flow line that discharges water from fresh water tank 92 . Flow line 100 can have valve 138 . A tee fitting 101 is provided for joining line 99 into line 100 . The flow line 103 is downstream of tee fitting 101 and communicates with variable speed pump or pump 102 . The pump 102 discharges fluid into flow line 104 which discharges into module 20 . Flow line 104 can be provided with a valve 105 and flow meter 106 .
[0085] In various embodiments, counterflow rinsing first uses the extracted water from tanks 93 and 94 followed by clean water from tank 92 . Flow line 107 is a flow line that receives fresh water from tank 92 and pump 108 . The flow line 107 discharges into hopper 26 . The flow line 107 can be provided with valve 109 and flow meter 110 . Flow line 111 is a flow line that produces counterflow from module 18 to module 17 . The flow in line 111 is boosted (i.e., increased pressure or head) by pump 112 which can be a variable speed pump. The line 111 has valve 113 and flow meter 114 . By providing the pump 112 , increased flow rate or pressure or increased head can be provided to the counter current or counter flow which begins at module 20 and then progresses to module 19 , then to module 18 , then to module 17 , then to module 16 , then to module 15 , then to module 14 . Flow line 115 is a flow line that conveys fluid from module 14 to hopper 26 . Pump 116 can be provided in flow line 115 .
[0086] Counterflow rinsing begins at module 20 , then to module 19 and then to module 18 . A pressure drop can occur from module 20 to module 18 . Thus, pressure for counterflow rinsing is increased by pump 112 which transfers counterflow rinse from module 18 to module 17 via flow line 111 .
[0087] A plurality of chemical inlets 117 can be provided, preferably one or more for each module 14 - 21 as shown. Additionally, steam inlets 118 can be provided for heat transfer, preferably one for each module 14 - 21 as shown. Steam inlets 118 can discharge into counterflow lines 121 - 125 for each module 14 - 21 . Module 21 provides a drain 119 . Flow line 95 has valve 120 for transferring fluid from module 21 to extracted water tank 93 . Arrow 141 schematically illustrates transfer of articles from module 21 to extractor 140 . Line 142 is a flow line for carrying extracted water from extractor 140 to extracted water tank 93 .
[0088] In FIG. 3 , there are a number of counterflow lines 121 - 125 . The counterflow line 121 enables counter flow of rinse fluid from module 20 to module 19 . The counterflow line 122 enables counter flow of rinse fluid from module 19 to module 18 . The counterflow line 123 enables counter flow of rinse fluid from module 17 to module 16 . The counterflow line 124 enables counter flow of rinse fluid from module 16 to module 15 . The counterflow line 125 enables counter flow of rinse fluid from module 15 to module 14 . A drain line 126 and valve 127 are provided for draining fluid from module 15 and for transferring that drain fluid to a sewer 130 . Drain line 126 can also be provided with valve 128 . Counterflow line 125 can be provided with valve 145 . When valve 145 is closed, fluid can drain from module 15 to sewer 130 . When valve 145 is open, counterflow line 125 enables counter flow of rinse fluid from module 15 to module 14 .
[0089] Drain line 129 enables draining of fluid from module 14 . The drain line 129 can be provided with valve 131 . The drain line 129 can be used to drain fluid from module 14 into a sewer 130 . Flow line 132 enables fresh water to be added to fresh water tank 92 from fresh water source 143 . The flow line 132 can be provided with valve 133 and flow meter 134 . The flow line 135 enables fresh water from source 144 to be added to the final module 21 . The flow line 135 can be provided with valve 136 and flow meter 137 . Line 135 enables flow of fresh water from source 144 to module 21 .
[0090] The following is a list of parts and materials suitable for use in the present invention.
[0000]
PARTS LIST
Part Number
Description
10
textile washing apparatus
10A
textile washing apparatus
10B
textile washing apparatus
11
tunnel washer
11A
tunnel washer
11B
tunnel washer
12
inlet end portion
13
outlet end portion
14
module
15
module
16
module
17
module
18
module
19
module
20
module
21
module
22
module
23
module
24
module
25
module
26
hopper
27
discharge
28
flow line
29
fresh water tank
30
water extraction device
31
interior
32
flow line
33
tank, extracted water tank
34
flow line
35
flow line
36
flow line
37
inflow tank
38
freshwater flow line
39
pump
40
pump
41
booster pump
42
booster pump
43
flow line
44
flow line
45
valve
46
valve
47
tee fitting
50
pump
51
flow line
52
flow line
53
valve
54
pulse flow tank
55
pump
56
pump
57
flow line
58
valve
59
flow meter
60
back flow preventer/check valve
61
suction line
62
pump
63
flow line
64
valve
65
flow meter
66
flow line discharge
67
flow line
68
valve
69
flow line discharge
70
flow line
71
valve
72
flow meter
73
flow line discharge
74
chemical inlet (alkali)
75
chemical inlet (detergent)
76
chemical inlet (peracetic acid)
77
chemical inlet (peroxide)
78
chemical inlet (bleach)
79
chemical inlet
80
chemical inlet (sour)
81
chemical inlet (softener)
82
chemical inlet (bacteriostat)
83
steam inlet
84
flow line
85
flow line
86
flow line
87
tee fitting
88
valve
89
flow meter
90
pump
91
flow line
92
fresh water tank
93
extracted water tank
94
reuse water tank
95
flow line
96
pump
97
flow line
98
valve
99
flow line
100
flow line
101
tee fitting
102
pump/variable speed pump
103
flow line
104
flow line
105
valve
106
flow meter
107
flow line
108
pump
109
valve
110
flow meter
111
flow line
112
pump/variable speed pump
113
valve
114
flow meter
115
flow line
116
pump
117
chemical inlet
118
steam inlet
119
drain
120
valve
121
counterflow line
122
counterflow line
123
counterflow line
124
counterflow line
125
counterflow line
126
drain line
127
valve
128
valve
129
drain line
130
sewer
131
valve
132
flow line
133
valve
134
flow meter
135
flow line
136
valve
137
flow meter
138
valve
139
valve
140
extractor
141
arrow
142
flow line
143
fresh water source
144
fresh water source
145
valve
[0091] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.
[0092] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A method of washing fabric articles in a tunnel washer that includes moving the fabric articles from the intake of the washer to the discharge of the washer and through multiple modules or sectors. Liquid can be counter flowed in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles. A dual use zone includes multiple of the modules or sectors. In a dual use zone, a module or modules can be used to both wash and thereafter rinse the fabric articles. While counterflow rinsing, the flow rate can be maintained at a selected flow rate or flow pressure head. One or more booster pumps can optionally be employed to maintain constant counterflow rinsing flow rate or constant counterflow rinsing pressure head. During rinsing, extracted water or reuse water is first used to rinse followed by a clean water rinse.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to a torque converter for an automatic transmission, and, in particular, to a hydraulic system that supplies oil to the converter, actuates an impeller clutch of the torque converter and provides a continuous supply of hydraulic lubricant to transmission components.
[0003] 2. Description of the Prior Art
[0004] A torque converter is a modified form of a hydrodynamic fluid coupling, and like a fluid coupling, is used to transfer rotating power from a prime mover, such as an internal combustion engine or electric motor, to a rotating driven load. A torque converter is able to multiply torque when there is a substantial difference between input and output rotational speed, thus providing the equivalent of a reduction gear.
[0005] A torque converter includes at least three rotating elements: an impeller, which is mechanically driven by the prime mover; a turbine, which drives the load; and a stator, which is interposed between the impeller and turbine so that it can alter oil flow returning from the turbine to the impeller to multiply torque. The stator is mounted on an overrunning clutch, which prevents the stator from counter-rotating the prime mover but allows for forward rotation. The torque converter is encased in a housing, which contains automatic transmission fluid (ATF), sometimes referred to as “oil,” “lube” or “lubricant.”
[0006] Hydrodynamic parasitic losses within the torque converter reduce efficiency and generate waste heat. In modern automotive applications, this problem is commonly avoided by use of a bypass clutch (also called lock-up clutch), which physically links the impeller and turbine, effectively changing the converter into a purely mechanical coupling. The result is no slippage, virtually no power loss and improved fuel economy.
[0007] Torque converter clutch designs include two basic types, a closed piston design and an open piston design. A closed piston design requires a dedicated hydraulic circuit into the torque converter, which communicates only with the apply side of the clutch piston. When pressure is high, the clutch applies. When pressure is low, the clutch releases. A more uncommon form is to have this circuit on the release side where high pressure releases the clutch and low pressure applies the clutch.
[0008] When the torque converter is multiplying torque, power loss occurs which significantly increases the temperature of ATF in the torque converter and must be cooled before returning to the transmission. Cooler return oil is usually routed into the transmission lubrication circuit to cool internal clutches, gear sets and bearings. The lubrication circuit is also used to fill or charge balance dams, which are intended to keep disengaged clutch pistons from drifting on when internal rotational speeds increase.
[0009] Hydraulic system logic that controls a torque converter is responsible for several functions including: 1) supplying the converter with sufficient pressure to keep the converter from cavitating, 2) flowing sufficient oil through the converter to remove heat generated in the torus and clutch, 3) controlling pressure in the lock-up clutch piston, 4) supplying oil to the cooling and lube circuits, and 5) minimizing system pump demand for flow and pressure when not required. Many controls systems do not properly control all of these functions
[0010] A need in the industry exists to control a closed piston torque converter bypass clutch using a simple valve arrangement, that improves clutch control, reduces converter flow demands without introducing risk to the transmission lubrication system.
SUMMARY OF THE INVENTION
[0011] A system for controlling hydraulic fluid supplied to a torque converter of an transmission includes a torque converter including a chamber containing an impeller and a turbine, and a bypass clutch having a variable torque capacity, a source of variable control pressure, a latch valve changes in response to the variable control pressure alternately between an unlatched state, wherein the latch valve produces a low pressure output, and a latched state, wherein the latch valve produces a high pressure output, a first valve for limiting hydraulic pressure in the chamber alternately at two magnitudes of pressure in response to the low pressure output and the high pressure output, and a second valve responsive to the variable control pressure for regulating a magnitude of hydraulic pressure that actuates the bypass clutch and changes the torque capacity of the clutch.
[0012] The system includes only two regulator valves instead of three to control converter charge pressure, converter clutch pressure and cooler/lube control, thereby reducing the probability of interactions among the regulators, regulator instability, regulator sticking and pressure variability.
[0013] The system also allows for independent and adjustable flows for the converter circuit, cooler circuit and the lube circuit.
[0014] Conventional two-pass and three pass converters send the locked converter oil flow directly to the transmission oil sump. This system saves this oil by sending it a transmission oil cooler and transmission lube circuit, effectively saving energy that would otherwise be required to pump a larger oil volume, allows for lower lug limits, and saves fuel. The flow rate is about two liters per minute in an automatic transmission operating in sixth gear at 1000 rpm, which results in a 33 percent reduction in oil flow to the converter, cooler and lube circuits during lock-up.
[0015] The system allows tuning of oil flow to the cooler and lube circuits when the converter clutch is locked, hard-locked or modulating torque transmitted between the converter's impeller and turbine.
[0016] The scope of applicability of the preferred embodiment will become apparent from the following detailed description, claims and drawings. It should be understood, that the description and specific examples, although indicating preferred embodiments of the invention, are given by way of illustration only. Various changes and modifications to the described embodiments and examples will become apparent to those skilled in the art.
DESCRIPTION OF THE DRAWINGS
[0017] The invention will be more readily understood by reference to the following description, taken with the accompanying drawings, in which:
[0018] FIG. 1 is a cross sectional side view of a three-pass torque converter to which the control can be applied; and
[0019] FIG. 2 is schematic diagram of a hydraulic system for controlling operation of a torque converter, such as that shown in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to the drawings, there is illustrated in FIG. 1 a torque converter 10 , which is arranged about a central axis 12 and includes an impeller 14 , turbine 16 , and stator 18 . The impeller, stator and turbine are located in a toroidal chamber that defines a toroidal fluid flow circuit, whereby the impeller is hydrokinetically connected to the turbine. The torque converter impeller 14 is driveably connected to an engine or another power source.
[0021] The stator 18 is secured to, and supported for rotation on a stationary stator support shaft 20 . An overrunning brake 22 anchors the stator to shaft 20 to prevent rotation of the stator during torque multiplication but allows free rotation at higher speeds when the turbine flow pushes the backside of the stator blades. The turbine 16 is secured to a rotating transmission input shaft 24 , which transmits torque to a transmission gear box (not shown). A torque converter housing 26 , surrounding the turbine, impeller and stator, is driveably connected to the crankshaft of an internal combustion engine (not shown) or another power source, such as an electric motor.
[0022] Located within a torque converter housing 26 is a bypass clutch 28 (sometimes called a lockup clutch) for alternately opening and closing a drive connection between turbine 16 and the impeller 14 . Clutch 28 includes a set of friction discs 30 , secured by internal splines to, and supported on a clutch hub 32 for rotation with the hub; a blocker plate 34 , secured by a snap ring 36 to housing 26 ; and clutch plates 38 , secured by splines to housing 26 for rotation with the housing, each plate interleaved between successive friction discs 30 . Hub 32 is secured to compression-spring, torsional dampers 40 , 42 , which are arranged in series between hub 32 and the transmission input shaft 24 .
[0023] A turbine shroud 44 , connected to each blade of turbine 16 , is connected by a series of rivets 48 to a turbine hub 50 and a ring 52 , which is driveably connected though a spline to clutch hub 32 . The output of damper 42 is driveably connected to a damper hub 54 , which is connected by a spline 56 to input shaft 24 .
[0024] Lockup clutch 28 is actuated by a piston 58 , which is supported for axial displacement along axis 12 . Piston is sealed at its outer periphery by a dynamic seal 60 to an inner surface of housing 26 and is sealed at its inner periphery by a dynamic seal 62 , thereby defining a sealed volume 64 located between piston 58 and housing 26 . When volume 64 is pressurized through clutch apply passage 66 (CAPY), piston 58 moves leftward forcing friction discs 30 and clutch plates 38 into mutual frictional contact, thereby engaging bypass clutch 28 . When clutch 28 is engaged, the engine and turbine 16 are mechanically interconnected and driveably connected to the transmission input shaft 24 . When lockup clutch 28 is disengaged, the turbine 16 and engine are mechanically disconnected, and the turbine is hydrokinetically driven by the impeller 14 .
[0025] ATF fills the toroidal volume in which the turbine 16 , impeller 14 and stator 18 rotate, at converter charge pressure (CCL) through an annular passage 70 between input shaft 24 and stator support 20 . ATF exits torque converter 10 at converter discharge pressure (COUT) through passage 72 , an annular passage between stator support 20 and a converter drive shaft 76 , on which impeller 14 is supported.
[0026] FIG. 2 illustrates a hydraulic system for controlling converter charge limit pressure (CCL) of the fluid that enters the toroidal chamber of converter 10 through line 70 , converter apply pressure (CAPY) that controls converter clutch 28 , and fluid exiting the converter (COUT) through line 72 .
[0027] The torque transmitting capacity of clutch 28 may vary among: (1) a locked condition, in which clutch 28 is applied but may be slipping; (2) a hard locked condition, in which the clutch is applied with zero slip, transmitting full engine torque; (3) a unlocked condition, in which clutch 28 is released and has zero torque capacity; and (4) a modulating condition, in which the clutch is slipping and transmitting a commanded torque equal to or less than engine torque.
[0028] The hydraulic system includes a converter charge pressure limit valve 80 , which may be a regulator valve or, as shown in FIG. 2 , a limit valve having no exhaust port.
[0029] A converter apply pressure regulator valve 82 , a differential regulator valve that regulates pressure and has a second feedback pressure (CRLZ), supplied through a converter release latch orifice AE.
[0030] A converter charge pressure control latch valve 84 has only two positions, between which it shuttles to hold or latch in either of two pressure magnitudes, which are supplied to valve 82 .
[0031] Clutch exhaust (CLEX) line 86 keeps oil exhausted out of clutch 28 from draining out, keeping circuit fluid filled for improved consistency and response. Converter-out-to cooler (COTC) flow in line 72 exits the transmission case at 90 to transmission oil cooler 92 , returns to the transmission case at 94 after exiting the cooler, and the cooled ATF flows to a transmission lube circuit 96 , through which bearings, shafts, gears and other mechanical components of the transmission are lubricated.
[0032] Converter-out-to-exhaust (COTX) line 98 carries ATF to the lube circuit 96 .
[0033] Converter release latch exhaust pressure (CRLX) is carried in line 88 between ports of valve 80 . Converter release latch orifice pressure (CRLZ) is generated by converter charge pressure control latch valve 84 and is carried in orifice line 99 between valves 80 and 82 .
[0034] Line Pressure (LP), a first priority output of main regulator 100 , is carried in line 102 to valve 82 . Line pressure exhaust (LPX), a second priority output of main regulator 100 , is carried in line 104 to valve 80 . R: Reverse pressure (R), an output from manual valve 106 , is carried in line to valve 82 .
[0035] Solenoid feed (SF), a regulated pressure carried in line 110 , is supplied to solenoid 112 , which controls TCC valve 114 . The output of solenoid 114 is torque converter clutch control pressure (TCCZ) carried in orifice line 116 to latch valve 84 and valve 82 . Torque converter clutch control pressure (TCCL), carried in line 118 , is the latched pressure output produced by latch valve 84 .
[0036] Ball valve (BV 10 ) opens and closes in response to differential pressure caused by COTX and COTC across valve 120 . A converter anti-drain back valve 122 prevents ATF from draining out of converter 10 through line 72 , when engine of off.
[0037] When clutch 28 is unlocked, solenoid control pressure TCCZ is less than about 7.3 psi, fluid at LPX pressure is supplied to valve 80 , and CRLZ pressure at the end of the spool 138 of valve 80 is zero as a result of its being vented at the VENT port of latch valve 84 . These pressures and the spring of valve 80 move spool 138 leftward from the position shown in FIG. 2 , thereby opening a connection between LPX pressure and the CRLX passages 88 of valve 80 . The feedback CRLX pressure on land 139 regulates CCL pressure to 100 psi in CCL line 70 , which is connected by valve 80 to the CRLX passage 88 .
[0038] Therefore, while clutch 28 is unlocked, torque converter 10 is supplied with CCL pressure at about 100 psi from the converter charge pressure limit valve 80 . Flow through the converter 10 is a function of CCL pressure. While clutch 28 is unlocked, oil exiting converter 10 through line 72 flows directly to cooler 92 and the lube circuit 96 . A thermostatic control valve will bypass the cooler 92 , when oil temperature is below 180 deg F., allowing the transmission to warm up faster, thereby reducing viscous drag, improving the transmissions efficiency. This bypass occurs by creating a lower resistance path between circuits COTC 130 and LUBE 96 . Converter apply pressure regulator 82 is not used while clutch 28 is unlocked, and is held off by exhausting CRLZ circuit through the converter charge pressure control valve 84 . Also, when the vehicle operator moves the gear selector to the Reverse position, R pressure in line 108 is fed to the converter apply pressure regulator 82 as an additional force to hold valve 82 off. Although this action is not necessary, it comes without added cost or complexity. Check ball (BV 10 ) 120 keeps oil from back flowing from COTC line 130 to COTX line 98 .
[0039] When clutch 28 is locked, hard locked or modulating, converter charge pressure control valve 84 must latch. Valve 84 is unlatched when TCCZ pressure is less than about 7.0 psi. Valve 84 is latched when TCCZ pressure is greater than about 10.0 psi. The magnitude of electric current supplied to solenoid 112 changes the magnitude of TCCZ pressure produced by valve 114 in response to the current.
[0040] To latch valve 84 , current supplied to solenoid 112 is increased toward 850 milliamps, which increases pressure TCCZ in line 116 to greater than the reference pressure, 10.0 psi, at which valve 84 latches. As TCCZ pressure increases toward 10 psi, the spool 132 strokes rightward opening a connection between TCCZ line 116 and TCCL line 118 , thereby adding to the pressure force on land 134 , which force opposes the force of spring 136 .
[0041] When valve 84 latches, CCL pressure line 70 is opened to CRLZ line 99 , and CCL pressure is sent to an addition pressure area on land 138 of the converter charge pressure limit valve 80 , causing valve 80 to reduce CCL pressure in line 70 to about 45 psi. This pressure reduction occurs because converter 10 does not need as much pressure while clutch 28 is locked or modulating, and because increasing the torque capacity of clutch 28 by leftward movement of the converter clutch piston 58 is facilitated by low CCL pressure in the toroidal chamber of converter 10 .
[0042] When valve 84 latches, CCL pressure is communicated to land 138 of the converter charge pressure limit valve 80 via CRLZ line 99 and to one of two feedback ports of valve 82 , causing the spool 140 of valve 82 to regulate converter apply pressure (CAPY), which is carried in line 66 to the converter clutch 28 . The pressure force effects of the two feedback pressures on valve 82 , CRLZ pressure at 45.0 psi in line 99 and variable TCCZ pressure greater than 10.0 psi in line 116 regulate CAPY pressure, which is carried in line 66 to the converter clutch 28 .
[0043] When valve 84 latches, the rightward stoking of its spool 132 connects CCL pressure in line 70 to cooler 92 through the COTX circuit line 98 , which is used to supplement flow to the COTC circuit 98 and LUBE circuit 96 , since circuits 98 and 96 will receive less oil from the COUT circuit 72 after valve 84 latches and CCL pressure drops to 45 psi. Flow in COUT circuit 72 is lower because the converter is now being fed oil at 45 psi instead of 100 psi. The diameter of orifices U 142 and SS 144 are sized to produce the correct flow rates in COTC circuit 130 and LUBE circuit 96 during locked and modulating operation of bypass clutch 28 .
[0044] In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that the alternate embodiments can be practiced otherwise than as specifically illustrated and described.
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A system for controlling hydraulic fluid supplied to a torque converter of an transmission includes a torque converter including a chamber containing an impeller and a turbine, and a bypass clutch having a variable torque capacity, a source of variable control pressure, a latch valve changes in response to the variable control pressure alternately between an unlatched state, wherein the latch valve produces a low pressure output, and a latched state, wherein the latch valve produces a high pressure output, a first valve for limiting hydraulic pressure in the chamber alternately at two magnitudes of pressure in response to the low pressure output and the high pressure output, and a second valve responsive to the variable control pressure for regulating a magnitude of hydraulic pressure that actuates the bypass clutch and changes the torque capacity of the clutch.
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RELATED APPLICATIONS
[0001] This application, pursuant to 37 C.F.R. §1.78(c), claims priority based on provisional application serial No. 60/284,551 filed Apr. 18, 2001 and provisional application serial No. 60/350,199 filed Jan. 18, 2002.
FIELD OF THE INVENTION
[0002] The invention relates to improved tungsten-carbide dies made by metal injection molding (“MIM”).
BACKGROUND OF THE INVENTION
[0003] Tungsten-carbide dies are currently made from cylindrical blanks produced by the press and sinter method known as Powder Metallurgy or “PM.” Cobalt, in various volume percentages, is blended with tungsten-carbide. A mixture of various powders are used in the process. Our process allows us to make our dies with lower percentages of cobalt (which is an advantage in itself because cobalt is expensive). This results in increased hardness and abrasion resistance when compared to dies with higher cobalt content. It is also possible to add other metals and alloys to our feedstock to give the resulting metal improved characteristics and performance.
[0004] Powder Metallurgy (“PM”) uses oblong or shard-shaped powders for various reasons. To begin with, they are typically less expensive than spherical powders. More importantly, spherical powders do not work well (if at all) in PM. When the tungsten-carbide and cobalt powders are pressed into the cylindrical die, they are compressed, which gives the part its stability during the sintering process. The shard particles of various sizes, “interlock” to a certain extent. Pressing spherical powders in a PM process does not provide that interlocking.
[0005] Further, the use of spherical powders would substantially exacerbate the deformation that occurs during the sintering of PM parts. The deformation is caused primarily when the cobalt particles melt and fall through the spaces between the tungsten-carbide particles. Such deformation is already a significant problem in producing tungsten-carbide dies by PM.
[0006] In the PM process, a selected powder is pressed into a die or mold at high pressures. The pressed part is then sintered at high temperature to fuse the powders into “solid” metal. The part is not really solid, however. It has porosity, which is measured as its density (expressed as a percentage of the theoretical 100% density of wrought metal).
[0007] It is well known in the PM field that, in general, increasing the density of a sintered powdered metal item (i.e. reducing its porosity) will significantly improve its strength and durability. At high levels of porosity (i.e. low density), the metal is brittle and of low fatigue strength. Accordingly, considerable effort is expended (and significant cost incurred) in trying to increase the density of the PM blanks, which typically have a density of approximately 85% after sintering. Some of the methods include hot forging, double pressing, double sintering, hot isostatic pressing (“HIPing”) and pressure assisted sintering (“PASing”). While higher densities (typically, 88% to 92%) are achievable by these methods, it is often at the cost of dimensional precision. And, there is the additional cost of those secondary processes. The blanks need further machining in order to make them into blanks ready for their inside diameter (“I.D.”) profiles. Typically, the outside diameters (“O.D.”) need to be brought within specifications (the ends need to be squared off and the outside surface ground down) and then the pilot hole running down the center of the blank needs to be made to a specific diameter and concentric to the O.D. The result is referred to as a “semi-finished” blank, which is ready to be made into a finished die.
[0008] Making the finished die involves cutting the I.D. profile into the blank. This is done by various means such as drilling, reaming, grinding, EDMing, etc. Tungsten carbide is very hard, so it is difficult (time-consuming and/or costly) to cut in the I.D. profile. The difficulty increases with the complexity of the I.D. profile, the tolerances that must be met and the hardness of the tungsten-carbide blank. Frequently, blanks with lower hardness and/or density are selected in order to overcome or reduce these difficulties.
[0009] The present invention provides improved tungsten-carbide dies, with improved physical properties, improved chemical properties and enhanced performance, and an improved method of manufacturing those dies. This invention relates to both the blanks and the finished dies as well as other fastener industry tools.
SUMMARY OF THE INVENTION
[0010] The present invention produces improved tungsten-carbide blanks and finished dies using MIM. MIM is an established manufacturing process. Heretofore, fine powdered metals (typically spherically-shaped) are mixed with various binders to form a feedstock. This feedstock is then heated and molded under pressure in an injection molding machine to produce a “green” part or preform. After molding, the binders are removed from the green part in a process called “debinding,” producing a “brown” part or preform. The debound part is then sintered, which fuses the powdered metal particles into a densified matrix. While there is porosity in an MIM part, substantially higher densities are achievable by MIM than by PM. However, we have found that significantly improved results are obtained by using polygonal-shaped powder instead of spherical, oblong, or shard-shaped particles, as defined in Powder Metallurgy Science by Randall M. German, 1994, Chapter 2 and pages 29 and 30, which are herein incorporated by reference.
[0011] The green part shrinks substantially during debinding and sintering (typically between 11% and 30%, depending upon the formula of the feedstock and the debinding and sintering parameters). The shrinkage amount, however, is predictable in all dimensions and, once the optimum feedstock formula and parameters are determined, the process is highly consistent and repeatable. The amount of shrinkage that occurs (which is expressed as a percentage equal to one minus the ratio of the size of the finished part to the size of the green part) is referred to as the “shrink factor” and the amount by which the green part must be “over-sized” in order to produce a sintered part of specified dimensions (which is expressed as a percentage that is approximately equal to the ratio of the size of the finished part to the size of the green part) is referred to as the “form factor.”
[0012] Once an appropriate tungsten-carbide feedstock is developed, and its shrink factors and form factors are determined, a mold is fabricated. The mold will produce a blank or finished die with a specified O.D. and length. A pin or pins is then fabricated to be suspended in the mold cavity, which will form the pilot hole (for a blank) or the I.D. profile (for a finished die). Both the mold cavity and the pin(s) are over-sized to take into account the shrinkage that will occur during debinding and sintering. The feedstock is then molded around the pin(s). When the pin or pins are removed, the pilot hole or I.D. profile has been formed in the green part, and when that green part has been debound and sintered, the blank or finished die has been produced with near net shape.
[0013] Producing tungsten-carbide dies by this method offers many advantages. Eliminating most if not all of the secondary operations to produce the blanks and the finished dies saves time and expense. In addition, the dies themselves have improved characteristics. The metal powders used to make tungsten-carbide MIM feedstocks are in the present invention polygonal powders. This produces substantially higher densities in the metal (in excess of 99%, compared to 85% by PM) without the need for secondary processes. The polygonal powders also produce an improved microstructure of the metal, with more uniform bonding. This results in increased transverse rupture strength, which is a widely-accepted method used to determine load-bearing properties. The polygonal powders also make it easier to cut in the I.D. profiles into the blanks than the shard-shaped powders used in PM. This allows the use of harder grades of tungsten-carbide to make the same die. All of these improvements result in enhanced performance and/or utility of the die. One additional benefit of these dies is that, when the die wears so that it is no longer within required tolerances, it can easily be reamed to a larger I.D. and re-used.
DESCRIPTION OF THE INVENTION
[0014] An improved tungsten-carbide die, including finished dies and blanks for dies, can be made according to the present invention using polygonal-shaped tungsten-carbide particles with metal injection molding (“MIM”) and has many advantages over the prior art. The MIM process is a known fabrication process as taught in, for example U.S. Pat. No. 4,113,480, the disclosure of which is incorporated herein by reference. The die has a cylindrical shape (although it can also be of other shapes) and is flat on both ends. The die has a hole down its middle, extending from one of the flat ends to the other (although the hole can also extend through only a portion of the length of the die). It also could have no hole, in which case it is a blank for a die. The hole is round (a die with a round hole of uniform diameter all the way through its length is referred to a “straight hole” die). The hole can be of any diameter and can also of more than one diameter (e.g. for an extrusion die). Straight hole dies are used as is, or are used as a starting point to make dies with different internal diameter (“I.D.”) profiles by various secondary operations. The dies of the present invention can also have an I.D. profile that is other than round.
[0015] The hole in the die can be formed by drilling the green part, but it is preferably formed by suspending a pin or pins in the cavity of the mold, and molding the MIM feedstock around the pin(s). The hole in the die is formed by removing the pin(s) from the molded part prior to the debinding and sintering operations (although the pin(s) can also be removed after debinding and prior to sintering). The outside diameter (“O.D.”) profile of the pin(s) is round for a straight hole die. In order to produce a die with an I.D. profile that is other than round, the pin(s) are made with the corresponding non-round O.D. profile.
[0016] The MIM feedstock contains, in addition to the binders that serve to carry the metal powders into the mold, 85% by weight tungsten-carbide (WC) and 15% by weight cobalt (although the percentages of each can vary widely and metallic binders other than cobalt (e.g. nickel) can be used, as well). In addition, other alloying metals or compounds can be added to the feedstock as additives (e.g. tantalum, tantalum-carbide, titanium-carbide, niobium-carbide, chromium-carbide, cobalt-nickel, nickel-tantalum, titanium-nitride, and diamond dust), which produce different chemical and physical properties in the resulting cemented carbide. In general, the additive (or mixtures thereof) may be present in an amount in the range of from about 0% to about 7% by weight of the sintered article, with about 1% to about 5% being preferred.
[0017] By way of example, a die with finished dimensions of 0.625″×0.625″ was made using a binder system having just over 50% by weight wax in the binder system offered by the AQUAMIM Division of Planet Polymer Technologies Ltd. of San Diego, Calif. which may be described in Planet Polymer's two patents. No. 5,977,230, issued Nov. 2, 1999, and No. 6,008,281, issued Dec. 28, 1999). Water debinding was unsuccessful with the tungsten-carbide feedstock used for an 85% WC-15% Co feedstock as the parts developed bubbles and blisters in the debinding process.
[0018] After considerable effort, we determined that the binders could be removed by dissolving in a hydrocarbon solvent, preferably mineral spirits. We subsequently determined that the mineral spirits should be maintained at a temperature of 80°-120° F. for best results. We have also found that n-propyl bromide is not only an acceptable solvent, but is presently preferred. In general, any liquid linear hydrocarbon such as an alkane solvent may be used, including hexane, heptane, octane or various mixtures of the alkanes. Depending on the thickness of the part, a sufficient amount of the primary binder such as a wax (minimum 70%, and preferably 80% or more) is removed during the rebinding process. The balance of the binders, such as a high molecular weight polyolefin of more than 5,000 gram molecular weight, which give the part its support prior to and during the sintering process, are removed during sintering.
[0019] The shrink factor of a particular feedstock and its corresponding form factor are determined by measuring the sintered part and comparing those measurements to those of the green part. It will vary with each feedstock formulation. We provide our toolmaker with the dimensions of the finished part and the form factor for the feedstock that we intend to use. Any toolmaker with reasonable knowledge and skills in the art of making molds could design and fabricate a mold that will produce a green part of the required size. The means to suspend a pin in the mold cavity, and the fabrication of that pin, are also within the toolmaker's purview. One important part of our invention, however, is the concept of using such a suspended pin (or multiple pins) to form the I.D. profile. Not only does this eliminate the secondary operations to cut in the I.D. profile, but it allows the mold that produces a die blank with certain O.D. dimensions to be used to produce an unlimited number of dies (both finished and semi-finished) with different I.D. profiles.
[0020] The tungsten-carbide feedstock with polygonal-shaped particles is molded in a conventional injection molding machine. The only modification is that the barrel and screw of the molding machine is made of harder metal than those used in molding plastics. In the barrel, which is heated, the feedstock softens to a toothpaste-like consistency. The optimum temperature of the feedstock will depend upon the formulation of the binders. In the present case, we maintain the barrel temperature within a range from 350° to 400° F. The polygonal-shaped particle feedstock is injected into the mold cavity, and a packing pressure is applied by the molding machine while the feedstock cools and the binders “set up”. Sufficiently high molding and packing pressures should be applied in order to achieve the greatest density in the green part, such as for instance 2000-2400 psi. The amount of the holding time depends upon the feedstock formulation, the molding temperature and the size of the part. In the present case, our hold time is 60 seconds. A person of ordinary skill in the operation of an injection molding machine can arrive at the appropriate combination of molding parameters (temperature, shot size, injection speed, injection pressure, packing pressure, hold time, etc.) to produce good molded “green” parts, which is also a function of the molding machine itself.
[0021] After the molded part has cooled, we remove as much of the vestiges of the gate and runner system with a saw (in a production mold, most of that vestige will be removed by the mold itself). After a sufficient number of parts have been molded and de-gated, the debinding process is commenced. The green parts are placed in the debinding tank. After the requisite amount of primary binders (as determined by the binder supplier) have been removed producing the brown preform or part (we determine that by drying and weighing the parts from time to time), the parts are placed in a high temperature sintering furnace. An appropriate sintering profile is developed, depending on the size of the part, the quantity and nature of the secondary binders and the characteristics of the metal powders all as is well known in the powder metallurgy art. Typically, the temperature is initially increased gradually so that the secondary binders can melt and/or evaporate without deforming the part. The temperature is then ramped up more rapidly to a higher temperature level, held at that level for a certain period of time, and then ramped up to a higher level, held again, etc., until the part reaches the optimum sintering temperature. The temperature is held at that level for a certain period of time. During that process, the metal powders fuse together forming a coherent, densified matrix. The temperature in the furnace is then brought down, typically in stages, as in the ramp-up phase. The temperatures, ramp rates and hold times of a complete sintering cycle are referred to as the sintering profile. A person of ordinary skill in the art of sintering tungsten-carbide can devise an appropriate profile, which is also a function of the furnace itself. Table 1 is a current profile used to sinter the 0.625″×0.625 die with the current formulation of our feedstock.
TABLE 1 Segment # (1 to 100) 1 2 3 4 5 6 7 8 9 10 Segment Type (ramp/soak) ramp soak ramp soak ramp soak ramp ramp soak soak Target Setpoint (0-1650) 275 275 475 475 1050 1050 1350 1370 1370 75 Ramp in Deg C./Min (Soak in Min) 3 60 3 90 3 60 5 2 60 5 Guaranteed Flag (Y/N) n n n n n n n n n y Positive Deviation (0-1650) 0 0 0 0 0 0 0 0 0 0 Negative Deviation (0-1650) 0 0 0 0 0 0 0 0 0 75 PID #1 = Ramp, 2-Soak (1-2) 1 2 1 2 1 2 1 1 1 2 Debind Cycle (Y/N) y y y y n n n n n n Heaters On (Y/N) y y y y y y y y y n Sinter Cycle (Y/N) n n n n y y y y y n Partial Pressure Setpoint (0-760) 300 300 300 300 300 300 300 300 300 700 H2 Hot Zone Setpoint* (0-35) 2 2 2 2 2 2 2 2 2 0 H2 Retort Setpoint* (0-35) 12 12 12 12 6 6 6 6 8 0 Process Gas* (Off. N2/Ar/Air/bub) off off off off off off off off off Ar Proc. Gas Hot Zone Setpoint (0-35) 0 0 0 0 0 0 0 0 0 30 Proc. Gas Retort Setpoint (0-35) 0 0 0 0 0 0 0 0 0 30 High Vacuum Cycle (Y/N) n n n n n n n n n n High Vacuum Hold (Y/N) n n n n n n n n n n Cool Down Event (Y/N) n n n n n n n n n y Cool Down Pressure (0-760) 0 0 0 0 0 0 0 0 0 760 Cool Down Temperature (0-1000) 0 0 0 0 0 0 0 0 0 1000 N2 Quench (Y/N) n n n n n n n n n n Retort Shutters (Y/N) n n n n n n n n n y Profile Name Ryerwcl Configured Date 1/26/01 Developer BCS
[0022] The inventive process is very consistent and highly repeatable. While the following is typical but not as good as the best results achieved, our most recent dies (which are made of 85% by volume tungsten-carbide and 15% by volume cobalt) consistently exhibit the following characteristics, based upon tests by an independent testing laboratory [the numbers in the brackets are the corresponding figures for a PM sample, which turned out to be 84% WC-16%Co]:
[0023] 1. Density (as a percentage of theoretical), based on ASTM B-276-91: 99.3%. We have densities as high as 99.7% [88%];
[0024] 2. Microhardness: 86-87 Ra [85-86 Ra],
[0025] 3. Transverse Rupture Strength (TRS), based on ASTM B-406-96: 275,000-325,000 psi [350,000-425,000 psi].
[0026] According to an independent testing service, the lower TRS for our dies is not necessarily a bad thing, especially for an impact application. The microstructure of the metal of our dies, because of the polygonal powders and higher densities, will likely make that metal tougher than the PM die, and more resistant to cracking. This latter condition also dictates the approximate atmosphere within the furnace chamber. Our dies have greater reamability than comparable PM dies. Our tungsten-carbide dies with 15 weight percent cobalt can be reamed with standard reaming tools used for tungsten-carbide die, but PM dies must have at least 20 weight percent cobalt to be reamed with standard tools.
[0027] In our process, we use polygonal metal powders. Typically, but not necessarily, that means a mean particle size of less than 15 μm, preferably 2 to 6 μm. However, submicron particles to particles having a mean particle size of 0.1 microns have been used. Mean particle diameters of up to about 30 microns have been used with the preferred range being between about 1.5 to about 5 microns. We vary the composition and the particle sizes of our feedstocks, depending on the application to which the die will be put. Some applications (such as header dies) produce better results with dies made from smaller particles. We also vary the distribution of particle sizes around the mean.
[0028] The dies made in accordance with the present invention have many applications, in many different industries. We have initially targeted applications in the fastener industry. In that industry, the inventive dies can be used in so-called “cold heading” machines, and would be referred to as “header dies”, but we can also use the inventive dies in so-called “hot heading”. Header dies are typically used in the fastener industry to form the body of a screw, nail, rivet or other fastener. There are many other “tools” used in the fastener industry that are currently made from tungsten-carbide, and still others that would be better if made from tungsten-carbide. These other types of tools include punches, upsets, hammers, fingers, transfer fingers, quills, cutters, trim dies, draw dies, saws, pinch point dies, forging dies and roll thread dies. Our dies can also be used in stamping applications. The method of our invention can be used to make all of these tools out of tungsten-carbide with or without an additive, as previously disclosed, using our injection molding process. As in the case of our dies, the metallurgical properties of the injection molded metals will result in improved tools.
[0029] We have varied the cobalt concentration from about 3 to about 35 percent by weight. At 6% by weight cobalt we have achieved greater than 99% of theoretical density without hipping. At 3% by volume cobalt, we have achieved abut 85% of theoretical density without hipping. Tools have been made using both 15% and 25% by weight cobalt as a percentage of the final article.
[0030] Moreover, we have made header dies (cylinders with a central aperture) with both inner and outer diameters with little shrinkage and superior densities.
[0031] While there has been disclosed what is considered to be the preferred embodiment of the present invention it is understood that various changes in the details may be made without departing from the spirit or sacrificing any of the advantages of the present invention.
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A process of making an article of a tungsten-carbide-cobalt alloy with or without an additive of one or more of tantalum, cobalt-nickel, nickel-tantalum, tantalum-carbide, titanium-carbide, niobium-carbide, chromium-carbide, titanium-nitride and diamond dust. The method includes forming a homogeneous mixture of polygonal-shaped powder tungsten- carbide-cobalt and a polygonal-shaped powder additive and a binder including wax and a high molecular weight polyolefin polymer and injecting the mixture under heat and pressure into a metal injection mold to form a green preform of the article. The green preform is immersed in a linear hydrocarbon or a halogenated hydrocarbon or mixtures to dissolve and remove the wax and convert the green preform into a brown preform which is sintered to remove the remainder of the binder and to densify the brown preform into an article having a density not less than 98%. Various tungsten-carbide articles are disclosed.
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FIELD OF THE INVENTION
The present invention relates generally to non-metal slings and, in particular, to an apparatus for manufacturing non-metal roundslings.
BACKGROUND OF THE INVENTION
The term “rigging” (sometimes referred to as industrial rigging or field rigging) is the branch of securing heavy loads in order to prepare the load to be lifted, moved or transported. Rigging usually refers to the ropes, wires, slings, and chains used to secure the load and not the cranes, boomlifts, air skates, forklifts, or other powered equipment that provides the actual force/energy to lift the object.
Wire rope slings made of a plurality of metal strands twisted together and secured by large metal sleeves or collars are common in the industry. Since wire rope slings are made of metal, they do not require any protection that may be afforded by a covering material. During the past thirty years, industrial metal slings have seen improvements in flexibility and strength. However, compared to non-metal or synthetic fiber slings, metal slings are relatively stiff and inflexible.
Synthetic fiber slings have gained popularity over the last approximately twenty years and are replacing metal slings in many circumstances. Thousands of synthetic slings are being used on a daily basis in a broad variety of heavy load lifting applications which range from ordinary construction (e.g., nuclear power plants, skyscrapers and bridges), plant and equipment operations, to ship building (e.g., oil rigs), and the like.
An advantage of synthetic slings over metal slings is that they have a very high load-lifting performance strength-to-weight ratio which provides for a lighter, more flexible and even stronger slings than their heavier and bulkier metal counterparts. An important disadvantage is that synthetic slings require extra steps (primarily encasing the lifting core inside a protective cover), in its manufacturing process.
Synthetic slings are usually comprised of a lifting core made of twisted strands of synthetic fiber and an outer cover that protects the core. The most popular design of synthetic slings is a roundsling in which the lifting core forms a continuous loop and the sling is generally ring-shaped in appearance. The lifting core fibers of such roundslings may be derived from natural materials (e.g., cotton, linen, hemp, etc.), but are preferably made of hemp, linen, etc. synthetic materials, such as polyester, polyethylene, nylon, and the like. The outer covers of synthetic slings are preferably made of synthetic materials and are designed to protect the core fibers from abrasion, cutting by sharp edges, or degradation from exposure to heat, cold, ultraviolet rays, corrosive chemicals or gaseous materials, or other environmental pollutants.
A popular method of manufacturing of prior art roundslings is to twist a plurality of yarns together to form a single strand; the strand was then rolled into an endless parallel loop that formed the core. In a separate step, the cover would be manufactured as a flat piece; then the lifting core would be laid on the flat material, and the flat piece of cover material would be bent around the endless core; finally, the edges of the cover are sewn together thereby encasing the core. This method of manufacturing roundslings is time consuming and labor intensive thus increasing the costs to manufacture the sling.
An important advancement in the rigging industry was the invention of multiple-path slings by Dennis St. Germain. (See U.S. Pat. No. 4,850,629, titled Multiple Path Sling Construction). The manufacturing process for a two-core roundsling is more difficult since it requires more time and labor than a single-core roundsling.
Machines used to manufacture round slings and multiple-path slings are still relatively labor intensive. Accordingly, there is a need in the industry to reduce the amount of labor needed in the manufacturing of synthetic slings.
SUMMARY OF THE INVENTION
It is a primary object of the present document to disclose an apparatus for manufacturing non-metal slings and, in particular, an apparatus for making multiple-path slings.
The subject sling-making apparatus may take on a number of embodiments. However, a preferred embodiment is the making of a two-path industrial sling, i.e., a roundsling having exactly two load-bearing cores.
The apparatus has three primary sections, namely, the yarn feeder assembly, the control assembly and the tail section assembly.
The yarn feeder assembly includes a yarn table consisting of a relatively flat table-top having a first end and a second end. The second end of the yarn table abuts the control assembly.
The control assembly includes an electric motor that provides the motive force for the sling-making apparatus, a power button used to turn the sling-making apparatus on and off, and a control circuit used to track the length of yarn used in the manufacturing of the load-bearing core.
The tail section assembly includes a pair of diametrically opposed rails on which an idler roller assembly rides. The pair of rails abut the side of the control assembly opposite to the side on which the yarn feeder assembly is located. The idler roller assembly is comprised primarily of an idler roller and the mating section for sliding on the rails. The length of the pair of rails depends on the maximum length of sling to which the sling-making apparatus is designed to make. In a preferred embodiment, the length of the rails is forty feet and the idler roller assembly can slide along the rails to make a roundsling up to eighty feet in circumference.
Once the length of the sling to be manufactured is determined, the idler roller assembly is slid, in a straight line, along the rails to the determined position—this is away from the controller assembly for long slings and towards the controller assembly for short slings. The idler roller may be allowed to spin or it may be locked into place.
As will be evident to one skilled in the art, and to provide maximum adaptability for its location, the sling-making apparatus may be left-handed or right-handed. When the yarn table is positioned to the left of the control assembly and the tail section assembly is positioned to the right of the control assembly, the sling-making apparatus is considered left-handed; when the yarn table is positioned to the right of the control assembly and the tail section assembly is positioned to the left of the control assembly, the sling-making apparatus is considered right-handed. However, the side on which each assembly is located with respect to the center control assembly does not affect the operation or process of making a sling.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the following description, serve to explain the principles of the invention. For the purpose of illustrating the invention, there are shown in the drawings embodiments which are presently preferred, it being understood, however, that the invention is not limited to the specific instrumentality or the precise arrangement of elements or process steps disclosed.
In the drawings:
FIG. 1A is a top plan view of an apparatus for making slings in accordance with the present invention;
FIG. 1B is a side view of the apparatus illustrated in FIG. 1A ;
FIG. 2A is a top plan view of the fiber guide/separator that forms a part of the yarn table assembly;
FIG. 2B is a side view of the fiber guide/separator shown in FIG. 2A ;
FIG. 3A is a top plan view of the control assembly and tail section assembly of the subject apparatus;
FIG. 3B is a side view of the control assembly and tail section assembly of FIG. 3A ;
FIG. 4A is a side view of the encoder wheel which forms a part of the control; and
FIG. 4B is a top view of the encoder wheel shown in FIG. 4A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In describing a preferred embodiment of the invention, specific terminology will be selected for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
Before the invention is disclosed, it is important to remember some terminology used in the rigging industry and to understand the parts of a sling is made. The term “roundsling” is used to refer to a sling having a ring-like or circular shape. A roundsling has two primary sections; namely, a load-bearing core and a tubular cover which protects the load-bearing core. In a single core roundsling, there is one endless load-bearing core. In a roundsling having exactly two load-bearing cores (e.g., TWIN-PATH® brand dual-core slings), the cover has two separate and distinct channels parallel to each other, and two endless load-bearing cores situated within its own respective channel in the cover.
DEFINITIONS
Abrasion: The mechanical wearing of a surface resulting from frictional contact with materials or objects.
Breaking Strength: The total force (lb. or kg.) at which the sling fails. The total weight strain which can be applied before failure, which is usually at least five times the rated capacity.
Core: The load-bearing multiple fibers of synthetic material which when wound into the seamless tubes becomes the load-bearing yarns of the sling.
Cover: The seamless tubes that contains the cores. Covers may be of polyester, covermax, Aramid, or other suitable material depending on the desired finished characteristics of the product. Preferably, the cover is made of an inner material hearing a high visibility color, and an outer material made of a contrasting color; when the outer cover material is damaged or worn through, the inner cover material becomes visible allowing for a quick inspection means.
Elongation: The measurement of stretch, expressed as a percentage of the finished length.
Fitting: A load-bearing metal component which is fitted to the sling. A fitting can be made from steel, aluminum or other material that will sustain the rated capacity of the sling. The fitting must be smooth and large enough to allow the sling to perform without bunching.
Length: The distance between bearing points of the sling when laid flat and closed. Measurements are taken from the inside points of contact.
Proof Test: A term designating a tensile test applied to the item for the sole purpose of detecting injurious defects in the material or manufacture.
Synthetic Fiber: Any of a multiple of man-made materials used to manufacture the cover, the core, and the thread of the non-metal slings.
Tell-Tails: Core yarns which extend past the tag area of each sling. When the sling is stretched beyond its elastic limit, they shrink and eventually disappear under the tag. If either tell-tail is showing less than ½″, the sling must be removed from service. If the tell-tails show evidence of chemical degradation, the sling must be removed from service. These may be a fiber-optic cable which will help identify core deterioration.
Thread: The synthetic yarn which is used to sew the slings, covers, tag and also to provide the stitch which separates the individual load covers.
Multiple-path non-metal slings were unknown approximately twenty-five years ago. Dennis St. Germain, the inventor herein, invented multiple-path slings in the mid-1980's. The multiple-path sling and, in particular, a sling having exactly two load-bearing cores, has been a commercial success. Slings having two load-bearing cores are sold under the TWIN-PATH® brand. The multiple-path sling is described in U.S. Pat. No. 4,850,629, titled MULTIPLE PATH SLING CONSTRUCTION. U.S. Pat. No. 4,850,629, is hereby incorporated by reference as if fully set forth herein.
Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings in which an apparatus for making slings in accordance with the present invention is generally indicated at 10 .
Referring now to FIGS. 1A and 1B , a yarn feeder assembly 20 , a control assembly 30 and a tail section assembly 40 are shown. The yarn feeder assembly 20 includes a yarn feeder table 22 having a flat table top 11 with a first end 12 and a second end 13 ; the second end is abutted up against and, is preferably attached to, the control assembly 30 . As illustrated in FIG. 1B , the yarn feeder table 22 has one or more legs 14 to support the table top 11 .
Spaced at regular intervals, the yarn feeder table 22 has a plurality of openings 23 for allowing an individual strand 25 of yarn to pass therethrough. The individual strands of yarn will be twisted together, as will be described herein, to make the load-bearing inner core of the sling. FIG. 1A illustrates an apparatus 10 having exactly eight yarns used to make the inner core; therefore, this particular yarn table has openings 23 A through 23 H. If the machine is set up to manufacture a multiple-path (e.g., a TWIN-PATH® brand dual-core sling), the yarns are twisted together to make each core of the multiple-path sling.
The individual strands are made in a separate manufacturing step. As an individual strand of yarn is manufactured, it is rolled onto a heavy-weight cardboard tube. Once the desired length of yarn is rolled onto the heavy-weight cardboard tube, the yarns are delivered to customers in a spool or roll 99 . The denier, weight and materials used to manufacture the yarn are chosen depending on the type and size of sling to be manufactured. However, in order to reduce inventory, to keep storage space at a minimum, and to streamline the manufacturing process, it is preferable to choose one medium-weight synthetic yarn.
Beneath the yarn feeder table 22 lies a spool table 24 for holding a plurality of spools 99 of yarn. In a preferred embodiment, as illustrated in FIG. 1B , yarn table 22 can hold two rows of four rolls of yarn (for a total of eight rolls), wherein yarn 25 A is unrolled from spool 99 A, yarn 25 B is unrolled from spool 99 B, etc. However, not every sling that will be manufactured will use the maximum number of yarns. For example, slings designed and rated to lift relatively small loads may use less than eight yarns.
The spool table 24 has a plurality of elongated extensions 26 A, 26 B, 26 C through 26 H (preferably rod-shaped) that extend from the top surface of the spool table towards the underside of the yarn table 22 . (Although extensions 26 E through 26 H cannot be seen from the drawings, each half of the spool table is identical.) A spool of yarn 99 is slid vertically over each of the extensions 26 on the spool table 24 and the spool's weight keeps it on the spool table.
The number of elongated extensions 26 are ultimately determined by the maximum size of sling to be manufactured on the apparatus 10 . The number of spools of yarn 99 used to manufacture a specific sling depends on the size of the sling to be manufactured at that time. The number of spools of yarn 99 should not exceed the number of elongated extensions on the spool table. Although the disclosure and the drawings illustrate that there are eight spools of yarn that are slid over eight elongated extensions 26 , the spool table can be enlarged to accommodate more elongated extensions 26 and more spools 99 in order to make larger slings. Similarly, apparatus 10 that are designed to make lower-strength slings may not require a yarn table that can accommodate eight yarns.
The number of spools that can be held by the spool table 24 corresponds to the number of openings 23 A, through 23 H in the yarn table. Once the size of the sling to be manufactured is determined, the number of yarns to be used to form the load-bearing core can be calculated based on the known weight an individual yarn can hold. Although the first time a sling is made, the number of yarns and other factors may be calculated, some of this information may be obtained through trial and error by manufacturing slings made of varying diameters of yarn, destructively testing the sling, and recording the results. Over time, the number of yarns needed to manufacture a specific load-bearing core will become well-known since all of the other measurements are known (e.g., the thickness of the yarn used, etc.) For example, by doing an initial calculation, then through years of experience in making slings, it is known that eight yarns of relatively medium weight synthetic (e.g., Kevlar® of Kevlar® blend) yarn are required to manufacture the load-bearing core of a 20,000 pound sling. This information can be collected and quantified in a chart which can be consulted by the operator immediately before the manufacturing process.
Referring again to FIGS. 1A and 1B , proximate each yarn opening 23 A through 23 H, is a spring-tensioning device 27 A through 27 H, respectively. The spring-tensioning devices 27 A through 27 H applies proper resistance to its respective yarn to prevent any slack in the yarn during the cover-making step. The spring-tensioning devices each have their own adjustment to increase or decrease the amount of tension applied to its respective yarn. The spring-tensioning devices are well-known in the industry.
The sling-making apparatus 10 includes an encoder 29 . The location of encoder 29 can be seen in FIGS. 1A , 1 B, 3 A and 3 B. The encoder 29 includes an encoder wheel 98 and its related circuitry that counts the number of revolutions of the encoder wheel.
Referring now to FIGS. 4A and 4B , an enlarged view of the encoder wheel 98 is shown. The encoder wheel 98 has a central groove 65 of known circumference. The circuitry is preferably stored in control box 34 . One of the yarns (preferably one farthest away from the control assembly) is wrapped at least partially around the encoder wheel 98 . Since the wheel's circumference is known, the length of the yarn used to manufacture the load-bearing core will be easy to compute. As one skilled in the art can appreciate, after reading the present disclosure, the encoder circuitry may be modified to provide a reading in any length measurement (e.g., feet, yards, meters, etc.)
A counter circuit that is connected to the wheel actually determines how many feet are used. Since the circumference of the wheel is known (2*pi*r—where “r” is the radius of the wheel 98 in feet), the number of rotations of the wheel will convey the number of feet of yarn that has been pulled from a roll 99 to make the inner core(s). The encoder and its associated circuitry are well-known off-the-shelf products.
Referring again to FIGS. 1A and 1B , the location of a comb or fiber guide 92 proximate the second end 13 of the yarn table 11 is shown. Preferably the fiber guide 92 is positioned at the junction between the yarn table assembly 20 and the control assembly 30 . The fiber guide 92 ensures that the yarns do not prematurely begin twisting and/or become tangled. The fiber guide 92 includes a base section 93 and a plurality of elongated projections 94 (sometimes referred to as “teeth” or “tines”). The base section 93 has a plurality of projection-holding receptacles 95 into which the elongated projections 94 may be inserted. The elongated projections 94 are preferably rod-shaped and are removable and can be re-inserted into different holding recesses to adjust the separation between each individual yarn with respect to adjacent yarns.
An enlarged view of the base section 93 of the fiber guide 92 is illustrated in FIGS. 2A and 2B . The base 93 may be made of wood or metal and is secured to the yarn table by using bolts 91 . The base 93 preferably has more projection-holding receptacles 95 than there are the elongated projections 94 . (commonly referred to as “teeth”). Each projection 94 is inserted into a desired receptacle 95 and secured preferably by a friction fit.
The receptacles 95 do not have to be spaced in a regular pattern but it may be easier to manufacture the base 93 if they are spaced apart in a regular or repeating manner. The operator of the machine 10 may insert one or more teeth 94 into the receptacles. The primary factor for determining the number of teeth 94 to be inserted into receptacles 95 is the size of the sling to be made which will determine the number of yarns that will be used to make the core.
The fiber guide 92 is designed to keep the yarns separated until the last possible second to ensure a tight twisting of the yarns as it forms the load-bearing core of the sling. In one embodiment, the teeth 94 are shaped like rods and are frictionally-fitted into the receptacles 95 . In another embodiment, one end of each projection 94 can be manufactured with threads, and the receptacles 95 can be manufactured with mating threads so that the projection 94 may be screwed into its respective receptacle. By moving the projection 94 into different receptacles 95 , the separation of the yarns can be controlled and managed, and ultimately the “tightness” of the wrap of yarns that form the load-bearing core can be controlled.
Referring again to FIGS. 1A and 1B , the control assembly 30 , including a control box 34 housing control circuitry, and control panel 31 are illustrated. As stated previously, the counter circuit for the encoder 29 may also be stored in the control box 34 . A display 35 that is electrically connected to the counter circuit may be mounted on the control panel 31 for conveying to the machine's operator the length of yarn pulled from the spool 99 of yarn and used to manufacture the load-bearing core.
The control assembly 30 also includes an electric motor 32 that provides the motive force for the apparatus 10 . The electric motor 32 turns a drive roller 38 and is connected by a chain (using sprockets), belt or preferably a worm gear reducer 33 . An on/off switch 39 controls power to the apparatus 10 and, more specifically to the control circuit.
The encoder 29 along with the encoder wheel 98 are illustrated as being mounted on the yarn table 11 , but may be placed anywhere so that at least one yarn can engage the wheel 98 to turn it, thereby allowing the encoder circuit to determine the length of yarn used to manufacture the load-bearing core. The encoder display 35 conveys to the operator how many feet of yarn was used in manufacturing the load-bearing core.
Referring now to FIGS. 3A and 3B , the control assembly is mounted on a table 61 supported by one or more legs 62 . The tail section assembly 40 may be mounted on a table or an open frame 47 so that the working area of the yarn table assembly 20 , control assembly 30 and tail section assembly 40 are all relatively in the same working plane. One or more legs 63 support the frame 47 of the tail assembly 40 . The apparatus 10 is designed to be somewhat modular to allow for easy assembly and disassembly.
The tail-back assembly 40 is positioned after the control assembly 30 . The tail-back assembly 40 includes a pair of rails 41 , 42 on which an idler roller section 44 slides. The rails ensure that the idler roller assembly 44 , and in particular the idler roller 45 , is parallel to the drive roller. This, in turn, ensures that the yarns that form the load-bearing core are properly twisted and slide with the least amount of friction into the cover of the sling.
The idler roller section 44 is slidably attached to the pair of rails 41 , 42 for moving the idler roller section in a straight line (i.e., horizontal motion) away from or towards the motor-driven roller 38 . The straight-line distance between the idler roller 45 and the driven roller 38 is approximately one-half the size of the sling that is being made. In other words, if it is desired to make a roundsling having a twenty-foot perimeter, the idler roller section is positioned ten feet away from the driven roller.
The idler roller section 44 includes means for locking down the idler roller section to one or both rails 41 , 42 thereby preventing the idler roller section 44 from sliding along the rails during the manufacture of the sling. The locking means may be one or more bolts that are secured to the idler roller section 44 and which can be tightened so the bolts frictionally engage one or both rails. As the drive roller 38 pulls the yarn into the cover of the roundsling, a certain amount of tension is created on the idler roller section 44 . By locking the idler roller section 44 into place, the load-bearing cores can be manufactured in substantially one continuous step.
In one embodiment, the operator keeps track of the number of feet as indicated on the encoder display 35 and stops the apparatus 10 using the on/off switch when the requisite length of yarn to form the load-bearing core is drawn from the spools 99 of yarn. The actual length of yarn pulled from the spools 99 and used to form the load-bearing cores is not precise as long as the minimum length that was calculated at the beginning of the process is used. A few extra feet will only strengthen the load-bearing cores.
In the preferred embodiment, an electronic decoder control circuit may be employed to automatically turn off the apparatus when the minimum length of yarn is pulled from the spool. As in the manual process, the encoder wheel 29 is used to determine the length of yarn pulled from the spool during the manufacturing of the load-bearing core. The counter circuit can be integrated into the control circuitry via the electronic decoder control circuit for turning off the power to the electric motor when a pre-determined number of feet is pulled from the spool. The operator will program the number of feet of yarn to be used to manufacture the load-bearing cores into the control circuitry at the beginning of the manufacturing process. After the operator turns on the machine 10 , the motor will continue to run until the number of feet programmed into the control circuitry is reached as determined by the encoder wheel 29 and signaled to the control circuitry. In this manner, the control circuitry will automatically turn the machine off thereby stopping the motor and the drive roller. Automating this step in the manufacturing process frees the operator to monitor other steps.
As indicated previously, the encoder and its associated circuitry are off-the-shelf items that can be easily incorporated in the power circuit of the present machine 10 .
During the manufacturing process, the cover of the sling is placed around the idler roller 45 . As indicated previously, a leader yarn has been threaded through the channel of the sling cover. In a sling having two load-bearing cores, the cover has two channels in parallel relationship; in this embodiment, a leader yarn is threaded through both channels in the cover. Similarly, for slings having more than two load-bearing cores, a leader yarn is thread through each channel of the cover.
The cover of the sling is cut to allow access to the interior of the cover. The exposed leader yarn has its ends tied together to form an endless loop. The leader yarn is then placed around the drive roller 38 . The idler roller section 44 is then slid away from the control assembly thereby placing tension on the leader yarn. The number of yarns (e.g., eight) that were determined to be needed to form each load-bearing core are then tied to each leader yarn.
When the machine 10 is turned on, the leader yarns, being in frictional contact with the driver roller 38 , begins to rotate within their respective cover channels. As the leader yarns rotate, they pull a plurality of yarns off of the spools. As the yarns are pulled from their spools, then through comb 92 , and they are drawn eventually through their respective channels in the cover in a circular motion. The plurality of individual yarns begin to twist in a regular manner as they are drawn within the channel of the cover thereby forming the endless-loop load-bearing cores.
A preferred embodiment is the making of a two-path industrial sling. The process of making a two-path sling using the apparatus that is the subject of this patent application is straight forward once the apparatus has been disclosed.
In order to streamline the manufacturing process, the covers are manufactured in an independent step. In this manner, hundreds or thousands of covers can be manufactured at a time. Moreover, the covers can be manufactured off-site using conventional manufacturing techniques. The covers are then shipped to the location where the subject sling-making apparatus is located to manufacture the load-bearing core and for final assembly of the sling. The covers are manufactured with a leader line in each channel. Therefore, if a two-core roundsling is to be made, the cover is manufactured having two channels and there are two leader lines placed in the cover-one for each channel.
The first step in the manufacturing of a sling is to determine the size of sling to be made (including diameter of load-bearing core which depends on the weight to be lifted and the overall length of the sling) and to determine the type of sling to be made. Based on the size (in particular the length), the idler roller assembly 44 is slid along the rails 41 , 42 to the proper position and secured by the lock-down means.
The next step in manufacturing a sling involves selecting the appropriate cover material as determined by the sling type and/or customer specifications. Generally, the required length of tubing to form the cover is twice the desired length plus five feet.
In a preferred embodiment, the inner-side of the cover material will be a contrasting color than the outer-side of the cover material to expedite the inspection process.
All multiple-core slings are fabricated using the same basic instructions. The required tube widths and requirements are determined by trial-and-error or through experience, and may be quantified and placed in a chart for future look-up.
Next, the operator moves the (non-rotating) tail stock to the appropriate position as determined by the sling length (2×sling length+about five feet) and secures the tail stock using securing clamps or other means provided to secure the tail stock.
Using a vise grip pliers or other suitable tool, the operator clamps the end of the cover with the long rolled back cuff to the cross bar 83 . The operator then pulls the cover towards the tail stock assembly 40 and loops the cover material around the idler roller 45 .
The next step in the manufacturing process is to tie the required number of yarns to the leader yarn in the cover. Any excess polyester leader yarn is cut off after tying it to the cover yarns 99 . The core yarn is inserted into this original loop, and secured (e.g., by taping) in place allowing a sufficient tail. This tail will be used to tie the beginning yarn to the end yarn after load-bearing core is made.
Once the yarns 99 are tied to the leader yarn, the operator hits the on/off switch 39 to start the electric motor 32 thereby turning the drive roller. The sling-making machine 10 is run until the requisite number of loops, or more accurately the requisite length of yarn 99 has been pulled from the spools. The minimum number of feet of yarn that was calculated at the beginning of the manufacturing process must be pulled from the spools for the size and load-bearing capacity of the sling to be made. (The number of loops of the load-bearing core that are formed depends on the distance between the idler roller and the drive roller.) The motor is pulsed on and off until the original loops and tails are positioned at the drive roller and are accessible to the operator. Since the cover does not rotate during the manufacturing process, the opening of the cover remains proximate to the driver roller.
The operator feeds each of the filler strands through its respective hole in yarn table and through the tension wheels. The operator adjusts the tension wheels to ensure that there is sufficient tension as the drive roller pulls the yarn from its respective spool.
Although any of the yarns may be used to wrap around the encoder wheel 98 , the yarn from the spool furthest from the drive roller is preferred.
The operator loops the filler yarns through the bowline knot of each leader string allowing a sufficiently long tail and then tapes them into an interlocking loop.
The operator then places pins in the fiber guide 92 to separate the strands entering the cover paths.
In order to ensure that an appropriate amount of tension is applied to the leader strings, the idler roller 45 may have to be readjusted. The leader strings must be snug against the drive roller 38 so that when the drive roller rotates, the leader string is pulled through its respective channel in the cover. For a multiple-path sling, each leader strings requires substantially equal tension.
The operator ties a (bowline) knot on each leader string at the end of the cuff. While holding the top knotted end of the leader string, the operator loops the bottom end around the drive roller. The operator pulls out any excess slack from each leader string. The operator then pulls the unknotted end until the desired tension is achieved and secures the unknotted end with two half hitches. The operator then cuts off any excess leader string. These steps are repeated for each of the remaining leader strings if all paths are to be run at the same time.
The operator then turns on the machine 10 by switching the switch 39 from off to on, and carefully feeds the yarn into the channels of the covers.
When the counter indicates that the appropriate amount of core material has been used to form the load-bearing cores, the control circuitry from the encoder 29 will automatically stop the machine. As a check, the operator may count the number of strands needed to form each of the load-bearing cores.
The ends of the load-bearing core are tied together. The sling can then be removed from the drive roller 38 and idler roller 44 . It should be noted that some slings are best manufactured locking the idler roller 44 to prevent rotation.
The cover is sewn over the opening and closed up allowing only the tell-tails to be seen outside the cover, thereby completing the sling.
Although this invention has been described and illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that various changes, modifications and equivalents may be made which clearly fall within the scope of this invention. The present invention is intended to be protected broadly within the spirit and scope of the appended claims.
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An apparatus for manufacturing industrial slings which is especially adapted for making roundslings. The apparatus can make slings having one load-lifting core or multiple load-lifting cores. The apparatus has three primary sections, namely, a yarn feeder assembly, a control assembly and a tail section assembly. The sling-making apparatus may be left-handed or right-handed.
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This invention was made with Government support under Contract Nos. ITS-61 and ITS-81, awarded by the National Academy of Sciences. The Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a sensor system capable of measuring the relative position and attitude of moving and stationary objects. In particular, this sensor system can detect and track objects equipped with surfaces that act as retroreflectors in the visible and near-infrared part of the spectrum. Such surfaces are already available in the taillights of all cars, trucks, and motorcycles, as well as in roadway lane markers, and can be easily and cheaply added to objects in other environments, such as railroads, factories, and airports.
2. Description of the Prior Art
One of the emerging trends in technology development is the addition of autonomous capabilities to many new products in ground transportation (cars, buses, trucks, trains), in aviation (commercial aircraft, military drones) and in specialized applications (factory automation, airport service facilities). This trend is greatly facilitated by the miniaturization of electronic components, the rapidly decreasing cost of computing power, and the recent surge of technology transfer from military to commercial applications. These advances have not only made it technically feasible to build systems that would have been unthinkable a few years ago, but have also dramatically decreased the cost of their implementation, thus making them suitable for mass production and commercial deployment.
The motivation for this trend towards autonomous operation comes primarily from considerations of safety, comfort, and cost.
Safety is the main beneficiary in cases where unmanned drones (all-terrain vehicles, airplanes, helicopters) are used in hazardous environments. Examples of such applications include: searching for trapped people in burning buildings, collapsed structures, and spaces filled with poisonous gases; filming exclusive footage of natural disasters such as exploding volcanoes; and military operations for de-mining, reconnaissance, and surveillance behind enemy lines. The use of human-operated vehicles in these environments would endanger the health or even the lives of the operators, and would also impose minimum size restrictions that would make it impossible to explore small spaces where people may be trapped. Increased safety is also the main concern in on-board vehicle systems such as collision warning, collision avoidance, lane departure warning, and lane keeping. These systems warn the driver/operator with an audible and visible signal when the vehicle is about to collide with another object or when it is about to leave its current lane on the roadway, and, if so equipped, they automatically activate the brakes and/or the steering to reduce speed and/or change course to avoid a collision or to maintain the vehicle's current course.
In applications such as adaptive cruise control, where the speed of the vehicle is automatically adjusted to follow the preceding vehicle at a safe distance, or vehicle following, where the vehicle's speed and direction are adjusted to follow the course of the preceding vehicle, the main consideration is the comfort and convenience of the driver/operator, with increased safety being a secondary but very important benefit.
Finally, significant cost savings motivate future applications such as electronic towing, highway platooning, automated airport vehicles, and automated manufacturing robots. In electronic towing, two or more commercial vehicles are operated in tandem, with the first vehicle being manually driven by a human operator, and the following vehicles being “electronically towed” without drivers, thereby reducing the number of drivers and the associated cost by 50% or more. In highway platooning, traffic is segmented into “platoons”, each composed of several cars that follow each other at very small distances of 1-2 m, driven not by their human occupants (who can resume manual operation once their car leaves the platoon), but by the on-board electronics that automate the steering, acceleration, and braking functions. This “automated highway system” has the potential of significantly increasing the traffic throughput of existing highways at a mere fraction of the cost of building new highways that would be able to handle the same additional traffic, while also improving the safety and comfort of the people who use this highway system for their transportation needs. While these applications may be several years away from their actual implementation, the same technology can be used in the near term to automate airport vehicles that carry baggage and goods between terminals and airplanes, at a much lower cost than human drivers. The same concept also applies to factory automation, where driverless vehicles can carry parts that are loaded and unloaded by automated robots.
These applications are currently in different stages of deployment. Collision warning, lane departure warning, and adaptive cruise control systems are already available as commercial products in high-end passenger cars and commercial trucks; unmanned drones are already used in military operations; and automated robots are already fully operational in many modern factories. Collision avoidance, lane keeping, vehicle following, and automated airport vehicles are still under development, but are approaching the point of commercial product release, while electronic towbars and automated highway systems are in the research stage, with several successful demonstrations already completed. The three major factors that differentiate these applications and influence the timeline of their deployment are: (1) whether their operation is autonomous or cooperative, (2) whether they operate in a controlled or uncontrolled environment, and (3) whether their role is passive or active. For example, collision warning systems are autonomous, because they rely only on measurements gathered by the host vehicle and do not require any special modifications to the surrounding cars and highway environment; they operate in the uncontrolled environment of public highways; and they passively warn the driver of an impending collision. Adaptive cruise control is also autonomous and operates in an uncontrolled environment, but it is an active system, since it actuates the throttle and brake to increase or decrease speed in order to maintain a safe distance from the preceding vehicle. Electronic towbar and automated highway systems are active (they actuate the steering in addition to the throttle and brake) and operate in an uncontrolled environment, but they are not autonomous since they rely on cooperation from their environment, namely from the preceding vehicle in the case of the electronic towbar, or from the other platoon members and the roadway infrastructure in the case of automated highways. Finally, airport and factory automation vehicles are active and cooperative systems, but they operate in a controlled environment where unexpected events can be kept to a minimum.
Despite their differences, all these applications share a common trait: they all need sensors that can provide accurate and reliable information about the surrounding environment. From collision warning to automated airport vehicles, and from adaptive cruise control to multi-car platooning, each of these systems depends critically on its “eyes”, namely the ranging sensors that “see” other cars on the highway or other robots and obstacles on the factory floor, and provide crucial information about how far each of these objects is, which direction it is coming from, and how fast it is approaching.
The currently available sensor technologies can be classified into five main categories: radar (microwave or millimeter-wave), computer vision, time-of-flight laser, sonar, and GPS. These are detailed below in order of increasing utility for the applications discussed above.
Sonar sensors emit acoustic pulses and measure the time it takes for the pulse to bounce off the target and return to the sensor, usually called the “time of flight”. Multiplying this time by the speed of sound yields the distance from the source to the target and back. This process provides very accurate and reliable measurements for targets that are less than 1 m away, but its performance drops off very quickly as the distance increases, and becomes unacceptable for obstacles more than 5 m away. Consequently, sonar is widely used in products whose operating range is up to approximately 3 m, such as systems that help the driver park in tight spaces by providing a visual or audible indication of the distance to the obstacles behind or in front of the host vehicle. In all of the applications discussed above, where the desired operating range is at least 20 m and up to 200 m, sonar is not a viable ranging technology.
Time-of-flight laser uses the same concept as sonar: an infrared laser emits pulses and the sensor measures the time it takes for each pulse to return. The two main differences are that (1) the energy of the laser beam is highly concentrated along a single direction, while the sonar pulses travel in all directions, and (2) the laser pulses travel at the speed of light, not at the speed of sound. The first difference implies that, in order to cover a reasonably wide field of view, the system needs either a lens that disperses the laser beam along the horizontal and vertical directions or a scanning mechanism that automatically points the laser beam at different directions. The advantage of the lens dispersion is that it is easy to implement; the disadvantage is that it makes it impossible to detect the specific direction of the target. One possible remedy for this problem is the use of several laser beams, each with its own small dispersion angle; the number of beams used is proportional to the desired resolution in terms of direction sensing, but also to the complexity and cost of implementation. The scanning mechanism, on the other hand, makes it very easy to detect the direction of the target (it is the same as the direction in which the beam was pointing when the pulse was emitted), but its construction and implementation is very complicated and very fragile, since it involves many moving or spinning parts that must be very accurately positioned with respect to each other. The second difference, namely the fact that the laser pulses travel at the speed of light, means that the time it takes for them to return to the source after being reflected off the target is about one million times shorter than for sonar. Therefore, the instruments that measure this time of flight must be extremely sensitive and accurate: in order to measure the distance to a target 30 m away with an error no larger than 1 m (a not very stringent requirement in the applications we are discussing), the sensor must be able to measure a time interval of 100 ns (30 m/3×10 8 m/s=10 −7 s) with an error no larger than 3.3 ns. While it is entirely possible to measure signals with such accuracy, the corresponding hardware is very expensive. Currently available prototypes intended for mass production use less expensive hardware with lower resolution; as a result, their reported errors are in the order of several meters, which is not suitable for most of the applications we are discussing. Another problem with this technology is that it does not operate reliably in rain, fog, snow, or whenever the road is wet and the preceding vehicle creates “road spray”. This problem is due to the fact that the laser energy reflected from airborne water particles or snowflakes confuses the sensor and results in “ghost images”. This makes time-of-flight laser unsuitable for open-road applications.
Millimeter-wave radar systems transmit a modulated waveform and measure the phase shift of the reflected signal to compute the distance of the target. Since they do not measure the time of flight, they are generally more accurate than time-of-flight laser. Furthermore, their operating frequency is in the order of 10-100 GHz, which means that their wavelength is in the order of 3-30 mm, which is several thousand times larger than the 800 nm wavelength of infrared lasers. The longer wavelength renders water particles, snowflakes, and the irregularities of most surfaces essentially invisible to radar. This has two direct results: First, radar can penetrate rain, fog, snow, and road spray, which makes it ideally suited for use in poor weather conditions. Second, radar waves are efficiently reflected by almost all surfaces and materials found in everyday objects, and therefore radar sensors can detect the presence of almost any obstacle around them. While this property is useful for avoiding potential collisions, it is also the source of the main problem with radar sensors, namely multiple returns. Almost every surface reflects the radar energy, so the returned wave contains the reflections from many different objects that are at different distances and different directions; since these returns are all added into one signal, it becomes very difficult to distinguish the objects that are real targets, such as cars ahead, from others that are not, such as the pavement of the road. This problem is dealt with at both the hardware and the software level with varying degrees of success. At the software level, the solutions include sophisticated algorithms that process the radar returns and attempt to isolate the signals that are produced by targets of interest; these algorithms can be tuned to correctly detect some types of targets, such as vehicles with metal sheet covering, but usually at the expense of not detecting others, such as low-profile fiberglass-bodied sports cars. At the hardware level, the solutions are similar to those employed in time-of-flight laser, including the use of multiple radar beams and scanning mechanisms. Scanning is usually implemented through the use of a multi-beam antenna array whose component antennas have electronically controlled relative phase; appropriate selection of the component phases yields a highly directional overall antenna whose direction of maximum sensitivity scans the desired field of view.
Yet another significant disadvantage of radar is the sensitivity of its own measurements to other similar devices operating around it. The signal sent from the transmitter is reflected in all directions; hence, this reflected signal affects all other receivers operating nearby. As a result, when there are many similar devices operating in the surrounding environment, as would be the case in dense highway traffic, each object in the scene will produce many returns at different time instants, and all of these returns will show up in the signal measured by each receiver. This means that the scene becomes heavily cluttered with multiple returns, and that makes it very difficult to identify the separate targets and reliably compute their respective locations. The problem becomes even worse in the case of vehicles with similar devices traveling in opposing directions of traffic. In that case, the transmitted signal of the oncoming vehicle is much stronger than the reflections of the host signal from surrounding objects. Thus, oncoming vehicles can flood the host vehicle's receiver and render it momentarily blind.
Computer vision differs from all the above technologies in the sense that it does not transmit anything. In contrast to sonar, laser, and radar, vision is a completely passive sensing approach that simply records images, relying on existing visible light (natural or artificial) to provide the necessary illumination. These images are then processed to extract the information that is needed for the particular application, such as the existence and location of obstacles, or the curvature of the road ahead. The main advantages of computer vision are its high resolution and its ability to track many different targets at the same time. The fact that computer vision can at best detect the same obstacles as human vision means that these sensors do not operate reliably in bad weather and especially at night, if the artificial lighting is inadequate. But the main disadvantage of computer vision is the fact that, in order to realize its potential and provide reliable and accurate data, it has to process images at a rate fast enough for the corresponding application. The computational power required for such real-time image processing depends on the desired accuracy, since higher accuracy is achieved through higher image resolutions, and on the desired speed of response. For applications where the ambient scene is static or changes very slowly, such as a slow factory automation task, these requirements may be satisfied by an inexpensive microprocessor. But for the highly dynamic environment of a busy highway, where it may be necessary to process 20 frames per second and extract the necessary information from each frame in less than 50 ms, the corresponding computing power may be prohibitively expensive. In existing implementations, this obstacle is overcome through the use of specialized image processing techniques that exploit the prior knowledge of the structure of the specific application environment (highway, factory floor, airport) to significantly reduce the computational requirements.
Finally, GPS-based ranging relies on the signals from the satellites of the Global Positioning System. Each host vehicle is equipped with a GPS receiver that processes the available signals to produce a measurement of the vehicle's current position. An on-board transmitter then broadcasts this measurement to the neighboring vehicles, while a separate receiver receives the transmitted locations of the neighbors (who are assumed to be equipped with the same hardware). Thus, each vehicle knows its own location and the location of its neighbors. The advantages of this technology are (1) that the GPS signals are available everywhere on the planet, and (2) that the necessary on-board hardware is inexpensive. The main disadvantage is that this technology is completely dependent on transmissions from the neighboring vehicles. Since any object that is not equipped with this system cannot be detected by any of its neighbors, this approach can only be used in cooperative scenarios, such as electronic towing or automated airport vehicles, and is entirely unsuitable for any of the near-term autonomous applications, such as collision warning or adaptive cruise control. Another disadvantage is that the position computation based on the commercially available GPS signals is not accurate, with errors in the order of 10-100 m. This problem can be overcome through the use of a Differential GPS (D-GPS) system. In this system, secondary local transmitters at fixed known locations retransmit the GPS satellite signal along with their own position. This allows the D-GPS receiver on a moving vehicle to compute its relative position with respect to the fixed local transmitter, and thus its absolute position, with errors that are claimed to be as small as 2-5 cm. However, this solution amplifies the dependency problem described above, since it requires that not only the other vehicles but also the surrounding environment (roadway, airport) be equipped with GPS receivers and transmitters.
In summary, existing ranging technologies have significant drawbacks, which limit their utility in applications that involve dynamically changing environments. Many of these limitations can be overcome through known techniques, which, however, usually involve a substantial increase in the associated cost of the sensor. Since cost is one of the most important criteria in commercial applications, especially those involving mass markets such as the automotive industry, it would be desirable to develop a sensor technology that can provide accurate and reliable measurements at a reasonable cost.
BRIEF SUMMARY OF THE INVENTION
The present invention discloses a new ranging method that eliminates many of the drawbacks of existing technologies, and does so through the use of low-cost components that are currently mass-produced and commercially available.
The corresponding apparatus has three primary components: (1) a fast on/off illuminator, i.e., a device that generates light and that can be switched on or off in less than 1 ms, such as an array of power Light-Emitting Diodes (LEDs) or a low-power laser, or even the gas-discharge or solid-state headlights used in many modern automobiles, (2) one or more imagers with on-board storage capability, i.e., devices that can record an image and store it on the device itself protecting it from further exposure to light, such as Charge-Coupled Device (CCD) or Complementary Metal-Oxide-Semiconductor (CMOS) imaging chips, and (3) a microprocessor that operates the illuminator and the imagers automatically, and processes the data collected from the imagers to produce ranging information about objects in the imagers' field of view.
The apparatus can detect objects with retroreflective surfaces, such as those contained in the taillights of all cars, buses, trucks, and motorcycles. The detection of these objects is achieved through the process of image subtraction. The microprocessor first instructs the imager to record an image of the scene in front of it, while the illuminator is turned off; then, the microprocessor turns the illuminator on and instructs the imager to record a second image of the scene. The first image is then subtracted from the second, leaving only the returns of the retroreflective surfaces in the subtracted image. This sparse image is then stored in the microprocessor and processed with appropriate software algorithms whose function is to filter out the noise, identify the targets, and compute the distance and azimuth angle of each detected target through triangulation. The distance can be computed in terms of an absolute measure in meters, or in changes in relative distance, such as a percentage change in a given unit of time or a multiple of some measure of distance in the field of view, such as the distance between the taillights or between the detectors.
In order to guarantee that the subtraction process eliminates all returns except for the reflections of the illuminator's light from retroreflective surfaces, the two images have to be recorded in rapid succession. The present invention discloses a procedure for drastically reducing the elapsed time between the recordings of the two images. In the simplest embodiment, the bottom ⅔ of the surface of the imaging chip is covered by an opaque mask, which protects the pixels behind it from further exposure. The remaining top ⅓ is exposed and that is where both images are recorded using a four-step “expose-shift-expose-shift” process: first, the image with the illuminator off is recorded in the exposed part of the chip; second, the contents of the imager are shifted down by ⅓ the total number of rows, which means that the first image now occupies the top half of the area behind the opaque mask and is protected from further exposure; third, the image with the illuminator on is recorded in the exposed part of the chip; fourth, the contents of the imager are again shifted down by ⅓ the total number of rows, which means that the first image now occupies the bottom half and the second image the top half of the covered area, and that both of the pictures are protected from further exposure. Since the process of shifting the contents of the imager down by one row is about 100 times faster than the process of digitizing and reading out one row of data, the on-chip storage scheme renders the invention suitable for use in rapidly changing environments, such as highway traffic.
In particular, the invention is embodied in an apparatus for ranging an object comprising an illuminator to illuminate a field of view potentially including the object and an imager to receive reflected signals from the field of view. The illuminator comprises an LED, a headlight, or a laser. The imager captures a first image having reflected signals from the field of view when the field of view is illuminated by the illuminator and a second image having reflected signals from the field of view when the field of view is not illuminated by the illuminator. A circuit is coupled to the imager to synchronously control the illuminator and the imager, and to generate a subtraction image of the field of view as a pixel difference between the first image and the second image. The imager captures one of the first image and the second image while the other one of the second image and the first image is still captured in the imager.
In one embodiment the illuminator comprises a first and a second illuminator. The first illuminator is arranged and configured to illuminate a near field of view and the second illuminator is arranged and configured to illuminate a far field of view.
The imager comprises an imaging pixel array in which the pixels of the array are organized into a two dimensional array comprised of pixel lines forming a first and a second group of pixel lines. The first group of pixel lines is unmasked and the second group of pixel lines is masked to prevent direct recording of imaged data therein. In a first exposure of the pixel array, the circuit records a first set of image data in the first group of pixel lines when the field of view is illuminated by the illuminator, and then shifts the first set of image data into the second group of pixels. In a second exposure of the pixel array the circuit records a second set of image data in the first group of pixel lines when the field of view is not illuminated by the illuminator, and then shifts the second set of image data into the second group of pixel lines. The second set of pixel lines then contain the stored values of the first and second sets of image data. Since a subtraction image is the goal of the foregoing process, it does not matter whether the first (illuminated) or the second (non-illuminated) images are recorded before the other. Hence, the first exposure can be taken when the field of view is not illuminated by the illuminator, and the second exposure can be taken when the field of view is illuminated by the illuminator.
In one embodiment, the second group of pixel lines comprises a contiguous subarray of pixel lines including two thirds of the pixel array. In a first version of this embodiment the pixel array comprises rows and columns of pixels and the contiguous subarray of pixel lines forming the second group of pixel lines forms a block of columns of the pixels. In a second version of this embodiment the contiguous subarray of pixel lines forming the second group of pixel lines forms a block of rows of the pixels.
In still another embodiment the first group of pixel lines comprises alternating pixel lines in a first half of the pixel array and the second group of pixel lines comprises all remaining pixel lines in the pixel array. In a first version of this embodiment, the pixel array comprises rows and columns of pixels and alternating pixel lines forming the first group of pixel lines forms a set of columns of the pixels. In a second version of this embodiment the alternating pixel lines forming the first group of pixel lines forms a set of rows of the pixels.
In yet another embodiment the first group of pixel lines comprises alternating pixels in each line in a first half of the pixel array with each alternating pixel being offset from ones of the alternating pixels in adjacent lines of pixels to form a checkerboard pattern. The second group of pixel lines comprises all remaining pixel lines in the pixel array. In a first version of this embodiment, the pixel array comprises rows and columns of pixels and the alternating pixel lines forming the first group of pixel lines forms a set of columns of the alternating pixels. In a second version of this embodiment, the pixel array comprises rows and columns of pixels and wherein alternating pixel lines forming the first group of pixel lines forms a set of rows of the alternating pixels.
In yet another embodiment the first group of pixel lines comprises contiguous pixel lines in a middle third of the pixel array, and the second group of pixel lines comprises all remaining pixel lines in the pixel array. In a first version of this embodiment the pixel array comprises rows and columns of pixels and the middle third of the pixel array forming the first group of pixel lines forms a contiguous block of columns of the pixels. In a second version of this embodiment the middle third of the pixel array forming the first group of pixel lines forms a contiguous block of rows of the pixels.
The first and second exposures are taken in time sequence without processing of the image data between each exposure. The first and second images are taken in time sequence separated by a time interval small enough to guarantee that no substantial changes occur between the first and second images of the field of view. The time interval is approximately 10 ms or less.
The circuit further determines distance to the object in the field of view, if any, from the imager. The circuit determines either absolute distance to the object or relative changes in distance to the object in the field of view, if any, from the imager.
In the illustrated embodiment, the illuminator has a substantially single or narrow frequency band. The imager is a camera and further comprises a bandpass filter interposed between the camera and field of view. The filter is centered on the single or narrow frequency band of illumination of the illuminator. The illuminator is modulated and the imager is locked to the modulation to receive reflected signals at the modulation.
In one embodiment, the circuit comprises a computer with a memory. The computer executes several software modules. A driver module activates the illuminator and the imager synchronously with each other to capture the first and second images. An image acquisition module transfers the first and second images from the imager to the circuit. An object detection module detects reflective images in the subtraction image. A ranging module computes the distance to the object.
In one embodiment there is a single imager that is coupled to the circuit, while in a second embodiment there are two imagers coupled to the circuit. The two imagers are separated from each other by a fixed predetermined distance.
The reflected signals indicative of the object are reflected signals from a retroreflective surface, such as taillight reflectors, on the object.
In one embodiment the circuit further comprises a sequence control circuit coupled to the imager for producing a stream of pixels from the imager corresponding to the first and second image. A subtraction circuit is coupled to the sequence control circuit for subtracting the second image from the first image on a pixel-by-pixel basis. An analog-to-digital converter is coupled to the subtraction circuit to generate a digitized subtraction image on a pixel-by-pixel basis. A processor is coupled to the analog-to-digital converter for generating ranging parameters.
Alternatively, the circuit comprises a sequence control circuit, an analog-to-digital converter, a field programmable gate array coupled to the analog-to-digital converter to generate a digitized subtraction image on a pixel-by-pixel basis, and a processor coupled to the field programmable gate array for generating ranging parameters.
Still further the circuit comprises a sequence control circuit, an analog-to-digital converter, an application-specific integrated circuit coupled to the analog-to-digital converter to generate a digitized subtraction image on a pixel-by-pixel basis, and a processor coupled to the application-specific integrated circuit for generating ranging parameters.
The invention is also described as a method for performing ranging as described in connection with the apparatus above. For example, the invention is a method for ranging comprising the steps of periodically or aperiodically illuminating a field of view with an illumination signal, which field of view potentially includes an object. Reflected signals are synchronously received from the field of view with illumination and absence of illumination of the field of view. A first image of the reflected signals is captured from the field of view within an image array when the field of view is illuminated. A second image of the reflected signals is captured from the field of view when the field of view is not illuminated within the array while the first image is still captured within the array. A subtraction image of the field of view is generated which is the pixel difference between the first and second images captured in the array.
The invention can be better visualized by turning to the following drawings, which depict illustrated embodiments of the invention. The invention is expressly not to be understood as necessarily limited by the illustrated embodiments which are depicted.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1D are photographic data of normal photographic images of a car, a first image of the same car as read by the imager, a second image of the same car as read by the imager, and their subtracted difference.
FIGS. 2A-2E are diagrammatic diagrams of the pixel content of the masked imager in a corresponding series of five cycles showing the capture, storage and shifting of two closely sequential images. FIG. 2A is a diagram of the basic ⅔ mask scheme, where the bottom two third of the surface of the CCD imaging chip is covered with opaque stripes in order to protect the pixels behind it from being exposed. FIG. 2B is a diagram of the CCD image after the first exposure with illuminator off. The top uncovered pixels are exposed, which is indicated in the Figure with the symbol “0”. FIG. 2C is a diagram of the CCD image after the first shift command. The top ⅓ exposed pixels are quickly shifted down into the middle covered part of the CCD imaging chip so that they are protected from further exposure. FIG. 2D is a diagram of the CCD image after the second exposure with illuminator on. The top ⅓ of the pixels are exposed, which is indicated in the Figure with the symbol “1”. The exposed pixels with illuminator off (indicated by “0”) are protected from further exposure by the opaque mask. FIG. 2E is a diagram of the CCD image after the second shift. All the exposed pixels (indicated by both “0”and “1”) are shifted down to the bottom covered part of the CCD imager to prevent further exposure and wait to be read out by the microprocessor.
FIG. 3 is a photograph of one embodiment of the invention.
FIG. 4 is a diagram of the conventional masking arrangement for an imager.
FIG. 5A is a diagram of an alternative masking arrangement for an imager of the invention in which every other row in the top half of the imager is covered by an opaque stripe. FIG. 5B is a diagram of the CCD image after the first exposure with illuminator off. The interlaced uncovered pixels are exposed, which is indicated in the Figure with the symbol “0”. FIG. 5C is a diagram of the CCD image after the first shift command. The exposed pixels are quickly shifted down only one row into the covered part of the CCD imaging chip so that they are protected from further exposure. FIG. 5D is a diagram of the CCD image after the second exposure with illuminator on. The uncovered pixels are exposed, which is indicated in the Figure with the symbol “1”. The exposed pixels with illuminator off (indicated by “0”) are protected from further exposure by the opaque stripes. FIG. 5E is a diagram of the CCD image after the second shift. All the exposed pixels (indicated by both “0” and “1”) are shifted down to the bottom covered area of the CCD imager to prevent further exposure and wait to be read out by the microprocessor.
FIG. 6 is a diagram of another embodiment of the masking of the imager which is a checkerboard mask scheme.
FIG. 7 is a diagram of another embodiment of the masking of the imager which is a mid-⅓ mask scheme.
FIG. 8 is a diagram of another embodiment of the masking of the imager which is a rotated ⅔ mask scheme.
FIG. 9 is a diagram of another embodiment of the masking of the imager which is a rotated interlaced mask scheme.
FIG. 10 is a diagram of another embodiment of the masking of the imager which is a rotated checkerboard scheme.
FIG. 11 is a diagram of another embodiment of the masking of the imager which is a rotated mid-⅓ mask scheme.
FIG. 12 is a diagram of another embodiment of the masking of the imager which is an array-to-array transfer scheme.
FIG. 13 is a block diagram of an imager coupled to readout circuitry which reads two rows or columns simultaneously using a sequence control circuit in which these two outputs are coupled to the two inputs of a subtraction circuit (such as a differential amplifier), whose output would then be the (analog) difference between the pixels.
FIG. 14 is a block diagram of an imager coupled to readout circuitry similar to FIG. 13 except a dedicated Field-Programmable Gate Array (FPGA) between the output of the ADC and the input to the microprocessor is employed instead of the subtraction circuit between the sequence control circuit and A/D converter.
FIG. 15 is an illustration of a typical subtracted image obtained with the IRIS-1 prototype.
FIG. 16 is an intensity plot corresponding to the taillight images of FIG. 15 .
FIG. 17 is a schematic diagram of a first embodiment of the invention, IRIS-1, where only one imager is used.
FIG. 18 is a schematic diagram of a second embodiment of the invention, IRIS-2, where two imagers are used, both with the same field of view.
FIG. 19 is a schematic diagram of a third embodiment of the invention, IRIS-1.2, where two imagers are used, one with a near-distance field of view and the other with a far-distance field of view.
FIG. 20 is a schematic diagram of a fourth embodiment of the invention, IRIS-2.2, where four imagers are used, two with a near-distance field of view and the other two with a far-distance field of view.
FIG. 21 is a flow chart illustrating exemplary method steps that can be used to practice the present invention.
The invention and its various embodiments can now be understood by turning to the following detailed description.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The claimed system measures the relative position of objects with retroreflective surfaces, such as those contained in the taillights of all cars, trucks, and motorcycles. This system comprises an illuminator operating in the visible or near-infrared waveband, one or more imagers, each placed behind an e.g. fixed-focus optical lens and a bandpass filter, and a microprocessor. The microprocessor runs the software that operates the illuminator and the imagers, and processes the data collected from the imagers to produce the ranging information. Each set of ranging data is obtained by recording two images, the first one with the illuminator turned off and the second one with the illuminator turned on, and then subtracting the first image from the second one. The purpose of the subtraction process is to remove all data from the resulting image except for the returns of the retroreflective surfaces. This requires that (1) the two images are recorded in rapid succession, so that the ambient scene does not change, and (2) that both images are recorded on the same device, so that irregularities in the image intensity are automatically canceled out. This is achieved through a masking arrangement of the imagers, which allow both images to be stored on the same device before they are digitized and transferred to the microprocessor. The ranging information is then extracted from the resulting subtracted image via standard triangulation methods.
Several preferred embodiments of the invention are described, each with its own advantages that make it most suitable for a specific application. All of these embodiments implement a ranging method that detects retroreflective targets with high reliability, measures their relative position with high accuracy, and can track multiple targets at the same time. The distinguishing features of the invention are:
1. it is self-illuminated, and thus does not depend on ambient light conditions;
2. it uses the process of image subtraction to greatly simplify the final image and reduce the computational complexity of the ranging software;
3. it uses an on-chip storage scheme, which allows both images to be recorded on the same pixels, and drastically reduces the elapsed time between the recording of the two images; and
4. it uses high-resolution imagers that allow the tracking of multiple targets at the same time.
These features eliminate many of the drawbacks of existing technologies, and, equally importantly, achieve this through the use of low-cost components that are currently mass-produced and commercially available.
The corresponding apparatus has three primary components:
1. a fast on/off illuminator, i.e., a device that generates tight and that can be switched on or off in less than 1 ms, such as an array of power LEDs (Light-Emitting Diodes), a low-power laser, or a gas-discharge or solid-state headlight lamp;
2. one or more imagers with on-board storage capability, i.e., devices that can record an image and store it on the device itself protecting it from further exposure to light, such as CCD or CMOS imaging chips; and
3. a microprocessor that operates the illuminator and the imagers automatically, and processes the data collected from the imagers to produce ranging information about objects in the imagers' field of view.
The invention can detect any object with a retroreflective surface. Retroreflective surfaces contain special corner-cube reflectors that reflect almost all of the incoming light that falls on them back to the direction it came from, namely its source. Such surfaces are contained in the taillights of all cars, buses, trucks, and motorcycles, because they are required by law. Their main purpose is to make parked vehicles visible to passing traffic at night, by reflecting the light from the headlights of the passing vehicle back to the direction of the driver of that vehicle. Retroreflective surfaces are also present in the lane markers, roadside markers, and overhead signs of many highways, where their purpose is again to make the lanes, road boundaries, and signs visible at night to drivers of passing vehicles. The same property, but with less reflective efficiency, is present in the special glass paint that covers the automotive license plates of many states, many roadside signs, and many “bumper stickers”.
The invention utilizes the retroreflective property of these surfaces to detect the corresponding objects through the process of image subtraction as illustrated in the sequence of photographs of FIGS. 1A-1D. FIG. 1A is a conventional photograph of a car parked with its rear taillight assembly facing the camera. Numerous other objects and pedestrians surround the car. A microprocessor 9 first instructs an imager 15 to record an image of the scene in front of it as shown in FIG. 1B, which is the image recorded by imager 15 ; then microprocessor 9 instructs imager 15 to shift the first image to the part of its pixel array that is protected by an opaque mask; then microprocessor 9 turns illuminator 16 on and instructs imager 15 to record a second image of the scene as seen in FIG. 1 C: finally, microprocessor 9 instructs imager 15 to shift the second image to the part of its pixel array that is protected by opaque mask. If illuminator 16 had not been turned on for the second image, the two images of FIGS. 1B and 1C would have contained the same information. But since illuminator 16 was on, its light produced strong reflections from any retroreflective surfaces in the field of view. These reflections are the only significant difference between the first and second image. Therefore, when the first image of FIG. 1B is subtracted from the second one of FIG. 1C, the resulting image of FIG. 1D contains nothing except for the returns 20 of the retroreflective surfaces 14 .
This sparse image is then stored in microprocessor 9 , and all the necessary ranging information can be extracted from its data via straightforward computations that are carried out by microprocessor 9 . The specifics of these computations depend on the number of imagers 15 which are employed and on the application in which sensor 100 is being used. In particular, we distinguish two cases. In the first one, sensor 100 tracks targets with reflectors 14 at known positions. Examples of such applications include electronic towing, where each truck is supposed to follow another truck of the same company; and automated airport vehicles. In such cases, sensor 100 is only supposed to recognize vehicles that are equipped with two or more reflectors 14 in a fixed pattern and at fixed distances to each other. Then, the range and azimuth angle of the preceding vehicle can be computed via triangulation from the apparent separation of the retroreflectors 14 on the imager screen and their known actual separation on the target vehicle.
The second case occurs when sensor 100 tracks targets whose reflectors 14 can have arbitrary positions, such as cars and trucks of different sizes, as well as motorcycles. In those applications, it is necessary to use two imagers 15 that are mounted at a fixed known distance to each other on the host vehicle. Microprocessor 9 collects subtracted images from both imagers 15 and computes the range and azimuth angle of each reflector 14 from its apparent position on each of the two imagers 15 and the known separation of the two imagers 15 . This second configuration with two imagers 15 results in a sensor 100 with the property of “stereoscopic vision”, which can thus compute the distance of every object with at least one retroreflective surface and is therefore suitable for use in open-road applications such as collision warning and adaptive cruise control.
From the above description it is evident that when the two successive images are indeed different only in the returns of the target retroreflectors 14 , then the process of image subtraction eliminates the ambient scene and makes the resulting image far less complicated and far easier to process than the corresponding images of a vision-based system. Indeed, after the image subtraction there are only a few very bright spots that can easily be located in the picture using simple detection algorithms. In contrast, in vision-based ranging sensors the target vehicle has to be identified in the ambient scene among many other objects of similar luminosity; this requires the use of very sophisticated image processing and motion tracking techniques.
In practice, however, the two successive images can record very different versions of the ambient scene. In that case, image subtraction does not eliminate the ambient scene and the task of detecting retroreflector 14 returns 20 and computing their apparent position on the image becomes much more complex. The most likely causes of these errors are the motion of the host vehicle and changes in the ambient lighting conditions, both of which result in a change of the ambient scene during the time that it takes to record and store the first image, then record and store the second image. The effect of changes in the ambient lighting is significantly reduced by placing each imager behind a bandpass filter 21 that only lets the light at the frequency of illuminator 16 pass through, but rejects light at different frequencies; such a filter 21 could be placed in front of lens 17 , or it could be implemented as a special coating on the lens 17 itself. It is to be understood that filter 21 is an optional addition and may be placed at any position, such as behind the lens 17 , as long as it provides the desired effect of allowing only filtered light to reach imager 15 .
The effect of the vehicle motion, on the other hand, can only be counteracted by reducing the time it takes to record and store the two images which are then subtracted from each other. The present invention uses a very short exposure time for each image, and it stores both images on the chip of imager 15 itself, thereby eliminating the (relatively very long) delays associated with digitizing an image and transferring its data to microprocessor 9 for storage. This on-chip storage scheme is achieved through the use of an opaque mask 22 that in the preferred embodiment covers the bottom two thirds of the surface of the imaging chip and protects the pixels behind it from further exposure as shown in FIG. 2 A. The remaining top ⅓ or portion 24 is exposed and that is where both images are recorded using a four-step “expose-shift-expose-shift” process, which are as follows:
1. “first expose cycle”: the image with illuminator 16 off is recorded in the exposed part 24 of the chip of imager 15 as shown in FIG. 2B, where the data recorded with the illuminator off are indicated by “0”;
2. “first shift cycle”: the contents of imager 15 are shifted down by ⅓ of the total number of rows of pixels, which means that the first image now occupies the top half of the area behind opaque mask 22 and is protected from further exposure as shown in FIG. 2C;
3. “second expose cycle”: the image with illuminator 16 on is recorded in the exposed part 24 of the chip of imager 15 as shown in FIG. 2D, where the data recorded with the illuminator on are indicated by “1”; and
4. “second shift cycle”: the contents of imager 15 are again shifted down by ⅓ the total number of rows of pixel detection cells, which means that the first image now occupies the bottom half and the second image the top half of the covered area 22 , and that both of the pictures are protected from further exposure as shown in FIG. 2 E.
In currently available low-cost imagers, the time to shift the image by one row is determined by the maximum transfer rate of the imager, and is typically in the order of 10 −6 s. The time it takes to digitize and read out one pixel of data is also limited by the maximum transfer rate of the image, as well as by the maximum speed of the analog-to-digital converter (ADC). Hence, it is at least as long as the time to shift by one row. As a result, the time it takes to digitize and read out one row of data, typically consisting of 750 pixels, is at least 750 times longer than the time it takes to shift by one row. Thus, on-chip storage is necessary in order to ensure the success of the image subtraction process. It is important to note that the on-chip storage scheme of the invention is different from the scheme used in many commercially available CCD chips. In conventional designs, the opaque mask covers the bottom half of the imaging surface, so the top half can be exposed to light and then shifted to the bottom half for protection from further exposure. In contrast, the on-chip storage scheme of the present invention requires at least ⅔ of the imaging surface to be covered by the opaque mask, to provide enough storage space for two images.
Another way to record two images in rapid succession without resorting to the disclosed on-chip storage scheme is to use two different imaging chips: one for recording the first (illuminator-off) image, and the other for recording the second (illuminator-on) image, with almost no time lapse between the end of the first exposure and the start of the second one. The two images are then digitized and transferred to the microprocessor for the subtraction process. There are two main disadvantages of this solution:
1. It is virtually impossible to find two imaging chips that have the same sensitivity to light in all of their pixels. Even two seemingly identical imaging chips of the same model from the same manufacturer will produce different images when exposed to the same scene under the same conditions for the same amount of time. This difference is caused by imperfections in the manufacturing process; it is present even in very expensive ($1000 or more) high-quality CCD chips, and becomes of course much more pronounced as the price of the imaging chip drops to $2-$10, namely levels that would be desirable for products aimed at any mass market, especially the automotive one.
2. Even if it were possible to find two identical imagers, their images would still not be the same, because it would be difficult to precisely match their optical paths. Since the two imaging chips are surrounded by circuitry, they could not be placed at precisely the same location, or even directly next to each other. In other words, there would have to be a minimum distance of a 4-6 cm between the two devices. With a simple optical setup, this distance would produce small differences in the images recorded by the two chips, which would corrupt the image subtraction process. The solution would be to use a sophisticated optical setup including a beam splitter in front of the two imagers; however, this would noticeably increase the cost of the system and reduce its robustness to vibrations.
The best and most cost-effective way to circumvent these problems and achieve good matching between the two images is to record both of them on the same pixels on the same imager 15 ; this way, even dead pixels (a not-so-rare occurrence in low-cost imagers) will be present at the same location in both images and thus they will not affect the subtraction process. The use of masking and on-chip storage makes it possible to record both images with the same imaging chip in rapid succession.
When the host vehicle is moving fast, even the disclosed approach might not be enough to guarantee perfect cancellation of the ambient scene. The resulting subtracted image will contain not only the returns from the reflective targets, but also other data that needs to be filtered out. Fortunately, this can be accomplished in the microprocessor using well-established software techniques such as thresholding and low-pass filtering of the data. The use of these fairly simple processing methods is made possible by the fact that retroreflectors are far more efficient at reflecting the incident light back to its source than any of the other surfaces; thus, their returns are much brighter than anything else that survives the subtraction process, and this makes it very easy to distinguish them from the noise that surrounds them.
One exception to this rule is the “blooming” effect that occurs in CCD imagers. When there is a very strong light source in the imager's field of view, such as the sun, and the exposure time is long enough, the pixels that receive the light of the strong source can “fill up” with electrons and start “spilling” their charge to neighboring pixels, usually saturating several columns of pixels in the CCD array. When this happens, the image is essentially useless and has to be discarded. The present invention reduces the effect of blooming as follows: When blooming is detected during the data processing phase, the software automatically reduces the exposure time and/or the aperture of the lens to prevent the reoccurrence of blooming in the next image sequence.
Another major advantage of the invention with respect to radar is its significantly longer operating range. This is due to the fact that, in the visible or near-infrared wavelength of illuminator 16 used in this invention, retroreflectors 14 in taillights, license plates, street signs, etc., act as mirrors. As a result, the power of the reflected light returned back to the host imagers 15 decreases with the distanced between the host and the target as 1/(2d) 2 . In contrast, at the wavelength of radar, which is thousands of times larger, all these objects act as point sources, and therefore the power of the reflected signal received back at the host detector decreases with distance as 1/d 4 . In other words, the received reflected power from a target 10 times farther away is 10,000 times weaker in the case of radar, and only 400 times weaker in the case of the disclosed invention. This significant factor of 250 explains why the present invention can detect targets at much longer distances than radar.
Yet another significant advantage of the invention with respect to other approaches that transmit energy, such as radar or sonar, is that its own measurements are unaffected by other similar devices operating around it. As we already explained, radar and sonar are adversely affected by the transmitted signals of other vehicles in the same or in the opposing direction of traffic. In contrast, the invention does not suffer from any of these problems. Due to the high directivity of retroreflectors 14 , almost all the incident power is reflected back to the source. In fact, experiments with typical taillight retroreflectors 14 show that if imager 15 is moved just 5 cm away from illuminator 16 , the reflected power it receives drops by about 90%; and if it is moved away by 15 cm, there is virtually no received reflection. The benefit of this very high directivity is that even when many similar devices are operating in close proximity, each of them sees only the reflection generated by its own illuminator 16 . On a highway or surface street, for instance, where the minimum distance between ranging devices would be no less than 2 m, such as for two small cars driving very close to each other side-by-side, and typically would be in the order of 3-8 m, the imager in each system would be completely unaffected by any of the other transmitters operating on the road.
The only situation where another nearby device would be detected is if its transmitter is pointed directly into the imager of the host vehicle, for example when a car traveling in the opposite direction of traffic is equipped with a similar ranging device. In that case, however, the detection of that other device is highly desirable. Its transmitter would register as a point target in the resulting image, and it would thus be very simple to compute the location of this oncoming vehicle, which would otherwise have gone undetected.
A prototype of the disclosed apparatus has been built by the inventors in the Electrical Engineering Department at UCLA, and several rounds of experiments have been performed. In these experiments, the prototype has been able to consistently detect target vehicles at distances up to 200 m, and compute their distance with accuracy that ranges from about 90% at distances of 150-200 m to about 99% at distances of 0.5-15 m. The dependence of the error on the distance to the target is explained by the fact that, as the target gets closer, the returns of its taillight reflectors fill up a larger portion of the CCD image, thus occupying more pixels and allowing their apparent location to be computed with higher accuracy. The ability to compute the range to the target with higher accuracy as the target gets closer is a very desirable feature. Another significant advantage of the invented method is its very high reliability and the near-complete absence of “false-positives” (detecting a target when there is none there) and “false-negatives” (failing to detect a target that is really there).
A picture of the IRIS-1 (Intelligent Ranging via Image Subtraction with 1 imager) prototype is shown in FIG. 3 . Illuminator 16 comprises a ring of power LEDs operating in the near-infrared wavelength of 800 nm and positioned around the CCD imager 15 . There are two sets of LEDs 5 , which are interwoven on the circular arrangement shown in the picture; one set transmits a 52° wide beam to illuminate objects that are within a 30 m radius but off to the side, and the other set transmits a 7° narrow beam to illuminate objects that are as far as 250 m away but directly in front of the host vehicle. This illuminator arrangement is suitable for automotive applications, where one is typically not interested in detecting objects that are both far away and far off to the side, since those objects are not in the path of the host vehicle.
Another possible choice of illuminator 16 would be an infrared laser whose narrow beam is dispersed through a wide-angle lens to give the desired wide illumination beam. Indeed, such a laser was used in the first implementation of the prototype. Both of these illuminator choices meet the requirement of being able to be switched on or off in less than 1 ms, which is necessary in order to be able to record the two images in rapid succession; in fact, both of these illuminators 16 can be pulsed on and off at rates higher than 20 KHz, which is much faster than the minimum 1 KHz requirement. The main reason for replacing the laser with the LED array was the issue of eye safety. The laser beam is very narrow before and right after it passes through the dispersion lens. Increasing the laser's transmitted power to improve the visibility of the retroreflective targets creates a potential for eye injury if someone were to look directly into the laser at a very short distance, for example a small child that happened to walk in front of a car equipped with such a device. One solution would be to use an array of less powerful illuminators to distribute the power over a wider surface even close to the source. This is exactly what has been achieved with LEDs 5 , which are eye-safe, much less expensive than lasers, consume less power, and do not require any special optics.
More generally, any visible or near-infrared light source that can be switched on and off in 1 ms or less would be a possible choice of illuminator for the IRIS system. In particular, the gas-discharge or solid-state headlights used in many modern automobiles could easily be modified to act as illuminators for the IRIS ranging system. All that would be necessary is a circuit that turns the headlamps off during the time when the “illuminator-off” image is recorded, very similar to the circuit that is used in the IRIS-1 prototype to turn the power LEDs 5 on and off. Since the necessary off-time is in the order of a few milliseconds, the resulting flicker would be imperceptible by the human eye, and it would not affect the ability of the headlights to adequately illuminate the scene ahead for night driving. In vehicles with daytime running lights, which are an increasingly popular option, this would indeed provide a very low cost illuminator 16 for the IRIS system 100 .
The imager 15 used in the IRIS-1 prototype 100 is a CCD camera that uses an array of 750×480 pixels, with an opaque mask 26 that covers the bottom half of the chip, namely the bottom 240 rows, as shown in FIG. 4 . This allows the user to record one image on the top half 28 of the chip and then shift it rapidly to the bottom half 30 , where it is protected from further exposure to light. This image can then be read out through the single readout channel connected to the very last row of bottom half 30 . The image is shifted down one row at a time, and the bottom row is shifted to the right one pixel at a time. Thus, each pixel is read out separately through the single channel, which includes a slow 12-bit ADC. As mentioned above, this readout process can be very slow. In the original camera implementation, the time it took to digitize and read out one row of pixels was approximately 5 ms, so reading out the entire image consisting of 240 rows took about 1.2 s. This means that, using the standard version of the camera without any special masking scheme, the elapsed time between the recordings of the two images would be at least 1.2 s, which is completely unacceptable for any fast-changing environment, and is suitable only for applications where neither the target nor the host vehicle is moving, and the ambient scene is not changing.
In order to make the prototype suitable for high-speed applications, the ADC was replaced with a much faster one, so that the camera could be driven at its maximum transfer rate. As a result, the readout time for one row of pixels was reduced by a factor of 50 to about 0.1 ms. Even with this acceleration, however, the elapsed time between the two images would be about 25 ms, which is still unacceptably slow for automotive applications. Therefore, the opaque mask was replaced with a larger one that covers the bottom 320 rows of the chip, namely ⅔ of the rows, as shown in FIGS. 2A-2E described above. This modified masking scheme facilitates the use of the four-step “expose-shift-expose-shift” on-chip storage scheme described above, which reduces the elapsed time between the two images by another factor of 150 to a mere 0.16 ms. This ⅔ masking scheme is simple to implement on a prototype and very inexpensive to build in mass production, since it is just a straightforward modification of the ½ masking scheme that already exists in many CCDs. However, it is by no means the only masking scheme within the scope and spirit of the claimed invention.
Another choice would be an interlaced scheme, where the bottom half 32 is covered by the standard mask 34 , and the top half 36 has every other row (or every other 2 rows, or every other 3 rows, etc.) covered by opaque stripes 38 , as shown in FIG. 5 A. With this arrangement, the recording process would be modified as follows: expose imager 15 as shown in FIG. 5B, shift down by one (or 2, or 3, etc.) rows as shown in FIG. 5C, then expose again as shown in FIG. 5D, and then shift the whole image down by 240 rows as shown in FIG. 5E, so that the two interlaced images are protected behind lower mask 34 . Indeed, the first implementation of the IRIS-1 prototype used this masking arrangement with every other row covered.
The main reason for replacing this interlaced scheme with the ⅔ scheme was the fact that it was very difficult to implement and to repair, and its implementation in mass production would be more costly than the ⅔ scheme, since it would require more extensive modification of existing CCD production lines. Moreover, the ⅔ scheme actually gives higher vertical resolution, since the subtracted image consists of 160 rows, while for the interlaced scheme it consists of only 120 rows.
There are of course other possible choices for a masking scheme, such as
the checkerboard pattern shown in FIG. 6, where the four-step process could be the same as for the interlaced pattern, namely “expose, shift down by 1 row, expose, shift down by 240 rows”, or it could be modified to “expose, shift right by 1 column, expose, shift down by 240 rows”;
the mid-⅓ scheme shown in FIG. 7, where the four-step process is “expose, shift the middle ⅓ up by 160 rows, expose, shift the middle ⅓ down by 160 rows”;
the rotated ⅔ scheme shown in FIG. 8, where the four-step process is “expose, shift right by 250 columns, expose, shift right by 250 columns”;
the rotated interlaced pattern shown in FIG. 9, where the four-step is “expose, shift right by 1 column, expose, shift right by 375 columns”;
the rotated checkerboard pattern shown in FIG. 10, where the four-step process could be “expose, shift right by 1 column, expose, shift right by 375 columns”, or “expose, shift down by 1 row, expose, shift right by 375 columns”;
the rotated mid-⅓ scheme shown in FIG. 11, where the four-step process is “expose, shift the middle ⅓ right by 250 columns, expose, shift the middle ⅓ left by 250 columns”; and
other combinations similar to the above.
The main advantage of the ⅔ masking scheme currently used in the IRIS-1 prototype is that it is the simplest one to implement with existing CCD chips, because the modification of the mask is easy, and because existing CCD chips have a single readout channel that reads the rightmost pixel of the bottom row. An additional advantage is that this scheme gives the maximum possible horizontal resolution (750 pixels), and good vertical resolution (160 rows). This makes it suitable for automotive applications, where typically the need for horizontal resolution is much greater than the need for vertical resolution, since most objects one is interested in tracking on the road are approximately at the same horizontal level. The other masking schemes listed above are typically much harder to implement in a prototype, and would cost more to mass-produce, although all of them are entirely feasible with existing CCD fabrication technology. The interlaced and checkerboard schemes can also use the bottom row for readout, but the other schemes need different readout channels: the first and last row (mid-⅓), the last column (rotated ⅔, rotated interlaced, rotated checkerboard), or the first and last column (rotated mid-⅓).
The interlaced and checkerboard schemes have an additional potential advantage: they facilitate a different recording scheme, called “streaming”. In this mode, the four-step process becomes “expose, shift down by one row, expose, shift down by one row” and it is repeated continuously. As a result, each row is exposed to light not once, but 120 times, either with illuminator 16 always on, or with illuminator 16 always off (of course, in order to avoid overexposure and blooming, the duration of each exposure would have to be made 120 times shorter). This means that each row that reaches the masked bottom half of the imager contains information that has been averaged in the vertical direction, and thus has no vertical resolution, while maintaining its full horizontal resolution. This mode of operation could be useful in applications where the target has been locked on and the host just needs to track the specific target's distance and azimuth angle.
Yet another alternative for on-chip storage would be to connect a regular CCD chip 40 with the ½ masking scheme to a second pixel array 42 of the same dimension which is completely protected from light, as shown in FIG. 12 . If the time it takes to transfer one row from one array to the next could be made as fast as the process of shifting the data down by one row, namely 10 −6 s, then this arrangement would work as well as any of the on-chip masking schemes described above, and would actually provide higher resolution (750×240) for the final subtracted image. However, it would inevitably be more expensive to produce, since it requires an additional pixel array and additional circuitry for connecting the two arrays.
An interesting variation of this scheme would be to replace CCD imager 15 with a CMOS imager and connect it either to one completely masked pixel array that has twice the rows or columns, or to two protected pixel arrays of the same dimension that are connected in series to each other. The advantage of CMOS imagers is that they are very inexpensive to produce. However, in currently available implementations they lack the ability to transfer the contents of one row or column to the neighboring row or column, and that is why they cannot be utilized with any of the masking schemes described above. Of course, if future implementations acquire this important shifting capability, those versions could be used in the disclosed apparatus in place of the CCD chips. The two configurations proposed here would work with existing CMOS imagers, provided of course that the transfer to the other arrays would be fast enough.
Two very important issues associated with the readout capability are whether the image subtraction is an analog or digital process, and whether it is performed by hardware or by software. In the IRIS-1 prototype, both the illuminator-off and the illuminator-on images are digitized and read out into a laptop computer, where they are subtracted digitally in software. The disadvantage of this process is that it makes a 12-bit ADC necessary, in order to obtain the accuracy needed to make the image subtraction process work properly. An alternative approach would be to modify the CCD readout path so that one can read two rows or columns simultaneously using the sequence control circuit as shown in FIG. 13, and connect these two outputs to the two inputs of a subtraction circuit (such as a differential amplifier), whose output would then be the (analog) difference between the pixels as shown in FIG. 13 . The main advantages of this approach would be:
an increase in data transfer speed, since now only the subtracted image, which consists of half the pixels, needs to be transferred to microprocessor 9 ;
a reduction in computational speed and memory, since the image subtraction process is already performed and does not need to be performed by microprocessor 9 ; and
the ability to use faster and less costly lower resolution (10-bit, 8-bit, 6-bit) ADCs, since there is no longer a need for the high conversion accuracy required for the digital subtraction process.
The implementation of this analog subtraction scheme would depend on the masking scheme used. The rows or columns that would have to be read out and connected to the differential amplifier could be rows 1 and 161 for the ⅔ scheme of FIGS. 2A-2E, rows 1 and 2 for the interlaced scheme of FIGS. 5A-5E and the checkerboard scheme of FIG. 6, rows 1 and 321 for the mid-⅓ scheme of FIG. 7, columns 500 and 750 for the rotated ⅔ scheme of FIG. 8, columns 749 and 750 for the rotated interlaced scheme of FIG. 9 and the rotated checkerboard scheme of FIG. 10, and columns 250 and 750 for the rotated mid-⅓ scheme of FIG. 11 .
Another possibility for fast subtraction would be to connect a dedicated Field-Programmable Gate Array (FPGA) 11 as depicted in FIG. 14 between the output of the ADC 10 and the input to the microprocessor 9 as shown in FIG. 14 . The FPGA 11 can download the digitized images from the imager significantly faster than microprocessor 9 can, and it can be designed to essentially perform a subtraction of the two digitized images in hardware. This solution would still increase the overall data transfer speed and would also reduce the computational speed and memory requirements on microprocessor 9 . However, it would not alleviate the need for a more expensive 12-bit ADC, since the subtraction process would take place after the digitization of the image data. The cost would also be increased by the addition of the FPGA and the interconnections. In a mass-production version, the FPGA could of course be replaced by an Application-Specific Integrated Circuit (ASIC) that would be faster and less expensive.
A typical subtracted image obtained with the IRIS-1 prototype of FIG. 3, is shown in FIG. 15 . It is clear that the reflections of the taillights are the only bright objects in the field of view, as confirmed by the corresponding intensity plot shown in FIG. 16 . In this experiment, the exposure time for each of the original images is 10 ms (typically it varies between 1 ms and 30 ms), and the system is ranging a single vehicle. It is clear that the returns from the taillights are much higher than the noise floor, and therefore they are virtually impossible to miss when they are present (no false-negatives), or to see when they are not present (no false-positives).
In this case, the distance, azimuth angle, and elevation of the vehicle in front is computed via a standard triangulation methodology by comparing the known separation between the taillights to their apparent separation on the subtracted image as shown in the schematic drawing of FIG. 17 . Since this prototype uses only one CCD imager, its ranging data is accurate only when it is tracking a target with a known retroreflector configuration, such as a vehicle whose taillight separation is known. This assumption could be satisfied in a controlled environment (electronic towbar, factory floor, airport runway), where the reflectors have to be added and could always be arranged in the same pattern.
However, in a general highway environment, vehicles of many different types with different taillight configurations have to be tracked accurately. Furthermore, it is necessary to detect and track motorcycles, which have only one taillight, as well as vehicles that have additional retroreflectors apart from the ones in their taillights. The solution to this problem is to use two imagers 15 on the host vehicle, whose separation is fixed and of course known. In this “stereoscopic” IRIS-2 configuration as shown in FIG. 18 triangulation is performed by comparing the different apparent positions of each reflective target on each of the two imagers to the known separation of imagers 15 . The location of each target 14 can be accurately computed, regardless of whether target 14 is a taillight, a bumper-sticker, a street sign, or a lane marker. Therefore, the IRIS-2 sensor can detect and track any object with at least one retroreflective surface, including motorcycles, cars with one broken or missing taillight, even bicycles and pedestrians wearing reflective clothing.
It has been already mentioned that the present invention can use two illuminator beams, one for the near field and one for the far field. This arrangement ensures that all targets of interest will be adequately illuminated. However, the accuracy in the computation of distance, azimuth, and elevation will still deteriorate as the actual distance of the target increases, since the accuracy is proportional to the number of pixels illuminated by the target reflection.
FIG. 19 illustrates a modification that can improve the ranging accuracy for targets that are far away using at least two separate imagers 61 and 62 . The first imager is a near-field CCD imager 61 , that operates with a lens system 65 having one or more lenses providing a wide field of view. The second imager is a far-field CCD imager 62 that includes a lens system 67 having one or more lenses providing a narrow field of view. This can be accomplished with a single illuminator having an illuminator field of view consistent with both the near field CCD imager 61 and the far-field CCD imager 62 . If desired, the illuminator capable of controlling the intensity of the beam can be used with the lower intensity illumination synchronized with the near-field imager 61 and the higher intensity illumination synchronized with the far-field imager 62 . This can also be accomplished by two illuminators, including a wide-beam illuminator 66 and a narrow beam illuminator 68 , as shown in FIG. 19 . In this embodiment, the wide beam illuminator 66 is synchronized with the near field CCD imager 61 , and the narrow beam illuminator 68 is synchronized with the far-field CCD imager 62 .
FIG. 20 illustrates another modification that can improve ranging accuracy for distant targets using two separate imager pairs 63 and 64 . Each imager pair 63 and 64 includes a different optical arrangement: one imager pair such as the near field imagers 63 with a wide-angle lens system 65 having one or more lenses and a wide-beam illuminator 66 for the near field, and the other imager pair with a narrow-angle lens system 67 having one or more lenses and a narrow-beam illuminator 68 for the far field. In this case, the wide beam illuminator is synchronized with the near field imager pair 63 and the narrow beam illuminator is synchronized with the far field imager pair 62 .
In both embodiments illustrated in FIGS. 19 and 20, targets 14 that are far away would show up significantly larger on far-field imager 62 or far-field imager pair 64 , whose total field of view could be as small as 5° or less, and thus their ranging accuracy would be accordingly improved. Further, targets such as reflective surfaces 14 that are near the host vehicle are tracked using the near-field imager 61 or near-field imager pair 63 , whose total field of view could be made as wide as 90° or more. This modification is suitable for both versions that have been discussed thus far, namely for IRIS-1 as well as IRIS-2, resulting in either the IRIS-1.2 configuration, with a total of two imagers, imager 61 for near and imager 62 for far, or the IRIS-2.2 configuration, with a total of four imagers arranged in two pairs separated by a fixed known distance on the host vehicle, imager pair 63 for near and imager pair 64 for far.
The final component of the IRIS-1 prototype is a general-purpose laptop computer, which is used for software development and debugging purposes. The laptop communicates with the camera through its parallel port, and this slows down the data transfer process. In the production version of the invention, this laptop computer would be replaced by a microprocessor connected to the camera via a fast bus. The software that runs on the laptop or the microprocessor processes the data obtained from the camera using standard image processing techniques to produce the distance, azimuth angle, and elevation measurement of each target. In particular, the software can include five different modules:
1. a driver module that activates the illuminator and the imager in the synchronous fashion necessary for the four-step “expose-shift-expose-shift” process;
2. an image acquisition module that transfers the image data from the CCD chip to the laptop and subtracts the illuminator-off image from the illuminator-on image;
3. an object detection module that filters the subtracted image using thresholding and low-pass spatial filtering to remove the remaining noise, detects all targets in the filtered image, and computes their apparent location and size;
4. a ranging module that computes the distance, azimuth angle, and elevation angle of each target; and
5. a tracking module that uses information from previous images to classify targets into objects (such as two taillights and a license plate that belong to the same vehicle) and tracks their motion relative to the host vehicle.
The foregoing functions can also be performed by differently organized software modules, which can combine or separate these functions among the software modules.
FIG. 21 is a flow chart illustrating exemplary method steps that can be used to practice the present invention. A field of view which potentially includes a target object is illuminated with an illumination signal. In one embodiment of the invention, the illumination is periodic, however, this need not be the case. For example, aperiodic illumination schemes can be employed wherein the field of view is illuminated according to the speed of the host vehicle or the difference between the speed of host vehicle and objects determined to be in the field of view. The frequency of illumination (and the computations associated with ranging) can also increase as measured data indicates that the target is nearing the host vehicle. Alternatively, the frequency of illumination can be adaptively increased when successive measurements indicate that the range or apparent position of the target is changing at a rate above a fixed or adaptive threshold.
Reflected signals from the field of view are received in synchronization with the illumination signal being turned on and off. The reflected signals include signals in the absence of illumination and with illumination.
As shown in block 202 , the field of view is illuminated with an illumination signal. Reflected signals are then synchronously received from the field of view with illumination and in the absence of illumination of the field of view. Signals from the field of view (with and without illumination) are synchronously received from the field of view, as shown in block 204 . One of a first image and a second image is captured within an array while the other of the second image and the first image is still captured in the array, wherein the first image includes reflected signals from the field of view with illumination and the second image includes reflected signals in the absence of illumination. This is depicted in block 206 . A subtraction image of at least a portion of the field of view is generated, the subtraction image comprising a pixel difference between the first and second images captured in the array. This is depicted in block 208 . The sparse image resulting from this subtraction is processed on a microprocessor to extract ranging information about any retroreflective surfaces within the field of view.
Since a subtraction image is the goal of the foregoing process, it does not matter which of the two images, the first (illuminated image) or the second (non-illuminated image) is recorded before the other. Hence, the first (illuminated) image may be captured in the array first and the second (non-illuminated) image may be captured in the array while the first (illuminated) image is still captured in the array, or, the second (non-illuminated) image may be captured in the array first and the first (illuminated) image may be captured in the array while the second (non-illuminated) image is still captured in the array. Hence, the terms “first image” and “second image” as used above are intended only to distinguish the two images from each other, and are not intended to infer any order in which the images are captured or stored.
Compared to the other ranging technologies discussed in the prior art section, ft b the invention has the advantages of much lower production cost ($30-$70 compared to $300-$1000 for the others), much higher accuracy and reliability, and longer operating range (more than 200 m compared to 150 m). More specifically:
Compared to sonar, the invention has similar production cost, much longer operating range (more than 200 m compared to less than 5 m), and much higher accuracy and reliability, but sonar can detect all objects within its short operating range, not just those with retroreflective surfaces on them.
Compared to time-of-flight laser, the invention has lower production cost ($30-$70 compared to $300-$500), longer operating range (more than 200 m compared to about 100 m), higher accuracy and reliability, better ability to track multiple targets at the same time due to its higher resolution, similar detection capabilities (since time-of-flight laser also depends on retroreflective surfaces for its strongest returns), and better operation in poor weather, because its higher resolution and image subtraction process make it less sensitive to returns from water particles.
Compared to millimeter-wave radar, the invention has much lower production cost ($30-$70 compared to $500-$1000), much higher accuracy and reliability for retroreflective targets, better ability to track multiple targets at the same time due to its higher resolution, longer operating range (more than 200 m compared to about 150 m), and much lower sensitivity to similar devices operating in close proximity. On the other hand, due to its longer wavelength, radar has much better operation in poor weather and can detect all objects, not just those with retroreflective surfaces on them.
Compared to computer vision, the invention has lower production cost, mainly because of its significantly reduced computational requirements, better operation at night, since it does not rely on ambient light, better operation in poor weather, due to the image subtraction process, and similar accuracy and ability to track multiple targets, due to its similar resolution. On the other hand, computer vision can detect all objects, not just those with retroreflective surfaces on them, as long as they are adequately illuminated by the ambient light.
Finally, compared to GPS systems, the invention has the major advantage of being able to operate autonomously, since it does not rely on additional infrastructure and does not require other vehicles to be similarly equipped. On the other hand, GPS systems can receive data from all vehicles around them, not just those in the immediate field of view, and with the D-GPS enhancement they can track them all with higher accuracy at longer distances, and most likely at a lower cost per vehicle.
Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations.
The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim.
Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.
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A method and system for ranging an object are disclosed. The method includes illuminating a field of view potentially including the object, synchronously receiving reflected signals from the field of view with and without illumination, capturing first and second images within an array, and generating a subtraction image using the images. One image is captured in the array while the other image is in the array. The first and second images include reflected signals from the field of view with and without illumination, respectively. The array includes first and second groups of lines that are unmasked and masked, respectively. In one exposure, the first group of lines is loaded with the first or second image. The image in the first group of lines is shifted into the second group. In another exposure, the first group of lines is loaded with the other image, which is shifted into the second group.
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DESCRIPTION
The present invention relates to fuel elements for water-cooled nuclear reactors.
For such nuclear reactors, they nuclear industry designs and manufactures fuel in the form of rods, which are combined in the reactor into parallel bundles as assemblies and are maintained in place according to a regular system or pattern by structural elements. These bundles of rods are vertically positioned in the reactor.
In known manner, the fuel rods generally have a tubular metal sheath or can, which is most frequently made from zirconium alloy and which contains stacks of fissile material pellets, fritted uranium oxide, mixed uranium-plutonium oxide, or any other fissile material, which may or may not be doped with a consumable absorbent. They are stacked in the can in the axial direction thereof. The ends of the can are sealed by two zirconium alloy plugs, sealing being ensured by welding the plugs to the can ends.
The column of fuel pellets is maintained in place, particularly during transportation and the handling operations preceding the placing in the reactor of said assemblies, by a helical spring located within the upper part of the can and compressed between the upper pellet of the fuel column and the upper plug of the rod.
In pressurized ordinary water-cooled nuclear reactors, the outer surface of the can is in operation subjected to a pressure of close to 16 MPa, which is the pressure of the cooling fluid. In order to avoid any deformation of the rods, within the can and following its filling by the fuel pellets and its sealing by the tight plugs, a pressure of an inert gas which is a good heat conductor is maintained and this can be between 0.1 and 8 MPa.
This internal pressure, increased by the thermal expansion of the inert gas in operation and the release of fission gases gives the fuel rods an adequate mechanical stablity to limit the effects of the sinking of the sheath or can and its coming into contact with the fuel pellets. The recess of the spring, in the upper part of the fuel rod, constitutes the expansion chamber. The volume of the expansion chamber plays a vital part in regularizing the developments of the internal pressure of the fuel rod. At the same time this expansion chamber collects the fission gases escaping from the fuel during the development of the chain reaction during the operation of the reactor.
The spring, which is usually made from austenitic stainless steel, is designed so as to apply a force to the fuel stack able to compensate an acceleration of approximately 6 g. Its volume must be minimum, in order to leave the maximum free space in the expansion chamber. Due to the enlargement of the rods under irradiation, it is not possible to unduly increase the height of the expansion chamber.
A fuel rod must have a length below 1 m in the case of an experimental reactor and exceeding 4 m in certain power reactors.
For certain recent designs of nuclear reactors, a known improvement to these fuel rods consists of breaking them down into rods of limited length, or rod sections which are joined end to end. These rod sections constitute the same number of autonomous rods with their own fuel column, their spring, their expansion chamber and their upper and lower plugs.
This new arrangement can be advantageously utilized for producing axial coverings. The rod can e.g. have three sections, namely a long central section and two short end sections. Each rod is then individualized with regards to its contribution to the neutron reaction occurring in the reactor core. For example, the end sections can contain pellets with a different enrichment and the sections can be replaced during the life of the rod. In the same way, during reprocessing, the sections can be detached and separately treated, because they do not necessarily have the same starting enrichments and they have not been subject to the same flux.
It would also be possible to have combinations with a larger number of sections, namely for industrial purposes, or for experimental purposes.
Such a known fuel element rod section structure is shown in the single drawing attached. In the drawing it is possible to see the rod section 1 constituted by a zirconium alloy can 2, which is sealed at its two ends by a zirconium alloy plug, namely the upper plug 3 and the lower plug 4. Within the can 2 there are two compartments, namely in the upper part the expansion chamber 5 and in the lower part the fuel pellets 6. The stack of fuel pellets 6 is surrounded by two insulating pellets 7, 8 made from alumina, zirconia or hafnium. In certain cases, it may only be possible to use the lower pellet 8. The function of these pellets, which have thermal insulation and possibly neutron absorption properties, is to avoid an increase in temperature facing the ends of the fuel pellet column and consequently an over-heating of plug 4 and the end of spring 9. The expansion chamber 5 contains the compression spring 9 of the fuel pellet column 6, said spring 9 being compressed between the upper plug 3 and the insulating pellet 7 terminating the stack of pellets 6 in the upper part. It is also pointed out that the plugs 3 and 4 have complimentary shapes permitting the sequential insertion of several rod sections identical to that in the drawing and plug 3 has a recess 10 for receiving a neutron absorbing material in order to compensate the neutron flux peak, which will be referred to hereinafter. Finally, the plugs 3 and 4 are welded to the can 2 with the aid of weld beads 11 and 12.
Such a fuel rod structure suffers from serious disadvantages as a result of the neutron flux peaks appearing in the reactor core, in areas where there is a deficiency of absorbing atoms, i.e. at the location of the expansion chambers of the sections, other than the upper section, and at the intermediate plugs.
Thus, although the nuclear material produces the neutron-generating chain reaction, said material also absorbs neutrons and consequently a neutron equilibrium is established within said material. However, in expansion chambers, which are empty apart from the spring, the neutron flux is more intense than in the combustible material due to the absorption deficit. Thus, at the ends of the stacks, if special precautions are not taken, there are areas affected by a neutron flux peak leading to unacceptable hot points on the rod in question and the adjacent rods.
At the intermediate plugs 3 and 4 between the different sections, the solution of this neutron problem consists of using hafnium plugs. This matrial absorbs neutrons and can be adequately welded to zirconium alloys. The neutron absorption continuity can also be ensured by absorbing material inserts (hafnium or the like) fixed in the intermediate plugs. At the expansion chambers 5, the neutron absorption continuity is more difficult to obtain.
In previously carried out tests, experimentally attempts were made to obviate this obstacle by introducing in the vicinity, in the centre or around the spring, pellets or inserts made from an absorbent material, usually hafnium.
Unfortunately, these absorbing elements coexist with the spring and occupy a large proportion of the volume of the expansion chamber, e.g. up to 25%. Thus, the latter has to be elongated in order to maintain the volume necessary for the fission gases, which is to the detriment of the fuel column. In addition, these absorbing elements cannot in general be present over the entire height of the expansion chamber. They must leave a free space of 15 to 20 mm long for the longitudinal expansion of the fuel column when it is heated. This free space without absorbent obviously disturbs the neutron flux, in the same way as the expansion chamber without absorbent.
Thus, hitherto, the two problems consisting of maintaining the pellets in the rods, particularly during transportation, and the compensation of the lack of absorption of the neutrons in the expansion chamber, could only be solved by the simultaneous presence of two different means, namely a spring and an absorbent insert, with all the disadvantages mentioned hereinbefore caused by their spatial coexistence in the expansion chamber.
The present invention relates to a fuel element rod for a pressurized light water-cooled nuclear reactor, which solves the aforementioned problems in a particularly simple manner.
This fuel element rod is essentially characterized in that the spring located in the expansion chamber is used both for maintaining the pellets in place and for compensating the absorption of the neutrons in said expansion chamber and is made from hafnium.
Thus, the Applicant has unexpectedly found that the volume of the conventional steel springs is close to that of the hafnium necessary for producing in the expansion chamber the neutron absorption leading to a uniform distribution of the neutron flux. Thus, by optimizing the geometry of the spring, i.e. the diameter of the wire and the number of turns, the desired hafnium volume is precisely obtained.
Obviously, the Expert can use all known metallurgical treatments for ensuring that the hafnium constituting the spring has all the requisite elastic qualities. In particular, a particular metallurgical treatment of the hafnium, relating more especially to an optimization of the cold hammering level, linked optionally with the addition of appropriate elements increasing the yield stress, is able to give adequate mechanical properties to said metal in order to form the spring for maintaining the fuel pellets in the expansion chamber of a fuel element rod or rod section.
According to the present invention, calculations have shown that a hafnium spring occupying the entire height of the expansion chamber would make it possible to exert a force corresponding to that of an acceleration of 6 g on the fuel column, whilst only occupying 20% of the expansion chamber volume. This hafnium quantity and its distribution also make it possible to harmoniously level out the neutron flux.
Moreover, due to its high melting point, there is no danger of hafnium melting during the connection by welding of the upper plug to the can, or during the operation of the rod, even if slightly outside the standard values.
The hafnium spring according to the invention can be used both in the expansion chambers of rod sections located in the full flux of reactors and as a spring for the upper section. In this case, it serves as an absorbant for limiting the neutron flux on the upper parts of assemblies, thus limiting the deterioration or damage thereof.
In summarizing, the hafnium spring according to the invention used in a nuclear fuel rod has three advantages compared with known solutions, whilst maintaining the integrity of the first confinement barrier constituted by the rod can:
(1) whilst ensuring the continuity of the neutron absorption along the expansion chamber, it levels out the neutron flux and eliminates the peaks in said expansion chambers;
(2) when used in the upper part of a rod, it limits the upward neutron leaks of the assemblies;
(3) in the case of use in independent rod sections located in full flux, it avoids any undue increase in the height of the expansion chamber.
As a non-limitative example, hereinafter are given the characteristics of a rod section equipped with a hafnium spring according to the invention:
total length of rod section 527.5 mm;
fuel column length 444.75 mm;
internal diameter of can 8.36 mm;
external diameter of fuel pellets 8.19 mm;
expansion chamber height 46 mm.
In this particular example, the spring characteristics are as follows: material: nuclear quality hafnium;
wire diameter: 1.4 mm;
spring diameter: 7.7 mm;
number of turns: 22;
free spring length: 55 mm;
shear modulus value: 45000 MPa;
wire cold hammering level: 50%.
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Fuel element rod for a pressurized water-cooled nuclear reactor having a cylindrical can (2) made from an alloy which is transparent to neutrons and closed at each of its ends by a plug (3, 4), namely an upper plug (3) and a lower plug (4) and having a first portion in which are stacked fuel material pellets (6), which is optionally inserted between two insulating pellets (7, 8), and a second portion or expansion chamber (5) containing a compressed spring (9) bearing at one end on the upper plug (3) and at the other end on the stack of fuel pellets (6) which it maintains in position, characterized in that the spring is made from hafnium.
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BACKGROUND OF THE INVENTION
This invention relates to a speed governor for use in a toilet or other structure having two openable closure members which are rotatable about an axis or center of rotation, and more specifically for use in a toilet having a toilet seat and a lid, a container having an openable lid, or the like.
For example, a western-style toilet includes a toilet seat mounted on a horizontal support shaft for pivotable movement. In accordance with the mode of use of the toilet, the toilet seat is pivotably movable between a closed position in which the toilet seat is held against the upper edge or rim of an open top of a toilet bowl or body, and an open position in which the toilet seat is spaced away from the upper edge of this open top. When the toilet seat is released during movement from the open to closed position, the seat descends pivotably by its own weight so that it strikes the upper edge of the toilet bowl to produce a great impact sound and in the worst case the seat is broken. This also is the case With the lid.
To deal with the above problems, speed governors have been proposed which brake the pivotable movement of the toilet seat. Examples of such governors include one utilizing a pneumatic cylinder (Japanese Patent Publication No. 37975/87 and Japanese Laid-Open (Kokai) Utility Model Application No. 118498/86) one utilizing a coil spring (Japanese Laid-Open (Kokai) Patent Application No. 106423/85 and Japanese Laid Open (Kokai) Utility Model Application Nos. 164596/84 and 32851/75), and one utilizing an oil damper (Japanese Laid-Open (Kokai) Utility Model Application No. 32851/75).
In the speed governor of the pneumatic cylinder type, the braking action begins from the start of the pivotable movement of the toilet seat, and therefore it suffers from the drawback that it takes a long time for the toilet seat to move. Also, the device becomes bulky. In the speed governor of the coil spring type, the torque of the pivotable movement of the toilet seat and the resilient force of the spring are designed to be in equilibrium, and therefore there is a problem in that a damping action occurs in the vicinity of the point of balance. The speed governor of the oil damper type has a problem that its construction becomes bulky since it must be constructed to protect against oil leakage.
A common drawback of all the above types is that when the mass of the toilet seat is changed (for example, as a result of attachment of a seat cover thereto), the braking force is varied, so that the intended function can not be completely fulfilled. Particularly where the speeds of the toilet seat and the toilet lid are to be regulated independently of each other, there is a problem in that the number of the component parts is increased, so that assembly efficiency is lowered The above problems are not limited to the toilet, but are encountered with a garbage box with a lid, a piece of furniture with an openable lid, and so on.
SUMMARY OF THE INVENTION
A first object of this invention is to provide a speed governor for a toilet or the like in Which the speeds of closing movement of two pivotable members (e.g., a toilet seat and a lid) can be regulated by one brake mechanism, and the pivotable movement in one direction (for example, in the opening direction) can be made lightly. With respect to the pivotable movement in the other direction (the closing direction), there is little difference between the time required for the pivotable movement of one of the two pivotable members and the time required for the simultaneous pivotable movement of both pivotable members.
A second object of the invention is to provide a speed governor for a toilet or the like in which there is no oil leakage encountered, in which stable speed regulation can be achieved regardless of a variation in mass of the pivotable members, and in which the number of the component parts is small so that assembly is efficient.
According to the present invention, a brake is rotatably connected through independent one-way transmission clutches to two pivotable members, such as a toilet seat and a lid, which are pivotably movable independently of each other. The brake has a speed-increasing portion for increasing the input rotation, and a brake portion at a final stage of the speed-increasing portion.
According to another aspect of the present invention, there is provided a speed governor for a toilet or the like having first and second pivotable members each rotatable about an axis of rotation, the speed governor including:
a first input shaft rotatable about the axis of rotation and connected to the first pivotable member;
a second input shaft rotatable about the first input shaft and connected to the second pivotable member;
a driven rotatable member rotatable about the above axis of rotation;
a first one-way transmission clutch provided between the first input shaft and the driven rotatable member, the first clutch transmitting the rotation of the first input shaft to the driven rotatable member when the first input shaft is rotated in a first direction, and the first clutch not transmitting the rotation of the first input shaft to the driven rotatable member when the first input shaft is rotated in a second direction opposite to the first direction;
a second one-way transmission clutch provided between the second input shaft and the driven rotatable member, the second clutch transmitting the rotation of the second input shaft to the driven rotatable member when the second input shaft is rotated in a first direction and the second clutch not transmitting the rotation of the second input shaft to the driven rotatable member when the second input shaft is rotated in a second direction; and
a brake mechanism, connected to the driven rotatable member, for braking the driven rotatable member when the driven rotatable member is rotated thereby braking the rotation of the input shaft rotating the rotatable member.
According to a further aspect of the invention, there is provided a speed governor for a toilet or the like having a reciprocally-pivotable member, the speed governor including:
an input shaft coupled substantially integrally to the pivotable member;
a brake mechanism, operable in response to angular movement of the input shaft, for braking the angular movement of the input shaft (that is, the pivotable movement of the pivotable member);
a one-way transmission clutch, provided between the brake mechanism and the input shaft, for transmitting the angular movement of the input shaft to the brake mechanism when the input shaft is angularly moved in a first direction, the clutch not transmitting the angular movement of the input shaft to the brake mechanism when the input shaft is angularly moved in a second direction opposite the first direction; and
a brake release, provided between the input shaft and the brake mechanism, for releasing the operation of the brake mechanism at a final stage of the angular movement of the input shaft in the first direction.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a toilet incorporating a speed governor according to a first embodiment of the present invention;
FIG. 2 is a fragmentary side-elevational view of the toilet, showing the and closing directions of pivotable members;
FIG. 3 is a vertical cross-sectional view of the speed governor of the first embodiment;
FIG. 4 is a horizontal cross-sectional view of the speed governor;
FIG. 5 is a rear view of the speed governor;
FIG. 6 is a plan view of the speed governor;
FIG. 7 is a vertical cross-sectional view of one example of a brake;
FIG. 8 is a front-elevational view of the brake;
FIG. 9 is a front-elevational view of a friction member of the brake;
FIG. 10 is a front-elevational view of a friction-receiving member of an overload prevention mechanism;
FIGS. 11(a) and 11(c) are side-elevational views of a member constituting part of a one-way transmission clutch, and FIG. 11(b) is a cross-sectional view thereof;
FIG. 12 is a side-elevational view of one example of a driven rotatable member;
FIG. 13 is a cross-sectional view of the driven rotatable member;
FIG. 14 is a plan view of a casing;
FIG. 15 is a cross-sectional view taken along the line A--A of FIG. 14;
FIG. 16 is a left side-elevational view of the casing of FIG. 14;
FIG. 17 is a cross-sectional view taken along the line B--B of FIG. 14;
FIG. 18 is a cross-sectional view taken along the line G--G of FIG. 14;
FIG. 19 is a cross-sectional view taken along the line E--E of FIG. 14;
FIG. 20 is a cross-sectional view taken along the line F--F of FIG. 14;
FIG. 21 is a cross-sectional view taken along the line D--D of FIG. 14;
FIG. 22 is a cross-sectional view taken along the line H--H of FIG. 14;
FIG. 23 is a cross-sectional view taken along the line J--J of FIG. 14;
FIG. 24 is a bottom view of a cover;
FIG. 25 is a right side-elevational view of the cover of FIG. 24;
FIG. 26 is a left side-elevational view of the cover of FIG. 24;
FIG. 27 is a cross-sectional view taken along the line A--A of FIG. 24;
FIG. 28 is a cross-sectional view taken along the line F--F of FIG. 24;
FIG. 29 is a cross-sectional view &taken along the line D--D of FIG. 24;
FIG. 30 is a cross-sectional view taken along the line B--B of FIG. 24;
FIG. 31 is a cross-sectional view taken along the line E--E of FIG. 24;
FIG. 32 is a plan view showing the cover and the casing connected together;
FIG. 33 is a rear view, showing the order of the assembly;
FIG. 34 is a right side-elevational view of FIG. 32;
FIG. 35 is a left side-elevational view of FIG. 32;
FIG. 36 is a fragmentary cross-sectional view of another example of a one-way transmission clutch;
FIG. 37 is a horizontal cross-sectional view of the clutch of FIG. 36;
FIG. 38 is a perspective view of a toilet incorporating a speed governor according to a second embodiment of the present invention;
FIG. 39 is a partially cross-sectional, side-elevational view of the speed governor of FIG. 38;
FIG. 40 is a horizontal cross-sectional view of the speed governor of FIG. 38;
FIG. 41 is a vertical cross-sectional, front-elevational view of the speed governor of FIG. 38;
FIG. 42 is a partly sectional, rear view of the speed governor of FIG. 38;
FIG. 43 is a bottom view of one example of a brake;
FIG. 44 is a bottom view of one example of a torque limiter;
FIG. 45 is a partially cross-sectional, fragmentary, plan view showing the manner of connection between input shafts and pivotable members;
FIG. 46 is a side-elevational view showing the angular positions of the pivotable members;
FIG. 47 is a side-elevational view showing the position of the input shaft relative to members associated therewith when the pivotable members are in a vertical position;
FIG. 48 is a graph showing a change in gear ratio of a gear train as a function of angle in the embodiment shown in FIG. 39;
FIG. 49 is a graph showing a change in speed of pivotable movement of members as a function of angle; and
FIG. 50 is a side-elevational View of a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the present invention, shown in FIGS. 1 to 37, now will be described in detail.
In FIG. 1, a toilet seat 2 (hereinafter referred to merely as "seat"), serving as a second pivotable member, and a lid 3 (hereinafter referred to merely as "lid"). serving as a first pivotable member, are pivotably or angularly-movably mounted on a rear end 1a of an upper edge of a body 1. The seat 2 and the lid 3 are connected through their hinge portions 2a, 2b and 3a, 3b to a speed governor 4 fixedly mounted on the rear end 1a. In FIG. 1, the seat 2 is in a closed position where the seat 2 is disposed substantially horizontally and held against the upper edge 1b of the opening of the body, and the lid 3 is in an open position where the lid 3 exposes the opening of the body and is standing upright away from its closed position The seat 2 is pivotably movable between its open position, indicated by a dash-and-dot line 2A in FIG. 2, and its closed position indicated by a solid line. The lid 3 is also pivotably movable between its closed position, indicated by a solid line, and its open position, indicated by a dash-and-dot line 2B in FIG. 2. The seat 2 and the lid 3 can be pivotably moved between their open and closed positions in unison in overlapping relation to each other.
The construction of the speed governor 4 now will be described with reference to FIGS. 3 and 4. The speed governor includes a housing composed of a casing 5 (see FIGS. 14 to 23) and a cover 6 (see FIGS. 24 to 31) which are connected together in a water-tight manner, a main shaft 7 contained in the housing and serving as a center or axis of rotation a first input shaft 8 rotatably supported on the main shaft 7, a second input shaft 9 rotatable about the first input shaft 8, a driven rotatable member 10 adjacent to the input shafts and rotatably mounted on the main shaft 7, first and second one-way transmission clutches 11 and 12 interposed between the input shaft 8 and the driven rotatable member 10 and between the input shaft g and the driven rotatable member 10, respectively and a brake 13 always connected to the driven rotatable member 10.
One end 7a of the main shaft 7 is supported by a shaft support member 14 which is received in a groove 5a (see FIGS. 14 and 15) of the casing 5 and in a groove 6a (see FIGS. 24, 27 and 30) of the cover 6 and is threadedly connected to the casing. A tubular shaft portion 8a of the first input shaft 8 is rotatably fitted on the other end portion 7b of the main shaft 7, and a tubular shaft portion 9a of the second input shaft 9 is rotatably fitted on the tubular shaft portion 8a. The tubular shaft portion 9a is rotatably supported by a bearing member 15 which is received in a groove 5b (see FIGS. 14 and 15) of the casing and in a groove 6b (see FIGS. 24, 27 and 28) of the cover, and is fixed by screws. The end portion of the tubular shaft portion 8a of the first input shaft extending outwardly from the tubular shaft portion 9a is partly cut-off or removed at its outer peripheral surface, and this cut portion 8b is fitted in an engaging hole 3ba in the hinged portion 31, of the lid 3 such that the cut portion 8b is integrally coupled to the engaging hole 3ba in the direction of rotation.
A cut portion 9b is formed on the outer peripheral surface of the tubular shaft portion 9a of the second input shaft 9, and is fitted in an engaging hole 2ba, formed through the hinge portion 2b of the seat 2, such that the cut portion 9b is coupled integrally to the engaging hole 2ba in the direction of rotation The other hinge portions 2a and 3a of the lid 3 and seat 2 are rotatably supported by a support shaft 17 threaded into a nut block 16. The nut block 16 has engaging grooves 16a which are engaged respectively with hooks 6c (see FIGS. 24 25, 32 and 33) on the side surface of the cover 6 and the nut block 16 is secured to the casing 5 by screws 16b.
The first input shaft 8 has a sleeve 8c of a greater diameter than that of the tubular shaft portion 8a, and the second input shaft 9 has a sleeve 9c of a still greater diameter surrounding the sleeve 8c. Metal reinforcing cups 18 and 19 are fitted respectively in the inner peripheral surfaces of the sleeves 8c and 9c so that each cup is coupled integrally to its mating sleeve in the direction of rotation Coil springs 20 and 21 are held at their outer peripheries in contact with the inner peripheral surfaces of the cups 18 and 19 respectively.
As best shown in FIGS. 11(a)-11(c) to 13 the driven rotatable member 10 has a boss 10b formed about a center hole 10a, serving as a center of rotation through, which the main shaft 7 extends, a retaining groove 10c receiving the proximal end of the coil spring 20, a retaining groove 10d receiving the proximal end of the coil spring 21, a retainer ring 22 retaining the coil spring 20 in the retaining groove 10c, a retainer ring 23 retaining the coil spring 21 in the retaining groove 10d, and inwardly-directed serrations or teeth 10e. One end of each of the coil springs 20 and 21 are fixedly connected to the driven rotatable member 10 by engaging those ends in the retaining grooves 10c and 10d, respectively, then fitting the rings 22 and 23 on the boss 10b and a stepped portion 10f, respectively, and then securing these rings to the driven rotatable member 10 by welding or other suitable attachment method.
The driven rotatable member 10 has spring seats 10g and 10h for receiving the initial portions of the turns of the coil springs which are inclined The ring 23 also has a spring seat 23a. The free ends of the coil springs 20 and 21 are held in contact with the inner peripheral surfaces of the cups 18 and 19, respectively. The direction of turn of the coil springs 20 and 21 is such that when the seat 2 and the lid 3 are rotated in a first direction a (FIG. 2) (i.e., their closing direction), the coil springs transmit the rotational forces of the input shafts 8 and 9 to the driven rotatable member but when the seat 2 and the lid 3 are rotated in a second direction b (FIG. 2) (i.e.. their opening direction) the coil springs do not transmit the rotational forces of the input shafts 8 and 9 to the driven rotatable member 10. Therefore, the sleeve 8c, the driven rotatable member 10 and the coil spring 20 constitute a first one-way transmission clutch 11, and the sleeve 9c, the driven rotatable member 10 and the coil spring 21 constitute a second one-way transmission clutch 12.
A train of speed-increasing wheels 24 are interposed between the driven rotatable member 10 and the brake 13, for increasing the speed of the driven rotatable member 10 and for transmitting this increased speed to the brake 13. The speed-increasing gear train 24 comprises idler gears 25 which always are enmeshed with the teeth 10e of the driven rotatable member 10, a gear 26 of a greater diameter rotatably supported on the main shaft 7 and having a smaller-diameter gear portion 26a enmeshed with the idler gears 25 idler gears 7 enmeshed with an inward gear portion 26b of the gear 26, and a worm gear 28 rotatably supported on the main shaft 7 and having a gear portion 28a enmeshed with the idler gears 27. The worm gear 28 has a gear portion 28b. The idler gears 25 are rotatably supported respectively on three shafts 29a (only one of which is shown) which are secured to a support plate 29 and are spaced at an angle of 120 degrees from one another, the support plate 29 being fixedly received in a groove 5d (see FIGS. 14, 15 and 20) of the casing 5 and in a groove 6d (see FIGS. 24, 27 and 31) of the cover 6.
The idler gears 27 are rotatably supported respectively on two shafts 30a which are secured to a support plate 30 and are spaced at an angle of 180 degrees from each other, the support plate 30 being fixedly received in a groove 5e (see FIGS. 14 and 15) of the casing 5 and in a groove 6e (see FIGS. 24, 27 and 29) of the cover 6. The speed of rotation of the driven rotatable member 10 is increased by the idler gears 25, the gear 26 and the idler gears 27 and is transmitted to the worm gear 28. The worm gear 28 is disposed perpendicularly to the main shaft 7 and is enmeshed with a worm shaft 31 which constitutes part of the brake mechanism 13.
As shown in FIG. 7, the brake mechanism 13 includes a worm shaft 31 rotatably supported by a bearing 32 and a bearing hole 33a in a brake cup 33 received a groove 5g (see FIG. 14), the bearing 32 being received in a groove 5f (see FIGS. 14 and 15) of the casing 5. The brake 13 further includes a friction member 35 mounted on the worm shaft 31 through an overload prevention mechanism 34 such that the friction ember 35 is rotatable relative to the worm shaft 31, the worm shaft 31 extending through the friction member 35. The bearing 32 and the cup 33 are retained by retainer portions 6f and 6g see FIG. 24) of the cover 6, respectively. The friction member 35 is made of an elastic material such as rubber, and as shown in FIG. 9, the friction member 35 has arms 35a extending radially from a central portion through which a hole for loosely receiving the worm shaft 31 is formed, and weight portions 35b extending circumferentially from the arms 35a, respectively. Each arm portion 35 a has a hole 35c in which a pin described later is engaged.
As shown in FIGS. 7 to 10, the overload prevention mechanism 34 includes a ratchet 34a which is press-fitted on a worm shaft 31, and a friction-receiving member 34d having recesses 34c with which engaging teeth 34b of the ratchet 34a are resiliently engaged. The friction-receiving member 34d is loosely fitted on the worm shaft 31 and at one side has pins 34e which are received respectively in the holes 35c of the friction member 35. Therefore, the friction member 35 and the friction-receiving member 34d are coupled together in the direction of rotation of the worm shaft 31. The ratchet 34a and a ring 36 mounted on the worm shaft 31 prevent the two members 35 and 34d from movement along the axis of the worm shaft 31. As will be described more fully hereinafter, when the worm shaft 31 rotates at a high speed, the weight portions 35b are moved outwardly, or opened, under the influence of a centrifugal force so that they are brought into frictional contact with the inner peripheral surface of the cup 33 to brake the rotation of the worm shaft 31.
The steps of assembling the above embodiment now will be briefly described. First, as shown in FIG. 7, the brake mechanism 13 is mounted by fitting the bearing member 32 and the cup 33 in their mating grooves of the casing 5, respectively. Then, as shown in FIGS. 3 and 4 the bearing members 14 and 15 are mounted on a sub-assembly comprising the first input shaft 8, the second input shaft 9, the driven rotatable member 10 and the speed-increasing gear train 24 all of which are rotatable about the main shaft 7. Then, the sub-assembly is set in position relative to the casing 5, with the worm gear 28 meshingly engaged with the worm shaft 31 and the bearing members 14 and 15 are fixed by screws. Then, the cover 6 is placed on the casing 5 and is fastened thereto by fastening screws (not shown) passing through holes 5i (see FIG. 14) of the casing 5 and threaded into tapped holes 6i (see FIG. 24) of the cover 6.
Then, as shown in FIG. 33, the nut block 16 is engaged with the cover 6 and is fastened to the casing 5 by a fastening screw 16b. Then the end of the second input shaft 9 is inserted in the hole 2ba of the hinge portion 2b of the seat 2, and then the end of the first input shaft 8 is inserted in the hole 3ba of the hinge portion 3b of the lid 3. The screw 17 is passed through the other hinge portions 2a and 3a of the seat 2 and lid 3 and is threaded into the nut block 16 (see FIGS. 3. 4 and 6). Then as shown in FIG. 5 mounting grooves 5j (see FIG. 22), formed in the casing 5 and extending from its rear portion to its front, are engaged respectively with locating screws 38 (each having a flange 38a) fixedly secured to the upper surface of the toilet bowl 1. The mounting of the seat 2 and lid 3 may be carried out after the speed goVernor 4 is mounted on the body 1.
The operation of this embodiment now will be described.
In FIG. 2, it is assumed that the seat 2 is lowered, as indicated by the solid line, with the lid 3 being open, as indicated by the dash-and-dot line 3A. When the lid 3 is pivotably moved in the first (closing) direction indicated by the arrow the first input shaft 8 connected to the lid 3 is rotated in the same direction. Upon rotation of the first input shaft 8 in the first direction a, the cup 18 associated therewith frictionally engages the coil spring 20 of the first one-way clutch 11 in a direction so as to increase the diameter of the coil spring 20, so that the spring 20 is substantially integrally coupled to the cup lB (and hence to the first input shaft 8) to drive or rotate the driven rotatable member 10 to which the proximal end of the spring 20 is secured The rotational force of the driven rotatable member 10 drives the worm shaft 31 for rotation at a high speed through the speed-increasing gear train 24. Upon rotation of the worm shaft 31 the weight portions 35b (see FIG. 9) of the friction member 35 are moved outwardly under the influence of a centrifugal force through the overload prevention mechanism 34, so that the weight portions 35b are brought into frictional contact with the inner peripheral surface of the braking cup 33 to brake the rotation of the worm shaft 31.
The braking force applied to the worm shaft 31 serves as a braking force for the speed-increasing gear train 24 (which drives the worm shaft 31 for rotation) and the first input shaft 8 to brake the rotation of the lid 3 connected to this input shaft. Therefore, the lid 3 pivotably moving in its closing direction, is gently and gradually moved at a predetermined speed to its closed position under the influence of the braking force applied thereto A similar operation is effected when the seat 2 indicated by the dash-and-dot line 2A (FIG. 2) is pivotably moved in its closing direction indicated by the arrow. In that case, the second one-way clutch 12 is operated, so that the coil spring 21 couples the second input shaft 9 and the driven rotatable member 10 together.
Next, the opening of the seat 2 from its closed position indicated by the solid line in FIG. 2 will be described. When the seat 2 is pivotably moved in its opening direction, that is, in the second direction b the second input shaft 9 connected to the seat 2 is rotated in the same direction. In response to the rotation of the second input shaft 9, the cup 19 is frictionally and slidingly engaged with the coil spring 21 but this rotating is in a direction so as to wind up or tighten the coil spring (i.e., to reduce the diameter of the coil spring). so that this rotation will not cause the driven rotatable member 10 to rotate. Therefore, the load under which the closed seat 2 is pivotably moved in the second direction is the mass of the pivotable member, and the opening operation is lightly carried out. When the lid 3 indicated by the solid lines in FIG. 2 is pivotably moved in the second direction b the coil spring 20 is wound up, and therefore the clutch is disengaged to interrupt the transmission of rotation between the driven rotatable member 10 and the first input shaft 8.
Also, when the seat and the lid, disposed in their respective positions indicated by the dash-and-dot lines 2A and 3A in FIG. 2, are pivotably moved together in the first direction a, either of the first and second transmission clutches 11 and 12 are operated to rotate the driven rotatable member to operate the brake mechanism 13. As a result the speed of pivotable movement of the seat and the lid is controlled so that they are closed slowly. In this case, the speed at which the seat and the lid are closed in unison is hardly different from the closing speed at which they are closed separately. The reason is that the brake of the type in which the frictional member frictionally engages the brake cup produces a predetermined braking force irrespective of the mass of the pivotable members.
Next, the situation will be explained in which, for example, the seat 2 in its open position indicated by the dash-and-dot line 2A in FIG. 2 is forcibly moved pivotably in the first direction a when the pivotable movement of the seat due to its own weight is felt to be undesirably slow. When the seat 2 is forcibly moved pivotably in the first direction a, the second input shaft 9 is rotated in the same direction, and the diameter of the coil spring 21 of the second one-way transmission clutch 12 is increased, so that the driven rotatable member 10 and the input shaft 9 are coupled together, thereby rotating the worm shaft 31 at a high speed through the speed-increasing gear train 24. Upon rotation of the worm shaft 31, the friction member 35 is rotated through the friction-receiving member 34d with which the ratchet 34a fixedly mounted on the worm shaft 31 is engaged. As a result, the weight portions 35b are moved outwardly under the influence of a centrifugal force and are brought into frictional contact with the inner peripheral surface of the cup 33 to apply the braking action. In this case, normally, this braking force brakes the pivotable movement of the seat 2, but since the seat is being forcibly moved pivotably, an overload is applied to the worm shaft 31. At this time the ratchet 34a rotating in a clockwise direction in FIG. 8 is flexed so that the engagement between its engaging teeth 34b and the recesses 34c of the friction-receiving member 34d is released so as to avoid the above overload. One of the seat 2 and the lid 3 may be connected to either of the first and second input shafts 8 and 9 while the other is connected to the remaining input shaft. However, considering the transmitting force of the clutches, it is preferred that the pivotable member of a greater mass (i.e., the seat 2 in the illustrated embodiment) be connected to the outer shaft of the double shaft construction (i.e. the second input shaft 9).
Another example of the one-way transmission clutch now will be described with reference to FIGS. 36 and 37. First and second input shafts 80 and 90 of a double shaft arrangement are rotatably supported on the main shaft 7. The input shafts 80 and 90 have tubular portions on their respective ends, on which respective retainer rings 80b and 90b are fitted. A driven rotatable member 10A has a double-tube arrangement at its one side opposed to the ends of the input shafts, and retainer rings 10Aa and 10Ab are fitted respectively on the inner and outer tubular portions of the double-tube arrangement of the driven rotatable member. The inner and outer tubular portions of the driven rotatable member 10 are equal in diameter to their respective mating tubular portions of the first and second input shafts 80 and 90, and coil springs 20A and 21A are wound respectively around the two pairs of mating tubular portions.
When each input shaft is rotated in the first direction, the coil spring is wound up or tightened transmitting the rotation of the input shaft to the driven rotatable member. When the input shaft is rotated in the second direction, the coil spring is loosened and does not transmit the rotation of the input shaft to the driven rotatable member. The one-way transmission clutches are not limited to the illustrated spring clutches and may be replaced by one-way rotation-transmitting mechanisms of other types
In the above embodiment, although the nut block 16 supporting the one hinge portions of the pivotable members is provided as a separate member, it may be formed integrally with the casing 5 or the cover 6 The brake mechanism 13 is not limited to the illustrated friction brake type, and may be replaced by an oil brake or other suitable types Further the clutches may be connected directly to the brake mechanism without the use of the speed-increasing gear train therebetween.
Although the illustrated embodiments have shown a toilet having a toilet lid and a toilet seat the invention is applicable to other articles having two pivotable members, such as a box or furniture.
A second embodiment of the invention will now be described with reference to FIGS. 38 to 49, the invention here embodying a speed governor for a toilet seat and a toilet lid both pivotably connected to a toilet body.
In FIG. 38, the toilet seat 2 and the toilet lid 3 are pivotably connected at their proximal ends to a rear end of an upper surface of the toilet body 1. The toilet here shown has a shower. A shaft mounted on a operating box 400 supports one end of the axis or center of rotation (for pivotable movement) of the toilet seat 2 and toilet lid 3 while a shaft (later described) mounted on a speed governor 500 supports the other end of the axis of rotation To install the speed governor 500, mounting portions 600a and 600a, formed respectively on the opposite sides of a casing 600, are placed on the upper surface of the toilet body 1, and then are fastened thereto by fastening screws 700 see FIG. 42).
In FIGS. 39 to 46, the speed governor 500 includes the casing 600, input shafts BOO and 900 partly extending outwardly from the casing 600 a brake 100 accommodated within the casing 600, a one-way transmission clutch 110 a brake release 120, and rotation transmitting structure 130. In the illustrated embodiment, the speeds of the toilet seat 2 and the toilet lid 3 serving as the pivotably members are regulated, and therefore the two input shafts 800 and 900 used are rotatable or pivotably movable about a common axis. The casing 600 includes a casing body 600b and a casing lid 600c fitted on the casing body and fastened thereto by tapping screws 150. In FIG. 39, reference numeral 150a denotes screw holes formed in the casing body.
A tubular shaft portion 900a of the input shaft 900 is extended through a bearing hole 600a (see FIG. 41) of the casing lid 600c. The input shaft 800 is extended through the tubular shaft portion 900a, and the proximal end 800a of the input shaft 800 is received in a bearing hole 600a in the casing body. The input shaft 900 projects outwardly from a cylindrical portion 600cb of the casing lid, and a cut portion 900b for preventing the rotation is formed in the outer peripheral surface of the projecting portion 900c of the input shaft 900. The projecting portion 900c is fitted in an engaging hole 3A formed through the toilet lid 3, the engaging hole 3A being complementary in cross-section to the projecting portion 900c so that the projecting portion 900c is substantially integrally coupled to the engaging hole 3A in the direction of rotation (see FIGS. 45 and 46). One end of the input shaft 800 projects further beyond the projecting portion 900c of the input shaft 900, and a cut portion 800c for preventing rotation is formed in the projecting portion 800b. The projecting portion 800b is fitted in an engaging hole 2A formed through the toilet seat 2, the engaging hole 2A being complementary in cross-section to the projecting portion 800b so that the projecting portion 800b is substantially integrally coupled to the engaging hole 2A in the direction of rotation (see FIGS. 45 and 46).
First gears 160 and 170, which are spaced from each other, are formed integrally respectively on those portions of the input shafts 800 and 900 disposed within the casing 600. The first gears 160 and 170 may be formed separately from the respective input shafts, and may be integrally connected to them. Each of the first gears 160 and 170 includes a partially-involute gear whose pitch gradually increases when the gear 160 (170) is moved angularly in a clockwise direction (FIG. 39). As shown in FIG. 39, the case body 600b has a stopper portion 600bb for preventing the overrunning of the first gears 160 and 170 when these gears are angularly moved in a first direction (i.e., in a clockwise direction in FIG. 39). A second gear 190 in mesh with the first gear 160 and a second gear 200 in mesh with the first gear 170 are rotatably mounted on a support shaft 180, formed on the casing body 600b, in spaced relation to each other. The distal end 180a of the support shaft 180 is fitted in a hole in the casing lid 600c. A third gear 210 of a greater diameter is rotatably supported on the support shaft 180 and interposed between the second gears 190 and 200. Each of the second gears 190 and 200 comprises a partially-involute gear which is smaller in diameter than the first gear.
The first gears 160 and 170 are disengaged from the second gears 190 and 200 respectively at a final stage of the pivotable or angular movement of the toilet seat 2 and the toilet lid 3 (i.e.. the position spaced about 80 degrees from the vertical position) where the toilet seat 2 and the toilet lid 3 are about to be brought into a horizontal position thereby releasing the transmission of the rotation of the input shafts 800 and 900 to the brake 100. Thus, these first and second gears constitute the brake release mechanism 120. The gear ratio of the first gear 160, 170 to the second gear 190, 200 in accordance with the angular position (the angle of opening from the vertical position) of the toilet seat 2 or the toilet lid 3 is shown in FIG. 48. From this Figure, it can be seen that the gear ratio increases as the toilet seat 2 or the toilet lid 3 approaches the horizontal position, and the first and second gears are disengaged from each other at the final stage of pivotable movement (from about 80 to 90 degrees).
Rings 220 and 220 are fitted respectively in tubular portions 190a and 200a of the second gears 190 and 200, and coil springs 230 and 230 are held in contact with respective inner peripheral surfaces of these rings, each of the coil springs 230 and 230 being capable of increasing its diameter One end of each of the coil springs 230 and 230 is fixed to respective portions of a boss 210a of the third gear 210 while the free ends of those springs are held in contact with respective inner peripheral surfaces of the rings together with their bodies When the toilet seat 2 and the toilet lid 3 (and hence the respective input shafts 800 and 900 coupled substantially integrally to them) are angularly moved in the first direction indicated by a solid line in FIG. 46, the coil springs 230 and 230 transmit the rotations of the second gears 190 and 200 to the third gear 210, respectively.
When the toilet seat and the toilet lid are pivotably moved in the second direction indicated by a broken line in FIG. 46, the second gears 190 and 200 are rotated in a direction so as to wind up or tighten the coil springs 230 and 230, so that the rotational forces of the input shafts are not transmitted to the third gear 210. In this manner, the second gears 190 and 200, the coil springs 230 and 230, and the third gear 210 constitute the one-way transmission clutch 110. As shown in FIG. 39, one side 200b (190b) of the second gears 200 (190) is abuttable respectively against stoppers 240 (only one of which is shown) which limit the rotations of these gears The stoppers 240 may be formed either integrally with the casing lid 600c or as separate members such as pins secured to the casing.
The third gear 210 of a greater diameter is always enmeshed with a fourth pinion 250 of a smaller diameter The fourth pinion 250 is formed integrally with a worm wheel 260 serving as a fourth gear, and is rotatably supported on a support shaft 270 formed on the casing body 600b. A distal end 270a of the support shaft 270 is fitted in a hole formed in the casing lid 600c. The worm wheel 260 is always in mesh with a worm 280. The worm 280 constitutes part of the brake mechanism 100. The rotations of the input shafts 800 and 900 are increased and are transmitted to the worm 280 through the rotation transmitting mechanism 130 constituted by the first gears 160 and 170, the second gears 190 and 200, the third gear 210, the fourth pinion 250, the worm wheel 260, and the worm 280. The rotation transmitting mechanism 130 includes the speed-increasing gear train and increases the rotation of the input shafts and transmits such increased rotation to the worm 280, thereby driving the worm for rotation at a high speed.
One end 280a of the worm 280 is supported by a bearing block 290 mounted on the casing body 600b while the other end 280b is received in a bearing hole 300a formed through brake a cup 300 mounted on the casing body. Thus, the worm 380 is rotatably supported. The bearing block 290 has a groove in which the one end 280a is received, and a holder portion 600d (see FIG. 42) formed on the casing lid 600c is received in this groove to support the end of the worm. A ratchet 310 capable of expanding is press-fitted on the worm 280, and arms 310a of the ratchet are resiliently engaged at their distal ends in respective engaging recesses 320a formed in one end face of a friction-receiving member 320. The friction-receiving member 320 is loosely fitted on the worm 280. The ratchet 310 and the friction-receiving member 320 constitute a torque limiter, whose operation will be described later A retainer ring 330 is mounted on the worm 280, and a friction member 340, made of rubber or a rubber-like material, is loosely mounted on the worm 280 and is interposed between the retainer ring 330 and the friction-receiving member 320.
As shown in FIGS. 39 and 43, the friction member 340 has arms 340a extending from its boss in three directions, and weight portions 340b extending respectively from the arms 340a along the inner peripheral surface of the cup 300. Pins 320b extending axially from the friction-receiving member 320 are engaged with the arms 340a respectively. Therefore, the friction-receiving member 320 and the friction member 340 are coupled together by the pins 320 in the direction of rotation.
The weight portions 340b of the friction member 340 are disposed close to the inner peripheral surface of the brake cup 300. When the worm 280 rotates at a high speed, the weight portions 340b of the friction member 340 are brought into frictional contact with the inner peripheral surface of the cup 300 under the influence of centrifugal force to brake the rotation of the worm. The braking of the worm 280 brakes the gear train which is driving the w©rm for rotation, and hence brakes the input shafts 800 and 900. The worm 280, the friction member 340, and the brake cup 300 constitute the brake mechanism 100.
FIG. 49 shows the relation between the closing speed and the angular position when the toilet seat of lid is pivotably moved from the vertical to the horizontal position From zero to about 10 degrees from vertical, the brake 100 is not effective, and therefore closing speed increases abruptly in this range. However for angles greater than 10 degrees, up to about 80 degrees (which would be one example of a final stage of pivotable movement), the brake is increasingly effective as the gear ratio increases, so that closing speed gradually decreases. Further from 80 degrees to 90 degrees (closed position), the first gears 160 and 170 become disengaged from the second gears 190 and 200, respectively, thereby releasing the brake and increasing the speed of closing. However since the seat lid does or not have far to fall, there is no great impact
The operation of the just-described embodiment now will be described with respect to the pivotable movement of the lid 3 from its vertical (open) position indicated by the dash-and-dot line in FIG. 46 to its horizontal (closed) position indicated by the solid line. When the lid 3 is vertical the first and second gears 170 and 200 mesh with each other as shown in FIG. 47. When the lid 3, at the position indicated by the dash-and-dot line in FIG. 46, is moved pivotably in the first direction indicated by a solid-line arrow, the input shaft 900 is rotated in a clockwise direction (FIG. 47). and the first gear 170 which is integrally coupled to this input shaft is rotated in the same direction, so that the second gear 200, in mesh with this first gear, is rotated in a counterclockwise direction. When the second gear 200 rotates in a first direction, the coil spring 230 of the one-way transmission clutch 110 increases in diameter, drivingly coupling the second gear 200 and the third gear 210 together. As a result, the third gear 210 drives the fourth gear 250 and the worm wheel 260, causing increased rotational speed The worm wheel 260 rotates the worm 280 at a yet further increased speed.
As the angle of the closing of the toilet lid 3 gradually increases, the gear ratio of the first gear 170 to the second gear 200 gradually increases, as shown in FIG. 48, and the speed of rotation transmission effected by the rotation transmitting mechanism 130 is correspondingly increased. When the worm 280 rotates at a high speed, the weight portions 340b of the friction member 340 rotated through the torque limiter are subjected to a centrifugal force and are moved radially outwardly in a centrifugal direction so that the weight portions are brought into frictional contact with the inner peripheral surface of the cup 300 to brake the rotation of the worm. The braking force acting on the worm 280 is transmitted to the input shaft 900 through the rotation transmitting mechanism 130 to brake the input shaft 900 and hence reduce the closing speed of the toilet lid 3.
The speed of rotation of the worm 280 gradually increases as the gear ratio varies in response to a change in angular position of the input shaft 900, and therefore the braking force produced by the friction member 340 and the cup 300 also increases gradually. Therefore, as shown in FIG. 49, at the angular position of zero to about 10 degrees from the start of the closing movement, the closing speed of the lid 3 abruptly increases because the gear train is not yet fully operated but thereafter the closing speed becomes moderate since a sufficient braking force begins to be produced. When the toilet lid 3 approaches the final stage of the pivotable movement (i.e. the angular position of about 80 degrees) immediately before the fully closed position of the lid 3, the one side 200b of the second gear 200 is brought into abutting engagement with the stopper 240 so that the rotation of the second gear is prevented and the brake release mechanism 120 constituted by the first and second gears 170 and 200 releases the meshing engagement between these two gears, so that the braking force ceases to act on the input shaft 900. As a result, the lid 3, which is substantially integrally coupled to the input shaft 900, moves pivotably at a high speed through the remaining 10 degrees or so without being subjected to a braking force, and is brought into the horizontal position that is, the toilet lid 3 is abutted against the seat 2 and thus is stopped. When the lid 3 moves through the remaining 10 degrees without undergoing a braking force, the lid 3 descends into the horizontal position without a great impact since the distance to be covered is short. In this horizontal position, cushions 3b (see FIG. 38) on the lid 3 are held against the toilet seat 2 and the seat 2 is held against the upper surface of the toilet bowl 1.
When the lid 3 which is being pivotably moved by its own weight in the closing direction is forcibly moved pivotably, the input shaft 900 forcibly drives the gear train of the rotation transmitting mechanism 130 for rotation As a result, the worm 280 is rotated at a high speed so that a braking force is applied by the friction member 340 to the worm, but when the friction between the friction member and the cup 300 exceeds a predetermined value, the arms 310a of the ratchet 310 are flexed and thus become disengaged from the engaging recesses 320a of the friction-receiving member 320 thereby allowing the rotation of the worm 280 By so doing, an overload is prevented from acting on the rotation transmitting mechanism 130 including the worm 280. Therefore, the lid 3 can be rotated without receiving a braking force from the brake mechanism 100. In this case, however, the meshing relation between the first gear 170 and the second gear 200 is not changed, and therefore logarithmic gears can be used as the first and second gears 170 and 200.
Next, the pivotable movement of the lid 3 from the horizontal position (closed position) indicated by the solid line (FIG. 46) to the vertical position (open position) indicated by the dash-and-dot line will be described. In this horizontal position, the first and second gears 170 and 200 are disengaged from each other as shown in FIG. 39. When the lid 3 is pivotably moved in the direction of a broken-line arrow (FIG. 46), the input shaft 900 is moved angularly in a counterclockwise direction (FIG. 39). At an initial stage of the rotation of the input shaft, the first and second gears 170 and 200 are not enmeshed with each other but upon movement of the shaft through an angle of about 10 degrees, the two gears are brought into meshing engagement with each other so as to move the gear train of the rotation transmitting mechanism 130 angularly. However, the second gear 200 angularly moving in the second direction (clockwise direction) acts on the coil spring 230 (see FIG. 40) of the one-way transmission clutch 110 in such a maner in as to wind up or tighten this coil spring, so that the coil spring cannot rotate the third gear 210.
Therefore, since the brake mechanism 100 does not apply a braking force to the rotation of the input shaft 900, the lid 3 moving in its opening direction can be opened with a light force. Incidentally, when the lid begins to be opened the coil spring 230 rotates the third gear 210, but this rotation is immediately prevented. More specifically, the worm 280 which is enmeshed with the worm sheet 260 which is rotated by a third gear 210 and the fourth pinion 250 is moved downwardly (FIG. 39) and is pressed at its lower end against the end 290a of the bearing block 290, so that the rotation of the worm wheel 260 is prevented thereby preventing the rotation of the third gear 210. When the rotation of the third gear 210 is prevented, the coil spring 230 and the second gear 200 slip relative to each other, and therefore the transmission of rotation between the input shaft 900 and the brake mechanism 100 is released.
When the lid 3 is pivotably moved to the vertical position, the first and second gears are disposed as shown in FIG. 47. At this time when the lid 3 is pivotably moved excessively, the one side of the first gear 170 is abutted against a stopper 600c (see FIG. 39).
The foregoing describes the opening and closing operation of the lid 3. The opening and closing operation of the seat 2 is the same as that of the lid 3. In this case the input shaft 800 and the first gear 160 are rotated and the gear train operatively connected thereto and including the second gear 160 is rotated. Also, the seat and the lid are pivotably moved in unison in the same manner.
A third embodiment of the present invention now will be described with reference to FIG. 50. This embodiment differs from the second embodiment mentioned above in that sector gears 1600 and 1700 are used as the first gears, and in that circular gears 1900 and 2000 are used as the second gears. Since the other parts are the same, they are denoted by the same reference numerals, respectively and will not be explained here. Recesses 1600a and 1700a (only one of which is shown) are formed respectively in the sector gears 1600 and 1700 and extend in the circumferential direction thereof. Positioning projections 1600b and 1700b (only one of which is shown) are formed respectively on those sections of their outer peripheral portions disposed adjacent to the recesses 1600a and 1700a, those sections being elastically deformable. A positioning projection 600bd is formed on a casing body 600b and is disposed in a circular path of angular movement of the projection 1600b 1700b. In the angular positions of the sector gears 1600 and 1700 shown in solid lines, the lid and the seat are disposed at their final stage of movement immediately before reaching the horizontal position, and their teeth have just been brought out of meshing engagement with the second gears Thereafter, in response to the pivotable movement of the seat or the lid in the first direction, the sector gear 1600, 1700 is angularly moved in a clockwise direction until it is brought into engagement with a stopper 600bb, so that the sector gear is held in that position, out of meshing engagement with the second gear 1900, 2000.
When the input shaft 800, 900 (corresponding respectively to the seat or the lid) is angularly moved so that the sector gear 1600, 1700 disposed at the position indicated by the solid line is angularly moved in a second direction (counterclockwise direction), the sector gear is brought into meshing engagement with the second gear 1900, 2000 to rotate it, and is angularly moved toward a position shown by a broken line. At this time, the rotation of the second gear is not transmitted to the third gear 210 since the one-way transmission clutch 110 is provided between the second gear 1900 2000 and the third gear 210. The sector gear 1600 1700 angularly moved to the position indicated by the broken line (the vertical position) is brought out of meshing engagement with the second gear 1900, 2000, with its one side abutted against a stopper 600bc. If the seat or the lid overruns the projection 1600b, 1700b of the sector gear 1600, 1700 goes past the stopper 600bc and is abutted against the positioning projection 600bd, thereby stopping the sector gear.
In this embodiment, when the lid or the seat is moved in the first direction from a vertical to a horizontal position, the sector gears 1600, 1700 disposed in the position indicated by the broken line are angularly moved in a clockwise direction, and are brought into meshing engagement with the second gear 1900, 2000 after being angularly moved through a non-meshing angle of about 10 degrees thereby angularly moving the second gear. The closing speed of the seat and the lid between the vertical position and the angular position of about 10 degrees is as shown in FIG. 49. However, between the angular position of 10 degrees and the final stage of movement (the angular position of about 80 degrees), the closing speed is substantially constant since the gear ratio of the sector gear to the second gear is not changed. When the angle of the pivotable movement reaches the final stage angle of 80 degrees, the sector gear and the second gear become disengaged from each other (see FIG. 50) As a result, the sector gear, and hence the lid or the seat is moved without receiving a braking force and thus descends by its own weight and is brought into abutting engagement with the upper surface of the seat or the upper surface of the lid, respectively.
In the above embodiments, although the pivotable members whose speed is to be regulated are a toilet seat and lid, the invention is applicable to a speed governor for other pivotable members such as a refrigerator door, a door of a building structure, and a video cassette holder. Further, in the illustrated embodiments, although the input shafts are of the double shaft type, a single input shaft may be used. Further, in the illustrated embodiments, since the input shafts constitute one end of axes or centers of rotation (pivotable movement) of the pivotable members, the mounting and removal of the speed governor can be made easily, and exchange of component parts such as those of the brake mechanism can be made quite easily.
As described above, according to the present speed governor for a toilet or the like, since a common structure from the one-way transmission clutch to the brake mechanism can be used, the construction can be simplified. The brake mechanism is not operated when the toilet seat and the toilet lid are lifted because of the one-way clutch and therefore they can be manipulated lightly. Also, the clutch, comprising the coil springs is not noisy.
The braking force is produced through the speed-increasing function of the gear train, and therefore a large braking force is produced with the use of the brake mechanism of a small size.
Particularly where the final stage of the speed-increasing wheel train includes a worm, the speed-increasing rate is increased which is advantageous in braking.
Where the brake mechanism is of the centrifugal type, the times required respectively for three different closing modes (i.e., the closing of the seat, the closing of the lid and the closing of both) do not differ much from one another.
Where a non-circular gear is used in the speed-increasing wheel train, the speed-increasing rate can be changed in a stepless manner, so that a desirable closing operation can be obtained.
Where the rotation is not transmitted to the pivotable member at the initial stage of the pivotable movement of the member from its upper position through a predetermined angle, the closing operation can be initiated with a light force.
Further, in the speed governor of the first embodiment, the number of the component parts is reduced so that the speed governor can be of a compact construction, can be manufactured at a lower cost, and can be assembled easily. Further, since the one-way transmission clutch is provided between the input shaft and the driven rotatable member only the input shaft is rotated when the pivotable member is rotated in the second direction, so that this manipulation can be carried out with a light force. Still further, when both of pivotable members are simultaneously rotated in the first direction, either of the first and second input shafts operate the one-way transmission clutch, and therefore the two pivotable members do not differ in speed of the pivotable movement.
In the speed governor of the second embodiment, the pivotable members can be closed without impact Further, since the brake mechanism is released at the final stage of the angular movement of the input shaft, the seat will not be even slightly spaced upwardly from the upper surface of the body, and when the user is seated on the seat, the seat never descends. Thus, the seat can be used quite conveniently. When the user is seated on the seat slightly spaced from the upper surface of the body, the brake mechanism and the gear train may be damaged or broken. In the present invention, however, the seat is positively held against the upper surface of the toilet bowl, and therefore such a problem is not encountered.
Various modifications within the scope and the spirit of the invention will be apparent to those of working skill in this area of technology. Thus, the scope of the invention is limited only by the appended claims.
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Braking of independently-movable pivotable members is carried out by independent one-way clutch mechanisms which provide minimal braking force to the pivotable members in the vicinity of the limit points of their pivotable movement, and provide optimal braking force in a middle range of pivotable movement. The braking mechanism provided may operate on one or both of the pivotable members at the same time, each of the independent clutch mechanisms providing suitable braking force to compensate for the mass of the respective pivotable members.
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TECHNICAL FIELD
The present invention relates to an active suspension system and an active suspension control method for a vehicle which actively and electronically controls the position and attitude of a vehicle body by using, hydraulic pneumatic or other fluid force actuators, and in particular to an active suspension control device and method which can improve the capability of the vehicle to undergo a turning maneuver in a high lateral acceleration condition.
BACKGROUND OF THE INVENTION
Conventionally, there is known a so-called active suspension system which improves the maneuvering capability and the riding comfort of the vehicle by electronically controlling hydraulic or pneumatic actuators arranged between the vehicle body and the wheels. For instance, Japanese patent laid open publication No. 63-11408 discloses an active suspension control system which improves the stability of a vehicle by controlling the actuators so as to change the ratio of loads acting upon the front and rear wheels and thereby modifying its dynamic properties related to turning maneuver depending on the conditions of the intended turning maneuver. Japanese patent laid open publication No. 62-295714 discloses an active suspension system for a vehicle which ensures a stable maneuvering of the vehicle by continually controlling a pressure control valve according to the magnitude of a lateral acceleration or a fore-and-aft acceleration of the vehicle so as to adjust a fluid pressure cylinder and reduces the roll or the yaw motion of the vehicle.
The stability of a vehicle is ensured as long as the cornering forces acting on the front wheel set and the rear wheel set are both large enough to support the vehicle against the lateral inertia force due to the lateral acceleration arising during a turning maneuver. In other words, in order for a four wheeled vehicle to maintain a stable running condition during a turning maneuver, both the front and rear wheel sets must continue to provide sufficiently large cornering forces. The cornering force of each of the wheel sets is given as the sum of the cornering forces of the right and left wheels.
It is well known that the relationship between the maximum cornering force of a vehicle tire undergoing a turning maneuver and its vertical load has a nonlinear property. The maximum cornering force increases in proportion with the increase in the vertical load of the tire when the vertical load is relatively small, but its rate of increase diminishes as the vertical load increases beyond a certain level as can be seen from FIG. 4. In other words, the maximum cornering force of a vehicle tire saturates and cannot increase indefinitely as the vertical load acting on the tire increases beyond a certain limit. Therefore, the total cornering force of either the front wheel set or the rear wheel set bearing a larger part of the overall vehicle weight is critical in determining the overall stability of the vehicle because the wheel set which is closer to the center of gravity of the vehicle is subjected to a larger lateral inertia force due to the lateral acceleration during a turning maneuver and a larger vertical load, and therefore reaches such a saturated part of the cornering force property before the other wheel set. The weight distribution varies depending on the position of the engine and the general layout of the vehicle, and is also affected by the weight of the vehicle occupants and the cargo as well as the acceleration and deceleration conditions of the vehicle.
Further, during a cornering maneuver, the vehicle is subjected to a rolling moment because the lateral inertia force acts upon the vehicle acts at its center of gravity which is located well above the road surface, and this rolling moment shifts the distribution of the load acting on the right and left wheels of each wheel set laterally or between them, and the vertical load acting on the outer wheel becomes greater than that acting on the inner wheel. As can be seen by referring again to FIG. 4, between the total cornering force of each wheel set when the shifting of the load to the outer wheel is small or C F1i +C F1o and the total cornering force when the shifting of the load to the outer wheel is large or C F2i +C F2o , the relationship C F1i +C F1o >C F2i +C F2o holds. Therefore, as the difference in the loads acting on the inner and outer wheels increases due to the increase in the lateral inertia force or the centrifugal force and the amount of lateral load shift thereby increases, the overall cornering force of each wheel set diminishes.
Therefore, according to the conventional passive suspension combining a spring and a damper, it was not possible to prevent the drop in the cornering force depending on the state of the turning maneuver of the vehicle, and improvements in the capability of the vehicle for turning maneuver and the stability of the vehicle were difficult to achieve.
BRIEF SUMMARY OF THE INVENTION
In view of such problems of the prior art and the recognitions by the inventors, a primary object of the present invention is to provide an active suspension system and a suspension control method which can prevent the drop in the cornering force due to the shifting of load between the inner and outer wheels during a turning maneuver involving a large lateral acceleration.
A second object of the present invention is to provide an active suspension system and a suspension control method which can improve the turning capability of a vehicle with a minimum amount of modification to an existing active suspension control system.
According to the present invention, such an object can be accomplished by providing an active suspension system for a vehicle having a first wheel set and a second wheel set, each wheel set including a right wheel and a left wheel, comprising: wheel supporting means pivotably coupling each of a plurality of wheels of a vehicle with a vehicle body so as to support the associated wheel in a vertically moveable manner; a power actuator interposed between the vehicle body and each of the wheels; sensor means for detecting turning maneuver of the vehicle; and control means for controlling operation of the actuators according to data obtained from the sensor means so as to reduce a vertical load acting on an inner one of the wheels of the second wheel set which bears a less vertical load than said first wheel set, for instance by lifting it, when it is detected by the sensor means that the vehicle is undergoing a turning maneuver which gives rise to a lateral acceleration exceeding a certain limit.
Thus, by reducing the vertical load acting upon the inner front or rear wheel of the second wheel set which is subjected to a relatively small load during the turning maneuver in question, and thereby decreasing the vertical load acting on the outer wheel of the first wheel set which is subjected to a relatively large load during such a turning maneuver, the difference in the loads acting upon the right and left wheels of the second wheel set which is subjected to a relatively small load can be reduced as compared with the prior art when the shifting of load takes place due to the lateral inertia force arising during the turning maneuver owing to certain relationships existing between the vertical forces acting on the respective wheels as set forth in detail in the following, and the overall running stability of the vehicle can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
Now a preferred embodiment of the present invention is described in the following with reference to the appended drawings, in which:
FIG. 1 is a block diagram of a preferred embodiment of the active suspension system according to the present invention;
FIG. 2 is a schematic perspective view illustrating the positions of the four wheels of a vehicle relative to its center of gravity and vertical loads acting thereon;
FIG. 3 is a schematic front view illustrating shifting of the overall vertical load acting on the vehicle;
FIG. 4 is a graph of the relationship between vertical load and the maximum cornering force; and
FIG. 5 is a block diagram showing an example of the transfer function of the main control action according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
According to the present invention, a suspension unit is provided between each of four wheels arranged on four diagonal parts of a four-wheel automobile and its vehicle body. Since the four suspension units 1 are substantially identical in structure, only the front right wheel is described in the following as an example by referring to FIG. 1.
In FIG. 1, the suspension unit 1 comprises a suspension arm 4 pivotably supported by a vehicle body 2 at its one end and supports a wheel 3 at its other end, a load sensor 5a carried by an upper suspension member 5 pivotably supported by the vehicle body 2, a hydraulic cylinder 6 coupled between the suspension arm 4 and the load sensor 5a, and a coil spring 7 connected in parallel with and surrounding the hydraulic cylinder 6. The load sensor 5a measures the vertical load acting on the wheel 3. The hydraulic cylinder 6 consists of a double-acting hydraulic cylinder which is internally divided into an upper chamber 9 and a lower chamber 10 by a piston 8, and hydraulic fluid can be supplied to either of the chambers at an appropriate pressure and flow rate. A piston rod 11 extending downwards from the piston 8 is connected to an intermediate part of the suspension arm 4 at its lower end in a freely pivotable manner. The coil spring 7 is intended to support only the static load of the vehicle body, and may have a small spring constant. As a matter of fact, the present invention can be implemented without using the coil spring 7 at all. A stroke sensor 12 is interposed between the upper suspension member 5 and the suspension arm 4 in parallel with the hydraulic cylinder 6 and the coil spring 7. The stroke sensor 12 may consist of, for instance, a potentiometer or a differential transformer, and detects the displacement of the suspension unit 1 in either direction from its rest position.
A servo valve 13 is connected to the upper chamber 9 and the lower chamber 10 of the hydraulic cylinder 6 for each of the wheels via a conduit system 19a to control the pressure and flow rate of the hydraulic fluid supplied thereto, and is connected to an oil tank 14 serving as a common source of hydraulic fluid for all the suspension units 1 via a conduit system 19b. The servo valve 13 consists of a normal four-port solenoid valve as illustrated in FIG. 1, and its operation is controlled by a control unit 15 consisting of a computer. The oil received in the oil tank 14 is drawn by a pump 17 actuated by an engine 16, and is sent, under pressure, to the conduit system 19b including a one-way valve 18. The oil is then supplied to each of the servo valves 13 of the different suspension units 1 after its pressure is controlled to a substantially fixed level by an accumulator 20. The pump 7 may not necessarily be actuated by the engine, but may be actuated by other force means.
The control unit 15 is also connected to the load sensor 5a and the stroke sensor 12 so as to obtain data on the magnitude of the vertical load acting on each of the wheels 3 and the displacement of each of the suspension units 1. The control unit 15 is additionally connected to a steering angle sensor 21, a lateral acceleration sensor 22, and a vehicle speed sensor 23. The steering angle sensor 21 is for instance mounted on the front steering gear box, and detects the steering angle of the front wheels and supplies its output to the control unit 15. The lateral acceleration sensor 22 detects the lateral acceleration or a lateral G value acting upon the vehicle. It is also possible to use a yaw sensor instead of a lateral acceleration sensor.
The control unit 15 receives data on the turning maneuver conditions of the vehicle according to the steering angle, the lateral acceleration (or the lateral G value) and the vehicle speed detected by the respective sensors. For instance, if all these values are higher than certain threshold levels, it can be determined that the vehicle is turning either to the right or to the left. The distribution of the weight of the vehicle to the front and rear wheel sets can be determined by the mounting position of the engine and the layout of the vehicle, but is also affected by the conditions of the vehicle occupants and the cargos as well as by the deceleration and acceleration of the vehicle. Therefore, the control unit 15 determines which of the front wheel set and the rear wheel set is bearing a larger part of the vehicle weight according to the distribution of the vertical loads among the wheels as supplied from the load sensor 5a of each of the suspension units.
For instance, when the front wheels are bearing a larger part of the vehicle weight as is the case with front engine, front wheel drive vehicles, the control unit 15 determines the direction of the steering angle detected by the steering angle sensor when the lateral acceleration as determined by the vehicle speed and the steering angle or the lateral acceleration as measured by the lateral acceleration sensor is high (alternatively, the control unit 15 may detect the direction of the steering angle as well as the magnitude of the lateral acceleration directly from the output of the lateral acceleration sensor), and controls the servo valve 13 and actuates the hydraulic cylinder 6 so as to lift the inner rear wheel which is diagonally opposed to the outer front wheel and to reduce the vertical load of the inner rear wheel. In other words, in the case of a vehicle having its front wheels bearing a larger part of the vehicle weight than its rear wheels, when the vehicle is turning right the right rear wheel is lifted, and when the vehicle is turning left the left rear wheel is lifted. In this instance, it is sufficient if the vertical load of the inner rear wheel is reduced substantially to zero even when the wheel is still in contact with the road surface.
Conversely, if the rear wheels bear a larger part of the vehicle weight than the front wheels as is the case with front engine, rear wheel drive vehicles, this control process is carried out so as to lift the front inner wheel. In this way, this invention can be applied to vehicles of various types, and can even be adapted to vehicles in which the wheel set carrying a larger part of the vehicle weight changes from the front wheel set to the rear wheel sent set and from the rear wheel set to the front wheel set according to the conditions of the vehicle. If desired, this change can be detected by analyzing data from the load sensors 5a which indicate the magnitudes of the vertical loads acting on the respective wheels.
The vertical loads acting on the individual wheels and the location of the overall vertical load of the vehicle during a rest condition are now considered in the following with reference to FIG. 2 in which W denotes the weight of the vehicle, b1 and b2 denote the threads of the front wheel set and the rear wheel set, respectively, and L1 and L2 denote the distance of the front axle and the rear axle from the gravitational center G of the vehicle, respectively. If the loads acting on the front and rear wheel sets are W1 and W2, respectively, and the vertical loads acting on the individual wheels are R1, R2, R3 and R4, the following relations hold:
W1=R1+R2=WL2/(L1+L2)
W2=R3+R4=WL1/(L1+L2)
Since the vertical loads acting on the right and left wheels are normally uniform in static condition, ##EQU1##
According to the present invention, when a vehicle having a relatively large front wheel load is making a right turn, the inner or the right rear wheel located diagonally opposite to the outer or left front wheel is lifted. In other words, when the vertical load R4 of the right rear wheel is reduced to zero, the vertical load of the left rear wheel is given by
R3=W2=WL1/2(L1+L2) (2)
As a result, a shifting of load occurs between the right and left front wheels. If the amount of load shift is given by δR, the vertical loads acting on the left and right wheels after the right rear wheel is lifted are given by the following equations:
R1=WL2/2(L1+L2)+δR (3)
R2=WL1/2(L1+L2)-δR (4)
When the balance of moment around a longitudinal axial line of the vehicle passing through the point of contact A of the left front wheel with the road surface is considered as illustrated in FIG. 3,
(R1×b1)=(W×b1/2)+{R3×(b1/2-b2/2)}=0 (5)
By solving equations (2) through (5) for δR, one obtains
δR=WL1b2/2(L1+L2)b1 (6)
Hence,
R1=W(L2b1-L1b2)/2(L1+L2)b1 (7)
R2=W(L2b1-L1b2)/2(L1+L2)b1 (8)
In order to maintain a stable state of the vehicle body even after the rear right wheel is lifted, it is necessary that R2>0 or L2b1-Lib2>0. If b1=b2, it suffices if L2>L1. A shifting of load occurs between the right and left rear wheels also, but since a larger part of the overall vertical load is born by the front wheel set the vertical load acting on the outer rear wheel would not reach the nonlinear part or the saturated part of the vertical load versus cornering force curve (FIG. 4). This is particularly the case, when the vehicle is decelerating and the overall vertical load is shifted forward thereby.
When the vehicle is turning, the vertical load thereof is shifted laterally from the inner wheels to the outer wheels due to the rolling moment arising from the centrifugal force acting on the gravitational center of the vehicle. If the amount of this shift is given by δR', the vertical loads acting on the right and left front wheels during a turning maneuver are given by:
R1=WL2/2(L1+L2)+δR-δR' (9)
R2=WL1/2(L1+L2)-δR+δR' (10)
Thus, the difference in the vertical loads acting on the right and left front wheels is reduced from 2δR' to 2(δR'-δR). Thus, it amounts to the shifting of the vertical load acting on the right and left front wheels is reduced, and the sum of the cornering forces of the right and left wheels being increased. This can be readily understood by referring to FIG. 4 which shows that the increase rate of the overall cornering force diminishes as the vertical load on the outer wheel increases and reaches a substantially nonlinear (saturated) part of the load versus cornering force curve while the vertical load on the inner wheel remains in the linear part of the curve (or C F1i +C F1o >C F2i +C F2o ). Therefore, overall cornering force of the vehicle is increased, and its turning limit can be increased.
The control of the hydraulic cylinder 6 by the control unit 15 consists of an initialization process for assigning initial values to a vehicle height reference value and the static loads acting of the wheels at the vehicle height reference value, a reading process for accepting data from the sensors, and a process of carrying out a bouncing control for each of the wheels according to a predetermined spring constant and damping factor.
The control unit 15 can control each of the suspension units according to a feedback circuit such as the one given in FIG. 5. Specifically, by comparing a load F W1 received from the load sensor 5a with a predetermined static load F O1 , and a target displacement X 1 is obtained by multiplying a certain predetermined coefficient G K1 to their difference. Then, this target displacement X 1 is compared with an actual displacement X FB1 from a neutral position of the suspension unit obtained from the stroke sensor 12, and the displacement of the suspension unit 1 which is to be corrected is obtained by using this difference X pC1 as a relative deviation. The control quantity X AC1 of the servo valve 13 is determined by multiplying a certain predetermined coefficient G PC1 to the relative deviation X PC1 . The control unit 15 drives the servo valve 13 according to this obtained control quantity X AC1 . Thus, the hydraulic cylinders 6 are actuated, and the suspension units 1 are moved in vertical direction. Then, the displacement X R1 of each of the suspension units 1 is detected by the associated stroke sensor 12, and the displacement X FB1 is obtained by multiplying the predetermined coefficient G FB1 thereto so that this quantity may be fed back and compared with the target displacement X 1 . This process is repeated until the displacement of the suspension unit reaches the target displacement. This process may be carried out as a digital control process by a CPU incorporated in the control unit 15.
During such a bouncing control process consisting of a feedback control process, a control action consisting of lifting of a desired wheel is carried out according to the running condition of the vehicle or according to the magnitude of lateral acceleration.
The control unit 15 can control each of the suspension units according to a feedback circuit such as the one given in FIG. 5. Specifically, by comparing a load F W1 received from the load sensor 5a with a predetermined static load F O1 , and a target displacement X 1 is obtained by multiplying a certain predetermined coefficient G K1 to their difference. Then, this target displacement X 1 is compared with an actual displacement X FB1 from a neutral position of the suspension unit obtained from the stroke sensor 12, and the displacement of the suspension unit 1 which is to be corrected is obtained by using this difference X PC1 as a relative deviation. The control quantity X AC1 of the servo valve 13 is determined by multiplying a certain predetermined coefficient G PC1 to the relative deviation X PC1 . The control unit 15 drives the servo valve 13 according to this obtained control quantity X AC1 . Thus, the hydraulic cylinders 6 are actuated, and the suspension units 1 are moved in vertical direction. Then, the displacement X R1 of each of the suspension units 1 is detected by the associated stroke sensor 12, and the displacement X FB1 is obtained by multiplying the predetermined coefficient G FB1 thereto so that this quantity may be fed back and compared with the target displacement X 1 . This process is repeated until the displacement of the suspension unit reaches the target displacement. This process may be carried out as a digital control process by a CPU incorporated in the control unit 15.
During such a bouncing control process consisting of a feedback control process, a control action consisting of lifting of a desired wheel is carried out according to the running condition of the vehicle or according to the magnitude of lateral acceleration.
In the above described embodiment, hydraulic cylinders were used as the actuators for the suspension units, but they may be replaced by other fluid pressure cylinders such as pneumatic cylinders, and electric motors.
Thus, according to the present invention, the shifting of load from either the front or the rear inner wheel supporting a relatively larger part of the vehicle weight to the associated outer wheel during a turning maneuver can be reduced by detecting a turning maneuver of the vehicle, and lifting the inner wheel which is diagonally opposed to the outer wheel supporting a relatively larger load with the associated hydraulic cylinder so as to reduce its vertical load to zero, the turning maneuver limit can be raised, and the overall cornering force of the vehicle can be increased, with the result that the turning capability of the vehicle is improved, and the stability of the vehicle motion can be increased.
While the invention has been particularly shown and described in reference to preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the spirit and scope of the invention.
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An active suspension system and an active suspension control method for a vehicle having a first wheel set and a second wheel set, comprising a power actuator interposed between the vehicle body and each of the wheels; a sensor for detecting turning maneuver of the vehicle; and a control unit for controlling operation of the actuators according to data obtained from the sensor so as to reduce a vertical load acting on the inner wheel of the second wheel set which bears a less vertical load than the first wheel set during the turning maneuver. Thereby, the shifting of the vertical load between the wheels of the first wheel set is reduced with the result that the overall cornering force of the vehicle is maximized because of the saturating property of the maximum cornering force of the tire in relation with the vertical load acting thereon.
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BACKGROUND OF THE INVENTION
This invention relates to a breather cap for closing an unthreaded spout or filler tube.
Hydraulic reservoirs, transmission cases and the like normally have a filler tube or spout for adding oil or other liquids thereto. The filler spout is normally closed by either a vented or nonvented closure cap. In some uses, hydraulic reservoirs, transmission cases, etc. must be vented to ambient to prevent buildup of pressure or the formation of a vacuum therein due to, for example, expansion and contraction of the liquid in response to temperature changes of the liquid, or due to an increase or decrease in the volume of liquid in response to retraction and/or extension of a hydraulic jack. Thus, when a nonvented cap is used, a separate breather must be provided thereby increasing the manufacturing cost, and in some cases the breathers are prone to permit excessive leakage of the liquid. Although the vent caps heretofore available are less prone to leakage, they have required additional machining steps such as threads on both the filler tube and closure cap.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming one or more of the problems as set forth above.
According to the present invention, a breather cap has first and second plates positioned at opposite ends of a resilient cylindrical element. A means is provided for selectively moving the plates toward one another and radially expanding the resilient element. A first means passes air through the breather cap and a second means filters the air passing through the first means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic sectional view through a breather cap of the present invention; and
FIG. 2 is a sectional view taken along line II--II of FIG. 1.
DETAILED DESCRIPTION
Referring now to the drawing, a breather cap is generally indicated by the reference numeral 10, and is shown connected to a filler tube 11. The cap includes first and second plates 12,13 positioned at opposite ends of a resilient cylindrical element 14 and a means 16 for selectively moving the plates toward one another and radially expanding the resilient element into sealing engagement with the inside of the filler tube 11. The resilient element has a central bore 17 extending axially therethrough and an annular flange 18 extending radially outwardly at one end thereof. The resilient element can be constructed from any suitable elastomer such as rubber.
The means 16 can be, for example, a threaded actuator 19 which has an elongated shank 21 extending through a central opening in the first plate and a threaded portion 22 extending through a threaded central bore 23 in the second plate. Thus, rotating a handle 24 of the actuator 19 in one direction causes the threaded portion to rotate in the threaded bore, thereby moving the plates toward one another. This causes the resilient element 14 to bulge or expand radially outwardly into sealing engagement with the inner surface of the filler tube 11. Preferably the length of the threaded portion 22 is selected to limit compression of the resilient element.
The first plate 12 has an annular lip 26 extending longitudinally toward the second plate 13 and encircles the flange 18. The lip is spaced a predetermined distance from the flange 18 thereby forming an annular opening 27.
The above described basic elements are all well known in the art.
A first means 28 passes air through the breather cap 10 between the inside of the filler tube 11 and ambient. The first means can be, for example, the bore 17, a pair of orifices 29 extending through the second plate communicating the inside of the filler tube with the bore 17, and vent means 31 positioned between the first plate 12 and the flange 18 of the resilient element 14 for communicating the bore with ambient.
The vent means 31 can be, for example, a disc 32 positioned between first plate 12 and flange 18 of resilient element 14, a central opening 33 in the disc in communication with bore 17, and a plurality of grooves 34 in the disc facing the first plate and connecting the central opening 33 with ambient through the annular opening 27. The grooves 34 are formed as indented portions 36 in the disc with the indented portions being imbedded within the flange 18 of the resilient elements.
A second means, for example, a filter material 37 such as an open cell urethane positioned within the bore 17, filters the air passing through the first means 16.
In use, air passing from ambient into the filler tube 11 passes through the annular opening 27, grooves 34, central opening 33, bore 17, filter material 37, and orifices 29. The filter material filters foreign material from the air to prevent contamination of the liquid within the tank to which the filler tube is connected. Air can also pass from the interior of the filler tube to ambient in the reverse direction. Since normally the only liquid coming in contact with the breather cap 10 is that caused by sloshing of the liquid in the tank, the orifices and filter material prevent the liquid from passing through the breather cap.
In view of the foregoing, it is readily apparent that the structure of the present invention provides an improved breather cap for closing a filler tube to retain a liquid within a tank while permitting the ingress and egress of air into the tank in response to changes in the volume of liquid within the tank. The breather cap can be sealingly connected to an unthreaded filler tube and not require any special machining on the filler tube for sealing thereagainst.
Other aspects, objects, and advantages of this invention can be obtained from a study of the drawings, the disclosure and the appended claims.
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A breather cap has a resilient element which is expanded radially by the movement of first and second plates toward one another. Air can pass through the breather cap and is filtered by a filter device provided in the breather cap.
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BACKGROUND OF THE INVENTION
Various industrial processes often require that a mass of porous material to washed in order to remove chemicals or other impurities. For example, this need appears in the sugar industry, where sugar is washed from bagasse; in the textile industry, where excess dyes are washed from the fabric; in mining, where impurities are washed from ore; and in the paper industry, as follows.
In a standard paper production line, wood chips are cooked with chemicals in aqueous solution, the precise composition of the cooking chemicals depending on the particular process. This step, normally carried out in a digester under heat and pressure, breaks down the wood by dissolving the organic compounds that hold the cellulose fibers together.
The mixture of pulp, spent cooking chemicals, and organic materials, collectively known as stock, is then fed to a series of washers. The most common type of washer system includes a rotary vacuum drum onto which the stock is spread. The drum is perforated, and a vacuum maintained inside causes the separation of liquid from the pulp. The mixture assumes the form of a pulp mat which is still impregnated with chemicals and organics. A washer usually disposed above, and extending axially along the drum directs water at and through the pulp mat to remove these substances. A typical installation would use three washer drums in sequence, with wash water being flowed counter-current to the direction of the pulp movement so that the final washing stage uses clean water. An additional washing stage to remove bleaching chemicals is required if the washed pulp is subsequently bleached.
The effluent from the washers, comprising water, spent cooking chemicals, and organic materials is referred to as liquor. In a kraft (or sulfate) process, it is called black liquor; in a sulfite process, red liquor. Typical liquor contains approximately 15% solid material. It is desirable to separate this solid material from the water to allow reuse of the inorganic pulping chemicals, and to eliminate the environmental problem of disposing of the liquor.
Evaporation is the standard separation method, with the liquor being passed through a series of evaporators, in which steam is passed countercurrent to the liquor flow. In this way, the liquor is concentrated until it contains approximately 60% solids, at which point it is burnt in a boiler. The organic materials provide the fuel value to generate the steam, and the inorganic chemicals smelt out the bottom of the boiler. In atypical paper mill, the steam from the liquor recovery part of the cycle supplies most of the mill's steam needs.
It is apparent that the more dilute the liquor, the more energy must be expended in evaporating the water in order to recover the solids. This is energy that is therefore unavailable for other energy needs of the paper mill. At the same time, it is necessary to efficiently remove the chemicals from the pulp to provide a satisfactorily clean pulp. A thorough washing militates toward the formation of dilute liquors.
Two standard types of paper pulp mat washers are the weir and the whistle shower. In the former, the water stored in a reservoir above the rotary vacuum drum on which the pulp mat is disposed is allowed to overflow a weir that extends axially along the entire length of the drum. Thus, in principle, a sheet of water falls along the entire width of the pulp mat. A difficulty with this type of a shower, is that the weir shower, a relatively long piece of equipment supported at its ends, has a tendency to sag, and is further prone to misalignment. In such cases, more water overflows the weir at its lowest portions than elsewhere, thereby washing some portions of the pulp mat less effectively than others. In a whistle shower, nozzles disposed above and axially along the pulp mat direct water at the mat. A difficulty with this type of washer is that the nozzles can easily become plugged, resulting in incomplete washing of the pulp mat. Satisfactory washing with weir or whistle showers typically requires three showers arranged in a parallel configuration above the drum.
Thus, there is a need for a washer having a high efficiency and not subject to problems that result in only a portion of the pulp mat's being washed.
SUMMARY OF THE INVENTION
The present invention is an improved washer for removing chemicals from a porous mat disposed over a vacuum rotary drum. The improved washer reliably washes substantially the entire width of the mat, and is able to accomplish washing equivalent to prior art washers with a smaller amount of water, and often with a smaller number of showers.
Broadly, the invention comprises an elongate chamber disposed axially above the drum. The chamber has a slot along its bottom with resilient downwardly extending skirts disposed around the edges of the slot. The water between the skirts and adjacent the mat is at an elevated pressure due at least in part to the static head of the water in the chamber. This pressure, in combination with the vacuum within the drum causes the water to flow into and through the pulp mat. The resilient skirts prevent the wash water from flowing outwardly (i.e., tangentially with respect to the mat) so that the flow of water into the mat is essentially perpendicular to the mat. In this fashion, the chemicals within the mat are positively displaced by the relatively clean wash water, resulting in improved efficiency.
According to one aspect of the invention, horizontal and vertical dispersion plates within the chamber provide an even flow of water under pressure so that the entire mat is washed with the same efficiency.
Adjustable jacks at both ends of the washer allow the height of the washer above the drum to be varied in order to accommodate pulp mats of different thicknesses. The washer height is set such that the flexible skirts graze the surface of the mat, thereby sealing the water to the rotating mat while allowing for variations in mat thickness.
The height of the water in the chamber above the drum represents potential energy for directing water through the mat. While conventional showers dissipate part of this energy by splashing the water against the mat, the present confines the water adjacent the mat so that the static pressure head is effectively used.
The improved penetration of the water into and through the mat, with a resultant positive displacement of the chemicals or other materials to be removed, results in a more effective washing for a given amount of water, or equivalently, a smaller water requirement for a given wash effectiveness. The water saving translates into an energy saving at the liquor recovery step.
The internal dispersion plates provide a generally uniform water pressure along a line transverse to the movement of the mat, and the resilient skirts seal the pressurized water to the mat in spite of variations in the mat thickness.
This manner of deploying the wash water ensures that the entire lateral dimension of the mat is washed. This often makes it possible to get reliable washing with fewer washers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall perspective view of a washer disposed above a paper pulp mat on a vacuum drum, partially cut away to show the internal components.
FIG. 2 is a schematic view showing a typical disposition of two washers on a drum.
FIG. 3 is a sectional view showing the skirt attachment to the washer.
FIG. 4 is a schematic section showing the operation of the washer.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Broadly, the present invention washes chemicals or other substances out of a porous mat by directing a pressurized column of water perpendicularly through the mat. The mat is typically disposed on a vacuum head, such as a rotary vacuum drum.
FIG. 1 shows a single axially extending washer 10 positioned above a paper pulp mat 12 which is formed on rotary vacuum drum 15. It should be understood that the washer need not be vertical, but may be tilted (see for example FIG. 2 which shows a typical disposition of washers with respect to the rotary vacuum drum.) For convenience, however, the components will be referred to as if the washer is vertically oriented as shown in FIG. 1.
In order to clearly set forth the features and operation of the present invention, a brief summary of the operation of rotary vacuum drum 15 is useful. This is best done with reference to FIG. 2. Rotary drum 15 is mounted for rotation about a horizontal axis in the direction of arrow 16. Stock comprising pulp, spent cooking chemicals and water is continuously fed from a digestor into a vat where it forms a pool 18 in which drum 15 is partially submersed. Drum 15 has a perforated outer shell and a source of vacuum inside that is communicated to the outside through the perforations. Therefore, as drum 15 rotates, pulp mat 12 forms on the outside of the drum and liquid is withdrawn by the vacuum.
At a position generally near the top of the drum, the mat passes under one or more washers whose purpose is to remove chemical impurities. If weir or whistle showers were used, three would be required, but with the present invention, proper washing can often be achieved with two washers per rotary vacuum drum. A typical alignment would have washers 20 and 21 situated above drum 15 at approximately 35° and 10° before top dead center, indicated by dashed lines 22 and 23 respectively.At a point approximately 70° beyond top dead center, indicated by dashed line 24, the vacuum is released and the pulp mat separated from the rotating drum. The separation is effected by a doctor blade 25 or the like, which may be a mechanical device or may comprises a linear array of nozzles for directing pressurized air or steam upwardly underneath the mat. The washed mat is then sent to subsequent washing stages with similar vacuum drum/washer configurations.
Having thus set forth the relation between the individual washers and the rotary vacuum drum, the particular configuration of a washer can be discussed. Referring to FIGS. 1 and 3, washer 10 comprises an elongate chamber defined by axially extending side walls 26 and 27, end walls 28 and 29, top 30, and sloping bottom panels 32 and 35. Downwardly sloping panels 32 and 35 are angled toward one another, but terminate before they meet, thereby defining an elongate slot 38 extending axially along the bottom of the chamber. Sloping panels 32 and 35 are provided with respective downwardly extending flanges 42 and 45 along their lengths. Resilient skirts 47 and 50 are affixed to flanges 42 and 45 along their respective lengths, and extend downwardly to contact the pulp mat along its axial dimension. Resilient end flaps 52 and 55 extend the width of slot 38, and together with skirts 47 and 50, provide a continuous sealing structure about the entire perimeter of slot 38. Skirts 47 and 50 may be attached to their respective flanges in any convenient manner. FIGS. 1 and 3 show a mounting using bolts. Thus, skirt 50 is attached to flange 45 by a plurality of bolts 56 and wingnuts 57. Perforated rigid strip 58 between wingnuts 57 and skirt 50 provides a relatively uniform fastening.
End wall 28 is fitted with mounting bracket 60 which engages screw jack 65. Jack 65 is affixed to support bracket 70 mounted to the fixed structure supporting rotary vacuum drum 15. A similar arrangement including jack 75 at the other end allows the height of washer 10 above pulp mat 12 to be adjusted so that resilient skirts 47 and 50 just touch pulp mat 12 along its entire axial dimension.
Disposed within the chamber of washer 10 are vertical dispersion plates 80 and 82, and horizontal dispersion plate 85. Vertical plates 80 and 82 are perpendicular to the axial dimension of the washer, and each extends horizoontally from side wall 26 to side wall 27. Plates 80 and 82 each extends vertically from sloping bottom portions 32 and 35 to a height part way up side walls 26 and 27. Each of plates 80 and 82 has a downwardly opening V-shaped notch into which is seated a downwardly facing V-shaped channel member 87. The V-shaped notches and V-shaped channel are sized so that the axially extending edges 89 and 90 of V-shaped channel 87 do not touch either sloping bottom portions 32 and 35 or flanges 42 and 45, but rather leave a small clearance, typically 1/4", for water flow as will be described below. Each of plates 80 and 82 is provided with a plurality of apertures, plate 80 having apertures 94 and plate 82 having apertures 96. These apertures are sufficiently large that they do not become plugged by fibers entrained in the wash water.
Horizontal dispersion plate 85 extends from side wall 26 to side wall 27, and from end wall 28 to end wall 29. Plate 85 has an axially extending central depression, thereby defining lower horizontal portion 100, paired upper horizontal portions 102 and 105, and vertical portions 107 and 110. Upper horizontal portions 102 and 105 are spaced horizontally by lower horizontal portion 100, and are spaced from lower portion 100 by vertical portions 107 and 110. The location of plate 85 and the depth of its central depression is such that horizontal lower portion 100 is slightly above the top edge of vertical dispersion plates 80 and 82. Each of vertical portions 107 and 110 is provided with a plurality of apertures, portion 107 having apertures 112, and portion 110 having apertures 115. Conduit 120 pierces cover 30, typically near one end thereof to provide fluid communication with the interior the chamber of washer 10.
FIG. 4 is a schematic showing the operation of the washer. Washer 10 is disposed above pulp mat 12 on rotary vacuum drum 15. Water entering the internal chamber of washer 10 through conduit 120 flows into the depression of horizontal dispersion plate 85, flows through apertures 112 and 115, past V-shaped channel 87, and into the region between skirts 47 and 50, thus contacting the outer surface of pulp mat 12. The water in contact with the mat is at a pressure above atmospheric due to the static pressure head resulting from the height of washer 10 above mat 12. Additional pressure may be achieved by ensuring that cover 30 is sealed to the walls, and introducing the water into the chamber under pressure. This is not typically done, so that the water pressure adjacent the mat normally arises from the static head alone. In such cases, water is generally maintained in washer 10 at a level somewhere around that of plate 85.
The water in contact with the pulp mat is at a higher pressure than the pressure on the inside of the rotary vacuum drum. This is partially due to the vacuum maintained within the drum, and partly due to the elevated pressure of the water between the skirts. The skirts 47 and 50 prevent movement of this water tangentially with respect to the mat. Since the mat is porous, the pressure differential causes the water to flow perpendicularly through the mat to the interior of the drum. As the water between the skirts flows through the mat, water above it in the chamber replaces it. The flow of water into the mat positively displaces water and chemicals within the mat, thereby effecting a cleaning.
The location of the washers (e.g. 35° and 10° before top dead center as described above) is chosen to allow most of the liquid in the mat to be withdrawn by the vacuum before the mat passes under the washers. That is, the mat approaches the first washer in a relatively dry state. The relative location of the washers is also chosen to allow withdrawal of most of the liquid injected by one washer before injection of liquid by a subsequent washer. In this way, the wash water is used most effectively.
The washer components with the exception of the skirts and end flaps are preferably made of stainless steel to resist the effect of the chemicals. This is usually important, since a typical installation uses wash water several times before it is sent to the liquor recovery step. Thus, only the last washer in the sequence would be using clean water, the earlier washers using water that has a considerable amount of chemicals in it. The skirts are preferably made of a resilient material to accommodate irregularities in the mat. At the same time, they must be rigid enough to prevent tangential flow of the water between the skirts which is at an elevated pressure. The material must also be resistant to chemical attack. Neoprene rubber is preferred.
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An improved washer for removing impurities or other substances from a porous mat disposed over a vacuum head. As disclosed, in connection with an industrial paper making process, the porous mat is paper pulp and an elongate chamber, disposed axially above the drum, has a slot along its bottom with resilient downwardly extending skirts disposed around the edges of the slot. Water under pressure in the chamber is directed downward, and into the pulp mat. The resilient skirts prevent the wash water from flowing tangentially with respect to the mat so that the flow of water into the mat is essentially perpendicular to the mat. The chemicals within the mat are positively displaced by relatively clean wash water.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 35 U.S.C. §371 National Stage entry of PCT/DE2006/001427, filed Aug. 14, 2006, which claims priority from German Patent Application No. DE 10 2005 038 617.2, filed Aug. 16, 2005, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an anti-trap device in the field of motor vehicles for preventing trapping of an object.
2. Description of Related Art
Although applicable to any desired movable components, the present invention and the problem on which it is based are explained in more detail on the basis of a body part in the field of motor vehicles, and in particular with regard to a rear flap of a vehicle.
SUMMARY OF THE INVENTION
In order to improve the operating comfort of motor vehicles and in particular of passenger vehicles, an increasingly large number of manually-driven components have in past years been replaced by motor-driven components, such as for example door windows or sliding roofs, which in the past were opened and closed by means of a hand crank and are now generally provided with a closing and opening mechanism which is driven by an electric motor.
Corresponding development has also commenced for closing or locking mechanisms of front and rear flaps, specifically both for flaps which close off an access to a passenger space or luggage space and also for flaps which, in the form of an engine hood, close off an access to an engine bay. In connection with front or rear flaps, it is possible for electric or hydraulic drives to be used both for pivoting the flap during a closing movement and also for locking the flap. Here, it is for example possible for the rear flap to be coupled by means of an actuating element to an electric or hydraulic motor of a closing mechanism which pivots the rear flap from an open position, in which it opens the opening, into a closed position, in which it closes off the opening. The operation of the motor of the closing and opening mechanism can for example take place from the passenger space or by means of remote control.
With said approach, however, it has proven to be disadvantageous that, during a closing movement for example of the rear flap by means of remote control or from the passenger space, the flap and in particular its free edge is usually not directly visible. In the case of such an automatic closure of the rear flap, it is therefore possible for injury to occur in the case of objects, and in particular of body parts of a person or animal, becoming trapped.
It is known to the applicant, for safety reasons, to provide automatically movable covers and flaps in a vehicle with a stop function in order to stop the component movement in the event of an exceedance of a limit load acting on the cover or on the flap, for example in the event of the rear flap abutting against an obstruction, for example a human hand or a trapped finger.
It is for example known to the applicant to use a tactile sensor strip as a direct anti-trap device, which tactile sensor strip is attached directly to the trapping edges of the rear flap. German laid-open specification DE 432 29 535 A1 describes using a hollow profile as a tactile sensor strip, which hollow profile provides two opposite conductive regions, a conductive base region and a conductive arched profiled region. The two regions are separated by means of insulating profiled sections. Under a corresponding pressure, for example as a result of a trapped hand, the hollow profile is compressed, and the two conductive regions come into contact and trigger an electrical contact and a switching process which stops the drive mechanism. A measurement of the pressure difference as a result of deformation of the sensor strip on account of contact against the trapped object is also conceivable.
With said approach, however, it has proven to be disadvantageous that a sensor strip attached directly to the trapping edges of the rear flap outputs a signal to a controller in order to stop the drive mechanism only in the event of trapping occurring, wherein it is possible, even in the event of correct detection, for the forces acting on the for example trapped hand until the drive mechanism is stopped to already be high enough to pose a considerable risk of injury.
It is also known to the applicant to provide an indirect anti-trap device which detects trapping on the basis of the motor rotational speed or current profile of the drive mechanism. For example, in the case of an electric motor being used as a drive mechanism, the power consumption is continuously measured and the motor is switched off if the power consumption exceeds a predetermined threshold value when an obstruction is impinged upon.
With said approach, however, it has proven to be disadvantageous that such protective measures are not suitable for a closing mechanism, for example of a rear flap of a motor vehicle, since the forces required for locking a rotary lock with a closing bar and their tolerances are relatively large, so that for example an additional resistance as a result of a trapped finger would not be measurable. As before, there is therefore a considerable risk of injury with said approach too.
It is therefore possible in the case of automatically moved body parts, such as for example in the case of rear flaps which are rotated by means of a hinge or a four-bar mechanism, for very large trapping forces to occur close to the center of rotation, so that a use of such indirect anti-trap devices is not suitable for preventing injuries.
It is therefore the object of the present invention to design an anti-trap device in such a way that, even in the case of automatically moved body parts, a reliable anti-trap function is ensured and the risk of injury is reduced.
SUMMARY OF THE INVENTION
The concept on which the present invention is based is that of the anti-trap device for preventing trapping of an object having an actuating means which can be coupled to a body part of a vehicle and, as a result of contact against the object, is movable relative to the body part; and a detection device for detecting a relative movement between the actuating means and the body part.
The actuating means therefore serves to create an indirect anti-trap device which, on account of the leading relative movement of the actuating means with respect to the associated body part, signals a trapped object already when high trapping forces are not yet acting on the trapped object. As a result, injuries to a for example trapped finger or a trapped hand can be prevented in a simple and cost-effective manner.
According to one preferred refinement, the anti-trap device has a fastening strip which can be fixedly attached to the body part of the vehicle and to which the actuating means is articulatedly connected so as to be pivotable about a rotary axle. As a result, in the event of contact against a trapped object, a relative movement takes place between the actuating means and the fastening strip or the body part to which the fastening strip is fixedly attached. The additional fastening strip ensures simple retrofitting to for example existing body parts, and therefore complex and expensive retrofitting processes are dispensed with. It is however obvious to a person skilled in the art that it is likewise possible for the actuating means to be directly mounted on the body part. In this case, the fastening strip can under some circumstances be dispensed with.
According to a further preferred refinement, the fastening strip has the rotary axle about which the actuating means is rotatably mounted and a guide means, which is spaced apart from the rotary axle, for the mounting and pivoting guidance of the actuating means. The guide means is for example embodied as a guide bolt which can be mounted on the fastening strip and which engages into a slot which is provided in the actuating means and which is aligned in the direction of the pivoting movement. The actuating means is therefore mounted in a stable fashion and so as to be pivotable about the rotary axle as a result of pivoting mounting by means of the rotary axle and as a result of guiding mounting by means of the slot.
According to a further preferred exemplary embodiment, the rotary axle is assigned to that region of the body part on which low trapping forces act, and the guide means is assigned to that region of the body part on which relatively large trapping forces act. This ensures that in particular a relative movement between the actuating means and the fastening strip or the body part is generated and detected in the region in which there is the greatest risk of injury in the event of for example a finger becoming trapped.
The actuating means can preferably be preloaded with respect to the fastening strip, or with respect to the body part in the case of the actuating means being directly mounted on the body part, by means of a spring device. This ensures that, in the event of a relative movement of the actuating means as a result of contact against an object, when the object is removed, the actuating means is returned to the initial position.
According to a further preferred refinement, the actuating means is embodied as a leader strip which is pivotable relative to the body part or the fastening strip about a rotary axle. Said leading leader strip preferably undergoes a relative movement with respect to the body part already before relatively large trapping forces can act on the trapped object.
In each case one leader strip is for example pivotably attached by means of in each case one associated fastening strip or directly in the region of the longitudinal side of a rear flap of a vehicle. In this way, a risk of injury on account of, for example, a trapped body part is reduced at both longitudinal sides of a rear flap during a closing movement of the latter.
According to a further preferred exemplary embodiment, the detection device is embodied as an electric mechanical or electromechanical inductive switch or the like, for example as a microswitch or proximity switch, which can be attached to the body part, to the actuating means and/or to the fastening strip. The detection device can for example be embodied as a switch of which the guide means, advantageously a steel guide bolt, forms a constituent part, for example the mating contact face of a microswitch or a constituent part of a Hall sensor. In this way, a relative movement between the actuating means and the fastening strip or the body part is detected quickly and reliably in a simple and cost-effective manner, so that the drive mechanism for an adjustment of the body part can quickly and reliably be deactivated in order to stop the movement of the body part.
It is alternatively or additionally possible for the detection device to be embodied as a tactile sensor strip as well which can be attached to the face, which comes into contact with the object, of the actuating means. In this way, the drive mechanism can be deactivated in good time in order to stop the movement of the body part in the event of the clamped object coming into contact with the sensor strip.
In addition, the detection device can additionally or alternatively also be embodied as a sensor which can be attached to a mating contact section, which is assigned to the body part. It is essential merely that a relative movement between the actuating means and the fastening strip or the body part can be quickly and reliably detected.
For example, when a relative movement between the actuating means and the body part or the fastening strip is detected, the drive mechanism of the body part can be deactivated in the case of an automatically actuable body part, and a warning signal, for example an audible warning signal, can be generated in the case of a manually actuable body part. The risk of injury is therefore considerably reduced in a simple and cost-effective manner.
The actuating means and/or the fastening strip are preferably produced from plastic. In this way, the anti-trap device according to the invention can be produced in a simple and cost-effective manner and can be mounted on and retrofitted to a body part using corresponding means.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail below on the basis of exemplary embodiments with reference to the appended figures of the drawing, in which:
FIG. 1 shows a perspective front view of an anti-trap device according to a preferred exemplary embodiment of the present invention;
FIG. 2 shows a perspective rear view of the anti-trap device from FIG. 1 ; and
FIG. 3 shows a perspective view of the anti-trap device from FIGS. 1 and 2 mounted on a longitudinal side of a rear flap.
In the figures of the drawing, the same reference symbols denote identical or functionally identical components unless specified otherwise.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 illustrate a perspective front view or rear view of an anti-trap device according to the invention as per one preferred exemplary embodiment of the present invention, not assembled on a body part.
As can be seen from FIGS. 1 and 2 , the anti-trap device as per the exemplary embodiment illustrated in the figures has a leading leader strip 1 which extends in the longitudinal direction and which serves as an actuating means. The leader strip 1 is preferably produced from a suitable plastic and is composed for example of a planar, elongate front face 15 and a suitably profiled lower face 12 which is angled with respect to said front face 15 for example by an angle of approximately 90°. The leader strip 1 also has an articulation section 10 on the front face 15 with a through hole for receiving a rotary axle 20 , as is explained in more detail further below.
In addition, the leader strip 1 in the front face 15 comprises a slot 11 which is spaced apart from the articulation section 10 and is advantageously arranged in the region of that end of the elongate front face 15 of the leader strip 1 which is situated opposite from the articulation section 10 . The slot 11 serves to hold a guide bolt as described in more detail further below.
As illustrated in FIG. 2 , a spring holding pin 14 is integrally formed approximately centrally on the upper side of the angled face 12 , onto which a spring 13 with a predetermined preload force is plugged in a positionally stable fashion.
The exemplary anti-trap device illustrated also has a fastening strip 2 which is embodied as a profiled carrier arm which preferably extends in the longitudinal direction. The fastening strip 2 as per the present exemplary embodiment is composed, as per FIG. 2 , of an upper section 24 which is preferably aligned perpendicular to the front face 15 and approximately parallel to the angled face 12 of the leader strip. Integrally formed on the upper section 24 of the fastening strip 2 are for example a plurality of perpendicularly, downwardly angled sections 25 , 26 , with the angled section 25 being arranged in the region of the section which comprises the rotary axle 20 and serving to hold the rotary axle 20 and to guide the spring 13 , and with the angled section 26 being provided in a region, which is assigned to the slot 11 , of the fastening strip 2 and serving as a mount for the guide bolt 21 . The guide bolt 21 is for example screwed by means of a screw nut in a through hole in the angled section 26 of the fastening strip 2 , as illustrated in FIG. 2 . The fastening strip 2 is preferably likewise produced from a suitable plastic.
The fastening strip 2 serves for fastening to an associated body part and for pivotably movably mounting the leader strip 1 . For fastening the fastening strip 2 to an associated body part, the fastening strip 2 has, at suitable sections, fastening holes 23 for receiving fastening screws.
Held in the region of the one end of the fastening strip 2 is the rotary axle 20 already mentioned above, on which the leader strip 1 is mounted in a pivotably movable fashion. In the region of the opposite end of the fastening strip 2 , the guide bolt 21 which is likewise already mentioned above is attached so as to extend in the transverse direction in such a way that the bolt shank can be inserted through the slot of the leader strip 1 and the bolt head engages behind the slot 11 .
As a result of the mounting of the leader strip 1 on the rotary axle 20 of the fastening strip 2 and on the guide bolt 21 of the fastening strip 2 , the leader strip 1 is pivotably guided by means of the bolt 21 which is guided in the slot 11 , and the leader strip 1 is therefore attached to the fastening strip 2 in a stable fashion and so as to be pivotable about the rotary axle 20 .
For a preload of the leader strip 1 with respect to the fastening strip 2 , the spring 13 which is plugged onto the spring holding pin 14 is supported on an associated spring contact section 22 of the fastening strip 2 . The spring contact section 22 can for example be formed by an additionally angled and horizontally-running section of the fastening strip 2 which is provided above the spring for contact against the latter. Alternatively, the spring contact section 22 can be formed by the lower face of the upper section 24 .
FIG. 3 illustrates a perspective view of the anti-trap device, explained with reference to FIGS. 1 and 2 , as per one preferred exemplary embodiment of the present invention, mounted on a rear flap 3 of a vehicle.
As can be seen in FIG. 3 , the fastening strip 2 is preferably fixedly mounted on a longitudinal side 30 of the rear flap 3 , by means of the fastening holes 23 and suitable screw means, in such a way that the fastening strip 2 and the leader strip 1 extend in the longitudinal direction of the longitudinal side 30 of the rear flap 3 .
Although FIG. 3 illustrates an attachment of an anti-trap device only to the left-hand longitudinal side of the rear flap 3 , it is self-evident to a person skilled in the art that anti-trap devices of said type are advantageously attached to both longitudinal sides of the rear flap 3 in order to prevent injuries at both sides.
The exemplary anti-trap device is preferably mounted on the associated body part or on the associated longitudinal side 30 of the rear flap 3 in such a way that the rotary axle 20 is assigned to the region of relatively low trapping forces 31 , for example to the region slightly below the rear window 33 , and that end of the fastening strip 2 or leader strip 1 which is situated opposite from the rotary axle 20 is assigned to the region of relatively high trapping forces 32 , for example the region at the level of the upper edge of the rear window 33 . In this way, it is ensured that, in particular in the region of relatively high trapping forces 32 , a relative movement of the leader strip 1 with respect to the fastening strip 2 or the longitudinal side 30 of the rear flap 3 takes place in the event of an object becoming trapped.
The anti-trap device also preferably has at least one detection device for detecting a relative movement between the leader strip 1 and the fastening strip 2 , with a signal being output in the event of a detected relative movement. For example, in the case of an automatically actuable rear flap 3 , when a relative movement is detected, a signal is generated which deactivates the drive mechanism for closing the rear flap 3 or initiates an opening movement of the rear flap 3 in the opposite direction. In this way, the closing movement is not continued, and trapping of an object, in particular of a body part, is prevented, so that injuries can be prevented.
In the case of a manually actuable rear flap, it is for example possible for an audible warning signal to be generated, so that the user who is closing the rear flap 3 is advised by the warning signal of the risk of an object becoming trapped. Injuries can advantageously be avoided in this case too.
The detection device for detecting a relative movement between the leader strip 1 and the fastening strip 2 , or between the leader strip 1 and the body part in the case of the leader strip 1 being directly mounted on the body part 3 , can be embodied as any type of sensor or switch which is suitable for detecting a relative movement of two components with respect to one another. As an electric detection device, use is preferably made of a proximity switch such as for example a Hall sensor or the like, or as an electromechanical detection device, use is preferably made of a microswitch, which detection devices are for example attached to the fastening strip 2 or to the rear flap 3 in such a way that they can detect a relative movement of the leader strip 1 .
It is for example possible for the guide bolt 21 to be formed from steel or the like and to form a constituent part of the switch or sensor, for example the mating contact face of a microswitch, or a constituent part of a Hall sensor. Alternatively, it is also possible for a switching cam or the like, which is correspondingly assigned to the switch, to be provided on the leader strip 1 .
The detection device can also be embodied as a tactile sensor strip which is attached to the underside of the leader strip 1 . In this way, in the event of the tactile sensor strip coming into contact against the object, a signal is generated, while the leader strip 1 performs a leading pivoting movement relative to the fastening strip 2 or the body part 3 without it being possible for excessively high trapping forces to act on the trapped object.
It is also possible for a sensor to alternatively or additionally be attached to a mating contact section 40 of the vehicle body 4 , which mating contact section 40 detects a relative movement of the leader strip 1 with respect to the fastening strip 2 or the body part 3 and generates a corresponding signal for deactivating the drive mechanism or an audible signal.
Although the present invention has been described above on the basis of preferred exemplary embodiments, the present invention is not restricted to these but can be modified in numerous ways.
It is obvious to a person skilled in the art that any type of detection devices can be used for detecting a relative movement between the fastening strip and the leader strip, for example electrical, electromechanical, mechanical, inductive switches or the like as long as the relative movement can be detected reliably and with a low delay time. Here, the switches or sensors can be attached at suitable sections to the leader strip, to the fastening strip, to the movable body part or to the vehicle body.
Although the present invention has been described on the basis of a rear flap of a vehicle, the anti-trap device according to the invention can be applied to any body parts which are movable relative to a body section of the vehicle. Examples of these are the motor vehicle doors, the engine hood, a sliding roof or a roof which can be folded open and closed, for example a hard top or soft top, of a cabriolet.
It is also obvious to a person skilled in the art that it is likewise possible for the actuating means to be directly mounted on the body part. In this case, the fastening strip can under some circumstances be dispensed with.
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The invention relates to an anti-jamming device in the field of motor vehicles, which is used for preventing an object from getting caught. Said anti-jamming device comprises an actuating means ( 1 ) which can be coupled to a body part ( 3 ) of a vehicle and can be moved relative to said body part ( 3 ) by resting the same against the object, and an apparatus for detecting a relative movement between the actuating means ( 1 ) and the body part ( 3 ).
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BACKGROUND OF THE INVENTION
[0001] This invention relates to the installation of a railway sleeper particularly at a railway line turnout or crossing.
[0002] At a turnout single railway lines are split into two. At a crossing a facility is provided whereby two lines cross each other. Due to the varying effective width over which the railway lines extend a need exists for railway sleepers of variable lengths.
[0003] In a new turnout or crossing it is possible to prefabricate sleepers to the appropriate lengths. At an existing turnout which is to be refurbished it is necessary to fabricate sleepers to replace existing sleepers taking into account the geometrical requirements of the existing installation.
[0004] Concrete sleepers are in widespread use in new installations and in refurbishing existing installations. As concrete sleepers are manufactured using moulds of precise dimensions under factory conditions it is not always economically feasible to cast a concrete sleeper, using customary techniques, to produce a product which can be substituted for an existing sleeper in an installed location.
SUMMARY OF INVENTION
[0005] The invention provides a method of installing a railway sleeper which include the steps of marking an elongate cast cementitious member at a plurality of locations, forming a plurality of holes through the member, each hole being at a respective location, placing at least a first element of a respective fastener in each respective hole, positioning the member below a railway line and engaging a second element of the respective fastener, with the first element, thereby to secure the railway line to the member.
[0006] The member may be marked at the plurality of locations by placing the member in a position, below the railway line, at which the member is to be secured to the railway line.
[0007] The positions of the holes, which are formed in the member, may be determined by reference to holes in at least one base plate to which the railway line is attached. By using the method of the invention the base plate is attached to the sleeper and the railway line, which is secured to the base plate, is thereby attached to the sleeper.
[0008] The holes in the member may be formed by drilling the member in situ.
[0009] Each hole may be drilled from what in use is an upper side of the member to what in use is a lower side of the member.
[0010] The first element may vary according to requirement but typically is a nut. The nut may be engaged with the member so that it does not protrude from a lower surface of the member. The nut may be fixed to the member in any appropriate way and for example may be adhesively secured to the member or grouted in position. Alternatively the nut may be mounted in a insulating holder such as a plastics sleeve or cup or the like which is frictionally or adhesively secured to the member.
[0011] In a variation of the invention the first element of a fastener is inserted into a respective hole in the cementitious member, from a lower side and a second element is inserted into the hole, from an upper side and then engaged, preferably threadedly, with the first element.
[0012] The first element may be a nut, with a head which bears on a surface of the lower side, and the second element may be an elongate bolt. An insulating sleeve or spacer may be used to prevent direct metal-to-metal contact between the fastener and a base plate to which the railway line is attached.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention is further described by way of examples with reference to the accompanying drawings in which:
[0014] FIG. 1 schematically illustrates a turnout in which a plurality of sleepers according to the invention can be used;
[0015] FIG. 2 is a plan view of a timber railway sleeper used in the turnout of FIG. 1 which is to be replaced using the method of the invention;
[0016] FIG. 3 is a plan view of a precast concrete sleeper;
[0017] FIG. 4 shows a fastener for use in the invention;
[0018] FIG. 5 illustrates the use of the fastener shown in FIG. 4 ; and
[0019] FIG. 6 shows a different type of fastener.
DESCRIPTION OF PREFERRED EMBODIMENT
[0020] FIG. 1 of the accompanying drawings illustrates in plan a turnout 10 in a railway line which is of known construction. The turnout illustrates a pair of railway tracks 12 which split into two pairs of railway tracks 14 and 16 respectively which diverge from each other. The tracks are supported on a plurality of sleepers 18 . It can be seen that the sleepers are of variable lengths. Sleepers 18 A, which support only the tracks 12 , 14 or 16 , have a conventional or standard length. Sleepers which serve both sets of tracks 14 and 16 are designated 18 B and are longer than the sleepers 18 A. The lengths of the sleepers vary significantly from one another.
[0021] Sleepers, historically, have been made from timber. This has given rise to problems when existing timber sleepers have to be replaced for there is a sortage of suitable timber, which is a valuable natural resource. Although concrete sleepers can be fabricated to replace the existing wooden sleepers this can normally only be done at a substantial cost. A difficulty in this connection is that the tracks 12 , 14 and 16 are already in place and the concrete sleepers must then be fabricated with fastening holes or formations so that they can directly be used with the tracks without any on-site adjustment being required.
[0022] FIG. 2 illustrates a timber sleeper 18 B which is engaged with lines 14 A and 14 B respectively of the tracks 14 , and with lines 16 A and 16 B of the tracks 16 . Each line rests on a respective base plate 22 and is secured to the base plate using conventional rail clips or fasteners which are known in the art and which, for this reason, are not further described herein. Each base plate has four holes 26 and coach bolts or similar fasteners, not shown in detail, are passed through the holes and threaded into the timber sleeper 18 B to fix the base plates to the sleeper.
[0023] The method of the invention is concerned, inter alia, with the replacement of a wooden sleeper 18 B of the type shown in FIG. 2 installed, as has been indicated, in a turnout or crossing as depicted in FIG. 1 .
[0024] FIG. 3 illustrates an elongate cementitious member 30 of rectangular cross section which is cast under factory conditions using conventional techniques. The member has a length 32 which is chosen according to requirement and which may be one of a number of standardised lengths. The length 32 is generally equal to or slightly greater than the length of a selected sleeper 18 B shown in FIG. 2 , which is to be replaced.
[0025] The member 30 , which has a standard cross section, is prefabricated and is reinforced using conventional prestressing techniques.
[0026] The member 30 is stored at an appropriate location and is drawn from stock, according to requirement, for use in refurbishing a rail turnout.
[0027] When a turnout is to be upgraded measurements are taken on site of the existing sleeper arrangement. A precast member 30 which, as stated, is more or less the same length as the sleeper 18 B which is to be replaced, is drawn from stock. At the installation site the fasteners which secure the base plates 22 to the selected sleeper 18 B are loosened. The base plates are however kept engaged with the lines 14 A, 14 B, 16 A and 16 B.
[0028] Once the sleeper 18 B has been loosened from the base plates it is withdrawn from its position below the lines and the concrete sleeper 30 is pushed into position below the lines. The member 30 may be cut so that it has the same length as the wooden sleeper 18 B using any appropriate technique, for example using a diamond-tip saw blade.
[0029] When the member 30 is correctly positioned below the base plates it is clamped in position and holes 34 , see FIG. 5 , are drilled through the member using the holes 26 in the base plates 22 as templates. Each hole is drilled through the member from what in use is its upper side 36 to its lower side 38 . Fasteners of the kind shown in FIG. 4 are then used to fix the rails to the sleeper.
[0030] FIG. 4 shows a fastener 80 with a first element 82 which comprises an internally threaded metallic sleeve 84 with an open mouth 86 and an enlarged hexagonal head 88 , and a second element 90 which comprises a shank 92 which is threaded over one end 94 and which has a hexagonal head 96 .
[0031] An insulating sleeve 98 of a suitable plastics material is engaged with the shank 92 , abuts the head 96 and, when installed, acts on an upper surface 36 of a concrete sleeper member 30 , via a base plate 22 through the medium of washers 100 .
[0032] The head 88 abuts the lower surface of the sleeper and thus can readily be accessed by a spanner (not shown).
[0033] The bolts are tightened so that they are firmly engaged with the nuts and the base plates are thereby secured in position. The railway lines which at all times remain secured to the base plates are thereby secured to the member 30 .
[0034] It is therefore possible to fix the railway line to the member 30 , via the intermediate base plate 22 directly, after the holes 34 have been drilled, in the manner shown, provided sufficient ballast underlying the member 30 has been cleared for the first element 82 to be inserted into the hole with the member 30 in situ.
[0035] The insulating sleeve 98 prevents direct metal-to-metal contact between the head 96 and the shank 92 on the one hand, and the base plate 22 on the other hand. This preserves the integrity of communication signals which are propagated through wheels and other structure of tracked vehicles on the railway lines. If this insulating action is not required then a modified fastener 80 A of the type shown in FIG. 6 can be used. This fastener has an enlarged shank region 92 A which effectively compensates for the removal of the insulating sleeve (i.e. increases the diameter of the shank accordingly). Another feature, which can be adopted for both fasteners, is the provision of friction enhancing formations such as splines or knurling 102 on the sleeve 84 , and protrusions 106 on an inner surface of the head 88 , to help the sleeve engage with the concrete sleeper so that, as the shank is tightened, there is a reduced tendency of the element 82 to rotate.
[0036] Through the use of the method of the invention the respective members 30 are accurately drilled, on site, as required so that they can directly replace wooden or other sleepers which have to be refurbished. All that is necessary in this regard is to ensure that the precast members 30 are of suitable lengths so that they can be cut to size on site to match the tracks with which they are to be used.
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An existing railway line is mounted to a fresh concrete sleeper by drilling a hole through a base plate which is attached to the line. A threaded sleeve with a large head is inserted into the hole from below and a threaded shank is passed through the base plate and into the hole from above and is then engaged with the sleeve.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 60/682,144 filed on May 18, 2005, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The utilization of engineering plastics for electronic packaging is desirable. The performance characteristics of engineering plastics can be significantly changed through appropriate alterations of structure, blends with other polymers, additions of stabilizers, additives, and the like. However, most of the time there is a price to be paid. For a “general” enhancement of properties or a more focused enhancement of a single property or even several properties, there is often a lowering of one or many other properties so that the composition can no longer perform its intended purpose. There is no formula, which can generally predict the effect of new components in a composition. Results can be surprising from a positive or negative direction.
[0003] Polyesters are known to be highly crystalline materials in their solid form. This is usually quite inhibiting to blow molding since the crystalline materials, such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) cannot expand properly, but rather break.
[0004] Desirable properties for thermoplastic packaging material include actually maintaining melt strength sufficiently so that the material does not crack or break when it is expanded. Moreover, it is desirable for the same composition to be contracted substantially upon heating so that it provides a film around a very small object, such as a micro-capacitor used in electronic equipment, without significant physical or chemical degradation.
SUMMARY OF THE INVENTION
[0005] In accordance with the invention there is a molding material composition comprising a polyethylene terephthalate,
[0006] a. having chemically incorporated within the polyethylene terephthalate a crystallinity reducing amount of an isophthalic acid, or a crystallinity reducing amount of diethylene glycol, or a crystallinity reducing amount of a combination of an isophathalic acid and diethylene glycol thereby making a modified polyethylene terephthalate,
[0007] b. having chemically incorporated in the modified polyethylene terephthalate a chain extending agent which has reacted with a carboxyl end group or an hydroxyl end group, and
[0008] c. having in the composition an amount of at least one anti-blocking agent that maintains the neck opening of a parison formed from the composition, the parison surrounding a capacitor.
BRIEF DESCRIPTION OF THE DRAWING
[0009] FIG. 1 . shows an electronic component in the form of a capacitor with lead wires and having a protective coating.
DESCRIPTION OF THE INVENTION
[0010] The composition of this invention can meet the rigorous requirements of an industry which requires high temperature stability and mechanical properties of protective coverings with additional requirements of great strength and flexibility in their final protective covering application. Still further the method of coating needs both an expansion and a contraction of a thin covering which has memory as well as all the final characteristics previously noted. A specific application of this inventive composition is the coating of a capacitor(s) utilized in computer(s). The purpose of the polyester film is to provide insulation and to protect the surface from insults such as humidity and various chemicals, for example keytones, glues, adhesives and the like. The film covers all the capacitor sides. With respect to the top and the bottom, the film covers as much as is necessary to satisfy the function of the coating. It is important that the film not extend beyond the side of the capacitor at the same angle as the sides of the capacitor. That is, the film should be folded in and contact the top and the bottom of the capacitor to at least a limited extent.
[0011] Such coated capacitor can be used in applications as computers, printed circuit boards, transistors, and any type of separate electronic component.
[0012] The film should be essentially the same thickness around all parts of the capacitor including the top and the bottom. There should be no kinks or breaks in the film at any point, particularly at the top or bottom of the capacitor. There should be no film turn up at top or bottom and the film should have a tight adherence to the substrate upon heat aging at 180° C. for 30 minutes and 105° C. for two hours. The side film surface should have no dimple, dent, wrinkle or unevenness after heating at both 180° C. for 30 minutes and 105° C. for two hours.
[0013] The capacitor is usually made of aluminum or any other light metal or alloy thereof which can perform as a capacitor. The general dimensions of a capacitor for example 40×70 mm or even larger up to 150×250 mm, or even higher (width by height)are such that the film covering must be highly flexible while retaining its overall strength and mechanical characteristics during cooling and “shrinking” around the capacitor.
[0014] The basic resin employed in the composition is a polyethylene terephthalate (PET). In order to properly perform the desired application, the PET is modified. Introduction of isophthalic acid (IPA) and/or diethylene glycol (DEG) within the PET chain during preparation of the PET is employed. Although not understood, it is believed that interrupting the crystallinity of the PET is helpful in successfully achieving the encapsulated capacitor.
[0015] The amount of IPA employed is a minimum of about 1.0 mole %, preferably about 1.5 mole % of the terephthalate. Below about 1.0, difficulty in expansion occurs. If the IPA level is too high, a high intrinsic viscosity (I.V.). cannot be readily obtained. A maximum IPA level is about 6 mole %, preferably about 5 mole %. For purposes of capacitor encapsulation, a DEG level which is too low will bring about surface defects in the application. If the DEG level is too high, an appropriately high I.V. is difficult to obtain. Generally a minimum level of DEG is about 1.0 mole % of diol, preferably about 1.5 mole %. A maximum level of DEG is about 6.0 mole %, preferably about 5.0 mole %. When DEG and IPA are used together the maximum is about 7 mole %, preferably about 6 mole % together of the DEG and IPA. The IPA and/or DEG are incorporated into the PET by well known methods during the synthesis of the PET. DEG is commonly present in PET as an unwanted but normal constituent in quantities up to somewhat lower that about 1 mole % of total diol.
[0016] The modified PET as previously described is of high intrinsic viscosity. Generally a minimum I.V. is about 0.75 preferably about 0.78. A maximum I.V. is about 0.90, preferably about 0.87 as measured in phenol/tetrachlorethane 60:40 by wt at about 25° C. Below about 0.75 the PET is very difficult to expand, probably because the melt strength is too low. Above an I.V. of about 0.90 there is too much crystallinity in the virgin pellets to comply with the previously noted application because of processing difficulties.
[0017] During both compounding and tube-forming processes, there is usually a severe thermal degradation leading to a significant drop in intrinsic viscosity of PET. In order to make PET blow-moldable and the formed tube with excellent mechanical properties, its molecular weight needs to be built up. This can be accomplished by using the active chain end groups of the PET. As opposed to other polymers such as polycarbonates the typical preparation of PET does not involve an end capping agent but rather prepares a “living” polymer; that is, the polymer segments have a reactive moiety at each end. In the case of PET this is an aromatic carboxy group and/or an aliphatic hydroxyl. These groups are reactive with a polyfunctional agent so as to connect separate PET strand(s) into a single or multiple strands thereby providing a higher I.V. to the composition.
[0018] Any polyfunctional reactive material can be used for the treatment of the modified PET. These can be either polymeric or non-polymeric. Examples of reactive groups include epoxides, carbodiimides, orthoesters, oxazolines, oxiranes, aziridines, and anhydrides. The reactive material can also include other functionalities that are either reactive or non-reactive under the described processing conditions. Non limiting examples of reactive moieties include reactive silicone containing materials, for example epoxy modified silicone monomers and polymeric materials. If desired, a catalyst or co-catalyst system can be used to accelerate the reaction between the polyfunctional carboxy-reactive material and the modified polyester. The term “poly” means at least two reactive groups.
[0019] Particularly useful reactive moieties for treatment of the modified PET include materials with more than one reactive epoxy group. The polyfunctional epoxy compound may contain aromatic and/or aliphatic residues. Typical examples used in the art include 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, epoxy novolac resins, epoxidized vegetable (soybean, linseed) oils, and styrene-acrylic copolymers containing pendant glycidyl groups.
[0020] Preferred materials with multiple epoxy groups are styrene-acrylic copolymers and oligomers containing glycidyl groups incorporated as side chains. Several useful examples are described in the International Patent Application WO 03/066704 A1 assigned to Johnson Polymer, LLC, incorporated herewith. These materials are based on oligomers with styrene and acrylate building blocks that have desirable glycidyl groups incorporated as side chains. A high number of epoxy groups per oligomer chain is desired, at least about 10, preferably greater than about 15, and more preferably greater than about 20. These polymeric materials generally have a molecular weight greater than about 3000, preferably greater than about 4000, and more preferably greater than about 6000. These are commercially available from Johnson Polymer, LLC under the Joncryl® trade name. Preferably, Joncryl® ADR 4368 is used.
[0021] These agents provide a higher molecular weight I.V. to the PET and introduce significant branching into the PET. These agents are not monomers in the PET synthesis but rather link one end of a PET strand to an end of a second PET strand. The process of accomplishing this result is through the reaction of an already synthesized PET, for example, in the melt, with the noted agent. Catalysts can be employed if needed and/or desired. The reaction can occur in any convenient reactor or an extruder during the compounding of the composition.
[0022] The quantity of such an agent is that amount which increases the I.V. sufficiently so that a stable parison can be readily prepared by extrusion. Quantities can vary from about 0.05 wt % of the PET to about 1.2 wt % of the PET. Below about 0.05 wt % there is generally too much degradation of the PET polymer during its own compounding or difficulty in preparation of a parison. Above about 1.2 wt % there is a “recovery” problem of the composition which can result in not accomplishing the desired encapsulation of the capacitor. Preferred minimums are about 0.1 to about 0.2 wt % of the PET. In general, the agent assists in maintaining the integrity, i.e. the molecular weight of the PET during processing of itself and the desired application of encapsulating a capacitor.
[0023] As stated previously the overall surrounding, encapsulation, of the capacitor is extremely difficult to achieve. One of the difficult problems to overcome is the collapsing of the parison around the top and/or bottom of the capacitor prior to successfully shrink wrapping the film about the capacitor. It has now been discovered that the addition of at least one antiblocking agent to the composition allows the composition to be successfully shrink wrapped about the top and the bottom of the capacitor. An antiblocking agent is a material that prevents sheets of tightly wound plastic rolls of film, such as polypropylene, from sticking to each other. By using appropriate quantities of an anti-blocking agent the collapsing of PET film at the top and/or the bottom of the capacitor can be sufficiently inhibited so that successful shrink wrapping can appropriately occur around the top and/or bottom of the capacitor at the proper time
[0024] Although the above paragraph and limitation (c) of the claims relate to appropriate shrink wrapping around the top and/or the bottom of a capacitor, the applications of the application and the breadth of the claims are not limited to this one application. Rather the composition should have the ability to accomplish this step if a parison is made from the composition.
[0025] The examples of anti-blocking agents include minusil, calcium carbonate, silicone oils, lithium stearate, clay(s), glass microbeads and the like. Preferred for usage are micro fine silicone resins such as Tospearl,® available from General Electric Company, in tightly controlled particle sizes which allow for faster processing (extrusion rates) and improved quality of the composition.
[0026] The antiblocking agent is incorporated into the composition through its usual method, i.e. during the compounding, i.e. finishing operation. The appropriate quantities depend upon the specific anti-blocking agent employed and are consistent with the manufacturer's prescribed amount. For example, a silicone oil is used in quantities of about 0.1 to about 2 wt. % of the composition while Tospearl® is from about 0.2 to about 1.0 wt. % of the composition.
[0027] The composition of the present invention may include additional components that do not significantly interfere with the previously mentioned desirable properties but enhance other favorable properties such as antioxidants, colorant, including dyes and pigments, lubricants, mold release materials, nucleants or ultra violet (UV) stabilizers. Examples of lubricants are alkyl esters, for example pentaerythritol tetrastearate, alkyl amides, such as ethylene bis-stearamide, and polyolefins, such as polyethylene.
[0028] It is through a combination of these modifications of the basic polymer and the addition of the antiblocking agent(s) that the successful encapsulation of a capacitor can occur. Of course the composition can be successfully employed for any other application as well, particularly those that require extreme flexibility, processing stability, maintenance of physical characteristics, lack of brittleness and the like. Examples of such applications include connector for wire and cable, packaging film, corrosion-proof tube and the like.
[0000] Processing Methods
[0029] (A) Method of making the modified polyester:
[0030] In a general synthesis utilized for making a PET, a sufficient amount of IPA and/or DEG is added together with the usual terephthalate precursor and ethylene glycol precursor to prepare the modified PET having the desired quantities of IPA and/or DEG.
[0031] (B) Preparing the final composition:
[0032] Using the PET made in A above, the ingredients of the examples shown in the table below, were tumble blended and then extruded on a co-rotating 37 mm Toshiba Twin Screw Extruder with a vacuum vented mixing screw, at a barrel and die head temperature between about 260 and about 280° C. and 300 rpm screw speed. A 100 mesh or above screen pack was generally used to keep the material clean. The extrudate was cooled through a water bath and then pelletized.
[0033] (C) Method(s) of making heat shrink tube and capacitor coating:
[0034] The compounded PET pellets of part B were dried sufficiently in a forced air-circulating oven. The water content was kept less than 0.01%. The dried pellets were then added through a hopper to a 35 or 45 mm single screw extruder where they were conveyed, plasticized and metered by heating the material in the temperature range above the melting point of PET but below its thermal decomposition temperature. An O-ring type die head with a specific slit thickness was equipped at the end of the extruder. By using compressed air flowing through the ring die, the PET melt was extruded and blow molded to form a hollow tube. Shortly after the departure from the ring die, the tube was then quenched in the cooled circulating water to freeze the shape in a certain original diameter. This was called the 1 st setting of the tube (undrawn stage).
[0035] The undrawn tube was then passed through a vacuum chamber to remove water on the surface. The dried, undrawn tube was heated by either infrared heater or hot water to facilitate the smooth expansion and stretching. Compressed air was used to expand the tube in the radial direction. Simultaneously, the tube was also stretched in the lengthwise direction by rotating two rolling pans at different speeds before and after drawing. Immediately after the biaxial stretching, the drawn tube was quenched again by dipping into cooling water to fix the draw ratio at predetermined values.
[0036] Usually, the draw ratio was kept in the range of 1.5-2.5 and 1.01-1.2 times in the radial and lengthwise direction, respectively. The above biaxial stretching was called the 2 nd setting of the tube (drawn stage). With help of a pair of rolling pans, the tube was pressed flat and wound into a roll. After secondary operation, if employed, such as surface printing, the roll of drawn tube was ready for capacitor coating.
[0000] (D)Coating the Capacitor:
[0037] The general method of coating the capacitor is simply to apply heat to the drawn tube inside which the naked capacitor is inserted. The heating temperature is usually set at 250+/−50° C. for a fraction of second. The tube is then shrunk instantly in both radial and lengthwise direction simultaneously to give a tight wrap outside the capacitor, thereby providing a coating around such capacitor.
[0038] Method of successful application and comparative example(s) showing unsuccessful application of parison film to capacitor:
[0039] Below are comparative examples, 3-6, showing inadequate film production and coating when parameters are outside the claimed invention and successful production, examples 1-2, when the inventive composition is used. The following symbols are employed: O is successful, x is unsuccessful
Comparative Example example Composition Unit 1 2 3 4 5 6 7 8 co-PET-1 wt.-% 100 100 100 100 100 100 co-PET-2 wt.-% 100 co-PET-3 wt.-% 100 Chain extender wt.-% 0.5 0.5 0.5 0.5 — 0.5 0.5 0.5 Anti-block agent wt.-% 0.2 0.2 0.2 0.2 0.2 — 0.2 0.2 External lubricant wt.-% 0.2 0.2 0.2 0.2 0.2 0.2 — 0.2 Nucleant wt.-% 0.2 — 0.2 0.2 0.2 0.2 0.2 0.2 Colorant package wt.-% 0.2 0.2 0.2 0.2 0.2 0.2 0.2 — Property Pcrocess ease — ◯ ◯ X ◯ ◯ ◯ X ◯ Blow moldable & — ◯ ◯ ◯ X X ◯ ◯ ◯ Expanda Heat resistant - A — ◯ ◯ X ◯ ◯ ◯ ◯ ◯ Heat resistant - B — ◯ ◯ ◯ X X ◯ ◯ ◯ Slipperyness — ◯ ◯ ◯ ◯ ◯ X X ◯ No transparency — ◯ ◯ ◯ ◯ ◯ ◯ ◯ X co-PET-1: components comprising of terephthalic acid 97.2 mol %, isophthalic acid 2.8 mol %, ethylene glycol 98 mol % and diethylene glycol 2 mol %; I.V. = 0.81 co-PET-2: components comprising of terephthalic acid 100 mol %, ethylene glycol 98.9 mol % diethylene glycol 1.1 mol %; I.V. = 0.99 co-PET-3: components comprising of terephthalic acid 100 mol %, ethyleneglycol 98.6 mol % diethylene glycol 1.4 mol %; I.V. = 0.64 Chain extender: Joncryl ADR 4368 Styrene-acrylate-epoxy oligomer Anti-block agent: Tospearl B2000 and Silicate Heat resistant - A: tube side surface has no dimple, dent, wrinkle and unevenness upon heating at both 180 deg C./30 min and 105 deg C./120 min Heat resistant - B: tube top and bottom surface has no film turn up and film should have a tight adherence to metal substrate upon heat ageing at both 180 deg C./30 min and 105 deg C./120 min
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A thermoplastic composition comprising a polyethylene terephthalate having chemically incorporated within the polyethylene terephthalate a) crystallinity reducing amount of an isophathalic acid, or a crystallinity reducing amount of diethylene glycol, or a crystallinity reducing amount of a combination of an isophathalic acid and diethylene glycol thereby making a modified polyethylene terephthalate; b) a chain extending agent which has reacted with a carboxy end group or an alcohol end group, and c) an amount of at least one antiblocking agent that maintains the neck opening of a parison formed from the composition, the parison surrounding a capacitor.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of entertainment and games, and more particularly, to the field of games of chance. The present invention is relevant more specifically to the field of casino games and parlor games.
[0003] 2. Background of the Related Art
[0004] Games incorporating elements of chance are well known. These games are known both in the context of casino games as well as parlor games. Games of chance generally revolve around the outcome or outcomes of some random or quasi-random event or events. These events have a limited set of possible outcomes, although the set of possible outcomes may be very large. Generally, game players attempt to predict the outcome of one or more events prior to their occurrence. Game winners may be determined by correctly predicting all or part of the outcome of the event or events.
[0005] Games of chance have particular application in the field of casino gaming. Casino gaming as used herein is understood to include gambling applications outside of actual casinos, for example, in locations such as bars, airports and the like which may have gambling. It is understood that casino gaming may include both table-based gaming, as well as machine-based gaming, including, for example, mechanical slot machine gaming and computer controlled machine gaming.
[0006] Well known casino games include craps, roulette, blackjack, pai gow poker, pai gow, the wheel of fortune, slot machines, video poker, keno, baccarat, mini-baccarat, Spanish-21, casino war, and poker. Also well know are games such as state lotteries and daily numbers drawings
[0007] The principal goal of games of chance are to provide entertainment. In the casino and gambling context, successful games attract and maintain the interest of players, thereby generating income for the casino or other game host. These games of chance ideally provide action and excitement for players, have relatively easy to learn rules which do not use complicated rankings of various outcomes (e.g., poker hand valuations), and permit a variety of different wagers to keep players' interest.
[0008] In order to create a sense of competition, and therefore excitement and interest, certain presently known games of chance determine winners by comparing the outcome of a player's event (such as the roll of one or more dice) against the results of a similar event of a “dealer” or other player.
[0009] One example of such a game of chance applicable in the casino setting is disclosed in U.S. Pat. No. 5,413,351, which discloses a dice game involving wagering on the outcome of a roll of three dice. One or more players place wagers and then roll dice against a dealer. Game results depend on the occurrence of a predefined set of outcomes and/or the relative values of the player's and dealer's outcomes.
[0010] U.S. Pat. No. 5,513,850 discloses a game in which a player and a dealer develop “hands” based on the outcome of one or more rolls of several dice by both the dealer and player. Game results depend on the value of the dealer's hand relative to the player's hand according to a predefined set of relatively complex rules.
[0011] U.S. Pat. No. 6,062,563 discloses a game in which a player and a dealer each rolls a set of dice. Wagers are made on the relative outcome of the two rolls. The player's dice ad dealer's dice may be differentiated from one another by color so as to avoid confusion upon each rolling his respective dice.
[0012] U.S. Pat. No. 5,695,193 discloses a game in which players play against one another or against a dealer. Game results are based on predefined combinations of dice outcomes Outcome combinations are compared to that of each player in turn and the combination with the highest value according to a pre-defined point values assigned to each possible outcome is deemed the winner.
[0013] Many players, however, seek to avoid confrontation and so disfavor games involving such inter-personal competition, even when such competition is against a casino as personified by a dealer.
[0014] Other presently known games attempt to create excitement by providing multiple wagering stages during the course of a single game. U.S. Pat. No. 5,513,851, for example, discloses a dice-based game requiring players to place at least one additional wager on at least one additional roll of several dice after successfully wagering on the outcome of a first roll of the several dice.
[0015] Still other presently known games attempt to attract players by providing a limited set of wagers which players may learn quickly. One such game is disclosed in U.S. Pat. No. 5,732,948, which discloses a dice-based game having a small set of available wagers. The outcome of the game is dependent on no more than two rolls of a pair of dice. The game may be terminated upon the occurrence of a pre-defined outcome during a first roll of dice, or upon the occurrence of certain outcomes of a second roll of dice relative to the outcome of the first roll the dice.
[0016] Similarly, U.S. Pat. No. 6,234,482 discloses a multiple dice game wherein players' wager relate to the outcome of a roll of three dice without differentiation of three dice. Wagers are limited to wagers regarding the total of the three dice and/or the existence of two or three identical numbers being rolled.
[0017] U.S. Pat. No. 6,508,469 discloses a multiple-dice game wherein players wager on the sum of the outcome of two rolls of three dice each and/or on poker-like outcomes (e.g., three-of-a-kind, straights, etc.) without differentiation of the dice. Wagers may be made before the first roll and/or between the first and second rolls.
[0018] U.S. Pat. No. 6,209,874 discloses a three-dice game having dice of three different colors. Players are limited to six types of wagers on the result of rolling three dice. A first type of wager is on the face-up sides of a selected two of the dice being equal both to each other and to a number selected by the player. A second type of wager is on the face-up side of a selected one of the dice indicating a selected number. A third type of wager is on the face-up side of a selected one of the dice indicating a number that is alternatively higher or lower than numbers indicated by the other two dice. A fourth type of wager is on the face up sides of the dice each being equal to each other and to a number selected by the player. A fifth type of wager is on the face-up sides of the dice indicating numbers having a sum which is a selected total number. A sixth type of wager is on the sum of numbers indicated by the face-up sides of the three dice being alternatively an odd number or an even number.
[0019] Due to the limited scope of available wagers, however, these games may not adequately maintain the interest of players. Certain presently known games address this issue by providing more complicated rules. One example is U.S. Pat. No. 5,350,175, which discloses a dice-based game wherein players wager on the outcomes of successive rolls of several dice. The game terminates upon the happening of certain pre-defined combinations of outcomes of the several rolls of the dice. Similarly, U.S. Pat. No. 6,070,872 discloses a combination card and dice-based game which proceeds through three distinct phases of random card and dice events. These games, however, may present rules which are too complicated for a number of typical players to comfortably learn or understand.
[0020] Finally, several currently known games involve game play which does not adequately develop excitement for players.
[0021] U.S. Pat. No. 5,806,847 discloses a game wherein players wager on the outcome of a single event such as the roll of a pair of dice. Several pre-defined wagers are disclosed, such as the outcome of the event being included in one or more predefined sets of outcomes. The single event results in a final and unequivocal outcome of all wagers, and so players are required to re-wager after each event, and no wager relies on the outcome of more than a single event.
[0022] U.S. Pat. No. 6,378,869 discloses a dice-based game wherein players wager on the outcome of rolls of two dice followed by the roll of a third die. Disclosed wagers include individual wagers for each possible sum of the dice values as rolled, hi/lo outcome sets (i.e., wagers that the sum of the values rolled will fall within 4 to 10 inclusive or 11 to 17 inclusive) and odd/even outcomes.
[0023] Games of chance in the parlor game context may include simulations of casino gaming, as well as point driven and other games not directly related to gambling.
[0024] With these considerations in mind, it is desirable to have a game which provides action and excitement for players, has relatively easy to learn rules which do not use complicated rankings of various outcomes, permits a variety of wagers to keep players' interest and builds excitement throughout each game.
SUMMARY OF THE INVENTION
[0025] The subject invention is directed to a new and useful game of chance particularly well suited for casino and parlor play. The present invention has the advantages of providing a variety of different wagers to players, both easy to learn as well as more complicated. Additionally, the present invention includes multi-staged play which builds excitement for players without forcing players to make multi-tiered wagers.
[0026] A method of playing a game of chance is disclosed, one preferred embodiment having the steps of defining a set of wagers on the outcome of a plurality of differentiable random events, the random events defining an aggregate event; defining a set of payout odds associated with the wagers, accepting at least one player wager for at least one wager in the set of wagers, generating the plurality of differentiable random events, and paying winning wagers according to the payout odds.
[0027] Also disclosed is a preferred embodiment of the present invention in the form of a method of playing a game of chance having the steps of: selecting a wager from a pre-defined set of wagers on the outcome of a plurality of differentiable random events, the random events defining an aggregate event and the pre-defined set of wagers having a pre-defined set of payout odds associated therewith, awaiting the outcome of the plurality of differentiable random events, and collecting payment for winning wagers according to the payout odds.
[0028] Finally, a preferred embodiment is disclosed in the form of a game of chance having a wager area for accepting wagers, the wager area having set of wagers on the outcome of a plurality of differentiable random events, the random events defining an aggregate event, a set of payout odds associated with the wagers and a random event generator for generating the plurality of differentiable random events, wherein winning wagers accepted in the wager area are paid in accordance with the payout odds.
[0029] The set of wagers may include a plurality of wager groups, the wager groups including a first wager group having single, double and trifecta wagers and a second wager group having wagers on the aggregate event. The plurality of differentiable random events may include a first, second, third and fourth random event, and the first wager group may include a single wager on the first random event, a double wager on the first and second random events, and a trifecta wager on the first, second and third random events.
[0030] The aforementioned first wager group further may include a single wager on the second random event, a double wager on the second and third random event, and a trifecta wager on the second, third and fourth random events.
[0031] The further step of generating a bonus random event may be included and the wager groups may then include a third wager group having wagers on the bonus random event.
[0032] The third wager group may include a single wager on the third random event, a double wager on the third and fourth random events, and a trifecta wager on the third, fourth and bonus random events. Additionally, the third wager group may include a single wager on the fourth random event and a double wager on the fourth and bonus random events.
[0033] The plurality of differentiable random events may include a first, second, third and fourth random event and the second wager group may include a plurality of wagers on aggregate values of the first, second, third and fourth random events. The second wager group may include an over-under wager.
[0034] The further step of generating a bonus random event may be included, and the wager groups may then include a third wager group having wagers on the bonus random event.
[0035] The third wager group may include a wager on a combination of an over-under and the bonus random event. Additionally, the second wager group may include one or more block wagers.
[0036] The aforementioned block wagers may have at least one of the group of: (a) wagers on blocks of two aggregate values of the first, second, third and fourth random events, (b) wagers on blocks of three aggregate values of the first, second, third and fourth random events, (c) wagers on blocks of four aggregate values of the first, second, third and fourth random events, (d) wagers on blocks of five aggregate values of the first, second, third and fourth random events, and (e) wagers on blocks of six aggregate values of the first, second, third and fourth random events.
[0037] In the foregoing embodiments, the second wager group may have at least one wager selected from the group of: four deuces, aces over any pair, any three of a kind, any four of a kind, 4-or-24, triple threes, big 6, any result over 20, all odd, all even, any straight, any two pair, and any result under 10.
[0038] The plurality of differentiable random events may be generated by random event generators having at least one of the group of: (a) one or more dice, (b) one or more prize wheels, (c) one or more roulette type wheels, (d) one or more air mix type random number generators, (e) one or more gravity fed random number generators, and (f) one or more pseudo random number generators.
[0039] These and other aspects of the subject invention will become more readily apparent to those having ordinary skill in the art from the following detailed description of the invention taken in conjunction with the drawings described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] So that those having ordinary skill in the art to which the subject invention pertains will more readily understand how to make and use the subject invention, preferred embodiments thereof will be described in detail herein with reference to the drawings.
[0041] FIG. 1 is a depiction of dice utilized in a preferred embodiment of the present invention.
[0042] FIG. 2 is a playing board having several wager groups in accordance with a preferred embodiment of the present invention.
[0043] FIG. 3 is a wager group of a preferred embodiment of the present invention.
[0044] FIG. 4 is another wager group of a preferred embodiment of the present invention.
[0045] FIG. 5 is another wager group of a preferred embodiment of the present invention.
[0046] FIG. 6 is another wager group of a preferred embodiment of the present invention.
[0047] FIG. 7 is another wager group of a preferred embodiment of the present invention.
[0048] FIG. 8 is a flow chart showing the steps of game play in a preferred embodiment of the present invention.
[0049] FIG. 9 depicts random event generators in the form of prize wheels.
[0050] FIG. 10 is a schematic depiction of a computer based machine embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] Referring now in detail to the drawings wherein like reference numerals identify similar structural features of the several embodiments of the subject invention, there is illustrated in FIG. 1 a set of dice for use in a preferred embodiment of the present invention. Each of the numbered dice, 1-4, includes six faces with representations of the numbers 1 through 6, although other symbols may be used for each face of a die, for example, horse names, shapes, letters or other symbols. In such cases, certain wagers based on mathematical calculations of results may not be directly applicable. If such calculation based wagers were desired in such cases, numeric values may be assigned to the various shapes, symbols, etc.
[0052] The numbered dice are color coded so as to differentiate themselves from one another. In one preferred embodiment, die 1 is colored red, die 2 is colored white, die 3 is colored blue and die 4 is colored white with red and blue stripes. Other differentiation schemes may be utilized to differentiate the dice, for example, dice may be of differing sizes, contained in color coded, named, or otherwise differentiable containers and the like.
[0053] The numbered dice 1 - 4 are rolled during game play to generate random events, and players may place one or more wagers on the outcome of the rolls of the numbered dice 1 - 4 , alone or in combination, as discussed in further detail below.
[0054] “Bonus die” 5 is a six-sided die having only three different indicia; that is, each indicia is repeated on two different faces of the die. In one preferred embodiment of the present invention, the indicia of the bonus die are colors; that is, two sides are red, two sides are white, and two sides are blue. Any other distinguishable indicia may also be utilized. The bonus die is rolled during game play to generate a bonus event and players may place one or more wagers on the outcome of the roll of the bonus die either alone or in combination with other dice.
[0055] Players may place wagers by placing money, chips, chits or other indicators on a wagering surface demarcated with wager areas. A preferred embodiment of a playing surface of the present invention is shown in FIG. 2 . Wager areas 14 are delineated by lines 11 drawn on the wagering surface. Wager indicators 12 contained within each wager area indicate the wager associated with the particular wager area. Payout indicators 13 may be placed on the wagering surface to indicated payout odds for the various wagers, thereby permitting players to readily determine what payouts they will receive for placing winning wagers. For example, payout odds of 4-1 means that for every one dollar placed on a winning wager (i.e., for every one dollar player wager), a player will receive four dollars payout. The wagering surface may be divided into two or more wager groups 10 containing similar or related wagers, for example, grouping one-roll wagers, red-white-blue wagers, white-blue-red wagers, blue-striped-bonus wagers, striped-bonus wagers, aggregate wagers, and the like, as discussed in further detail below.
[0056] FIG. 3 illustrates a wager group of a preferred embodiment of the present invention. Wager areas 14 included in this wager group include wagers dependent on the total rolled values of dice 1 - 4 , as well as the value of bonus die 5 , and may be called “aggregate wagers”, “final roll wagers” or “final roll bets”. These final roll wagers are wagers on an aggregate event defined by combining the outcomes of the individual events; that is, the aggregate event may defined by combining the values of the outcome of the rolls of dice 1 - 4 , 1 - 4 plus bonus die 5 , or combinations thereof. Examples of aggregate events may therefore include “total of 17 for dice 1-4” and “total of 17 for dice 1-4 and red for dice 5”, among others.
[0057] Wager areas in this wager group include wagers on the total of the rolled values of dice 1 - 4 , 21 , wagers that the total of the rolled values of dice 1 - 4 are over or under 14 (“over-under” wagers), 22 , and block wagers, that is, wagers that the total of the rolled values of dice 1 - 4 will be one of a predefined block of several values, 23 . For example, block wagers may be on: blocks of two aggregate values (e.g., that the total will be one of 18 or 22), blocks of three aggregate values (e.g., that the total will be one of 7, 14 or 21), blocks of four aggregate values (e.g., that the total will be one of 6, 11, 17 or 22), blocks of five aggregate values (e.g., that the total will be one of 4, 9, 13, 18 or 22), or blocks of six aggregate values (e.g., that the total will be one of 4, 9, 13, 18, 21 or 22).
[0058] Also included in this wager group are “specialty wagers”, 24 , such as “four deuces” (i.e., that each die, excluding the bonus die, will show a two), any two pair (i.e., that the dice, excluding the bonus die, will show two numbers each repeated on two dice), all even (i.e., that the value of each die, excluding the bonus die, will be an even value), three of a kind (i.e., that the dice, excluding the bonus die, will show the same number repeated on three dice), four of a kind (i.e., that the dice, excluding the bonus die, will show the same number repeated on all four dice), and the like.
[0059] The over-under wagers just discussed are best implemented in embodiments having an even number of dice or other random event generators such as prize wheels so that the set of all possible outcomes includes a “pivot number”; that is, a single median value within the set of all possible outcomes. Other embodiments may include sets of all possible outcomes which have more than a single pivot number; that is, two or more median values within the set of all possible outcomes. In such embodiments, over or under wagers may be adjusted to be over the highest of pivot numbers and below the lowest of pivot numbers. The pivot number may also be referred to as the “house number”.
[0060] Tables 1 and 2 provide a complete list of wagers illustrated in FIG. 2 , including odds of winning and payout odds of the present preferred embodiment.
TABLE 1 Single Aggregate Value Wager Odds Payout 4, 24 1296-1 1000-1 5, 23 324-1 250-1 6, 22 129.6-1 100-1 7, 21 64.8-1 50-1 8, 20 37-1 28-1 9, 19 23.1-1 18-1 10, 18 16.2-1 12-1 11, 17 12.5-1 10-1 12, 16 10.4-1 8-1 13, 15 9.3-1 7-1 14 8.9-1 6-1
[0061]
TABLE 2
Wager
Odds
Payout
Any Five-Result Block Wager (e.g., total
3.5-1
3-1
equaling any of 4, 9, 13, 18 or 22, etc.)
Four-Result Block Wagers 4-10-12-21, 6-11-
4.7-1
4-1
17-22 and 7-16-18-24
Four-Result Block Wagers 5-9-13-20 and 8-
4.5-1
4-1
15-19-23
Any Three-Result Block Wager (e.g., total
6-1
5-1
equaling any of 4, 11 or 18, etc.)
Over/Under (i.e., over 14 or under 14)
1.3-1
1-1
Over/Under plus Bonus Die (e.g., over 14 plus
5.8-1
5-1
red)
Any Triple
10.1-1
8-1
Under 10
9.3-1
9-1
Any Two Pair
12.5-1
12-1
All Even/Odd (i.e., each die even or each die
15-1
14-1
odd)
Any Straight (e.g., 2-3-4-5, etc.)
26-1
18-1
Over 20 (i.e., the total of the dice being
36-1
35-1
greater than 20)
Big 6 (i.e., total equaling any of 4, 5, 6, 22, 23
42.2-1
40-1
or 24)
Triple 3's (i.e., three dice each showing 3)
60.7-1
50-1
Aces Over Any Pair (i.e., a pair of aces and
80-1
75-1
any other pair)
Any Four of a Kind
215-1
200-1
4 or 24 (i.e., the total equaling 4 or 24)
647-1
500-1
Four Deuces (i.e., each die showing 2)
1295-1
1000-1
Any Four of a Kind Plus White
647-1
600-1
4 or 24 Plus Blue
1943-1
1500-1
Four Deuces Plus Red
3887-1
3000-1
[0062] FIG. 4 illustrates another wager group of a preferred embodiment of the present invention. Wager areas 14 included in this wager group include wagers on the outcome of the roll of the red die (“single” or “single wager”), red and white dice (“double” or “double wager”), or red, white and blue dice (“trifecta” or “trifecta wager”). For example, a single wager made in wager area 31 wins when the number 3 is rolled on the red die. A double wager made in wager area 32 wins when the number 3 is rolled on the red die and the number 6 is rolled on the white die (that is, both conditions must be met for the wager to be successful). In a similar fashion, a trifecta wager made in wager area 33 wins when the number 3 is rolled on the red die and the number 6 is rolled on the white die and the number 2 is rolled on the blue die (that is, all three conditions must be met for the wager to be successful). The payout odds for winning single wagers are shown in box 34 , for winning double wagers in box 35 , and for winning trifecta wagers in box 36 . Table 3 provides a complete list of wagers illustrated in FIG. 4 , including odds of winning and payout odds of the present preferred embodiment.
TABLE 3 Wager Odds Payout Any Single (e.g., 1, 2, etc.) 5-1 4.5-1 Any Double (e.g., 1-1, 1-2, etc.) 35-1 33-1 Any Trifecta (e.g., 1-1-1, 1-1-2, etc.) 215-1 200-1
[0063] FIG. 5 illustrates another wager group of a preferred embodiment of the present invention. Wager areas 14 included in this wager group include wagers on the outcome of the roll of the white die (single), white and blue dice (double), or white, blue and striped dice (trifecta). These wagers operate in the same manner as the wagers disclosed in connection with FIG. 4 , with the white die substituted for the red die of the previous wager group, the blue die substituted for white die of the previous wager group, and the striped die substituted for the blue die of the previous wager group. The odds of winning and payout odds are the same as those tabulated in Table 3.
[0064] FIG. 6 illustrates an additional wager group of a preferred embodiment of the present invention. Wager areas 14 included in this wager group include wagers on the outcome of the roll of the blue die (single), blue and striped dice (double), or blue, striped and bonus dice (trifecta). The odds of winning an payout odds for the wagers of this wager group are shown in Table 4.
TABLE 4 Wager Odds Payout Any Single (e.g., 1, 2, etc.) 5-1 4.5-1 Any Double (e.g., 1-1, 1-2, etc.) 35-1 33-1 Any Trifecta (e.g., 1-1-red, 1-1-blue, etc.) 107-1 100-1
[0065] Finally, FIG. 7 illustrates another wager group of a preferred embodiment of the present invention. Wager areas 14 included in this-wager group include wagers on the outcome of the roll of the striped die (single) or striped and bonus dice (double). The odds of winning and payout odds for the wagers of this wager group are shown in Table 5.
TABLE 5 Wager Odds Payout Any Single (e.g., 1, 2, etc.) 5-1 4.5-1 Any Double (e.g., 1-red, 1-blue, etc.) 18-1 15-1
[0066] From the foregoing, it may be seen that wager groups having wagers on the bonus random event may include wagers which are determined in whole or in part by the outcome of the bonus event.
[0067] The steps of the present preferred embodiment may be summarized by the flow chart of FIG. 8 . The game begins with the one or more wagers being made in step 1 . Following step 1 , the random events are generated in step 2 . Next, in step 3 , the aggregate results are determined, for example, by summing the resulting values of dice 1 - 4 . Finally winning wagers are paid in step 4 according the payout odds defined for them. Of course, other sequences may be employed without departing from the present invention. For example, each random event may be generated individually, with all wagers capable of being determined upon the completion of such event being paid at that point (as opposed to being paid only upon the completion of all events).
[0068] While the preceding preferred embodiments utilize dice, other random or pseudo-random event generators may be utilized. These include, among others, carnival, “wheel of chance”, or prize-wheel type wheels, such as those manufactured by Kardwell International, Inc., P.O. Box 33, Mattituck, N.Y. 11952 and as illustrated in FIG. 9 , multiple roulette type wheels, air mix type random number generators such as is disclosed in U.S. Pat. No. 5,121,920 and those manufactured by Smartplay International Inc., One Linda Lane, Suite B, Southampton, N.J. 08088, gravity fed random number generators such as those manufactured by Smartplay International Inc., bingo cages, such as those manufactured by Kardwell International, Inc., and the like.
[0069] Similarly, the entirety of the present invention may be implemented as an electronic or computer based game. In such embodiments, a computer consisting of a display device, 91 , central processing unit, 92 , input device such as a keyboard, touchscreen or dedicated mechanical buttons, 93 , volatile and non-volatile memory, 94 , central processing unit, 95 , pseudo-random number generator, 96 (which may be in the form of a computer routine executed by central processing unit 95 ), may be utilized to implement the game of chance of the present invention. Alternatively, dedicated logic may be utilized in place of a programmed computer. Such devices, which may be in a form similar to video poker type machines currently well known to those of skill in the art, may be programmed to present applicable wagers to players, accept wagers from players, generate the necessary random or pseudo-random events, and pay winning wagers in accordance with payout odds associated with the winning wagers.
[0070] While particular embodiments of the present invention have been shown and described, it will be apparent to those skilled in the pertinent art that changes and modifications may be made without departing from the invention in its broader aspects.
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A method of playing a game of chance comprising the steps of defining a set of wagers on the outcome of a plurality of differentiable random events, said random events defining an aggregate event, defining a set of payout odds associated with said wagers, accepting at least one player wager for at least one wager in said set of wagers, generating said plurality of differentiable random events, and paying winning wagers according to said payout odds.
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TECHNICAL FIELD
[0001] The disclosure relates to the field of bluetooth wireless communications, specifically to a method and system for orderly connection of a bluetooth headset controlled by a terminal.
BACKGROUND
[0002] Bluetooth is an open standard of wireless data and voice transmission, which links together various communication devices, computers and terminal devices thereof, various digital data systems, etc., in a wireless manner, mainly to solve the problem of the wireless communication of a short distance (the effective communication distance is no more than 10 meters in general). The bluetooth headset refers to a hands-free headset in which the bluetooth technology is applied, which makes the user can easily communicate by the telephone in various ways without the annoyance of wires.
[0003] The bluetooth Special Interest Group (SIG) draws up and issues the bluetooth protocol standard, in which different profiles are defined according to different logic functions of the bluetooth. Wherein a HeadSet Profile (HSP) and a Hands-Free Profile (HFP) are formulated to enable answering and dialing a voice telephone via the bluetooth headset; an Advanced Audio Distribution Profile (A2DP) is formulated to enable hearing stereo music via the bluetooth headset; and an Audio Video Remote Control Profile (AVRCP) is formulated to realize controlling of the played music while listening to stereo music, for example, playing, halting, pausing, previous, next, etc. In the above four profiles, the HFP can be viewed as a superset of the HSP, and the HFP and HSP can be treated as the same profile application. Although the A2DP and AVRCP are two different profiles, and are independent from, not dependent on each other in the bluetooth protocol standard, they are usually coexistent and provide bluetooth stereo music function to the user together.
[0004] During the application process of the bluetooth device, respective connection operations must be performed for different profiles respectively before using the functions corresponding to respective profiles. In the existing technology, when the user uses a bluetooth headset integrated with the three profiles HFP, A2DP and AVRCP, the bluetooth headset will initiate three different connection requests to a terminal, and correspondingly, the terminal will frequently pop out prompt boxes to inform the user that there are different profiles having been connected. This is too professional for the user of the bluetooth headset, and in fact, the user needs only one connection prompt informing that the bluetooth headset has been connected. It can be seen that the existing bluetooth headset is poor in ease of use and usage friendliness.
[0005] In addition, the bluetooth SIG only formulated the application specifications of respective profiles, but has not regulated a processing flow when the three profiles HFP, A2DP and AVRCP are coexistent, namely, has not regulated a connection order of the three profiles HFP, A2DP and AVRCP. In the prior art, when the terminal actively initiates a connection to the bluetooth headset, the terminal can control the order of the connection initiated by the bluetooth headset, however, when the bluetooth headset actively initiates a connection to the terminal, the terminal cannot control the order of the connection initiated by the bluetooth headset. Therefore, when the bluetooth headsets which are manufactured by different bluetooth headset manufacturers and have different profile connection processing flows actively initiate a connection to the terminal, a problem of incompatible profile connection will occur at the terminal, resulting in that some profiles have been connected with the terminal, while some profiles are not connected with the terminal, and furthermore, connection information displayed on the terminal interface may be not in accordance with the actual connection situation of the profile, thus decreasing the user experience.
SUMMARY
[0006] In view of this, the disclosure mainly aims to provide a method and system for orderly connection of a bluetooth headset controlled by a terminal, for solving the problem of incompatibility due to different profile connection order when the bluetooth headset actively initiates a connection to the terminal.
[0007] To achieve the above purpose, the technical solution of the disclosure is realized as follows.
[0008] The disclosure provides a method for orderly connection of a bluetooth headset controlled by a terminal, and the method includes:
[0009] setting, by a terminal, its Hands-Free Profile (HFP) service status as visible and connectable, and setting its Advanced Audio Distribution Profile (A2DP) service status and Audio Video Remote Control Profile (AVRCP) service status as invisible and unconnectable;
[0010] sending, by a bluetooth headset, an HFP connection request to the terminal; and
[0011] sending, by the terminal, a response of accepting an HFP connection to the bluetooth headset.
[0012] Wherein the method may further include: after the bluetooth headset sends the HFP connection request to the terminal, inquiring, by the terminal, whether the bluetooth headset has A2DP and AVRCP services after receiving the HFP connection request, and then orderly executing an operation of connection with the bluetooth headset after determining that the bluetooth headset has A2DP and AVRCP services.
[0013] Wherein the method may further include: after the terminal inquires whether the bluetooth headset has A2DP and AVRCP services,
[0014] sending, by the terminal, the response of accepting the HFP connection to the bluetooth headset after determining that the bluetooth headset does not have A2DP and AVRCP services, and ending the connection establishing process.
[0015] In the above solution, orderly executing the operation of connection with the bluetooth headset by the terminal after determining that the bluetooth headset has A2DP and AVRCP services may be specifically as follows:
[0016] initiating an AVRCP connection request to the bluetooth headset, accepting, by the bluetooth headset, establishment of an AVRCP connection, and informing the terminal of a connection result; and initiating, by the terminal, an A2DP connection request to the bluetooth headset after receiving a message that an AVRCP connection has been established, then accepting, by the bluetooth headset, establishment of an A2DP connection and informing the terminal of a connection result; or
[0017] initiating the A2DP connection request to the bluetooth headset, accepting, by the bluetooth headset, the establishment of the A2DP connection, and informing the terminal of the connection result; and initiating, by the terminal, the AVRCP connection request to the bluetooth headset after receiving a message that the A2DP connection has been established, then accepting, by the bluetooth headset, the establishment of the AVRCP connection and informing the terminal of the connection result.
[0018] In the above solution, the method may further include: after the terminal sends the response of accepting the HFP connection to the bluetooth headset, informing, by the terminal, a user of successful establishment of the connection between the bluetooth headset and the terminal.
[0019] Furthermore, the method may further include: after the terminal receives the HFP connection request, popping out, by the terminal, a dialogue box on an interface to prompt the user that there is a bluetooth headset initiating a connection.
[0020] The disclosure further provides a system for orderly connection of a bluetooth headset controlled by a terminal, and the system includes a terminal and a bluetooth headset, wherein
[0021] the terminal is configured to set its HFP service status as visible and connectable, and set its A2DP service status and AVRCP service status as invisible and unconnectable; and send a response of accepting an HFP connection to the bluetooth headset; and
[0022] the bluetooth headset is configured to send an HFP connection request to the terminal, and receive the response of accepting the HFP connection sent by the terminal.
[0023] Wherein the terminal may be further configured to inquire whether the bluetooth headset has A2DP and AVRCP services after receiving the HFP connection request sent by the bluetooth headset, and then orderly execute an operation of connection with the bluetooth headset after determining that the bluetooth headset has A2DP and AVRCP services; and
[0024] correspondingly, the bluetooth headset may be further configured to orderly execute an operation of connection with the terminal after the terminal determines that the bluetooth headset has A2DP and AVRCP services.
[0025] Wherein the terminal may be further configured to send the response of accepting the HFP connection to the bluetooth headset after determining that the bluetooth headset does not have A2DP and AVRCP services; and
[0026] correspondingly, the bluetooth headset may be further configured to receive the response of accepting the HFP connection sent by the terminal.
[0027] In the above solution, the terminal may be further configured to, after receiving the HFP connection request, pop out a dialogue box on an interface to prompt the user that there is a bluetooth headset initiating a connection; and further configured to inform the user of successful establishment of the connection between the bluetooth headset and the terminal after sending the response of accepting the HFP connection to the bluetooth headset.
[0028] In the method and system for orderly connection of a bluetooth headset controlled by a terminal provided by the disclosure, the terminal sets its HFP service status as visible and connectable, and sets its A2DP service status and AVRCP service status as invisible and unconnectable; the bluetooth headset sends the HFP connection request to the terminal; and the terminal sends the response of accepting the HFP connection to the bluetooth headset. The disclosure successfully avoids different connection order of the profiles due to different manufacturers of bluetooth headset when the bluetooth headset actively initiates the connection, which solves the problem of incompatible connection of the profiles.
[0029] Furthermore, according to the disclosure, after sending the response of accepting the HFP connection to the bluetooth headset, the terminal informs the user of the successful establishment of connection between the bluetooth headset and the terminal, which avoids that the terminal frequently pops out prompt boxes to inform the user that there are different profiles having been connected, thus improves the ease of use and usage friendliness of the bluetooth headset.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a schematic diagram of realization flow of a method for orderly connection of a bluetooth headset controlled by a terminal according to the disclosure; and
[0031] FIG. 2 is a structural schematic diagram of a device for orderly connection of a bluetooth headset controlled by a terminal according to the disclosure.
DETAILED DESCRIPTION
[0032] The main idea of the disclosure is: a terminal sets its HFP service status as visible and connectable, and sets its A2DP service status and AVRCP service status as invisible and unconnectable; a bluetooth headset initiates an HFP connection request to the terminal; the terminal sends a response of accepting the HFP connection to the bluetooth headset.
[0033] Here, after the bluetooth headset initiates the HFP connection request to the terminal, the method further includes the step of: after receiving the HFP connection request, the terminal inquires whether the bluetooth headset has A2DP and AVRCP services, and then orderly executes connection operations with the bluetooth headset after determining that the bluetooth headset has A2DP and AVRCP services.
[0034] Furthermore, after sending the response of accepting the HFP connection to the bluetooth headset, the terminal informs the user of the successful establishment of connection between the bluetooth headset and the terminal.
[0035] In the disclosure, the basis for the terminal to set the HFP service status as visible and connectable is: the existing low-end bluetooth headset only provides the HFP service, while the middle-end and high-end HFP bluetooth headset provides A2DP and AVRCP services in addition to the HFP service, that is to say, it is the common function for the bluetooth headset to provide the HFP service.
[0036] In the disclosure, the step of the bluetooth headset actively initiates the connection refers to that the bluetooth headset initiates the connection to the terminal firstly.
[0037] The disclosure is explained below with reference to accompanying drawings and embodiments in detail.
[0038] FIG. 1 is a schematic diagram of realization flow of a method for orderly connection of a bluetooth headset controlled by a terminal according to the disclosure; as shown in FIG. 1 , the flow comprises following steps.
[0039] Step 101 : the terminal sets its HFP service status as visible and connectable;
[0040] specifically, after the terminal is started, a host in the terminal sends an instruction of setting device class, that is, HCI_Write_Class_of_Device, to a Link Manager (LM) in the terminal; after receiving the instruction HCI_Write_Class_of_Device, the LM in the terminal returns an instruction of setting device scannable, that is, HCI_Write_Scan_Enable, to the host in the terminal, such that the HFP service of the terminal is visible and connectable.
[0041] The step further comprises at the same time: the terminal sets its A2DP service status and AVRCP service status as invisible and unconnectable, namely, the A2DP service status and the AVRCP service status of the terminal cannot be found by the bluetooth headset and cannot be connected by the bluetooth headset, and the specific process is carried out at the same time with the process that the terminal sets the HFP service status as visible and connectable, namely, the instruction HCI_Write_Class_of_Device sent by the host in the terminal and the instruction HCI_Write_Scan_Enable returned by the LM in the terminal comprise setting parameters of the HFP service status, as well as setting parameters of the A2DP service status and AVRCP service status.
[0042] Here, the step of setting the A2DP service status and the AVRCP service status as invisible and unconnectable is: the A2DP and the AVRCP of the terminal cannot be found by the bluetooth headset and the terminal cannot actively initiate a connection to the bluetooth headset, but the terminal can actively initiate the A2DP and AVRCP connections to the bluetooth headset.
[0043] Step 102 : the bluetooth headset initiates an HFP connection request to the terminal;
[0044] specifically, a host in the bluetooth headset sends a create connection instruction HCI_Create_Connection (HFP) to an LM in the bluetooth headset; after receiving the HCI_Create_Connection (HFP), the LM in the bluetooth headset sends a host connection request signaling LMP_host_connection_req (HFP) to the LM in the terminal; after receiving the LMP_host_connection_req (HFP), the LM in the terminal sends a connection request instruction HCI_Connection_Request (HFP) to the host in the terminal.
[0045] Here, the bluetooth headsets supporting the HFP, A2DP and AVRCP services manufactured by different manufactures will further initiate the A2DP or AVRCP connection request to the terminal, but the bluetooth headset should initiate a signaling of requesting to acquire feature, namely LMP_features_req_ext before actively initiating the connection request, such that the A2DP service status and the AVRCP service status of the terminal are both invisible and unconnectable due to the setting in step 101 , namely, a signaling LMP_features_res_ext responding to the feature request returned by the terminal will not contain the information of A2DP or AVRCP, therefore the bluetooth headset only initiates the HFP connection request to the terminal.
[0046] Step 103 : after receiving the HFP connection request, the terminal inquires whether the bluetooth headset has A2DP and AVRCP services;
[0047] specifically, after receiving the instruction HCI_Connection_Request (HFP), the host in the terminal inquires in the local device information whether the bluetooth headset has A2DP and AVRCP services, wherein the local device information is internal exchange information between the bluetooth headset and the terminal before the bluetooth headset initiates the connection request to the terminal.
[0048] Here, after receiving the HFP connection request, the terminal further pops out a dialogue box on the interface to prompt the user that there is a bluetooth headset initiating a connection, for example, the bluetooth headset requests to establish a connection with the terminal, if the user accepts, the terminal inquires whether the bluetooth headset has A2DP and AVRCP services, and performs the subsequent connection operations, or if the user does not accept, the connection is ended.
[0049] Step 104 : after determining that the bluetooth headset has A2DP and AVRCP services, the terminal initiates an AVRCP connection request to the bluetooth headset;
[0050] specifically, after the terminal determines that the bluetooth headset has A2DP and AVRCP services, the host in the terminal sends a create connection instruction HCI_Create_Connection (AVRCP) to the LM in the terminal; after receiving the HCI_Create_Connection (AVRCP), the LM in the terminal sends a host connection request signaling LMP_host_connection_req (AVRCP) to the LM in the bluetooth headset, then the LM in the bluetooth headset sends a connection request signaling HCI_Connection_Request (AVRCP) to the host in the bluetooth headset.
[0051] Here, if the terminal determines that the bluetooth headset does not have A2DP and AVRCP services, namely the bluetooth headset only has the HFP service, then the terminal sends the response of accepting the HFP connection to the bluetooth headset, and the connection establishing process is ended.
[0052] Step 105 : the bluetooth headset accepts the establishment of the AVRCP connection, and informs the terminal of a connection result;
[0053] specifically, after receiving the instruction HCI_Connection_Request (AVRCP), the host in the bluetooth headset sends a connection request accepting instruction HCI_Accept_Connection_Request (AVRCP) to the LM in the bluetooth headset; after receiving the HCI_Accept_Connection_Request (AVRCP), the LM in the bluetooth headset sends an accepting signaling LMP_accepted (AVRCP) to the LM in the terminal; after receiving the LMP_accepted (AVRCP), the LM in the terminal sends the connection complete instruction HCI_Connection_Complete (AVRCP) to the host in the terminal.
[0054] Here, since the bluetooth headset is a dumb terminal relative to the terminal, the bluetooth headset will automatically accept the connection request initiated by the terminal.
[0055] Step 106 : after receiving a message that the AVRCP connection has been established, the terminal initiates an A2DP connection request to the bluetooth headset;
[0056] specifically, after receiving the HCI_Connection_Complete (AVRCP), the host in the terminal sends a create connection instruction HCI_Create_Connection (A2DP) to the LM in the terminal; after receiving the HCI_Create_Connection (A2DP), the LM in the terminal sends a host connection request signaling LMP_host_connection_req (A2DP) to the LM in the bluetooth headset, then the LM in the bluetooth headset sends a connection request instruction HCI_Connection_Request (A2DP) to the host in the bluetooth headset.
[0057] In the disclosure, if the terminal determines that the bluetooth headset has A2DP and AVRCP services, the terminal may also initiate the A2DP connection request to the bluetooth headset first, then initiate the AVRCP connection request after receiving a message that the A2DP connection has been established.
[0058] Step 107 : the bluetooth headset accepts the establishment of the A2DP connection, and informs the terminal of the connection result;
[0059] specifically, after receiving the instruction HCI_Connection_Request (A2DP), the host in the bluetooth headset sends a connection request accepting instruction HCI_Accept_Connection_Request (A2DP) to the LM in the bluetooth headset; after receiving the HCI_Accept_Connection_Request (A2DP), the LM in the bluetooth headset sends an accepting signaling LMP_accepted (A2DP) to the LM in the terminal; after receiving the LMP_accepted (A2DP), the LM in the terminal sends a connection complete instruction HCI_Connection_Complete (A2DP) to the host in the terminal.
[0060] Step 108 ˜ 109 : after receiving a message that the A2DP connection has been established, the terminal initiates a message of accepting the establishment of the HFP connection to the bluetooth headset, and the connection establishing process is ended;
[0061] specifically, after receiving the HCI_Connection_Complete (A2DP), the host in the terminal sends a connection request accepting instruction HCI_Accept_Connection_Request (HFP) to the LM in the terminal; after receiving the HCI_Accept_Connection_Request (HFP), the LM in the terminal sends an accepting signaling LMP_accepted (HFP) to the LM in the bluetooth headset; after receiving the LMP_accepted (HFP), the LM in the bluetooth headset sends an HCI_Connection_Complete (HFP) to the host in the bluetooth headset.
[0062] After step 108 , the process further comprises: the terminal informs the user of the successful establishment of the connection between the bluetooth headset and the terminal, for example, a connection between the bluetooth headset and the terminal have been established, and the bluetooth headset is usable.
[0063] To realize above method, the disclosure further provides a system for orderly connection of a bluetooth headset controlled by a terminal; as shown in FIG. 2 , the system includes a terminal and a bluetooth headset, wherein
[0064] the terminal is configured to set its HFP service status as visible and connectable, and set its A2DP service status and AVRCP service status as invisible and unconnectable; and send a response of accepting the HFP connection to the bluetooth headset; and
[0065] the bluetooth headset is configured to send an HFP connection request to the terminal, and receive the response of accepting the HFP connection sent by the terminal.
[0066] The terminal is further configured to, inquire whether the bluetooth headset has A2DP and AVRCP services after receiving the HFP connection request sent by the bluetooth headset, and then orderly execute an operation of connection with the bluetooth headset after determining that the bluetooth headset has A2DP and AVRCP services; and correspondingly,
[0067] the bluetooth headset is further configured to orderly execute an operation of connection with the terminal after the terminal determines that the bluetooth headset has A2DP and AVRCP services.
[0068] Wherein the terminal further comprises a host and an LM, the bluetooth headset further includes a host and an LM; correspondingly,
[0069] the terminal sets its HFP service status as visible and connectable, specifically:
[0070] the host in the terminal sends an instruction HCI_Write_Class_of_Device to the LM in the terminal; after receiving the instruction HCI_Write_Class_of_Device, the LM in the terminal returns an instruction HCI_Write_Scan_Enable to the host in the terminal;
[0071] inquiring, by the terminal, whether the bluetooth headset has A2DP and AVRCP services after receiving the HFP connection request sent by the bluetooth headset is specifically as follows:
[0072] after receiving the instruction HCI_Connection_Request (HFP), the host in the terminal inquires in the local device information whether the bluetooth headset has A2DP and AVRCP services;
[0073] the step that the terminal sends the response of accepting the HFP connection to the bluetooth headset and the bluetooth headset receives the response of accepting the HFP connection sent by the terminal is specifically as follows:
[0074] the host in the terminal sends the instruction HCI_Accept_Connection_Request (HFP) to the LM in the terminal; after receiving the HCI_Accept_Connection_Request (HFP), the LM in the terminal sends a signaling LMP_accepted (HFP) to the LM in the bluetooth headset; after receiving the signaling LMP_accepted (HFP), the LM in the bluetooth headset sends an HCI_Connection_Complete (HFP) to the host in the bluetooth headset; and
[0075] the step that the bluetooth headset sends the HFP connection request to the terminal and the terminal receives the HFP connection request sent by the bluetooth headset is specifically as follows:
[0076] the host in the bluetooth headset sends an instruction HCI_Create_Connection (HFP) to the LM in the bluetooth headset; after receiving the HCI_Create_Connection (HFP), the LM in the bluetooth headset sends a signaling LMP_host_connection_req (HFP) to the LM in the terminal; after receiving the LMP_host_connection_req (HFP), the LM in the terminal sends an instruction HCI_Connection_Request (HFP) to the host in the terminal.
[0077] The terminal is further configured to set its A2DP service status and the AVRCP service status as invisible and unconnectable.
[0078] The terminal is further configured to send the response of accepting the HFP connection to the bluetooth headset after determining that the bluetooth headset does not have A2DP and AVRCP services; and
[0079] correspondingly, the bluetooth headset is further configured to receive the response of accepting the HFP connection sent by the terminal.
[0080] The terminal is further configured to pop out a dialog box on the interface to prompt the user that there is a bluetooth headset initiating a connection after receiving the HFP connection request.
[0081] The terminal is further configured to inform the user of successful establishment of connection between the bluetooth headset and the terminal after sending the response of accepting the HFP connection to the bluetooth headset.
[0082] The above is only preferred embodiments of the disclosure and not intended to limit the protection scope of the disclosure, and any modifications, equivalent replacements, improvements and the like within the spirit and principle of the disclosure shall fall within the protection scope of the disclosure.
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The disclosure provides a method for orderly connection of a bluetooth headset controlled by a terminal. The method includes: a terminal sets Hands-Free Profile (HFP) service status as visible and connectable, and sets Advanced Audio Distribution Profile (A2DP) service status and Audio Video Remote Control Profile (AVRCP) service status as invisible and unconnectable; a bluetooth headset sends an HFP connection request to the terminal; and the terminal sends a response of accepting an HFP connection to the bluetooth headset. The disclosure also provides a system for orderly connection of a bluetooth headset controlled by a terminal. Application of the method and system may avoid different connection order of the profiles due to different manufacturers of the bluetooth headset when the bluetooth headset actively initiates a connection, which achieves a compatible connection of the profiles.
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PRIORITY CLAIM
This application claims the benefit of U.S. Provisional Application Ser. No. 60/831,394 filed Jul. 15, 2006 and entitled REMOTE CONTROL OFFICE COMMUNICATION SYSTEM.
FIELD OF THE INVENTION
This invention relates generally to an office communication system having a number of units that are spatially separated and in communication with one another such that information may be exchanged between or among the units.
BACKGROUND OF THE INVENTION
A medical office setting relies on unobtrusive methods to communicate information regarding office personnel needs and whereabouts, front desk needs and patient flow information. For example, the front desk or other office personnel may need to determine whether a particular doctor is in a particular exam room. Frequently, there are multiple examination rooms as well as multiple doctors, which can pose a challenge to continually monitor and track the whereabouts of various office personnel.
By way of example, a technician may need to notify a particular doctor that his or her patient has been placed in a certain exam room and is ready to be seen. Frequently, a doctor in a room with a patient needs to alert a medical technician outside of the room that assistance is needed in the room.
One commonly used, low-tech approach to solving the aforementioned problems includes a system of colored flags that are rotated into view and visible down a hallway of the office. Different colored flags can be manually rotated into view to signal various needs.
Intercom systems are also available to communicate between various locations in the office setting, but such systems often require hard wiring. In addition, intercom systems must be used with caution when patients are present due to privacy issues and the Health Insurance Portability and Accountability Act of 1996, commonly referred to as HIPAA.
Traditionally pagers have been used in medical settings, but pagers are more appropriate in a hospital based setting to call a doctor for a particular need or emergency and are impractical in smaller office environment such as a medical clinic or dental office.
SUMMARY OF THE INVENTION
In one embodiment, an office communication system provides intra-office communication, for example, within a medical or dental office. The system includes a door or wall unit, a table or desk unit and a wearable or portable unit. The door and desk units may be configured to transmit and receive optical, radio frequency, and other types of data or information carrying signals that are preferable sent and received wirelessly, but may be sent and received via other methods. For example, the door and desk units may be configured to send and receive infrared light signal encoded with a unique address or identifier. The portable unit may also include a transceiver configured to transmit and receive optical, radio frequency, and other types of data or information carrying signals. In an alternative embodiment, for example in order to conserve power, the portable unit may be substantially dormant until such time as it receives a low level radio frequency communication signal, such as from a radio frequency identification (RFID) device
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
FIG. 1 is a schematic view of an office environment utilizing an office communication system in accordance with an embodiment of the present invention;
FIG. 2 is a top plan view of a first communication unit mountable on a vertical surface in accordance with an embodiment of the present invention;
FIG. 3 is a schematic diagram of a number of inter-related components within the first communication unit of FIG. 2 in accordance with an embodiment of the present invention;
FIG. 4 is a top plan view of a second communication unit mountable on a horizontal surface in accordance with an embodiment of the present invention;
FIG. 5 is a schematic diagram of a number of inter-related components within the second communication unit of FIG. 4 in accordance with an embodiment of the present invention;
FIG. 6 is a top plan view of a portable communication unit attachable to an item of apparel of an office personnel in accordance with an embodiment of the present invention; and
FIG. 7 is a schematic diagram of a number of inter-related components within the portable communication unit of FIG. 6 in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an office environment 100 having a first unit 101 , a second unit 200 , and a portable unit 300 according to an illustrated embodiment of the invention. The office environment 100 may be a medical office, dental office, or a similar office where patients or clients are seated in various rooms to be seen by at least one of the office personnel, for example a nurse, a doctor, a dentist, or a hygienist. In a preferred embodiment, the first unit 101 is mounted on a substantially vertical surface 106 such as an exterior surface of a door or wall of an examination room 108 such that the first unit 101 may be visible to those outside of the examination room 108 when the door 106 is closed. Likewise, the second unit 200 is positioned on a substantially horizontal surface 110 such as a desk or counter located in the examination room 108 and may be visible from within the examination room 108 . Alternatively, the first unit 101 and the second unit 200 may be mounted or supported on a variety of surfaces being horizontal, vertical, or having other slopes, and thus are not limited to being mounted or supported on the above-described vertical and horizontal surfaces. The portable unit 300 is attachable to an apparel item 112 such as a coat or scrubs typically worn by medical or dental office personnel. Preferably, the portable unit 300 is attached to the apparel item 112 so that it is visible to other personnel in the office environment 100 .
FIG. 2 shows a schematic view of an external, viewable configuration of the first unit 101 (e.g., door unit) according to an embodiment of the invention. The door unit 101 includes a housing 114 having switches 116 , 118 , and 120 , an audible sensory device 122 , optical sensory devices 124 , 126 , and 128 , and a receiving element 130 for receiving a wireless signal (not shown). The door unit 101 may have a number of purposes such as, but not limited to, helping office personnel schedule and prioritize the occupancy of various exam rooms 108 ( FIG. 1 ), providing a notification that someone in the exam room 108 needs assistance, for example a doctor may need a particular medical instrument or indicating that the exam room needs to be cleaned, and for indicating specifically whether a particular individual, such as a particular doctor or dentist, is inside the exam room 108 . In one embodiment, the first and second units 101 and 200 , the door and desk units, respectively, may not be identical in appearance, structural configuration, purpose, or function. For example, the room unit 200 may not include any type of visible indicator to designate who is in the room and may not be battery powered. It is appreciated and discussed below, however, that the room unit 200 would be configured to provide information about who was in the room to another desk or room unit located in a remote part of the office or at least located outside of the particular room.
The switches 116 , 118 , and 120 may be touch sensitive switches that are manually activated and cooperate with optical sensory devices 124 , 126 , and 128 . In the illustrated embodiment, the switches 116 , 118 , and 120 are located on a front surface 132 of the housing 114 below and approximately aligned with corresponding optical sensory devices 124 , 126 , and 128 . In one embodiment, the optical sensory devices 124 , 126 , and 128 are light emitting diodes (LEDs) and the audible sensory device 122 may be a piezoelectric beeper (not shown) for emitting an audible sound. It is appreciated that the number and arrangement of the switches and sensory devices may vary depending on different office configurations and office communication needs.
In one embodiment, the receiving element 130 operates as a light transmissive lens or filter for receiving a predetermined type of light, such as infrared light from an infrared LED source. Alternatively, the receiving element 130 may be configured as radio reception device capable of receiving a predetermined radio frequency (RF), which may include but is not limited a low frequency radio signal generally in a range of about 30 KHz to 500 KHz, a high frequency radio signal generally in a range of about 850 MHz to 950 MHz and 2.4 GHz to 2.5 GHz, or substantially any other radio frequency or rate in an overall range of about 3 Hz to 30 GHz. In an alternative embodiment, the light array 134 includes an array of different colored LEDs in which each color corresponds to an individual working in the office environment 100 ( FIG. 1 ). For example, the LED array 134 may have separate and discretely colored LEDs that represent each doctor or dentist working in the office environment 100 ( FIG. 1 ). Accordingly and by way of example, a blue LED within the LED array 134 will light up when a Dr. Doe enters the exam room 108 ( FIG. 1 ) and will remain lit while the doctor remains in the exam room 108 .
FIG. 3 shows a schematic view of the working components located within the housing 114 of the door unit 101 . In one example of the present invention, switches 116 , 118 , and 120 are electronically connected to a circuit 152 , which in turn communicates with a microprocessor 154 . The microprocessor 154 is operably connected to a radio frequency transmitting module 156 , LED lights 124 , 126 , and 128 , the LED array 134 , the audible sensory device 122 , and a radio frequency (RF) receiving module 158 . In one embodiment, the transmitting module 156 and the receiving module 158 are combined to take the form of a transceiver that operates to both send and receive signals. A transmission antenna 160 is connected to the RF transmitting module 156 and a reception antenna 162 is connected to the RF receiving module 158 . A power supply source 164 , such as a battery, supplies power to the at least some of the working components within the first unit 101 .
In addition, the microprocessor 154 is operably connected to an infrared receiver module 166 located behind the receiving element 130 ( FIG. 2 ) for receiving and processing infrared light. In one embodiment, the receiver module 166 communicates with an intermediate microprocessor 168 . In addition, the microprocessor 154 and the intermediate microprocessor 168 may include timing devices 170 .
FIG. 4 shows a schematic view of an external, viewable configuration of the second unit 200 (e.g., desk unit) according to an embodiment of the invention. For purposes of this description, the configuration of the desk unit 200 is sufficiently identical to the configuration of the door unit 101 described above. One difference between the door unit 101 and the desk unit 200 is how or where the unit is located within the office environment 100 ( FIG. 1 ). For example, the door unit 101 may be mounted outside of the exam room 108 on a substantially vertical surface, whereas the desk unit 200 may be supported on a substantially horizontal surface such as a table, desk, or countertop within the office environment 100 ( FIG. 1 ).
The desk unit 200 includes a housing 214 having switches 216 , 218 , and 220 , an audible sensory device 222 , optical sensory devices 224 , 226 , and 228 , and a receiving element 230 for receiving a wireless signal (not shown). The desk unit 200 may have a number of purposes such as, but not limited to, helping office personnel schedule and prioritize the occupancy of various exam rooms 108 ( FIG. 1 ), providing a non-obtrusive means to request assistance within the exam room 108 without opening the door 106 ( FIG. 1 ) of the exam room 108 . By way of example, the desk unit 200 may provide an indication that a certain task, activity, or function is required to be performed in the exam room 108 . For example, the desk unit 200 may have color-coded LED that indicates to a person entering the room 108 that the room needs to be refreshed before the next patient arrives. It is appreciated that a variety of other tasks, activities, or functions may be coded on the desk unit 200 depending on the needs of the particular office environment.
The switches 216 , 218 , and 220 may be touch sensitive switches that are manually activated and cooperate with optical sensory devices 224 , 226 , and 228 . In the illustrated embodiment, the switches 216 , 218 , and 220 are located on a front surface 232 of the housing 214 below and approximately aligned with corresponding optical sensory devices 224 , 226 , and 228 . In one embodiment, the optical sensory devices 224 , 226 , and 228 are light emitting diodes (LEDs) and the audible sensory device 222 is a piezoelectric beeper 240 for emitting an audible sound. It is appreciated that the number and arrangement of the switches and sensory devices may vary depending on different office configurations and office communication needs.
In one embodiment, the receiving element 230 operates as a light transmissive lens or filter for receiving a predetermined type of light, such as infrared light from an infrared LED source. Alternatively, the receiving element 230 may be configured as sound reception device capable of receiving a predetermined sound within a desired frequency range. Preferably, the desired frequency range is outside of an audible range (i.e., not detectable by a human ear). The receiving element 230 may cooperate with a light array 234 .
In one embodiment, the light array 234 includes an array of different colored LEDs in which each color corresponds to an individual working in the office environment 100 ( FIG. 1 ). For example, the LED array 234 may have separate and discretely colored LEDs that represent each doctor or dentist working in the office environment 100 ( FIG. 1 ).
FIG. 5 shows a schematic view of the working components located within the housing 214 of the second or desk unit 200 . In one example of the present invention, switches 216 , 218 , and 220 are electronically connected to a circuit 252 , which in turn communicates with a microprocessor 254 . The microprocessor 254 is operably connected to a radio frequency (RF) transmitting module 256 , LED lights 224 , 226 , and 228 , the LED array 234 , the audible sensory device 222 , and a radio frequency (RF) receiving module 258 . In one embodiment, the transmitting module 256 and the receiving module 258 are combined to take the form of a transceiver that operates to both send and receive signals. A transmission antenna 260 is connected to the RF transmitting module 256 and a reception antenna 262 is connected to the RF receiving module 258 . A power supply source 264 , such as a battery, supplies power to the at least some of the working components within the desk unit 200 . One purpose of the desk unit 200 is to transmit a signal to a remote portion of the office carrying information about who is in the room at a particular time. In view of this, the desk unit 200 does not necessarily require any visible indicators on the desk unit 200 . If a visible indicator is provided, the indicator may take the form of a single LED with the capability to change colors depending on who is in the room or depending on whether a certain task, activity, or function is required in the room or the indicator may take the form of a panel of LEDs where each individual LED represents discrete and independent information. Further, the visible indicator may take a non-optical form, such as providing a particular sound or beep.
In addition, the microprocessor 254 is operably connected to an infrared receiver module 266 located behind the receiving element 230 ( FIG. 4 ) for receiving and processing infrared light. In one embodiment, the receiver module 266 communicates with an intermediate microprocessor 268 . In addition, the microprocessor 254 and the intermediate microprocessor 268 may include timing devices 270 . The timing device 270 may operate to automatically trigger the microprocessor 268 either ON or OFF so that it is not constantly in an “ON” state.
FIG. 6 shows the portable unit 300 , which may operate as a name tag and as a wireless office management device. One purpose of the portable unit 300 is to provide a means for office personnel to locate a particular individual within the office environment 100 ( FIG. 1 ). Preferably, the portable unit 300 includes a name 302 within a bordered region 304 located on a front surface 306 of a housing 308 of the portable unit 300 . The portable unit 300 further includes a transmitter lens 310 through which light or another type of wireless signal is transmitted to the first unit 101 , the second unit 200 , or both. In one embodiment, the transmitter lens 310 includes an optical filter for transmitting only infrared light. As will be explained in greater detail below, the transmitter lens 310 cooperates with the receiving elements 130 , 230 of the first and second units 101 , 200 , respectively.
In addition, an audible sensory device 312 is coupled to the portable unit 300 for emitting an audible sound, for example a beeping sound. In one embodiment, the audible sensory device 312 is a piezoelectric beeper. A pin 314 with a corresponding hook 316 , or other equivalent mechanical attachment means, is coupled to the housing 308 and may be manipulated to attach the portable unit 300 to an item of apparel such as a doctor's coat or a medical scrub shirt 112 ( FIG. 1 ).
FIG. 7 shows a schematic view of the working components of the portable unit 300 . Continuing the above-described example of the present invention, an RF receiving module 318 is connected to a microprocessor 320 which connects to a small vibrator motor 322 and a piezoelectric beeper 324 . The microprocessor 320 further includes a timing device 326 . The pin 148 functions as an antenna for the RF receiving module 172 in the illustrated embodiment. The antenna, however, may take other forms and may be located on other portions of the portable unit 300 . The transmitter lens 144 receives infrared light from an infrared transmitting module 328 , which may be coupled to an intermediate microprocessor 330 and may include another timing device 326 . A power supply source 332 , such as a battery, supplies power to the at least some of the working components within the portable unit 300 . In another embodiment, the receiving module 318 receives an infrared signal and the transmitting module 328 transmits an RF signal. Alternatively, the receiving module 318 and the transmitting module 328 may be configured to receive and transmit, respectively, other types of data or information carrying signals.
In one embodiment, the portable unit 300 is configured to be a passive RF unit. By way of example, the portable unit 300 may operate without a separate external power source and instead obtain operating power from the door unit 101 , the desk unit 200 , some other remote power source, or a combination of the above. Some possible advantages of a passive unit are a lower weight, less expensive, and a longer operational lifetime.
The timing devices 170 ( FIG. 3 ), 270 ( FIG. 5 ), and 326 ( FIG. 5 ) conserve power by allowing the respective microprocessors, transmitters and receivers to pulse on and off in a coordinated way. In one embodiment, the timing devices 170 , 270 and 326 are configured to switch the respective units 101 , 200 , and 300 from a sleep mode to an active mode, or vice-versa. Consequently, the timing devices 170 , 270 and 326 may operate to reduce the overall power consumption and prolong battery life, which is likely more important for the portable unit 300 because the portable units 300 will likely be worn by office personnel throughout an entire workday.
Referring to FIGS. 1-7 described above and using an office environment of a family practice medical clinic as an example, the general operation and intra-office communication of the door unit 101 and the desk unit 200 will now be described. If the doctor, nurse, or other person in the examination room 108 needs assistance, they may press or otherwise activate a desired switch 216 , 218 , or 220 of the desk unit 200 to communicate with the microprocessor 254 . For example, activating the switch 216 signals the microprocessor 254 to briefly turn on the corresponding LED 224 and may further signal the RF transmitting module 256 to open radio frequency communication on a desired channel with the door unit 101 .
The door unit 101 receives the radio signal from the desk unit 200 via the RF receiving module 158 , which communicates with the microprocessor 154 of the door unit 101 to illuminate the LED 124 and may briefly activate or sound the audible sensory device 122 of door unit 101 . The LED 124 of the door unit 101 stays lit until one of the office personnel outside of the exam room 108 touches the switch 116 of the door unit 101 to turn off LED 124 . In one embodiment the office personnel outside of the exam room 108 may be alerted by the audible sensory device 122 , and can look up to see which room has the LED lit. Similarly, personnel outside of the exam room may touch switch 118 of the door unit 101 to sound beeper 222 and LED 224 of the desk unit 200 .The doctor or other person in the room would then be prompted to turn off the LED 224 of the desk unit 200 by touching the switch 220 of the desk unit 200 . Thus, a type of wireless 3-way switch is created between the door unit 101 and the desk unit 200 . The electronics can be designed so that LEDs stay on via a brief RF signal with the microprocessor providing an ON and OFF toggling function. In addition, the door unit 101 and the desk unit 200 may operate on a three-way switch meaning that same button is not required to turn features on the respective units either ON or OFF. For example, the LED 224 of the desk unit 200 may be turned ON or OFF remotely, by personnel using another desk unit 200 in a front office area.
If the officer personnel want to communicate that a particular exam room 108 is next to be seen by the doctor, the switch 116 of the door unit 101 may be touched, which signals the touch-sensitive circuit 152 and the microprocessor 154 and turns on the LED 124 . If the office personnel wish to turn off the LED 124 , the switch 116 is simply touched again. Similarly, the doctor may active the switch 218 on the desk unit 200 to signal a particular need, such as the assistance of one of the office personnel to obtain or clean a medical instrument.
Various embodiments of this invention can consist of multiple door and desk units, each with multiple rows of touch sensitive switches and LEDs. Each switch of each box with a remote control function can have a unique RF signal or channel. Alternatively, some switches can have a common channel, thus allowing the front desk to signal all rooms with one button. Additionally, other embodiments may allow an individual switch to be selected to act either as an individual on/off switches or as paired remote switches.
In one embodiment, a front desk unit 200 includes a central panel having and LED array showing various activities in the multiple rooms of the office environment, for example indicating which doctor is in which room at any given time. The central panel permits the front office personnel to schedule and prioritize aspects of the office by having real time information about what is happening in a selected room. The LED array may take the form of a map or a layout of the office environment with each room having at least one LED indicator associated therewith.
The operation of the portable unit 300 will now be described. There may be times where the doctor needs to signal the assistant for help when the location of the assistant is not known. Or similarly, for the assistant or front desk to alert the doctor when his whereabouts in the office are not known. The doctor, needing to call the assistant for help, presses the touch switch 220 on desk unit 200 , which activates the circuit 252 of the desk unit 200 , which then triggers the microprocessor 254 to briefly light LED 224 . In addition, the microprocessor 254 controls the RF transmitting module 256 of desk unit 200 for communicates on a unique channel with RF receiving module 328 of the portable unit 300 , which signals the microprocessor 330 to briefly activate the vibrator motor 322 and beeper 324 of the portable unit 300 . Each portable unit 300 may have a unique RF communication address, which permits the signaling of a specific person. In addition or alternatively, each portable unit 300 may have a common address, which permits at least a majority of the office personnel to be alerted. Other embodiments of the portable unit 300 may allow for switching between a common address and a unique address to increase the versatility of the overall system. In another embodiment, each portable unit 300 may have separate and discrete beeper tones to designate specific signals.
In one embodiment, the infrared transmitting module 328 of the portable unit 300 transmits a unique signal at a particular interval determined by the timing device 326 in communication with the intermediate microprocessor 330 . When the doctor wearing the portable unit 300 enters the examination room 108 , the receiving element 230 of the desk unit 200 receives the infrared light from the portable unit 300 . Then, the desk unit 200 , using the RF transmitting module 256 , signals the RF receiving module 156 of the door unit 101 to activate the microprocessor 154 of the door unit 101 to controllably turn on one of the LEDs in the LED array 134 of the door unit 101 . The particular LED which is lit may be associated with unique address corresponding to the infrared transmitting module 328 of portable unit 300 .
Thus, no matter which room the doctor enters, the same color LED will be lit on the door unit 101 outside that particular exam room 108 . At the same time the LED array 134 is signaled on the door unit 101 when the doctor enters the exam room 108 , either the door unit 101 or the desk unit 200 , or both, depending on the embodiment, may communicate with the other regarding the status of the doctor and provide instructions to turn on or off the LED However, the above-identified LED of the LED array 134 on the door unit 101 will remain lit until the doctor exits the exam room 108 . At that point, the infrared receiving module 266 of the desk unit 200 no longer receives the infrared signal from portable unit 300 . Once the desk unit 200 has failed to receive any infrared light from the portable unit 300 for a predetermined amount of time, the desk unit 200 signals the microprocessor 154 of the door unit 101 to turn off the individual LED of LED array 134 .
In yet another example of the operation of the system, one of the office personnel signals which room the doctor will be entering next by touching the switch 116 on the door unit 101 , which turns on one of the LEDs 124 , 126 , or 128 . When the doctor enters that room the lit LED 124 , 126 , or 128 automatically turns off, and the LED light unique to that doctor within the LED array 134 is turned on. When the doctor leaves the room, the unique LED light on the LED array 134 of the door unit 101 is automatically turned off. Consequently, anyone in proximity to a particular door unit 101 may be able to determine which doctor is in which room looking at which color LED within the LED array 134 happens to be lit.
In yet another embodiment, the door unit 101 works directly with the portable unit 300 without any intermediate communication with the desk unit 200 . Other embodiments may include radio frequency identification technology having a directional capability, rather than infrared sensing modules. Further, the wireless signals may be transmitted and received using short range radio frequency technology, blue tooth type technology, or an equivalent technology. Moreover, many different variations of LED colors, flashing LEDs, bi-color or tri-color LEDs, LED array configurations or layouts, different sounds or different types of beepers, may be included in the above-described embodiments. Additionally, the portable unit 300 may include a belt clip (not shown) so that it may be worn similar to a pager.
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.
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An office communication system provides intra-office communication within a medical or dental office, for example. The system includes a door or wall unit, a table or desk unit, and a wearable or portable unit. The door and desk units are configured to transmit and receive both infrared and radio frequency type wireless signals. The portable unit may include an infrared light transmitter configured to transmit infrared light encoded with a unique address or identifier. The system operates to non-obtrusively notify office personnel whether a practitioner has entered or is presently within a particular exam room of the office, even if a door of the exam room is closed.
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RELATED APPLICATIONS
This application claims the benefit of German Patent Application No. DE 102013213996.9, filed Jul. 17, 2013. The entire contents of the priority document are hereby incorporated herein by reference.
TECHNICAL FIELD
The present teachings relate generally to apparatuses for displaceably (e.g., moveably) mounting a C-arm in a C-arm holding unit with the aid of a cage guide. In some embodiments, the present teachings further relate to x-ray imaging devices including a C-arm that is displaceable in the C-arm holding unit.
BACKGROUND
X-ray imaging devices are used in fluoroscopy and radiography. In the x-ray imaging process, x-ray beams emitted by an x-ray emitter pass through an object before being incident on an x-ray detector, having been attenuated by the object. Some configurations of an x-ray imaging device include a C-arm.
In the laid-open document DE 101 097 54 A1, a C-arm x-ray device is described as a ceiling device. An x-ray emitter and an x-ray detector are fastened to the ends of the C-arm. The C-arm is mounted in a movable manner and may be rotated about a patient by a drive. In the process described in DE 101 097 54 A1, the C-arm moves along its own axis on guides that are embedded into the profile of the C-arm. The guide of the C-arm about the orbital axis has a plurality of rollers or roller pairs and guide wires that are made of steel and that have been introduced into the C-arm that is made of aluminum.
The utility model document DE 202011107140 U1 describes a roller guide of a C-arm. In the roller guide described therein, a stable mount is provided through complete overlap between a C-arm holder and the C-arm. As a result of the length of the C-arm, the length of the C-arm holder, and the guide of the C-arm, the described systems are restricted to a displacement range around the orbital axis of approximately 100°.
BACKGROUND AND SUMMARY
The scope of the present invention is defined solely by the appended claims, and is not affected to any degree by the statements within this summary.
The present embodiments may obviate one or more of the drawbacks or limitations in the related art. For example, in some embodiments, an apparatus for mounting a C-arm and an x-ray imaging device are provided that are able to carry out larger rotational movements of the C-arm about the orbital axis as compared to conventional approaches.
In accordance with the present teachings, a C-arm and a C-arm holding unit may be moveably mounted by a cage guide arranged therebetween. The phrase “cage guide” refers to a linear guide without a rolling body return section. A cage guide may include a guide rail pair and the rolling bodies arranged therebetween. The rolling bodies are held in a rolling body cage. In some embodiments, a transmission ratio between the rolling body cage and the C-arm of greater than 1:2 may be obtained by suitably configuring the rolling bodies and/or the C-arm holding unit and the C-arm whereupon the rolling bodies may roll.
A C-arm mounting apparatus for an x-ray imaging device in accordance with the present teachings includes a C-arm and a C-arm holding unit. The apparatus further includes at least one cage guide unit that is moveably arranged between the C-arm and the C-arm holding unit. The C-arm is moveably mounted on the at least one cage guide unit in the C-arm holding unit. The cage guide unit includes a plurality of rolling bodies and at least one rolling body cage. In accordance with the present teachings, greater displacement ranges of the C-arm may be achieved due to the small overlap between the C-arm and the C-arm holding unit.
In some embodiments, the C-arm holding unit and the C-arm may be configured such that the cage guide unit generates a transmission ratio of greater than 1:2, thereby facilitating passage of the C-arm over a great track around the orbital axis.
In other embodiments, the rolling bodies may be configured such that the cage guide unit generates a transmission ratio of greater than 1:2, thereby facilitating passage of the C-arm over a great track around the orbital axis.
In other embodiments, two guide wires may be formed on the C-arm holding unit and two guide wires may be formed on the C-arm. The rolling bodies are configured to roll on the guide wires, and the guide wires are configured with respect to one another such that the cage guide unit is configured to generate a transmission ratio of greater than 1:2.
The rolling bodies may have a first rolling radius and a second rolling radius. The first rolling radius defines the distance between the rolling body centers and points of support on the C-arm holding unit. The second rolling radius defines the distance between the rolling body centers and points of support on the C-arm. The first rolling radius is less than the second rolling radius.
In some embodiments, the cage guide unit may have an arcuate shape.
In some embodiments, the C-arm may be moveably arranged within the C-arm holding unit, and the C-arm may be mounted between at least two cage guide units.
In some embodiments, a first cage guide unit may be formed on a side of the C-arm facing an isocenter, and a second cage guide unit may be formed on a side of the C-arm facing away from the isocenter.
In some embodiments, the C-arm may be moveably mounted on the C-arm holding unit, and the C-arm may be mounted like a carriage between two cage guide units.
In some embodiments, the two cage guide units may be formed at the same distance from an isocenter.
The present teachings also provide an x-ray imaging device that includes an x-ray emitter, an x-ray detector, and a C-arm mounting apparatus of a type described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-sectional view of an example of a cage guide.
FIG. 2 shows a cross-sectional view of an example of a cage guide with a 1:4 transmission ratio based on an exemplary configuration of the points of support of the rolling bodies.
FIG. 3 shows a cross-sectional view of an example of a first cage guide with a 1:4 transmission ratio based on an exemplary configuration of the guide wires.
FIG. 4 shows a cross-sectional view of an example of a second cage guide with a 1:4 transmission ratio based on an exemplary configuration of the guide wires.
FIG. 5 shows a cross-sectional view of an example of a cage guide with a 1:4 transmission ratio based on an exemplary configuration of the rolling bodies.
FIG. 6 shows a perspective view of an example of a C-arm mounting apparatus.
FIG. 7 shows a cross-sectional view of an example of a C-arm x-ray device with a cage guide of the C-arm in a home position.
FIG. 8 shows a cross-sectional view of an example of a C-arm x-ray device with a cage guide of the C-arm in an upper end position.
FIG. 9 shows a cross-sectional view of an example of a C-arm x-ray device with a cage guide of the C-arm in a lower end position.
FIG. 10 shows an exemplary configuration of a cage guide as a linear carriage.
DETAILED DESCRIPTION
In order to increase the displacement range of a C-arm, the concept of a guide has been modified. For example, the C-arm is mounted by a cage guide unit rather than by using stationary rollers. As a result, the overlap between the C-arm and a C-arm holding unit may be reduced, and the displacement range may be increased.
In contrast to conventional designs, the rolling bodies (e.g., rollers, spheres, needles) of the guide are not mounted in the C-arm holding unit in a stationary manner. Rather, the cage guide unit (e.g., a rolling body cage with rolling bodies) is displaced in the C-arm holding unit according to the 1:2 cage guide principle. The transmitting mounting element is not assembled in a stationary manner but rather is automatically positioned in the C-arm holding unit. As further described below in reference to FIG. 1 , a guide of the C-arm is thus provided. The guide may be telescopic.
FIG. 1 shows a cross-sectional view of an example of a cage guide with a first guide rail 7 , a second guide rail 8 , and a sphere 9 . The sphere 9 is situated between the first guide rail 7 and the second guide rail 8 as a rolling body, and is held in a rolling body cage 10 . The guide is based upon the principle of a rolling wheel.
The first guide rail 7 may be equated with a first velocity v 1 =0. If the sphere 9 rolls, the center of the sphere 9 moves with a velocity v. Due to the position of the sphere 9 (e.g., the distance from the resting point of the sphere 9 ), the second guide rail 8 moves with a second velocity v 2 that has twice the magnitude of the velocity v, as indicated by the following equation: v 2 =2*v.
By linking a plurality of spheres 9 at the sphere center points thereof by the rolling body cage 10 , a cage may be constructed. Thus, the rolling body cage 10 moves at the velocity v, and the second guide rail 8 moves at twice the velocity v. Since the whole structure is observed during the same time interval, it may be determined that the second guide rail 8 always travels over twice the path length as compared to the rolling body cage 10 . This 1:2 transmission ratio is independent of the type of rolling bodies employed (e.g., cylinder rollers, spheres, etc.).
In order to reduce the track of the cage guide in the C-arm holding unit, the transmission ratio between the cage guide unit and the C-arm may be increased. FIG. 2 depicts a transmission concept wherein a rolling body (e.g., a sphere) rolls over various radii.
In FIG. 2 , the principle of a cage guide in accordance with the present teachings is exemplified for a transmission ratio of 1:4. The left-hand drawing shows an exemplary front view and the right-hand drawing shows an exemplary side view. A sphere 9 that comes into contact with first guide rail 7 and second guide rail 8 via points of support 13 is arranged between the first guide rail 7 and the second guide rail 8 .
While the first guide rail 7 rolls on a smaller first rolling radius R 1 of the sphere 9 , the second guide rail 8 rolls on a larger second rolling radius R 2 of the sphere 9 . As a result, if a first guide rail 7 is stationary, the sphere 9 may move with a velocity v. Moreover, as a result of the 1:2 ratio of the radii, the second guide rail 8 may move with a second velocity v 2 having four times the magnitude, as shown in the following equation: v 2 =4*v.
As a result, a 1:4 transmission is created. By rolling the sphere 9 over different rolling radii R 1 and R 2 , almost any transmission ratio may be set. Since the production of guide rails with a stepped configuration may be complicated, suitably configured guide wires may also be used in place of the first guide rail 7 and the second guide rail 8 .
Each of FIGS. 3 and 4 shows a cross-sectional view of a sphere 9 being guided between guide wires 14 while the sphere 9 rotates about its rotational axis 15 . Exemplary geometric dimensions for a 1:4 transmission ratio are depicted. As described above in reference to FIG. 2 , the sphere 9 is rolled over two different rolling radii R 1 and R 2 . The rolling of sphere 9 over two different rolling radii R 1 and R 2 is achieved via an angular shift of the guide wires 14 with respect to one another. In accordance with the present teachings, the guide wires 14 do not have a rectangular arrangement.
Although all four guide wires may be arranged in a rectangle in conventional sphere cage guides with sphere races, guide wires in accordance with the present teachings are arranged at different variable angles. As a result, the sphere 9 rolls over different rolling radii R 1 and R 2 . The two rolling radii R 1 and R 2 have values of 9 mm and 18 mm, respectively. By rolling over two different rolling radii R 1 and R 2 , an additional 1:2 transmission is created. Since the sphere 9 per se already has a transmission of 1:2 between the sphere center point (or cage) and the points on the second rolling radius R 2 , an overall transmission of 1:4 between the cage and C-arm is achieved for a normal square arrangement of the guide wires 14 (cage principle).
The above-described configuration of the guide wires 14 may provide a simple and cost-effective solution to the problem of transmission. A cage guide is created by connecting the plurality of spheres 9 , thereby providing direct positioning of the cage (e.g., friction between spheres 9 and guide wires 14 ) depending on the rolling radii R 1 and R 2 whereby the spheres 9 roll on the guide wires 14 .
The difference in the cage guides in FIG. 3 and FIG. 4 merely lies in the embodiment of the guide wires.
In some embodiments, as shown in FIG. 5 , a specialized configuration of a roller 16 may be used as the rolling body as an alternative to using an angle-offset configuration of guide wires. In such embodiments, any desired transmission may be created by redesigning conventional rollers. FIG. 5 shows an exemplary front view on the left-hand side, and an exemplary side view on the right-hand side. By way of example, the rollers 16 (only one being shown in FIG. 5 for the sake of simplicity) may include a first cylinder 17 and a second cylinder 18 that are offset from one another. While the smaller first cylinder 17 rolls on the first guide rail 7 , the second larger cylinder 18 rolls on the second guide rail 8 .
Therefore, the roller 16 (and, therefore, a cage connected thereto) moves at the velocity v on a stationary first guide rail 7 . As a result, the second guide rail 8 moves with the n-times second velocity v 2 if the second rolling radius R 2 is n/ 2 times larger than the first rolling radius R 1 . The second velocity may be expressed as follows:v 2 =n*v.
Since the whole design is observed over a constant time interval, the second guide rail 8 always travels over n-times the path length of the roller 16 , thereby resulting in a transmission between roller/cage and the second guide rail of 1:n.
As a result of configuring the rollers 16 with an offset and rolling the rollers 16 over different rolling radii R 1 and R 2 , any desired transmission (1:n) may be created. By linking a plurality of rollers, a cage that may be used for guiding a C-arm about the orbital axis is created. As a result of rolling friction between the first guide rail 7 , the second guide rail 8 , and the rolling cage, a C-arm may be positioned without additional aids.
FIG. 5 shows an example of a cage guide with an exemplary configuration for a transmission of 1:4. The roller 16 includes first cylinders 17 and second cylinder 18 offset from one another. While the smaller first cylinder 17 rolls on the first guide rail 7 with the first rolling radius R 1 , the larger second cylinder 18 rolls only on the second guide rail 8 with the rolling radius R 2 that has twice the size compared to the first rolling radius R 1 . The rolling radius R 2 may be expressed as follows: R 2 =2*R 1 .
As a result, in the case of a stationary first guide rail 7 , the roller 16 may move at the velocity v, and the second guide rail 8 may move at the second velocity v 2 with four times the magnitude. The second velocity v 2 may be expressed as follows: v 2 =4*v.
Thus, a 1:4 transmission is created. By linking a plurality of rollers 16 on the roller axis, cage may be constructed. The cage moves at the velocity v and the second guide rail 8 moves at the second velocity v 2 (=4*v).
Since the whole structure is observed over the same time intervals, the guide rail 8 always travels over four times the path length compared to the cage, thereby resulting in a 1:4 transmission.
For embodiments that use a different first cylinder 17 and second cylinder 18 , any desired transmission may be created by rolling the roller 16 over different rolling radii R 1 and R 2 . As a result, direct positioning of the cage (e.g., friction between rollers and guide rails) may be achieved depending on the rolling radii R 1 and R 2 of the first cylinder 17 and second cylinder 18 .
FIG. 6 depicts an exemplary embodiment of a C-arm guide and a mount in accordance with FIG. 5 . A C-arm holding unit 2 is arranged on a stand 6 . The C-arm 1 is moveably mounted in the C-arm holding unit 2 by the cage guide unit 3 . For lateral fastening, guide wires 14 have been introduced into the C-arm 1 and into the C-arm holding unit 2 (not visible in FIG. 6 ). The guide wires serve as a race and a guide for the non-visible rollers of the cage guide unit 3 by introduced notches. The rollers include two cylinders offset from one another as shown in FIG. 5 .
While the smaller first cylinder rolls on the C-arm holding unit 2 , the larger second cylinder rolls on the C-arm 1 . Therefore, the C-arm 1 always travels over four times the path length compared to the cage guide unit 3 , thereby resulting in a transmission between the cage guide unit 3 and the C-arm 1 of 1:4.
If the principle described above in reference to FIGS. 1-5 is applied to a C-arm guide, a configuration as shown, for example, in FIGS. 7-9 may be obtained. Each of FIGS. 7-9 shows a cross-sectional view of a C-arm x-ray device with a cage guide of a C-arm 1 . An x-ray emitter 4 and an x-ray detector 5 are fastened opposite to one another on the C-arm 1 . The C-arm 1 is mounted within a C-arm holding unit 2 . Four cage guide units 3 are arranged between the C-arm holding unit 2 and the C-arm 1 . The C-arm is moveably arranged on the cage guide units around an isocenter 11 . In FIGS. 7-9 , only two of the four cage guide units 3 are visible.
Two cage guide units 3 are arranged within the C-arm 1 , and two cage guide units 3 are arranged outside of the C-arm 1 . As a result, the C-arm 1 may be guided in a stable manner. The rolling bodies (not shown) of the cage guide units 3 run on guide wires or guide rails (not shown).
In order to extend the displacement path of the C-arm 1 , the C-arm holding unit 2 may also provide in a telescopic-type embodiment that includes a plurality of stacked cage guide units 3 .
FIG. 7 shows the C-arm 1 in a home position. FIG. 8 shows the C-arm 1 in an upper end position, with the cage guide unit 3 being displaced up to the upper end of the C-arm holding unit 2 . FIG. 9 shows the C-arm 1 in a lower end position, with the cage guide unit 3 being displaced down to the lower end of the C-arm holding unit 2 .
Other configurations of the cage guide unit 3 may be used. By way of example, FIG. 10 shows a linear carriage wherein the C-arm 1 (depicted as a section) is mounted in a moveably fitted manner between two cage guide units 3 that slide in the C-arm holding unit 2 . The rolling bodies are embodied as needles 12 and form a V-shaped groove, wherein a complementarily shaped guide rail of the C-arm may be displaced.
For embodiments of C-arms 1 with a cage guide, larger displacement ranges may be achieved due to the smaller overlap between the C-arm 1 and the C-arm holding unit 2 . Through application of a rolling wheel principle, driven positioning of the rolling body cage may be avoided. Instead, the C-arm 1 may be positioned relative to the C-arm holding unit 2 . The rolling body cage automatically travels over half the path length of the C-arm 1 (e.g., friction between the rolling body and the guide rails and the 1:2 displacement resulting therefrom). Furthermore, a rigid and resilient mount of the C-arm 1 may be achieved by a relatively large number of supporting rolling bodies.
The present teachings are applicable in both floor-mounted (e.g., floor stand) and ceiling-mounted (e.g., second plane) x-ray devices. In addition, the present teachings may be used in connection with telescopic guides.
While the present invention has been described above by reference to various embodiments, it should be understood that many changes and modifications may be made to the described embodiments. It is therefore intended that the foregoing description be regarded as illustrative rather than limiting, and that it be understood that all equivalents and/or combinations of embodiments are intended to be included in this description.
It is to be understood that the elements and features recited in the appended claims may be combined in different ways to produce new claims that likewise fall within the scope of the present invention. Thus, whereas the dependent claims appended below depend from only a single independent or dependent claim, it is to be understood that these dependent claims may, alternatively, be made to depend in the alternative from any preceding claim—whether independent or dependent—and that such new combinations are to be understood as forming a part of the present specification.
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A C-arm mounting apparatus for an x-ray imaging device includes a C-arm, a C-arm holding unit, and at least one cage guide unit. The at least one cage guide unit is moveably arranged between the C-arm and the C-arm holding unit. The C-arm is moveably mounted on the C-arm holding unit. The at least one cage guide unit includes a plurality of rolling bodies and at least one rolling body cage. The small overlap between the C-arm and the C-arm holding unit may facilitate greater rotations about an isocenter. An x-ray imaging device includes a C-arm mounting apparatus.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a heat exchanger, and more particularly to a heat exchanger which is used as a condenser installed in an air conditioner for an automobile and the like.
2. Description of the Related Art
In FIG. 5 and FIG. 6 which show conventional heat exchanger, fins 5 and tube elements 6 are alternately stacked together. First and second tank elements 3, 4 are installed on both sides of the fins 5 and the tube elements 6. The coolant, before flowing into the heat exchanger, is high temperature steam. At first the coolant flows into an entrance 1 and inlet pipe 2 and runs in an inner space 3d of first tank element 3, which is divided by partition wall 9. After that it runs through the tube elements 6 and each inner space 4d, 3e, 4e of the first and second tank element 3, 4, as shown by arrows 6A, 6B, 6C, and flows through outlet pipe 7 and outlet pipe 8.
The coolant flow exchanges heat with cooling air-flow shown as an arrow 15 through the surface of the tube elements 6 and the fins 5. As a result of this heat exchange, the heat of the coolant flow is removed by the cooling air-flow. As the coolant flow is cooled, it is compressed and liquefies, and its volume decreases. Considering the decrease of the volume of the coolant flow, the total cross-sectional area of the tube elements 6 needed to carry the coolant flow becomes smaller as the coolant flow runs from the entrance to the exit as shown in FIG. 5. In general, the tube elements 6 and the tank elements 3 are formed by extrusion molding. They are constructed and soldered to the fins 5.
The heat exchanger shown in FIG. 5 is a an orthogonal flow type, namely the coolant flow intersects at right angles with the cooling air flow. Though the shape of the orthogonal flow type is compact, the heat exchange efficiency is less than that of the opposite flow type (the coolant in the opposite flow type flows opposite to the cooling air flow) in general. Because the heat of the coolant is removed and the temperature of the coolant goes down between the upper reaches and the lower reaches of the exchanges, the difference between the two flows is slowly reduced.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved heat exchanger which obviates the above conventional drawbacks.
It is another object of the invention to provide an improved heat exchanger which is highly efficient and, which is easy to construct and in a short time.
In order to attain the foregoing objects, a heat exchanger of this invention is formed by alternately stacking together tube elements having coolant flow passages therein and fins. It performs a heat exchange between air flows and coolant flows which are supplied into the coolant flow passages through a pair of tank elements which are disposed on both sides of the tube elements.
One of the tank elements is formed of brazing materials and comprises a pair of plates which have a sectional U shape. A pair of such plates are connected to form an inner space. Between the plates partition plates are brazed. They divide the inner space into an inside space near the tube elements and an outside space near the inside space, and they have penetrating holes.
The tube elements comprises first coolant flow passages which project from the penetrating hole to the outside space and second coolant flow passages whose end portions communicate with the inside space. One of the first and second coolant flow passages is situated higher than the other coolant flow passage and on the rear side of the air flow.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will be more apparent and more readily appreciated from the following detailed description of preferred exemplary embodiments of the present invention, taken in connection with the accompanying drawings, in which;
FIG. 1 is a front view showing a heat exchanger according to this invention from a direction that air flows to;
FIG. 2(a) is a cross sectional view taking along line 2a--2a FIG. 1;
FIG. 2(b) is a cross sectional view taking along line 2b--2b in FIG. 1;
FIG. 3 is a schematic plan view showing coolant flow in the heat exchanger shown in FIG. 1;
FIG. 4 is a schematic plan view showing coolant flow in the heat exchanger according to the prior art;
FIG. 5 is a front view showing a heat exchanger according to the prior art from a direction that air flows to.
FIG. 6 is a cross sectional view taking along line 6--6 in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, FIG. 2(a) and FIG. 2(b), the heat exchanger of this invention is formed as following. Tube elements 6 and fins 5 formed as corrugated fins are alternately stacked together and side plates 14 are installed on an upper surface and a lower surface of the laminated product.
A pair of tank elements 3, 4 are attached on both sides of each passage of the tube elements 6. As shown in FIG. 2(a) and FIG. 2(b), the tank elements 3, 4 are formed of outside plates 31, 41 and inside plates 32, 42 which are made by press fitting. The outside plates 31, 41 and the inside plates 32, 42 make an inner space therein. Each plate is formed of brazing sheet material which is made of brazed aluminum. The outside surfaces of the inside plates 32, 42 which in a cross sectional view are U shaped are fixed in the inner surface of the outside plates 31, 41 which also have a cross sectional U shape.
Partition plates 33, 43 made of brazing sheet material are fitted in the middle between the inside plates 32, 42 and the outside plates 31, 41. The partition plates 33, 43 are fixed in each plate by brazing and each partition plate has a hole into which is fixed a projecting part of a tube element 4. The inner space of each tank element is divided into inside spaces 3b, 3c, 4b which are near the tube element 6 and outside spaces 3a, 4a which are far from the tube element 6. The outside space 3a of the first tank element 3 communicates with inlet pipe 2. The inside space 3b, 3c of the first tank element 3 is divided by partition wall 9. The edge of the partition plate 43 is closed by partition wall 11 which separates the outside space 4a from the inside space 4b. The inside space 3c of the first tank element 3 communicates with outlet pipe 7.
The tube element 6 consists of three passages, namely a rear passage 61 which is the first coolant flow passage and is situated on the back side away from the air flow side, a center passage 62 which is a second coolant flow passage and a front passage 63 which is a third coolant flow passage and is situated on the front side. Each passage is defined by partition walls 10 which are integral with the tube element 6. Both end portions of the rear passage 61 project through partition plates 33, 43. Furthermore end portions of the other passages, the center passage 62 and the front passage 63 are within the partition plates 33, 43 and in the inside space 3b, 4b.
Each tube element 6 is formed to be flat and oblong by extrusion molding, and the length of the vertical sides is shorter than the length of the horizontal sides. The tube elements 6 and the fins 5, the tube elements 6 and the inside plates 32, 42, and the tube elements 6 and the partition plates 33, 43 are fixed by being brazed together. The brazing is done at the same time because all parts of the tank elements are formed of brazing sheet materials.
The partition plates 33, 43 are used for protecting the tank elements 3, 4 against the external force and pressure.
The direction of the coolant flow in the tube elements 6 is shown in FIGS. 2-4 with arrows. The coolant flow enters from the inlet tube 2 and flows from the outside space 3a of the first tank element 3 to the outside space 4a of the second tank element 4 through all the rear passages 61 of the tube elements 6 as shown by arrow 6A. After that the coolant flows from space 4a to the inside space 3b of the first tank element 3 through the center passages 62 and the front passages 63 of the upper four tube elements as shown by arrow 6B. The coolant then flows to the inside space 4b of the second tank element 4 through the center and front passages 62, 63 of the center three tube elements as shown by arrow 6C. It then flows to the inside space 3c of the first tank element 3 through the center and front passages 62, 63 of the lower two tube elements as shown by arrow 6D, and flows out from exit 8.
FIG. 3 shows the coolant flows in the heat exchanger in this embodiment and FIG. 4 shows the coolant flows in the conventional heat exchanger. In the case of this embodiment in FIG. 3, the temperature of the upper reaches of the coolant flows 65 which flow in the rear passages 61 is high. The temperature of the lower reaches of the coolant flows 66 which flow in the center and front passages 62, 63 is low, because the lower reaches of the coolant flows 66 have been cooled by the air flow. The temperature of the air flow in the front side is low, because the air flowing in the front side has not exchanged heat with the coolant flows. On the other hand, the temperature of the air flowing in the rear side is high, because the air in the rear side has already exchanged heat. Because of that structure, the difference in temperature between the coolant flow and the air flow is averaged between the air flow in the front side (the lower reaches of the coolant flows) and the air flow in the rear side (the upper reaches of the coolant flows). Thus the heat exchanger of this embodiment has a favorable formal character as an orthogonal type and performs favorably compared to the opposite flow type. So this heat exchanger can be of high efficiency.
In the case of the conventional heat exchanger, the temperature of the coolant flows 67 which are near entrance 1 is still high and the difference in the temperature between the coolant flows and the air flow is large enough. But the coolant flows 68 which are near the exit 8 have exchanged heat with the air flow, so that the difference in temperature between the coolant flows and the air flow is small and the amount of heat exchanged in this part is not enough. Therefore the orthogonal flow type conventional heat exchanger is of low efficiency. The heat exchanger in this embodiment solves that problem.
In the conventional heat exchanger, the tube elements which have a high difference in the temperature between the air flows and the coolant flows and are on the upper reaches of the coolant flows are increased. But diversification of the tube element has limits and increasing the number of the tube elements makes the sectional area of the coolant flows in the upper reaches too big, and makes the speed of the coolant slower. As a result, the efficiency of heat exchange is reduced.
But in this embodiment, the inner spaces of the tube elements are divided and the coolant flows of the upper and lower reaches are in each tube element so that the whole sectional area of the coolant flows can be controlled under a fixed area. Thus the speed of the coolant flows is not reduced no matter where the upper reaches of the coolant flows are arranged. The volume of the coolant flow becomes smaller as condensation and cooling occur, and the passages which are arranged in the front side opposite to the air flow are divided into three groups. The upper group has more passages than the lower group. In this embodiment, this structure of the passages and the averaging of the difference between the temperatures increases the efficiency of the heat exchange.
In the case of the heat exchanger of this embodiment, all of the tank elements are formed of brazing sheet material which is an alloy made of brazed aluminum, etc. So each plate which is formed as a partition plate, an inside plate, or an outside plate is brazed to the tube elements or each other without using brazing materials. This brazing work can be performed in the same furnace where the tube elements and the fins are brazed together. Thus, the time for the plates to be brazed is shortened and the cost of the heat exchange element is reduced so that the heat exchanger of this invention has a lower cost and a high efficiency.
Furthermore the holes in the partition plates are penetrated by the tube elements and they are fixed to each other by brazing. Thus the strength of the partition plate is improved and it can better resist pressure. On the second tank element, when the partition plate is placed from end to end and some penetration holes are formed and the inside space and the outside space of the tank element is created, the strength of the partition plate and the tank element is improved.
In this heat exchanger as mentioned above, the passages of the tube elements are divided into three passages, that is the front passage, the center passage and the rear passage, and each passage is guided to another space of the tank elements and each tube element includes the passages which goes to the space and back. But each tube element of the heat exchanger of this invention may comprise not only three passages but also two passages and/or more passages. Moreover the coolant flows in the tube elements can be opposite flows between the center passage and the front passage.
Obviously numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A heat exchanger includes a plurality of tube elements, and a plurality of fins which are alternately stacked together with the tube elements. A tank element is disposed on both sides of the tube elements. At least one of the tank elements is formed of brazing materials and comprises a pair of plates which are U-shaped in cross-section and form an inner space. A partition plate is positioned in the inner space and divides the inner space into a first space adjacent the tube elements and a second space separated from the tube elements by the first space. The partition plate is also provided with a penetrating hole. Each of the tube elements contain at least first and second coolant flow passages. The first coolant flow passages extend through the penetrating holes and into the second space, and the second coolant flow passages extend into the first passage.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/322,357, filed Apr. 14, 2016, which is incorporated by reference as if fully set forth herein.
FIELD OF THE INVENTION
[0002] The embodiments herein relate to devices and methods for reading a coupon that displays a pattern when a target substance is detected.
BACKGROUND
[0003] A “coupon reader” is a device that accepts a “coupon,” typically a planar tray having a chemically reactive section that is imbued with a chemical mixture that is designed to react to a target substance and forms a visually detectable indicator pattern after a predetermined development time. A common implementation is the lateral flow immunoassay. The term “ticket” is also sometime used to refer to a coupon. Generally, coupons are designed to be read by a human technician, although coupon readers are also becoming common. The reader automates detection of the indicator pattern, removing reliance on human interpretation. Typically, a single company makes both coupons and the readers for those coupons, but there are also companies that do not make coupons, but do make coupon readers for coupons made by other companies (“third-party coupon readers”). Some coupons have only one section that reacts to a single target substance, whereas other coupons have a number of sections, each one designed to react to a different target substance. Coupons come in various sizes, but it appears that no currently available coupons are greater than 15 cm in any dimension.
[0004] Coupons are used to detect substances of interest in the medical and public safety fields. For example, some coupons are designed to accept a bodily fluid onto the chemically reactive sections, to detect a naturally occurring target compound, such as a hormone, or a toxin. A public safety coupon can accept samples from many sources, including aerosolized particulates, liquids, and solids. Air-derived samples, mixed and concentrated into a liquid solution, and placed onto the chemically reactive sections, can provide an indication of an aerosol poison. Typically, the sample is incorporated into a buffer solution that is applied to the coupon, to facilitate the exposure of the coupon chemicals to the atmospheric agent or test specimen. Each chemically reactive section is referred to as a channel. Coupons may have multiple channels, each detecting a different target substance, allowing for multiple assays on a single coupon. Each channel typically includes a control section, which will develop in tandem with the test section of the coupon, but unlike the test section will display the indicator pattern, whether or not the target substance is present. The control section performs two functions, first, if the control section does not display the indicator pattern it is generally an indication that something has gone wrong with the process of exposure. Accordingly, a negative reading does not, in that instance, indicate an absence of the target substance, but only indicates a test that was not performed correctly. Also, it shows the test personnel what the indicator pattern looks like.
[0005] In many situations, it is important to obtain a quick result from the coupon exposure, but the coupon manufacturer may have designated a set period of time for the indicator pattern to develop. Human technicians may set the coupon aside, and attend to other tasks while the coupon develops for the manufacturer specified time period. Variation in buffer solution and how it is applied can cause the same coupon to develop differently even when exposed to the same concentration of target substance. The use of a reader can lead to a faster detection of the indicator pattern when compared to a human, particularly in low light or stressful situations.
[0006] For the purpose of analyzing the visually detectable indicator pattern of the coupon, it is desirable to provide uniform illumination over the surface of the coupon, as this allows full use of the camera's dynamic range over the entire field of view. As an example, if pixels directly under the light source have a reflected intensity of 255 units while more dimly illuminated pixels at the edge of the coupon have a maximum reflected intensity of 128, then the dynamic range and resolution of a measurement may be lower by a factor of two for assay channels near the coupon edge as compared to channels directly under the light source. In addition, if light rays illuminate a particular part of the coupon surface at oblique angles only, shadows can be created that confound analysis of assay results. These issues are compounded by the fact that a compact portable device is desirable. Most bioassay coupons are on the order of 11 cm in maximum diagonal measurement, and in the interests of having a compact device, it is desirable that the distance from the coupon to the camera lens is of similar magnitude. To maximize the number of pixels in the analysis, it is also essential that the coupon fill the field of view as much as possible. That is, a near-field macro imaging design is preferred.
[0007] Light sources typically used for camera systems are so-called “white LEDs.” Uniform near-field illumination is sometimes accomplished using a circular array of white LEDs surrounding the camera lens, referred to as a ring light. Ring lights may have multiple circular rings of LEDs and may contain more than 100 LEDs. Such a large number of LEDs could significantly reduce battery life and thus operation lifetime in a battery-operated instrument. In addition, commercially-available ring lights still produce an illumination field in which intensity peaks in the center and drops off radially, albeit much more gradually than with a single LED. Since bioassay coupons are typically rectangular, ring lights may not provide uniform edge-to-edge illumination.
[0008] Using a single LED light source is far preferable, but the hotspot problem must be solved. The LED cannot be mounted on the same axis as the camera lens: It must be physically located to the side of the lens, and the hotspot consequently appears at an off-axis camera image point. This does not improve the situation since parts of the coupon remain farther away than others from the LED, and light intensity over the coupon surface can be significantly nonuniform across the face of the coupon.
[0009] Some improvement in light uniformity can be realized if a piece of ground glass or opalescent glass is mounted directly under the light source. This causes light to be re-emitted in a Lambertian pattern by virtue of the ground glass's surface roughness or by internal refraction in the opalescent glass. That is, the distribution of light emerging from the surface approximates a cosine function relative to a surface normal. These methods more broadly disperse the light, but there still remains a radial distribution of ever-decreasing light intensity relative to an axis passing through the LED source's center point and perpendicular to its surface.
[0010] Therefore, there remains a need in the art for improved methods of reading a coupon that, among other things, minimize or compensate for variations in illumination over the surface of the coupon.
SUMMARY
[0011] The teachings herein are directed to methods for reading a coupon that displays an indicator pattern when a target substance is detected, comprising providing a device having a computer readable memory, a digital camera, a logic assembly and a user interface; providing a target indicator pattern representative of an exposed and developed coupon; placing the target indicator pattern representation into the memory; exposing the coupon to a test fluid mixture; automatically repeatedly using the digital camera to take a digital image of the coupon after the exposure; after each of the digital images is taken, automatically using the logic assembly to compare it to the target indicator pattern representation to determine if it passes a similarity threshold; and in response to a digital image passing the similarity threshold, automatically providing a human perceptible indication that the target substance has been detected.
[0012] Further embodiments are directed to methods for reading a coupon that displays an indicator pattern when a target substance is detected, comprising providing a device having a computer readable memory, a digital camera, a logic assembly and a user interface; providing a digitized target indicator pattern representative of an exposed and developed coupon, which is provided by taking a digital photograph of a coupon that has been exposed to the target substance after the predetermined development time has elapsed since exposure; placing the target indicator pattern representation into the memory; exposing an unused coupon to a test fluid mixture; automatically repeatedly using the digital camera to take a digital image of the coupon after the exposure; after each of the digital images is taken, automatically using the logic assembly to compare it to the target indicator pattern representation to determine if it passes a similarity threshold; and in response to a digital image passing the similarity threshold, automatically providing a human perceptible indication that the target substance has been detected.
[0013] Additional embodiments are directed to methods for reading a coupon that displays an indicator pattern when a target substance is detected, comprising providing a device having a computer readable memory, a digital camera, a logic assembly and a user interface; wherein the device includes a substantially light tight enclosure which is lighted with an internal lighting assembly; providing a target indicator pattern representation representative of an exposed and developed coupon; placing the target indicator pattern representation into the memory; exposing the coupon to a test fluid mixture; placing the coupon into the enclosure and illuminating it with the internal lighting assembly, thereby illuminating the coupon in a manner that is repeatable between coupon exposures; automatically repeatedly using the digital camera to take a digital image of the coupon after the exposure; after each of the digital images is taken, automatically using the logic assembly to compare it to the target indicator pattern representation to determine if it passes a similarity threshold; and in response to a digital image passing the similarity threshold, automatically providing a human perceptible indication that the target substance has been detected.
[0014] Additional embodiments are directed to methods for reading a coupon that displays an indicator pattern when a target substance is detected, comprising providing a device having a computer readable memory, a digital camera, a logic assembly and a user interface; providing a target indicator pattern representation representative of an exposed and developed coupon; placing the target indicator pattern representation into the memory; exposing the coupon to a test fluid mixture; automatically repeatedly using the digital camera to take a digital image of the coupon after the exposure; after each of the digital images is taken, automatically using the logic assembly to compare it to the target indicator pattern representation to determine if it passes a similarity threshold, including finding the coefficient of the target indicator pattern pixels that minimizes the sum of the squared differences between a nonlinear function of the target indicator pattern and the corresponding pixels of the digital image, and thresholding this coefficient to determine if a test indicator pattern of sufficient clarity has formed; and in response to a digital image passing the similarity threshold, automatically providing a human perceptible indication that the target substance has been detected.
[0015] Still further embodiments are directed to an apparatus for reading coupons that display an indicator pattern after the passage of a predetermined development time after being exposed to a target substance, comprising a computer readable memory; a digital camera; a logic assembly, that controls the digital camera and interprets the data from the digital camera; a user interface; a user perceptible output; a substantially light tight chamber; a positional guide for placing one or more coupons into the substantially light tight chamber in predetermined and repeatable positions; and a lighting assembly for substantially evenly illuminating the predetermined and repeatable positions; and wherein the logic assembly controls the camera to repeatedly take an image of the coupon, after being user activated and after each of the digital images is taken, automatically comparing it to a target indicator pattern representation to determine if it passes a similarity threshold, and in response to a digital image passing the similarity threshold, automatically activating the user perceptible output.
[0016] Additional embodiments are directed to an apparatus for reading coupons that display an indicator pattern after the passage of a predetermined development time after being exposed to a target substance, comprising a computer readable memory; a digital camera; a logic assembly, controlling and responsive to the digital camera; a user interface; a user perceptible output; a substantially light tight chamber; a positional guide for placing one or more coupons into the substantially light tight chamber in predetermined and repeatable positions; and a lighting assembly including at least one light source and a light diffusing assembly for substantially evenly illuminating the predetermined and repeatable positions, wherein substantially no light travels directly from the light source to the coupon, but all of the light illuminating the coupon has reflected off of a reflective surface on its path to the coupon; and wherein the logic assembly controls the camera to repeatedly take an image of the coupon, after being user activated and after each of the digital images is taken, automatically comparing it to a target indicator pattern representation to determine if it passes a similarity threshold, and in response to a digital image passing the similarity threshold, automatically activating the user perceptible output.
[0017] Yet additional embodiments are directed to an apparatus for reading coupons that display an indicator pattern after the passage of a predetermined development time after being exposed to a target substance, comprising a computer readable memory; a digital camera; a logic assembly, controlling and responsive to the digital camera; a user interface; a user perceptible output; a substantially light tight chamber; a positional guide for placing one or more coupons into the substantially light tight chamber in predetermined and repeatable positions; and a lighting assembly including at least one light source and a light diffusing assembly for substantially evenly illuminating the predetermined and repeatable positions, wherein the at least one light source is substantially opposed to the positional guide, and wherein light from the light source is redirected by a negative axicon lens; and wherein the logic assembly controls the camera to repeatedly take an image of the coupon, after being user activated and after each of the digital images is taken, automatically comparing it to a target indicator pattern representation to determine if it passes a similarity threshold, and in response to a digital image passing the similarity threshold, automatically activating the user perceptible output.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a block diagram of a preferred embodiment.
[0019] FIG. 2 is an illustration of common exposed coupon channel combinations of test and control pattern indications.
[0020] FIG. 3 is a cross section of an apparatus for reading coupons according to one preferred embodiment, showing the position of the coupon relative to the apparatus and the path taken by light passing through the negative axicon lens.
[0021] FIG. 4 is a graph showing the elimination of light intensity effects in a developed coupon pattern due to defining a ratiometric signal variable.
[0022] FIG. 5 is a graph showing the application of least-squares nonlinear correlation to identify line strength and pixel location in a developed coupon pattern.
DETAILED DESCRIPTION
[0023] Referring to FIG. 1 , which is a block diagram of a preferred embodiment, in one preferred embodiment a coupon reader 10 includes a generally tight light chamber which is adapted to permit the introduction of any currently commercially available coupon (anything that is smaller than a 15 cm×10 cm×1 cm cuboid). The reader 10 includes a user interface 12 that prompts a user to enter the type of coupon being introduced into reader 10 . In one embodiment interface 12 includes a liquid crystal display coupled with a few keys, for making a choice of options presented on the display, and for providing a user perceptible indication. Interface 12 may also include a light or sound indicator for providing the human perceptible indication. In another embodiment, a voice recognition element is included. In yet another embodiment a USB port (not shown) is provided for a keyboard or a computer to be connected for commands and information to be sent to reader 10 . A computer readable memory 14 and a microcontroller 24 , driven by a clock 22 , collectively forms a logic assembly for controlling a digital camera 16 and interpreting digital imagery taken by camera 16 , to form a detection, or determine that no detection has occurred. A GPS receiver 20 determines location, which is input to microcontroller 24 . The location information together with test results is sent by way of a cellular network transceiver 18 over a cellular network link 28 to a remote station 30 , for storage. In one preferred embodiment, remote station 30 includes a mapping feature permitting users to see test results displayed on a map at the locations where the various test results were formed.
[0024] In one embodiment, means are provided to introduce a target pattern representation (an image of a developed coupon) into a computer readable memory 14 of reader 10 . This data entry may be performed by placing a developed coupon or a control section into reader 10 , and using user interface 12 to command reader 10 to use a digital camera 16 to take a digital photograph of the developed coupon and store it in the computer readable memory 14 , properly labeled as a digitized image of a target pattern. In another preferred embodiment, reader 10 is provided with digitized target images already stored. Otherwise digitized target images may be introduced into reader 10 by way of the USB port {not shown}, or may be downloaded by way of a cellular network transceiver 18 .
[0025] After an exposed coupon is introduced into reader 10 , the microcontroller 24 controls the digital camera 16 to repeatedly form images of each coupon channel and effectively compare each image with the digitized target image stored in computer readable memory 14 .
[0026] Coupon manufacturers typically identify a specific time period that should elapse between exposing the coupon to the substance to be tested and reading the results on the coupon. In some cases, results may be visible before this predetermined development time has elapsed and time may be wasted by continuing to wait for the entire predetermined time period. The ability of the coupon reader 10 to determine when an indicator pattern has been detected and to alert any nearby people that detection has occurred helps to eliminate this wasted time. It will be appreciated that this ability is particularly important when the coupon reader is being used to detect the presence of toxic or harmful compounds in a public safety context, where time may be of the essence.
[0027] Many other algorithms, including least squares detection and various linear algorithms are used in alternative embodiments. FIG. 2 is an illustration of test patterns that are commonly encountered and which are amenable to interpretation and quantification using the mathematical and algorithmic approaches revealed herein.
[0028] Prior to channel analysis, all embodiments require that the coupon image is recognized in the digital image being analyzed. Immediately following coupon image capture, image recognition routines analyze the captured image and identify channel locations based on the detection of characteristic coupon features. In embodiments, the user has entered the coupon type, and this information facilitates the recognition of the channel locations. The processing described below relates to each channel analyzed.
[0029] Known optical features of the coupon are pre-loaded into the device before use. Image recognition tools identify the coordinates of these characteristic features for each different coupon type. The pixel coordinates of these features provide reference points and allow each coupon image to be overlaid by a coordinate map which can then be used to locate the assay channels.
[0030] Upon positive recognition and satisfaction of location criteria, coupon analysis is allowed to continue. Upon detection of an abnormal situation, such as the coupon being inserted 90 or 180 degrees from the correct orientation, the user is alerted to the type of error. Once the error is remedied and location criteria are satisfied, sample analysis procedures may proceed.
[0031] In one embodiment, each time a reader 10 processes a coupon, the results are time, position and device code stamped, with position being provided by a GPS reader 20 and time being provided by a clock 22 controlled by microcontroller 24 , and stored in computer readable memory 14 . In a preferred embodiment, this information is uploaded periodically via cell network link 28 using cell network transceiver 18 , to a remote station 30 . In one embodiment, remote station 30 includes a display and may be commanded to display a map of an area, showing the locations, times, results and device codes of each coupon reading.
[0032] Referring to FIG. 2 , illustration 1 shows a coupon channel in which neither test line T nor control line C developed. This could indicate an unused coupon channel, but could also indicate a coupon channel that has not been properly exposed to buffer solution. The absence of a control pattern indication, in this instance, prevents a false conclusion that the target substance is not present. Illustration 2 is a weak positive indication, due to the weak pattern. Illustration 3 is a strong positive, whereas illustration 4 shows an absence of the target substance. Illustration 5 indicates that something has gone wrong with the test, as the control line should always develop, especially if the test line appears.
[0033] Referring now to FIG. 3 , which is a cross section of an apparatus for illuminating and capturing coupon images, in one preferred embodiment the coupon reader 10 includes a light diffusing assembly 34 comprising side walls 36 having reflective interior surfaces 38 and a negative axicon lens 40 . The negative axicon lens 40 alters the path of light rays 42 emitted from light source 48 and passing thought the lens such that the light rays 42 reflect off the interior surfaces 38 prior to reaching the coupon surface 44 . The negative axicon lens 40 is designed to prevent any light from directly impinging on the coupon surface 44 . All LED output light is first operated on by the light diffusing assembly 34 before it impinges on the coupon. An optimum shape for the light diffusing assembly 34 is empirically determined, but it has been found that for illuminating a rectangular coupon, a concave structure that has a rectangular cross-section works well if the lower skirt of the structure approximates the coupon's outer shape.
[0034] In one embodiment, the light diffusing assembly comprises side walls 36 which form a rectangular cross-section approximately 8 cm on a side. The side walls 36 meet the coupon surface 44 at angles that maximize uniformity of illumination over the coupon surface and compensate for the light source's off-center location. In a preferred embodiment, the included angle 46 between the side walls 36 and the coupon surface 44 is:
[0035] Face 1 =70 degrees
[0036] Face 2 =70 degrees
[0037] Face 3 =70 degrees
[0038] Face 4 =70 degrees
[0039] In one embodiment, the distance between the coupon surface 44 and the negative axicon lens 40 is 15 cm.
[0040] Diffuse reflection may be obtained from the reflective interior surfaces 38 by covering them with a flat or gloss white paint, or by constructing the structure using a white polymer. However, commercially available white polymers may absorb a significant amount of the optical power impinging on them, and this may need to be taken into consideration.
[0041] Optionally, the reflective interior surfaces 38 may be covered with a colored coating rather than a white coating. A colored coating may be desirable in circumstances where a specific light spectrum distribution is preferred for illuminating certain types of coupon. In a further option, the reflective interior surfaces may be covered by a hybrid coating that provides a mixture of specular and diffuse reflection.
[0042] Axicons are special lenses that have at least one active surface that is conic in shape. They will typically take a point source of light and transform it into either a line or circle of light. A negative axicon lens is used for coupon reader 10 . Typical commercially available axicon lenses are designed to form a specific geometric shape, and for that reason are considered “positive axicons.” The negative axicon, in contrast, takes a point of light and transforms it into an annular fan of light. Instead of a centrally located solid cone of material as in a positive axicon, the negative axicon has a conic pocket into which source light expands.
[0043] Refraction at the conic top surface and at the optionally planar lower surface cause rays from a point source to be distributed over a range of angles determined by the conic profile, the distance of the source from the lens, the lens thickness, and the refractive index of the lens material. Angular emission of the lens can be tuned so that no light hits the coupon surface 44 without first reflecting off the reflective interior surfaces 38 . That is, in a preferred embodiment, no light passing through the negative axicon lens 40 falls directly on the coupon surface 44 , particularly at the spot immediately below the lens where a hotspot would normally occur. In this way, all light impinging on the coupon surface 38 is diffuse light re-emitted or reflected by the reflective interior surfaces and the uniformity of illumination over the coupon is greatly improved, even if the coupon is in close proximity to the light source and lens.
[0044] It is not necessary that the conic profile of the negative axicon lens 40 be a simple cone. By adjusting the surface profile of the lens, the distribution of emitted optical power can be modified in an angular sense. Since the objective of the negative axicon lens and light diffusing assembly is to provide diffuse illumination, minor errors in the surface profiles are not critical. In one embodiment, the lenses are manufactured on a CNC lathe, followed by vapor polishing to remove macroscopic tooling marks.
[0045] In one embodiment, a negative axicon lens with planar output surface for supplying optical power to the reflective interior surfaces is constructed of clear polycarbonate. In one embodiment, the negative axicon lens has the following dimensions: the overall height of the lens may be 3.5 mm, the diameter may be 10 mm, and the maximum depth of the cone may be 2.5 mm.
[0046] In one embodiment, the cone profile is described as: Radius=1.98543z−0.18142z 2 +0.04361z 3 (where z is the distance in mm from the cone's vertex).
[0047] In one embodiment, nonuniformity of illumination across the coupon surface is compensated for by color-based ratiometric analysis of pixel data. Most color cameras provide at least three color channels; typically red, green, and blue. It has been found that light intensity variations over a coupon due to geometric issues are very similar in the three color bands. Most lateral flow immunoassay coupons use colloidal gold as the line colorant and its peak absorption is typically in the wavelength range of 540 nm to 580 nm, which is principally apparent in the camera pixels sensitive to green and red. It has been discovered that by forming a pixel-by-pixel ratio of color channel intensities, a remarkable reduction in background nonuniformity is seen. For the common colloidal gold colorant, the red and green channels may be most useful in this regard, but creating a ratiometric intensity variable using other color channels may be preferred for other colorants.
[0048] FIG. 4 shows raw intensity data for the green and red channels of a coupon imaged using a solid state white light flash illuminator. This coupon had previously been exposed to a liquid containing the target substance, and hence displayed the target pattern indicating a positive result. In this case, the target pattern constituted two colorimetric lines running the width of the channel. The coupon was imaged and the image pixels were divided into columns running parallel to the colorimetric lines. The values of the pixels in each column were summed to create the pixel data set. The large signal perturbation on the left side of FIG. 4 exhibits the two absorbance maxima at approximate pixel locations 65 and 185 , respectively, due to colorimetric reactions on the test strip. The pixel signal minimum on the right, between pixel positions 400 and 500 is due to the control line and should always be present if the coupon is working properly. Note that there are significant intensity fluctuations in the baselines of both the red and green data sets.
[0049] In one embodiment, a new variable is created when the green pixel intensities are divided by the corresponding red pixel intensities and the resultant curve is normalized to an arbitrary value of 1.0 (or 100%) at some arbitrary pixel location distant from the test and control lines. The resulting ratiometric variable is also shown in FIG. 4 , normalized to a value of 100. Note the removal of spurious non-signal fluctuations seen in the green and red pixel backgrounds in sections away from the three absorbance maxima, caused by variations in the background light level. This allows the test and control lines to show up much more clearly as deviations from a near-constant ratiometric background signal.
[0050] The fluid dynamic and chemical processes that create the test and control lines are typically identical or very similar. For most coupons, even those with multiple identification channels, all test and control lines produce pixel signal responses that are similar in shape and substantively differ only in overall intensity. Therefore, the relative concentration of a targeted material may be estimated by simply comparing the maximum deviation of the ratiometric signal from background and comparing it to the maximum deviation of the fully-formed control line. However, this may not be the most suitable method for test lines that have a small peak intensity because there may be too high of a signal to noise ratio to determine the peak value accurately.
[0051] In addition, the test and target lines are of finite width and vary in intensity over the line's width. Therefore, the quantity of target material in the sample is more appropriately proportional to the integrated total response over the entire line width. Using the integrated response over the entire line width will also serve to smooth out pixel signal noise. For example, if a signal is averaged over 100 pixels, random background noise as a fraction of the mean signal value will typically be reduced by a factor of 10 times compared to the noise associated with a single pixel measurement process.
[0052] In one embodiment, the following mathematical strategy and corresponding algorithm automatically provide a measure of the test and control line integrated areas and the pixel locations of each. The control and test line locations may indicate whether the assay coupon was correctly assembled or not, or if it was subsequently mishandled by the user.
[0053] The coupon typically includes a control line, which develops even in the absence of the target substance to indicate that the coupon is functioning properly and that the correct procedures were used to expose and develop the coupon. In one embodiment, the control line is used as the source of reference information that permits the coupon reader to determine whether a test line is present or absent. In other embodiments, a different source of reference information may be used, such as a pre-printed line on the coupon, data from a different coupon, or an abstract representation of a developed control line, showing the expected result when the tested for substance is present.
[0054] Because the test and control lines extend across the width of each coupon channel, the pixels are divided into columns running parallel to the test and control lines and then summed across each column. Each column sum defined in this way is identified by pixel position, and the value of the sum at that position is the pixel signal value for that position. The pixel signal values associated with a coupon's test and control lines can be approximated as the sum of a slowly varying background signal and a characteristically-shaped nonlinear absorbance signature, Y*(i), where “i” is pixel position. The aforementioned ratiometric signal between approximate pixel positions 400 and 500 in FIG. 4 is such a characteristic control line signature Y*(i). In one embodiment, a two-variable nonlinear least squares regression technique may be used to test for the presence of signal lines with absorbance signatures similar to Y*(i). This is done by comparing test line data, Y(i), to a fitting equation, Y f (I), which is given as
[0000] Y f ( i )= a+b×i+c×Y *( i )
[0055] In this equation, “a” is the average baseline value, “b” is the rate of baseline change per pixel, and “c” is a measure of the goodness-of-fit of experimental data to the reference signature, Y*(i). To obtain an unbiased measure of this goodness-of-fit, we minimize the sum of squares of the deviations between the experimental data and the curve fit, Y f (i),
[0000]
η
=
∑
i
[
Y
(
i
)
-
Y
f
(
i
)
]
2
[0056] The procedure determining the values of the parameters “a”, “b,” and “c” to minimize η are well-known in statistical mathematics. When this procedure is performed, it is found that the best-fit value of “c” is given by the following equation:
[0000]
C=K
1
×S
iY
+K
2
×S
Y
−K
3
×S
YS
[0057] The values K 1 , K 2 , and K 3 are constants that involve the reference signature Y*(i), and are easily calculated by someone knowledgeable in statistical mathematics. The other equation factors are calculated for each sectional pixel array of N+1 pixels length, [0, i, N], to be examined as follows:
[0000]
S
iY
=
∑
i
=
0
N
i
×
Y
(
i
)
S
Y
=
∑
i
=
0
N
Y
(
i
)
S
YS
=
∑
i
=
0
N
Y
(
i
)
×
Y
⋆
(
i
)
[0058] The three summations are easily and quickly calculated and the constants K 1 , K 2 , and K 3 are only calculated once: After that they may be stored as look-up values for the channel. If the pixel data presented for comparison is the reference pixel array Y* i itself, the value of “c” will be exactly 1.0 at the pixel location identical to the midpoint of the control line.
[0059] As previously discussed, the test line in most cases is essentially identical in shape to the control line, but less intense overall. Hence, when the value of “c” is computed by scanning the test line section of the coupon channel pixel data with an array of [0, N] size, it will have maximum values when the signal data most closely matches the control line shape Y*(i). This allows identifying the location of each test line center point while the value of “c” represents the relative integral size of the discovered line as compared to the control line. For the example ratiometric pixel signal data in FIG. 5 , it can be seen that the two test lines were robustly found and that the value of “c” for the control line is 1.0, as expected.
[0000] This method is favored for several reasons:
Small variations in the baseline are common due to lighting variations, shadows, and residual color in the coupon substrate. This method automatically estimates and corrects for a non-constant baseline. The integral value “c” is an unbiased best estimate of the baseline-corrected integral value. Due to the use of all data points associated with a line, signal-to-noise is improved and a wide dynamic range is realized of as much as 100 to 1. That is, a test line with a value of “c” on the order of 0.01 may be detected. The method allows development of a calibration curve that quantitatively correlates the targeted material's concentration with the test line integral value. The method allows a quantitative determination that a test line's response is statistically above background noise. The method provides the lines' peak value location, which is useful in identification of manufacturing or user errors. While the method can be applied to raw data as well as ratiometric data, the integral value from ratiometric data provides a measure of signal strength that is independent of absolute light intensity or light exposure time as long as the color channels all change proportionately the same when these factors are varied. This is a reasonable assumption for changes in exposure time or temperature, since both the control line and test line will see the same environmental shifts.
[0066] In a preferred embodiment, for a multichannel coupon the three constants K 1 , K 2 , and K 3 are empirically determined for each individual channel by running one or more assays and calculating these least-squares constants for each channel's control line. This may be of particular value if there are differences in channel construction or if assay reagents are significantly different among the channels.
[0067] In addition, in a multi-channel coupon the channel control lines may be compared one against another and these relative “c” values stored in the device's memory. During later use, the control lines can be compared to each other to see if any have deviated from the expected relative “c” values. The device may then issue a warning to the user that there may be a problem with one or more channels.
[0068] In a preferred embodiment, digital images of the coupon are repeatedly taken over a period of time, starting shortly after addition of the sample and well before the time period suggested by the manufacturer has passed. These images are processed sequentially to determine if a test line has developed. As soon as detection positive result is found, a human perceivable signal is given. Depending on the coupon type, it is possible to gather useful information as early as 1 minute after development has been initiated. Some explosives coupons have a peak color at 2 minutes after application of a test fluid, and noticeably fade after 3 minutes. Accordingly, the time after exposure at which a first digital image is formed may be as little as 10 seconds or even 1 second. The techniques described herein have been shown to reduce the time to detection for bio-coupons to as little as 5 minutes, a third of the time period that the manufacturer recommends waiting, before evaluating an exposed coupon.
[0069] Accordingly, in embodiments the taking of digital imagery begins well before the manufacturers development time has passed. In various embodiments, the taking of digital imagery begins at least 4, 3, 2 and 1 minute prior to the passing of the recommended time to develop, after exposure to said test fluid mixture. Described in different terms, in various embodiments a first digital image is formed no more than 1, 2, 3 and 4 minutes after the coupon channel is exposed to said test fluid mixture.
[0070] In a further inventive feature, digital imagery is also repeatedly taken of the control section of each channel, beginning shortly after exposure to a test fluid mixture. This permits early detection of a coupon that has been ineffectively exposed to the test fluid mixture. As soon as ineffective exposure is determined, the test can be terminated and a new test begun, thereby greatly decreasing the time before an accurate reading is determined.
[0071] In a further embodiment, the sequence of images are integrated together, to enhance the signal to noise ratio and, in some instances, provide earlier detection than would otherwise be possible. In one variant, time integration is performed on the raw pixels, but in another least squares fitting as described above is applied to the data from each digital image and the multiple results are then integrated over time.
[0072] The invention may be embodied in other specific forms besides and beyond those described herein. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting, and the scope of the invention is defined and limited only by the appended claims and their equivalents, rather than by the foregoing description.
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When reading a coupon that displays a pattern when a target substance is detected, recognition of the target pattern can be hindered by nonuniform illumination of the coupon. In one aspect, methods and devices are disclosed for uniform illumination of a coupon using a negative axicon lens and a light diffusing assembly. In another separate aspect, methods are disclosed for mathematically compensating for nonuniform illumination of a coupon.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. Ser. No. 07/724,018 filed Jul. 1, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to thermoplastic condensation polymers which are terpolymers having aliphatic polyester, polysiloxane and polycarbonate segments (blocks). These polymers exhibit advantageous melt flows, advantageous low temperature properties and resistance to solvents, chemicals, hydrolysis and to photodecomposition. The terpolymers are especially useful as engineering thermoplastics.
2. Brief Description of the Related Art
Condensation copolymers having polysiloxane and polycarbonate blocks are known. Representative of such polymers are those disclosed by Schmidt et al., U. S. Pat. No. 4,681,922 (July 1987), Vaughn, U.S. Pat. No. 3,189,662 (June 1965), Vaughn, U.S. Pat. No. 3,419,635 (Dec. 1968), and Merritt, U.S. Pat. No. 3,832,419 (Aug. 1974). Some of these copolymers, while useful, have slower than desired flow properties, requiring high torque or high molding pressures during processing. From the standpoint of ease of processing, it is desirable for a thermoplastic to have higher melt flow properties. This makes possible rapid and complete mold filling and is especially important for molding complex and thin-walled articles.
Other siloxane-carbonate copolymers, such as described by Vaughn, U.S. Pat. No. 3,419,635, have an elastomeric character and are not considered as engineering thermoplastics, being more useful as adhesives, coatings, sealants, roofing material, impact modifying additives and the like.
A shortcoming of other siloxane-carbonate polymers is inadequate impact strength at low temperatures.
Another property which needs improvement beyond the levels achieved with the prior art copolymers is solvent resistance, as manifested for instance by resistance to crazing upon exposure to solvents, motor fuels, and the like.
A shortcoming of certain other known polycarbonate-siloxane copolymers is the presence of an aryloxysilicon linkage, which is hydrolysisprone. Some other known polycarbonate-siloxane copolymers have aromatic acyloxyphenoxy linkages which are photolabile, causing discoloration on exposure to sunlight or fluorescent light (believed to be caused by the known photo-Fries rearrangement reaction).
The thermoplastics of the present invention exhibit advantageous low temperature impact strengths, melt flow solvent resistance, hydrolytic stablility and photo-stability.
An advantageous feature of the invention from a process standpoint is the formation of the block polymer in a convenient and novel one-step process which forms the aliphatic polyester and carbonate block and links it with the polysiloxane block. This is in contrast to processes for making block copolymers, where it is usually necessary to synthesize the individual blocks and to combine them in a separate step, thus imposing additional labor and time on the process.
SUMMARY OF THE INVENTION
The invention comprises a thermoplastic block terpolymer, which comprises;
(a) about 1 to about 30 % by weight of the terpolymer of a siloxane from recurring polysiloxane blocks of the formula: ##STR2## where R 1 and R 2 are each independently selected from hydrogen, hydrocarbyl, halogen-substituted hydrocarbyl (R 1 preferably is methyl and R 2 preferably is methyl or phenyl); D is an integer of from about 10 to about 120, preferably about 30-70, and more preferably 40-60; and Y is hydrogen, alkyl or alkoxy (and where alkoxy, preferably methoxy);
and
(b) about 70 to about 99% by weight of the terpolymer of a polycarbonate-aliphatic polyester condensation copolymer block consisting essentially of from about 80 to about 99% by weight, relative to the total weight of recurring units in (b), of polycarbonate units of the formula: ##STR3## where R 3 and R 4 are each selected from hydrogen, hydrocarbyl or halogen-substituted hydrocarbyl, (preferably methyl); and
from 1 to 20% by weight, relative to the total weight of the recurring units in (b), of aliphatic diester units of the formula: ##STR4## where A is an alkylene moiety, preferably a primary alpha,omega-alkylene, of about 6 to about 18 carbon atoms.
The term "hydrocarbyl" as used herein means the monovalent moiety obtained upon removal of a hydrogen atom from a parent hydrocarbon. Representative of hydrocarbyl are alkyl of 1 to 25 carbon atoms, inclusive such as methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, undecyl, decyl, dodecyl, octadecyl, nonodecyl eicosyl, heneicosyl, docosyl, tricosyl, tetracosyl, pentacosyl and the isomeric forms thereof; aryl of 6 to 25 carbon atoms, inclusive, such as phenyl, tolyl, xylyl, napthyl, biphenyl, tetraphenyl and the like; aralkyl of 7 to 25 carbon atoms, inclusive, such as benzyl, phenethyl, phenpropyl, phenbutyl, phenhexyl, napthoctyl and the like; cycloalkyl of 3 to 8 carbon atoms, inclusive, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl and the like.
The term "alkylene" means the divalent moiety obtained on removal of two hydrogen atoms, each from a non-adjacent carbon atom of a parent hydrocarbon and includes alkylene of 3 to 18 carbon atoms, inclusive, such as 1,3-propylene, 1,4-butylene, 1,5-pentylene, 1,8-octylene, 1,10-decylene and the like.
The term "halogen-substituted hydrocarbyl" as used herein means the hydrocarbyl moiety as previously defined wherein one or more hydrogen atoms have been replaced with a halogen atom.
The term "halogen" is embracive of chlorine, bromine, iodine and fluorine.
DETAILED DESCRIPTION OF THE INVENTION
The following description presents embodiment compositions of the invention and the manner and process of conducting the process of the invention.
The process of this invention comprises reacting a carbonate precursor such as phosgene simultaneously or consecutively with (1) a siloxane, terminated by phenolic hydroxyls, of the formula: ##STR5## where R 1 , R 2 , D and Y are as defined above, (2 ) a bisphenol of the formula: ##STR6## where R 3 and R 4 are as defined above; and (3) an aliphatic dicarboxylic acid having the formula: ##STR7## where A is as defined above; in the presence of sufficient aqueous alkali to maintain an alkaline pH and in the presence of a substantially water-immiscible solvent; the reactants (1), (2) and (3) being in the ratio required for the terpolymer structure described above.
The procedure is the well-known interfacial polymerization technique, used to prepare polycarbonate resins.
The method of preparation of polycarbonates by interfacial polymerization are well known; see for example the details provided in the U.S. Pat. Nos. 3,028,365; 3,334,154; 3,275,601; 3,915,926; 3,030,331; 3,169,121; 3,027,814; and 4,188,314, all of which are incorporated herein by reference thereto.
Although the reaction conditions of the preparative processes may vary, several of the preferred processes typically involve dissolving or dispersing the bisphenol (V) reactants in aqueous caustic soda or potash, adding the resulting mixture to a suitable water immiscible solvent medium and contacting the reactants with the carbonate precursor, such as phosgene, in the presence of a suitable catalyst and under controlled pH conditions. The most commonly used water immiscible solvents include methylene chloride, 1,2-dichloroethane, chlorobenzene, toluene, and the like.
A catalyst may be employed to accelerate the rate of polymerization of the dihydroxy reactants with the carbonate precursor. Representative catalysts include but are not limited to tertiary amines such as triethylamine, quaternary phosphonium compounds, quaternary ammonium compounds, and the like. The preferred process for preparing resins of the invention comprises the phosgenation reaction. The temperature at which the phosgenation reaction proceeds may vary from below 0° C., to above 100° C. The phosgenation reaction preferably proceeds at temperatures of from room temperatures (25° C.) to 50° C. Since the reaction is exothermic, the rate of phosgene addition may be used to control the reaction temperature. The amount of phosgene required will generally depend upon the amount of the dihydric reactants (IV) and (V) and the amount of dicarboxylic acid also present.
The process of the invention may be conducted without a chain limiting amount of a monohydric phenol chain stopper, but it is preferable that such an agent be present so that the molecular weight is controlled. Any monohydric phenol can be used, unsubstituted or with one or more substituents such as hydrocarbyl, hydrocarbyloxy or halogen, but the preferred monohydric phenol is phenol itself. The typical amount of monohydric phenol to result in the desired molecular weight (chain length) being in the desired range is about 0.5% to 5.0% by weight of bisphenol (V). The preferred end groups for the terpolymers of the invention are aryloxy groups, especially phenoxy, optionally substituted by one or more hydrocarbyl, hydrocarbyloxy, and/or halogen substituents. Preferred endcapping phenols are phenol, p-tertiary butyl phenol, p-cumyl phenol, and the like.
The terpolymers of the invention comprise recurring blocks of Formulae (I), (II) and (III) as set forth above.
Particularly preferred polysiloxane blocks (I) are made from bisphenolpolysiloxanes (IV), which may be prepared in accordance with the method described in U.S. Pat. No. 3,419,635. A preferred compound(IV) is readily provided by eugenol (2-methoxy-4-allylphenol) reacted to cap a hydrogen-terminated polysiloxane by an addition reaction advantageously catalysed by platinum or its compounds. The essential features of the capping process are described by Vaughn, U.S. Pat. No. 3,419,635 (December 1968), which is incorporated by reference. For instance, the process is exemplified in example 8 of this Vaughn patent which describes the addition of a hydrogen-terminated polydimethylsiloxane to allylphenol in the presence of a catalytic amount of platinum catalyst at an elevated temperature.
The bisphenol (V) for preparation of the polycarbonate block (b) (Formula (II)) will have the structure depicted above in Formula (V). Examples of preferred groups R ' and R 4 are hydrogen, methyl, ethyl, n-propyl, isopropyl, octyl, eicosyl, vinyl, cyclohexyl, phenyl, trifluoromethyl, chlorophenyl, benzyl, and pentabromophenyl. The most preferred R 3 and R 4 groups are methyl, thus the most preferred bisphenol (V) is bisphenol A. Representative of other bisphenol (V) are those listed in U.S. Pat. No. 4,994,532 (col. 3, lines 33-55) which is incorporated herein by reference thereto.
The aliphatic dicarboxylic acid of Formula (VI) may be straight or branched chain, saturated or unsaturated. For instance, the acid (VI) can be 2-octylsuccinic acid, dimethyladipic acid, or the like. However, the preferred aliphatic dicarboxylic acids are those with a linear, saturated aliphatic chain, for instance suberic, azelaic, sebacic, undecanedioic, dodecanedioic, brassylic, pentadecanedioic, hexadecanedioic, heptadecanedioic, octadecadioic, nonadecanedioic and eicosanedioic acids. It will be obvious to one skilled in the art that the acids (VI) may not be present in the reaction mixture as the free acids but as corresponding salts, formed by reaction with the requisite base, although they could also be added as preformed salts.
The amount of alkali to be used in the process of the invention is at least that amount needed to convert the dicarboxylic acid (VI) to its di salt and to neutralize the hydrochloric acid stoichiometrically produced by the reaction of the phosgene with the phenolic groups of the bisphenol (V) and the phenolically-terminated siloxane (IV), although an excess over this amount can be used. The alkali is conveniently an alkaline metal hydroxide, such as sodium, potassium or lithium hydroxide, although a soluble alkali carbonate can also be used. The preferred alkali is aqueous sodium hydroxide.
The process of the invention features the simultaneous formation and incorporation of the siloxane and aliphatic polyester-polycarbonate blocks into the terpolymer product.
The terpolymers of the invention may be compounded with the addition of various types of additives known to the art of plastics compounding. Such additives can include for example fillers (such as clay or talc), reinforcing agents (such as glass fibers), impact modifiers, other resins, antistats, plasticizers, flow promoters and other processing aids, stabilizers, colorants, mold release agents, other flame retardants, ultraviolet screening agents, and the like. The thermoplastic of the invention can also be blended with other resins such as ABS and thermoplastic polyesters to produce useful thermoplastic blends.
The invention will be better understood with reference to the following examples, which are presented for purposes of illustration rather than for limitation, and set forth the best mode contemplated for carrying out the invention.
Preparation 1
Representative preparation of eugenol capped polydimethylsiloxane fluid: Octamethylcyclotetrasiloxane (8.3 kg, 28.0 moles), tetramethyldisiloxane (330 g, 2.46 moles) and Filtrol 20 (86 g, 1% by weight, Harshaw/Filtrol Clay Products) were combined in a 12 L flask and heated to 45° C. for 2 hours. The temperature was raised to 100° C. and the mixture was rapidly agitated for 5 hours. The mixture was allowed to cool then filtered through a plug of Celite filtering aid. To the crude product was added a mixture of eugenol (774 g, 4.72 moles) and Karstedt's platinum catalyst (1.57 g, 10 ppm Pt) at a rate of 40 g/minute. Reaction completion was monitored by the disappearance of the siloxane hydrogen in the FTIR spectrum. The reaction product was stripped of volatiles using a falling thin film evaporator operating at 200° C. and 1.5 torr. The isolated material was a light brown oil with a viscosity of 100 cstokes at 25° C. and a degree of polymerization of 49 siloxane units. The material was used without further purification.
Preparation 2
Representative preparation of the terpolymer compositions of the invention: Dodecanedioic acid (916 g, 39.8 moles) was dissolved in 50% aqueous sodium hydroxide solution (5 L) and combined with bisphenol-A (9.07 kg, 39.8 moles), phenol (94.0 g, 0.958 mole), triethylamine (115 mL) and sodium gluconate (15 g) in dichloromethane (35 L) and water (30 L). The pH of the mixture was brought to 8.0 by the addition of 50% aqueous sodium hydroxide solution. Phosgene was introduced into the rapidly agitated and recirculating reaction mixture at a rate of 260 g/minute. The pH was maintained between 8.0 and 8.5 for the first half of the reaction. After 50% of the phosgene had been introduced the pH was increased to 10.0. The eugenol capped polydimethylsiloxane D49 fluid prepared according to the method of Preparation 1, supra. (600 g, 0.152 mole, 5 weight percent) was introduced all at once to the reaction mixture as a solution in dichloromethane (2 L) after 50% of the phosgene had been introduced. The pH of the reaction mixture was maintained between 10.0 and 10.5 until the remainder of the phosgene was added (5.2 kg, 52.5 moles, total). After purging the reaction mixture with nitrogen, additional dichloromethane (20 L) was added and the organic phase was separated from the brine layer by liquid/liquid centrifugation. The organic phase was worked up by washing with 1% aqueous hydrochloric acid solution and water by means of phase to phase contact followed by liquid/liquid centrifuge separation. The resin was isolated as white granules (9.98 kg) by steam precipitation from the dichloromethane solution. The material was characterized by standard analytical methods: Tg 123 C; IV 0.61 g/dL; Gel Permeation Chromatography (polystyrene standard using a K factor to polycarbonate molecular weights) Mw 35110, Mn 14111, Disp 2.49; Siloxane content by 1H NMR was 5 weight percent; Aliphatic diester content by 1H NMR was 10 weight percent.
Preparation 3
For the purpose of having a control composition, a polysiloxane copolymer without the aliphatic diester component was prepared using a similar interfacial reaction procedure. Bisphenol-A (9.07 kg, 39.8 moles), the D49 eugenol capped polydimethylsiloxane fluid (600 g, 0.152 moles, 5 percent by weight siloxane), triethylamine (115 mL), phenol (94.0 g, 0.958 mole) and sodium gluconate (15.0 g) were combined with water (30 L) and dichloromethane (35 L). The biphasic mixture was stirred vigorously and brought to pH 10 by the addition of 50% aqueous sodium hydroxide solution. Phosgene (4.53 kg, 45.8 moles) was added over the course of 30 minutes with the reaction pH maintained in the range of 10.0 to 10.5. After purging the reaction mixture with nitrogen, additional dichloromethane (20 L) was added and the organic phase was separated from the brine layer by liquid/liquid centrifugation. The organic phase was worked up by washing with 1% aqueous hydrochloric acid solution and water by means of phase to phase contact followed by liquid/liquid centrifuge separation. The resin was isolated as white granules (9.07 kg) by steam precipitation from the dichloromethane solution. The material was characterized by standard analytical methods: Tg 149° C.; IV 0.55 dL/g; Gel Permeation Chromatography (polystyrene standard using a K factor to polycarbonate molecular weights) Mw 34723, Mn 15538, Disp 2.23. Siloxane content by 1H NMR was 5 wt %.
Preparation 4
For the purpose of having a control composition, an aliphatic diester copolycarbonate was prepared in accordance with Fontana, et. al. in U.S. Pat. No. 4,983,706. Materials were compounded with a phosphite stabilizer (0.05 wt. %) and tumbled in a stainless steel can prior to extrusion on a Werner and Pfleiderer 30 mm co-rotating twin screw extruder operating at 500° to 600° F. barrel temperatures. Test specimens were prepared by injection molding at 570° to 600° F. melt temperature and 180° F. mold temperature. Notched IZOD impact of single gated bars and unnotched IZOD impact of double gated bars were determined according to ASTM D-256. Flexural yield and flexural modulus were determined according to ASTM D-790. Tensile yield, tensile break and tensile elongation were determined according to ASTM D-638. Melt flow rating was determined by modified ASTM D-1238. Ignition resistance was determined by UL94 test. Rheological comparison of the terpolymer of the invention with the siloxane copolymer control was made at 300° C.
______________________________________Property Control Terpolymer of Invention______________________________________Wt % siloxane 5 5Siloxane degree of 49 49polymerizationWt % aliphatic diester 0 10Mw 34723 35110Melt flow rating 2 5Viscosity at 500 sec-1 1000 590(Pa-sec)Viscosity at 1000 sec-1 700 450(Pa-sec)Viscosity at 3000 sec-1 300 200(Pa-sec)______________________________________
These results show the processing advantages of the terpiolymer of the invention where for a similar molecular weight the terpolymer of the invention has lower melt viscosity and higher melt flow.
EXAMPLE 1.
A control composition, 1, was prepared from LEXAN grade polycarbonate resin (General Electric Company, Mount Vernon, Ind.) and appropriate stabilizers. A composition of the present invention, 2, was also prepared as described above, with appropriate stabilizers. The materials were compounded, extruded and molded as described above and found to have the following properties.
______________________________________ Terpolymer ofProperty Control 1 Invention 2______________________________________Wt % siloxane 0 5Siloxane degree of -- 49polymerizationWt % aliphatic diester 0 10Melt flow rating (g/10 min) 6 5.5125 mil notched IZOD 16* 18*(ft-lbs/in)125 mil notched IZOD 3† 15*@ -50° C.250 mil notched IZOD 3† 16*(ft-lbs/in)250 mil notched IZOD -- 9*@ -40° C.craze resistance to <5 (broke) >1000acetone.sup.1 (sec)craze resistance to <5 (broke) 73diacetone alcohol.sup.1 (sec)______________________________________ *indicates ductile failure; †indicates brittle failure .sup.1 Time to initial craze formation after exposing a 125 mil thickness bar in a 3400 psi constant radius strain jig to solvent.
These data show the superior impact performance and chemical resistance of the terpolymer of the invention.
EXAMPLE 2.
A control composition, 3, was prepared: 90 parts LEXAN 100 grade polycarbonate resin, (supra.), 10 parts chopped glass fibers (Owens Corning Fiberglass 415), 2.0 parts TIONA RCL-69 titanium dioxide (made by SCM) and appropriate stabilizers. A control composition, 4, was also prepared: 90 parts polyestercarbonate resin (prepared in accordance with Fontana, et. al. in U.S. Pat. No. 4,983,706 using 10 weight percent dodecanedioic acid), 10 parts chopped glass fibers (Owens Corning Fiberglass 415), 2.0 parts TIONA RCL-69 titanium dioxide (made by SCM) and appropriate stabilizers. A composition of the present invention, 5, was also prepared: 90 parts of a terpolycarbonate (of bisphenol-A, eugenol capped polydimethylsiloxane with a degree of polymerization of 49 at 5 weight percent siloxane loading and dodecanedioic acid at 10 weight percent loading), 10 parts chopped glass fibers (Owens Corning Fiberglass 415), 2.0 parts TIONA RCL-69 titanium dioxide (made by SCM) and appropriate stabilizers. The materials were compounded, extruded and molded as described above and found to have the following properties.
______________________________________ Composition ofProperty Control 3 Control 4 Invention 5______________________________________Wt % siloxane 0 0 5Siloxane degree -- -- 49of polymerizationWt % aliphatic 0 10 10diesterMelt flow rating 4.5 7 5(g/10 min)Tensile @ break 7100 6400 6100(psi)Tensile @ yield 8600 8700 7900(psi)Tensile 18 15 11elongation (%)Flex modulus 389100 398500 407800(psi)Flex yield (psi) 13700 13400 12700125 mil double 17† 11† 9*gated IZOD(ft-lbs/in)125 mil notched 2† 1† 4*IZOD (ft-lbs/in)250 mil notched 2† 1† 3*IZOD (ft-lbs/in)______________________________________ †indicates brittle failure; *indicates ductile failure These data indicate the superior impact performance of the terpolymer of the invention.
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Block condensation copolymers with improved processability, low temperature impact strength and solvent resistance have a polysiloxane block such as ##STR1## where D is about 10 to 120, and a polycarbonate-aliphatic polyester block. Such polymers are made by an interfacial reaction of phosgene with a bisphenol, a phenol-terminated siloxane, and an aliphatic dicarboxylic acid salt.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/141,494, filed on May 7, 2002, now U.S. Pat. No. 7,097,627 which is a continuation of U.S. application Ser. No. 09/608,940, filed on Jun. 30, 2000, now U.S. Pat. No. 6,383,156, which claims the benefit of U.S. provisional application Ser. No. 60/156,342, filed on Sep. 27, 1999. Each of the priority applications is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present application relates to orthopaedic braces adapted with an adjustable-length strut for use in stabilizing ajoint after invasive surgery.
2. Description of the Related Art
In order to ensure the proper healing of a human joint after an injury or invasive surgery, it is often desirable to limit the pivotal motion of the human joint to a predetermined angular range between full extension and full flexion. The pivotal motion may be limited by a range of motion hinge disposed between an upper strut and a lower strut. In order for the orthopaedic brace to function properly, the struts must be adaptable to the body proportions of the patient.
The following U.S. patents, which describe orthopaedic braces of this general type, are herein incorporated by reference to establish the nature of such range of motion braces, and how and why such equipment is used. U.S. Pat. No. 552,143 issued on Dec. 31, 1895; U.S. Pat. No. 649,237 issued on May 8, 1900; U.S. Pat. No. 4,776,326 issued to Young et al., on Oct. 11, 1988 entitled “Modular Lower Limb Bracing System”; U.S. Pat. No. 4,817,588 issued to Bledsoe on Apr. 4, 1989 entitled “Motion Restraining Knee Brace”; U.S. Pat. No. 4,982,732 issued to Morris on Jan. 8, 1991 entitled “Orthopedic Rehabilitation Knee Brace”; U.S. Pat. No. 5,052,379 issued to Airy et al., on Oct. 1, 1991 entitled “Combination Brace and Wearable Exercise Apparatus for Body Joints”; and U.S. Pat. No. 5,018,514 issued to Grood et al., on May 28, 1991 entitled “Knee Brace”.
It is well known that the orthopaedic braces described in the aforementioned incorporated patents suffer various problems, shortcomings and disadvantages. In some cases such braces cannot be adjusted to fit the patient, rather, the braces come in various fixed sizes. Alternatively, the braces are not easily adjustable, requiring, for example, tools to change the size of the struts. Some braces require actual cutting or breaking off pieces of the struts to permanently change the length of the struts. Others rely upon friction, as from a tightening screw, to less than positively lock the strut at the desire length.
It is thus an object of the present invention to provide an orthopaedic brace that is easy to adjust.
It is thus another object of the present invention to provide an orthopaedic brace that is adjustable without a need for tools.
It is thus further an object of the present invention to provide an orthopaedic brace that is adjustable without cutting or breaking a strut.
SUMMARY OF THE INVENTION
The present invention is an orthopaedic brace that has adjustable length struts.
In one form, the present invention is an orthopaedic brace including a first strut, a second strut, a hinge disposed between the first and second struts, and an adjustment assembly disposed on one of the first and second struts. The hinge is configured to allow movement of one of the first and second struts about an axis defined by the hinge. The adjustment assembly is configured to cooperate with the one of the first and second struts to adjustably set an operative length of the one of the first and second struts.
In another form, the present invention is an orthopaedic brace including an upper strut, a lower strut, a hinge disposed between the upper strut and the lower strut, and an adjustment assembly disposed on one of the first and second struts. The hinge is configured to allow movement of one of the upper and lower struts about an axis defined by the hinge. One of the upper and lower struts has a plurality of notches defining a plurality of strut length settings. The adjustment assembly is configured to cooperate with any one of the plurality of notches of the one of the first and second struts to selectively set a length of the one of the first and second struts.
In yet another form, the present invention is an orthopaedic brace including an upper strut, a lower strut, a hinge disposed between the upper strut and the lower strut, an upper adjustment assembly disposed on the upper strut, and a lower adjustment assembly disposed on the lower strut. The hinge is configured to allow movement of one of the upper and lower struts about an axis defined by the hinge. The upper adjustment assembly is configured to cooperate with the upper strut to adjustably set a length of the upper strut. The lower adjustment assembly is configured to cooperate with the lower strut to adjustably set a length of the lower strut.
Accordingly, the present invention improves upon the prior art by providing an orthopaedic brace strut that may be changed in length without the use of tools and with the ability to return to the original length, or some other length as desired.
The present invention also provides for a single-action positive lock for a strut length adjustment assembly rather than relying on friction. The ability to size and resize the struts provides a cost-effective and comfortable means to apply an orthopaedic brace to virtually any joint on the human body and eliminates the need to carry large inventories of braces that cannot be sized. By providing a positive lock, the improved brace also better protects the patient and speeds recovery.
The present invention also allows contoured wings, with cushioning material and/or non-slip material attached, to be used to limit movement of the brace after it has been attached and to provide increased comfort to the patient.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a side perspective view of an adjustable orthopaedic brace assembly having adjustable-length strut assemblies that embodies principles of the present invention showing the brace operatively connected to a human leg;
FIGS. 2A and 2B are, respectively, top and underside perspective views of an adjustable-length strut assembly for the orthopaedic brace of FIG. 1 ;
FIG. 3 is an exploded, perspective view of the adjustable-length strut assembly of FIGS. 2A and 2B ;
FIGS. 4A and 4B are cross-sectional views through the adjustable-length strut assembly taken along line 4 - 4 of FIG. 3 ;
FIG. 5 is a perspective view of a second embodiment of an adjustable-length strut assembly;
FIG. 6 is a cross-sectional view through the second embodiment of the adjustable-length strut assembly taken along line 6 - 6 of FIG. 5 ;
FIG. 7 is a cross-sectional view through the second embodiment of the adjustable-length strut assembly taken along line 7 - 7 of FIG. 6 ; and
FIG. 8 is a perspective view of a third embodiment of an adjustable-length strut assembly.
Corresponding reference characters indicate corresponding parts throughout the several views.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An orthopaedic brace 10 is shown in FIG. 1 operatively attached to a leg 64 using a plurality of straps 54 mounted on an upper strut 12 and a lower strut 14 with a hinge assembly 16 disposed between the upper strut 12 and the lower strut 14 . While only one side of the orthopaedic brace 10 is shown (i.e. the hinge assembly 16 , the upper strut 12 , and the lower strut 14 or “assembly”) it should be understood that an identical, but mirror image, assembly is provided on the opposite side of the leg 64 .
Each strut 12 and 14 is provided with a preferably identically configured wing assembly 18 although variations in either are contemplated, which is slidably mounted for adjustable movement on the elongated struts 12 and 14 . Stated in another manner, each strut 12 and 14 is adjustable in length relative to the length of the strut between the hinge 16 and the straps 54 through adjustable strut assemblies 18 . Such will be considered hereafter as the length adjustment of a strut. It should be appreciated that such assemblies 18 may be provided on both struts 12 and 14 , or only on one of the two struts 12 and 14 . As well, it should also be appreciated that adjustability of the length of a strut may be considered as either or both the adjustment of the assembly 18 relative to a strut ( 12 and/or 14 ), or as the adjustment of a strut ( 12 and/or 14 ) relative to the assembly 18 .
The adjustable mounting of the wing assembly 18 on elongated struts 12 and 14 allows the struts to telescope or move in and out, one in opposition to the other, of the respective wing assembly 18 , as will be described subsequently, to accommodate long or short legs, as one example, or long or short arms, as another example. Because the structure and function of the wing assembly is similar regardless of whether mounted to the upper strut 12 or the lower strut 14 , reference will be made to only the upper strut 12 in the following description and its wing assembly 18 . As well, because the structure and function of the struts 12 and 14 are identical (assuming each strut terminates in a wing assembly 18 ), reference to strut 12 in the following description will be construed to pertain to strut 14 .
Referring to FIG. 2A , the wing assembly 18 has a wing body 20 , which is preferably formed of a relatively rigid material, as for example plastic. The wing body 20 has an arcuate profile and is provided with one or more strap-retaining loops 22 for receiving the one or more adjustable straps 54 that are threaded through the loops 22 to encircle both the wing assembly 18 and a human limb, such as the leg 64 (as depicted in FIG. 1 ), thereby immovably securing the brace 10 to the leg 64 , for example. FIG. 2B shows that the underside of the arcuate-shaped wing body 20 is provided with a generous layer of non-slip cushioning 50 , both to pad the wearer's limb and to assure that the brace 10 remains in place.
FIGS. 2B , 3 , 4 A and 4 B reveal that the underside of the wing body 20 defines a unitary channel 46 that runs longitudinally down the entire length the wing body 20 . While the channel 46 is generally open, splitting the cushioning 50 into two halves, a lip 48 portion of the wing body 20 overhangs the channel 46 at each of the side edges of the channel 46 down the entire longitudinal length of each side of the channel 46 . The channel 46 with opposing lips 48 receives the elongated strut 12 and retains and guides the strut 12 as it telescopes in and out of the channel 46 . The open nature of the channel 46 also helps to reduce the overall weight of the orthopaedic brace 10 .
Referring to FIGS. 2B and 3 , the strut 12 has formed through its body a longitudinal slot 60 . The length of the slot 60 may be varied depending upon the desired maximum and minimum lengths of the orthopaedic brace 10 . Longitudinally spaced down each side of the slot 60 are a plurality of arcuate-shaped, stop notches generally designated 62 . The notches 62 are equally divided into a plurality of notches 62 a that are mirror images of, and directly across the slot 60 from, a plurality of opposing notches 62 b , such that the opposing, arcuate-shaped pairs of notches 62 a and 62 b would define a circle if their ends were connected by an arc of constant radius equal to the distance from the center of the slot 60 to the center of the opposing notches. One end of the slot 60 contains an arcuate-shaped notch 62 c and the other end of the slot 60 contains a mirror image arcuate-shaped notch 62 d . Notches 62 c and 62 d are connected on each end to the outer ends of notches 62 a and 62 b . It should be appreciated that the notches may be shaped other than that shown.
Referring to FIG. 3 , it can be seen that the wing body 20 also defines a depression or chamber 28 on the top of the body 20 which is shown as circular but can be any shape. The wing body 20 also defines an aperture 26 of smaller diameter than the chamber 28 that extends through the center of the chamber 28 all the way to the slot 60 on the underside of the wing body 20 . The chamber 28 and aperture 26 are adapted to house a positive-lock, adjustment or button assembly 30 .
The adjustment assembly 30 ( FIG. 3 ) has a generally flat pushbutton top 32 that has a cylindrical extension 34 extending downward away from and perpendicular to the top. The cylindrical extension 34 has a radius that allows it to freely travel through the aperture 26 and the slot 60 without engaging any of the notches 62 a and 62 b . With additional reference to FIGS. 4A and 4B , a threaded aperture 36 extends down through the center of the top 32 and the extension 34 and is adapted to receive a screw 42 from the underside of wing body 20 . Fitting over the extension 34 is a biasing spring 38 of smaller diameter than the chamber 26 . A retaining bushing 40 , with a radius approximating that of the notches 62 a , 62 b , 62 c and 62 d , is secured to the adjustment assembly 30 (extension 34 ) from the underside of the wing body 20 by the screw 42 , which runs through the aperture 28 into the threaded aperture 36 in the extension 34 and thus the button 32 . The spring 38 is thereby secured and sandwiched between the underside 33 of the top of the button 32 and a bottom 27 of the chamber 28 .
FIGS. 2B and 4A show the positively locked position of the adjustment assembly 30 . The spring 38 normally urges (biases) the push-button top 32 up and away from the bottom of the chamber 27 and thereby captively urges the attached bushing 40 up into the selected pair of opposing notches 62 a and 62 b to retain the strut 12 . The bushing 40 prevents the strut 12 from longitudinally moving relative to the wing assembly 18 while the bushing 40 is within a notch.
When a finger 66 applies downward pressure on the push-button top 32 , the spring 38 is compressed and pushes the connected bushing 40 down out of the opposing notches 62 a and 62 b . With pressure still applied, the entire wing assembly 18 can be translated up or down the slot 46 (or vice-versa) until the pressure on the button 32 is removed and the bushing (stop member) 40 re-engages one of the pair of opposing notches 62 a and 62 b.
FIGS. 5 , 6 and 7 depict a second embodiment of a wing assembly, generally designated 118 that telescopes in the exact manner just described with respect to the wing assembly 18 . The second embodiment functions the same as the wing assembly 18 with respect to the adjustment of the length of the strut 12 . The wing assembly 18 is provided with at least one strap-retaining channel 72 that runs transversely across the wing member 20 . A strap-retaining loop 74 extends longitudinally outward from an adjustment assembly housing 131 that retains the adjustment assembly 30 across the entire width of the channel 72 and is flush with the top of the adjustment housing 131 . The loops 74 may be formed of plastic, metal, or other suitable material that is resilient enough to be repeatedly bent and still spring downward to retain the strap 54 . The adjustment assembly 30 is structured and functions in like manner to the adjustment assembly 30 . Features and/or functions not discussed below with respect to the wing assembly 118 should be considered to be the same as those features and/or functions with respect to the wing assembly 18 unless noted to the contrary.
This configuration gives the wing assembly 118 a lower and sleeker profile that is less likely to get caught on obstructions during use. In addition, one end 78 of the retaining loop 74 is not connected to the wing body 20 . The end 78 has a nub 80 to keep the strap 54 in place ( FIGS. 6 and 7 ). The end 78 may also have a snap or other positive locking mechanism that is releasably engageable with the wing assembly 118 . Referring to FIG. 6 , the retaining loop 74 can be pivoted or bent up at the unconnected end 78 in order easily to slip in the strap 54 . When the end 78 is released, the nub 80 ensures that the strap 54 will not slip out of the retaining channel 72 . The arrow in FIG. 5 depicts where and how another strap may be placed.
FIG. 8 depicts a third embodiment of a wing assembly, generally designated 218 . This third embodiment telescopes in the exact manner described with respect to the wing assemblies 18 and 118 . Other features and/or functions not discussed below with respect to the wing assembly 218 should be considered to be the same as those features and/or functions with respect to the wing assemblies 18 and 118 .
The wing assembly 218 is similar in design/appearance to the wing assembly 118 . The wing assembly 218 includes a body or housing 20 having a unitary retaining loop 74 that defines two channels 72 for receipt of straps ( 54 ). The adjustment assembly 230 is oval rather than round to provide easier manipulation, and is situated at an end of the body 20 , proximate the strut 12 . The adjustment assembly 230 is surrounded by an adjustment housing 231 .
Although the invention has been described in detail with reference to a preferred embodiment and an alternative embodiment, variations and modifications exist within the scope and spirit of the invention. Additional features of the invention will become apparent to those skilled in the art upon consideration of the detailed description of preferred embodiments exemplifying the best mode of carrying out the invention as presently perceived.
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An orthopaedic brace includes a strut length adjustment assembly to change the operable length of the strut for sizing the brace on a patient without the need for special tools or cutting of the strut. The adjustment assembly includes a biased adjustment mechanism that coacts with a plurality of notches in the strut to variably set/position the strut relative to the adjustment assembly to set the struts length. Each upper and lower strut preferably includes a strut length adjustment assembly to independently set the length of each strut. The strut length adjustment assembly retains a strut and includes a strap retention mechanism that is configured to releasably engage the strap.
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BACKGROUND OF THE INVENTION
The invention relates to a sorting machine, especially for sorting mixtures of refuse, especially household rubbish, trade waste, industrial waste, refuse from demolition, waste from building sites, and also waste from wood or the like.
A sorting plant for sorting useful material has been published in the inventors' older German application No. 34 15 090 A1. In it, a sorting machine is disclosed which consists of a vibrating conveyor belt which is inclined transversely to the direction of conveying and rises in the direction of conveying, for separation of three-dimensional material to be sorted from two-dimensional material. There is no screening operation by means of a mesh.
The separation of dry waste, and sorting into individual components which can be re-utilized, causes great problems because of the severe entanglement of the waste that arrives. In particular, all types of screens tend to a greater or lesser extent to create blockages, because individual components can become stuck in the screening mesh. This is particularly the case for materials without any fixed structure or shape, such as stockings, scraps of cloth, string, and tape, which partly fall through the screening mesh and partly are retained by the remaining refuse. In this way the width of the mesh is automatically reduced.
For this reason, screening devices with meshes, or of screen form of any kind, can only be introduced into the treatment of refuse to a limited extent and with special measures. For this reason the way of separating materials is more or less restricted. Drum screens have indeed the advantage that the material introduced is continuously thrown on top of itself by the rotation, and hence is pulled apart. Nevertheless, drum screens are not suitable for sorting refuse, for again the meshes tend strongly to blockage by refuse components. Moreover the support and drive construction of drum screens needs axial space, which may be undesired.
From the totally foreign field of the sorting of hops, a device has been disclosed in U.S. Pat. No. 2,116,006, which consists of a circulating conveyor belt, that has a multiplicity of pockets. The operation of separation of the hop from the hop stem occurs by a brush shearing off and flinging away the hop stems projecting out of the pockets. On return of the belt, the remaining portions of hop fall into a container provided.
This device is not suited to the sorting of refuse, because a separating operation by means of a brush device is not possible. Moreover the pocket shape of the conveyor belt has merely the function of a holder for getting rid of the stems which stick up above it.
SUMMARY OF THE INVENTION
The object underlying the invention is to provide a sorting machine for the treatment of refuse, which in particular permits separation and sorting, as far as possible free of blockages, of mixtures of refuse, especially household rubbish, trade waste, industrial waste, and the refuse which is particularly difficult to handle from demolition of buildings, waste from building sites, and also waste from old timber.
Starting from a sorting machine of the kind indicated in the introduction, this object is achieved according to the invention with a circulating endless conveyor device which is inclined transversely to the direction of movement, wherein the mixture of recoverable material can be supplied in the region of the upper lateral edge of the conveyor device formed as a screen conveyor belt, coarser material to be sorted being able to be transported in the transverse direction of the screen conveyor belt by gravity and/or vibration, and finer material to be sorted being able to be transported in the longitudinal direction of the screen conveyor belt by means of screen pockets provided on the screen conveyor belt.
The invention operates firstly according to the principle of separated bulk flow of material in the longitudinal and transverse direction of a conveyor device. For this purpose the mixture of useful material to be sorted is supplied onto one side of an inclined conveyor belt and can cross over the circulating conveyor belt transversely to the direction of travel, under the action of gravity and/or assisted by vibration or oscillation. One part of the mixture of useful material falls into the screen pockets provided on the screen belt and is carried along in the longitudinal direction of transport of the conveyor device, until the screen pockets tip over on the return roller. The screen pockets thus constitute an aperture screen, but with limited height for falling through. In this way the whole screen system is practically free from blockage.
According to the invention the screen device is so constructed that, in the region of the screening run, the conveyor belt is formed like a drum screen, i.e. the conveyor belt is directed sagging in an arc like a cylindrical shell. By this means the mixture of useful material transported on this drum-like screen is continuously turned over, which leads to loosening up and separation of the constituents. The drum-like effect of the transporting screen belt, which would normally be flat, is achieved in that the longitudinal axes of the return rollers are journalled at a higher level than the lowest point on the transport/treatment surface. By these means, the sorting machine according to the invention works with the advantageous effects of a drum screen, without its disadvantages as regards the tendency to blockage, nor the need to keep in mind the unfavourable constructional length. The device according to the invention can make full use in the input and output region of the additional axial length as compared with conventional screens.
Furthermore, the formation of the screen pockets according to the invention is particularly advantageous in that, upon the returning motion over the upper return roller, they open automatically, and hence enable perfect emptying of the screen pocket. Each individual rear wall, which is common to two successive screen pockets, is tipped away from one pocket during the returning motion, so that an opening occurs in this region.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages which are important to the invention appear from the following exemplary embodiments, which are described i more detail with reference to the drawings in which
FIG. 1 is a perspective view of a sorting machine according to the invention, shown schematically,
FIG. 2a is a longitudinal section in the direction of transport through the view in FIG. 1,
FIG. 2b is the view x in FIG. 2a,
FIG. 3 is a sectional view similar to FIG. 2a of an alternative embodiment,
FIG. 4a is a perspective view of the shapes of screen pockets in the region of the drum screen cross-section,
FIG. 4b is a perspective view of the screen pockets in the region of the return rollers, and
FIG. 5a and 5b are perspective views similar to FIGS. 4a and 4b of alternative embodiments of the screen pockets with resilient intermediate strips between the pockets.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The sorting machine (10) shown in FIG. 1 consists of a circulating, endless conveyor device with a lower return roller (12) and an upper return roller (13). The conveyor device is formed as a screen conveyor belt (11), with screen pockets (14) provided on it, arranged in a layout side-by-side and one behind the other. In FIG. 1 the screen pockets are only shown schematically, in selected places on the screen conveyor belt. The screen conveyor belt (11) is fitted with such screen pockets all over its transporting surface.
The screening machine (10) stands on a base frame (15), the screen conveyor belt (11) being designed inclined across the direction (16) of movement at an angle (α). The longitudinal direction of the screen conveyor belt is indicated by the reference character (16), and the transverse direction of the screen conveyor belt by the reference character (17).
In the region of the higher lateral edge (18) of the screen conveyor belt (11) there is shown the supply device (19) in the form of a chute with oscillating drive (20), for the mixture (32) of useful material which is to be supplied to the sorting machine. On the opposite, lower lateral edge (21) there is shown the discharge device (22) for the coarse material (29).
The return rollers (12 and 13) for the screen conveyor belt (11) are so arranged in relation to the arrangement and length of the screen conveyor belt that, in the region of the conveyor run for the material to be transported, a construction results which is like a drum screen. For this purpose the transporting surface for the material to be sorted travels along a cylindrical shell (23). The radius of curvature of this cylindrical shell is chosen according to the material to be treated. The drum-like construction in the conveying region is attained by placing the longitudinal axes (24 and 25) of the return rollers (12 and 13) at a higher level in relation to the lowest point (26) on the screen conveyor belt. In the exemplary embodiment in FIG. 1, the longitudinal axis (25) of the return roller (13) is arranged spatially higher than the longitudinal axis (24) of the return roller (12).
This produces the steep rising inclination of the screen conveyor belt (11) and also the drum-like construction for continuous turning over of the mixture of useful material on it.
The drive of the return roller (13), and hence of the screen conveyor belt (11), is indicated as the driving motor (27), the drive taking place via a chain drive (43), which is covered by the conveyor belt (11).
The transport of material transversely to the longitudinal direction (16) of the screen conveyor belt, i.e. in the transverse direction (17) of the screen conveyor belt, takes place as a result of the inclination of the screen conveyor belt (11) through the angle (α). The angle (α) is chosen in the range of magnitude between 5° and 20° as in drum screens. It can however also assume other values according to the material composition of the mixture of useful material to be sorted. Accordingly, the transport of material is effected by gravity, as in a drum screen with material-turning properties. Additionally or alternatively an oscillating drive or a shaking drive can also be provided for the screen conveyor belt (11).
The screen pockets (14) provided over the whole surface of the screen conveyor belt (11) constitute a kind of aperture screen into which finer screened material falls and is carried onwards in the longitudinal direction (16) of the screen conveyor belt. The fine material (28) does not fall out as a separate sorted fraction until the returning motion over the return roller (13). On the other hand, the material that is too large for the screen pockets (14) is carried onwards in the transverse direction (17) of the screen conveyor belt, and is carried off in the discharge device (22) as coarse material (29). In order to ensure a sufficient residence time of the mixture of useful material on the screen conveyor belt (11), the latter must have a certain minimum width (B), which corresponds to the length of a drum-screen device including supporting structure. The width (B) lies in the order of magnitude of B≃4 m. The screen pockets (14) arranged on the screen conveyor belt can, as regards their pocket size, be made either all of equal size or of differing size. Thus it would be possible to arrange coarser pockets in the region of the supply device (19) and finer screen pockets in the region of the discharge device (22), in order to take account of the continuous loosening and separation of the mixture of useful material during the screening operation. Then different sized fractions could be taken off as a coarse fraction (28a) and as a fine fraction (28b) in the region of the return roller (13). The screen pockets (14) can also be formed as longitudinal channels, with a longitudinal extent in the direction of the transverse direction (17) of the screen conveyor belt. Then for example elongated objects, such as sticks and planks etc., can be received into these channels. In addition in FIG. 1 there is shown a deflecting wall (50) with a flexible curtain (51), e.g. made of a chain curtain or the like. This deflecting wall restrains material that is thrown backwards by the drum effect.
The longitudinal section through the longitudinal direction of the screen conveyor belt, shown in FIG. 2a shows clearly the construction and the action of the screen conveyor belt (11) like a drum screen. The cylindrical shell (23) extends over nearly a complete semicircle with the radius (r). The transport direction of the screen conveyor belt (11) in the longitudinal direction of the screen conveyor belt is indicated by an arrow (30). An arrow (31) indicates the turning over action of the mixture (32) of useful material, caused by the drum screen effect. The fine material (28) is collected in the screen pockets (14) and is transported in the direction of the arrow (33) to the upper return roller (13) and is carried round it. In the region of the transport arrow (34), the fine material (28) tips out of the rotating and opening screen pockets (14).
The longitudinal axis (25) of the upper return roller (13) is at a height (H 1 ≃2.1 to 2.4 m) above the longitudinal axis (24) of the return roller (12). In conjunction with the lateral length (L 1 ≃5.1 m), this height (H 1 ) determine the radius of curvature (r) of the screen conveyor belt (11) resembling a drum screen. In the exemplary embodiment in FIG. 2a, the lowest point (26) of the screen conveyor belt is at about the same level as the longitudinal axis (24) of the return roller (12). The total length (L 2 ) shown in FIG. 1 amounts to about L 2 ≃7.2 m, the lateral length (L 1 ≃5.1 m), this height (H 1 ) determines and the total height (H 2 ) of the screen conveyor device without the support frame (15) amounts to about H 2 ≃5.2 m.
In FIG. 2b there is shown the view "X" in FIG. 2a. According to it, the mixture (32) of useful material is supplied to the screen conveyor belt (11) at the laterally upper edge (18) (arrow 35) (see also FIG. 1). The mixture of useful material then travels in the direction of the transverse direction (17) of the screen conveyor belt, because of the inclination of the screen conveyor belt (11) and because of the further transport in the drum-like device, the coarse material (29) being discharged at the edge (21) opposite to the lateral edge (18) (arrow 29, 36), while the fine material is conveyed in the longitudinal direction (16) of the screen conveyor belt by the screen pockets (14). The arrows (30, 33) shown in FIG. 2a are directed along the longitudinal direction (16) of the screen conveyor belt. The lower return roller (12) and the upper one (13) are shown schematically in FIG. 2b. The chain lines (37) in FIG. 2b correspond to those in FIG. 2a and indicate and external radius of the screen pockets running over the return rollers (12, 13).
The exemplary embodiment according to FIG. 3 shows a variant of the embodiment in FIG. 2a. By a modified arrangement or shape of the lower return roller (12), a screen conveyor belt is provided which is at first flat in the region of the arrow (38). This can if necessary have the advantage that the supply of the mixture of useful material and corresponding distribution on the conveyor belt can take place over a longer supporting range.
But in principle this screen conveyor belt works in the same way as has already been shown in FIGS. 1 and 2a. The same items are indicated with the same reference characters.
In FIGS. 4a and 4b there is shown the construction of the screen pockets (14) and also the arrangement in different conditions of operation. Each screen pocket (14) consists of two side walls (39, 40) in the longitudinal direction (16) of the screen conveyor belt, and also two transverse walls (41, 42) in the transverse direction (17) of the screen conveyor belt. The longitudinal walls (39, 40) together with the transverse wall (41) form a container enclosed on three sides, while the fourth side wall (42) in each case is constituted by the rear wall (41) of the next-following screen pocket. For this reason, in FIG. 4a the screen pocket (14) for example is constituted by the walls which are connected rigidly together (39 to 41), while the transverse wall (42) is formed by the following screen pocket (14').
As shown in FIG. 4a, the transverse wall (42) which is movable relative to the screen pocket (14) fits closely against the side walls (39, 40) and forms a closed container. This condition occurs in the region of the drum-like shape with a radius of curvature (r). For this reason, the schematically-shown chain conveyor (43) is designed so as to be bent in FIG. 4a in the shape of a drum screen.
In the region of the return rollers (11, 12) the chain conveyor (43) is bent round in the opposite direction to that in the drum screen region, so that the screen pockets (14) open by swinging away of the transverse wall (42). Hence the volume of the screen pockets is increased in the region of the bending of the return roller (13), so that the contents can fall out still more easily. The opening and closing of the transverse walls (42) occur as the chain conveyor (43) bends since the respective floors (44) of each the pockets (14) are connected to the pivotally connected sections of the conveyor (43) as shown for example in FIGS. 4a and 4b.
So that no fine material can fall out between the tipping away transverse wall (42) and the container (14) consisting of the walls (39 to 41), the transverse walls (41, 42) are formed as a U-shaped trap (45) in their region below the floor (44). Parts (arrow 46) sliding off from the screen pocket floor (44) are therefore caught in the U-shaped recess (45) and cannot lead to sticking of the chain conveyor (43).
The side walls (39, 40) and transverse walls (41, 42) can also have additional flanges (47) in their upper region, for stiffening the screen pocket and for avoiding pieces sliding out.
An alternative embodiment of the screen pocket in FIGS. 4a and 4b is shown in FIGS. 5a and 5b. In place of the U-shaped trap (45) there is provided a flexible connecting strip (48) between the screen pocket floor (44) and the lower part of the transverse wall (42) which can be tipped away. The movable transverse wall (42) fits against the side walls (39, 40) in the region of the drum-like formation or flat formation of the screen conveyor belt (11). Only when the chain conveyor (43) moves around the return rollers (12, 13) does the screen pocket (14) open, and the transverse wall (42), which forms the rear wall of the next-following screen pocket, swing away from the screen pocket. The opening (49) which results from this is closed by the flexible connecting strip (48).
For the formation of larger screen pockets (14), several side walls (39, 40) can be omitted, so that a kind of transverse channel is produced, extending in the transverse direction (17) of the screen conveyor belt.
The invention is not limited to the exemplary embodiments shown and described. Rather, it includes all constructions which would be known to an expert, and developments without inventive content.
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A sorting machine which serves for treatment of mixtures of refuse, especially household rubbish, trade waste, industrial waste, refuse from demolition, waste from building sites, and also waste from wood or the like. To achieve a drum-like motion, a mixture of useful material is supplied to a conveyor belt which is inclined transversely to the direction of transport, the conveyor belt having the shape of part of a cylindrical shell. For the production of a screen effect, the screen conveyor belt is provided with screen pockets on its surface, so that fine material falling into the screen pockets is transported in the longitudinal direction of the screen conveyor belt, and coarse material is transported in the transverse direction of the screen conveyor belt, and thereby they are separated.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to coaxial cable connectors. More particularly, the present invention relates to coaxial F-connectors adapted to insure the establishment of a proper ground during installation. Known prior art is classified in United States Patent Class 439, Subclasses 241, 247, 322, 548, 553, 554, 585, and 587.
2. Description of the Related Art
Popular cable television systems and satellite television receiving systems depend upon coaxial cable for distributing signals. As is known in the satellite TV arts, coaxial cable in such installations is terminated by F-connectors that threadably establish the necessary signal wiring connections. The F-connector forms a “male” connection portion that fits to a variety of receptacles, forming the “female” portion of the connection.
F-connectors include a tubular post designed to slide over coaxial cable dielectric material and under the outer conductor at the prepared end of the coaxial cable. The exposed, conductive sheath is usually folded back over the cable jacket. The cable jacket and folded-back outer conductor extend generally around the outside of the tubular post and are typically coaxially received within the tubular connector. A continuity contact between the sheath and conductive portions of the connector is needed. Moreover, electrical contact must be made with the threaded head or nut of the connector that should contact the female socket to which the connection is made.
F-connectors have numerous advantages over other known fittings, such as RCA, BNC, and PL-259 connectors, in that no soldering is needed for installation, and costs are reduced as parts are minimized. For example, with an F-connector, the center conductor of a properly prepared coaxial cable fitted to it forms the “male” portion of the receptacle connection, and no separate part is needed. A wide variety of F-connectors are known in the art, including the popular compression type connector that aids in rapid assembly and installation. Hundreds of such connectors are seen in U.S. Patent Class 439, particularly Subclass 548.
However, the extremely high bandwidths and frequencies distributed in conjunction with modern satellite installations necessitates a variety of strict quality control factors. For example, the electrical connection established by the F-connector must not add electrical resistance to the circuit. It must exhibit a proper surge impedance to maintain a wide bandwidth, in the order of several Gigahertz. Numerous physical design requirements exist as well. For example, connectors must maintain a proper seal against the environment, and they must function over long time periods through extreme weather and temperature conditions. Requirements exist governing frictional insertion and disconnection or withdrawal forces as well.
Importantly, since a variety of coaxial cable diameters exist, it is imperative that satisfactory F-connectors function with differently sized cables, such as RG-6 and RG-59 coaxial cables that are most popular in the satellite television art.
It is important to establish an effective electrical connection between the F-connector, the internal coaxial cable, and the terminal socket. Proper installation techniques require adequate torquing of the connector head. In other words, it is desired that the installer appropriately tighten the connector during installation. A dependable electrical grounding path must be established through the connector body to the grounded shield or jacket of the coaxial cable. Threaded F-connector nuts should be installed with a wrench to establish reasonable torque settings. Critical tightening of the F nut to the threaded female socket or fixture applies enough pressure to the inner conductor of the coaxial cable to establish proper electrical connections. When fully tightened, the head of the tubular post of the connector directly engages the edge of the outer conductor of the appliance port, thereby making a direct electrical ground connection between the outer conductor of the appliance port and the tubular post; in turn, the tubular post is engaged with the outer conductor of the coaxial cable.
Many connector installations, however, are not properly completed. It is a simple fact in the satellite and cable television industries that many F-connectors are not appropriately tightened by the installer. The common instillation technique is to torque the F-connector with a small wrench during installation. In some cases installers only partially tighten the F-connector. Some installations are only hand-tightened. As a consequence, proper electrical continuity may not be achieved. Such F-connectors will not be properly “grounded,” and the electrical grounding path can be compromised and can become intermittent. An appropriate low resistance, low loss connection to the female target socket, and the equipment connected to it, will not be established. Unless an alternate ground path exists, poor signal quality, and RFI leakage, will result. This translates to signal loss or degradation to the customer.
U.S. Pat. No. 3,678,445 issued Jul. 18, 1972 discloses a shield for eliminating electromagnetic interference in an electrical connector. A conductive shielding member having a spring portion snaps into a groove for removably securing the shield. A second spring portion is yieldable to provide electrical contact between the first shell member and a second movable shell member.
U.S. Pat. No. 3,835,443 issued Sep. 10, 1974 discloses an electromagnetic interference shield for an electrical connector comprising a helically coiled conductive spring interposed between mating halves of the connector. The coiled spring has convolutions slanted at an oblique angle to the center axis of the connector. Mating of the connector members axially flattens the spring to form an almost continuous metal shield between the connector members.
U.S. Pat. No. 3,739,076 issued Jun. 12, 1973 discloses a coaxial connector with an internal, electrically conductive coil spring is mounted between adjacent portions of connector. As an end member is rotatably threaded toward the housing, an inwardly directed annular bevel engages the spring and moves it inwardly toward an electrically shielded portion of the cable. The spring is compressed circumferentially so that its inner periphery makes electrical grounding contact with the shielded portion of the cable.
U.S. Pat. No. 5,066,248 issued Nov. 19, 1991 discloses coaxial cable connector comprising a housing sleeve, a connector body, a locking ring, and a center post. A stepped annular collar on the connector body ensures metal-to-metal contact and grounding.
U.S. Pat. No. 4,106,839 issued Aug. 15, 1978 shows a coaxial connector with a resilient, annular insert between abutting connector pieces for grounding adjacent parts. A band having a cylindrical surface is seated against an internal surface. Folded, resilient fingers connected with the band are biased into contact. The shield has tabs for mounting, and a plurality of folded integral, resilient fingers for establishing a ground.
U.S. Pat. No. 4,423,919 issued Jan. 3, 1984 discloses a connector having a cylindrical shell with a radial flange, a longitudinal key, and a shielding ring fitted over the shell and adjacent to the flange. The shielding ring comprises a detent having end faces configured to abut connector portions when the detent fits within the keyway, whereby the shell is prevented from rotating.
U.S. Pat. No. 4,330,166 issued May 18, 1982 discloses an electrical connector substantially shielded against EMP and EMI energy with an internal, conductive spring washer seated in the plug portion of the connector. A wave washer made from beryllium copper alloy is preferred.
U.S. Pat. No. 6,406,330 issued Jun. 18, 2002 employs an internal, beryllium copper clip ring for grounding. The clip ring forms a ground circuit between a male member and a female member of the electrical connector. The clip ring includes an annular body having an inner wall and an outer wall comprising a plurality of circumferentially spaced slots.
U.S. Pat. No. 7,114,990 issued Oct. 3, 2006 discloses a coaxial cable connector with an internal grounding clip establishing a grounding path between an internal tubular post and the connector. The grounding clip comprises a C-shaped metal clip with an arcuate curvature that is non-circular. U.S. Pat. No. 7,479,035 issued Jan. 20, 2009 shows a similar F-connector grounding arrangement.
U.S. Pat. No. 7,753,705 issued Jul. 13, 2010 discloses an RF seal for coaxial connectors. The seal comprises a flexible brim, a transition band, and a tubular insert with an insert chamber defined within the seal. In a first embodiment the flexible brim is angled away from the insert chamber, and in a second embodiment the flexible brim is angled inward toward the insert chamber. A flange end of the seal makes a compliant contact between the port and connector faces when the nut of a connector is partially tightened, and becomes sandwiched firmly between the ground surfaces when the nut is properly tightened. U.S. Pat. No. 7,892,024 issued Feb. 22, 2011 shows a similar grounding insert for F-connectors.
U.S. Pat. No. 7,824,216 issued Nov. 2, 2010 discloses a coaxial connector comprising a body, a post including a flange having a tapered surface, and a nut having an internal lip with a tapered surface which oppositely corresponds to the tapered surface of the post when is assembled, and a conductive O-ring between the post and the nut for grounding or continuity. Similar U.S. Pat. Nos. 7,845,976 issued Dec. 7, 2010 and 7,892,005 issued Feb. 22, 2011 use conductive, internal O-rings for both grounding and sealing.
U.S. Pat. Nos. 6,332,815 issued Dec. 25, 2001 and 6,406,330 issued Jun. 18, 2002 utilize clip rings made of resilient, conductive material such as beryllium copper for grounding. The clip ring forms a ground between a male member and a female member of the connector.
U.S. Pat. No. 6,716,062 issued Apr. 6, 2004 discloses a coaxial cable F connector with an internal coiled spring that establishes continuity. The spring biases the nut toward a rest position wherein not more than three revolutions of the nut are necessary to bring the post of the connector into contact.
For an adequate design, structural improvements to compressible F-connectors for improving continuity or grounding must function reliably without degrading other important connector requirements. Compressible connectors must adequately compress during installation without excessive force. An environmental seal must be established to keep out water. The coaxial cable inserted into the connector must not be mechanically broken an short circuited during installation. Field installers and technicians must be satisfied with the ease of installation. Finally, the bottom line is that a reliable installation must result for customer satisfaction
BRIEF SUMMARY OF THE INVENTION
Our coaxial cable connectors are of the compressible type. The connectors comprise a rigid nut with a faceted drive head adapted to be torqued during installation of a fitting. The head has an internally threaded, tubular stem, for threadably mating with a typical socket or receptacle. An elongated post coupled to the nut includes a shank, which can be barbed, that engages the prepared end of a coaxial cable. An elongated, tubular body is coupled to the post. When the device is compressed, an end cap is press fitted to the body, coaxially engaging a body shank portion and closing the fitting.
In known F-connector designs the internal post establishes electrical contact between the coaxial cable sheath and metallic parts of the coaxial fitting, such as the nut. Also, the elongated, tubular shank extends from the post to engage the coaxial cable, making contact with the metallic, insulative sheath.
However, since improper or insufficient tightening of the nut during F-connector installation is so common, and since continuity and/or electrical grounding suffer as a result, our design includes internal grounding inserts that remedy the problem. All embodiments of our grounding insert include means for contacting and grasping the post, and means for contacting the nut, to establish a redundant grounding path between the nut, the post, and the coaxial cable to which the fitting is fastened.
A preferred grounding insert comprises a circular band, preferably made of beryllium copper alloy. In assembly, the grounding insert band coaxially engages the post. Multiple radially spaced spring clips defined around the band securely grasp a flange portion of the post. The band is seated within a ring groove within the nut, making electrical contact.
An alternative grounding insert comprises a tubular band for contacting and grasping the post flange. The band is integral with a flared, projecting skirt having a polygonal cross section. The skirt comprises a plurality of vertices and a plurality of facets therebetween. In assembly the band yieldably grasps the periphery of the post flange to establish electrical contact. Skirt vertices abut the nut's internal ring groove. Electrical contact between the insert, the post, the nut, and the coaxial cable is thus insured, despite insufficient tightening of the nut.
Thus the primary object of our invention is to provide suitable grounding within an F-connector to overcome electrical connection problems associated with improper installation.
More particularly, an object of our invention is to provide dependable electrical connections between coaxial connectors, especially F-connectors, and female connectors or sockets.
Another object of the present invention is to provide internal coaxial cable structure for establishing a grounding path in an improperly-tightened coaxial cable connector.
A similar object is to provide a proper ground, even though required torque settings have been ignored.
Another related object of the present invention to provide a reliable ground connection between a connector and a target socket or port, even if the connector is not fully tightened.
It is another object of the present invention to provide such a coaxial cable connector which establishes and maintains a reliable ground path.
It is still another object of the present invention to provide such a coaxial connector that can be manufactured economically.
Another object of our invention is to provide a connector of the character described that establishes satisfactory EMP, EMI, and RFI shielding.
A related object is to provide a connector of the character described that establishes a decent ground during installation of the male connector to the various types of threaded female connections even though applied torque may fail to meet specifications.
Another essential object is to establish a proper ground electrical path with a socket even where the male connector is not fully torqued to the proper settings.
Another important object is to minimize resistive losses in a coaxial cable junction.
A still further object is to provide a connector suitable for use with demanding large, bandwidth systems approximating three GHz.
A related object is to provide an F-connector ideally adapted for home satellite systems distributing multiple high definition television channels.
Another important object is to provide a connector of the character described that is weather proof and moisture resistant.
Another important object is to provide a compression F-connector of the character described that can be safely and properly installed without deformation of critical parts during final compression.
These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:
FIG. 1 is a frontal isometric view of a typical coaxial connector in which the instant grounding inserts are deployed;
FIG. 2 is a rear isometric view of the connector of FIG. 1 ;
FIG. 3 is an exploded, longitudinal sectional view of the connector of FIGS. 1 and 2 showing the first embodiment of our grounding insert;
FIG. 4 is an enlarged, fragmentary assembly view of the connector of FIGS. 1-3 showing the first embodiment of our grounding insert, with portions thereof broken away or shown in section for clarity;
FIG. 5 is an enlarged end view of a first embodiment of our grounding insert;
FIG. 6 is an enlarged, side elevational view of the grounding insert of FIGS. 3-5 ;
FIG. 7 is an enlarged, isometric view of the grounding insert of FIGS. 3-6 ;
FIG. 8 is an exploded, longitudinal sectional view of a connector such as that of FIGS. 1-2 , showing the second embodiment of our grounding insert;
FIG. 9 is an enlarged, fragmentary assembly view showing the grounding insert of FIGS. 5-7 , with portions thereof broken away or shown in section for clarity;
FIG. 10 is an end view of the second embodiment of our grounding insert;
FIG. 11 is a side elevational view of the second embodiment of our grounding insert;
FIG. 12 is an isometric view of the second embodiment of out grounding insert of FIGS. 10 and 11 ; and,
FIG. 13 is an enlarged sectional view similar to FIG. 9 , but showing the connector threadably mated to a threaded socket.
DETAILED DESCRIPTION OF THE INVENTION
Coaxial cable F-connectors are well known in the art. The basic constituents of the coaxial connector of FIGS. 1 and 2 are described in detail, for example, in prior U.S. Pat. No. 7,841,896 entitled “Sealed compression type coaxial cable F-connectors”, issued Nov. 30, 2010, and in prior U.S. Pat. No. 7,513,795, entitled “Compression type coaxial cable F-connectors”, issued Apr. 7, 2009, which are both owned by the same assignee as in the instant case, and which are both hereby incorporated by reference for purposes of disclosure as if fully set forth herein. However, it will be appreciated by those with skill in the art that coaxial cable connectors of other designs may be employed with the grounding inserts described hereinafter.
Referring initially to FIGS. 1-4 of the appended drawings, a coaxial F-connector has been generally designated by the reference numeral 20 . As will be recognized by those skilled in the art, connector 20 is a compressible F-connector, that is axially squeezed together longitudinally when secured to a coaxial cable. As is also recognized in the art, connector 20 is adapted to terminate an end of a properly prepared coaxial cable, which is properly inserted through the open bottom end 22 of the connector 20 . Afterwards, the connector is placed within a suitable compression hand tool for compression, assuming the closed configuration of FIGS. 1 and 2 and making electrical contact with the cable.
Connector 20 comprises a rigid, tubular, metallic nut 24 with a conventional faceted, preferably hexagonal drive head 26 integral with a protruding, coaxial stem 28 . Nut 24 is torqued during installation. Conventional, internal threads 30 are defined in the stem interior for rotatably, threadably mating with a suitably-threaded socket. The open, tubular front end 21 connects through the open interior to a reduced diameter rear passageway 34 at the back of nut 24 . Circular passageway 34 concentrically borders an annular, non-threaded, internal ring groove 36 that borders an internal shoulder 37 proximate passageway 34 .
An elongated post 40 rotatably, coaxially passes through the hex headed nut 24 . In most F-connector designs the metallic post 40 establishes electrical contact between the braid of the coax and the metallic nut 24 . The tubular post 40 defines an elongated shank 41 with a coaxial, internal passageway 42 extending between its front 43 and rear 44 . Shank 41 may or may not have barbs formed on it for engaging coaxial cable. A front, annular flange 46 ( FIG. 3 ) is spaced apart from an integral, reduced diameter flange 48 , across a ring groove 50 . A conventional, resilient O-ring 52 is preferably seated within post groove 50 when the connector 20 is assembled. O-ring 52 is preferably made of a silicone elastomer. A barbed, collar 54 having multiple, external barbs 56 is press fitted into the plastic body 60 described below. In assembly it is noted that post flange 46 (i.e., FIGS. 3 , 4 ) axially contacts inner shoulder 37 ( FIG. 4 ) within nut 24 . Inner post flange 48 and the O-ring 52 are coaxially, frictionally disposed within passageway 34 at the rear of nut 24 .
The rear tapered end 44 of post shank 41 penetrates the prepared end of the coaxial cable, such that the inner, insulated coaxial cable conductor penetrates passageway 42 and enters the front 21 of the nut 24 . Also, the braided shield of the coax is positioned around the exterior of post shank 41 , making electrical contact, and hopefully establishing a good ground, or continuity between the coaxial cable sheath, the post 40 , and the nut 24 .
An elongated, hollow, tubular body 60 , normally molded from plastic, is coupled to the post 40 . Body 60 preferably comprises a tubular stop ring 62 that is integral with a reduced diameter body shank 64 . The elongated, outer periphery 66 of shank 64 is smooth and cylindrical. The larger diameter stop ring 62 has an annular, rear wall 68 that is coaxial with shank 64 . Ring 62 defines an internal passageway 70 through which the post 40 is inserted. In assembly, the barbed post collar 54 is frictionally seated within body passageway 70 .
An end cap 76 is pressed unto body 60 , coaxially engaging the body shank 64 . The rigid, preferably metallic end cap 76 smoothly, frictionally, grips body shank 64 , with maximum travel or displacement limited by stop ring 62 . In other words, when the end cap 76 is compressed unto the body 60 , and the connector 20 assumes a closed position (i.e., FIG. 2 ), annular wall 63 on the body stop ring 62 will limit deflection or travel of the end cap 76 . Preferably the open end 78 of the end cap includes internally barbed region 79 that couples to the shank 64 of the body 60 . When the body 60 and the cap 76 are compressed together, body travel is limited within cap passageway 82 by contact with internal cap shoulder 85 . The reduced diameter passageway 88 is sized to receive coaxial cable, which is inserted through the flared opening 89 . An outer ring groove 90 at the cap rear can seat a desired O-ring.
In most F-connectors, grounding or continuity is established by mechanical and electrical contact points between abutting, conductive, metallic parts. Noting FIGS. 3 and 4 , for example, normal grounding should occur between nut shoulder 37 and post flange 46 . The coaxial cable sheath bearing against the post shank 41 would thus electrically interconnect with the post and the nut 24 , which would in turn establish electrical contact with the socket to which nut 24 is attached. However, grounding or continuity depend on proper tightening of the nut 24 . In the real world, installers often neglect to properly tighten the nut, so less internal, mechanical pressure is available within the F-connector to urge the parts discussed above into abutting, conductive contact.
Therefore our electrical grounding inserts have been proposed. The first embodiment of our insert is generally designated by the reference numeral 100 ( FIGS. 5-7 .)
Ground insert 100 comprises an annular, circular band 102 of beryllium copper alloy. Means are provided for contacting and grasping the post flange, and for contacting the nut interior. Insert ends 103 and 104 border one another across a gap 105 . As best viewed in FIG. 6 , the band midsection 108 is substantially equal in diameter to the opposite, integral spaced apart band edges 109 and 111 . It will be noted that a plurality of radially, spaced apart clips 112 are formed at regular intervals along the circumference of the band 102 . Preferably clips 112 project inwardly towards the center of the band 102 .
In assembly, the grounding insert 100 coaxially surmounts the post 40 . Specifically, the band 102 coaxially seats upon post flange 46 which is securely grasped at multiple points by the clips 112 . Insert resilience is provided by a combination of the natural “springiness” of the beryllium copper alloy, the gap 105 , and the multiple clips 112 that yieldably grasp the periphery of post flange 46 . Electrical contact between the insert and the post is thus insured by clips 112 . Electric contact between the insert 100 and the nut 24 is insured by the band 102 coaxially seated within annular ring groove 36 ( FIG. 3 ) and the clip end 111 ( FIG. 6 ) that internally abuts nut shoulder 37 (i.e., FIGS. 3 , 4 ).
The alternative embodiment is seen in FIGS. 8-12 . Alternative F-connector 23 , is externally identical with connector 20 , discussed above. However, connector 23 includes a modified grounding insert 130 described hereinafter. Like connector 20 , the alternative connector 23 comprises a nut 24 , a post 40 , a body 60 and an end cap 76 , all of which are described above.
Ground insert 130 comprises means for contacting and grasping the post flange, and for contacting the nut interior. Insert 130 comprises a tubular band 132 of beryllium copper alloy for contacting and grasping the post flange. The cross section of insert 130 is circular. Ends 133 and 134 border one another across a gap 135 . Band 132 is integral with a flared, skirt 138 characterized by a polygonal cross section ( FIG. 10 ). Like a regular polygon, skirt 138 comprises a plurality of vertices 140 and a plurality of facets 142 . The diameter of skirt 138 is maximum, and equal to the diameter of band 132 , between opposed vertices (i.e., between vertices 140 and 140 A in FIG. 10 ). The gently curved facets 143 establish a smaller internal diameter. For example, the distance between opposite facets 142 and 142 A in FIG. 10 , corresponding to minimal skirt diameter, is less than the distance between vertices 140 and 140 A.
Preferably, band 132 is provided with a plurality of radially, spaced apart clips 112 B like clips 112 previously described that are defined around insert 100 . In assembly, clips 112 B make contact with the post flange 46 within the ring groove 36 B.
In assembly ( FIG. 9 ), the front 145 of grounding insert 130 points exteriorly of the connector 23 towards nut 24 . The insert rear 146 ( FIG. 11 ) points inwardly. Band 132 coaxially seats upon a post flange 46 and yieldably grasps the periphery of the flange to establish electrical contact with the post. In assembly, band 132 occupies space between flange post 46 and internal annular ring groove 36 in nut 24 . Skirt vertices 140 abut the annular ring groove 36 B (i.e., FIGS. 8 , 9 ) in the nut. It is to be noted that ring groove 36 B is longer than similar groove 36 in connector 20 , as the insert 130 is longer than insert 100 .
Further electrical continuity is established by skirt contact with the socket or terminal to which the connector is coupled. Referencing FIG. 13 , the connector has engaged a conventional socket 150 that includes the typical external threads 152 . When the connector is attached, the skirt facets, such as facets 142 , 142 A will externally contact a portion of the socket threads to help establish continuity between the socket 152 and the connector.
Insert resilience is provided by a combination of the natural “springiness” of the beryllium copper alloy, the gap 135 , and the multiple facets 142 and vertices 140 of the skirt configuration. Electrical contact between the insert 130 and the post 40 is thus insured. Electric contact between the insert 130 and the nut 24 is also maintained.
From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.
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Axially compressible, F-connectors for conventional installation tools for interconnection with coaxial cable include grounding inserts for establishing electrical continuity despite inadequate nut tightening. The connector has a rigid nut, a post penetrating the nut, a tubular body, and an end cap. The conductive post coaxially extends through the connector, linking the nut and body. A post end penetrates the coaxial cable. Internal grounding inserts comprise a circular band coaxially engaging the post and portions on the band engaging the nut. Multiple radially spaced apart spring clips defined around the band grasp a flange portion of the post. The band is seated within a ring groove within the nut, making electrical contact. An alternative insert comprises a tubular band for contacting the post and an integral skirt abutting the nut's internal ring groove and contacting a portion of the socket to which the connector is coupled.
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TECHNICAL FIELD OF THE INVENTION
[0001] Embodiments of the present invention relate to the field of flow control. More particularly, embodiments of the present invention relate to systems and methods for an attitude insensitive flow device.
BACKGROUND OF THE INVENTION
[0002] The manufacture of semiconductors typically requires precise control of fluids (e.g., gasses, liquids, gas-vapor mixes) through the process path to a process chamber. Regulation of mass flow is often achieved through the use of a thermal mass flow controller. These mass flow controllers generally operate by directing fluid flow through a capillary tube path that runs parallel to a bypass area of the main flow path. Two thermally sensitive resistors are wound around the capillary tube. As fluid travels through the capillary tube, heat is conducted away from the resistors, or imparted to the fluid, causing the resistance of each of the resistors to change and the temperature of the fluid to change. Based on the difference in resistance between the two resistors, a controller, executing a control algorithm can determine the flow through the mass flow controller. Many mass flow meters work on a similar principle.
[0003] Thermal mass flow controllers and meters, such as those described above, are subject to a phenomenon known as “thermal siphoning” wherein heated fluid in the capillary tube initiates convective flow with the cooler fluid in the main flow path. While this flow may be small, it can cause measurable changes in the zero of the mass flow controller. This problem is exacerbated if the attitude (i.e., angle from the horizontal of the main flow path) changes. Because of thermal siphoning, prior art mass flow controllers must typically be calibrated on a controller-by-controller basis for the orientation in which each mass flow controller will be installed.
[0004] Several schemes for attitude compensation have been developed to try to offset the effects of thermal siphoning. U.S. Pat. No. 5,763,774 describes a system for minimizing thermal siphoning by reducing the internal volume of the capillary tubes and bypass area. While this method reduces the effects of thermal siphoning, a small amount of thermal siphoning remains.
[0005] Another prior art system for addressing thermal siphoning is to increase the flow restriction in the bypass area and/or the capillary tube area, as described in U.S. Pat. No. 6,763,774. This method can adversely affect sensing in some applications because it increases the differential pressure required across the sensing element.
[0006] U.S. Pat. No. 6,044,701 describes another prior art method for addressing thermal siphoning. In this scheme, the capillary tube is orthogonal to the main axis of flow through the flow measurement/control device. This method requires a complicated flow path that is difficult to manufacture. Moreover, this method simply reorients the axis of the capillary tube ninety degrees and will experience the same difficulties as other flow measurement devices if installed in an orientation that is rotated ninety degrees around the main axis of flow relative to the intended installation orientation.
[0007] U.S. Pat. Nos. 4,100,801 and 4,956,975 describe a method for reversing the flow path. While this system acts to reduce the effects of thermal siphoning, mass flow measurement/control devices incorporating this system can be more expensive to manufacture. Moreover, reversing the flow path, or even making the flow path orthogonal to the main flow path through the thermal mass flow sensor, can increase the internal volume of the thermal mass flow sensor. The increase in internal volume can make the device unsuitable for use in systems with low vapor pressure.
SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention provide an attitude insensitive flow device system and method that eliminates, or at least substantially reduces, the shortcomings of prior art flow device systems and methods.
[0009] One embodiment of the present invention can include a flow device comprising a processor and a computer readable medium accessible by the processor storing a set of computer instructions executable by the processor. The computer instructions can comprise instructions executable to receive an orientation, receive a sensed flow and determine a flow through the flow device based on the sensed flow and the orientation.
[0010] Another embodiment of the present invention can include a flow device method comprising determining the orientation of a thermal mass flow sensor, determining a sensed flow and determining the flow through the flow device based on the sensed flow and the orientation.
[0011] Yet another embodiment of the present invention can include a computer program product comprising a computer readable medium accessible by the processor, storing a set of computer instructions. The set of computer instructions can comprise instructions executable to receive an orientation, receive a sensed flow and determine a flow through a flow device based on the sensed flow and the orientation.
[0012] Yet another embodiment of the present invention can include a mass flow controller that has a thermal mass flow sensor with an inlet, an outlet, a bypass area in fluid communication with the inlet and outlet, a capillary tube in fluid communication with the bypass area, an upstream sense element and a downstream sense element to sense flow in the capillary tube. The mass flow controller can further include sensor logic connected to the upstream sense element and downstream sense element that outputs a sensed flow and an orientation sensor that outputs an orientation of the thermal mass flow sensor. The mass flow controller can also include a processor that receives the sensed flow and the orientation, a computer readable medium accessible by the processor and a set of computer instructions stored on the computer readable medium. The set of computer instructions can comprise instructions executable to receive the sensed flow, receive the orientation, select an offset based on the orientation, derive an indicated flow based on the sensed flow and offset, receive a set point and generate a valve control signal based on a difference between the indicated flow and the set point.
[0013] Embodiments of the present invention provide a technical advantage over prior art mass flow controllers by compensating for thermal siphoning with no or minimal increase to the internal volume of the flow device. Because the internal volume of the flow device is not increased, flow devices according to the present invention can be used in low vapor pressure delivery systems.
[0014] Embodiments of the present invention provide another advantage by allowing the same mass flow controller to be installed in a variety of orientations.
[0015] Embodiments of the present invention provide yet another advantage as the device orientation can be a software accessible parameter that can be used in diagnostics.
BREIF DESCRIPTIONS OF THE DRAWINGS
[0016] A more complete understanding of the present invention and the advantages thereof may be acquired by referring to the following description, taken in conjunction with the accompanying drawings in which like reference numbers indicate like features and wherein:
[0017] FIG. 1 is diagrammatic representation of a flow control device;
[0018] FIG. 2 is a diagrammatic representation of one embodiment of a thermal mass flow sensor;
[0019] FIG. 3 is a diagrammatic representation of one embodiment of a control system;
[0020] FIG. 4 is a diagrammatic representation of a control algorithm, according to one embodiment of the present invention; and
[0021] FIG. 5 is a flow chart illustrating one embodiment of a method for measuring flow.
DETAILED DESCRIPTION
[0022] Embodiments of the present invention provide a system and method for attitude insensitive flow controllers. Embodiments of the present invention can include a flow device with a controller for determining flow. The controller can include an orientation sensor that is sensitive to the angle of the flow device. Based on the reading of the orientation sensor, the controller can apply a predetermined offset to flow measurements to account for thermal siphoning.
[0023] FIG. 1 is a diagrammatic representation of one embodiment of a flow controller. Mass flow controller 100 comprises inlet fitting 110 , flow restrictor 120 , thermal mass flow sensor 130 , control valve 140 , solenoid 150 , outlet fitting 160 , and I/O coupling 170 for communicating with a control system or process management system. Thermal mass flow sensor 130 , which can include upstream and downstream resistors, and solenoid 150 may be coupled to an embedded control system. The control valve is driven by a current controlled solenoid valve drive circuit.
[0024] Fluid (e.g., gas, liquid, gas-vapor mix) enters mass flow controller 100 through inlet fitting 110 flows through flow restrictor 120 , control valve 140 and outlet fitting 160 . The volume of gas flowing through outlet fitting 160 is controlled by control valve 140 , which is in turn controlled by solenoid 150 . The embedded control system monitors the set point input and flow sensor output(s). A control algorithm, such as a closed loop control algorithm executed by the embedded control system, operates to output a valve control signal to solenoid 150 . In response to the valve control signal, solenoid 150 exerts a force on valve stem 162 to move poppet 164 away from valve seat 166 . The mass flow controller of FIG. 1 is provided by way of example only, and embodiments of the present invention can be implemented in a variety of mass flow controllers including those described in U.S. patent application Ser. No. ______, entitled “Method and System for a Mass Flow Controller with Reduced Pressure Sensitivity”, filed Jul. 8, 2004 (Attorney Docket No. MYKR1490), by Kenneth E. Tinsley et al., which is hereby fully incorporated by reference herein, (the “Reduced Pressure Sensitivity Application”).
[0025] FIG. 2 is a diagrammatic representation of one embodiment of a thermal mass flow sensor 130 . Thermal mass flow sensor 130 can include, for example, a bypass region 202 and a capillary tube 204 . Bypass region 202 can include a flow restrictor 120 . According to one embodiment of the present invention, flow restrictor 120 can produce a generally laminar flow through bypass region 202 . Capillary tube 204 can be surrounded by an upstream sense element 206 and a downstream sense element 208 that can be connected to additional logic. As fluid enters thermal mass flow sensor 130 , a portion of the fluid is diverted through capillary tube 204 . The fluid is heated by upstream sense element 206 and downstream sense element 208 , which creates a region of heated fluid 210 . The fluid flow through bypass region 202 , on the other hand, can remain relatively cool to create a region of cool fluid 212 . As heat is drawn away from upstream sense element 206 and downstream sense element 208 the resistance of the sense elements changes. Based on the difference in resistances, the flow through flow sensor 130 can be determined.
[0026] In the embodiment illustrated in FIG. 2 , the main axis of flow through thermal mass flow sensor 130 is approximately horizontal. As the attitude of the mass flow sensor 130 changes, that is, as the main axis of flow deviates from the horizontal, convective flow can be established in capillary tube 204 through the temperature differences of the fluid in flow sensor 130 . This convective flow can cause the temperature change in upstream sense element 204 and downstream sense element 206 to inaccurately reflect the net flow through thermal mass flow sensor 130 . Generally, the convective flow will cause the sensed net flow to be offset by some amount. The amount of offset is influenced by the orientation of thermal flow sensor 130 , the pressure of the process fluid and the type of process fluid. According to one embodiment of the present invention, the controller to which thermal mass flow sensor 130 is connected can compensate for the convective flow.
[0027] FIG. 3 is a diagrammatic representation of one embodiment of a control system 300 that can include logic (hardware and/or software programming) to compensate for thermal siphoning. Control system 300 can include sensor logic 302 connected to the upstream and downstream sense elements. Sensor logic 202 can include any sensor logic known in the art, such as the interface logic of U.S. Pat. No. 6,575,027, entitled “Mass Flow Sensor Interface Circuit”, issued Jun. 10, 2003 to Larsen et al., which is hereby fully incorporated by reference herein. Sensor logic 302 can output a sensed flow signal that is generated based on the resistances of the upstream and downstream sense elements. Processor 306 (e.g., CPU, ASIC, or other processor known in the art) can be connected to sensor logic 302 by an analog to digital (“A/D”) converter 304 . A/D converter 304 can receive the sensed flow signal from sensor logic 302 and convert the received signal to a digital representation of the sensed flow. Processor 306 can receive the sensed flow from A/D converter 304 .
[0028] Control system 300 can further include an orientation sensor 308 . Orientation sensor 308 can include any sensor capable of outputting a signal (analog or digital) that represents the orientation of the thermal flow sensor. One embodiment of orientation sensor 308 is the OMRON D6B position sensor manufactured by OMRON Corporation of Kyoto, Japan. This sensor is a microminiature position sensor that has a 2-bit binary output with distinct states for each of four possible 90-degree orientations around a single axis. The position resolution of the D6B is limited to about ± forty-five degrees. The sensor can be positioned such that it outputs the orientation of the main flow axis through the thermal mass flow sensor relative to a horizontal orientation. It should be noted that the OMRON DB6 is provided by way of example only and other sensors, with higher or lower resolutions, can be used for orientation sensor 308 . Orientation sensor 308 can be placed on the same circuit board as processor 306 or can be located elsewhere in the flow control device.
[0029] Processor 306 can execute computer instructions 310 , stored on a computer readable medium 312 (RAM, ROM, Flash Memory, magnetic storage device and/or other computer readable medium known in the art), to correlate the sensed flow to a mass flow or a valve control signal. According to one embodiment of the present invention, processor 306 can access a set of stored offsets 314 and apply the appropriate offset during execution of the control algorithm to account for the orientation of the thermal mass flow sensor.
[0030] The offset applied for a particular sensed orientation can be calibrated for a particular mass flow controller. In the example above of an orientation sensor that can indicate four orientations, a mass flow controller can be placed in each of the four orientations (e.g., thermal mass flow sensor inlet up, thermal mass flow sensor inlet down, horizontal with capillary tube up, horizontal with capillary tube down) and the offsets for that mass flow controller can be recorded and saved. According to another embodiment of the present invention, the offsets stored for a particular mass flow controller can be based on offsets determined for other mass flow controllers having, for example, the same combination of valve and restrictor.
[0031] It should be noted that offsets can be stored for any number of orientations if the orientation sensor is capable of greater resolution. For example, if the orientation sensor is capable of determining every ten degrees of orientation, control system 300 can store offsets for each orientation (e.g., horizontal, the thermal mass flow sensor outlet elevated ten degrees, the thermal mass flow sensor outlet elevated 20 degrees and so on). Additionally, as the amount of thermal siphoning that occurs is a factor of gas density and pressure, offsets can be stored for a variety of gasses and expected upstream gas pressures. As with calibration flow curves, the offsets for one gas, say Nitrogen, and set of flow conditions can be extended to other gases, Argon for example, and flow conditions. The extension of calibration flow curves to different gasses and flow conditions is discussed in U.S. patent application Ser. No. 10/444,249, entitled “System and Method for Mass Flow Detection Device Calibration”, to Stuart Tison, filed May 23, 2003, which is hereby fully incorporated by reference herein.
[0032] Control system 300 can, thus, receive an indication of the thermal mass flow sensor orientation, access a corresponding offset and apply the offset to the control algorithm. The offsets can be applied to the sensed flow, the indicated flow or other point in the control algorithm. This allows embodiments of the present invention to compensate for thermal siphoning without complex rerouting of the capillary tube and further allows for the same mass flow device to be installed in a variety of orientations without recalibration.
[0033] FIG. 4 is a diagrammatic representation of one embodiment of a control algorithm 400 . Control algorithm 400 can be implemented, according to one embodiment of the present invention, by executing a set of computer instructions stored on a computer readable medium. According to one embodiment of the present invention, the control algorithm can be executed by an embedded controller of a mass flow control device.
[0034] According to one embodiment of the present invention, the controller can receive a digital representation of the sensed flow (block 402 ) and apply a low pass filter (block 404 ) to the sensed flow. The controller can further access an offset (block 406 ). According to one embodiment of the present invention, the offset selected can be based on an orientation received from, for example, an orientation sensor, the gas flowing through the flow device and the pressure of the gas. The controller can add or subtract the offset to the sensed flow (summer 408 ). Additional values can also be applied to the sensed flow to account for other factors that can contribute to a zero offset.
[0035] The sensed flow with the offset applied can be compared to a gas flow curve (block 410 ). The curves can be stored and accessed according to any mass flow calibration scheme known in the art. The controller can apply a low pass filter (block 412 ) to the results of the curve fitting and apply a predetermined gain factor to the derivative of the output of the curve fitting (block 414 ). The results of the curve fitting and the derivative of the curve fitting multiplied by a gain can be combined (summer 416 ) to produce an indicated flow (block 418 ).
[0036] In a mass flow controller, the controller can receive a set point (block 420 ) and can subtract the indicated flow from the set point (summer 422 ) to generate an error signal. The control algorithm can further add a pressure factor (e.g., a second gain multiplied by a change in pressure over time), as described in the Reduced Pressure Sensitivity Application, in generating the error signal. The controller can apply any proportional-integral control technique (block 424 ) known in the art to generate a valve control signal based on the error signal. The valve control signal can be output to a solenoid controller (block 426 ). According to one embodiment of the present invention, the controller can output the valve control signal using multiple channels as described U.S. patent application Ser. No. ______, entitled “Valve Control System and Method”, filed Jul. 8, 2004, to Dwight Larson, which is hereby fully incorporated by reference herein.
[0037] In the example of FIG. 4 , the offset is applied to the sensed flow prior to the curve fitting. In this case, the stored offset will be the offset in terms of the sensed flow. According to other embodiments of the present invention, however, the offset can be applied at other points of control algorithm 400 . For example, the offset can be applied to the indicated flow or to the valve control signal. According to yet another embodiment of the present invention, the offset can be applied piecemeal at various stages in the control algorithm.
[0038] FIG. 5 is a flow chart illustrating one embodiment of a method for an attitude insensitive flow device. The method of FIG. 5 can be implemented, for example, as hardware or software programming in a controller of a flow device. At step 502 , an orientation can be determined. This can be done, for example, when the controller is powered up, when a set point is asserted or at the occurrence of a predetermined event. The controller, at step 504 , can load an offset from memory based on the orientation, process gas and expected flow conditions.
[0039] The controller, at step 506 , can receive a sensed flow from the thermal mass flow sensor. At step 508 , the offset determined at step 504 can be applied to the sensed flow to generate a corrected sensed flow. The controller, at step 510 , can apply any control algorithm known in the art to the corrected sensed flow generate a valve control signal to open or close a valve in response to a set point. Thus, the controller can receive an orientation, receive a sensed flow and determine a flow through the flow device based on the orientation and the sensed flow. Additionally, the controller can generate a valve control signal based on the sensed flow and orientation. The process of FIG. 5 can be arbitrarily repeated as needed or desired.
[0040] Thus, embodiments of the present invention provide a system and method for an attitude insensitive flow device. While the flow device has been discussed primarily in terms of a mass flow controller, the flow device can be any flow device, such as a mass flow meter, that experiences thermal siphoning. According to one embodiment of the present invention, the flow device can include an orientation sensor to determine the orientation of the flow device and a set of stored offsets corresponding to each orientation. Based on the orientation determined by the orientation sensor, the flow device can access the appropriate offset. The offset selected can also be influenced by the process gas and one or more flow parameters (e.g., gas pressure). The flow device can apply the offset to account for thermal siphoning when determining flow through the device.
[0041] While the present invention has been described with reference to particular embodiments, it should be understood that the embodiments are illustrative and that the scope of the invention is not limited to these embodiments. Many variations, modifications, additions and improvements to the embodiments described above are possible. It is contemplated that these variations, modifications, additions and improvements fall within the scope of the invention as detailed in the following claims.
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Embodiments of the present invention provide systems and methods for attitude insensitive flow devices. One embodiment of the present invention can include a flow device comprising a processor and a computer readable medium accessible by the processor that stores a set of computer instructions executable by the processor. The computer instructions can comprise instructions executable to receive an orientation, receive a sensed flow, and determine a flow through the flow device based on the sense flow and the orientation.
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[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 14/295,883, filed Jun. 4, 2014, now U.S. Pat. No. 9,486,656, which claims the priority benefit of U.S. provisional application No. 61/840,414, filed Jun. 27, 2013.
BACKGROUND
[0002] Wildfires are common in western states, for example California, wherein approximately two million homes face extreme wildfire hazards, particularly in the southern part of the state, due to a proximity to fuels such as trees grass and brush.
[0003] Current fire fighting tactics require intensive coordination as ground and air resources are deployed to fight fires threatening homes. Ground resources typically include teams or groups of people with little fire fighting training, who are deployed to dig fire lines in advance of approaching flames. Frequently, wildfires are of such intensity and occur in such strong winds that burning debris blows over the fire line and subsequent fire lines must be created. This process can occur many times over as ground crews attempt to stay ahead of the fire.
[0004] Fire suppression covers or blankets are known in the art. U.S. Pat. No. 2,720,269 to Diacos discloses a fire blanket made of fire-resistant material. The Diacos reference is designed for small in-home fires and includes a weighted hem. Diacos is not suited for outdoor tire suppression due to its size, and if expanded to adequately cover a large area, would be prohibitively heavy.
[0005] U.S. Pat. No. 6,125,941 to Lokken discloses a blanket for smothering fires or protecting items from a fire comprising a wettable polymer capable of high volume water retention, a water reservoir and heat activatable valves to permit water to flow from the reservoir into the blanket. While Lokken may be adapted for fighting outdoor wildfires, it is disfavored due to its complex and expensive construction, requirement for water, and the difficulty of cleaning and re-using the blanket.
[0006] U.S. Pat. No. 8,297,371 to Musser, Jr. discloses a fire protection system for preventing an area from catching fire, comprising as large tarp for draping over the area. Cables slidably attached along the side edges of the tarp via eyelets help guide the tarp around structures. Musser, Jr. is disfavored because it must be supported by a support structure, such as a crane or helicopter in order to function. It also is deployed directly against a structure, increasing the likelihood that a fire will ignite the structure.
[0007] Grasslands, chaparral, and other generally arid treeless areas are prone to hotter and more intense wildfires due to the highly combustible nature of their flora, which serves as a fuel source once ignited. Wild fires burning in such areas are also prone to flare-ups when denser fuel areas ignite simultaneously, resulting in fire storms. By regulating the burn characteristics of such fires, for example, by breaking a wildfire fire line down into a series of uniform individual fires helps control the spread of a fire and prevent flare-ups.
[0008] There is therefore a need for a blanket-type fire suppression device which is lightweight, inexpensive and easy to construct, which avoids the need for water or support materials in order to function. There is also a need for an apparatus, deployable as a ground fire suppression resource, capable of reducing a fire to a more manageable size and intensity, allowing it to be more easily extinguished by trained fire fighters. A need also exists for a blanket-type fire suppression apparatus that separates a fire burning under the apparatus into uniformly spaced burn zones, thereby further dissipating heat and energy from the fire.
SUMMARY
[0009] A fire suppressing blanket for fighting grass and scrub (defined as low shrub) fires along a fire line includes a sheet made of a fire resistant material. The sheet has a lattice defining multiple openings. The openings vary in size from larger openings along a front edge of the sheet to smaller openings toward an opposing back edge of the sheet. The lattice is formed by woven strips of fire resistant material. Preferably, a first sheet may be attachable to additional sheets, allowing the sheets to be laid out side by side along the fire line, and the sheet material is flexible for rolling.
[0010] The fire resistant material may include or be made from fiberglass coated in vermiculite, and the woven strips of fire resistant material may be woven in a substantially perpendicular warp and well orientation in keeping with the sheet's rectangular shape. Connectors secured the woven strips together at points where the woven strips overlap to preserve the shape of the sheet.
[0011] In order to suppress an outdoor grass or scrub fire, a user first obtains one or more sheets of fire suppressing lattice having larger openings along a front edge varying to smaller openings along a back edge. The sheet is laid atop or near the grass or the scrub at risk of burning, and is arranged so that the front edge is toward the fire and the back edge is away from the tire. If necessary, multiple sheets may be placed end to end along the fire line to counter a large approaching fire. Once the risk of burning passes, the sheet may be removed from the grass or scrub and rolled up for storage or transport.
[0012] Preferably in addition to the openings varying in size from larger openings along a front edge of the sheet to smaller openings toward an opposing back edge of the sheet, the openings also vary in size between larger openings and smaller openings along the front edge and the back edge of the sheet (i.e., from side to side, lateral to a fire line) to form a plurality of burn zones. The burn zones help to divide and isolate the fire into multiple smaller fires.
[0013] The sheet is formed by woven strips of the fire resistant material, that share a common width, preferably twelve inches wide in one embodiment, and the woven strips form a lattice of the fire resistant material. The woven strips are attached together at places where they overlap, including using fire resistant grommets, and are woven in a substantially perpendicular warm and well orientation.
[0014] Each of the plurality of burn zones is parabola shaped, and open toward the front edge of the sheet, thus allowing the fire to enter along the front edge and be divided as it drives further into each burn zone. In one embodiment each sheet comprises two burn zones, which may be equally spaced apart. By configuring the sheet to be attachable to a second sheet, sheets can be connected together to present a uniform series of burn zones along a fire line. In a preferred embodiment, the front edge and the back edge of the sheet are approximately twenty five feet long.
BRIEF DESCRIPTION OF THE FIGURES
[0015] FIG. 1 is a perspective view of a lattice made of thermal and fire resisting fabric in a rolled-out arrangement.
[0016] FIG. 2 is a top view of the lattice showing the increasingly tight lattice pattern oriented against wind direction.
[0017] FIG. 3 is a top view of an enlarged portion of the lattice showing its orientation to the wind and the individual components of the fire resisting lattice fabric pattern and gaps.
[0018] FIG. 4 is a side view of a fire moving across the lattice in relation to wind direction, and showing the decreasing size of the lattice apertures as a fire is pushed further into the lattice by the wind.
[0019] FIG. 5 shows a house in the path of a fire and placement of several lattices in series in relation to wind direction.
[0020] FIG. 6 is a to view of an alternative embodiment lattice having as repeating side-to-side pattern arranged along the lattice.
[0021] FIG. 7 is a top view of the alternative embodiment lattice showing isolated fire sections corresponding to the side-to-side pattern along the lattice.
DESCRIPTION
[0022] Referring to FIGS. 1-5 , in a preferred embodiment, a loose, thin pattern of light weight fire resistant material is formed in a lattice 10 and placed in the path of a fire. While not appropriate for tires in trees, the lattice 10 is adapted to cover low-lying grasses and small shrubs. By covering grass and scrub, the lattice 10 introduces thermal resistance and makes it difficult for the fire to maintain its rate of speed, height, and intensity.
[0023] The lattice 10 presents a horizontal fabric “fence” that lies on the ground. Preferably, a series of lattices 10 (see, e.g., FIG. 5 ) are arranged in series as long as necessary to compensate for the size of an approaching fire. In one embodiment the lattice 10 may he approximately twenty five feet long and ten feet wide. The lattice 10 presents a pattern of thermal resistance against the fire without moving parts or electronics, no requirement for assembly and no requirement for water or fire suppressing chemicals. In addition, the lattice 10 is lightweight, reusable, and may be discarded or repaired and re-used as desired.
[0024] For example, when several of lattices 10 are lined up together as a defensive system end to end in a line of 300 feet, which can be accomplished in several minutes, the back lot lines of between six and eight standard tract homes can be effectively protected from an approaching fire. By quickly protecting a broad area, valuable resources can be reallocated to other firefighting activities, reducing the effort required by multiple fire lines.
[0025] By rolling out the lattice 10 on the ground and over the small shrubs and other fuels downwind of the path of the flames, the wind will effectively push the fire into the lattice 10 which snares it in an alternating and repeating lattice pattern 22 , 24 ( FIG. 3 ) which grows smaller and smaller, reducing open areas while increasing the material covered areas creating further resistance.
[0026] The capturing and dissipating effect that occurs when the fire is “entangled” in the pattern is accomplished by the fire resistant material preventing the fuel below the lattice 10 from igniting due to the flames above the pattern. Secondly, any existing fire under the pattern is enclosed in a loose structure providing less open air and an increasing fire resistant material surface area the farther the fire is pushed into the pattern. This incremental closing of the open spaces or apertures in the lattice 10 increases resistance and further reduces the availability of adequate ventilation and fuel to effectively choke out the fire.
[0027] As a fire burns under the lattice 10 , it pushes the dames through the apertures 22 , 24 in an inverted funnel pattern upward. Since the same gaps are also needed to provide adequate ventilation fur burning, any path below the pattern is constricted reducing the oxygen available to the fire. This increasingly constrictive process dissipates the energy output, weakening the fire and causing the flame height to decrease and re-stabilize as a lower intensity fire.
[0028] As the fire is pushed by the wind toward areas o the lattice 10 where the strips of fire-resistant material (primary strip 12 , secondary strip 14 , tertiary strip 16 and quaternary strip 18 ) are placed closer together than in previous rows, the cycle is repeated. The constricting effect of increasing the area covered by fire resistant material while decreasing the available open area creates a cascading effect, ultimately driving the fire to smaller and smaller remaining openings in the pattern the farther it advances until there are no more open areas left in the pattern effectively denying fire the fuel and open areas to re-generate and grow while under the lattice 10 .
[0029] In use, the lattice 10 allows firefighters to lay out as many individual lattices as necessary and wait until a fire has navigated through the pattern and been significantly reduced in both height and intensity before engaging the fire using traditional fire fighting methods. The lattice 10 also adds a barrier providing a level of safety for firefighters by providing a fire resistant barrier between the fire and the firefighter.
[0030] Referring to FIG. 1 , a perspective illustration of the overall look and design of a preferred embodiment of the lattice 10 is shown including the differential nature of the tightness of the lattice 10 . When oriented relative to wind direction, the front of the lattice pattern encountered first by a fire has greater apertures or openings, which decrease in size as the fire travels across the lattice. By the time the fire reaches the other side the lattice, the apertures are at their smallest size, thereby denying open space and fuel to the fire.
[0031] Referring to FIG. 2 , a top view of the lattice 10 is shown depicting more detail of the individual components of the design, and the proper orientation in relation to wind direction. In particular, as the apertures in the lattice 10 decrease in size, additional strips of fire resistant material are used to increase the surface area of the lattice.
[0032] FIG. 3 is a top view of a section of the lattice 10 and shows a detailed and enlarged view of its components. The individual elements required for manufacturing, the completed lattice 10 are shown as follows:
[0033] In a preferred embodiment, the lattice 10 has a standard size of approximately 25 feet long and 10 feet wide (see, FIGS. 1 and 2 ), although other sizes are contemplated according to preference and application. The standard material is a fire-resistant flexible fiberglass having a thickness of approximately 1/16 of an inch which creates a thickness of ⅛ inch at each intersection of material.
[0034] Still referring to FIG. 3 , the preferred lattice 10 pattern requires four different lengths of material and three different widths of material in order to create the lattice 10 . Primary strips 12 of fiberglass material approximately 25 feet long and 6 inches wide, run the length of the lattice 10 . Secondary strips 14 of fiberglass material approximately 9 feet long and 8 inches wide, which run the width of the lattice 10 . Tertiary strips 16 of fiberglass material approximately 6 feet long and 4 inches wide, are long inserts, which partially cover the width of the lattice, and quaternary strips 18 of fiberglass material approximately 3 feet long and 4 inches wide representing the short inserts, which partially cover the width of the lattice 10 . A series of brass or other metal grommets 20 are used to fasten the material at intersections, in some embodiments every intersection of material, to create the lattice pattern shown in FIGS. 1-3 .
[0035] Still referring to FIG. 3 , the primary strips 12 , secondary strips 14 , tertiary strips 16 and quaternary strips 18 are shown intersecting and creating a woven pattern. The intersections have grommets 20 , thereby preserving the orientation of the strips and holding them in a square lattice pattern. The grommets 20 also preserve the distance between the strips. In one embodiment, the grommets 20 compress washers against the strips 12 , 14 , 16 , and 18 in order to better grip the material. Preferably rubber hose washers are used in connection with the grommets 20 . The pattern of the primary strips 12 and secondary strips 14 creates a series of large apertures 22 in the portion of the lattice first encountered by a fire. The large apertures 22 decrease in sue as a fire progresses through the lattice 10 .
[0036] Once a fire reaches approximately mid-way across the lattice 10 it encounters the tertiary strips 16 and quaternary strips 18 , also intersecting in a woven pattern. The tertiary strips 16 and quaternary strips 18 help to take up the spaces between the primary strips 12 and secondary strips 16 . All of the primary strips 12 are placed incrementally closer and closer together until they eventually touch at the far edge of the lattice 10 , eliminating all open areas of the lattice 10 as shown in FIGS. 1-3 . The tertiary strips 16 and quaternary strips 18 are made of the same material as the overall lattice but are preferably 4 inch wide strips of varying lengths for placement in the 8 inch wide openings. This arrangement reduces the apertures in the lattice to suppress the fare as it approaches the rear of the lattice.
[0037] Another important aspect of the preferred embodiment includes an available factory coating of the fire resistant material with vermiculite. Such a coating improves the thermal characteristics of the fiberglass and provides the capability of withstanding tires of up to 2000 degrees Fahrenheit for up to 15 minutes.
[0038] Referring to FIG. 4 , a preferred embodiment of the lattice 10 is shown in side view. As a fire passes across the lattice, the openings in the lattice decrease in size causing a corresponding decrease in the height of the flames. Predictably, at the edge of the lattice furthest from the ignition point of the fire, no openings are present which prevents air from reaching the fire under the lattice 10 . Although embers may remain present under the lattice 10 , by leaving the lattice in place for a sufficiently long period of time, the likelihood of a fire continuing past the lattice 10 is greatly reduced.
[0039] Referring to FIG. 5 , several lattices 10 according to a preferred embodiment are shown pre-positioned in a fire resisting pattern in the back of a house 26 threatened by tire. By pre-positioning the lattices 10 , the house 26 is protected when fire crews arc unavailable to spray water on the fire, as in the case of an evacuation,
[0040] Referring to FIGS. 6 and 7 , an alternative embodiment lattice 110 is shown with repeating parabolic aperture features. Like the primary embodiment lattice 10 , the alternative embodiment lattice 110 comprises a loose, thin pattern of light weight fire resistant material to be placed in the path of a fire, covering low-lying grasses and small shrubs. The differences are that the lattice 110 incorporates wider strips of fire resistant material, and both the primary strips 112 and the secondary strips 114 are preferably of equal width. Additionally, in the alternative embodiment lattice 110 , both the primary strips 112 and the secondary strips 14 anchored together with grommets 120 and arranged to have variably sized spaces for isolating the fire into sections.
[0041] Referring to FIG. 6 , the lattice 110 is created using only different lengths of fire resistant material having the same width, designated primary strips 112 and secondary strips 114 . Using only primary strips 112 and secondary strips 114 reduces labor costs, since fewer intersections require securing with grommets 120 requires less assembly time. Material costs are also reduced, since the lattice 110 is formed using a single width of fire resistant material. Essentially, a roll of fire resistant material can be cut into primary strips 112 and secondary strips 114 which are woven together. Omitting tertiary strips 16 and quaternary strips 18 ( FIGS. 1-5 ) also results in a reduced number of intersections and reduces the weight of the lattice 110 .
[0042] In a preferred embodiment, both the primary strips 112 and secondary strips 114 are approximately twelve inches wide. The primary strips 112 are approximately twenty live feet long, running the length of the lattice 110 parallel to a fire while the secondary strips 114 are approximately nine feet long, running the width of the lattice 110 (i.e., perpendicular to a fire line). Although the illustrated embodiment shows a grommet 120 installed at the intersection of each primary strip 112 and secondary strip 114 , in various other embodiments, fewer grommets 120 may be used sufficient to preserve the overall lattice 110 structure when rolled up, and when unrolled for installation during a fire event.
[0043] Still referring to FIG. 6 , the primary strips 112 and the secondary strips 114 are spaced apart with the spacing, at varying distances. Like the primary embodiment shown in FIGS. 1-5 , the primary strips are spaced apart to their greatest extent where the lattice 110 initially encounters a fire (not shown) along a front edge 132 of the lattice 110 . Usually this is the windward side of the lattice 110 and thus the side approached by a fire line 134 . Extending across the lattice 110 , the primary strips 112 are spaced increasingly close closer together until virtually no spaces exist between the primary strip 112 comprising a back edge 136 of the lattice 110 , thus depriving oxygen and extinguishing a fire traveling under it.
[0044] In this embodiment, the secondary strips 114 are also variably spaced apart. The variable spacing of the secondary strips 114 is arranged such that there is little or no space between the secondary strips 114 adjacent a first side edge 122 and adjacent a second side edge 12 $ of the lattice 110 , and also on either side of a center secondary strip 126 located midway between the first side edge 122 and the second side edge 124 . Spaces between the secondary strips 114 are arranged progressively larger, such that they reach their greatest width midway between the first side edge 122 and the center secondary strip 126 , and midway between the second side edge 124 and the center secondary strip 126 .
[0045] Referring to FIG. 7 , due to the variable spacing of the primary strips 112 in conjunction with the spacing of the secondary strips 114 , each lattice 110 is divided into a first fire isolation zone 128 and a second fire isolation zone 130 . The first fire isolation zone 12 $ and second fire isolation zone are each characterized by a parabola-shaped burn isolating area 140 open toward an approaching fire line 134 . When the fire line 134 reaches the lattice 110 and burns under the primary strips 112 and secondary strips 114 , the spacing between them causes the fire to divide into the first fire isolation zone 128 and second fire isolation zone 130 due to spaces between the secondary strips 114 . As the fire continues burning under the lattice 110 , the reduced spacing between the primary strips 112 extinguishes the fire. By dividing the fire once it enters the lattice 110 , combustion energy is evenly spaced out along the lattice 110 , enhancing its effectiveness.
[0046] A series of four small scale wind tunnel tests at 4-5 MPH were performed on Mar. 15, 2013 in a US Department of Agriculture Fire Science testing facility located near Corona Calif., in order to demonstrate that a large fire can be entangled, take longer to move a given distance and be influenced while being reduced in size using a thin fiberglass material only 1/16″-⅛″ thick.
[0047] Three different sizes of the same pattern were assembled using the same material (2″, 3″, and 4″) strips of temperature resistant fiberglass material. The material is coated with vermiculite to increase the temperature rating up to 2000 F for a duration of 15 minutes of direct exposure. The material was laid out in a pattern with holes throughout the pattern for the energy to be focused and dissipated.
[0048] A 6-8″ thick bed of Excelsior was used on 4 separate tests as fuel to test the patterns which were all placed loosely on top and spread out to encompass the entire fuel bed which was roughly 3′ wide by 6′ long A 1 foot length of excelsior was used as the wick to get a large fire started before impacting the pattern. The 4th test was the control test to show the height and intensity of the same fire with no pattern placed on top to impede it.
[0049] In test no. 1, the height of the flame before contacting the pattern was approximately 5½-6 ft tall. The height of the flame immediately after contacting the pattern was approximately 4-5 ft tall, and the height of the flame 1 minute after contacting the pattern was approximately 3-4 ft tall.
[0050] In test no. 2, the height of the flame before contacting the pattern was approximately 5 ft tall. The height of the flame immediately after contacting the pattern was approximately 4-5 ft tall, and the height of the flame 1 minute after contacting the pattern was approximately 3-4 ft tall.
[0051] In test no. 3, the height of the flame before contacting the pattern was approximately 6½-7 ft tall. The height of the flame immediately after contacting the pattern was approximately 5 ft tall, and the height of the flame 1 minute after contacting the pattern was approximately 3-4 ft tall.
[0052] In test no. 4, the height of the flame in 1st 15 seconds was approximately 6½-8 ft tall. The height of the flame in the next 30 seconds was approximately 6½-7 ft tall, and the height of the flame 1 minute after was approximately 6½-7 ft tall.
[0053] Observations of these tests indicated that in the 3rd experiment, the smallest pattern (2×2) seemed to take the longest to burn through to the end. It also appeared to cut down the intensity the most. The smaller the opening translated into the longer it will take for the fire to consume the fuel underneath. The wider the material the less holes are in the material. Using a wider material with small opening provided the best results. The fire was effectively steered into an area of the pattern on the 3×3 setup evidenced by the burn pattern photos by leaving an opening greater than the area around it.
[0054] Other observations included that the heat patterns on the sides of all 3 showed little heat degradation compared to the center of the pattern directly on top of the fuel bed where the path of the fire could be traced by looking at the brass fasteners and the different color patterns. The thin nature of the material gives it flexibility and is still able to disrupt the normal fire behavior effectively snaring it and creating a repeating resistance beneath the material. The fire did not “skip” across the pattern even with a 4-6 MPH wind but went under and slowed down due to the fabric above it and the structure of the pattern blocking the wind. The intensity and ferocity in each burn was significantly reduced and calmed when compared to the control burn #4. Finally, the controller; Dr. Weiss from the Department of Forestry, stated the experiment did reduce the fire and that a smaller fire is an easier managed fire. His observation indicated that all 3 tests patterns were effective in achieving the size reduction needed for extinguishing a fire with less effort.
[0055] A major benefit of the lattice includes the improved effectiveness of water. Without the lattice, a larger amount of water would be needed due to the higher evaporation rate due to the temperatures of the flames. With the lattice breaking down the fire, water can be strategically sprayed at the back end of the pattern when the fire has been reduced down and temperatures are lessened.
[0056] Another benefit involves its immediate reusability allowing a lattice to be re-deployed several times during a fire if needed; providing an immediate benefit in utility, availability and value. The fire-resistant fabric will degrade as a result of multiple fire exposures and is not to be considered as having unlimited life, but rather several lives depending on the cumulative exposure to fire. The time required for the fire to pass through the pattern is about five minutes given a slight 4-5 mile per hour wind and the material is rated for 15 minutes; therefore it is reasonable to expect the material to be reusable 2 or 3 times.
[0057] Another benefit is that lattice patterns are customizable with regard to lengths, widths, thicknesses, inserts, and color; providing the most flexibility. Weight can be reduced or increased by adding or subtracting length, width and thickness depending on the customer need.
[0058] The foregoing description of the preferred embodiment of the invention is sufficient in detail to enable one skilled in the art to make and use the invention. It is understood, however, that the detail of the preferred embodiment presented is not intended to limit the scope of the invention, in as much as equivalents thereof and other modifications which come within the scope of the invention as defined by the claims will become apparent to those skilled in the art upon reading this specification.
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A blanket for fighting grass and scrub fires along a fire line includes a sheet of fire resistant material forming a lattice with multiple openings. The openings vary in size from larger openings along the sheet's front edge to smaller openings at the sheet's back edge, and vary in size across the lattice to form parabolic-shaped burn zones that separate a fire burning into the blanket, dissipating its energy. The blanket is a rectangular sheet of woven fire resistant fiberglass strips coated in vermiculite and is flexible for rolling, with connectors securing the woven strips together at points of overlap. The sheet can be placed atop or near grass or scrub at risk of burning, arranged with the front edge toward the fire and the back edge away from the fire. Once the burning risk passes, the sheet or sheets may be removed and rolled up for storage or transport.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims priority from prior Indian Patent Application No. 1817/Del/2004, filed on Sep. 24, 2004, the entire disclosure of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to an improved LUT based multiplexer architecture. More particularly, the invention relates to a method and apparatus for implementing multiplexers in Field Programmable gate arrays (FPGA) and other programmable devices that have a Lookup Table (LUT) based logic architecture.
[0004] 2. Description of the Related Art
[0005] A multiplexer is a basic digital electronics component composed of n select lines and at most 2 n data lines. The multiplexer selects one of its inputs and provides it at its output according to the state of the select line/s. Multiplexers are typically used in digital Integrated Circuit (IC) designs by either direct use through schematic based design tools or indirectly through synthesis tools. The synthesis tools take designs expressed in Hardware Description Language (HDL) such as Verilog or VHDL as input and map them to the target technology. During the synthesis of a design, multiplexer components may be inferred amongst others, which are then mapped onto the target technology used for implementing these designs.
[0006] One such target technology used to implement IC design is the programmable integrated circuit. These programmable devices could be Field Programmable Gate Arrays (FPGAs).
[0007] A Lookup Table can be programmed to generate one or more than one output/s that correspond to a desired Boolean function of its inputs. The logic architecture of a LUT based programmable device is hierarchical in nature i.e. a few LUTs are grouped together along with additional components to form a logic cluster known as Configurable Logic Block (CLB) or Programmable Logic Block (PLB), etc. These logic clusters (CLBs) are interconnected through programmable routing resources. FIG. 1A and FIG. 1B illustrate an LUT based logic architecture configuration having logic elements, e.g. a logic gate or a multiplexer.
[0008] FIG. 2A shows a common implementation of multiplexers using LUTs. In this implementation the multiplexer is decomposed into a large number of smaller 2:1 multiplexers as shown in the Figure. These 2:1 multiplexers are implemented either in LUTs or special resources within the LUTs that are themselves 2:1 multiplexers.
[0009] In another implementation shown in FIG. 2B the multiplexer is realized using LUT based logic architecture. In this architecture the select lines are decoded by a logic element associated with each input. The signals corresponding to each input are then received and passed to the output through an OR gate as shown in the figure. The logic for decoding is implemented in LUTs while the OR gate can be a cascade gate chain.
[0010] In another prior art two 4-input LUTs are connected back to back to implement a 4:1 multiplexer as illustrated in FIG. 2C . Many such 4:1 multiplexers can then be connected to form a large multiplexer. U.S. Pat. No. 6,489,830 describes an invention for implementing a 4:1 multiplexer using two 4-input LUTs as shown in FIG. 2C . The drawback of this invention is that it increases the logic depth of the multiplexer logic thereby increasing the delay. Also this invention does not consider the use of additional resources (logic gates) available along with the LUT.
[0011] In another prior art a multiplexer is implemented using a horizontal chain of CLBs (available in a specific FPGA logic architecture) which makes the implementation conducive to better floor planning for certain types of design applications. One such implementation of multiplexer is described in U.S. Pat. No. 6,466,052. The architecture according to this patent is illustrated in FIG. 2D . In this patent 4 CLBs are used for implementing an 8:1 multiplexer on the Virtex-II FPGA using a distributed structure. The concept used for implementation of the multiplexer is also based on decoding the select lines for each input and then using an OR gate to generate a multiplexer. The OR gate horizontal chain which is a special resource available in the Xilinx Virtex-II FPGA is exploited to implement the OR gate. However this architecture requires a large number of LUTs for implementing a multiplexer.
[0012] In U.S. Pat. No. 6,505,337 shown in FIG. 2E a tree structure (basic concept illustrated in FIG. 2A ) is used for implementation of a multiplexer but its implementation is based upon the specific resources that are available along with the LUT in a certain family of devices (Xilinx's Virtex FPGA series). These resources are known as F5 & F6 muxes. The 4-input LUT under this embodiment is used as a 2:1 multiplexer. A major disadvantage of this architecture is that it requires specialized resources (F5 & F6), which are device specific and may not be available in all types of programmable devices.
[0013] Further in the case of logic architecture that do not have the F5/F6 type of resources, the 2:1 multiplexer will be implemented using LUTs only. The number of LUTs required in this case will be 2ˆ(N−1)+2ˆ(N−2)+ . . . +2ˆ0. For N=7 the number of LUTs required will be 127 as compared to 85 when a carry/cascade chain is assumed. Therefore this architecture is not suitable for devices in which the specific resources F5/F6 are not available.
[0014] Furthermore in the same patent another method based on decoding (basic concept illustrated in FIG. 2B ) of select lines for each input and then using an OR gate to generate a multiplexer is explained. Consider implementation of a multiplexer with 7 select lines using this prior art as shown in FIG. 1A using an LUT ONLY implementation. This method requires a total of more than 200 LUTs (16 LUTs for implementation of common product terms of 4 select lines (after optimization), 2ˆ7=128 LUTs for product terms of 3 select lines and each of the inputs, and 2ˆ7/2=64 LUTs for AND-OR). In case of implementing the multiplexer using LUT+CASCADE/CARRY the number of LUTs required will be in excess of 2ˆ8=256 (no optimization of common product terms of the 4 select lines is possible because of the use of cascade/carry chain). The large LUT requirement has been highlighted in the patent as it has been argued that this method is better only when the number of inputs is significantly less than 2ˆN.
[0015] Accordingly, there exists a need for overcoming the disadvantages of the prior art as discussed above.
SUMMARY OF THE INVENTION
[0016] It is an object of the invention to obviate the above and other drawbacks from the prior art.
[0017] It is another object of the invention to provide an architecture for implementing a multiplexer, which is preferably based on partial decoding and/or partial tree architecture.
[0018] It is yet another object of the invention to provide an architecture for implementing multiplexers, which utilizes the additional resources present in the logic architecture optimally and provides a multiplexer implementation with a smaller logical depth while retaining a small number of LUTs.
[0019] It is a further object of the invention to provide an architecture for implementing a multiplexer that can be implemented on any commonly available programmable device.
[0020] It is yet a further object of the invention to provide an architecture for implementing a multiplexer, which is provided a compressed logic mapping and therefore can map large logic on a small area.
[0021] It is still an object of the invention to provide a method for multiplexer implementation for LUT based logic architecture that requires less number of LUTs than existing prior art.
[0022] It is still a further object of the invention to provide a multiplexer implementation method for LUT logic that requires least depth therefore providing a faster multiplexing without requiring additional area.
[0023] It is a further objection of the invention to provide a method for implementing logic that utilizes the maximum capability of the available resources.
[0024] It is an additional object of the invention to provide a flexible multiplexer implementation using logic chains (carry-cascade) in a limited fashion thus imposing lesser constraint on the relative location of the constituent CLBs of the multiplexer implementation.
[0025] To achieve the above objectives and embodiment of the present invention provides an improved LUT based multiplexer, comprising:
a first set of muxlets, each receiving a subset of input data lines at its inputs; and one or more muxlet stages cascaded together to form a tree structure in which the roots are said first set of muxlets and the last stage of muxlet produces the final output.
[0028] The largest size muxlet defined is the smallest muxlet that can be implemented most efficiently on the selected logic architecture.
[0029] A muxlet comprises a plurality of muxlet tiles each of which multiplexes a subset of the muxlet inputs.
[0030] An embodiment of the present invention also provides an improved method for implementing LUT based multiplexers comprising:
defining the largest size of muxlet that can be efficiently implemented on the target logic architecture; connecting the input lines to a plurality of muxlets of a size less than or equal to said largest size; and forming additional muxlets and cascading them together to generate the final multiplexed output.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Other characteristics and advantages of the invention will become clear after reading the following description that is given for guidance and is in no way limiting, with reference to the attached drawings in which:
[0035] FIG. 1A shows LUT logic architecture with a cascade gate.
[0036] FIG. 1B shows LUT logic architecture with a carry multiplexer.
[0037] FIG. 2A shows a multiplexer implementation by generating a tree of 2:1 multiplexers.
[0038] FIG. 2B shows a multiplexer implementation using a complete decoding scheme.
[0039] FIG. 2C shows a multiplexer implementation using two 4-input LUTs
[0040] FIG. 2D shows a multiplexer implementation using four 4-input LUTs, carry chain, and horizontal OR chain on Virtex-II FPGA
[0041] FIG. 2E shows a multiplexer implementation according to U.S. Pat. No. 6,505,337.
[0042] FIG. 3A shows a 2ˆn:1 Multiplexer.
[0043] FIG. 3B shows a multiplexer implementation using a Muxlet.
[0044] FIG. 3C shows another multiplexer implementation using a Muxlet.
[0045] FIG. 4A shows an exemplary Muxlet.
[0046] FIG. 4B shows an exemplary Muxlet Tile.
[0047] FIG. 4C shows another exemplary Muxlet composed of Tiles.
[0048] FIG. 5 shows a 32:1 Multiplexer composed of 2 Muxlets.
[0049] FIG. 6 shows an implementation of a multiplexer using Muxlets.
[0050] FIG. 7A shows a Muxlet Tile of size 1 for 4-input LUT with cascade nand gate.
[0051] FIG. 7B shows a Muxlet tile of size 2 for 4-input LUT with cascade nand gate.
[0052] FIG. 8 shows a 32:1 Multiplexer implementation on a 4-input LUT with cascade nand gate.
[0053] FIG. 9A shows a Muxlet tile of size 1 for 5-input LUT with cascade and gate.
[0054] FIG. 9B shows a Muxlet tile of size 2 for 5-input LUT with cascade and gate.
[0055] FIG. 9C shows a Muxlet tile of size 3 for 5-input LUT with cascade and gate.
[0056] FIG. 10 shows a 32:1 multiplexer implementation on a 5-input LUT with cascade and gate.
[0057] FIG. 11 shows a 64:1 Multiplexer implementation on a 4-input LUT with cascade nand gate.
DETAILED DESCRIPTION
[0058] The FIGS. 1A, 1B , 2 A, 2 B, 2 C, 2 D, 2 E, have already been described in detail above under the heading “BACKGROUND OF THE INVENTION”.
[0059] According to an embodiment of the present invention a multiplexer is implemented in a number of stages where each stage is of size R and is termed as a muxlet. The first stage (first muxlet) of the multiplexer takes as input some select lines of the multiplexer and all data inputs. A muxlet performs partial multiplexing by producing output data lines that are multiplexed from the input data lines that are greater in number by a factor of 2ˆR. The multiplexing is based on the value (signal value) of R input select lines. The resultant output is used as data input for the next stage. Many such stages (muxlets) form a tree structure to implement the multiplexer. Thus each muxlet decodes the input data lines based on the value of some select lines and many such muxlets form a tree structure to implement the multiplexer.
[0060] FIGS. 3A to 3 C illustrate an exemplary muxlet and the construction of a multiplexer. FIG. 3A shows a 2ˆN:1 multiplexer comprising muxlets. For a given logic architecture a certain number of muxlets can be defined. Each of these muxlets has a characteristic number of select lines that are input to it. A multiplexer can be implemented using these muxlets. For implementing an N select line multiplexer a combination of muxlets with select lines R 1 , R 2 . . . Rm can be used. The largest size muxlet defined is the smallest muxlet that can be implemented most efficiently on the logic architecture. The other muxlets are created so that the N select line multiplexer can be composed by the combination of these and the most optimum muxlet. The flowchart of FIG. 6 explains (discussed in detailed later) how a multiplexer is implemented for a given logic architecture using muxlets defined for that logic architecture. The muxlet definition for a given logic architecture is a key aspect of the invention.
[0061] FIG. 3B shows a multiplexer implementation according to an embodiment of the invention using two muxlets. The first muxlet uses R 1 select lines out of N select lines and multiplexes 2ˆN input to produces 2ˆ(N−R 1 ) outputs. In the subsequent stage the second muxlet uses the remaining select line and the outputs of the previous muxlet to realize a 2ˆN:1 multiplexer. Similarly FIG. 3C shows a multi stage multiplexer according to an embodiment of the present invention in which recursive formation of the muxlets creates a final multiplexer.
[0062] FIGS. 4A to 4 C show a detailed structure of a muxlet. FIG. 4A shows a muxlet that receives R select lines, 2ˆN input lines and produces a 2ˆ(N−R) output. A muxlet is composed of a muxlet tile that takes (2ˆR) input data lines and gives one output data line, many such tiles are placed together to make a (2ˆN) input data line muxlet. The inputs of the muxlet tiles are identified such that the state of each select line decodes which input of the muxlet is to be propagated to the output. An exemplary muxlet tile is shown in FIG. 4B . The muxlet comprising muxlet tiles is shown in FIG. 4C .
[0063] The muxlet and muxlet tile implementation for a few LUT based logic architectures through examples has been explained in the subsequent discussion. However a person of ordinary skill in the art will appreciate, in view of the present discussion, that the invention is not limited to these examples only. The method for generating muxlet and muxlet tiles can be applied to other logic architectures that may not be explicitly mentioned here without deviating from the scope of the present invention.
[0064] A muxlet can be generated using one or more muxlet tiles. According to one possible method a muxlet tile can be created for R select lines and 2ˆR data lines providing a single output data line. Each tile is configured to decode the input data line for a specific logic value of the select lines. The data lines that have the same value of select lines for the next stage of muxlet (i.e. the remaining select lines) are grouped together within a tile. This arrangement is illustrated in FIG. 5 . Note that this arrangement leaves some flexibility for arranging the data input lines within the muxlet tile.
[0065] According to another possible method for creating muxlet tiles of an embodiment for LUT based logic architectures having carry/cascade chains such as those described in FIGS. 1A and 1B .
[0066] FIG. 7A and FIG. 9A show a further exemplary method for implementing muxlet tile for two input and one select line using an 3 and 5 input LUT respectively.
[0067] FIG. 7B and FIG. 9B show another exemplary method for implementing a muxlet tile for 4 data lines and 2 select lines using two, 4 and 5 input LUTs and a cascade logic gate.
[0068] FIG. 9C shows another implementation for a muxlet tile for 8 data and 3 select lines using a 5 input LUT and cascade gates.
[0069] The muxlet tile of size 1 is an LUT that takes as input 1 select line and two data lines as shown in FIG. 7A . The functionality of the LUT 701 is as defined by f 1 . The muxlet tile of size two has two LUTs and a cascade gate as shown in FIG. 7B . The functionality of the two LUTs 702 & 703 is as defined by f 2 and f 3 respectively and that of the cascade gate 704 (nand gate) is as defined by fnand. The function f 1 , f 2 , f 3 , and fnand can be written as follows.
f 1=( S 1 & I 1)+(˜ S 1 & I 2)
f 2=( S 2+ S 1+˜ I 1) & ( S 2+˜ S 1+˜ I 2)
f 3=(˜ S 2+ S 1+˜ I 3) & (˜ S 2+˜ S 1+˜ I 4)
fn and=˜( f 2& f 3)=˜ f 2+˜ f 3
[0070] Similarly for a 5-input LUT architecture shown in FIGS. 9A , FIG. 9B , and FIG. 9C the following is true.
[0071] The muxlets of size 3 , 2 & 1 are defined for such logic architecture. The muxlet tile of size 1 will use one 5 input LUT 901 having functionality f 1 (see FIG. 9A ). A muxlet tile of size 2 will be implemented using two LUTs, 902 & 903 and a cascade gate 804 having functionality f 2 , f 3 and fand 1 respectively (see FIG. 9B ). A muxlet of size 3 will have 4 LUTs ( 905 , 906 , 907 , 908 ) and 3 cascade gates ( 909 , 910 , 911 ) having functionality f 4 , f 5 , f 6 , f 7 and fand 2 , fand 3 , fand 4 respectively (see FIG. 9C ). These functions are as follows:
f 1=( S 1 & I 1)+(˜ S 1 & I 2)
f 2=(˜ S 2 & ˜ S 1 & I 1)+(˜ S 2 & S 1 & I 2)+ S 2
f 3=( S 2 & ˜ S 1 & I 3)+( S 2 & S 1 & I 4)+˜ S 2
fand1=f2 & f3
f 4=(˜ S 3 & S 2 & ˜ S 1 & I 1)+(˜ S 3 & ˜ S 2 & S 1 & I 2)+(˜ S 3 & S 2)+( S 3)
f 5=(˜ S 3 & S 2 & ˜ S 1 & I 3)+(˜ S 3 & S 2 & S 1 & I 4)+(˜ S 3 & S 2)+( S 3)
f 6=( S 3 & ˜ S 2 & ˜ S 1 & I 5)+( S 3 & ˜ S 2 & S 1 & I 6)+( S 3 & S 2)+(˜ S 3)
f 7=( S 3 & S 2 & ˜ S 1 & I 7)+( S 3 & S 2 & S 1 & I 8)+( S 3 & ˜ S 2)+(˜ S 3)
f and2 =f 4 +f and3
f and3= f and4+ f 5
f and4= f 6+ f 7
[0072] For a logic architecture having a carry multiplexer chain the multiplexer can be configured to work as a AND gate by connecting the zero input logic of the multiplexer to logic zero.
[0073] A number of muxlet tiles of various sizes (R 1 to Rm) are defined each of size 1 to m. A multiplexer of N select lines and 2ˆN data input lines can now be generated for the given architecture using the steps illustrated in FIG. 6 .
[0074] In FIG. 6 , step 601 involves arranging the input select lines in an array of Select_Lines, the input data lines along with their index in Data_Input_Lines and finally the Muxlet Bank that has information regarding the sizes of muxlets available for the targeted logic architecture. In this step we initialize the number of select lines S.
[0075] In step 602 we find the best muxlet of size R available for implementation of a S select line multiplexer such that R<=S. As an example consider that for a given logic architecture there are muxlets of size 1 , 2 , 3 & 4 then if S=7 we will choose R=4 but if S=3 then we choose R=3.
[0076] In step 603 we first identify the number of muxlet tiles that will be required for the Data_Input_Lines. If number of Data_Input_Lines are 2ˆN (or less than 2ˆN but greater than 2ˆ(N−1)) then number of muxlet tiles required will be 2ˆ(N−R). For each tile we identify the inputs to that tile. Each tile is assigned a number from 1 to 2ˆ(N−R). The index of each data input line is considered and two numbers (X, Y) are generated from the number Z=(index−1). Masking off the first R bits (MSB) of the number Z generates a number X′. This number X′, incremented by 1 corresponds to the muxlet tile number X to which this data input line will be connected. The remaining part of the Z (first R bits) is right shifted by (N−R); the resultant number incremented by 1 is Y. Y corresponds to the index of the muxlet tile input to which this data input line will connect. As an example consider N=5, R=2 and the data input line index be 12. Then the muxlet tile number will be 4 (12−1=11=01011 in binary; masking first 2 bits we get 3; increment by 1 we get 4). The index number to which this line will be connected will be 2 (1+1). For further clarification one can refer to the FIG. 8 . In this figure the input data line I 12 is the 2 nd input to muxlet tile 4 having output line as I′ 4 .
[0077] In step 604 we assign the output line index as the number of the corresponding muxlet tile. This index will serve as input for the generation of the next stage muxlet.
[0078] In step 605 we generate the actual muxlet by making the connections as identified and generating the new output lines.
[0079] In step 606 the inputs for the next stage of muxlet are prepared. The Data_Input_Lines are assigned the data output lines of the muxlet just generated along with index values. Refer to FIG. 8 , where the lines marked I′ 1 to I′ 8 are the input to the next stage. The value of S is decreased by a value R.
[0080] In the step 607 it is checked whether or not an additional muxlet stage is required. If no additional stage is required then the output of the previous stage is the final output of the multiplexer otherwise, step 602 onwards is repeated.
[0081] The FIG. 8 illustrates the implementation of a 32 to 1 multiplexer (5 select lines). The arrangement of input data lines calls for special attention.
[0082] FIG. 10 and FIG. 11 illustrate multiplexer possible embodiments according to the present invention for a 32:1 multiplexer implementation on a 5-input Lut with cascaded AND gate and a 64:1 Multiplexer implementation on a 4-input Lut with cascaded nand gate respectively.
[0000] Advantages of the Invention
[0083] The present invention provides many advantages over the existing art. Some of the prominent advantages are listed below however, a person of ordinary skill in the art in view of the present discussion will appreciate that the advantages of the invention are not limited to these aspects alone.
1. The partial-decode and tree method of the invention is applicable to a wide variety of LUT based logic architectures that generally have common resources such as carry or cascade gate chains. 2. The number of LUTs required to implement multiplexer by the partial-decode and tree method is far less than in the methods of the prior art. 3. The LUT logic depth of the multiplexer generated by the partial-decode and tree method is half as compared to prior art that uses same number of LUTs except for the fact that additional resource (carry or cascade chains) are not used in the prior art. Since these resources are generally attached to an LUT in most logic architectures therefore there is no extra area required. 4. The partial-decode and tree method makes use of all inputs of a LUT i.e. it uses the k-input LUT as a function of k inputs. Thus the method uses the full capacity of an LUT. 5. The partial-decode and tree method uses the chains (carry-cascade) in a limited fashion thus imposing less constraint on the relative location of the constituent CLBs of the multiplexer implementation.
[0089] In particular an embodiment of the present invention provides the following advantages.
[0090] The proposed method when applied to the Virtex-II logic architecture would take 5 LUTs and use the carry chain (configured as AND gate) within the CLB while still providing the flexibility of implementing a multiplexer in a distributed fashion. The partial-decode method provides flexibility of distribution in both dimensions. The horizontal chain structure will require 2 data inputs in one CLB (vertical routing channel) and also requires 4 CLBs to be horizontally adjacent (as they need to be chained). In comparison to this, partial-decode method implementation needs 4 data inputs to be clustered into one CLB (using only one slice of the CLB) and the other CLBs may be placed anywhere, as they don't use any chains between them, which would have constrained their relative location. Thus the partial-decode and tree method would require 5 LUTs to implement a 8:1 multiplexer that has horizontal as well as vertical distribution flexibility; without using special horizontal chains that may not be available in our FPGA logic architectures.
[0091] Further, an embodiment of the present invention requires as few as 85 LUTs (85) for the discussed example whereas a prior art implementation would require more than 200 LUTs.
[0092] While there has been illustrated and described what is presently considered to be embodiments of the present invention, it will be understood by those of ordinary skill in the art that various other modifications may be made, and equivalents may be substituted, without departing from the true scope of the present invention.
[0093] Additionally, many modifications may be made to adapt a particular situation to the teachings of the present invention without departing from the central inventive concept described herein. Furthermore, an embodiment of the present invention may not include all of the features described above. Therefore, it is intended that the present invention not be limited to the particular embodiments disclosed, but that the invention include all embodiments falling within the scope of the appended claims.
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An improved LUT based multiplexer, including a first set of muxlets, each receiving a subset of input data lines at its inputs and one or more muxlet stages cascaded together to form a tree structure in which the roots are the first set of muxlets and the last stage of muxlet produces the final output.
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FIELD
The present invention relates to the technical field of fertilizers, more specifically to a curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops and its preparation method.
BACKGROUND
Heavy metals such as cadmium, lead and mercury are non-essential elements for plants and are even hazardous to the growth of plants. They are deemed as heavy-metal pollutants for plant growth and food safety. The excessive accumulation of these hazardous heavy metals in food will enable them to enter into the food chain, and even threaten human health. According to the results of a quality and safety survey of rice in various regions of China in 2002 and 2003 made by the Quality Inspection and Supervision Center of Rice and Rice Products, Ministry of Agriculture, one of the quality and safety issues of rice is the over-the-limit content of heavy metals such as cadmium and lead. The over-the-limit rate is more than 10%. Three industrial wastes, non-ferrous metal mining and sewage irrigation are causes that may lead to an excessive amount of toxic heavy metals in the soil and excessive absorption by the plant, being the main source of the accumulation of heavy metals in plants or crops. Therefore, strict limiting criteria for heavy metals in soil and foods (or grains) have been established in various countries. For example, in China, the limit of cadmium in cereals is 0.2 mg/kg, that of lead 0.2 mg/kg and that of mercury 0.02 mg/kg.
Cadmium, lead and mercury that are accumulated in plant foods, such as rice, barley and wheat, are mainly absorbed by the roots from the soil and finally accumulated in the harvest parts after flowing to the top upon transpiration. Research shows that the contents of cadmium, lead and mercury in the soil, especially the effective content (namely absorption by the roots) are the key factors when the roots absorb cadmium, lead and mercury from the soil. Hence, to reduce and control the effective cadmium, lead and mercury content in the soil by various agronomic means is always a key study subject at home and abroad. For instance, lime is applied on acidic and slightly acidic soil to raise the pH value of the soil, which obviously decreases the effectiveness of cadmium, lead and mercury in the soil and finally reduces the absorption of such heavy metals by the roots. However, the application of lime has also a lot of side effects. For example, it may cause the rise of the pH value in the soil, leading to the reduction of the required contents of multiple microelements like iron, manganese and zinc while decreasing such heavy metals, easily resulting in nutrient deficiency in the crops and their failure to thrive. On the other hand, the considerable difference of pH values and pH buffer capacities for different regions and soils gives rise to a great difficulty in accurately controlling the lime application amount. As to paddy rice, the inundation can facilitate the increase of soil reducibility, and the increase of elements such as ferrous iron in the soil and the promotion of the deposit of cadmium, lead and mercury in the form of sulfide, on one hand, decreases the soil effectiveness of these heavy metals. On the other hand, a decrease in the roots' absorption capacity for these elements, greatly reduces the roots' absorption and accumulation of toxic heavy metals from the soil. But for paddy rice itself, long-term inundation is not conducive to its growth and is apt to cause an increase of arsenic absorption in rice.
It is a key orientation of studies around the world to add a curing agent or adsorbent in the soil to combine and fix or absorb heavy metals in the soil like cadmium, lead and mercury. The curing agent or adsorbent reported mainly includes zeolite, kieselguhr, sepiolite, bentonite and limestone, and even alkaline cinder, but there is still no curing agent or adsorbent for heavy metals in the soil that is produced and applied broadly. The mainly reasons lie in their being non-environmentally-friendly, high cost and no popularization efforts as to their use value.
SUMMARY
The objective of the present invention is to provide a curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops and a technical solution to its preparation method to address the problems in the prior art.
The curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops is characterized in that it is made from the following parts of raw materials by weight:
60˜140 parts of a substance containing carbon-carbon double bond; 1˜400 parts of sulfo-compound by sulfur; 50˜500 parts of organic matter by 10% water content; 0˜400 parts of water; 0˜100 parts of initiator; 0˜200 parts of a reducer; and 0˜200 parts of a strong base.
The curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops is characterized in that it is made from the following parts of raw materials by weight:
80˜120 parts of the substance containing carbon-carbon double bond; 50˜300 parts of sulfo-compound by sulfur; 100˜400 parts of organic matter by 10% water content; 50˜300 parts of water; 10˜80 parts of initiator; 50˜150 parts of a reducer, and 50˜150 parts of a strong base.
The curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops is characterized in that it is made from the following parts of raw materials by weight:
90˜110 parts of the substance containing carbon-carbon double bond; 80˜150 parts of sulfo-compound by sulfur; 200˜300 parts of organic matter by 10% water content; 100˜200 parts of water; 40˜60 parts of initiator; 80˜110 parts of a reducer; and 80˜110 parts of a strong base.
The curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops is characterized in that the substance containing carbon-carbon double bond is selected from more than one of polyisoprene, polyisoprene analog, polyisoprene derived polymer and unsaturated fatty acids, the polyisoprene analog and the polyisoprene derived polymer are natural rubber, natural latex, polyacetylene, polybutadiene or polypentadiene and the unsaturated fatty acid is vegetable oil or gutter oil.
The curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops is characterized in that the sulfo-compound is selected from more than one of sulphur, hydrosulfide, sodium sulfide or ferrous sulfide.
The curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops is characterized in that the organic matter is selected from more than one of colza cake, soybean cake, bean pulp, straw stalk, barley/wheat stalk, sugarcane chip/bagasse, rape stalk, corn sorghum stalk, wood chip, weed stalk, Astragalus sinicus stalk, clover stalk, waste paper or water hyacinth.
The curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops is characterized in that the initiator is hydrogen peroxide, peroxyformic acid or peroxy benzoic acid.
The curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops is characterized in that the reducer is selected from more than one of sodium sulfite, zinc powder, iron powder and magnesium powder.
The curing agent for heavy metals in the soil to control ale accumulation of heavy metals in crops is characterized in that the strong base is quicklime, sodium hydroxide or potassium hydroxide.
The preparation method of the curing agent for heavy metals in the soil or to control the accumulation of heavy metals in crops is characterized in that it includes the following processing steps:
1) melt the stated parts by weight of the substance containing carbon-carbon double bond into a liquid state at a temperature of 100˜400° C.;
2) add the stated parts by weight of the sulfo-compound and the stated parts by weight of the initiator into the high-temperature liquid solution obtained in Step 1), boil it for 0.5˜3 h and keep mixing at a constant speed;
3) cool it to room temperature, add the stated parts by weight of the organic matter into the mixed polymer obtained in Step 2), mix and crush it to a uniform size to get the solid mix polymer;
4) add the stated parts by weight of water, reducer and strong base into the solid mix polymer obtained in Step 3), crush it to a uniform size again, place the crushed solid mix polymer in a steam bath and steam for 0.5˜2 h, and then cool it to get the solid mix polymer;
5) put the solid mix polymer obtained in Step 4) to a place of 30˜100° C. for airing and drying or exposure in the sun until the water content is no more than 20%;
6) crush the solid mix polymer obtained in Step 5) to a granularity of 60˜150 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
The preparation method of the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops is characterized in that it includes the following processing steps:
1) melt the stated parts by weight of the substance containing carbon-carbon double bond into a liquid state at a temperature of 100˜400° C.;
2) add the stated parts by weight of the sulfo-compound and the stated parts by weight of the initiator into the high-temperature liquid solution obtained in Step 1), boil it for 0.5˜3 h and keep mixing at a constant speed;
3 cool it to room temperature, mix and crush it to a uniform size to get the powdered solid mix polymer, then add the stated parts by weight of water, reducer and strong base into the powdered solid mix polymer, place the resultant mixture in a steam bath and steam for 0.5˜2 h or boil for 0.1˜2 h, and then cool it to get the semi-jelly mixture;
4) add the stated parts by weight of the organic matter to the semi-jelly mixture obtained in Step 3), thoroughly mix to get the jelly mixture;
5) put the jelly mixture obtained in Step 4) to a place of 30˜100° C. for airing and drying or exposure to the sun until the water content is no more than 20%;
6) crush the solid mix polymer obtained in Step 5) to a granularity of 60˜150 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
The curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops mentioned above features a reasonable design and simple preparation. Through a sulfidation and persulfidation reaction of the substance containing carbon-carbon double bond at a high temperature by means of the sulfo-compound in the presence of a certain amount of the initiator, a polymer with a high sulfur content is formed. In the alkaline condition, by relying on the reducibility of the reducer as well as the organic matter itself, the carbon-sulfur bond and sulfur-sulfur bond in macromolecular substances are broken under a high-temperature and high-humidity environment to produce a polymer type curing agent containing a high amount of mercaptan (organic sulfur or sulphydryl). The curing agent is crushed to powder and then applied onto the land. The sulphydryl in the curing agent can form a very stable organic sulfur—a heavy metal composite different from water after combination with cadmium, lead and mercury in the soil, thus reducing the contents of cadmium, lead and mercury in the soil solution and further greatly decreasing the roots absorption of these heavy metals.
There is a high amount of free sulfur in the curing agent which can be used as sulfur fertilizer in the soil to guarantee the demand for sulfur for the crops. Moreover, the curing agent will not cause any harm to the soil. The curing agent according to the present invention boasts of a simple application, low consumption amount, low selling price and low cost. It is generally applicable to dry land with a heavy, medium or slight cadmium contamination and to all kinds of crops.
The curing agent according to the present invention is preferably used as a basic fertilizer applied to the soil once before planting and during land preparations or as an additional fertilizer applied during different growth periods of crops. By taking the sulfur content of the curing agent (vulcanized product of polymer) as a basic measuring component, it is preferable to apply 1.0-1.5 kg of the curing agent (by sulfur) on each mu of farmland. Due to the slow degradation speed, from the next year, only half or three quarters of the amount of the curing agent shall be applied each year.
DETAILED DESCRIPTION
The present invention is further described hereinafter in combination with embodiments.
Embodiment 1
1) melt 100 parts of the polyisoprene into a liquid state at a temperature of 100° C., 150° C. or 300° C.;
2) add 300 parts of sulphur into the high-temperature liquid solution obtained in Step 1), boil it for 0.5, 1, 1.5 or 3 h, and also add 50 parts of the hydrogen peroxide and keep mixing it at a constant speed;
3) cool it to room temperature, add 300 parts of colza cake into the mixed polymer obtained in Step 2), mix and crush it to a uniform size to get the solid mix polymer;
4) add 150 parts of water, 100 parts of sodium sulfite and 150 parts of quicklime into the solid mix polymer obtained in Step 3), crush it to a uniform size again, place the crushed solid mix polymer in a steam bath and steam for 1, 2 or 3 h, and then cool it to get the solid mix polymer;
5) put the solid mix polymer obtained in Step 4) to a place of 30° C. 40° C., 60° C. 80° C., or 100√ C. for airing, and drying or exposure to the sun until the water content is no more than 20%;
6) crush the solid mix polymer obtained in Step 5) to a granularity of 60, 80, 100, 120 or 150 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
The same technical effect as Embodiment 1 can be also achieved if the polyisoprene above is replaced by more than one of polyisoprene, polyisoprene analog, polyisoprene derived polymer and unsaturated fatty acid. The sulphur is replaced by sodium hydrosulphide or sodium sulfide. The hydrogen peroxide is replaced by peroxyformic acid or peroxy benzoic acid, the sodium sulfite is replaced by zinc powder, iron powder or magnesium powder. The quicklime is replaced by sodium hydroxide or potassium hydroxide. The polyisoprene analog and the polyisoprene derived polymer in this embodiment can be natural rubber, natural latex, polyacetylene, polybutadiene or polypentadiene and the unsaturated fatty acid can be vegetable oil or gutter oil.
Embodiment 2
1) melt 60 parts of natural rubber into a liquid state at a temperature of 150° C.;
2) add 50 parts of sodium sulfide into the high-temperature liquid solution obtained in Step 1), boil it for 2.5 h, and also add 20 parts of peroxyformic acid and keep mixing it at a constant speed;
3) cool it to room temperature, add 50 parts of straw stalks into the polymer mix obtained in Step 2), mix and crush it to a uniform size to get the solid mix polymer;
4) add 50 parts of water, 50 parts of zinc powder and 20 parts of sodium hydroxide into the solid mixed polymer obtained in Step 3), crush it to a uniform size again, place the crushed solid mix polymer in a steam bath and steam for 1.5 h, and then cool it to get the solid mix polymer;
5) put the solid mix polymer obtained in Step 4) to a place of 85° C. for airing and drying or exposure to the sun until the water content is no more than 20%;
6) crush the solid mix polymer obtained in Step 5) to a granularity of 120 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
The same technical effect as Embodiment 1 can be also achieved if the straw stalk above is replaced by one of or a mixture of more than one of colza cake, soybean cake, bean pulp, straw stalks, barley/wheat stalks, sugarcane chip/bagasse, rape stalks, corn/sorghum stalks, wood chips, weed stalks, Astragalus sinicus stalks, clover stalks, waste paper or water hyacinth.
Embodiment 3
1) melt 140 parts of polybutadiene into a liquid state at a temperature of 150° C.;
2) add 400 parts of sodium hydrosulphide into the high-temperature liquid solution obtained in Step 1), boil it for 2.5 h, and also add 100 parts of peroxy benzoic acid and keep mixing it at a constant speed;
3) cool it to room temperature, add 500 parts of waste paper into the polymer mix obtained in Step 2), mix and crush it to a uniform size to get the solid mix polymer;
4) add 400 parts of water, 200 parts of iron powder and 200 parts of potassium hydroxide into the solid polymer mix obtained in Step 3), crush it to a uniform size again, place the crushed solid polymer mix in a steam bath and steam for 2 h, and then cool it to get the solid mix polymer;
5) put the solid mix polymer obtained in Step 4) to a place of 20° C. for airing and drying or exposure to the sun until the water content is no more than 20%;
6) crush the solid mix polymer obtained in Step 5) to a granularity of 100 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
Embodiment 4
1) melt 80 parts of natural latex into a liquid state at a temperature of 150° C.;
2) add 200 parts of sodium hydrosulphide into the high-temperature liquid solution obtained in Step 1), boil it for 2.5 h, and also add 80 parts of peroxy benzoic acid and keep mixing it at a constant speed;
3) cool it to room temperature, add 200 parts of Astragalus sinicus stalks into the mix polymer obtained in Step 2), mix and crush it to a uniform size to get the solid mix polymer;
4) add 300 parts of water, 150 parts of magnesium powder and 80 parts of potassium hydroxide into the solid mix polymer obtained in Step 3), crush it to a uniform size again, place the crushed solid mix polymer in a steam bath and steam for 0.5 h, and then cool it to get the solid mix polymer;
5) put the solid mix polymer obtained in Step 4) to a place of 20° C. for airing and drying or exposure to the sun until the water content is no more than 20%;
6) crush the mix polymer obtained in Step 5) to a granularity of 100 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
Embodiment 5
1) melt 110 parts of polyacetylene into a liquid state at a temperature of 100° C.;
2) add 150 parts of sodium hydrosulphide into the high-temperature liquid solution obtained in Step 1), boil it for 3 h, and also add 40 parts of peroxy benzoic acid and keep mixing it at a constant speed;
3) cool it to room temperature, add 250 parts of clover stalks into the mix polymer obtained in Step 2), mix and crush it to a uniform size to get the solid mix polymer;
4) add 250 parts of water, 120 parts of magnesium powder and zinc powder, respectively, and 120 parts of potassium hydroxide into the solid mix polymer obtained in Step 3), crush it to a uniform size again, place the crushed solid mix polymer in a steam bath and steam for 2 h, and then cool it to get the solid mix polymer;
5) put the solid mix polymer obtained in Step 4) to a place of 20° C. for airing and drying or exposure to the sun until the water content is no more than 20%;
6) crush the solid mix polymer obtained in Step 5) to a granularity of 100 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
Embodiment 6
1) melt 100 parts of polyisoprene into a liquid state at a temperature of 160° C.;
2) add 200 parts of sulphur powder into the high-temperature liquid solution obtained in Step 1), boil it for 1 h and keep mixing it at a constant speed;
3) cool it to room temperature, add 250 parts of colza cake into the mix polymer obtained in Step 2), mix and crush it to a uniform size to get the solid mix polymer;
4) add 100 parts of magnesium powder and 100 parts of potassium hydroxide into the solid mix polymer obtained in Step 3), crush it to a uniform size again, place the crushed solid mix polymer in a steam bath and steam for 2 h, and then cool it to get the solid mix polymer;
5) put the solid mix polymer obtained in Step 4) to a place of 20° C. for airing and drying or exposure to the sun until the water content is no more than 20%;
6) crush the solid mix, polymer obtained in Step 5) to a granularity of 100 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
Embodiment 7
1) melt 120 parts of vegetable oil or gutter oil into a liquid state at a temperature of 250° C.
2) add 120 parts of sodium sulfide and 25 parts of hydrogen peroxide into the high-temperature liquid solution obtained in Step 1), boil it for 1.5 h and keep mixing it at a constant speed;
3) cool it to room temperature, mix and crush it to a uniform size to get the powdered solid mix polymer, then add 120 parts of water, 100 parts of zinc powder and 150 parts of quicklime into the powdered solid mix polymer, place the resulting mixture in a steam bath and steam for 1.5 h or boil for 0.8 h, and then cool it to get the semi-jelly mixture;
4) add 380 parts soybean cake into the semi-jelly mixture obtained in Step 3), thoroughly mix to get the jelly mixture;
5) put the jelly mixture obtained in Step 4) to a place of 80° C. for airing and drying or exposure to the sun until the water content is no more than 20%;
6) crush the solid mix polymer obtained in Step 5) to a granularity of 120 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
Embodiment 8
1) melt 85 parts of vegetable oil (peanut oil, bean oil, linseed oil, castor oil or rapeseed oil, etc.) into a liquid state at a temperature of 350° C.;
2) add 60 parts of ferrous sulfide, 60 parts of sulphur and 70 parts of peroxy benzoic acid into the high-temperature liquid solution obtained in Step 1), boil it for 2.5 h and keep mixing it at a constant speed;
3) cool it to room temperature, mix and crush it to a uniform size to get the powdered solid mix polymer, then add 220 parts of water, 50 parts of zinc powder, 60 parts of magnesium powder and 150 parts of quicklime into the powdered solid mix polymer, place the resulting mixture in a steam bath and steam for 1.5 h or boil for 0.8 h, and then cool it to get the semi-jelly mixture;
4) add 60 parts of soybean cake, 70 parts of bean pulp and 80 parts of waste paper into the semi-jelly mixture obtained in Step 3), thoroughly mix to get the jelly mixture;
5) put the jelly mixture obtained in Step 4) to a place of 80° C. for airing and drying or exposure to the sun until the water content is no more than 20%;
6) crush the solid mixed polymer obtained in Step 5) to a granularity of 120 mesh to get the curing agent for heavy metals in the soil to control the accumulation of heavy metals in crops.
Embodiment 9
Experiment on the absorption of solution cadmium, lead and mercury for the curing agent: take the curing agent prepared according to Embodiment 1 as the test agent. Prepare 6 L of cadmium, lead and mercury solution with concentrations of 5, 30 and 0.5 mg/kg, respectively. Place the 6 L of solution in 6 clean black plastic barrels, each barrel containing 1 L. Set up CK and 0.5 g/barrel for two treatments for the curing agent and repeat three times. Add the curing agent, mix thoroughly and keep this state for 8 h stirring occasionally. Take 50 mL of the solution, keep centrifugation for 10 min with a centrifuge at a speed of 4000 and take the supernatant and then measure the cadmium, lead and mercury with an ICP-AES and an atomic fluorescence spectrophotometer, respectively. The result shows that the concentrations of solution cadmium, lead and mercury treated by the curing agent are 0.21±0.017, 1.38±0.099 and 0.03±0.001 mg/kg, respectively (three duplicate values); while those from CK are 4.87, 30.8 and 0.51 mg/kg, respectively. After treatment with the curing agent, the concentrations of cadmium, lead and mercury in solution are reduced greatly, exhibiting that the curing agent has very strong curing or adsorption capacity for cadmium, lead and mercury in solution.
Make the experiment under the same condition as in Embodiment 9 to the curing agent prepared according to Embodiment 2-8. The concentrations of cadmium, lead and mercury in the resultant solution are below 0.21, 1.38 and 0.03 mg/kg.
Embodiment 10
Experiment of absorption of soil cadmium for the curing agent: take the paddy field soil contaminated by cadmium which was previously prepared and was devoted to rice cultivation for many years as the material, where the total cadmium content is 5.76 mg/kg. Air to dry and crush the soil and sieve it at the opening size of 60 mesh. Take 6 clean beakers whose volume is 1 L, take 1 kg dry soil accurately weighed and put it into the beakers, respectively. Add 1 L of distilled water into the beakers, mix thoroughly and keep them for 3 days.
Take the curing agent prepared according to Embodiment 5 as the study material, set up CK and 0.5 g/beaker for the curing agent, and allow three repetitions. After adding to the beakers, mix thoroughly and keep for another 3 days. Take 20 g of wet soil, place it into a centrifuge tube, keep centrifugation for 15 min with a high-speed centrifuge at a speed of 8000, and take the supernatant for element measurement (obtain sufficient supernatant by multiple repeated samplings and centrifugation). The measurement result shows that upon treatment with the curing agent, the concentration of cadmium in soil solution is 0.17±0.06 mg/kg, while without applying the curing agent is 1.46±0.19 mg/kg. After treatment by the curing agent, the concentration of cadmium in the soil solution is reduced greatly, exhibiting that the curing agent has a very strong curing or adsorption capacity for cadmium in the soil.
Make the experiment under the same condition as in Embodiment 10 to the curing agent prepared according to Embodiments 1, 2, 3, 4, 6, 7 and 8. The concentration of cadmium in the resulting soil solution is below 0.17 mg/kg.
Embodiment 11
Experimental Material: Miyang 46
Experimental soil: use the soil from the test fields of the China National Rice Research Institute (Fuyang of Zhejiang), dry the soil in the sun and then crush to 60 mesh, add cadmium sulfate to make the cadmium content in the soil become 25 mg/kg. Weigh 4.5 kg of cadmium-contaminated soil into a black plastic barrel of 5 L, add water and mix thoroughly. Keep the soil in a wet state for 2 weeks for further use.
Experiment treatment: set up CK (the curing agent not added), conduct surface application (application on surface and mixing up on surface) and deep application (thoroughly mixing up). Treatment of the curing agent: add 1.25 g of the curing agent prepared according to Embodiment 7 in the barrel, and let it rest for a night. Transplant the rice seedlings with the leaf age in the period of three leaves and one core, each pot containing 4 holes and each hole containing 3 seedlings. During the growth of the paddy rice, keep a 1 cm thick water layer.
Determination items: 30 days after the planting of the seedlings, take the soil on top, rinse it from 2-3 times in 0.1% diluted flood water, roast for 2 h at a temperature of 120° C. and then dry at a temperature of 60° C. until a constant mass is obtained. Crush the dry sample to powder, weigh 0.5000 g of the powder, nitrate-boil it with a mixing solution of concentrated nitric acid and perchloric acid (1:3), and then add redistilled water until a total volume of 25 mL is reached. Finally, measure the contents of elements such as Mn, Pb, Cd, Fe, Cu and Zn with a full-spectrum direct-reading inductively coupled plasma atomic emission spectrometry (ICP-AES).
Results and Analysis:
TABLE 1
Influences of the curing agent to the absorption and accumulation of
elements such as Cd in paddy rice
Lead
Copper
Iron
Zinc
Cadmium
(mg/
(mg/
Manganese
(mg/
(mg/
Treatment
(mg/kg)
kg)
kg)
(mg/kg)
kg)
kg)
CK
0.76
0.21
29.9
632.85
125.0
71.74
CK
0.79
0.75
30.42
706.22
152.36
76.87
Shallow
0.59
0.21
29.58
669.21
127.07
74.31
application
on surface
Shallow
0.59
0.27
52.58
715.14
167.97
67.21
application
on surface
Deep
0.28
0.18
23.5
594.09
122.41
61.19
application
and thorough
mixing
Deep
0.38
0.22
28.0
643.0
130.66
65.62
application
and thorough
mixing
After the curing agent is shallowly applied on the surface, cadmium in the plant is reduced by 23.87%; while after deep application and thorough mixing, it is reduced by 57.42%, showing a highly significant effect. No matter the shallow application on the surface or a deep application and thorough mixing, the accumulation of elements such as iron, manganese, copper and zinc in plants caused by the curing agent has no significant difference. The result shows that the curing agent has a strong control effect on the accumulation of cadmium in paddy rice.
Make the experiment under the same condition as in Embodiment 11 to the curing agent prepared according to Embodiments 1, 2, 3, 4, 5, 6 and 8. After a shallow application of the curing agent on the surface, cadmium in the plant is reduced by over 23%; while upon deep application and thorough mixing, cadmium in plant is reduced by over 57%, showing a highly significant effect.
Embodiment 12
Experiment Design:
Carefully select 500 seeds of tobacco type K326, use 2% H2O2 for surface disinfection for 20 min, then wash the seeds with distilled water, soak them for 3 h at 25° C., keep accelerating germination for 1 d at 25° C., then place them in the greenhouse of Zijingang Campus of Zhejiang University, use vermiculite for plug seeding at a temperature of 25° C./20° C. (day/night). The four-leaf period comes 60 d after seeding. Select seedlings in the consistent growth condition and transplant them to the treated soil (April 19). Mix Cd and soil thoroughly 14 d before transplanting, treat the curing agent 7 d before transplanting and keep the soil wet. Use 5 L plastic barrels for the experiment with each barrel containing 4.5 kg of soil, 4 plants, 3 repetitions, 4 barrels/treatment, a total of 144 plants (9×4×4), and then take samples in the 6-leaf period 20 d after transplanting (May 9), where only the top part is sampled. A total of 9 treatments are set up:
1. CK, Cd and the curing agent not added; 2. A, 1.25 gA/pot; 3. B. 1.25 gB/pot; 4. Cd1, 1 mg/kg CdCl2; 5. Cd1+A, 1 mg/kg CdCl2+1.25 gA/pot 6. Cd1+B, 1 mg/kg CdCl2+1.25 gB/pot 7. Cd2, 5 mg/kg CdCl2; 8. Cd2+A, 5 mg/kg CdCl2+1.25 gA/pot 9. Cd2+B, 5 mg/kg CdCl2+1.25 gB/pot
B is the curing agent prepared according to Embodiment 7; A is the raw materials used in Embodiment 7, which are obtained by simple mixing and then high-temperature distillation and used for control.
Experiment Results:
1. Agronomic Properties:
TABLE 2
Agronomic properties in the experiment for heavy metal cadmium to be relieved by
the curing agent in tobacco
Treatment
Plant height (cm)
Fresh weight (g)
Dry weight (g)
SPAD
Cond stomatal
24.80 ± 0.71
a
9.59 ± 0.95
ab
2.338 ± 0.18
ab
33.64 ± 1.73
a
conductivity
A
23.53 ± 4.81
ab
8.86 ± 0.85
ab
2.462 ± 0.22
a
32.78 ± 1.54
ab
B
24.27 ± 2.56
ab
10.2 ± 1.33
ab
2.651 ± 0.39
a
33.4 ± 1.48
a
Cd1
19.70 ± 1.48
cd
7.91 ± 0.77
a
1.894 ± 0.26
c
33.02 ± 2.00
ab
Cd1 + A
20.50 ± 1.97
bcd
8.36 ± 1.33
b
2.021 ± 0.38
bc
33.64 ± 2.55
a
Cd1 + B
22.70 ± 0.46
abc
9.65 ± 1.21
b
2.075 ± 0.45
bc
33.44 ± 0.68
a
Cd2
21.47 ± 2.42
abc
8.95 ± 1.30
ab
1.990 ± 0.21
bc
32.72 ± 1.26
ab
Cd2 + A
17.53 ± 0.58
d
6.82 ± 0.09
b
1.809 ± 0.21
c
34.1 ± 1.80
a
Cd2 + B
17.30 ± 1.39
d
7.85 ± 0.72
ab
1.936 ± 0.40
c
31.0 ± 0.75
b
Note:
the letters in the table show significant level, the same as in the report.
Concentration of heavy metal cadmium:
TABLE 3
Contents of cadmium in various treatments to be relieved by the curing agent in tobacco
Content
of fertilizer
Cd
sulfur (g/pot)
Cd concentration (μg/g)
Code
(mg/kg)
A
B
Repeat I
Repeat II
Repeat III
Average
CK
0
0
0
0.019
0.020
0.016
0.018
A
0
1.25
0
0.007
0.005
0.003
0.005
B
0
0
1.25
0.020
0.016
0.016
0.018
Cd1
1.0
0
0
0.584
0.764
0.670
0.673
Cd1 + A
1.0
1.25
0
0.354
0.158
0.406
0.306
Cd1 + B
1.0
0
1.25
0.146
0.136
0.197
0.160
Cd2
5.0
0
0
1.432
2.356
2.960
2.249
Cd2 + A
5.0
1.25
0
2.419
3.825
1.848
2.698
Cd2 + B
5.0
0
1.25
1.420
2.119
0.651
1.396
3. Light and Parameters
TABLE 4
Photosynthetic parameters of tobacco leaves
Stomatal
Intercellular CO2
Photosynthetic rate
conductivity
concentration
Transpiration rate
Code
(μmol CO2 m-2 s-1)
(mol H2O m-2 s-1)
(μmol CO2 mol-1)
(mmol H2O m-2 s-1)
CK
15.28 ± 1.25
a
0.2716 ± 0.05
bc
310.8 ± 13.29
e
3.348 ± 0.77
bc
A
15.16 ± 1.61
ab
0.3062 ± 0.13
abc
313.2 ± 16.27
e
3.696 ± 1.29
ab
B
14.06 ± 0.50
cd
0.3464 ± 0.09
ab
322.2 ± 10.99
de
4.458 ± 0.57
a
Cd1
13.78 ± 0.52
d
0.2614 ± 0.07
c
344 ± 10.63
ab
2.676 ± 0.87
c
Cd1 + A
14.14 ± 0.79
bcd
0.332 ± 0.05
abc
328.6 ± 5.94
cd
3.942 ± 0.67
ab
Cd1 + B
14.96 ± 0.48
abc
0.3618 ± 0.04
a
337 ± 6.52
bc
4.06 ± 0.43
ab
Cd2
12.52 ± 0.55
e
0.3328 ± 0.00
abc
329.6 ± 4.56
cd
4.374 ± 0.23
a
Cd2 + A
11.42 ± 0.77
f
0.3038 ± 0.03
abc
351.4 ± 7.64
a
4.62 ± 0.82
a
Cd2 + B
12.46 ± 0.44
ef
0.272 ± 0.01
bc
320 ± 1.87
de
4.49 ± 0.07
a
Result Analysis:
1. Influences of A and B on the growth of tobacco seedlings under cadmium stress
A negative correlation is found between the concentration of cadmium and the inhibition to growth 20 d after transplanting (Table 2). High-concentration cadmium facilitates the growth of the top part of the tobacco, but not significantly. Meanwhile, upon the treatment with low-concentration cadmium, A and B effectively relieve the inhibition to the growth of tobacco. With high-concentration cadmium, A and B aggravate the inhibition to the growth of tobacco, which shows that the curing agent in this condition facilitates the accumulation of cadmium in the tobacco leaf, thus further causing the aggravated inhibition to the growth of tobacco after the tobacco is contaminated by cadmium. This indicates that, antagonism occurs between sulfur and cadmium when cadmium is in low concentrations and synergy occurs when cadmium is in high concentration. This may be caused by the curing agent which facilitates the accumulation of cadmium in the roots and stems to transfer to the leaves (An Zhizhuang et al, 2004), while Fertilizer A has a higher transfer effect to cadmium than Fertilizer B.
2. Influences of A and B on the chlorophyll content (SPAD value) of tobacco seedlings under cadmium stress
A positive correlation is found between the SPAD value of leaves and the chlorophyll content. The measuring result is a relative value reflecting the chlorophyll content of the leaves. In this experiment, cadmium treatment reduces the chlorophyll content of tobacco leaves (Table 2), but not significantly. The application of A and B increases the chlorophyll content of leaves, but still not significantly. This may be because the low cadmium concentration in the leaves cannot lead to big destruction of the chlorophyll structure.
3. Influences of A and B on the cadmium content in tobacco seedlings under the cadmium stress
After cadmium is absorbed by the plants, most cadmium enriches the roots and little cadmium transfers to the aboveground part (Table 3). With the low-concentration cadmium, both A and B can significantly reduce the concentration of cadmium in tobacco seedlings, especially under the treatment of B, the aboveground cadmium content is reduced by 76% than the single-cadmium treatment. Under the treatment of high-concentration cadmium, Fertilizer B significantly reduces the accumulated cadmium content at the roots only. This shows that Fertilizer A is effective only for the reduction of the aboveground cadmium content under the treatment of low-concentration cadmium, but Fertilizer B is effective in the reduction of the cadmium content under the treatment of cadmium with different concentrations.
4. Influences of A and B on the photosynthetic parameters of tobacco leaves under cadmium stress
Compared with the control level, the cadmium stress reduces the photosynthetic rate (9.81% in Cd1, 18.1% in Cd2), as shown in Table 4. Both A and B in Cd1 increase the photosynthetic rate, but the application of A in Cd2 significantly reduces the photosynthetic rate. However, it is worth mentioning that application B leads to the photosynthetic rate to be restored to almost the control level. B effectively relieves the reduction of the photosynthetic rate caused by the cadmium.
The cadmium treatment has a complicated impact on the stomatal conductivity of tobacco. The stomatal conductivity is reduced in Cd 1, increased in Cd2, but both not significantly. A and B have inhibition effect on the stomatal conductivity only when the cadmium concentration is high. No matter the increase or reduction of the stomatal conductivity, B is more significant than A.
Cadmium also increases intercellular CO 2 concentration in the leaves. Between the two fertilizers, A is more susceptible to the concentration of cadmium. Under the cadmium stress with two concentrations, B can reduce inter-cellular CO 2 concentration, but not significantly.
After the cadmium treatment, compared with the control level, the transpiration rate in Cd1 is significantly reduced while that in Cd2 is significantly increased. Under the cadmium treatment with different concentrations, both A and B can increase the transpiration rate (both showing significant increase in Cd1), but the increase in the transpiration rate for A is higher than that for B only in Cd2, A and B have also inconsistent change of the transpiration rate under the cadmium treatment with the two concentrations.
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The present invention provides a soil heavy metal curing agent for controlling accumulation of heavy metals of crops and its preparation method. The curing agent is made from the following parts of raw materials by weight: 60˜140 parts of substance containing carbon-carbon double bond; 1˜400 parts of sulfo-compound by sulfur; 50˜500 parts of organic matter by 10% water content; 0˜400 parts of water; 0˜100 parts of an initiator; 0˜200 parts of a reducer; and 0˜200 parts of a strong base. The curing agent for heavy metals in the soil according to the present invention can reduce the cadmium, lead and mercury content in the soil and further greatly reduce the roots' absorption of these heavy metals.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of priority to Korean Patent Application No. 10-2012-0143088 filed in the Korean Intellectual Property Office on Dec. 10, 2012, the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
The present inventive concept relates to an automatic transmission for a vehicle. More particularly, the present inventive concept relates to a planetary gear train of an automatic transmission for a vehicle that can improve mountability by reducing a length thereof and reduce fuel consumption by improving power delivery performance.
BACKGROUND
Typically, a planetary gear train is realized by combining a plurality of planetary gear sets and friction members. It is well known that when a planetary gear train realizes a greater number of shift speeds, speed ratios of the planetary gear train can be more optimally designed, and therefore a vehicle can have economical fuel or gas mileage and better performance. For that reason, the planetary gear train that is able to realize the greater number of shift speeds is under continuous investigation.
Though achieving the same number of speeds, the planetary gear train has a different operating mechanism according to a connection between rotation elements (i.e., sun gear, planet carrier, and ring gear). In addition, the planetary gear train has different features such as durability, power delivery efficiency, and size, depending on the layout thereof. Therefore, designs for a combining structure of a gear train are also under continuous investigation.
In addition, the planetary gear train realizes a plurality of shift-speeds. However, another friction member must be operated after one friction member is released so as to shift to a neighboring shift-speed from a view of shift control. In addition, a step ratio between the neighboring shift-speeds should be controlled to be suitable according to the planetary gear train.
The above information disclosed in this Background section is only for enhanced understanding of the background of the inventive concept and therefore it may contain information that does not form the prior art.
SUMMARY
The present inventive concept has been developed to provide a planetary gear train of an automatic transmission for a vehicle having advantages of improved mountability by shortening a length thereof and reducing fuel consumption by improved power delivery performance. The advantages are obtained as a consequence of achieving eight forward speeds and one reverse speed having excellent operating conditions of frictional elements and step ratios by combining three planetary gear sets separately disposed on an input shaft and an output shaft, three externally-meshing gears, and five frictional elements.
According to an exemplary embodiment of the present inventive concept, a planetary gear train of an automatic transmission for a vehicle includes: an input shaft receiving torque of an engine; an output shaft disposed in parallel with the input shaft; a first planetary gear set disposed on the input shaft, the first planetary gear set including a first ring gear directly connected to the input shaft so as to be always operated as an input element, a first planet carrier selectively operated as an output element, and a first sun gear selectively operated as an output element and a fixed element, as rotation elements thereof; a second planetary gear set disposed on the output shaft, the second planetary gear set including a second sun gear connected to the first planet carrier through an externally-meshed gear, a second planet carrier selectively connected to the first sun gear through an externally-meshed gear, and a second ring gear operated as an output element, as rotation elements thereof; a third planetary gear set disposed on the output shaft, the third planetary gear set including a third sun gear selectively connected to the first ring gear and the input shaft through an externally-meshed gear, a third planet carrier directly connected to the second ring gear and the output shaft, and a third ring gear selectively connected to the first sun gear through an externally-meshed gear and selectively connected to the second planet carrier, as rotation elements thereof; three transfer gears forming the externally-meshed gears; and frictional elements selectively interconnecting the rotation elements or selectively connecting the rotation elements to a transmission housing.
The first planetary gear set may be a double pinion planetary gear set and each of the second and third planetary gear sets may be a single pinion planetary gear set.
The three transfer gears may include: a first transfer gear including a first transfer drive gear selectively connected to the first ring gear and the input shaft and a first transfer driven gear connected to the third sun gear; a second transfer gear including a second transfer drive gear connected to the first planet carrier and a second transfer driven gear connected to the second sun gear; and a third transfer gear including a third transfer drive gear selectively connected to the first sun gear and a third transfer driven gear connected to the third ring gear.
The frictional elements may include: a first clutch disposed between the first ring gear as well as the input shaft and the first transfer gear; a second clutch disposed between the second planet carrier and the third ring gear; a third clutch disposed between the first planet carrier and the first transfer gear; a fourth clutch disposed between the first sun gear and the third transfer gear; and a first brake disposed between the first sun gear and the transmission housing.
The first brake and the first and fourth clutches may be operated at a first forward speed; the first brake and the third and fourth clutches may be operated at a second forward speed; the first, third, and fourth clutches may be operated at a third forward speed; the second, third, and fourth clutches may be operated at a fourth forward speed; the first, second, and fourth clutches may be operated at a fifth forward speed; the first, second, and third clutches may be operated at a sixth forward speed; the first brake and the first and second clutches may be operated at a seventh forward speed; the first brake and the second and third clutches may be operated at an eighth forward speed; and the first brake and the second and fourth clutches may be operated at a reverse speed.
A planetary gear train of an automatic transmission for a vehicle according to another exemplary embodiment of the present inventive concept includes: an input shaft receiving torque of an engine; an output shaft disposed in parallel with the input shaft; a first planetary gear set disposed on the input shaft, the first planetary gear set including a first ring gear directly connected to the input shaft so as to be always operated as an input element, a first planet carrier, and a first sun gear selectively operated as a fixed element, as rotation elements thereof; a second planetary gear set disposed on the output shaft, the second planetary gear set including a second sun gear connected to the first planet carrier, a second planet carrier selectively connected to the first sun gear, and a second ring gear, as rotation elements thereof; a third planetary gear set disposed on the output shaft, the third planetary gear set including a third sun gear selectively connected to the first ring gear and the input shaft, a third planet carrier directly connected to the second ring gear and the output shaft, and a third ring gear selectively connected to the first sun gear and selectively connected to the second planet carrier, as rotation elements thereof; a first transfer gear connecting the first ring gear and the input shaft to the third sun gear; a second transfer gear connecting the first planet carrier to the second sun gear; a third transfer gear connecting the first sun gear to the third ring gear; and frictional elements selectively interconnecting the rotation elements or selectively connecting the rotation elements to a transmission housing.
The frictional elements may include: a first clutch disposed between the first ring gear as well as the input shaft and the first transfer gear; a second clutch disposed between the second planet carrier and the third ring gear; a third clutch disposed between the first planet carrier and the first transfer gear; a fourth clutch disposed between the first sun gear and the third transfer gear; and a first brake disposed between the first sun gear and the transmission housing.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the inventive concept will be apparent from a description of various exemplary embodiments of the inventive concept described herein, as illustrated in the accompanying drawings in which like reference characters may refer to the same or similar parts throughout different views. The illustrated drawings are not necessarily to scale, an emphasis is instead placed on illustrating the principles of the exemplary embodiments of the inventive concept.
FIG. 1 is a schematic diagram of a planetary gear train according to an exemplary embodiment of the present inventive concept.
FIG. 2 is an operational chart of friction members at each shift-speed applied to a planetary gear train according to an exemplary embodiment of the present inventive concept.
FIG. 3A is a lever diagram of a planetary gear train at the first forward speed according to an exemplary embodiment of the present inventive concept.
FIG. 3B is a lever diagram of a planetary gear train at the second forward speed according to an exemplary embodiment of the present inventive concept.
FIG. 3C is a lever diagram of a planetary gear train at the third forward speed according to an exemplary embodiment of the present inventive concept.
FIG. 3D is a lever diagram of a planetary gear train at the fourth forward speed according to an exemplary embodiment of the present inventive concept.
FIG. 3E is a lever diagram of a planetary gear train at the fifth forward speed according to an exemplary embodiment of the present inventive concept.
FIG. 3F is a lever diagram of a planetary gear train at the sixth forward speed according to an exemplary embodiment of the present inventive concept.
FIG. 3G is a lever diagram of a planetary gear train at the seventh forward speed according to an exemplary embodiment of the present inventive concept.
FIG. 3H is a lever diagram of a planetary gear train at the eighth forward speed according to an exemplary embodiment of the present inventive concept.
FIG. 3I is a lever diagram of a planetary gear train at a reverse speed according to an exemplary embodiment of the present inventive concept.
DESCRIPTION OF SYMBOLS
PG 1 , PG 2 , PG 3 : first, second, and third planetary gear sets
S 1 , S 2 , S 3 : first, second, and third sun gears
PC 1 , PC 2 , PC 3 : first, second, and third planet carriers
R 1 , R 2 , R 3 : first, second, and third ring gears
IS: input shaft
OS: output shaft
B 1 : first brake
C 1 , C 2 , C 3 , C 4 : first, second, third, and fourth clutches
TF 1 , TF 2 , TF 3 : first, second, and third transfer gears
DETAILED DESCRIPTION
Exemplary embodiments of the present inventive concept will hereinafter be described in detail with reference to the accompanying drawings. In the following detailed description, only certain exemplary embodiments of the present inventive concept have been shown and described, simply by way of illustration. Various descriptions of components that are not necessary for explaining the exemplary embodiment are omitted for simplicity, and the same constituent elements are denoted by the same reference numerals in this specification. As those skilled in the art would realize, the described exemplary embodiments can be modified in various different ways, all without departing from the spirit or scope of the present inventive concept. Accordingly, the drawings and following detailed description are to be regarded as being illustrative in nature and not restrictive.
Further, in the detailed description, ordinal numbers are used for distinguishing constituent elements having the same terms, and have no specific meanings. Like reference numerals or symbols designate like elements throughout the specification. Hereinafter, exemplary embodiments of the present inventive concept are described in detail with reference to the accompanying drawings.
FIG. 1 is a schematic diagram of a planetary gear train according to an exemplary embodiment of the present inventive concept.
Referring to FIG. 1 , a planetary gear train according to an exemplary embodiment of the present inventive concept includes first, second, and third planetary gear sets PG 1 , PG 2 , and PG 3 , five frictional elements B 1 , C 1 , C 2 , C 3 , and C 4 , and three transfer gears TF 1 , TF 2 , and TF 3 .
The first planetary gear set PG 1 is disposed on an input shaft IS, and the second and third planetary gear sets PG 2 and PG 3 are disposed on an output shaft OS disposed apart from and in parallel with the input shaft IS.
The input shaft IS is an input member, supporting the first planetary gear set PG 1 and transmitting torque from an engine to the first planetary gear set PG 1 .
The output shaft OS supports the second and third planetary gear sets PG 2 and PG 3 and transmits torque of an output member of the third planetary gear set PG 3 to a final reduction gear (not shown) and a differential apparatus (not shown).
Therefore, the torque input from the input shaft IS is changed into eight forward speeds and one reverse speed by cooperation of the first, second, and third planetary gear sets PG 1 , PG 2 , and PG 3 , and is then output through the output shaft OS.
The first planetary gear set PG 1 is a double pinion planetary gear set, and includes a first sun gear S 1 , a first ring gear R 1 , and a first planet carrier PC 1 rotatably supporting a first pinion P 1 engaged with the first sun gear S 1 and the first ring gear R 1 as rotation elements thereof.
The second planetary gear set PG 2 is a single pinion planetary gear set, and includes a second sun gear S 2 , a second ring gear R 2 , and a second planet carrier PC 2 supporting a second pinion P 2 engaged with the second sun gear S 2 and the second ring gear R 2 are rotation elements thereof.
The third planetary gear set PG 3 is a single pinion planetary gear set, and includes a third sun gear S 3 , a third ring gear R 3 , and a third planet carrier PC 3 rotatably supporting a third pinion P 3 engaged with the third sun gear S 3 and the third ring gear R 3 as rotation elements thereof.
The first ring gear R 1 is directly connected to the input shaft IS, the second ring gear R 2 is directly connected to the third planet carrier PC 3 , and the third planet carrier PC 3 is directly connected to the output shaft OS in the first, second, and third planetary gear sets PG 1 , PG 2 , and PG 3 . In addition, the rotation elements of the first, second, and third planetary gear sets PG 1 , PG 2 , and PG 3 are combined with each other through the first, second, and third transfer gears TF 1 , TF 2 , and TF 3 , and the frictional elements consisting of the first brake B 1 and the first, second, third, and fourth clutches C 1 , C 2 , C 3 , and C 4 .
The first, second, and third transfer gears TF 1 , TF 2 , and TF 3 respectively have first, second, and third transfer drive gears TF 1 a , TF 2 a , and TF 3 a and first, second, and third transfer driven gears TF 1 b , TF 2 b , and TF 3 b externally meshed with each other.
The first transfer gear TF 1 connects the first ring gear R 1 as well as the input shaft IS to the third sun gear S 3 . The second transfer gear TF 2 connects the first planet carrier PC 1 to the second sun gear S 2 . The third transfer gear TF 3 connects the first sun gear S 1 to the third ring gear R 3 .
Therefore, the rotation elements connected to each other by the first, second, and third transfer gears TF 1 , TF 2 , and TF 3 are rotated in opposite directions to each other. Gear ratios of the first, second, and third transfer gears TF 1 , TF 2 , and TF 3 are set according to speed ratios demanded at shift-speeds.
Arrangements of the frictional elements B 1 , C 1 , C 2 , C 3 , and C 4 will be described in detail.
The first brake B 1 is disposed between the first sun gear S 1 and the transmission housing H.
The first clutch C 1 is disposed between the first ring gear R 1 and the input shaft IS together with the first transfer drive gear TF 1 a.
The second clutch C 2 is disposed between the second planet carrier PC 2 and the third transfer driven gear TF 3 b.
The third clutch C 3 is disposed between the first planet carrier PC 1 and the first transfer drive gear TF 1 a.
The fourth clutch C 4 is disposed between the first sun gear S 1 and the third transfer drive gear TF 3 a.
The frictional elements consisting of the first, second, third, and fourth clutches C 1 , C 2 , C 3 , and C 4 and the first brake B 1 are conventional multi-plate friction elements of a wet type that are operated by hydraulic pressure.
FIG. 2 is an operational chart of frictional elements at each shift-speed applied to a planetary gear train according to an exemplary embodiment of the present inventive concept.
As shown in FIG. 2 , three frictional elements are operated at each shift-speed in the planetary gear train according to an exemplary embodiment of the present inventive concept.
For example, the first brake B 1 and the first and fourth clutches C 1 and C 4 are operated at a first forward speed 1 ST . The first brake B 1 and the third and fourth clutches C 3 and C 4 are operated at a second forward speed 2 ND . The first, third, and fourth clutches C 1 , C 3 , and C 4 are operated at a third forward speed 3 RD . The second, third, and fourth clutches C 2 , C 3 , and C 4 are operated at a fourth forward speed 4 TH . The first, second, and fourth clutches C 1 , C 2 , and C 4 are operated at a fifth forward speed 5 TH . The first, second, and third clutches C 1 , C 2 , and C 3 are operated at a sixth forward speed 6 TH . The first brake B 1 and the first and second clutches C 1 and C 2 are operated at a seventh forward speed 7 TH . The first brake B 1 and the second and third clutches C 2 and C 3 are operated at an eighth forward speed 8 TH . The first brake B 1 and the second and fourth clutches C 2 and C 4 are operated at a reverse speed Rev.
FIGS. 3A-3I are lever diagrams of the planetary gear train at each shift-speed according to the exemplary embodiment of the present inventive concept, and illustrate shift processes of the planetary gear train according to the exemplary embodiment of the present inventive concept by a lever analysis method.
Referring to FIG. 3A to FIG. 3I , three vertical lines of the first planetary gear set PG 1 are set as the first sun gear S 1 , the first ring gear R 1 , and the first planet carrier PC 1 ; three vertical lines of the second planetary gear set PG 2 are set as the second sun gear S 2 , the second planet carrier PC 2 , and the second ring gear R 2 ; and three vertical lines of the third planetary gear set PG 3 are set as the third sun gear S 3 , the third planet carrier PC 3 , and the third ring gear R 3 from the left to the right.
In addition, a middle horizontal line represents a rotation speed of “0”, an upper horizontal line represents a rotation speed of “1.0”, and a lower horizontal line represents a rotation speed of “−1.0”. A symbol “−” means that rotational elements are rotated in an opposite direction of a rotational direction of the engine. It is because the rotation elements are externally meshed with each other through the first, second, and third transfer gears TF 1 , TF 2 , and TF 3 without an idling gear. In addition, the rotation speed of “1.0” represents the same rotational speed as that of the input shaft IS. Distances between the vertical lines of the first, second, and third planetary gear sets PG 1 , PG 2 , and PG 3 are set according to each gear ratio (i.e., a teeth number of a sun gear/a teeth number of a ring gear).
Hereinafter, referring to FIG. 2 and FIGS. 3A-3I , the shift processes of the planetary gear train according to an exemplary embodiment of the present inventive concept will be described in detail.
[First Forward Speed]
Referring to FIG. 2 , the first brake B 1 and the first and fourth clutches C 1 and C 4 are operated at the first forward speed 1 ST .
As shown in FIG. 3A , the rotation speed of the input shaft IS is input to the first ring gear R 1 , and is changed according to the gear ratio of the first transfer gear TF 1 and is then input to the third sun gear S 3 as an inverse rotation speed by operation of the first clutch C 1 . At this state, the first sun gear S 1 and the third ring gear R 3 are operated as fixed elements by operation of the first brake B 1 and the fourth clutch C 4 .
Therefore, the rotation elements of the third planetary gear set PG 3 form a first shift line SP 1 and D 1 is output through the third planet carrier PC 3 that is the output element.
[Second Forward Speed]
The first clutch C 1 that was operated at the first forward speed 1 ST is released and the third clutch C 3 is operated at the second forward speed 2 ND .
As shown in FIG. 3B , the rotation speed of the input shaft IS is input to the first ring gear R 1 , and the first sun gear S 1 and the third ring gear R 3 are operated as the fixed elements by operation of the first brake B 1 and the fourth clutch C 4 . In addition, a rotation speed of the first planet carrier PC 1 is changed according to the gear ratio of the first transfer gear TF 1 and is then input to the third sun gear S 3 as an inverse rotation speed by operation of the third clutch C 3 . Therefore, the rotation elements of the third planetary gear set PG 3 form a second shift line SP 2 and D 2 is output through the third planet carrier PC 3 that is the output element.
[Third Forward Speed]
The first brake B 1 that was operated at the second forward speed 2 ND is released and the first clutch C 1 is operated at the third forward speed 3 RD .
As shown in FIG. 3C , the rotation speed of the input shaft IS is input to the first ring gear R 1 and the first planetary gear set PG 1 becomes a direct-coupling state by operation of the first and third clutches C 1 and C 3 . Therefore, the rotation speed of the input shaft IS is changed according to the gear ratios of the first and second transfer gears TF 1 and TF 2 and is then input to the third sun gear S 3 and the second sun gear S 2 as inverse rotation speeds, respectively. In addition, a rotation speed of the first sun gear S 1 is changed according to the gear ratio of the third transfer gear TF 3 and is then input to the third ring gear R 3 as an inverse rotation speed by operation of the fourth clutch C 4 . Therefore, the rotation elements of the third planetary gear set PG 3 form a third shift line SP 3 and D 3 is output through the third planet carrier PC 3 that is the output element.
[Fourth Forward Speed]
The first clutch C 1 that was operated at the third forward speed 3 RD is released and the second clutch C 2 is operated at the fourth forward speed 4 TH .
As shown in FIG. 3D , the rotation speed of the input shaft IS is input to the first ring gear R 1 , and the rotation speed of the first planet carrier PC 1 is changed according to the gear ratio of the first transfer gear TF 1 and is then input to the third sun gear S 3 as the inverse rotation speed by operation of the third clutch C 3 . In addition, the rotation speed of the first sun gear S 1 is changed according to the gear ratio of the third transfer gear TF 3 and is then input to the third ring gear R 3 and the second planet carrier PC 2 as the inverse rotation speeds by operation of the fourth clutch C 4 and the second clutch C 2 , respectively. Therefore, the rotation elements of the third planetary gear set PG 3 form a fourth shift line SP 4 and D 4 is output through the third planet carrier PC 3 that is the output element.
[Fifth Forward Speed]
The third clutch C 3 that was operated at the fourth forward speed 4 TH is released and the first clutch C 1 is operated at the fifth forward speed 5 TH .
As shown in FIG. 3E , the rotation speed of the input shaft IS is input to the first ring gear R 1 , and is changed according to the gear ratio of the first transfer gear TF 1 and is then input to the third sun gear S 3 as the inverse rotation speed by operation of the first clutch C 1 . In addition, the rotation speed of the first planet carrier PC 1 is changed according to the gear ratio of the second transfer gear TF 2 and is then input to the second sun gear S 2 as the inverse rotation speed. The rotation speed of the first sun gear S 1 is changed according to the gear ratio of the third transfer gear TF 3 and is then input to the third ring gear R 3 and the second planet carrier PC 2 as the inverse rotation speeds by operation of the fourth clutch C 4 and the second clutch C 2 , respectively. Therefore, the rotation elements of the third planetary gear set PG 3 form a fifth shift line SP 5 and D 5 is output through the third planet carrier PC 3 that is the output element.
[Sixth Forward Speed]
The fourth clutch C 4 that was operated at the fifth forward speed 5 TH is released and the third clutch C 3 is operated at the sixth forward speed 6 TH .
As shown in FIG. 3F , the rotation speed of the input shaft IS is input to the first ring gear R 1 , and the first planetary gear set PG 1 becomes the direct-coupling state by operation of the first and third clutches C 1 and C 3 . Therefore, the rotation speed of the input shaft IS is changed according to the gear ratios of the first and second transfer gears TF 1 and TF 2 and is then input to the third sun gear S 3 and the second sun gear S 2 as the inverse rotation speeds, respectively. In addition, the second planet carrier PC 2 is connected to the third ring gear R 3 by operation of the second clutch C 2 . Therefore, the rotation elements of the third planetary gear set PG 3 form a sixth shift line SP 6 and D 6 is output through the third planet carrier PC 3 that is the output element.
[Seventh Forward Speed]
The third clutch C 3 that was operated at the sixth forward speed 6 TH is released and the first brake B 1 is operated at the seventh forward speed 7 TH .
As shown in FIG. 3G , the rotation speed of the input shaft IS is input to the first ring gear R 1 , and is changed according to the gear ratio of the first transfer gear TF 1 and is then input to the third sun gear S 3 as the inverse rotation speed by operation of the first clutch C 1 . In addition, the first sun gear S 1 is operated as the fixed element by operation of the first brake B 1 . The rotation speed of the first planet carrier PC 1 is changed according to the gear ratio of the second transfer gear TF 2 and is then input to the second sun gear S 2 as the inverse rotation speed, and the second planet carrier PC 2 is connected to the third ring gear R 3 by operation of the second clutch C 2 . Therefore, the rotation elements of the third planetary gear set PG 3 form a seventh shift line SP 7 and D 7 is output through the third planet carrier PC 3 that is the output element.
[Eighth Forward Speed]
The first clutch C 1 that was operated at the seventh forward speed 7 TH is released and the third clutch C 3 is operated at the eighth forward speed 8 TH .
As shown in FIG. 3H , the rotation speed of the input shaft IS is input to the first ring gear R 1 and the first sun gear S 1 is operated as the fixed element by operation of the first brake B 1 . Therefore, the rotation speed of the first planet carrier PC 1 is changed according to the gear ratio of the first transfer gear TF 1 and is then input to the third sun gear S 3 as the inverse rotation speed by operation of the third clutch C 3 . In addition, the rotation speed of the first planet carrier PC 1 is changed according to the gear ratio of the second transfer gear TF 2 and is then input to the second sun gear S 2 as the inverse rotation speed. At this state, the second planet carrier PC 2 is connected to the third ring gear R 3 by operation of the second clutch C 2 . Therefore, the rotation elements of the third planetary gear set PG 3 form an eighth shift line SP 8 and D 8 is output through the third planet carrier PC 3 that is the output element.
[Reverse Speed]
As shown in FIG. 2 , the first brake B 1 and the second and fourth clutches C 2 and C 4 are operated at the reverse speed Rev. As shown in FIG. 3I , the rotation speed of the input shaft IS is input to the first ring gear R 1 , and the first sun gear S 1 , the second planet carrier PC 2 and the third ring gear R 3 are operated as the fixed elements by operation of the first brake B 1 and the second and fourth clutches C 2 and C 4 . In addition, the rotation speed of the first planet carrier PC 1 is changed according to the gear ratio of the second transfer gear TF 2 and is then input to the second sun gear S 2 as the inverse rotation speed. Therefore, the rotation elements of the third planetary gear set PG 3 form a reverse shift line RS and REV is output through the third planet carrier PC 3 that is the output element. Since three planetary gear sets are separately disposed on the input shaft and the output shaft disposed apart from and in parallel with each other in the planetary gear train according to an exemplary embodiment of the present inventive concept, a length thereof may be reduced and mountability may be improved.
In addition, optimum gear ratios may be set due to ease of changing gear ratios by using three external-meshing gears as well as the planetary gear sets. Since gear ratios can be changed according to target performance, starting performance may be improved. Therefore, a start-up clutch instead of a torque converter may be used.
Since three frictional elements are operated at each shift-speed, non-operated frictional element may be minimized and drag torque may be reduced. In addition, fuel consumption may be reduced by increasing power delivery efficiency.
In addition, since a torque load of each frictional element can be reduced, a compact design is possible.
While this inventive concept has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the inventive concept is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A planetary gear train of an automatic transmission for a vehicle may include: an input shaft, an output shaft disposed in parallel with the input shaft, a first planetary gear set disposed on the input shaft, a second planetary gear set disposed on the output shaft, a third planetary gear set disposed on the output shaft, three transfer gears forming an externally-meshed gears, and frictional elements selectively interconnecting rotation elements or selectively connecting the rotation elements to a transmission housing. The first planetary gear set includes a first ring gear, a first planet carrier, and a first sun gear. The second planetary gear set includes a second sun gear, a second planet carrier, and a second ring gear. The third planetary gear set includes a third sun gear, a third planet carrier, and a third ring gear.
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FIELD OF THE INVENTION
[0001] Embodiments of the present invention relate generally to compliance tools. More specifically, embodiments of the present invention relate to system and methods for determining and documenting compliance with a requirement (e.g., law or regulation) involving at least some degree of computation.
BACKGROUND OF THE INVENTION
[0002] It has become common for regulating bodies (e.g., federal or state governments) to enact regulations that require a regulated entity (e.g., a business) to comply with regulations having multiple compliance paths, or options, and then to demonstrate compliance with the regulation through the completion of tedious documentation. The tax laws may be the most common such example. Pollution reduction laws are a more recent example.
[0003] In some cases, the regulations provide a “prescriptive” compliance method that may require little or no computation but also provide an “alternative” compliance method that is computationally challenging. Such is the case with California's Title 24, specifically Part 6, which regulates certain roofing systems.
BRIEF SUMMARY OF THE INVENTION
[0004] Embodiments of the invention provide a compliance system configured to assist a user with the selection of building materials that comply with a regulatory requirement. The system includes a processor, a forms generator, and a user interface. The processor is programmed to receive a first user input via the user interface, which first user input identifies a geographic area within a larger compliance region to which the regulatory requirement relates. The geographic area has particular compliance parameters associated therewith. The processor also is programmed to receive a second user input via the user interface, which second user input identifies a first building material, based on the first and second user inputs, identify a second building material usable in combination with the first building material to comply with the regulatory requirement, and, via the forms generator, generate one or more forms that document compliance with the regulatory requirement. According to certain embodiments, users are advantageously able to easily identify products usable to satisfy regulatory requirements specific to their jurisdiction and complete the forms necessary to demonstrate compliance with the requirements.
[0005] In some embodiments, the regulatory requirement relates to energy efficiency requirements for a building. The regulatory requirement may relate to a roofing requirement. The regulatory requirement may relate to California Code of Regulations Title 24, Part 6. The first user input may be a zip code. The zip code may be usable by the processor to identify a climate zone within which the building materials are to be used. The first and second building materials may be different components of a roofing system. The compliance system may include a material list generator and the processor may be further configured to, via the material list generator, generate a list of materials. The compliance system also may include a jurisdictional table identifying regulatory requirements for one or more jurisdictions within which the building materials are usable, a climate zone table identifying climate data for a plurality of climate zones within which the building materials are usable, and a material properties table identifying material properties for a plurality of building materials.
[0006] Other embodiments provide a method of complying with a regulatory requirement relating to energy efficiency. The method includes providing a computer-implemented compliance tool, providing data to the tool that defines a first building material and a compliance location, and receiving from the tool information defining a second building material usable in combination with the first building material to comply with the regulation at the compliance location. The regulatory requirement may relate to a roofing requirement. The regulatory requirement may relate to California Code of Regulations Title 24, Part 6. The first and second building materials may be different components of a roofing system. The method may include generating a project-specific materials list. The method also may include generating one or more project-specific compliance forms.
[0007] Still other embodiments provide a method of complying with an energy efficiency standard relating to roofing systems. The method includes providing a compliance tool that is configured to receive information from a user defining at least a first component in a multi-component roofing system and to identify at least a second component in the multi-component roofing system. The first and second components are usable in combination to comply with the energy efficiency standard. The compliance tool is further configured to generate one or more forms acceptable to a regulatory agency as documentation of compliance with the energy efficiency standard. The method also includes inputting into the tool data defining the first component and outputting from the tool data defining the second component. The energy efficiency standard may relate to California Code of Regulations Title 24, Part 6. The method also may include generating a project-specific materials list. The method may include generating one or more project-specific compliance forms.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] A further understanding of the nature and advantages of the present invention may be realized by reference to the following drawings. In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
[0009] FIG. 1 depicts a building standards compliance system according to embodiments of the invention.
[0010] FIG. 2 depicts a building standards compliance method according to embodiments of the invention, which method may be implemented in the system of FIG. 1 .
[0011] FIGS. 3A to 3F depict display screens in an exemplary compliance tool.
[0012] FIGS. 4A to 4C depict exemplary forms that may be generated using a compliance tool according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Embodiments of the present invention relate to building standards compliance systems and methods. In order to provide a context for describing embodiments of the present invention, embodiments of the invention will be described herein with reference to systems and methods for complying with energy standards for roofing systems. Those skilled in the art will appreciate, however, that other embodiments are possible. For example, embodiments of the invention may be used to comply with standards for whole house energy efficiency and the like.
[0014] The ensuing description provides preferred exemplary embodiment(s) only, and is not intended to limit the scope, applicability or configuration of the invention. Rather, the ensuing description of the preferred exemplary embodiment(s) will provide those skilled in the art with an enabling description for implementing a preferred exemplary embodiment of the invention. It is to be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention as set forth in the appended claims.
[0015] Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, systems may be shown in block diagrams in order not to obscure the embodiments in unnecessary detail. In other instances, well-known processes, structures and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
[0016] Also, it is noted that the embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed, but could have additional steps not included in the figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination corresponds to a return of the function to the calling function or the main function.
[0017] Moreover, as disclosed herein, the term “storage medium” may represent one or more devices for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory, magnetic disk storage mediums, optical storage mediums, flash memory devices and/or other machine readable mediums for storing information. The term “computer-readable medium” includes, but is not limited to portable or fixed storage devices, optical storage devices, wireless channels and various other mediums capable of storing, containing or carrying instruction(s) and/or data.
[0018] Furthermore, embodiments may be implemented by hardware, software, firmware, middleware, microcode, hardware description languages, or any combination thereof. When implemented in software, firmware, middleware or microcode, the program code or code segments to perform the necessary tasks may be stored in a machine readable medium such as storage medium. A processor(s) may perform the necessary tasks. A code segment may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing and/or receiving information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, network transmission, etc.
[0019] Specific embodiments of the invention are directed to systems and methods for complying with Part 6 of California's Title 24, which provides energy efficiency standards for, among other things, roofing systems. Title 24 includes a prescriptive compliance method that sets minimum reflectivity and emissivity standards for certain roofing systems. As long as a selected roofing system meets the standards—0.70 and 0.75, respectively—then the roofing system is in compliance. But reflectivity and emissivity are merely components of a more important energy efficiency standard: heat gain or heat loss (i.e., negative gain).
[0020] Heat gain is a measure of a building's energy efficiency with respect to heating and cooling. While reflectivity and emissivity are factors that affect a building's heat gain, Title 24 compliance recognizes that a roofing system may fail to comply with the prescriptive emissivity and/or reflectivity standards yet produce an energy budget that is better than the budget a prescriptively-compliant roofing system would produce. Title 24 therefore allows a building owner to demonstrate compliance with Title 24 while using roofing systems having reflectivity and/or emissivity factors that do not meet the prescriptive standards. The owner demonstrates compliance by documenting that the chosen roofing system improves the annual energy budget with respect to a prescriptively-compliant system.
[0021] Embodiments of the present invention therefore provide systems and methods for compliance, specifically compliance with energy efficiency standards for buildings. The system receives user inputs, performs calculations based on the user's inputs, and suggests or identifies building components necessary for compliance. The system also produces approved forms that document compliance, which forms the user may provide to a regulating body.
[0022] Having described embodiments of the invention generally, attention is directed to FIG. 1 , which depicts an exemplary compliance system 100 according to embodiments of the invention. Those skilled in the art will appreciate that the system 100 is merely exemplary of a number of possible embodiments. The system 100 includes a compliance tool 102 , which may be any of a variety of suitable computing devices (e.g., desktop computer, lap top computer, server, etc.) appropriately programmed to implement embodiments of the invention. For example, the compliance tool 102 may include a processor and software and may be configured to serve web pages via a network 104 to user computers 106 . Those skilled in the art will appreciate that the compliance tool 102 may be embodied in a single computing device or may be embodied in a number of geographically-distributed computing devices. The compliance tool 102 also may include a variety of input and output devices and/or other peripherals.
[0023] In this specific embodiment, the compliance tool 102 includes a number of components that function together to perform method embodiments of the present invention. For example, the compliance tool 102 includes: a table of jurisdictions 108 that allows the same tool to aid compliance in multiple jurisdictions; a table of climate zones 110 that allows the compliance tool 110 to be used across a number of different climate zones; a forms database 112 that allows the tool 102 to produce a variety of compliance forms; a materials database 114 that provides information on a number of different materials; a forms generator 116 that generates project specific compliance forms; and a materials list generator 118 that produces a project specific materials list. Those skilled in the art will appreciate that other exemplary embodiments may include different components than those listed and described herein.
[0024] According to embodiments of the invention, users may access the tool using the user computers 106 . The user supply project data that is used to select project-specific parameters from the table of jurisdictions 108 and/or the table of climate zones 110 . The parameters may include temperature coefficients, compliance standards, and/or the like. Users also provide information that generally defines the type of building system the user desires to implement. For example, in a specific embodiment relating to roofing systems, a user may specify a bituminous roof, which has several components, namely a membrane and a cover board. The system also may include insulation. The user may select a specific component to use in the system. Based on the user's selection of a particular system and component, the tool will locate material properties for the selected component and provide one or more possible selections for other components, such as the cover board. If the user has additional options, then the user may select from among the other options (e.g., cover board), and the tool may finally specify a minimum amount of insulation needed to implement a compliant system.
[0025] Continuing with a description of this specific embodiment relating to roofing systems, in determining additional suitable materials to suggest or require, the tool may calculate an energy budget for a prescriptively-compliant roofing system for the specific project. The energy budget is based on a specific period of time (e.g., annual) to thereby account for seasonal variation. As the user specifies roofing system components to be used in an alternative compliance roofing system, the tool narrows the range of acceptable complementary components necessary for the alternative system to have the same or better energy budget as the prescriptively-compliant system. In some cases, the range of acceptable components may not meet the energy budget for a prescriptively-compliant system, in which case additional materials (e.g., insulation) may be required to bring the total system into compliance.
[0026] Once the compliant system is determined, the tool may generate a materials list for the project. The tool also may generate compliance forms that document that the roofing system complies with the standards.
[0027] Having described an exemplary system according to embodiments of the invention, attention is directed to FIG. 2 , which depicts an exemplary method 200 according to embodiments of the invention. The method may be implemented in the system 100 of FIG. 1 or other appropriate system. It should be understood that other exemplary method embodiments may include more, fewer, or different steps than those illustrated and described herein. Moreover, other exemplary embodiments may traverse the steps herein in orders different that that shown here.
[0028] The method 200 begins at block 202 at which point the user supplies general project data. The project data may include a site address (including zip code), building size (square feet, number of floors, etc), type of construction (new or rework, stick, steel, cement, etc.), building type (commercial or residential, etc.), and/or the like. FIG. 3A depicts a display screen 300 that may be used to receive such project data from the user. The display screen includes data entry fields, which may include drop down menus, pick lists, radio buttons, and/or the like. Once the user submits the project data, the tool selects geographically-specific and/or jurisdictionally-specific coefficients and/or standards at block 204 .
[0029] For this specific embodiments relating to roofing systems compliant with energy efficiency standards, the user may identify a particular roof system and/or identify a specific component of the system. For example, as depicted in FIG. 3B , the display screen 302 may be used to specify a bituminous roof. Then the display screen 304 of FIG. 3C may be used to specify a particular membrane, in this case the GlasKap CR™ membrane, a product of Johns Manville. These steps are depicted as block 206 of FIG. 2 .
[0030] Based on the information provided by the user to this point, the tool provides selection criteria for additional system components. For example, based on the reflectivity and emissivity characteristics of GlasKap CR, the climate zone, building size, construction type, jurisdictional requirement, etc., the tool determines acceptable cover board thicknesses. This is depicted as block 208 of FIG. 2 and shown in the display screen 306 of FIG. 3D . If the user has options, then the user selects from among the options.
[0031] As indicated, the method 200 may cycle through the actions of block 208 , specifying additional components. For example, as depicted in the display screen 308 of FIG. 3E , a cover board thickness of ¾″, together with the chosen membrane may require additional insulation. In this example, insulation having an R-Value of 8.92 is needed.
[0032] Once all materials are identified, the tool may generate a materials list. This is depicted as block 210 of FIG. 2 and shown in the display screen 310 of FIG. 3F . In this example, the materials list includes GlasKap Cr membrane, ¾″Fesco® cover board, and 1.5″ of Energy 3 insulation.
[0033] Another valuable benefit provided by embodiments of the present invention is compliance forms generation. Depicted as block 212 of FIG. 2 , the tool may generate forms, suitable for submission to the appropriate regulatory agency, that document that the chosen system complies with the requirements. FIGS. 4A to 4C depict exemplary forms to demonstrate compliance with California Code of Regulations Title 24, Part 6. The form includes information necessary for the agency to evaluate compliance. Those skilled in the art will appreciate that the tool may be used to generate compliance forms relating to other jurisdictions.
[0034] Having described several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit and scope of the invention. Additionally, a number of well known processes and elements have not been described in order to avoid unnecessarily obscuring the present invention. For example, those skilled in the art know how to arrange computers into a network and enable communication among the computers. Moreover, those skilled in the art will appreciate that the concepts discussed herein may be directed toward other types of compliance systems and methods. Accordingly, the above description should not be taken as limiting the scope of the invention, which is defined in the following claims.
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A compliance system configured to assist a user with the selection of building materials that comply with a regulatory requirement includes a processor, a forms generator, and a user interface. The processor is programmed to receive a first user input via the user interface, which first user input identifies a geographic area within a larger compliance region to which the regulatory requirement relates. The geographic area has particular compliance parameters associated therewith. The processor also is programmed to receive a second user input via the user interface, which second user input identifies a first building material, based on the first and second user inputs, identify a second building material usable in combination with the first building material to comply with the regulatory requirement, and, via the forms generator, generate one or more forms that document compliance with the regulatory requirement.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 13/371,842, filed Feb. 13, 2012, which is a continuation of application Ser. No. 12/805,437, filed Jul. 30, 2010, which is a continuation of application Ser. No. 09/902,707, filed Jul. 12, 2001, which is a continuation of application Ser. No. 08/817,528, filed Aug. 5, 1997, which claims priority to International Application No. PCT/FR94/01185, filed Oct. 12, 1994, and French Application No. 95/08391, filed Jul. 11, 1996, the entire contents of each of which are incorporated herein in its entirety by reference.
[0002] This application is related to our co-pending commonly assigned applications:
[0000]
USSN 08/817,690
(Corres. to PCT/FR94/01185
filed Oct. 12, 1994);
USSN 08/817,689
(Corres. to PCT/FR95/01333
filed Oct. 12, 1995);
USSN 08/817,968
(Corres. to PCT/FR95/01335
filed Oct. 12, 1995);
USSN 08/817,437
(Corres. to PCT/FR95/01336
filed Oct. 12, 1995)
USSN 08/817,426
(Corres. to PCT/FR95/01337
filed Oct. 12, 1995); and
USSN 08/817,438
(Corres. to PCT/FR95/01338
filed Oct. 12, 1995).
BACKGROUND OF THE INVENTION
Field of the Invention
[0003] The invention relates to a communications process for a payment—triggered audiovisual reproduction system.
[0004] These audiovisual reproduction systems are generally found in cafes or pubs. This type of system is composed of a sound reproduction machine usually called a jukebox linked to a monitor which displays video images or video clips. To do this the jukebox is equipped with a compact video disk player and a compact video disk library and includes selection buttons which locate the titles of pieces of music which are available. Payment of a proper fee followed by one or more selections authorizes activation of the system with automatic loading in the player of the disk on which the selected piece is found, the desired audiovisual reproduction then being able to start.
[0005] These systems, although allowing faithful and good quality reproduction, nevertheless have major defects. Thus, a first defect relates to the space necessary for storing the library; this consequently entails that the system will have large dimensions and will be bulky. Likewise these systems which call on mostly mechanical hardware using sophisticated techniques have high fault rates; this is another defect. Finally, it is very unusual for all the pieces on a disk to be regularly heard; some are almost never played, but still cannot be eliminated. Besides this defect, the additional problems are caused by the companies which manage and distribute these systems. More particularly, placing in the circuit a limited number of identical disks and imposing a certain rotation on their customers sometimes results in an unpleasant wait for the customers when a disk is not available.
[0006] In addition, patent application PCT/WO 93 18465 discloses computerized jukeboxes which allow reception via a telecommunications network and a modem connecting the jukeboxes to the network, digital data comprising remotely loaded songs or musical pieces in a mass storage of the jukeboxes. The communications systems is likewise used for remote loading of representative files of digitized graphics information, the songs and graphics files being compressed before they are sent over the network. The jukebox processor then uses these files by decompressing them and sending the graphics data to the video circuit and the song data to the audio circuit.
[0007] However, the processor also manages the man/machine interface, and management of these different elements is done by sequentially displaying the graphics images representative of the song, then by responding to the touch action of the user, then checking that the user has paid the prescribed amounts, and finally when the required amount has been accounted, placing the selection in a queue for its subsequent performance. This system can only operate by first displaying the graphics images and then starting performance of the song because the processor cannot, according to the flowcharts, execute two tasks at one time. Finally, the graphics representations are uniquely data digitized by a scanner table of the album cover of the song. In no case does this jukebox allow display of moving images during the broadcast of the song or music. Likewise, since the processor is used for digital data decompression and processing for conversion into audio signals, it cannot consider the new actions of a user making a new selection. This is apparent, notably on page 12 of the PCT application, lines 25 to 27. Selection of new songs can only be done when the jukebox is in the attraction mode, i.e., the mode in which it displays graphics representations of different songs stored in the jukebox in succession.
[0008] U.S. Pat. No. 4,956,768 discloses a broadband server for transmitting music or images formed by a main processor communicating by a DMA channel with a hard disk and output cards, each controlled by a supplementary local processor which manages an alternative mode of access to two buffer memories A and B. Memory A is used to deliver, for example, musical data to a user, while the other is filled. Each of the output cards is connected to a consultation station, which can be local and situated in the same vicinity as the server or, alternatively, at a distance and connected by an audio or video communications network. The server receives data block-by-block and ensures that the sample parities are correct and rejects a block including more than two successive wrong samples. Each of these blocks is of course designated by a number. Once a block has been accepted, it can be stored on the local hard disk by recording its ordinal number which has no relation to its physical address on the hard disk. The consultation stations have audio and video outputs such as loudspeakers or headphones and a television monitor which makes it possible to listen to music or display images in response to requests received from terminals included in the consultation stations. In this system, the consultation stations where the first communications processor exists must have specific software for management of selection requests for musical pieces or video. It is only when the request has been made and addressed to the broadband server processor that it can transfer, under the authority of the local processor, the data in the buffer memories, such that this local processor ensures that the data are sent to the consultation stations. Moreover, it is specified that the output cards and buffer memories are filled only after having received the authorization of the local processor of the card.
[0009] Consequently, this system can only function within the framework of a multiprocessor device and does not in any way suggest use of this server for a jukebox controlled by a single processor operating in an multitask environment. This system proposed by this U.S. patent thus implements a complex process which allows delivery of a service to several consultation stations; this complex process is thus costly and incompatible with a system of jukeboxes, of which the cost and price should be as low as possible.
[0010] Moreover the process of downloading by a central site of digitized audio and video files to the local servers is accomplished via a specialized line communicating unidirectionally with the V35 interfaces of the local server, and allowing passage of 64 kilobit frames. Thus a second parallel communication must be established via the switched telephone network by a serial interface to allow exchange of service data. It is specified that it is preferable to transmit new musical pieces to the broadband server at night to leave the system free for users during the day, and that transmission can be done continuously and simultaneously for all local servers, provided that they can register continuously, i.e., at night.
[0011] This device can only work to the extent that the central server is the master and the local servers are slaved. This thus entails availability of local servers at the instant of establishing communications; this is enabled by the local servers having a double processor which relieves the communication processor for a sufficient interval. In a single—processor architecture it is thus difficult to establish communications according to this protocol determined with a variable number of jukebox stations to allow remote operations such as downloading of music or video following a selection by the jukebox manager or sending statistics to the center, or recovering data concerning billing or security management of the units, or recovery for analysis and survey distribution.
[0012] The object of the invention is to eliminate the various aforementioned defects of the systems of the prior art, and to provide a system of communications between jukebox units allowing reproduction and display of audiovisual digital information and a central server which supports, among various functions, downloading of data.
[0013] This object is achieved by the communications process operating in a conference mode and it includes the following stages:
sending a heading before any transaction which includes the identity of the destination, identity of the sender, and the size of the packets; sending a server response in the form of a packet of data, each packet sent by the server being encoded using the identification code of the jukebox software; receiving a data packet by the decoding jukebox, wherein the packet at the same time checks the data received using the CRC method and sending a reception acknowledgment to the server indicating the accuracy of the received data to allow it to prepare and send a new packet to the unit destination.
[0017] According to another operating mode the server can send the data by stream, the stream including several packets, and the receiver unit will then perform decoding and storage, and after receiving the indicator of the last packet, will signal the defective packets received at the server.
[0018] According to another feature, each packet contains a first field allowing identification of the seller, a second field allowing indication of the identification of an application, this 32 bit field making it possible to specify whether it is a digital song, digital video, stationary image, software update, statistics, billing, or update of the unit database, a third field indicating the identification of a single type of application such as the identification number of the product, the type of billing, the difference between a midi song and a digital song, last block indication, finally a fourth field indicating the sequence number of the block in the transmission, a fifth block indicating the length of this block in octets, a sixth field composed of variable length data, a seventh field composed of cyclic redundancy verification data.
[0019] An object of the invention is to eliminate the various defects of the systems of the prior art by providing an intelligent digital audiovisual reproduction system which is practical to implement, compact, reliable, authorizes storage at the title level as well as easy deletion or insertion of titles not listened to or wanted, all this while maintaining performance and a high level of reproduction quality.
[0020] Another object of the invention is to provide a standard protocol which moreover allows the features mentioned above for remote updating of software.
[0021] The objects are achieved by the fact that the jukebox units contain software for interpretation of the second field of the communications packets which detect the code corresponding to remote updating of the software and after having verified that the software version number is greater than the version installed on the unit, initiates a system status verification procedure to ensure than there is no activity underway on the jukebox. If yes, the unit displays a wait message, during reception of the new software version on the screen, copies the back—up of the software version installed on the unit, modifies the system startup file for startup with the backup version, then begins execution of the new version of the software, verifies the state of system status after execution of this new version, reinitializes the system startup files for startup with the new version. In the case in which the status is not OK, the software reinitializes the system with the old version and signals a reception error to the central server.
[0022] According to another feature, each audiovisual reproduction system contains a multitask operating system which manages, using a primary microprocessor, the video task, the audio task, the telecommunications task, the input task (keyboard, screen, touch) and a status buffer is linked to each of the tasks to represent the activity or inactivity of this task.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Other advantages and features of the invention follow from the following description, with reference to the attached drawings, given by way of a non-limiting example only, in which:
[0024] FIG. 1 shows a circuit diagram of the hardware comprising the invention;
[0025] FIG. 2 shows an organizational chart of the service modules specific to a task and managed via a multitask operating system, the set of modules being included in a library stored in the storage means;
[0026] FIG. 3 shows the organization of the multitask system which manages the set of hardware and software;
[0027] FIG. 4 shows a flowchart describing the operation of the multitask management system;
[0028] FIG. 5 shows a flowchart for verifying task activity;
[0029] FIG. 6 schematically shows the database structure;
[0030] FIG. 7 shows the structure of the packets used in the communications protocol;
[0031] FIG. 8 shows a method of updating the software which can be done using the invention protocol.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] Preferably, but in a nonrestrictive manner, the audiovisual reproduction system uses the aforementioned listed components.
[0033] Microprocessor central unit 1 is a high performance PC-compatible system, the choice for the exemplary embodiment being an Intel 80486 DX/2 system which has storage means and the following characteristics:
compatibility with the local Vesa bus, processor cache memory: 256 kO, RAM of 32 MO high performance parallel and serial ports, SVGA microprocessor graphics adapter, type SCSI/2 bus type controller, battery backed-up static RAM
[0041] Any other central unit with similar, equivalent or superior performance can be used in accordance with the invention.
[0042] This central unit controls and manages audio control circuit ( 5 ), telecommunications control circuit ( 4 ), input control circuit ( 3 ), mass storage control circuit ( 2 ), and display means control circuit ( 6 ). The display means consist essentially of a 14 inch (35.56 cm) flat screen video monitor ( 62 ) without interleaving of the SVGA type, with high resolution and low radiation, which is used for video reproduction (for example, the covers of the albums of the musical selections), graphics or video clips.
[0043] Likewise comprising part of the storage means, storage modules ( 21 ) using hard disks of the high speed and high capacity SCSI type are connected to the storage means already present in the microprocessor device. These modules allow storage of audiovisual data.
[0044] High speed 28.8 k/bps telecommunications modem adapter ( 41 ) is integrated to authorize the connection to the audiovisual data distribution network controlled by a central server.
[0045] To reproduce the audio data of the musical selections, the system includes loudspeakers ( 54 ) which receive the signal from tuner amplifier ( 53 ) connected to electronic circuit ( 5 ) of the music synthesizer type provided to support a large number of input sources, while providing an output with CD (compact disk) type quality, such as for example a microprocessor multimedia audio adapter of the “Sound Blaster” card type SBP32AWE from Creative Labs Inc. on which two buffer memories ( 56 , 57 ) are added for a purpose to be explained below.
[0046] Likewise the control circuit of the display means includes two buffer memories ( 66 , 67 ) for a purpose to be explained below.
[0047] A thermally controlled 240 watt ventilated power supply provides power to the system. This power supply is protected against surges and harmonics.
[0048] The audiovisual reproduction system manages via its input controller circuit ( 3 ) a 14 inch (35.56 cm) touch screen “Intelli Touch” ( 33 ) from Elo Touch Systems Inc. which includes a glass coated board using “advanced surface wave technology” and an AT type bus controller. This touch screen allows, after having displayed on video monitor ( 62 ) or television screen ( 61 ) various selection data used by the customers, management command and control information used by the system manager or owner. It is likewise used for maintenance purposes in combination with external keyboard ( 34 ) which can be connected to the system which has a keyboard connector for this purpose, controlled by a key lock ( 32 ) via interface circuit ( 3 ).
[0049] Input circuit ( 3 ) likewise interfaces with the system a remote control set ( 31 ) composed for example of:
an infrared remote control from Mind Path Technologies Inc., an emitter which has 15 control keys for the microprocessor system and 8 control keys for the projection device. an infrared receiver with serial adapter from Mind Path Technologies Inc.
[0052] A fee payment device ( 35 ) from National Rejectors Inc. is likewise connected to input interface circuit ( 3 ). It is also possible to use any other device which allows receipt of any type of payment by coins, bills, tokens, magnetic chip cards or a combination of means of payment.
[0053] To house the system a chassis or frame of steel with external customizable fittings is also provided.
[0054] Besides these components, wireless microphone ( 55 ) is connected to audio controller ( 5 ); this allows transformation of the latter into a powerful public address system or possibly a karaoke machine. Likewise a wireless loudspeaker system can be used by the system.
[0055] Remote control set ( 31 ) allows the manager, for example from behind the bar, access to and control of various commands such as:
microphone start/stop command, loudspeaker muting command, audio volume control command; command to cancel the musical selection being played.
[0060] The system operating software has been developed around a library of tools and services largely oriented to the audiovisual domain in a multimedia environment. This library advantageously includes an efficient multitask operating system which efficiently authorizes simultaneous execution of multiple fragments of code. This operating software thus allows concurrent execution, in an orderly manner and avoiding any conflict, of operations performed on the display means, audio reproduction means as well as management of the telecommunications lines via the distribution network. In addition, the software has high flexibility.
[0061] The digitized and compressed audiovisual data are stored in storage means ( 21 ).
[0062] Each selection is available according to two digitized formats: hi-fi and CD quality.
[0063] Prior to describing and reading this organization chart in FIG. 2 , it must be noted that while all these modules described separately seem to be used sequentially, in reality the specific tasks of these modules are executed simultaneously in an environment using the multitask operating system. Consequently the organizational chart indicates the specific operations which the module must perform and not a branch toward this module which would invalidate all the operations performed by the other modules.
[0064] The first module, labeled SSM, is the system startup module. This module does only one thing, consequently it is loaded automatically when the system is powered up. If the system is started with a correct registration number it then directly enters the “in service” mode of the module labeled RRM.
[0065] The REG module is the registration mode module which, when it is activated for the first time or when approval for a new registration is necessary, indicates its software serial number and requests that the user enter his coordinates, such as the name of the establishment, address and telephone number.
[0066] The RMM module is the module of the “in service” mode which is the mode of operation which the system enters when its registration number has been validated. In this mode the system is ready to handle any request which can be triggered by various predefined events such as:
customers touching the screen: when a customer or user touches the screen, the system transfers control of the foreground session to the customer browsing and selection mode CBSM module, telecommunications network server call requests: when the system detects a loop on the phone line, it emits an asynchronous background procedure: the telecommunications services mode TSM module, requests concerning key switch ( 32 ): when the manager turns the key switch the system hands over control of its foreground session to the management mode SMM module, reception of a remote control signal: when a command is received, it is processed in a background session by the system command 5MM module while the foreground session remains available for other interventions, appearance of end of timing, showing inactivity of the system: when one of the various timers is activated, control is temporarily handed over to the inactivity routines IPM module for processing.
[0072] The system remains in the “in service” mode until one of the above described events takes place.
[0073] The IRM module is the inactivity routines module. It contains the routines which perform predetermined functions such as album cover display, broadcast of parts of musical pieces present in the system, reproduction of complete selections for internal promotional proposes, audio reproductions for external promotional purposes, spoken promotional announcements of new musical selections, withdrawal to an auxiliary source which can be called when the system is inactive and when a predefined but adjustable time interval corresponding to a timer has expired.
[0074] The SMM module is the system commands module. This module allows execution of functions which command the system to accept a required input by an infrared remote control device, these functions being handled instantaneously without the process underway being stopped. A very large number of these functions are possible, only some are listed below, in a nonrestrictive manner:
audio volume control of the played selections, audio volume control of the auxiliary played source, microphone start/stop command, microphone audio volume control, balance control, left channel, right channel, control of base frequency level, control of treble frequency level, command to cancel or skip a musical selection, panoramic effects command, zoom forward, zoom back, triggering of reset of the software program.
[0085] The MMM module is the management mode module. This module is triggered when the key switch is turned by the manager. The display of an ordinary screen is replaced by a display specific to system management. With this new display the manager can control all the settings which are possible with remote control. He can likewise take control of additional low level commands allowing for example definition of commands to be validated or invalidated on the remote control. He is also able to define a maximum of high and low levels for each system output source, these limits defining the range available on the remote control. Using this screen the manager can access the mode of new selection acquisitions by touching a button located on the touch screen. When the manager has succeeded in defining these commands as well as the system configuration, it is then enough to remove the key and the system returns automatically to the “in service” mode.
[0086] The NSAM module is the new selections acquisition mode module.
[0087] The CBSM module is the customer browsing and selection mode module. Access to this module is triggered from the “in service” when the customer touches the screen. The display allows the user to view a menu provided for powerful browsing assisted by digitized voice messages to guide the user in his choice of musical selections.
[0088] The TSM module is the telecommunications services mode module between the central server and the audiovisual reproduction system. This module allows management of all management services available on the distribution network. All the tasks specific to telecommunications are managed like the background tasks of the system. These tasks always use only the processing time remaining once the system has completed all its foreground tasks. Thus, when the system is busy with one of its higher priority tasks, the telecommunications tasks automatically will try to reduce the limitations on system resources and recover all the microprocessor processing time left available.
[0089] The SSC module is the system security control module. This module manages security, each system is linked to a local controller system according to a preestablished time pattern for acquisition of the approval signal in the form of the registration number authorizing it to operate. In addition, if cheating has been detected or the system cannot communicate via the network, said system automatically stops working.
[0090] The SPMM module allows management of musical selections, songs or video queued by the system for execution in the order of selection.
[0091] Finally, the SMM module allows remote management of system settings by the manager by remote control.
[0092] The multitask operating system comprises the essential component for allowing simultaneous execution of multiple code fragments and for managing priorities between the various tasks which arise.
[0093] This multitask operating system is organized as shown in FIG. 3 around a kernel comprising module ( 11 ) for resolving priorities between tasks, task supervisory module ( 12 ), module ( 13 ) for serialization of the hardware used, and process communications module ( 14 ). Each of the modules communicates with application programming interfaces ( 15 ) and database ( 16 ). There are as many programming interfaces as there are applications. Thus, module ( 15 ) includes first programming interface ( 151 ) for key switch ( 32 ), second programming interface ( 152 ) for remote control ( 31 ), third programming interface ( 153 ) for touch screen ( 33 ), fourth programming interface ( 154 ) for keyboard ( 34 ), fifth programming interface ( 155 ) for payment device ( 35 ), sixth programming interface ( 156 ) for audio control circuit ( 5 ), seventh programming interface ( 157 ) for video control circuit ( 6 ), and last interface ( 158 ) for telecommunications control circuit ( 4 ).
[0094] Five tasks with a decreasing order of priority are managed by the kernel of the operating system, the first ( 76 ) for the video inputs/outputs has the highest priority, the second ( 75 ) of level two relates to audio, the third ( 74 ) of level three to telecommunications, the fourth ( 73 ) of level four to interfaces and the fifth ( 70 ) of level five to management. These orders of priority will be considered by priority resolution module ( 11 ) as and when a task appears and disappears. Thus, as soon as a video task appears, the other tasks underway are suspended, priority is given to this task and all the system resources are assigned to the video task. At the output, video task ( 76 ) is designed to unload the video files of the mass memory ( 21 ) alternately to one of two buffers ( 66 , 67 ), while other buffer ( 67 or 66 ) is used by video controller circuit ( 6 ) to produce the display after data decompression. At the input, video task ( 76 ) is designed to transfer data received in telecommunications buffer ( 46 ) to mass storage ( 21 ). It is the same for audio task ( 75 ) on the one hand at the input between telecommunications buffer ( 46 ), and buffer ( 26 ) of mass memory ( 21 ), and on the other hand at the output between buffer ( 26 ) of mass memory ( 21 ) and one of two buffers ( 56 , 57 ) of audio controller circuit ( 5 ).
[0095] The task scheduler module will now be described in conjunction with FIG. 4 . In the order of priority this module performs first test ( 761 ) to determine if the video task is active. In the case of a negative response it passes to the following test which is second test ( 751 ) to determine if the audio task is still active. In the case of a negative response third test ( 741 ) determines if the communications task is active. After a positive response to one of the tests, at stage ( 131 ) it fills memory access request queue ( 13 ) and at stage ( 132 ) executes this storage request by reading or writing in the mass storage, then loops back to the first test. When the test on communications activity is affirmative, scheduler ( 12 ) performs a test to determine if it is a matter of reading or writing data in the memory. If yes, the read or write request is placed in a queue at stage ( 131 ). In the opposite case, the scheduler determines at stage ( 743 ) if it is transmission or reception and in the case of transmission sends by stage ( 744 ) a block of data to the central server. In the case of reception the scheduler verifies that the kernel buffers are free for access and in the affirmative sends a message to the central server to accept reception of a data block at stage ( 747 ). After receiving a block, error control ( 748 ) of the cyclic redundancy check type (CRC) is executed and the block is rejected at stage ( 740 ) in case of error, or accepted in the opposite case at stage ( 749 ) by sending a corresponding message to the central server indicating that the block bearing a specific number is rejected or accepted, then loops back to the start tests. When there is no higher level task active, at stage ( 731 or 701 ) the scheduler processes interface or management tasks.
[0096] Detection of an active task or ready task is done as shown in FIG. 5 by a test 721 to 761 respectively on each of the respective hardware or software buffers ( 26 ) of the hard disk, ( 36 ) of the interface, ( 46 ) of telecommunications, ( 56 and 57 ) of audio, ( 66 and 67 ) of video which are linked to each of respective controller circuits ( 2 , 3 , 4 , 5 , 6 ) of each of the hardware devices linked to central unit ( 1 ). Test ( 721 ) makes it possible to check if the data are present in the buffer of the disk input and output memory, test ( 731 ) makes it possible to check if the data are present in the buffers of the hardware or software memory buffers of the customer interface device, test ( 741 ) makes it possible to check if the data are present in the buffers of the hardware or software memory of the telecommunications device, test ( 751 ) makes it possible to check if the data are present in the buffer of the hardware or software memory for the direction, test ( 761 ) makes it possible to check if the data are present in the hardware or software memory buffers of the video device. If one or more of these buffers are filled with data, scheduler ( 12 ) positions the respective status buffer or buffers ( 821 ) for the hard disk, ( 831 ) for the interface, ( 841 ) for telecommunications, ( 851 ) for audio, ( 861 ) for video corresponding to the hardware at a logic state illustrative of the activity. In the opposite case the scheduler status buffers are returned at stage ( 800 ) to a value illustrative of inactivity.
[0097] Due, on the one hand, to the task management mode assigning highest priority to the video task, on the other hand, the presence of hardware or software buffers assigned to each of the tasks for temporary storage of data and the presence of status buffers relative to each task, it has been possible to have all these tasks managed by a single central unit with a multitask operating system which allows video display, i.e., moving images compared to a graphic representation in which the data to be processed are less complex. This use of video display can likewise be done without adversely affecting audio processing by the fact that audio controller circuit ( 5 ) includes buffers large enough to store a quantity of compressed data sufficient to allow transfer of video data to one of video buffers ( 66 , 67 ) during audio processing while waiting for the following transfer of audio data.
[0098] Moreover, the multitask operating system which includes a library containing a set of tools and services greatly facilitates operation by virtue of its integration in the storage means and the resulting high flexibility. In particular, for this reason it is possible to create a multimedia environment by simply and efficiently managing audio reproduction, video or graphics display and video animation. In addition, since the audiovisual data are digitized and stored in the storage means, much less space is used than for a traditional audiovisual reproduction system and consequently the congestion of the system according to the invention is clearly less.
[0099] Database ( 16 ) is composed, as shown in FIG. 6 , of several bases: first ( 161 ) with the titles of the audiovisual pieces, second ( 162 ) with the artists, third ( 163 ) with the labels, fourth ( 164 ) with albums, fifth ( 165 ) with royalties. First base ( 161 ) contains first item ( 1611 ) giving the title of the piece, second item ( 1612 ) giving the identification of the product, this identification being unique. Third item ( 1613 ) makes it possible to recognize the category, i.e., jazz, classical, popular, etc. Fourth item ( 1614 ) indicates the date of updating. Fifth item ( 1615 ) indicates the length in seconds for playing the piece.
[0100] Sixth item ( 1616 ) is a link to the royalties base. Seventh item ( 1617 ) is a link to the album. Eighth item ( 1618 ) is a link to the labels. Ninth item ( 1619 ) gives the purchase price for the jukebox manager;
[0101] Tenth item ( 1620 ) gives the cost of royalties for each performance of the piece;
[0102] Eleventh item ( 1610 ) is a link to the artist database, This link is composed of the identity of the artist. The artist database includes, besides the identity of the artist composed of item ( 1621 ), second item ( 1622 ) composed of the name of the artist or name of the group. The label database includes first item ( 1631 ) composed of the identity of the label, establishing the link to eighth item ( 1618 ) of the title database and second item ( 1632 ) composed of the name of the label. The album database contains first item which is the identity of the album ( 1641 ) which constitutes the link to seventh item ( 1617 ) of the title base. Second item ( 1642 ) comprises the title, third item ( 1643 ) is composed of the date of updating of the album, and fourth item ( 1644 ) composed of the label identity. The royalty base is composed of first item ( 1651 ) giving the identity of the royalty and corresponds to sixth item ( 1616 ) of the title base. Second item ( 1652 ) comprises the name of the individual receiving the royalties. Third item ( 1653 ) is composed of the destination address of the royalties. Fourth item ( 1654 ) is composed of the telephone and fifth item ( 1655 ) is composed of the number of a possible fax.
[0103] It is apparent that this database ( 16 ) thus makes it possible for the manager to keep up to date on costs, purchases of songs and royalties to be paid to each of the artists or groups of artists performing the songs or videos, this provided that a communications protocol allows loading of the songs and modification of the content of the database depending on the songs loaded and allows communications with the central server by uploading or downloading the corresponding information. This communication protocol is composed of a first stage during which the center requests communication with the unit to which the communication is addressed. The unit decodes the heading sent by the center and if it recognizes it, indicates to the center if it is available or not depending on the state of its system status determined as explained above. If it is not available the center will then send a new request. If it is available, the center begins to send a first data block and the following blocks in succession. Each of the blocks is composed of a plurality of fields as shown in FIG. 7 . First field ( 810 ) indicates the identification number of the seller; this allows multiple sellers to share a single communications link with the central site. Second field ( 811 ) indicates the application identity and makes it possible to distinguish between a digital song, a digital motion video, a stationary video or an stationary digital graphical image, allows updating of software, transmission of statistics, billing, updating of the database, transmission of surveys. Third field ( 812 ) makes it possible to identify a subtype of application such as the identity number of the product, type of billing, indication of a song in the MIDI standard or a digital song, or finally indication of whether it is the last block of a transmission. The following field ( 813 ) makes it possible to recognize the number of the block assigned sequentially to the block in this transmission. Fourth field ( 814 ) makes it possible to recognize the octet length of each transmission block. Fifth field ( 815 ) makes it possible to recognize variable length data of the transmission and sixth field ( 816 ) contains cyclic redundancy verification information which allows the jukebox to verify that there has not been any error in transmission by recomputing the values of this information from the received data. The data are coded with the identification number of the receiving station, i.e., the number of the jukebox; this prevents another station from receiving this information without having to pay royalties. This is another advantage of the invention because in the processes of the prior art it is not exactly known which stations have received messages and at the outside a cheat could indicate that the information has not been correctly received to avoid having to pay the royalties. Here this operation is impossible since the cheat does not have access to his identification number known solely by the computer and encoding done using this secret identification number makes it possible to prevent cheating and reception by other units not authorized to receive the information. Finally it can be understood that this protocol, by the information which the blocks contain, allows high flexibility of use, especially for transmitting video images or digitized songs, or again to allow updating of software as explained below according to the process in FIG. 8 . In the case of software updating, the central system sends at stage ( 821 ) a first start signal allowing the jukebox for which it is intended to be recognized by its identification number and to indicate to this jukebox the number of the software version. At this stage ( 821 ) the jukebox then performs an initial verification to ensure that the version number is higher than the number of the versions installed and then initiates the process of verification of the system status indicated by stage ( 801 ). This verification process has already been described with reference to FIG. 7 . In the case in which at stage ( 822 ) there is no system activity, at stage ( 823 ) the jukebox initiates display of a waiting message on the display device to prevent a user from interrupting the communication, and during this time receives the data composed of the new software to be installed. At stage ( 824 ) the unit backs up the current version and at stage ( 825 ) the unit modifies the startup file for startup with the backup version. After having completed this modification the unit at stage ( 826 ) applies the software received to the system software and restarts the system software at stage ( 827 ). After having restarted the system, the unit reverifies status ( 801 ) and at stage ( 828 ) determines if the system statuses are valid or not. In the case in which no errors are detected, at stage ( 829 ) the unit updates the startup files with the newly received version and returns to a waiting state. If an error is detected, the unit reinitializes the system at stage ( 830 ). Once installation is completed, the unit awaits occurrence of an event representative of a task in order to handle its tasks as illustrated above.
[0104] Due to the flexibility of the multitask system and its communications protocol, each unit of the jukebox can thus be selected independently of the units connected to the network and can update the databases or the version of the desired song or again the software version without disrupting the operation of the other units of the network and without having to wait specifically for all the units of a network to be available. This is independent of the modems used which can be of the high speed type for a standard telephone line or a specialized modem on a dedicated data link or a SDN modem for fiber optic transmission or again an IRD modem for satellite connection.
[0105] If one or more packets are not received correctly by the jukebox during transmission, it does not interrupt transmission since other jukeboxes can also be in communication. However when communication is stopped by the central server, each jukebox which has had a incident takes a line and signals the numbers of the packets not received to the center. This allows the center to resend them. If registration of one or more songs or videos or part of a song or video has not be done due to lack of enough space on the disk or storage means, the system of each jukebox signals to the manager by a display or audio message the packet number if it is part of a song or a video, or the numbers of the song or video which have not be registered for lack of space. This allows the manager, after having decided to erase certain songs or videos from the hard disk, to again request that the center send these songs or videos or the part not received.
[0106] Any modification by one skilled in the art is likewise part of the invention. Thus, regarding buffers, it should be remembered that they can be present either physically in the circuit to which they are assigned or implemented by software by reserving storage space in the system memory.
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Method for communication between a central server and a computerized juke-box which operates in a conference mode, including: sending a header before any transaction, which includes the identity of the destination together, the identity of the emitter, and the size of the packets; responding from the server in the form of a data packet, each packet sent by the server being encoded using the identification code of the juke-box software; and receiving a data packet by the juke-box, which decodes the packet, simultaneously performs a check on the data received by the CRC method and sends an acknowledgement of receipt to the server indicating the accuracy of the information received, to allow it to prepare and send another packet to the juke-box.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a §371 national stage entry of International Application No. PCT/DE2008/000759, filed May 6, 2008, which claims priority to German Patent Application No. 10 2007 021 494.6, filed May 8, 2007, both of which are hereby incorporated by reference.
BACKGROUND
The invention relates to a device and a process for mechanically grasping and setting down impact-sensitive plates of various formats on a stack arrangement such that they are ready for dispatch.
The production and sale of plates of various materials require special care when large and thin plates are involved. A particularly sensitive material in this respect is glass.
Despite the fact that it is taken for granted ubiquitously, flat glass processed to give window panes or auto glass is one of the most astonishing materials of our time. In contrast to hollow glass, it took several millennia longer until glass makers in the Middle Ages were able to produce flat glass panels that could be used for windows.
The most recent milestone in flat glass production was the development of the so-called float glass method in 1959. The novelty of the float method consists in the so-called “float ribbon”. This consists of molten tin. This tin bath is about 4 to 8 meters wide and up to 60 meters long. In this method, the liquid glass floats on the ideally flat liquid tin. When the glass mass is drawn from the melting furnace onto the tin bath, the tin is at a temperature of 1000° C. At the end of the tin bath, when the now solidified glass ribbon leaves the tin bath, the tin is at a temperature of 600° C. Tin is the only metal which satisfies the conditions required for this method: these are those of already being liquid at 600° C. and still not developing any disturbing vapor pressure at 1000° C.
After the solidified glass ribbon has been divided into the required formats after it has left the tin bath, the glass surfaces obtained in this way have to be stacked in order to be transported further.
DE-AS 1 259 783 discloses a device for depositing glass plates, panels or similar objects and picking them up again, said device having a latticed pivoting frame which uses its support bars to grip between rollers in a roller table when in a horizontal position. This pivoting frame can be pivoted out of its horizontal position about an axis which is placed horizontally on one side to the roller table and is perpendicular to the roller axes of the roller table, and, on the side which faces away from its pivot axis, this frame bears grippers for holding the objects. This device is substantially based on the object of depositing objects from the pivoting frame from a horizontal position on a roller table both in a horizontal position on a box and in a substantially vertical position on a stand laterally next to the roller table.
This object is achieved in DE-AS 1 259 783 in that at least one gripper chuck, which can be pivoted as a whole about an axis parallel to the pivot axis of the frame, is coupled to the pivoting frame as the gripper, the gripper jaws of this chuck being movable symmetrically in opposite directions in order to support the pivoting frame, and in that the pivoting frame has extension supports which are arranged in its plane and in parallel between its support bars and can be extended and retracted toward that side which faces its pivot axis.
Although this known device is also used to set down impact-sensitive plates on a stack arrangement, this process still takes place without the use of a multi-axis robot arm.
DE-AS 17 56 787 discloses a device for shifting glass panels between a conveyor and a bearing block on which the glass panels are stacked in upright fashion, in which essentially one supporting frame, which receives the glass panels to be stacked and has holding heads for the lower side of the glass panels, is arranged on a movable slide, wherein the holding heads can be deposited below the support plane of the glass panels. The object in this case is to provide a device for removing glass panels from stacks, which makes it possible to rapidly shift even fracture-sensitive glass panels, which are stacked on a bearing block, to a conveyor which receives the glass panels horizontally.
This object is achieved in DE-AS 17 56 787 in that the supporting frame is coupled, above its transverse center line, in a freely suspended manner on a frame support arranged on the slide, and a holding device which flexibly holds the supporting frame at a slight inclination counter to the inclination of the stacked glass panels is arranged between the frame support and the supporting frame and, when the holding heads are abutted against, permits a resultant pivoting movement of the frame beyond the perpendicular. Although the supporting frame in this case is likewise freely suspended, the glass plates are transferred substantially from the vertical position into a horizontal position. No gripping device in the form of a multi-axis robot is provided here either.
DE 10 2004 057 228 A1, as the closest prior art, discloses a process and a device for the high-speed stacking of plates, in particular glass plates, guided along a plate conveyor; this is based on the object of making it possible to stack plates of this type more quickly.
SUMMARY OF THE INVENTION
In order to achieve this object, it is claimed in the process as claimed in claim 1 that the respective plate is lifted up slightly from the plate conveyor at a stacking station by producing suction pressure on the upper side of the plate, is then grasped by frictional engagement or in some other way likewise on the upper side of the plate while retaining the suction pressure acting on the upper side of the plate, and is moved away from the plate conveyor to a position above a stacking table where it is deposited on the plate table by releasing the suction pressure and/or by mechanical pressure on the upper side of the plate counter to the action of the suction force, with the stacking table being lowered by the thickness of a plate after each plate has been deposited.
The plate stacks deposited on the stacking table can then be conveyed further by a downstream receiving device in the form of a horizontal conveyor, which has a laterally movable fork with prongs which can be inserted beneath the plate stack in order to receive it, can pick up the stack through interspaces in the stacking table and can then be moved away from the stacking table position.
Another possibility is to design the receiving device with elements for grasping the upper side of the plate stack. A further possibility is to design the receiving device connected downstream of the stacking table in such a way that it removes the respectively stacked plate stack from the stacking table and transfers it to a stacking stand using an upright transfer robot, wherein the transfer robot has a gripper mechanism which grips the plate stack in the region of its upper edge. The latter type of mounting offers the best options for transporting the plate stacks to further-processing customers since it makes it possible to access plate stacks of various formats. However, an increase in productivity requires the turnover time to be shortened and a simultaneous desirable reduction in the fracture rate.
In this known stacking device, a control device in the form of a multi-axis robot arm has a gripping device and means for mechanically gripping the plates.
The device from DE 10 2004 057 228 A1 does not have a special embodiment of this gripping device.
The present patent application is based on the object of specifying a device and a process which make it possible to optimally stack impact-sensitive plates.
Multi-axis robot gripping arms are used in a very wide variety of technical fields where they serve, equipped with the widest variety of gripping tools and functional tools, for automatically carrying out the respective work.
In order to achieve the object on which it is based, the device is equipped, via a special gripping device in conjunction with a robot arm, with the following functional units:
a) an integrated displacement slide, b) specially adjustable clamping jaws, c) a pneumatically adjustable pressure finger, d) special position sensors, and e) a special control program.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in more detail with reference to the following figures. In detail:
FIG. 1 : shows a cross section of the constituent parts of the gripping device,
FIG. 2 : shows some characteristic gripping processes,
FIG. 3 : shows the pivoting cylinders for the clamping jaws,
FIG. 4 : shows the cross section of a clamping jaw,
FIG. 5 : shows a plan view of the displacement unit of the clamping jaws,
FIG. 6 : shows a sectional drawing of details of the displacement unit, and
FIG. 7 : shows the function on the production line.
DETAILED DESCRIPTION
FIG. 1 shows a cross section, as seen from the side of the left-hand clamping jaw ( 7 ), of parts of the gripping device.
The chassis ( 1 ) of the gripping device of the device is connected via the flange ( 2 ) to a multi-axis robot arm, which is not shown here but can be seen in the overall view from FIG. 7 .
The tilting plate ( 8 ) is connected to the flange ( 2 ) via a stable axis of rotation D shown in cross section, in FIG. 1 , in the form of two concentric circles and can be tilted in relation to the flange ( 2 ) via this axis of rotation. This tilting operation is carried out via the control of the tilting cylinders ( 9 ) which are assigned in terms of position to a respective clamping jaw ( 3 ) and ( 4 ).
The stack, which is to be grasped, of the plates to be conveyed is clamped via the clamping jaw bar ( 7 ) between the clamping jaw ( 3 ), which is on the left-hand side in the case shown, and the clamping jaw support ( 5 ) thereof. The force to be used for this purpose is applied via the working cylinder ( 12 ). The position of the associated right-hand clamping jaw ( 4 ) can be seen from the perspective illustration in FIG. 3 . This right-hand clamping jaw ( 4 ) has a dedicated further working cylinder ( 12 ).
The hydraulically actuated pressure finger ( 6 ), which may also be provided in multiple numbers, stabilizes the position of the plates clamped in the clamping jaws ( 3 ) and ( 4 ). This is particularly important in the case of large plates and is explained in more detail in the statements relating to FIG. 2 .
The integrated displacement slides ( 10 ) constitute one constituent part of the device. The entire gripper is fastened inclined at a slight angle of incidence, that is to say suspended slightly forward, in relation to the plane of the robot flange ( 2 ) via these displacement slides ( 10 ) which are assigned separately to each clamping jaw. This design measure affords two essential advantages.
Firstly, this measure provides protection against collision since, in the event of an unintended collision, the entire chassis ( 1 ) can recede in a specific region in relation to a specific position of the robot arm and simultaneously rotate about the above-mentioned stable axis of rotation D. For this purpose, it is merely necessary to displace the displacement slides ( 10 ) against an adjustable spring force and overcome the counterforce built up by the tilting cylinders ( 9 ).
Secondly, this measure makes possible the positionally accurate and gentle movement of the plate stack in the gripper onto stacks which have already been set down. As a result of this, firstly the stacks are not pressed against one another and destroyed by unintentionally high setting forces and secondly the stacks can be stacked behind one another without an undesirable interspace.
The characteristic gripping processes shown in FIG. 2 are preceded by the device being guided along a glass stack ( 13 ). For this purpose, the slides ( 10 ) are unlocked pneumatically such that the entire gripper is held in its front position which is predefined by the design-induced inclination of the flange ( 2 ) and is stabilized via the force of gravity. The clamping jaws ( 3 ) and ( 4 ) are then rotated upward and the gripper is moved toward the glass stack ( 13 ) to be transported.
If the gripper then comes into contact with the set-down glass stack ( 13 ) as it is guided along, this pushes the gripper, or the clamping jaw supports ( 5 ), to the rear counter to the direction of movement until the robot movement is stopped and the position reached is stored.
The clamping jaws ( 3 ) and ( 4 ) are rotated downward, the glass stack ( 13 ) is clamped in and the thickness of the glass stack ( 13 ) is determined via the distance achieved between the clamping jaws and the clamping jaw support ( FIG. 2 a ). After the plates to be transported have been guided along to the vicinity of the final set-down position, these are deposited virtually without any impact.
For this purpose, after the collet chucks ( 3 ) and ( 4 ) have been loosened, the gripping device is moved back by a specific distance in the direction which leads away from the positioning location, and the glass stack ( 13 ) is thereby tilted by a small angle by the collet chucks. The respective distance over which the gripping device moves back depends on the previously determined thickness of the glass stack ( 13 ) and is predefined by program technology ( FIG. 2 b )
In order to prevent the inclined glass stack ( 13 ) from fanning out, one or more pressure fingers ( 6 ) are moved on 2 to the lower parts of the surface of the respective glass stack ( 13 ). At the same time, the gripper is pivoted such that the clamping jaws ( 3 ) and ( 4 ) are aligned parallel to the surface of the inclined glass stack ( 13 ) ( FIG. 2 c ). As a consequence, the glass stack ( 13 ) is grasped by the clamping jaws ( 3 ) and ( 4 ) with a specific contact pressure and positioned on the bottom edge of the rear wall of the positioning container together with a pressure finger ( 6 ). The corresponding positional coordinates were determined beforehand ( FIG. 2 c ).
The clamping jaws are then pivoted upward out of the positioning region and the glass stack ( 13 ) is pressed into the end position by the clamping jaw supports ( 5 ) ( FIG. 2 e ). This process ensures that the glass plates rest on one another as tightly as possible.
FIG. 3 shows the clamping jaws ( 3 ) and ( 4 ) with their respective pivoting device. The pivoting cylinder ( 14 ) is set up for the pivoting operation of the right-hand clamping jaw ( 4 ) and the pivoting cylinder ( 15 ) is set up for pivoting the left-hand clamping jaw ( 3 ). The perspective view also shows the holder ( 20 ) of the pivoting cylinder ( 15 ) and part of the chassis ( 1 ).
FIG. 4 shows the functional elements which are operatively connected to a clamping jaw. Here, the working cylinder ( 12 ) uses the piston rod ( 17 ) to move the relevant clamping jaw ( 3 ) or ( 4 ), forward or backward as required. The thickness of the glass stack ( 13 ) which is grasped between the respective clamping jaw and the relevant clamping jaw support ( 5 ) is detected by the thickness measuring device ( 16 ) and processed further by data technology.
The clamping jaw supports ( 5 ) can be coated with a coating layer ( 31 ). The coating layer ( 31 ) can include a composite of cellular rubber, or a material with similar elasticity behavior, and a plastic, wherein the coating layer ( 31 ) represents the surface which makes direct contact with the plates 13 .
FIG. 5 shows a plan view of the displacement slides ( 22 ) assigned to each clamping jaw. In the illustration on the left, the spacing between the two displacement slides ( 22 ) is small, and the illustration on the right shows a correspondingly larger gripping region of the clamping jaws ( 3 ) and ( 4 ). This illustration also shows the respective working cylinders ( 12 ) assigned to the clamping jaws. Both the displacement slides ( 22 ) are guided on the cross piece ( 21 ) for the displacement device over the displacement rail ( 23 ). The position of the displacement slides ( 22 ) is fixed via the respective locking system ( 18 ). Both the illustration on the left and that on the right of FIG. 5 show “cut-away detailed drawings” in the region of the locking systems ( 18 ). One of these locking systems can be seen in the side view of FIG. 6 .
Here, the use of an unlocking finger ( 24 ) causes the spring-loaded locking of the respective displacement slide, ( 22 ) to be, released and, in conjunction with a corresponding horizontal movement of the robot ( 29 ), causes the displacement slide to be moved to the desired location. For this purpose, the gripper has to move in a static conversion device and adjust the width of the clamping jaws one after another. The position of the respective displacement slide ( 22 ) which is reached in this way is fixed by removing the unlocking finger ( 24 ). The position sensors ( 19 ) register the position of the displacement slides ( 22 ) and thus represent the basis for detecting the position thereof by data technology. The sensors ( 19 ) can be ultrasonic sensors and/or sensors on the basis of electromagnetic processes and/or sensors that operate with electromagnetic waves.
FIG. 6 shows a side view of details of the mechanism for displacing the clamping jaws. This additionally shows the robot arm ( 25 ).
FIG. 7 shows the position of the device in association with the entire production line. The aligning unit ( 26 ), which is used to align the individual plate formats, is followed by the stacking unit ( 27 ) and the transfer unit ( 28 ), from which the glass stacks to be aligned for transport are picked up. The robot ( 29 ) can then distribute the glass stacks onto different stacking stands ( 30 ).
Since the upper side with which the individual glass plates are positioned on the respective stacking stand ( 30 ) may play an important role for the further processing of these plates, the robot ( 29 ) may grip the plates positioned on the transfer unit ( 28 ) from the front side or the rear side. This is because, since each glass plate is produced on a liquid tin bath, it has a so-called bath side and a so-called air side. It is usually only possible to use the air side for any type of subsequent coating.
The gripper can be held so tightly that the glass stacks can be gripped and additionally also rotated in three different ways, specifically from above and from each side, which results in a total of six different ways of accessing the glass stacks.
If a specific orientation of glass plates is additionally required, this can be taken into account by the robot ( 29 ) by means of corresponding rotation through 90 degrees on the vertical.
In order to save weight, the gripping device may be composed of lightweight materials such as, for example, aluminum, GFP or titanium. The weight saved in this way can consequently be invested in an electromechanical displacement device of the slides ( 22 ). This makes it possible to adjust the width of the clamping jaws required in each case more quickly.
Two devices according to the solution can also be used for grasping various plate formats more quickly, one such device preferably being set up for grasping larger stacks and the other, by contrast, being set up for grasping smaller plates.
The computer program with a program code for carrying out the process, and a machine-readable storage medium for storing the computer program with the corresponding program code, likewise form part of the solution.
LIST OF REFERENCE NUMERALS
( 1 ) Chassis
( 2 ) Flange for robot arm
( 3 ) Left-hand clamping jaw
( 4 ) Right-hand clamping jaw
( 5 ) Clamping jaw support
( 6 ) Pressure finger
( 7 ) Clamping jaw bar
( 8 ) Tilting plate
( 9 ) Tilting cylinder
( 10 ) Displacement slide
( 11 ) Rail
( 12 ) Working cylinder for clamping jaws
( 13 ) Glass stack
( 14 ) Right-hand pivoting cylinder for clamping jaws
( 15 ) Left-hand pivoting cylinder for clamping jaws
( 16 ) Thickness measuring device
( 17 ) Piston rod of a working cylinder
( 18 ) Locking system
( 19 ) Position sensors
( 20 ) Holder of a pivoting cylinder
( 21 ) Cross piece for the displacement device
( 22 ) Displacement slide
( 23 ) Displacement rail
( 24 ) Unlocking finger
( 25 ) Robot arm, control device
( 26 ) Aligning unit
( 27 ) Stacking unit
( 28 ) Transfer unit
( 29 ) Robot
( 30 ) Stacking stand
( 31 ) Coating layer
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A device, method and computer readable-storage for mechanically handling impact-sensitive sheets of various formats ready for dispatch is described. The device has the following features: a) a control device in the form of a multi-axis robotic arm connected to a gripper device and means for mechanically gripping the sheets; b) the gripper device is hinged onto and suspended from the control device at a gentle incline by means of an adjustable damping device; c) the gripper device has sliding sections for the relative displacement of the means for mechanically gripping the sheets; d) the gripper device has means for determining the geometric dimensions of the sheets to be seized and for determining their set-down position; e) the gripper device has means for determining the exact positional co-ordinates of the set-down position; and f) the gripper device has means for gently feeding and depositing the sheets in the set-down position.
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BACKGROUND OF THE INVENTION
This invention relates to a roller blind box, the side walls of which carry face walls, which are inserted into the side walls, interconnecting same, which support a roller blind shaft and are connected via detachably carried guide members to the roller blind guides.
In a prior art roller blind box of this type, the face walls are made double-walled, and the partial wall facing the interior of the roller blind box is opened. Thus, for an assembly of the roller blind box of prefabricated parts, four longitudinal walls and two face walls are required differing from one another in their structures. Considerable storage space is consequently required.
An object of the present invention is to improve the prior art roller blind boxes so that only a single face wall is required which is shaped in such a way that it cannot only be used for each of the two sides, but in addition thereto also in such a way that the roller blind box may be used for left-hand or right-hand rolling.
SUMMARY OF THE INVENTION
According to the invention, it is provided that each face wall is formed symmetrical with respect to a vertical plane passing through the axis of the roller blind shaft, the vertical plane being perpendicular to this axis, and that at each of the two lower corners of each face wall there is an insertion opening for receiving a guide member.
In this way, the face wall formed in this fashion may be used both as a left-hand and as a right-hand termination wall for the roller blind box without additional passages having to be provided or breakouts having to be made.
For a face wall which carries a push-in guide inwardly displaced by the wall thickness of the longitudinal walls, the push-in guide in furtherance of the invention may include four strips formed integrally with the face wall, the widths of which are in excess of that of a roller blind belt. The strip adjacent to the lower longitudinal wall preferably has breakouts in the corner regions defining the insertion openings. Thereby, it is permitted to provide at the inner surface of the face wall a drive for the roller blind shaft which includes either belt wrapping pulleys or a cone drive.
The insertion openings are preferably formed polygonal and merge into an insertion channel closed at the end in order to be able to connect the guide members which represent the connection between the face walls and the lateral roller blind guides to the face wall in the proper position.
Since the gearing rods leading to the bevel wheel drives for the roller blind shaft must have different exit openings for right-hand and left-hand rollers, recesses are provided in the lower strip and in the lateral strips adjacent to the insertion guides and above thereof, the recesses permitting a passage of a gearing rod.
When, instead of a bevel gear, drive belt pulleys are used for the operation of the roller blind shaft, the lateral strips are provided with recesses in the vicinity of their upper ends, preferably, said recesses permitting the passage of a roller blind belt.
In order to be able to connect the guide members non-rotatably to the face walls, each guide member includes an insertion arbor formed according to the cross-section of the insertion opening and an inlet funnel laterally adjacent to the outer end thereof.
In order to be able to assemble the inlet funnel in alignment with the roller blind guide, tabs preferably project from the side of the inlet funnel remote from the insertion arbor, these tabs being insertible into a roller blind guide.
In order to prevent a lateral displacement of the individual sections defining the roller blind assembly and in order to prevent an intrusion of outside atmosphere via the part of the inner space of the roller blind box receiving the roller blind assembly into a living space, the face walls are each covered by a plate. Since these must have a passage opening for the roller blind shaft, outside atmosphere is nevertheless able to intrude into the living space through the annular gap about the shaft. In order to avoid this, the roller blind shaft has a cylindrical end portion, and the annular gap between this end portion and the edge of the passage opening is closed by a seal.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of a roller blind box according to the present invention has been illustrated in the accompanying drawings, wherein:
FIG. 1 is a horizontal longitudinal sectional view of the roller blind box;
FIG. 2 is a perspective illustration of the face wall illustrated at the left hand of the drawings, the covering plate being broken away;
FIG. 3 is a partial view illustrated partially broken away, as viewed from the plane designed by section line III--III of FIG. 1, however, with the covering plate being omitted;
FIG. 4 is a sectional view taken along section line IV--IV of FIG. 3, the covering plate being illustrated, however;
FIG. 5 is a cross-sectional view of the roller blind box; and
FIGS. 6, 7, 8 and 9 are examples of the roller blind box associated with window openings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The roller blind box has four longitudinal walls 1a, b, c, d and includes two face walls 2 and 3. The face walls 2 and 3 are pushed into the channel-like roller blind box defined by the longitudinal walls 1a, b, c, d from both sides. They thereby rigidify the roller blind box and serve to connect the longitudinal walls 1a, b, c, d to one another. For a rigidification of the roller blind box, each face wall 2 or 3 carries strips 4, 5, 6, and 7 projecting from the edge in a spacing corresponding to the thickness of the longitudinal walls. In the middle of each face wall, a rotary spigot 8 for the roller blind shaft directed in the same direction as the strips 4,5,6,7 is firmly connected to the face walls 2, 3.
The strip 6 adjacent to the lower longitudinal wall carries reinforcements 9, 10 at both corners, in which insertion openings 11, 12 are provided. These openings receive an insertion arbor of a guide member 13 which serves to connect the face walls 2, 3 to a roller blind guide. In FIG. 2 of the drawings, such a guide member 13 has been illustrated which is inserted into the insertion opening 11 positioned at the top in FIG. 1 of the drawings.
As shown in FIG. 1, the lower longitudinal wall 1d of the roller blind box has a slit 14 at this location for the passage of the roller blind assembly.
A covering plate P is respectively applied to the face walls 2 and 3, this covering plate dividing the interior space of the roller blind box in communication with outside atmosphere from the interior of the face walls 2 or 3. Since the roller blind shaft extends through the covering plate P, a passage opening 34 is provided therein. In order to prevent the outside atmosphere from entering and contacting the interior of the face walls 2 or 3 from the interior of the roller blind box, the end portion 35 of the roller blind shaft W is formed cylindrical, and the annular gap between this end portion and the edge of the passage opening 34 is closed by a seal 36.
As will be noted from FIGS. 3 and 4, the guide member 13 includes an insertion arbor 15 introducable into an insertion opening 11 or 12 and an inlet funnel 16, which, as will be noted from FIG. 2, projects from the face wall 2. From the side of the inlet funnel 16 remote from the insertion arbor 15, two tabs 17 project which serve to aligningly introduce the guide member 13 into a roller blind guide. The inlet funnel is, as will be noted from FIG. 3, formed tapered toward the roller blind guide, so that the individual strips of the roller blind are reliably fed to the slit 14 when rolling off the roll.
In FIG. 5 of the drawings, a cross section of an assembled roller blind box has been illustrated. The roller blind box is connected with its lower longitudinal wall to the top portion of a window frame 18. At the left hand side of the window frame, as viewed in the drawing, the roller blind guide 19 is connected thereto. The face wall 3 carries a bevel-wheel drive 20 on the bearing spigot 8, which is connected to the face wall 3 by means of screws 21. A two-piece gear rod 22 leads to the bevel-wheel drive, the parts of said rod being connected to one another by a universal joint 23. In this use of the roller blind box, the slit 14 aligned with the roller blind guide 19 is disposed at the left-hand side of the lower longitudinal wall. For this reason, the guide member 13 has been pushed into the insertion opening 12 positioned at the lower left hand in FIG. 5 of the drawings. The tabs 17 project into the upper portion of the roller blind guide 19. In this embodiment, the window frame and the roller blind box connected thereto are placed as a complete structural unit into a window opening and are secured therein. After anchoring and applying the lintting 24, the entire built-in unit is firmly connected to the wall.
In FIG. 6 of the drawings, it has been illustrated how such a unit is placed into a window opening. The roller blind is in this instance used as left-hand roller, and the roller blind shaft is driven via a gear rod 22.
In FIG. 7 of the drawings, as a first example a later buit-in roller blind has been illustrated; it may be assembled as a unit into the window opening in front of the window frame. The two later roller blind guides 19 are thereafter pushed inclined onto the tabs 17 of the guide members 13, moved to the window opening and secured thereto. In this built-in example, the roller blind shaft is driven by a roller blind belt 25 which passes through the top portion of the window frame 18. The roller blind assembly in this instance also is a right-hand roller.
In FIG. 8, the roller blind is assembled as a left-hand roller, so that the roller blind guide 19 directly rests on the outer surface of the window frame 18. Here also the roller blind shaft is driven by a belt 25 which extends through an according opening in the window frame.
In FIG. 9 of the drawings, an assembly situation has been illustrated in which the roller blind box is applied to the outer surface of the masonry. Here also the roller blind is defined as a left-hand roller, and the roller blind guide 19 rests on the outer surface of the masonry. The belt 25 driving the roller blind shaft extends through a breakout of the masonry.
In order to suffice all requirements of practice, the strips 4, 5, 6, 7 of the face wall are provided with all exit openings for the various drive parts of the roller blind shaft occurring in the possible examples of use. The two lateral strips 5 and 7 have recesses 26 and 27 above the reinforcements 9 and 10. So that selectively a gear rod 22 or a belt 25 may be used, the size of the recesses 26, 27 is selected such that a gear rod 22 is able to pass with clearance.
The strip 6 adjacent to the lower longitudinal wall next to the reinforcements 9 and 10 has recesses 28, 29 corresponding to the recesses 26 and 27, in order to also be able to use gear shafts 22 according to the uses of the roller blind box illustrated in FIGS. 5 and 6. When the roller blind box, as illustrated in FIG. 7, is used, when thus the roller blind shaft is driven by means of a belt 25 and the roller blind is formed as a right-hand roller, the belt 25 extends in the vicinity of the strip 4 and passes through the breakouts in the vicinity of the upper corners of the strips 5 and 6. For this reason, recesses 30, 31 are provided in the strips 5 and 7 in the vicinity of the upper corners of the face wall, said recesses just being so wide that a belt 25 is able to pass through with clearance.
In order to prevent that the belt is damaged at sharp inner edges of the recesses 26 to 31, the inner edges of all recesses are provided with rim beads 32. The free edge portion of each face wall disposed outside of the strips 4, 5, 6 and 7 has coextensive thereto fastener openings 33. Through these fastener openings 33, fastener elements may be introduced up to in the faces of the longitudinal walls, in order to connect all structural parts of the roller blind box into a rigid unit.
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A roller blind box includes four longitudinal walls and two face walls interconnecting the longitudinal walls. The face walls support a roller blind shaft and are connected via detachably carried guide members to the lateral roller blind guides. Each face wall is formed symmetrical in relationship to a vertical plane passing through the axis of the roller blind shaft. At each of the lower corners of each face wall there is an insertion opening for receiving a respective guide member.
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RELATED APPLICATION
[0001] This application is a continuation-in-part application of U.S. patent application Ser. No. 11/762,497 filed Jun. 13, 2007, for all commonly disclosed subject matter. U.S. application Ser. No. 11/762,497 is expressly incorporated herein by reference in its entirety to form part of the present disclosure.
FIELD OF THE INVENTION
[0002] This invention relates to carrying cases, and, more particularly, to carrying cases with a double throw, triple action latch mechanism having a locking feature which substantially prevents inadvertent opening of the latch mechanism.
BACKGROUND OF THE INVENTION
[0003] Carrying cases typically include a top case shell and a bottom case shell pivotally connected by a hinge. The two shells are maintained in a closed position by one or more latch mechanisms located along the front and/or the sides of the case. A variety of latch mechanisms have been employed in the past, such as single throw and double throw latches, some of which may be locked with combination locks or key locks.
[0004] Carrying cases intended for the transport of valuable items, and items which are relatively fragile, are preferably rugged in construction and not subject to inadvertent opening. While combination locks or key locks may reduce the incidence of inadvertent opening of a case, such features are more suitable for cases intended for use by one individual, e.g. brief cases and the like. If a carrying case may be used by several people, it is difficult to convey the combination of a lock to a group, whose members may change, and keys are easily lost. Further, security requirements at airports do not permit locking of cases or luggage, and such cases may be inadvertently opened by baggage handlers. There is therefore a need for a carrying case having a rugged construction with a locking feature which substantially prevents inadvertent opening of the case without the use of combination locks, key locks or the like.
SUMMARY OF THE INVENTION
[0005] This invention is directed to a carrying case with a latch mechanism having a locking feature which prevents inadvertent opening of the case.
[0006] In the presently preferred embodiment, the carrying case of this invention includes a top case shell and a bottom case shell pivotally connected by a hinge. A double throw, triple action latch mechanism maintains the case shells in the closed position. The latch mechanism comprises a latch body pivotally mounted to the bottom case shell, a latch locking element pivotally mounted to the latch body and a latch release coupled to the latch body. With the case in the closed position, the latch locking element engages a seat formed in the top case shell and clamps the two shells together. In response to pivotal motion of the latch body, the latch locking element may be disengaged from the top shell allowing the case to be opened.
[0007] The purpose of the latch release is to prevent inadvertent pivotal motion of the latch body, which, in turn, would allow the latch locking element to disengage the top case shell. As described in detail below, the latch release is movable between a locked position and a release position. In the locked position, the latch release engages the front wall of the bottom case shell and prevents pivotal motion of the latch body. In turn, the latch locking element is maintained in position against the seat of the top case shell thus retaining the case in the closed position. Upon movement of the latch release to the release position, the latch body is free to pivot thus allowing the latch locking element to disengage from the top case shell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The structure, operation and advantages of the presently preferred embodiment of this invention will become further apparent upon consideration of the following description, taken in conjunction with the accompanying drawings, wherein:
[0009] FIG. 1 is perspective view of the carrying case with the latch mechanism of this invention;
[0010] FIG. 2 is an exploded, disassembled perspective view of the components forming the latch mechanism herein;
[0011] FIG. 3 is view similar to FIG. 2 , except viewing the latch mechanism from the front;
[0012] FIG. 4 is an assembled, rear perspective view of the latch mechanism;
[0013] FIG. 5 is a view similar to FIG. 4 , except viewing the assembled latch mechanism from the front;
[0014] FIG. 6 is a cross sectional view of the latch mechanism mounted to the carrying case with the case closed and the latch release in the locked position;
[0015] FIG. 7 is a view similar to FIG. 6 except with the latch release moved to the release position;
[0016] FIG. 8 is a view similar to FIG. 6 except with the latch release pivoted relative to the bottom shell of the case;
[0017] FIG. 9 is view similar to FIG. 8 except with the latch locking member disengaged from the seat formed in the top case shell;
[0018] FIG. 10 is a perspective view of an alternative embodiment of the latch release of this invention;
[0019] FIG. 11 is a view similar to FIG. 4 except depicting the latch body connected to the embodiment of the latch release shown in FIG. 10 ;
[0020] FIG. 12 is a view similar to FIG. 6 , except with the latch release of FIG. 10 ;
[0021] FIG. 13 is a view similar to FIG. 7 , except with the latch release of FIG. 10 ;
[0022] FIG. 14 is a view similar to FIG. 8 , except with the latch release of FIG. 10 ; and
[0023] FIG. 15 is a view similar to FIG. 9 , except with the latch release of FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring initially to FIGS. 1 and 6 , a carrying case 10 is depicted having a top case shell 12 pivotally connected to a bottom case shell 14 . Two latch mechanisms 16 and 18 are located along the front wall 20 of shell 12 and front wall 22 of shell 14 on either side of a handle 24 . As best shown in FIG. 6 , the front wall 20 of top case shell 12 is formed with a seat 26 and a downwardly facing slot 28 which receives the upper edge 30 of the front wall 22 of bottom case shell 14 when the case 10 is closed. The front wall 22 of the bottom case shell 14 is formed with a ledge 32 , for purposes to become apparent below. Except as noted above, the detailed construction of the case 10 forms no part of this invention and is not described herein. Additionally, for purposes of the present discussion, the terms “top,” “bottom,” “upper,” “lower,” “downwardly,” “upwardly” and the like refer to the vertical orientation of the case as it is depicted in the Figs.
[0025] With reference to FIGS. 2-5 , the latch mechanism 16 of this invention is shown in detail. It should be understood that the two latch mechanisms 16 , 18 are identical to one another, and therefore only the latch mechanism 16 is discussed herein. The latch mechanism 16 comprises a latch body 34 , a latch locking element 36 and a latch release 38 . The latch body 34 includes a top wall 39 , a front wall 40 , and, a cavity 42 defined by spaced inner side walls 44 and 46 , a bottom wall 48 and a portion of the top wall 39 . An outer side wall 50 is spaced from the inner side wall 44 and an outer side wall 52 is spaced from the other, inner side wall 46 forming a bearing surface 54 between the side walls 44 and 50 and a bearing surface 56 between the side walls 46 and 52 . As best seen in FIG. 3 , the front wall 40 of latch body 34 is formed with a window 58 to provide access to the latch release 38 , as described below. Aligning bores 60 and 62 are formed in the inner side walls 44 and 46 , respectively. Additionally, a bore 64 is formed in each of the inner and outer walls 44 , 50 which aligns with a bore 66 formed in the inner and outer walls 46 and 52 .
[0026] The latch locking element 36 comprises a front wall 68 , spaced pivot arms 70 and 72 and a hook element 74 . The pivot arm 70 is formed by an outer side plate 76 and an inner side plate 78 . Similarly, the pivot arm 72 is formed by an outer side plate 80 and an inner side plate 82 . A cross brace 84 spans the inner side plates 78 and 82 . The front wall 68 has an opening 86 , and the two pivot arms 70 , 72 are formed with a through bore 88 , 90 , respectively.
[0027] The latch release 38 is sized and shaped to fit within the cavity 42 formed in the latch body 34 . It includes a front wall 92 , a back wall 94 , a top wall 96 and a bottom wall 98 which are interconnected and collectively form a hollow interior within which a sleeve 102 is mounted. A button 100 extends from the bottom wall 98 through an opening 101 in the front wall 92 . The top wall 96 has a recess 104 and an upwardly extending locking member 106 with a tapered top surface. As best seen in FIGS. 6-9 , a cylindrical-shaped projection 110 is mounted to the underside of the bottom wall 98 . The projection 110 is located within an opening 112 defined by the lower ends of the front wall 92 and back wall 94 which extend beyond the bottom wall 98 . A coil spring 114 encircles the projection 110 and seats within a spring holder 115 .
[0028] The latch mechanism 16 is assembled by first inserting the latch release 38 within the cavity 42 of the latch body 34 . The lower ends of the front and back walls 92 , 94 of the latch release 38 , and the holder 115 , rest atop the bottom wall 48 of the latch body 34 . The latch locking element 36 is then placed on the latch body 34 so that the pivot arm 70 rests atop the bearing surface 56 of the latch body 34 , and the pivot arm 72 engages the bearing surface 54 . With the latch locking element 36 and the latch release 38 in this position, a latch assembly pin 116 may be inserted through the bore 88 of pivot arm 70 , through the bore 62 in the inner side wall 46 of the latch body 34 , into the sleeve 102 of the latch release 38 , through the bore 60 in the inner side wall 44 of latch body 34 and then into the bore 90 of pivot arm 72 . This secures both the latch locking element 36 and the latch release 38 to the latch body 34 , as depicted in FIGS. 4 and 5 . The assembled latch mechanism 16 is pivotally connected to the bottom case shell 14 of the case 10 by a case mounting pin 118 which extends through the aligning bores 64 and 66 formed in the latch body 34 .
Operation of Latch Mechanism of FIGS. 1-5
[0029] Referring now to FIGS. 6-9 , the operation of the latch mechanism 16 of this invention is illustrated. In FIG. 6 , the latch mechanism is shown in a locked position with the hook element 74 of the latch locking element 36 in engagement with the seat 26 in the front wall 20 of the top case shell 12 and the locking member 106 of the latch release 38 contacting the ledge 32 in the front wall 22 of the bottom case shell 14 . The hook element 74 cannot disengage the seat 26 unless the latch body 34 is pivoted in a clockwise direction relative to the front wall 22 of the bottom case shell 14 , as seen in FIGS. 8 and 9 . If one pulls on the tab 120 formed by the downwardly extending end of the front wall 40 of latch body 34 , with the latch mechanism 16 in the position shown in FIG. 6 , the locking member 106 of the latch release 38 bears against the ledge 32 of the bottom case shell 14 , thus preventing such clockwise pivotal motion.
[0030] The latch release 38 is maintained in the locked position by operation of the spring 114 . As seen in FIG. 6 , the spring 114 urges the latch release 38 in an upward direction so that the locking member 106 bears against the ledge 32 . At the same time, the case mounting pin 118 is received within the recess 104 in the top wall 96 of the latch release 38 , and the latch assembly pin 116 is located at the bottom of the sleeve 102 carried by the latch release 38 .
[0031] In order to allow pivotal movement of the latch body 34 , and, in turn, permit disengagement of the hook element 74 of the latch locking element 36 from the seat 26 in the top case shell 12 , the latch release 38 must be moved to a release position shown in FIG. 7 . One may insert his or her finger through the window 58 in the front wall 40 of the latch body 34 and into contact with the button 100 extending through the opening 101 in the front wall 92 of the latch release 38 . The latch release 38 is then pushed downwardly, against the force exerted by the spring 114 , to a release position wherein the locking member 106 formed in the top wall 96 of the latch release 38 disengages the ledge 32 in the front wall 22 of the bottom case shell 14 . The user is provided with an indication of the release position because the latch assembly pin 116 will contact the upper end of the sleeve 102 in the latch release 38 when the latch release 38 is pushed downwardly to the release position.
[0032] With the latch release 38 in the release position, the latch body 34 may be pivoted in a clockwise direction about the case mounting pin 118 by grasping the tab 120 at the bottom of the latch body 34 and pulling outwardly relative to the bottom case shell 14 , as illustrated in FIG. 8 . Such motion is the first “throw” of the latch mechanism 16 . With the latch body 34 in the position depicted in FIG. 8 , the hook element 74 of the latch locking element 36 can begin to disengage from the seat 26 . When the hook element 74 assumes the position shown in FIG. 8 , the latch body 34 may then be pivoted in the opposite, counterclockwise direction, e.g. the second “throw” of the latch mechanism 16 , so that the hook element 74 may completely disengage the seat 26 as shown in FIG. 9 . The top and bottom case shells 12 , 14 may then be opened.
[0033] Closure of the latch mechanism 16 is accomplished by reversing the steps noted above. The latch body 34 is initially pivoted in the clockwise direction to allow the hook member 74 of the latch locking element 36 to assume the position relative to the seat 26 shown in FIG. 8 . The latch body 34 may then be pivoted in the counterclockwise direction so that it rests along the front wall 22 of the bottom case shell 14 as depicted in FIGS. 6 and 7 . The spring 114 urges the locking member 106 of latch release 38 to the locked position, and the case 10 is now locked in such a way that inadvertent contact with the latch body 34 cannot cause the latch mechanism 16 to open without first moving the latch release 38 to the release position.
Latch Mechanism of FIGS. 10-15
[0034] Referring now to FIGS. 10-15 , an alternative embodiment of a latch mechanism 130 according to this invention is illustrated. It may be desirable in some applications to provide additional security against inadvertent opening of the case 10 when in the locked position. Such added security is provided by certain changes to the construction of the latch mechanisms 16 and 18 , and the bottom case shell 14 , as described below. Except for such changes, the structure and operation of the latch mechanism 130 is the same as that of latch mechanisms 16 , 18 , and therefore the same reference numbers are employed to identify common structure. Only one latch mechanism 130 is shown in FIGS. 10-15 , it being understood that a second latch mechanism 130 would be employed with case 10 .
[0035] Retention of the latch mechanisms 16 , 18 in the embodiment of FIGS. 1-9 is achieved by the engagement of locking member 16 extending from the top wall 96 of latch release 38 and a ledge 32 on the front wall 22 of the bottom case shell 14 . It is possible with this construction to grasp the tab 120 at the bottom of the latch body 34 and pull upwardly, causing the latch body 34 to pivot outwardly in a manner such as shown in FIG. 8 .
[0036] The latch mechanism 130 is designed to avoid the potential, inadvertent pivoting of the latch body 34 prior to movement of the latch release 38 to its release position. To that end, a latch release 132 is provided having a front wall 134 , a back wall 136 , a top wall 138 and a bottom wall 140 which are interconnected to collectively form an interior within which a sleeve 142 is mounted. A cavity 141 is formed between the front and back walls 134 , 136 which receives the coil spring 114 . See FIG. 12 . A button (not shown), such as button 100 of the latch release 38 , extends from the bottom wall 140 through an opening 144 in the front wall 134 . The top wall 138 has a recess 146 and an upwardly extending first locking member 148 having a generally U-shaped upper surface. A second locking member is provided in the form of a lip 150 , which is joined to the back wall 136 by a horizontally extending support 152 . The latch mechanism 130 is assembled by mounting the latch release 132 to the latch body 34 in the same manner as described in connection with a discussion of FIGS. 1-6 , and as shown in FIGS. 4 , 5 and 11 .
[0037] The operation of the latch mechanism 130 depicted in FIGS. 12-15 is the same as that described above for the latch mechanism 16 , and shown in FIGS. 6-9 , except for the added second locking member or lip 150 that substantially prevents inadvertent release of the latch mechanism 130 prior to movement of the latch release 132 to its release position. As shown in FIG. 12 , for example, with the latch release 38 in a locked position the second locking member or lip 150 is located within a cavity 156 formed by a locking arm 158 extending outwardly from the front wall 22 of bottom case shell 14 . The locking arm 158 engages the lip 150 and prevents movement of the latch release 132 upwardly relative to the bottom case shell 14 unless the latch release 132 is first moved to its release position illustrated in FIG. 13 . The first locking member 148 formed in the top wall 138 of the latch release 132 performs essentially the same function as the locking member 106 of the latch mechanisms 16 and 18 . In both embodiments, the locking members 106 and 148 engage the ledge 32 formed in the front wall 22 of bottom case shell 14 to provide additional protection from inadvertent pivoting movement of the latch body 34 . Movement of the latch release 132 to its release position shown in FIG. 13 allows the first locking member 148 to clear the ledge 32 , and the second locking member or lip 150 to extend past the locking arm 158 , thus allowing pivotal movement of the latch body 34 in the same manner as described above in connection with a discussion of FIGS. 6-9
[0038] While the invention has been described with reference to a preferred embodiment, it should be understood by those skilled in the art that various changes may be made and equivalents substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A carrying case includes a top case shell hinged to a bottom case shell which may be maintained in a closed position by a double throw, triple action latch mechanism comprising a latch body pivotally mounted to the bottom case shell, a latch locking element pivotally mounted to the latch body and a latch release coupled to the latch body. With the case in the closed position, the latch locking element engages a seat formed in the top case shell and clamps the two shells together. After moving the latch release to a release position, the latch body may be pivoted relative to the bottom case shell to permit disengagement of the latch locking mechanism from the top shell allowing the case to be opened.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Application No. 60/875,651, filed Dec. 19, 2006, the entire contents of which is incorporated herein by reference for all purposes.
TECHNICAL FIELD
[0002] The present invention relates to vapor depositions sources, systems, and related deposition methods. More particularly, the present invention relates to vapor deposition sources for use with materials that evaporate or sublime in a difficult to control or otherwise unstable manner. For example, the present invention is particularly applicable for depositing organic materials such as those for use in an organic light-emitting device (OLED).
BACKGROUND
[0003] An organic light-emitting device, also referred to as an organic electroluminescent device, is typically constructed by sandwiching two or more organic layers between first and second electrodes. In a passive matrix organic light-emitting device of conventional construction, a plurality of laterally spaced light-transmissive anodes, for example indium-tin-oxide anodes, are formed as first electrodes on a light-transmissive substrate such as, for example, a glass substrate. Two or more organic layers are then formed successively by vapor deposition of respective organic materials from respective sources, within a chamber held at reduced pressure, typically less than a millitorr. A plurality of laterally spaced cathodes is deposited as second electrodes over an uppermost one of the organic layers. The cathodes are oriented at an angle, typically at a right angle, with respect to the anodes.
[0004] Applying an electrical potential (also referred to as a drive voltage) operates such conventional passive matrix organic light-emitting devices between appropriate columns (anodes) and, sequentially, each row (cathode). When a cathode is biased negatively with respect to an anode, light is emitted from a pixel defined by an overlap area of the cathode and the anode, and emitted light reaches an observer through the anode and the substrate.
[0005] In an active matrix organic light-emitting device, an array of anodes are provided as first electrodes by thin-film transistors, which are connected to a respective light-transmissive portion. Two or more organic layers are formed successively by vapor deposition in a manner substantially equivalent to the construction of the passive matrix device described above. A common cathode is deposited as a second electrode over an uppermost one of the organic layers. The construction and function of an exemplary active matrix organic light-emitting device is described in U.S. Pat. No. 5,550,066, the entire disclosure of which is incorporated by reference herein for all purposes.
[0006] Organic materials, thicknesses of vapor-deposited organic layers, and layer configurations, useful in constructing an organic light-emitting device, are described, for example, in U.S. Pat. Nos. 4,356,429, 4,539,507, 4,720,432, and 4,769,292, the entire disclosures of which are incorporated by reference herein for all purposes.
[0007] An exemplary organic material used in OLED's is Alq3 (Aluminum Tris (8-Hydroxyquinoline)). This material and others like it are typically characterized as having poor thermal conductivity, which makes it difficult to uniformly heat the material to vaporize it. Moreover, these organic materials are typically provided in powder or granular form, which also makes it difficult to uniformly heat the material. Such nonuniformity in heating the material causes nonuniform vaporization of the material (by sublimation). Such nonuniform vapor flux, directed at a substrate or structure, will cause the formation of an organic layer thereon which will have a nonuniform layer thickness in correspondence with the nonuniform vapor flux.
[0008] A source for thermal physical vapor deposition of organic layers onto a structure for making an organic light-emitting device is described in U.S. Pat. No. 6,237,529 to Spahn. Another source for deposing organic layers is described in U.S. Pat. No. 6,837,939 to Klug et al. The Spahn and Klug et al. sources for depositing organic layers are representative of the current state of the art. These sources attempt to address the nonuniformity experienced in depositing these materials by using solid or bulk material instead of the granular form of the material. The Spahn source uses an arrangement of baffles and apertured plates to help minimize particulates that can be ejected by the source material but does not address the above-noted uniformity issue. The Klug et al. source uses a mechanism that advances compacted pellets of deposition material into a heated zone and an arrangement of baffles and apertured plates to address the uniformity problem. However the Klug et al. source is complex and cannot regulate and/or meter the vaporized material.
SUMMARY
[0009] The present invention thus provides vapor deposition sources and deposition methods that provide stable and controllable flux of materials that evaporate or sublime nonuniformly or in an unstable manner. Such materials are typically characterized as having one or more of low or poor thermal conductivity, a granular, flake, or powder consistency, and one or more inorganic components. Moreover, such materials typically sublime from a solid state rather that evaporate from a liquid (molten) state and do so in an unstable or difficult to regulate manner. Materials that sublime are also sensitive to thermal treatment as they may sublime as desired yet decompose undesireably within a narrow range of temperatures.
[0010] Deposition sources and methods in accordance with the present invention thus provide the ability to controllably heat a deposition material in a manner that optimizes evaporation or sublimation and minimizes nonuniform heating, heating of undesired portions of a deposition material within a crucible, and undesired decomposition of a deposition material when heated to evaporate or sublime the material.
[0011] Deposition sources and methods of the present invention are particularly applicable to depositing organic materials for forming one or more layers in organic light emitting devices.
[0012] Accordingly, in an aspect of the present invention, a vacuum deposition source is provided. The vacuum deposition source comprises a body attachable to a vacuum deposition system, the body comprising first and second body portions separable from each other; a valve positioned at least partially in the first body portion, the valve having an input side and an output side; a crucible at least partially positioned in the second body portion and in communication with the input side of the valve, the crucible comprising a plurality of distinct deposition material cells; and a nozzle comprising at least one exit orifice, the nozzle at least partially positioned in the first body portion and in communication with the output side of the valve.
[0013] In another aspect of the present invention, a vacuum deposition source is provided. The vacuum deposition source comprises a body attachable to a vacuum deposition system, the body comprising first and second body portions separable from each other; a valve positioned at least partially in the first body portion, the valve having an input side and an output side; a crucible at least partially positioned in the second body portion, detachably sealed to the input side of the valve, and isolated from the second body portion, the crucible comprising at least one deposition material cell; and a nozzle comprising at least one exit orifice, the nozzle at least partially positioned in the first body portion and in communication with the output side of the valve.
[0014] In another aspect of the present invention, a vacuum deposition system is provided. The vacuum deposition system comprises a vacuum chamber; a vacuum deposition source attached to the vacuum chamber, the vacuum deposition source comprising first and second body portions separable from each other, a valve positioned at least partially in the first body portion, the valve having an input side and an output side, a crucible at least partially positioned in the second body portion and in communication with the input side of the valve, the crucible comprising a plurality of distinct deposition material cells, and a nozzle comprising at least one exit orifice, the nozzle at least partially positioned in the first body portion and in communication with the output side of the valve; a deposition material provided in one or more of the plurality of deposition material cells of the crucible; and a substrate positioned in the vacuum chamber and relative to the nozzle of the vacuum deposition source.
[0015] In another aspect of the present invention, a crucible for a deposition source is provided. The crucible comprises a body portion; a flange comprising a knife-edge capable of providing a seal with a gasket when the flange is attached to a similar flange; and a plurality of distinct cells for holding deposition material.
[0016] In another aspect of the present invention, a method of vaporizing material for vacuum deposition is provided. The method comprises the steps of providing a crucible comprising a plurality of distinct deposition material cells; positioning deposition material in at least one of the plurality of deposition material cells of the crucible; and heating the crucible to vaporize the deposition material.
[0017] In another aspect of the present invention, a method of vaporizing material for vacuum deposition is provided. The method comprises the steps of providing a crucible comprising at least one deposition material cell at least partially defined by a plural rods; positioning deposition material in at least one deposition material cell of the crucible; and heating the crucible to vaporize the deposition material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0019] FIG. 1 is a perspective view of an exemplary vapor deposition source in accordance with the present invention;
[0020] FIG. 2 is a schematic cross-sectional view of an exemplary vapor deposition source in accordance with the present invention showing in particular a crucible having plural distinct cells for holding deposition material;
[0021] FIG. 3 is a schematic perspective partial cross-sectional view of the deposition source of FIG. 1 taken along a different cross-sectional line than that of FIG. 2 ;
[0022] FIG. 4 is a schematic cross-sectional view of a vapor deposition source similar to the source shown in FIG. 1 and having a different exemplary nozzle;
[0023] FIG. 5 is a perspective view of the crucible of the deposition source of FIGS. 1-3 ;
[0024] FIG. 6 is a perspective view of another exemplary crucible in accordance with the present invention showing, in particular, plural deposition material cells of concentric channels;
[0025] FIG. 7 is a top view of the crucible of FIG. 6 ;
[0026] FIG. 8 is a cross-sectional view of the crucible of FIG. 6 ;
[0027] FIG. 9 is a top view of another exemplary crucible in accordance with the present invention showing, in particular, plural deposition material cells of parallel channels;
[0028] FIG. 10 is a cross-sectional view of the crucible of FIG. 9 ;
[0029] FIG. 11 is cross-sectional perspective view of another exemplary crucible in accordance with the present invention showing, in particular, an array of rods that define, together with the wall of the crucible, a single deposition material cell;
[0030] FIG. 12 is a perspective view of another exemplary crucible in accordance with the present invention showing, in particular, an array of distinct material deposition cells supported by a plate at an opening of the cells;
[0031] FIG. 13 is a cross-sectional view of the crucible of FIG. 12 ;
[0032] FIG. 14 is a schematic cross-sectional view of another exemplary crucible in accordance with the present invention showing, in particular, an array of distinct material deposition cells supported by a plate at a base of the cells;
[0033] FIG. 15 is a perspective view of another exemplary crucible in accordance with the present invention showing, in particular, a single deposition material cell;
[0034] FIG. 16 is another exemplary deposition source in accordance with the present invention showing, in particular, an alternate valve orientation;
[0035] FIG. 17 is cross-sectional perspective view of another exemplary crucible in accordance with the present invention showing, in particular, an array of rods that define, together with the wall of the crucible, a single deposition material cell and plural heaters integrated with the rods;
[0036] FIG. 18 is a schematic cross-sectional view of a vapor deposition source similar to the source shown in FIG. 1 and having a different exemplary nozzle wherein the nozzle comprises a heating device;
[0037] FIG. 19 is a perspective view of a vapor deposition source similar to the source shown in FIG. 1 and having a different exemplary nozzle.
DETAILED DESCRIPTION
[0038] The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present invention.
[0039] Referring initially to FIGS. 1-3 an exemplary vapor deposition source 10 in accordance with the present invention is illustrated. In FIG. 1 a perspective view of deposition source 10 is shown. In FIG. 2 a schematic cross-sectional view of deposition source 10 is shown. FIG. 3 shows a partial schematic cross-sectional perspective view along a different cross section line than that of FIG. 2 .
[0040] The exemplary deposition source 10 illustrated in FIGS. 1-3 is designed for vacuum deposition and, as illustrated, generally includes mounting flange 12 for attaching deposition source 10 to a deposition system (not shown), body 14 attached to flange 12 , valve 16 , crucible 18 comprising plural cells 20 , nozzle 22 , and heater assembly 24 for providing heat, preferably radiant, to evaporate or sublime material located in crucible 18 and prevent deposition of such material on undesired surfaces (valve 16 and nozzle 22 , for example). Valve 16 comprises valve portion 17 and valve body 19 . Deposition source 10 , as shown, also preferably comprises water jackets 23 and 25 for cooling, power feedthrough 15 for providing power to heater assembly 24 , and feedthrough 26 for a thermocouple, or similar sensor. Although crucible 18 is illustrated with plural cells, a crucible having a single cell can be used.
[0041] Body 14 of exemplary deposition source 10 , as shown, comprises first body portion 28 attached to mounting flange 12 and second body portion 30 attached to first body portion 28 . Body 14 preferably comprises stainless steel as is well known for vacuum deposition components. Body 14 is preferably designed so crucible 18 can be accessed and/or removed for maintenance, replacement, and so deposition material can be added/removed as needed. In particular, first body portion 28 includes flange 29 removably connected to flange 31 of second body portion 30 . In the illustrated embodiment, second body portion 30 is separable from first body portion 28 to access crucible 18 . Crucible 18 , as shown, is separably attached to plate 32 by flange 33 of plate 32 and flange 35 of crucible 18 . The connection between crucible 18 and plate 32 is preferably vacuum tight and resealable. For example, a Conflate style seal can be used which seal comprises flanges having knife-edges that embed into a soft metal seal gasket such as a copper or niobium gasket or the like. Alternatively, a graphite seal material can be used such as a flexible graphite gasket material positioned between polished flange surfaces. Such graphite material is available from GrafTech Advanced Energy Technology, Inc. of Lakewood, Ohio. Plate 32 , as shown, is welded to valve body 19 to provide a vacuum tight enclosure between crucible 18 and valve 16 . In the illustrated design, second body portion 30 can be separated from first body portion 28 to access crucible 18 and crucible 18 can be separated from plate 32 to replace crucible 18 , add/remove source material, for example.
[0042] Plate 32 , as shown, is attached to valve body 19 , which is attached to nozzle 22 , via tube 34 as shown. Plate 32 , valve body 19 , and tube 34 are preferably welded to each other but other connection techniques can be used for permanent connection of one or more of the components of assembly 36 (brazing, for example) or resealable connections (using gaskets, for example). Crucible 18 , plate 32 , valve body 19 , and tube 34 preferably comprise vacuum compatible materials such as titanium and stainless steel and the like. Preferably, as illustrated, assembly 36 comprising crucible 18 , plate 32 , valve body 19 , tube 34 , and nozzle 22 is thermally isolated from body 14 of deposition source 10 . In the illustrated design, such isolation is accomplished by supporting or hanging assembly 36 from first body portion 28 . Preferably, support legs 38 connected to first body portion 28 and connected to plate 32 , as shown, are used.
[0043] Preferably, as illustrated, crucible 18 , plate 32 , valve body 19 , and valve portion 17 define first vacuum zone 40 distinct from second vacuum zone 42 defined by the valve body 19 , valve portion 17 , tube 34 , and nozzle 22 . Communication between first and second vacuum zones, 40 and 42 , respectively, is controlled by valve 16 . A third distinct vacuum zone 44 is defined by the space between first and second body portions 28 and 30 , respectively, and crucible 18 , plate 32 , valve body 19 , tube 34 , and nozzle 22 . Third vacuum zone 44 is in communication with a vacuum chamber (not shown) when the deposition source 10 is attached to such vacuum chamber. In use, third vacuum zone 44 is preferably maintained at a vacuum level that minimizes convective heat transfer between first and second body portions 28 and 30 , respectively, and crucible 18 , plate 32 , valve body 19 , tube 34 , and nozzle 22 . For example, maintaining third vacuum zone 44 below about 50 millitorr helps to minimize such convective heat transfer.
[0044] Deposition source 10 includes heater assembly 24 for providing thermal energy that functions to evaporate or sublime material located in crucible 18 . Crucible 18 or a desired portion(s) thereof can be heated radiatively (indirectly) or can be heated directly such as by resistively or conductively heating crucible 18 or a desired portion(s) of crucible 18 . Combinations of indirect, direct, radiative, resistive, conductive heating, and the like can be used. In the illustrated embodiment, heater portion 46 is schematically shown positioned in first body portion 28 . Plural distinct heaters can be used. Preferably such a heater comprises one or more filaments that are resistively heated to provide radiant thermal energy. Here, heater portion 46 radiatively heats nozzle 22 , tube 34 , valve 16 , and plate 32 . Such heating may be direct, indirect, or combinations thereof. One or more heaters can be used that are spaced from and/or in contact with component(s) desired to be heated. Heating such components functions to prevent deposition of material onto such components especially valve body 19 and valve portion 17 , which could cause unwanted build up of material. Crucible 18 is partly heated by conduction between valve 16 , plate 32 and crucible 18 as well as radiation from plate 32 and valve body 19 . In this design, the deposition material in each cell 20 of crucible 18 is primarily heated from above as the conductive heating between plate 32 and crucible 18 is minimal. That is, radiative heat from plate 32 and valve body 19 is the primary source of heating for crucible 18 and particularly for deposition material provided in crucible 18 .
[0045] Second body portion 30 can include one or more optional heater(s) 48 for heating crucible 18 , directly or indirectly. Such heater can be spaced from and/or in contact with crucible 18 . Preferably, heater portion 48 for second body portion 30 is distinct from heater portion 46 in first body portion 28 so heater portion 46 and heater portion 48 can be operated independently from each other. Whether or not second body portion 30 includes one or more heaters to heat crucible 18 depends on factors such as the particular deposition material, desired flux uniformity, desired flux rate, crucible design, deposition source geometry, and combinations thereof, for example. Deposition source 10 can be designed to include plural heaters (of the same of different types) in any of first and second body portions 28 and 30 , respectively, or within any of the vacuum zones. Thus, depending on the particular deposition material, any single or combination of heaters can be used. Determining what portion(s) of deposition source 10 is heated, not heated, or cooled, and how, is generally at least partially dependent on the characteristics of the particular deposition material used and can be determined empirically to obtain desired performance objective(s) such as one or more of deposition uniformity, flux rate, flux stability, material usage efficiency, and minimizing coating of valve components for example.
[0046] Valve 16 is designed for vacuum use and can preferably withstand being heated during use of deposition source 10 . Valve 16 preferably includes a driver or actuator 21 (see FIG. 3 ) to provide computer (signal-based) control of valve 16 . An exemplary actuator is Part No. SMC-II, available from Veeco Compound Semiconductor Inc. of St. Paul, Minn. Depending on the deposition material and/or deposition process valve 16 can provide regulating, metering, on/off functionality, combinations thereof, for example. Preferably, valve 16 is capable of creating a pressure differential between first and second vacuum zones, 40 and 42 , respectively, such as for providing a backpressure in first vacuum zone 40 . As shown, valve portion 17 moves along an axis (identified by reference numeral 50 ) different from the axis of material evaporation and/or sublimation from crucible 18 (identified by reference numeral 52 ). In an alternative design, valve portion 17 can move along the axis of material evaporation as shown schematically in FIG. 10 and described below. Effusion cells having valves for use in the context of vapor deposition are described in U.S. Pat. No. 6,030,458 to Colombo et al., for example, the entire disclosure of which is incorporated by reference herein for its entire technical disclosure including, but not limited to, the disclosure of such valves and for all purposes.
[0047] Deposition source 10 , as shown, includes nozzle 22 . Nozzle 22 is preferably designed to provide desired deposition performance. Typically, nozzle 22 includes one or more openings (orifices) for emitting and/or directing deposition material in a predetermined direction and/or rate. Nozzle orifices are preferably arrayed to provide optimal uniformity across a wide substrate. Typically there is a uniform set of orifices across the nozzle with a higher concentration near the ends of the nozzle to compensate for the flux roll off at the end of the nozzle. As illustrated, nozzle 22 comprises plural exit orifices 27 but a single exit orifice may be used. Factors used in designing the nozzle include deposition material, deposition uniformity, deposition rate, deposition system geometry, and the number, type, and size of substrates deposited on. Such nozzles can be designed using empirical data, information, and/or techniques. Another exemplary nozzle 110 is shown with deposition source 112 in FIG. 19 . Nozzles that can be used with deposition sources in accordance with the present invention are available from Veeco Compound Semiconductor Inc. of St. Paul, Minn.
[0048] An alternative nozzle 54 is illustrated in FIG. 4 and is designed to provide increased areal coverage by the emitted vapor deposition flux. As shown, nozzle 54 comprises tube 56 and body portion 58 having plural exit apertures 60 . Tube 56 functions to space body portion 58 from flange 12 of deposition source 10 . Such spacing is dependent on the particular deposition application for which deposition source 10 is used. As shown, body portion 58 extends linearly and orthogonally relative to tube 56 . Body portion 58 may be provided at any desired angle relative to tube 56 . As shown, body portion 58 comprises a tube (cylinder) but may comprise a planar structure such as a cube, rectangle, or disk or may comprise an arcuate structure such as a sphere or similar arcuate surface or the like. Body portion 58 may comprise any number of exit apertures (including a single exit aperture). Such exit apertures may comprise any shape (e.g., circular, elliptical, square, rectangular) or combinations of such shapes. Nozzle 54 does not need to be symmetric and the density of such exit apertures may vary between regions of nozzle 54 . A nozzle is not required for some applications and a single orifice may be sufficient. That is, tube 34 also functions as a nozzle in the absence of nozzle 22 and nozzle 54 .
[0049] An alternative nozzle 112 is illustrated in FIG. 18 . As shown, nozzle 112 comprises tube 113 and body portion 114 having plural exit apertures 116 . Tube 113 functions to space body portion 114 from flange 118 of deposition source 120 . Tube 113 also functions to house thermocouple feedthrough 122 and power feedthrough 124 for nozzle 112 . Nozzle 112 also comprises heating elements 126 connected to power feedthrough 124 the temperature of which can be controlled by feedback from thermocouple feedthrough 122 . Plural heating elements are shown but a single element may be used. Heating elements 126 are shown on an exterior surface of nozzle 112 but may be provided inside nozzle 112 . As shown, body portion 114 extends linearly and orthogonally relative to tube 113 . Body portion 114 may be provided at any desired angle relative to tube 113 . As shown, body portion 114 comprises a tube (cylinder) but may comprise a planar structure such as a cube, rectangle, or disk or may comprise an arcuate structure such as a sphere or similar arcuate surface or the like. Body portion 114 may comprise any number of exit apertures (including a single exit aperture). Such exit apertures may comprise any shape (e.g., circular, elliptical, square, rectangular) or combinations of such shapes. Nozzle 112 does not need to be symmetric and the density of such exit apertures may vary between regions of nozzle 112 .
[0050] Deposition source 10 also preferably includes other components and/or design aspects as needed depending on the particular deposition material and/or deposition process. For example, the illustrated deposition source 10 includes a thermocouple 62 for temperature measurement and is used for controlling deposition flux. Thermocouple 62 is preferably designed to be in contact with valve body 19 . Type-K and Type-J thermocouples can be used. Plural thermocouples or temperature sensors or control systems can be used. The illustrated deposition source 10 also incorporates liquid cooling jacket 25 , preferably water, for managing and/or cooling desired portions of deposition source 10 .
[0051] As shown, crucible 18 is designed to provide plural distinct cells or chambers for holding deposition material but a single cell can also be used. Exemplary crucibles that provide plural distinct cells are shown in FIGS. 5-15 .
[0052] FIG. 5 shows a perspective view of exemplary crucible 18 , as shown, crucible 18 is designed to contain about 500 cubic centimeters of deposition material as measured by adding the volume of all cells 20 but any volume can be used depending on the application. Depending on the application, crucible 18 can be made from a thermally conductive material or thermally insulative material. Representative materials include metals, ceramics, glasses, and composites, for example. Specific examples include titanium, stainless steel, copper, aluminum, graphite, silicon carbide, nickel based alloys, and alumina. Cells 20 can have any cross-sectional shape, volume, aspect ratio, number, and/or arrangement depending on the particular application and/or deposition material and depending on the particular functionality desired. For example, cells 20 can be designed to provide uniform heating of material in cells 20 or can alternatively be designed to insulate cells 20 from each other. Crucibles in accordance with the present invention may include heating devices integrated with such crucibles. For example, a heating device may be provided on an external surface of a crucible. Alternatively, a heating device may be in or adjacent to one or more cells of a crucible in accordance with the present invention.
[0053] FIG. 6 shows another exemplary crucible 64 in accordance with the present invention that comprises concentric channels that provide plural distinct cells 66 for holding deposition material. A top view and cross-sectional view are provided by FIGS. 7 and 8 , respectively. Cells 66 are not required to be concentric channels as illustrated and can have any shape, number, and/or density. Also, the arrangement of cells 66 is not required to be symmetrical.
[0054] FIG. 9 shows another exemplary crucible 68 in accordance with the present invention that comprises parallel channels that provide plural distinct cells 70 for holding deposition material. A cross-sectional view is provided by FIG. 10 . Cells 70 are not required to be parallel to each other as illustrated and can be provided at one or more angles relative to each other. Also, cells 70 are not required to be linear and may be arcuate, or serpentine, for example. Any shape, number, and/or density of cells 70 can be used in accordance with the present invention. Further, the arrangement of cells 70 is not required to be symmetrical.
[0055] FIG. 11 shows another exemplary crucible 72 in accordance with the present invention. Crucible 72 comprises rods 73 that, together with wall 75 , define cell 74 for holding deposition material. Rods 73 can comprise any desired shape, number, and/or density. A single rod may be used. The region between the outside surfaces of rods 73 and inside surface of crucible wall 75 is considered a single deposition material cell in accordance with the present invention. Also, the arrangement of rods 73 is not required to be symmetrical.
[0056] FIG. 17 shows another exemplary crucible 132 in accordance with the present invention. Crucible 132 is similar to crucible 72 of FIG. 11 and comprises rods 134 that, together with wall 136 , define cell 138 for holding deposition material. Crucible 132 additionally includes heating devices 140 integrated with rods 134 . Heating devices 140 can be controllable heated to provide thermal energy for vaporizing a deposition material provided in cell 138 of crucible 132 .
[0057] FIGS. 12 and 13 show exemplary crucible assembly 76 in accordance with the present invention that comprises an array of plural distinct crucibles 78 for holding deposition material wherein the crucibles are supported by a support plate 80 at the top (at the openings) of the crucibles. Crucibles 78 are not required to be parallel to each other as illustrated and can be provided at one or more angles relative to each other. Also, crucibles 78 are not required to be tubular in cross-section and may be square, rectangular, or elliptical in cross-section, for example. Any shape, number, and/or density of crucibles 78 can be used in accordance with the present invention. Further, the arrangement of crucibles 78 is not required to be symmetrical.
[0058] FIG. 14 shows another exemplary crucible assembly 82 in accordance with the present invention that comprises an array of plural distinct crucibles 84 for holding deposition material wherein the crucibles are supported by a support plate 86 at the bottom (at the bases) of the crucibles. Crucibles 84 can be supported by support plate 86 anywhere between the top and bottom of the crucibles. Crucibles 84 are not required to be parallel to each other as illustrated and can be provided at one or more angles relative to each other. Also, crucibles 84 are not required to be tubular in cross-section and may be square, rectangular, or elliptical in cross-section, for example. Any shape, number, and/or density of crucibles 84 can be used in accordance with the present invention. Further, the arrangement of crucibles 84 is not required to be symmetrical.
[0059] FIG. 15 shows another exemplary crucible assembly 118 in accordance with the present invention that comprises single cell 120 for holding deposition material and that can be used with deposition sources in accordance with the present invention.
[0060] Another exemplary deposition source 94 in accordance with the present invention is illustrated in FIG. 16 . Deposition source 94 includes first body portion 96 , second body portion 98 , crucible 100 , valve 102 , valve actuator 104 , and nozzle port 106 . Deposition source 94 is similar to deposition source 10 shown in FIGS. 1 and 2 but has a different valve orientation. That is, valve 102 comprises drive axis 108 , which is oriented along the direction of material evaporation and/or sublimation from crucible 100 . Any of the crucibles described herein may be used in deposition source 94 .
[0061] The present invention has now been described with reference to several embodiments thereof. The entire disclosure of any patent or patent application identified herein is hereby incorporated by reference. The foregoing detailed description and examples have been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. It will be apparent to those skilled in the art that many changes can be made in the embodiments described without departing from the scope of the invention. Thus, the scope of the present invention should not be limited to the structures described herein, but only by the structures described by the language of the claims and the equivalents of those structures.
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Vapor depositions sources, systems, and related deposition methods. Vapor deposition sources for use with materials that evaporate or sublime in a difficult to control or otherwise unstable manner are provided. The present invention is particularly applicable to deposition of organic material such as those for forming one or more layer in organic light emitting devices.
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FIELD OF THE INVENTION
[0001] This present invention relates generally to computer power management, and more particularly to managing power for subsystems, such as graphics, in the absence of explicit operating system support.
BACKGROUND
[0002] All computer systems require electrical power to operate. In many instances, it is desirable to manage electrical power to a computer system, responsive to near-term requirements or observed usage, prior settings, etc. For instance, a computer may be configured such that after some number of minutes without activity, the computer may spin down its hard drives, remove power from its graphics output, power down its network interface card(s), slow or halt its central processing unit, etc. After additional time passes, the computer may automatically enter a suspend state where, except for low-power memory self-refresh operations, all computer functions draw essentially zero current. The computer may even be placed in a hibernate state, where an image of memory is saved to hard disk and the computer is completely powered down, with its hibernation state saved indefinitely.
[0003] For portable, battery-powered computers, power management is almost essential if the computer is expected to run on battery power for more than an hour or two. And even with stationary computers that rely on a building's electrical power supply, significant reductions in electricity usage are possible with computers that utilize effective power management.
[0004] Several specifications have been developed in the interest of effecting robust computer power management. Intel Corporation and Microsoft Corporation released one such specification that has enjoyed wide adoption, Advanced Power Management ( APM ) BIOS Interface Specification , Rev. 1.2, February 1996 (and previous versions). FIG. 1 illustrates the general structure of an APM implementation. An APM BIOS (Basic Input/Output System) 30 provides a software interface to those power-managed hardware subsystems 35 located in the standard computer configuration (e.g., motherboard devices and some attached components).
[0005] Although some limited power management is often possible with the APM BIOS alone, more comprehensive power management generally requires the cooperation of an operating-system-resident APM driver. An APM interface 45 is standardized for operating system (OS) communication with APM-compliant BIOS software. An operating system vendor desiring to utilize APM functionality supplies an APM driver 40 that also complies with the APM interface specification. The APM driver calls APM BIOS functions to accomplish APM tasks. The APM BIOS expects to be polled frequently (e.g., at least once/second) by the APM driver for the occurrence of power management events.
[0006] For each OS using an APM driver, the OS vendor determines how it will involve APM-aware applications (e.g., 50 and 55 ), and in some cases APM-aware device drivers (e.g., 60 and 70 ) that provide power control for an add-in device (e.g., 65 and 75 ), such as a PCI (Peripheral Component Interconnect) device. In many Microsoft Windows® OS implementations, for instance, APM driver 40 places messages in the message loop of registered applications, to notify the applications of a power event. The messages allow those applications to take necessary actions before a power event occurs, or in some cases to even prevent the power event from occurring.
[0007] A second, more ambitious approach to power management is described in Advanced Configuration and Power Interface Specification , Rev. 2.0a, Mar. 31, 2002, hereinafter referred to as ACPI. ACPI uses different interrupt mechanisms than APM, and defines global system states, device power states, and processor power states. A more detailed understanding of ACPI is not necessary for understanding of the invention described herein, as embodiments of the present invention generally solve problems not present with ACPI systems.
BRIEF DESCRIPTION OF THE DRAWING
[0008] The embodiments may be best understood by reading the disclosure with reference to the drawing, wherein:
[0009] [0009]FIG. 1 illustrates basic software layering for a prior-art APM implementation;
[0010] [0010]FIG. 2 shows a block diagram for an exemplary computer system to which an embodiment of the present invention may be applied;
[0011] [0011]FIG. 3 shows components of an embodiment of the invention and other related software, and illustrates communications that occur at initialization;
[0012] [0012]FIG. 4 shows a BIOS-initiated suspend event, and how the components of an embodiment of the invention respond to place the graphics subsystem in a quiescent state, where the OS provides no explicit support for graphics power management;
[0013] [0013]FIG. 5 shows a process timeline corresponding to the suspend event of FIG. 4;
[0014] [0014]FIG. 6 illustrates a BIOS-initiated resume event to resume graphics after the suspend event of FIG. 4;
[0015] [0015]FIG. 7 shows a process timeline corresponding to the resume event of FIG. 6;
[0016] [0016]FIGS. 8 a , 8 b , and 8 c illustrate video BIOS/video driver co-operation in saving graphics state;
[0017] [0017]FIG. 9 depicts a BIOS-initiated suspend event causing graphics to enter a quiescent state in an embodiment of the invention, where the OS provides no explicit support for graphics power management but the platform includes a third-party power management (PM) driver; and
[0018] [0018]FIG. 10 depicts a BIOS-initiated suspend event for an embodiment of the invention, where an APM or ACPI driver resides in the OS.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0019] Some operating systems provide support for APM and/or ACPI. Some do not. Most computer users do not understand—or expect to have to understand—such subtleties, but simply expect an extant and robust power management scheme on their computer, regardless of whether the support is provided by the operating system or not. Thus hardware manufacturers almost inevitably provide an APM BIOS with their systems. Some even provide an OS-independent third-party PM (power management) driver in an attempt to provide wider PM support. Unfortunately, many computer subsystems (such as graphics, network interfaces, disk controllers) tend to be highly complex, cached, and/or pipelined, sensitive to the manner in which power transitions occur, and not necessarily well understood by system manufacturers. It is recognized herein that it would be desirable to have such subsystems participate in their own power transition preparation, whether under the control of a driver for APM, ACPI, or some other PM, or even in the absence of any PM driver. And yet no mechanism currently exists for universal and automatic participation of a subsystem in power management under all OS support scenarios.
[0020] This description presents embodiments of such a mechanism in the context of a graphics subsystem. This mechanism generally senses whether a resident APM or ACPI driver is available to support graphics subsystem power management. When such a driver is unavailable, the software components of the graphics subsystem automatically coordinate with the system BIOS and/or a PM driver to effectuate robust graphics power transitions.
[0021] To provide a reference context for the embodiments, FIG. 2 depicts a block diagram for one exemplary computer system 100 to which an embodiment of the invention applies. In system 100 , a processor 110 (or multiple such processors, and often including local cache memory embedded on the processor), handles the primary computing tasks for system 100 . Other subsystems communicate with processor 110 across system bus 115 .
[0022] Graphics/memory controller hub (GMCH) 120 and I/O (Input/Output) hub 160 are often referred to as a chipset. The chipset typically provides some computer subsystem functionality, provides for orderly and efficient access by processor 110 to system memory 140 and other computer subsystems, and also allows other computer subsystems to access some portions of system memory. GMCH 120 communicates with processor 110 across system bus 15 . I/O hub 160 communicates with GMCH 120 across hub bus 165 .
[0023] GMCH 120 typically supports multiple high-speed bus interfaces in addition to system bus 115 and hub bus 165 . The GMCH includes a memory controller 124 that communicates with system memory 140 across memory bus 145 . An AGP (Accelerated Graphics Port) interface supports AGP bus 135 , and, when included, an AGP graphics device 130 . GMCH 120 includes an embedded graphics controller 128 that has access not only to the memory controller, but also to graphics local memory 150 , and provides output via a CRT out connector 154 and/or a bus to a digital display 158 . (It is noted that when an AGP graphics device is used, graphics local memory 150 and display outputs 154 and 158 generally connect directly to the AGP graphics device).
[0024] I/O hub 160 provides for attachment of other devices to the computer system. Low Pin Count (LPC) bus 185 provides an interface to BIOS storage and other firmware 180 . PCI (Peripheral Component Interconnect) bus 175 generally provides slots for connecting one or more PCI devices 170 (e.g., audio cards, network cards, video cards, etc.) to system 100 . ATA (AT Attachment) bus 195 provides an interface to fixed and removable media disk drives, tape drives, etc. USB (Universal Serial Bus) 194 connects a USB root hub (e.g., on I/O hub 160 ) to one or more USB ports 198 , which support a wide range of peripherals that are generally hot-swappable.
[0025] In additional to read/write disk drives and system memory, sensitive state information may exist in other subsystems. For instance, modern graphics controllers and AGP graphics devices often support sophisticated hardware capabilities for off-loading graphics tasks from processor 110 (tasks such as overlay, texturing, shading, z-buffering, digital video motion compensation and block decoding, and other rendering operations). Such graphics devices may support internal graphics pipelines and maintain context pointer tables to textures, objects, and other graphical data cached in memory. Without an orderly shutdown and resumption procedure, a graphics subsystem performing such tasks for the processor would likely hang a computer system responding to power management events.
[0026] [0026]FIG. 3 shows several software and register components of a computer system, in a configuration 200 useful in an embodiment of the present invention. The software components are generally classified in FIG. 3 according to the mode in which they run during power management operations: System BIOS (SBIOS) 220 and video BIOS (VBIOS 300 ) run in System Management Mode (SMM); most other components run in Kernel Mode, including Graphics Device Interface (GDI) 260 , an APM or ACPI driver 400 (if included), a PM driver 420 (if included), and three display driver components, a display driver 340 , a PAL (Platform Abstraction Layer) 310 , and a video miniport driver 320 ; the COM component 360 runs in user mode (GDI 260 has a user-mode component as well). Two registers are also used for graphics power management-status flag register 230 and interrupt trigger register 235 . Each component will be briefly described in turn as it relates to power management, followed by a description of component interaction.
[0027] SBIOS 220 is a system-level component that receives (or generates) low-level PM events, and physically controls the power to computer subsystems. SBIOS 220 may, e.g., include an APM BIOS, and provides some sort of handshaking mechanism to communicate PM events to other software components.
[0028] VBIOS 300 , PAL 310 , video miniport driver 320 , display driver 340 , and COM 360 are each part of the graphics software stack. VBIOS 300 controls the graphics hardware configuration, and is generally provided by the maker of that hardware. As it relates to this embodiment, VBIOS 300 is responsible for maintaining some parts of status flag register 230 , initiating interrupts using register 235 , and providing PM handshaking with SBIOS 220 when a PM driver is absent from the system.
[0029] PAL 310 is a software component capable of exposing interfaces from a PM driver, and exchanging signaling with such a driver. When a third-party PM driver is used for power management, PAL 310 provides an interface between the PM driver and video miniport driver 320 .
[0030] Although video miniport driver 320 and display driver 340 are shown and described as separate software components, this distinction is largely one of convenience as it follows Microsoft conventions—these drivers function together as a single “graphics driver”, and may be considered as such. Different display drivers may sometimes be paired with a miniport driver, or vice versa, to yield different “graphics driver” configurations.
[0031] Display driver 340 provides rendering services, working in conjunction with GDI 260 and providing a direct interface to video frame buffers and/or other video memory. Display driver 340 knows what rendering commands are supported by the graphics adapter/controller/processor, and hooks those commands that are supported by graphics hardware; all other rendering commands are left for GDI 260 to process. In the described embodiments, the display driver is largely unmodified, except for a few tasks that will be discussed below.
[0032] Video miniport driver 320 is the kernel mode graphics component that interfaces with the OS for non-GDI operations. Video miniport driver 320 manages video resources, maps graphics memory to standard memory address, performs hardware mode set operations and other hardware-peculiar operations, and responds to hardware interrupts. In the described embodiments, miniport driver 320 becomes a middleman in graphics power management.
[0033] COM 360 is preferably a user-mode application, such as a hot-key or display-setting application that is, e.g., resident in the background. COM 360 is usually distributed with and loaded along with the graphics driver components. Although COM 360 can in some embodiments notify the user of impending graphics shutdown and/or allow a user to turn off graphics manually, the primary purpose of COM 360 in the described embodiments is to work with miniport driver 320 and the OS to set the graphics to a safe state for graphics transitions.
[0034] GDI 260 is the OS component that provides a device-independent graphics interface to applications. While various functions present in GDI 260 are leveraged during graphics power management, GDI 260 will not typically need modification to work with an embodiment of the invention.
[0035] APM or ACPI driver 400 , and PM driver 420 , are optional components that provide power management. When a PM driver 420 is present, video miniport driver 320 works with the PM driver to effect graphics power management. When an APM or ACPI driver is present, that driver is expected to place graphics in a quiescent state. The inclusion of such a driver generally pre-empts graphics-state-saving operations initiated by video miniport driver 320 .
[0036] Status Flag register 230 is a software-writeable static register that is accessible to the kernel mode and system management mode components of the graphics subsystem. This register may be, e.g., an I/O register, a memory-mapped I/O register, or a register located in the PCI configuration space of the GMCH (or other graphics processor). Status Flag register 230 provides a mechanism for the video BIOS and graphics driver to communicate power management information between their respective contexts. All graphics software components may read the information stored in register 230 , and obtain the value of a flag by applying an appropriate bit mask to the register information. The flags are divided into two sets, depending on which component is allowed to modify those flags.
[0037] The first two flags are set by the video BIOS to inform the driver of pending power events, and are reset by the driver once it has received and begun action on the information. The flag description is as follows:
Name Size/Default Description APM Size = 3 bits Set by the Video BIOS to: Power Default = 0h 0 - No change in status State 1 - System is transitioning to APM Standby 2 - System is transitioning to APM Suspend 3 - System is transitioning to APM Hibernate 4 - System is transitioning to APM Resume Reset by a driver to: 0 - After receiving the flag and initiating an appropriate graphics transition APM Size = 1 bit Set by the Video BIOS to: Request Default = 0h 0 - When no Switch Display event is pending 1 - When a Switch Display has occurred or is required Reset by a driver to: 0 - to indicate that the change has been registered, when the Video BIOS is respon- sible for performing the switch 0 - to indicate that the driver has switched mode, when the driver is responsible for performing the switch
[0038] The remaining flags are set by the graphics driver (usually by the video miniport driver). The Video BIOS can read these flags, but is not allowed to change them:
Name Size/Default Description Driver- Size = 1 bit 0 - No OS is loaded (or a non- Controlled Default = 0h driver OS, e.g., DOS, is loaded) OS 1 - An OS that uses drivers has loaded (the video miniport driver sets this flag when it loads) APM OS Size = 2 bits 0 - Unknown APM support Default = 0h 1 - APM 1.1-supported OS 2 - APM 1.2-supported OS 3 - PM driver (but not APM 1.1 or 1.2) APM Size = 2 bits Set by Display Driver after Status Default = 0h receiving an APM request 0 - No change 1 - Save or Restore operation is pending 2 - Save or Restore operation completed successfully 3 - Save or Restore operation failed ACPI OS Size = 2 bits 0 - Unknown ACPI support Default = 0h 1 - ACPI 1.0b supported 2 - ACPI 1.0b & Video Extensions supported 3 - ACPI 2.0 & Video Extensions supported APM Size = 1 bit 0 - Graphics State is saved BIOS Default = 0h through OS drivers, state-saving Memory memory not allocated for use by Allocated Video BIOS 1 - Driver has allocated state- saving memory for use by Video BIOS, address/length stored in registers Pipeline Size = 1 bit Valid when APM BIOS Memory Allo- State Default = 0h cated bit is set Saved 0 - Video BIOS should save MMIO state and 3D pipeline state 1 - Video BIOS should save MMIO state; 3D pipeline state saved by driver
[0039] The use for each of these flags will become more apparent in the following description. It is noted at the outset, however, that the APM BIOS Memory Allocated flag refers to two other registers not shown in FIG. 3—registers for storing a base address and the number of 4-Kbyte pages starting at that address that have been allocated for use by the Video BIOS to save graphics state to memory.
[0040] Interrupt Trigger Register 235 can be a register dedicated for use in responding to PM events. Alternately, it can be a register used for other graphics interrupts, where the video miniport driver reads other register values upon receiving an interrupt in order to discover that it has been interrupted for a PM event. Referring back to FIG. 3, tasks that run at system initialization, according to an embodiment of the invention, are indicated. Each will be described in turn.
[0041] When VBIOS 300 loads, it performs task A. Task A initializes status flag register 230 to all zeros, and resets interrupt trigger register 235 .
[0042] As the operating system loads, video miniport driver 320 and PAL 310 load. In its initialization routines, miniport driver 320 executes task B by attempting to connect to an APM or ACPI driver. Likewise, PAL 310 attempts to communicate with a PM driver 420 .
[0043] If a PM driver is present, PAL 310 executes task C to register for notification of PM events. With some PM drivers, task C involves the PAL calling an interface defined by the PM driver, in essence issuing an Interrupt Request Packet (IRP) to PM driver 420 , requesting callback upon the occurrence of a power event. With other PM drivers, task C may involve the PAL registering with the kernel message stack to receive an IRP or IOCTL (Input/Output Control) command when the PM driver places a power management event on the stack. On video miniport driver 320 , task C involves registering with PAL 310 for a callback when the PAL is notified of a PM event. This registration is only necessary if cooperation with a PM driver will be the method of power management.
[0044] Task D includes setting status flags in flag register 230 to indicate the power management mode for this boot session. The Driver-Controlled OS flag is set to indicate that the miniport driver has loaded. The APM OS flag is set to the proper state if an APM or PM driver has been detected. The ACPI OS flag is set to the proper state if an ACPI driver has been detected. If the miniport driver determines that the video BIOS will be used to save graphics state, it allocates memory for that purpose, saves the base address and memory size to predefined registers accessible to the video BIOS, and sets the APM BIOS Memory Allocated flag. If the video BIOS is to save the graphics pipeline state, miniport driver 320 ensures that the Pipeline State Saved flag is reset.
[0045] It is noted that if the video miniport driver never loads, the flags in status flag register 230 remain set to zero, indicating to the video BIOS that it should not use the miniport driver interrupt, as the driver has not loaded. Consequently, the video BIOS would not attempt to handle power management events.
[0046] COM 360 loads as a user-mode application when other user startup applications load. When COM 360 loads, one of its initialization tasks is task E. Task E calls OS functions to create event handles for power suspend and resume events. These events will be referred to herein by the names APMSuspendEvent and APMResumeEvent. It is noted, however, that any event names not already reserved by the OS will work, so long as the software components that use those events have knowledge of the selected names. Task F passes the event and associated semaphore handles to display driver 340 , e.g., with an ExtEscape function call in the Microsoft family of operating systems. The display driver executes task G to pass the event and semaphore handles down to the miniport driver 320 , e.g., with an IOCTL function call. Upon receiving these event and semaphore handles, video miniport driver 320 knows: that the upper software layers have been configured to help respond to power management events; how to signal COM 360 when events occur; and what semaphores indicate that COM 360 has caused a graphics reset.
[0047] Once the components of configuration 200 have been initialized, the system is ready to respond to power management events. Note that the initialization process has automatically configured the graphics subsystem to respond to graphics power management events in an appropriate way, no matter what operating system has loaded and what power management support (if any) is provided by that operating system.
[0048] [0048]FIGS. 4 and 5 illustrate how a properly initialized configuration 200 responds to a suspend event when no APM, ACPI, or PM driver is present. A suspend event A, caused e.g., by a user input or system timeout, causes a System Management Interrupt (SMI). The SMI places the processor in System Management Mode (SMM) and calls an SMI handler routine. The SMI handler calls the APM core in SBIOS 220 , which begins executing commands in the “pre-suspend phase” (see FIG. 5). Eventually, the APM core reaches a point where it is ready to notify VBIOS 300 of the suspend event. For an Intel video BIOS, the video BIOS may be called through an interface such as the Int10h Sub-Function 5F66h routine, shown as call B in FIG. 4.
[0049] Referring back to FIG. 5, the video BIOS checks the state of registers 230 and 235 , to insure, e.g., that a miniport driver is loaded and expects to handle PM events, that the driver has unmasked its interrupt, and that an APM operation is not already pending. If these status checks are passed, video BIOS 300 sets the APM Power State flag to 2h at point C, and at point D sets interrupt trigger register 235 to cause an interrupt to the miniport driver after the processor exits from SMM. The video BIOS then returns a status to the SBIOS indicating that the driver has been signaled. The SBIOS APM core sets an SMI timer callback and exits to allow the driver to process the interrupt request.
[0050] When SMM exits to the OS context and the processor begins kernel mode processing, it processes the interrupt request (IRQ) initiated by the video BIOS and calls the video miniport driver's interrupt service routine (ISR). The video miniport driver ISR reads interrupt trigger register 235 at point E and determines that an APM event has occurred. The driver then reads the APM Power State flag from status flag register 230 to determine that the event is an APM suspend event.
[0051] Miniport driver 320 then calls its routine for responding to an APM suspend event. During execution of this routine at F, miniport driver 320 calls an OS function to signal the APMSuspendEvent registered by COM 360 during initialization. Miniport driver 320 also sets the APM Status flag in register 230 to a value 1h, indicating that the suspend event is pending. The miniport driver then returns from its ISR.
[0052] The OS places the APMSuspendEvent in the message loop for COM 360 . When COM 360 is called in user mode, it receives the event message and executes code that will have the effect of placing the graphics subsystem in a quiescent mode. For instance, at G, COM 360 can create a full screen, exclusive display context, and set the display mode to this context by calling a GDI function. COM 360 then fills the screen with black using another GDI function. At J, COM 360 sets the semaphore associated with APMSuspendEvent to signal that is has set the graphics in a quiescent state.
[0053] GDI 260 responds to the display mode request by signaling display driver 340 , at H, to set the driver mode. In Microsoft Windows implementations, a call to DrvAssertMode with the bEnable parameter set to FALSE will cause the hardware to be reset to its default mode so that the miniport driver can assume control. The display driver, by definition, places the graphics in a quiescent state when a mode switch is requested.
[0054] At point I, display driver 340 signals miniport driver 320 to reset the graphics device. The reset signal, coupled with the semaphore set by COM 360 , confirm to miniport driver 320 that graphics has successfully been placed in a quiescent state. Upon receiving notice that the hardware is in a quiescent state, miniport driver 320 will proceed to save any fragile state that may exist. At point K, driver 320 sets the APM Status flag in register 230 to indicate that the graphics state has been successfully saved, and graphics shutdown may now proceed.
[0055] According to the callback time set by the SMI handler, an SMI timer callback will cause the system at some point to reenter SMM. The SBIOS APM core calls VBIOS 300 once again. This time, when VBIOS 300 checks status flag register 230 , it finds that the APM Status flag indicates successful completion of a graphics transition. At L, VBIOS 300 exits to the APM core with a return code indicating that the driver has completed, and is ready for the graphics suspend. SBIOS 220 can then remove power from graphics components.
[0056] Several attractive features are evident in the solution just described. One, the modifications necessary to support this OS-independent procedure by and large reside within the graphics software. Two, this solution provides synchronization between software that is truly asynchronous at the user, kernel, and system management levels. Three, this solution is initiated outside of the operating system, but then works with the OS by elevating the power event all the way up to the user level, so that when the event comes back down it is handled just like any other user event. This not only ensures that the driver can handle the event cleanly, but also ensures that other applications will be notified of the event and have a chance to respond (since GDI will notify all applications, in a way that they understand, that a display mode switch is imminent). The ability of this method to leverage OS behavior to effect PM, even though the OS may not explicitly handle power management events, is a true advantage over an approach that would attempt to handle power transitions independent of the OS environment.
[0057] [0057]FIGS. 6 and 7 show an analogous procedure for resuming the graphics state that existed prior to the suspend operation of FIGS. 4 and 5. In response to an APM resume event, the same procedure as described in the preceding example is followed, with the following differences. At point C, the APM Power State flag is set to 4h, indicating that the system is transitioning to APM resume. At point F, the video miniport driver restores any fragile state that it has saved on suspend, and signals APMResumeEvent. COM 360 recognizes this message as a request to exit exclusive, full screen mode, and responds at G by calling DrvAssertMode with the bEnable parameter set to TRUE, to return the graphics to the original state it was in prior to the suspend operation. Finally, video miniport driver 320 looks for the semaphore associated with APMResumeEvent at J.
[0058] The preceding discussion has not addressed the state of the flags APM BIOS Memory Allocated and Pipeline State Saved. Assuming that the video BIOS was responsible for saving the graphics fragile state, it would have been informed to save graphics state via these flags. Normally, however, the miniport driver is responsible for saving and restoring state, and would do so after COM 360 has set the driver mode. In some instances, a DrvAssertMode(FALSE) call will automatically cause state to be saved; otherwise, the miniport driver can call a helper routine (e.g., through a Deferred Procedure Call or DPC) to save the state.
[0059] [0059]FIGS. 8A, 8B, and 8 C show this process for one situation. In FIG. 8 a , processing proceeds similar to FIG. 5, except that the miniport driver ISR detects that it is to save fragile state, and calls, e.g., PAL 310 to begin saving state.
[0060] In FIG. 8 b , the SMI timer callback causes the processor to reenter SMM. Since the miniport driver is still saving graphics state, the video BIOS reads the status flag register, notifies the SBIOS that the save is still pending, and the SBIOS APM core then sets another SMI timer callback.
[0061] In FIG. 8 c , the miniport driver completes saving the graphics state, and sets the APM Status flag to indicate successful completion. On the next SMI timer callback, the VBIOS detects successful completion, and notifies the SBIOS that suspend can now proceed.
[0062] The previously described embodiments are also intended to be configurable so as to cooperate with a PM driver to provide similar advantages. For instance, FIG. 9 illustrates how a suspend event is processed with a resident PM driver cooperating with the graphics software. When the suspend event A is received by the APM core in SBIOS 220 , it passes notification of the suspend event to PM driver 420 at B (via some method that will depend on the PM driver vendor). The PM driver issues an IRP to PAL 310 at C (or notifies PAL 310 indirectly by one of the other methods previously described). PAL 310 triggers an interrupt to video miniport driver 320 at D, which causes the miniport driver to execute the same routines that were executed when it was interrupted by the video BIOS in the previous example. Event processing proceeds through COM 360 , GDI 260 , display driver 340 , and back to video miniport driver 320 as previously described. At J, video miniport driver 320 sets the APM Status flag in register 320 to indicate success. On the next callback to PAL 310 by PM driver 420 , PAL 310 observes that the APM Status flag is set, and signals PM driver 420 at K that the graphics subsystem is ready to suspend. At L, PM driver signals SBIOS 220 (by whatever means it has defined) that graphics may be suspended.
[0063] Timing diagrams and the resume graphics process flow have not been illustrated explicitly for the PM driver case of FIG. 9, as such are fairly evident from the material previously presented. It is noted, however, that although it is possible that SBIOS 220 may still call VBIOS 300 during a PM event in this configuration, VBIOS 300 will recognize from the status flag register contents that a PM driver is resident, and will not attempt power management.
[0064] [0064]FIG. 10 shows a configuration with an APM or ACPI driver 400 loaded with the OS. In this case, the video miniport driver 320 has set the status flag register 230 to indicate that support will be provided by driver 400 , thereby disabling the separate PM functionality existing in COM 360 , display driver 340 , video miniport driver 320 , PAL 310 , and VBIOS 300 . Suspend request B and reply D are handled in the appropriate APM or ACPI way. The APM or ACPI driver broadcasts the suspend event at C to registered applications, which may include COM 360 and display driver 340 . Although these components may react to the event broadcast using the prior technique for capturing the display and setting a quiescent state, such measures are likely unnecessary. The described graphics PM functionality remains in place, however, in case the system is booted with a different OS.
[0065] Although the preceding description uses a graphics subsystem as an exemplary application of the invention, similar principles can be used to effect power management support for other computer subsystems. The subsystem needs some power-management firmware that can receive notification of power management events, a device driver, and a defined register that can be used to asynchronously pass power management status flags between the two. A support application should also exist to respond to power management event notification from the device driver by issuing commands to place the subsystem in a safe state during transitions to a lower power state, and to restore the original state when the subsystem returns to a fully operational power state.
[0066] Many variations on the above embodiments will become apparent to those skilled in the art upon reading this disclosure. The specific interrupt and messaging techniques, flag definitions and format, software partitioning, and sequencing that have been disclosed are merely part of one group of techniques for implementing one set of embodiments, and many others may serve equally well in a given situation. Some operating systems will distribute driver component functionality differently, and may even place driver components at the user level. It is acknowledge that some functions described as software could be implemented in hardware as well. One of ordinary skill in the art will recognize that the concepts taught herein can be tailored to a particular application in many other advantageous ways.
[0067] The preceding embodiments are exemplary. Although the specification may refer to “an”, “one”, “another”, or “some” embodiment(s) in several locations, this does not necessarily mean that each such reference is to the same embodiment(s), or that the feature only applies to a single embodiment.
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Methods and devices for power management of graphics or other computer subsystems are disclosed. In one embodiment, graphics software components are configurable in a manner that allows them to place the graphics subsystem is a “safe” state prior to a suspend event, and back into a “working” state after a resume event, without explicit support from an operating system (OS) power management driver. When operating in the absence of an OS-supplied driver, the graphics driver receives notification of power management events, and sends a message to a support application, which then causes the graphics to enter a quiescent state by taking exclusive ownership of the display and issuing standard device-independent OS graphics calls (for a power-down event) or to relinquish display ownership (for a power-up event). From within this quiescent state the graphics may be safely power managed without adverse effects to the graphics chips and without creating any instabilities in other graphics applications. These graphics software components detect the level of power management provided by the OS during system initialization, and self-configure such that an appropriate graphics power management scheme is in place for whatever level of power management is supplied—or not supplied—by the operating system.
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[0001] This application is a National Stage completion of PCT/FR2009/001129 filed Sep. 23, 2009, which claims priority from French patent application serial no. 08/05278 filed Sep. 25, 2008.
FIELD OF THE INVENTION
[0002] The present invention relates to a heat generator with magnetocaloric material comprising at least one thermal flux generation unit provided with at least one thermal module containing a magnetocaloric element across which a heat transfer fluid circulates according to an alternating movement on both sides of the magnetocaloric element, the heat generator comprising also a magnetic arrangement put in motion to alternately subject the magnetocaloric element to a magnetic field variation and create alternately in the magnetocaloric element a heating cycle and a cooling cycle, generating the creation of, and then maintaining, a temperature gradient between the two opposite ends of the magnetocaloric element, the alternating displacement of the heat transfer fluid being synchronized with the magnetic field variation, the magnetocaloric element being integrated in a closed heat transfer fluid circulation circuit connecting the two opposite ends of the magnetocaloric element and the closed circuit comprising a single means of displacement of the heat transfer fluid through the magnetocaloric element in both displacement directions.
BACKGROUND OF THE INVENTION
[0003] Magnetic refrigeration technology at ambient temperature has been known for more than twenty years and the advantages it provides in terms of ecology and sustainable development are widely acknowledged. Its limits in terms of its useful calorific output and its efficiency are also well known. Consequently, all the research undertaken in this field tends to improve the performance of such a generator, by adjusting various parameters, such as the magnetization power, the performance of the magnetocaloric element, the surface for heat exchange between the heat transfer fluid and the magnetocaloric elements, the performance of the heat exchangers, etc.
[0004] One of the difficulties in the realization of generators that use one or more magnetocaloric elements lies in the exchange of thermal energy between these magnetocaloric elements and the circuit(s) that use, consume or exchange the thermal energy with the generator, and that are connected with the latter. A solution for performing this exchange consists in making a heat transfer fluid, liquid or not, circulate through the magnetocaloric elements, in synchronization with the variation of the magnetic field which the magnetocaloric elements are subjected to and to perform then a thermal exchange between the heat transfer fluid and the circuits.
[0005] The publication WO 03/016794 gives an example of implementation in which the magnetocaloric elements are in a closed fluid circuit including a circulation pump for the heat transfer fluid, located outside of the thermal module and requiring specific control and connection means.
[0006] In the French patent application no. 07/07612, the applicant presents a heat generator with magnetocaloric material in which the heat transfer fluid is circulated between the magnetocaloric elements and two exchange chambers called a hot chamber and a cold chamber. This circulation is carried out by means of two sets of pistons that are positioned opposite the magnetocaloric elements and driven by a control cam connected to an actuator.
[0007] This generator nevertheless has a disadvantage related to the need for two cams to drive the two sets of pistons positioned opposite each magnetocaloric element. This leads to an increase of the number of parts making up the generator, and more specifically of the number of moving parts and thus to an increase of the risk of malfunction, to a higher risk of wear due to the permanent contact between the cam and the pistons, and to a degradation of the efficiency of the generator. Furthermore, the high number of parts also increases the space requirement of the generator and thus limits its ability to be integrated in environments in which the available space is reduced and limited.
SUMMARY OF THE INVENTION
[0008] The present invention aims to overcome these disadvantages by offering a heat generator in which the number of moving elements is reduced and whose configuration allows an important reduction of the space requirement of the generator.
[0009] For this purpose, the invention concerns a heat generator comprising a thermal flux generation unit comprises a field closing device arranged to loop the magnetic flux generated by the magnetic arrangement and in that the field closing device is provided with a control device of the means of displacement.
[0010] The closed circuit can be made of one or several conduits or channels connecting the opposite ends of the magnetocaloric element.
[0011] The integration of a single means of displacement allows limiting the number of parts of the heat generator and thus reducing its production cost. Likewise, the use of a device necessary for the operation of the generator as a device allowing to actuate the means of displacement of the heat transfer fluid allows for an even further reduction of the number of parts making up the generator and, furthermore, to reduce its space requirement.
[0012] The means of displacement can be a piston that moves in a jacket formed in the corresponding closed circuit.
[0013] Advantageously, the field closing device can be made out of a magnetizable material and be coupled magnetically with the mobile magnetic arrangement.
[0014] In a first embodiment variant, the control device can be a cam profile with an approximately sinusoidal shape whose amplitude determines the stroke of the pistons and whose sinusoidal phase corresponds globally to a heating cycle and to a cooling cycle of the magnetocaloric elements.
[0015] For that purpose, the piston can comprise a groove in which the cam profile circulates.
[0016] In a second embodiment variant, the piston can include a zone of magnetizable material and can be coupled magnetically with the field closing device making up the control device.
[0017] In a first embodiment, the thermal flux generation unit can be provided with several thermal modules and have a circular structure in which the magnetocaloric elements are arranged on a circle around a central axis, the magnetic arrangement can be rotated around the central axis and the magnetocaloric elements can be arranged between the magnetic arrangement and the field closing device.
[0018] In this configuration, the field closing device can be coupled magnetically with the magnetic arrangement and the closed circuit and the jacket of the piston can be made of two circular parts meant for being assembled, the circular parts can be approximately symmetrical with respect to their assembly plane, and can each comprise at least one recess forming a part of the jacket of a piston and a groove with open ends and forming a connection channel between the recess and the corresponding magnetocaloric element.
[0019] According to a second embodiment, the thermal flux generation unit can have a linear structure in which the magnetocaloric elements are aligned and the magnetic arrangement can be driven in reciprocating translation along the magnetocaloric elements.
[0020] In this embodiment, the field closing device can have a yoke-shaped profile whose both legs are provided, on their internal faces, with permanent magnets with opposite polarities and making up the magnetic arrangement and the control device can have the shape of a driving pin housed in a corresponding groove of each piston.
[0021] As a variant, the field closing device can also have a yoke-shaped profile whose both legs are provided, on their internal faces, with permanent magnets with opposite polarities and making up the magnetic arrangement, the control device can nonetheless comprise two permanent magnets with different polarities located at a distance and opposite from each other and the piston can comprise a magnet arranged with respect to the permanent magnets of the control device so as to be pushed back by each of the latter, and thus follow their displacement. The movement of the control device thus leads to that of the piston, without contact between them, apart from the magnetic arrangement. For that purpose, the piston can be located approximately between the two permanent magnets of the control device and preferably above them.
[0022] In order to ensure that the heat exchange between the magnetocaloric element and the heat transfer fluid occurs after a phase change of the magnetocaloric element, the generator can also comprise, in its linear version, an offset means suitable for anticipating and/or delaying the movement of the piston with respect to that of the magnetic arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The present invention and its advantages will be better revealed in the following description of an embodiment given as a non limiting example, in reference to the drawings, in which:
[0024] FIG. 1 is an exploded view of a heat generator with a circular configuration, according to a first embodiment of the invention,
[0025] FIG. 2 is a transparent front view of the thermal module of the generator of FIG. 1 ,
[0026] FIG. 3 is a section view along plane III-Ill of FIG. 2 ,
[0027] FIG. 4 is a view of detail B of FIG. 3 ,
[0028] FIG. 5 is an exploded view of an embodiment variant of a circular heat generator,
[0029] FIG. 6 is a longitudinal sectional view of the generator represented in FIG. 5 ,
[0030] FIGS. 7A and 7B are perspective views of a heat generator with a linear configuration, according to a second embodiment of the invention, in two positions of the magnetic arrangement, and
[0031] FIG. 8 is a partial section view of FIG. 7A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] In the implementation examples shown, identical parts or sections have the same numerical references.
[0033] FIGS. 1 to 6 represent a heat generator 1 according to a first embodiment of the invention, in which the structure of the generator 1 is circular.
[0034] The heat generator 1 represented in FIGS. 1 to 4 comprises only one thermal flux generating unit 2 . This unit is provided with several thermal modules 3 each comprising a magnetocaloric element 4 across which a heat transfer fluid is circulated by a means of displacement 5 in the form of a piston. For simplification reasons, only one piston 5 is represented in FIG. 1 . The magnetocaloric elements 4 are arranged in a circle around a central axis A and a magnetic arrangement 9 rotates around the central axis A so as to submit the magnetocaloric elements 4 to a variable magnetic field to perform alternately a heating cycle and a cooling cycle in the latter.
[0035] The magnetocaloric elements 4 are permeable to the heat transfer fluid and can be made of one or several magnetocaloric materials. They comprise open fluid passages that can be made of the pores of a porous material, the mini or micro-channels machined in a full block or obtained by assembling for example superposed grooved plates.
[0036] The heat transfer fluid is moved in each thermal module 3 in a reciprocating movement through the magnetocaloric element 4 , on either side of the latter. For that purpose, the thermal module 3 also comprises a closed circuit 6 for the circulation of the heat transfer fluid. This circuit is made of channels connecting the two opposite ends 7 and 8 of the magnetocaloric element 4 and comprises a means of displacement 5 that moves the heat transfer fluid in a reciprocating movement. In the represented examples, the means of displacement 5 , 50 , 60 is a piston. It can nevertheless be realized in any other form, such as a membrane for example, suitable for generating reciprocating movement of the heat transfer fluid.
[0037] All the described embodiments show that by fluidly connecting both ends 7 and 8 of the magnetocaloric element 4 only one means of displacement 5 , 50 , 60 is needed to circulate the heat transfer fluid in both directions through the magnetocaloric element 4 . This makes the construction of the heat generator according to the invention easier and also limits its space requirement since, on the one hand, only one means of displacement 5 , 50 , 60 is required for the circulation of the heat transfer fluid in each thermal module and, on the other hand, this implies the installation of only one control device of the means of displacement.
[0038] The heat generator 1 also comprises a magnetic arrangement 9 put in motion to subject alternately each magnetocaloric element 4 to a magnetic field variation and create alternately in the magnetocaloric element 4 a heating cycle and a cooling cycle, generating the creation of, and then maintaining, a temperature gradient between the two opposite ends 7 and 8 of the magnetocaloric element 4 and the reciprocating movement of the heat transfer fluid is synchronised with the variation of the magnetic field.
[0039] The piston 5 is moved in a jacket 11 by means of a cam profile 19 forming a control device, provided on the side of a field closing device 30 arranged to loop the magnetic flux generated by the magnetic arrangement 9 . This field closing device 30 is located opposite the jacket 11 of the piston 5 . For minimizing the space requirement, all pistons 5 , the magnetocaloric elements 4 , the magnetic arrangement 9 and the field closing device 30 are arranged concentrically around the central axis A. The jacket 11 comprises an opening 17 to facilitate positioning the cam profile 19 in a corresponding groove 18 of the piston 5 in order to actuate the latter. For that purpose, the cam profile 19 has an approximately sinusoidal shape, with an amplitude that determines the stroke of the pistons 5 and a sinusoidal phase that corresponds globally to a heating cycle and a cooling cycle of the magnetocaloric elements 4 . Rotation of the field closing device 30 , and thus of the cam profile 19 , leads to the displacement of the pistons 5 , according to a reciprocating movement. This rotation is generated through the intermediary of the rotation of the magnetic arrangement 9 , with which the field closing device 30 is coupled magnetically.
[0040] For that purpose, the magnetic arrangement 9 is made of an assembly of magnetized parts 20 and non magnetized parts 21 and the field closing device 30 is made in the shape of a ring out of a magnetizable material, for example iron, comprising bosses or protuberances 22 located opposite the magnetized parts 20 to allow magnetic coupling with the magnetic arrangement 9 and obtain this way the rotational drive of the field closing device 30 when the magnetic arrangement 9 rotates. Even though the field closing device 30 represented comprises four bosses 22 , only one boss is sufficient to obtain the magnetic coupling.
[0041] The magnetic arrangement 9 can be coupled with an actuator (not represented) in order to be mobile in rotation with respect to the magnetocaloric elements 4 . The simultaneous movement of the magnetic arrangement 9 and of the field closing device 30 in particular avoids the generation of eddy currents. The magnetocaloric elements 4 are arranged around the magnetic arrangement 9 and between the latter and the field closing device 30 . This way, displacement of the magnetic arrangement 9 subjects the magnetocaloric elements 4 to a magnetic field variation and simultaneously leads to displacement of the field closing device 30 .
[0042] The heat generator 1 represented in FIGS. 1 to 4 has a configuration that favours a limited space requirement, in particular thanks to the concentric structure around the central axis A and formed by the magnetic arrangement 9 , the field closing device 30 in form of a ring, the magnetocaloric elements 4 also arranged concentrically around the central axis A and finally the pistons 5 integrated in the jackets 11 provided in two circular parts 12 and also concentric with the above-mentioned elements. Such a heat generator 1 can thus have a width of a few centimetres.
[0043] The two circular parts 12 are symmetrical with respect to their assembly plane and comprise recesses 15 which form a part of the jacket 11 of the pistons 5 and a groove 16 fluidly connecting each recess 15 with the corresponding magnetocaloric element 4 . The circular parts 12 are arranged so that the cam profile 19 is positioned in the groove 18 of each piston 5 . The recesses 15 and the grooves 16 of the circular parts 12 can be produced by boring, drilling, moulding or any other similar process and form a part of the closed circuit 6 for the circulation of the heat transfer fluid.
[0044] The generator 1 also comprises two protective covers 23 that tightly close the grooves 16 of the circular parts 12 .
[0045] The heat generator 100 represented in FIGS. 5 and 6 is made according to a variant of the embodiment in which the structure of the generator 100 is circular and comprises a circular thermal flux generation unit 102 . The configuration of this generator is approximately identical with that of the generator 1 represented in FIGS. 1 to 4 and offers the same advantages, in particular regarding the reduced space requirement. However, the piston 50 is driven differently. As previously, the control device of the pistons 50 is made up of the field closing device 31 . But the pistons 50 are provided with a ring 51 made of a magnetisable material that couples magnetically with the field closing device 31 and follows the rotation of the latter without contact. The field closing device 31 can also comprise a cam profile 19 like that of the heat generator 1 of FIGS. 1 to 4 . However, in this example, it is not necessary to provide a groove in each piston 50 , since the field closing device 31 drives each piston 50 without any contact, by magnetic coupling. There is thus no risk of wear between the control device and the pistons 50 . The pistons 50 are preferably approximately cylindrical and have an area of magnetizable material 51 in the form of a ring mounted in a circular groove of the piston 50 .
[0046] Any other piston form can also suit and can be determined to minimize the hydraulic head losses.
[0047] FIGS. 7A , 7 B and 8 represent a heat generator 200 according to a second embodiment of the invention, in which the structure of the generator 200 is approximately linear. FIG. 8 represents more specifically, at the level of the cut section, the closed heat transfer fluid circulation circuit 6 , the magnetocaloric element 4 and the piston 60 .
[0048] The thermal flux generation unit 202 is linear, the magnetocaloric elements 4 being aligned. In the represented example, the heat generator 200 is made up of only one unit 202 comprising a thermal module 3 . The invention covers, of course, heat generators comprising several thermal flux generation units. The number of units and thermal modules will be determined as a function of the power of the heat generator.
[0049] The field closing device 32 has a yoke-shaped profile whose both legs are provided, on their internal faces, with permanent magnets 24 with opposite polarities and making up the magnetic arrangement 9 . The reciprocating translational movement (according to arrow F) of the field closing device 32 and of the magnetic arrangement 9 subjects the magnetocaloric elements 4 aligned between the magnets 24 to a magnetic field variation. Furthermore, the field closing device 32 comprises, for each piston 60 , a driving pin 192 to drive it. The driving pin ensures the mechanical coupling between the field closing device 32 and the heat transfer fluid displacement means, here in the form of pistons 60 . This way, the movement of the magnetic arrangement 32 leads on the one hand to a variation of the magnetic field in the magnetocaloric elements 4 , and thus to an alternation of heating and cooling cycles of the latter and, on the other hand, to the simultaneous movement of the driving pins 192 which in turn move the pistons 60 in the corresponding jacket 11 , and thus the heat transfer fluid in the closed circuit 6 .
[0050] Furthermore, the represented generator 200 comprises an offset means 10 that allows offsetting the movement of the piston 60 with respect to that of the magnetic arrangement 32 . This means is implemented in the form of two stops 13 , 14 made in a U-shaped part that is mounted on the field closing device 32 . These two stops 13 , 14 are arranged underneath the piston 60 and co-operate with the driving pin 192 . The latter is thus driven by these two stops 13 , 14 when the field closing device 32 moves according to arrow F. They allow controlling the movement of the piston 60 in synchronism with the movement of the field closing device 32 .
[0051] So, in FIG. 7A , when the field closing device 32 moves towards the right, it only drives the driving pin 192 , and thus the piston 60 associated to the latter, when the stop 14 comes in contact with the driving pin 192 , position represented in FIG. 7B . During this movement, the magnetocaloric element 4 has left the magnetic field of the magnets 24 and was subjected to a cooling cycle without movement of the piston 60 . The heat exchange between the hear transfer fluid and the magnetocaloric element 4 thus takes place when the stop 14 arrives in contact with the driving pin 192 and the field closing device 32 moves further towards the right in the figure, thus moving the piston 60 in the closed circuit 6 . The complete stroke of the field closing device 32 is not transmitted totally to the piston 60 .
[0052] Conversely, during the movement of the field closing device 32 towards the left on FIG. 7B , the magnetocaloric element 4 is subjected to a magnetic field and thus to a heating cycle, without any move of the piston 60 , and thus of the heat transfer fluid. When the driving pin 192 comes in contact with the stop 13 , the latter drives it, which induces a movement of the corresponding piston 60 , and thus movement of the heat transfer fluid in the closed circuit 6 and thus heat exchange between the latter and the magnetocaloric element 4 .
[0053] Such an offset means enables optimizing the heat exchange between the heat transfer fluid and the magnetocaloric element 4 by performing it after a phase change of the magnetocaloric element 4 , and thus increasing the efficiency of the generator 200 .
[0054] In a non represented variant, the field closing device can have a yoke-shaped profile whose both legs are provided, on their internal faces, with permanent magnets with opposite polarities and making up the magnetic arrangement, the control device can nonetheless comprise two permanent magnets with different polarities located at a distance and opposite of each other and the piston can comprise a magnet arranged with respect to the permanent magnets of the control device so as to be pushed back by each of the latter, and thus follow their displacement. The displacement of the control device thus leads to that of the piston, without contact between the latter, apart from the magnetic arrangement. For that purpose, the piston can be located approximately between the two permanent magnets of the control device and preferably above them.
[0055] Even though all attached drawings illustrate heat generators 1 , 100 , 200 comprising only one thermal flux generation unit 2 , the invention also provides for the production of a heat generator having a stepped structure with several thermal flux generation units 2 , 102 , 202 . Such a configuration allows increasing the efficiency of the heat generator according to the invention.
POSSIBILITIES FOR INDUSTRIAL APPLICATION
[0056] This description shows clearly that the invention allows reaching the goals defined, that is to say to offer a heat generator 1 , 100 , 200 with a simple design and with a reduced space requirement, limiting the number of moving elements for the circulation of the heat transfer fluid in the thermal modules 3 .
[0057] Such a heat generator 1 , 100 , 200 can find an application, in industry as well as domestic, in the area of heating, air conditioning, tempering, cooling or others, at competitive costs and with reduced space requirements.
[0058] Furthermore, all parts making up this heat generator 1 , 100 , 200 can be manufactured according to reproducible industrial processes.
[0059] The present invention is not restricted to the example of embodiment described, but extends to any modification or variant which is obvious to a person skilled in the art while remaining within the scope of the protection defined in the attached claims.
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A thermal generator ( 1 ) comprises at least one thermal flow generation unit ( 2 ) that is provided with at least one thermal module ( 3 ) each containing a magnetocaloric member ( 4 ) through which a coolant flows. A magnetic arrangement ( 9 ) is actuated for alternatively subjecting each magnetocaloric member ( 4 ) to a variation in magnetic field, the alternating movement of the coolant is synchronized with the magnetic field variation, the magnetocaloric member ( 4 ) is integrated into a closed flow circuit ( 6 ) that connects the two opposite ends ( 7 ) of the magnetocaloric member ( 4 ), and the closed circuit includes a single element ( 5 ) for moving the coolant through the magnetocaloric member ( 4 ).
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of our prior application Ser. No. 09/642,548, filed Aug. 17, 2000, now U.S. Pat. No. 6,427,426, and entitled Method and Apparatus for Safely Riding An Animal, that in turn is a continuation of our application Ser. No. 09/026,850, filed Feb. 20, 1998, now U.S. Pat. No. 6,105,345, and entitled Safety Apparatus and Method for Riding an Animal.
FIELD OF THE INVENTION
The present invention pertains to a latch for an animal rigging and to a method for its use and more particularly to a releasable latch that is insertable in a rigging that is attached to an animal and that can be quickly and controllably unlatched.
BACKGROUND
Riggings are used on animals for various purposes including to provide a hand-hold for a bull rider, as discussed in more detail below, but animal riggings for other purposes are well known in the art.
Bull riding is considered the rodeo's roughest, wildest, and most dangerous event. It is easy to see why. Bull riders are usually of slight build, weighing from one hundred thirty to one hundred fifty pounds. In contrast, the roughstock selected for bull riding are usually specially cross-bred and managed Brahma bulls with known reputations and characteristics. These bulls have great strength and ferocity, are extremely quick despite their size, and have a predisposition to attack a human. Such a bull can weigh more than a ton, can lift more than its weight, has the agility to jump higher than its height, and can have sharp horns exceeding one foot in length. Unlike a horse that will look back and interact with its rider and avoid stepping on him if thrown, a bull has little empathy for its rider and will attempt to trample on and gore a down rider.
As is well known, while the bull is in the chute, a bull rope is wrapped around the girth of the bull and provides a hand-hold back of the bull's hump. The bull rider mounts the bull and grasps the hand-hold with one hand by which he holds the rope tightly around the bull. The other hand remains free and must not touch the bull or the rope during the ride, or else the rider will be disqualified. Prior to grasping the hand-hold, the rider puts his holding hand in a glove saturated with rosin. The gloved hand is placed in the hand-hold, and the free end of the bull rope is wrapped around the hand so that the rider can obtain a tight grasp on the rope.
From the moment the gate opens, the rider must remain on the bull for at least eight seconds or be disqualified. During the ride, the bull ferociously tries every movement to dismount and injure the rider—bucking, spinning, twisting, bolting forward and then abruptly stopping, flying completely off the ground and then slamming down hard, cocking his head and neck back and forth and from side to side thereby attempting to hook the rider with its horns, and rolling fore and aft and from side to side. Moreover, in contrast to a horse, the bull's skin is relatively loose on its body, causing the bull's hide to roll simultaneously with its other wild movements.
The rider must rely only on his single-handed grip of the bull rope, along with his training that provides him with a sense of timing, anticipation, and balance. Still, the odds greatly favor the bull in this contest in that statistics show that only about one out of ten or twelve riders remain on a bull for the required eight seconds. A rider may be considered lucky if he is thrown clear of the bull or if the attending cowboys, or so-called clowns, are able to distract the bull from a downed rider. Too often, the result of being thrown is serious injury or death.
In a desperate attempt to remain on the bull, the rider attempts to achieve a very tight grip on the rope before the chute is opened. Although a tight grip may be an advantage for staying mounted, it is a disadvantage if the rider is thrown from the beast. One of the most serious problems occurs when a rider is thrown from the bull but his hand remains caught in the bull rope. This can easily occur because before leaving the chute, riders typically pound their rosin-soaked glove hand around the rope, trying to tighten the grip. Also, because of the twists and turns of the bull, the rider's hand may become entangled in the hand-hold and the rope as he is thrown from the bull. Moreover, riders sometimes pack their hands too securely even to the extent of doing what is termed a “suicide wrap,” that is, wrapping the bull rope around the gloved hand in such a way that it is almost inextricably connected to the bull rope under the riding conditions.
When a thrown rider's hand is caught, the clowns rush in and attempt to dislodge the hand. With the rigging currently used, the clowns must try to untie and unwind the rope from the caught hand or to slip the hand out of the rope and in this manner free the rider. For this purpose, a cowbell is often attached to the bull rope under the bull's belly to provide a large object that can be grabbed in an effort to control the rope.
These rescue efforts are by no means a satisfactory solution to the problem. It may be extremely difficult or impossible to dislodge the rider's hand while the bull continues to gyrate wildly. It also places the clowns, in addition to the rider, at risk. Every second is critical in this rescue mission. In severe situations, a dozen or more cowboys may encircle the bull attempting to control and to release the rider from the bull. In the meantime, the rider or one or more of the cowboys may be severely injured or killed.
SUMMARY
A latch is provided that may be inserted in an animal rigging and is controllably releasable for quick unlatching. Such a rigging is normally cinched about the body of the animal for various purposes, but with the latch in the rigging, the rigging can be quickly released from the animal when desired. For a bull rigging, the latch is inserted in the rope that assists a rider in maintaining balance on the animal and allows the rider to be quickly separated from the animal if a limb of the rider becomes caught in the rope when the rider is thrown from the animal. The bull rigging includes a holder or handle interfittingly engaged by a limb of the rider while mounted on the animal to aid the rider in remaining balance on the animal. The inserted latch is normally closed but may be released, that is, unlatched, either by the rider if possible or by an attendant or otherwise if the limb of the rider is entangled with and caught in the rigging when the rider is thrown from the animal whereby the rider and the rigging can be pulled from or otherwise separated from the animal.
An object of this invention is to provide a releasable latch for an animal rigging.
Another object is enable a rider to become separated, released, and/or pulled away from an animal if thrown therefrom while a limb of the rider remains caught in the rigging on the animal.
Another object is to enable a rider to maintain balance on an animal being ridden and yet to allow the rider to escape from the animal if thrown therefrom while a limb of the rider remains hung up in the rigging around the animal.
A further object is to enable a bull, or other rough animal, or any animal to be ridden in a safer manner.
An additional object is to reduce or prevent severe accidents or perhaps the deaths of bull riders as a result of being thrown from the bull while the rider's hand remains caught in the bull rope.
Yet another object is to allow bull riders to obtain tighter grips on the bull rope thereby to improve the rider's chances of remaining on the bull during a regulation ride while reducing the fear of being hung up in the bull rope if the rider is thrown from the bull while the rider's hand remains caught in the rope.
Another object is to provide a latch that dependably maintains the integrity of a bull rope for cinching around the bull during a bull riding session and yet can be quickly released to establish a break or separation in the rope if the rider is thrown from the animal and cannot release his hand from its grip on the rope.
An additional object is to enable a bull rider or an attendant such as a clown or other cowboy to release the bull rope from its cinched condition around the bull if the rider is thrown from the bull while his hand remains caught in the bull rope.
A still further object is to provide a safety latch for a bull rope having visible space thereon for indicia such as the rider's name, awards or insignia, a manufacturer's name, or other advertising material.
Yet another object is to provide a safety latch for a bull rope that is easy to incorporate in a standard bull rope.
Another object is to provide a safety latch which does not interfere with the operation of a standard bull rope.
An additional object is to provide a safety latch for the rigging on an animal being ridden that does not injure the animal.
These and other objects will become apparent upon reference to the following drawings and accompanying description.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a Brahma bull with the bull rope cinched around the body of the bull and including the safety apparatus of the present invention.
FIG. 2 is an enlarged transverse vertical section taken generally along line 2 — 2 in FIG. 1 .
FIG. 3 is an enlarged face view of the safety apparatus as seen from the left side of FIG. 2 with bull rope being grasped by the gloved hand of a rider, but with the remainder of the bull rope, the bull's back, and the arm of a rider only partially shown.
FIG. 4 is a still further enlarged fragmentary face view of the safety apparatus shown in its latched position with parts of covers shown in phantom to reveal latching members underneath.
FIG. 5 is a fragmentary face view of the safety apparatus, at the same sale as FIG. 3, in its covered, latched position and also showing a pull strap extending rearwardly from the latch pin of the apparatus.
FIG. 6 is an fragmentary edge view of the bull rope and the safety apparatus as shown in FIG. 3 but showing less of the rope and omitting any showing of the animal.
FIG. 7 is an enlarged fragmentary section taken along line 7 — 7 in FIG. 4 .
FIG. 8 is a fragmentary plan view of the subject safety apparatus on the same scale as FIG. 4 but showing the latch in unlatched position and oriented ninety degrees from FIG. 4 .
FIG. 9 is an exploded face view of one of the latching members of the present invention and its associated latching end portion of the bull rope.
FIG. 10 is a section taken on line 10 — 10 in FIG. 9 .
DETAILED DESCRIPTION
A Brahma bull 20 of the type used in rodeo competition for bull riding is generally shown in side elevation in FIG. 1 . These are specially bred and managed animals, usually weighing more than a ton and standing about five feet in height. For purposes of subsequent reference, the bull has front legs 22 , a back 24 , a front hump 26 , horns 28 , a girth 30 , and a belly 32 . A bull rope or rigging 40 incorporating a latch 42 in accordance with the present invention is generally indicated in FIGS. 1 and 2. Except for the latch of the present invention, the bull rope is of well-known construction, the particular bull rope shown and described herein being manufactured by the Barstow Pro-Rodeo Equipment Company of 701 South Main Street, Suite 114, Corsica, Tex. 75110. The subject latch is not limited to use with this particular bull rope, however, as will be evident from the following description. Moreover, the present invention is not limited to use with a bull rope nor to bull riding but may be incorporated in other types of animal rigging where problems similar to those described herein are also encountered.
Before describing the latch 42 (FIGS. 1 and 2) of the present invention, the bull rope 40 shown in the drawings is described in some detail so that the manner of incorporating the latch may be better understood. Thus, the bull rope has a first-end portion 50 that is approximately eighty-seven inches long in the embodiment sold by the Barstow Company, a second-end portion 52 that is about seventy-seven inches long in the particular Barstow rope, and a handle or hand hold 54 that is about ten and a half inches long in the Barstow rope and that interconnects the first- and second-end portions of the rope. It is also to be noted that the invention is not limited to these or any other particular dimensions, such dimensions being given by way of providing a more complete description of the apparatus.
The first-end portion 50 (FIGS. 2 and 3) of the bull rope 40 is unchanged from the standard Barstow rope and is thus a single layer 61 of braided strands 63 of polyurethane or “poly” fibers 64 , each strand being about one-eighth inch in diameter, and the layer being about seven-eighths inch wide by one-quarter inch thick, thus having a generally uniform rectangular cross-section. The first-end portion terminates in a free end 60 that is finished in a terminal wrapping 62 of a small diameter cord, thereby exposing a tassel of the poly fibers.
The handle 54 (FIGS. 2, 3 , and 6 ) is unmodified from the standard Barstow bull rope 40 and thus is a single layer of braided strands in which is embedded a steel wire, not shown, and which includes a leather strap intertwined with the strands and encircling the steel wire throughout its length. In the Barstow rope, this handle is about three-quarters of an inch wide and about one-half inch thick at its maximum dimension along the path of the embedded wire. The handle has a first end 70 joined to the first-end portion 50 of the rope, and a first wrapping 72 of leather straps encircles this juncture. The handle has a second end 74 that is raised relative to the first end, thereby to provide a convenient opening for the rider's hand and which is maintained by the shape of the embedded wire. This second end of the handle is joined to the second-end portion 52 of the rope, and a second leather wrapping 76 is intertwined with the strands of the rope to strengthen this juncture. The first wrapping is approximately one and five-eighths inch wide by three-quarters inch thick, and the second wrapping is about two inches wide and one and a quarter inch thick in the standard Barstow rope being described.
The second-end portion 52 of the bull rope 40 (FIGS. 2 and 3) is modified to incorporate the subject latch 42 and thus includes a looped section 80 and a latching section 82 , the latter including the latch of the present invention. The looped section is a twisted pair 84 of polyurethane strands 86 , each strand being about five-sixteenths of a inch in diameter. This pair of strands extends from the latching section to a doubled-back end 88 thereby providing a loop. A plurality of braided retaining rings 90 of corded material are slideably fitted over the stands 84 thereby to maintain the twisted pairs in adjacent spaced relation and to define a loop of restricted size at the end 88 .
The latching section 82 (FIGS. 3, 4 , and 6 ) includes separable upper and lower latching end portions 100 and 102 respectively joined to the handle 54 and the looped section 80 . The upper and lower latching-end portions are of similar construction, each including inner and outer layers 104 and 106 , each layer being composed of braided strands 108 of polyurethane fibers. The upper latching-end portion has an upper end 110 joined to the second end 74 of the handle 54 and a lower latching end 114 . The lower latching-end portion 102 has a lower end 118 joined to the upper end of the looped section 80 and an upper latching end 120 . The double layers 104 and 106 of each latching-end portion have a width of approximately one and one-quarter inch and a thickness of approximately three-quarters of an inch.
As best shown in FIGS. 7, 9 , and 10 , the latching ends 114 and 120 of the latching-end portions 100 and 102 are blocks 125 of plastic caused by heating the polyurethane fibers, whereby they soften and flow together, forming blocks upon cooling and hardening. A pair of front holes 130 , a pair of rear holes 132 , and a center hole 134 are drilled all the way through the blocks in a particular pattern as shown in FIG. 9 and for a purpose to be described.
The latch 42 (FIGS. 3 through 10) also includes upper and lower, U-shaped latching members 140 and 142 of a high-strength material such as steel or a high-strength plastic. In the preferred embodiment of the invention illustrated, these latching members are made of steel and are approximately one and five-eighths inch wide by two inches long by one-half inch thick, although it is reiterated that the invention is not limited to any particular dimensions. Each latching member includes generally rectangular inner and outer plate 146 and 148 (FIGS. 9 and 10, especially), connected by an arcuate bight 150 . Each bight is formed with a pair of aligned-spaced eyelets 154 (FIGS. 8 through 10 ), and a stop tab 156 (FIGS. 7 and 10) projects inwardly from the inner plate toward the outer plate between the eyelets. The inner and outer plates of each latching member has two pair of aligned front holes 162 (FIGS. 9 and 10 ), two pair of aligned rear holes 164 , and a pair of aligned center holes 166 . The pattern of these holes is the same as the holes 130 , 132 , and 134 in the ends 114 and 120 .
The lower and upper latching ends 114 and 120 (FIGS. 8 through 10) of the upper and lower latching-end portions 100 and 102 are respectively fitted in the upper and lower latching members 140 and 142 so that the respective front, rear, and center holes 162 , 164 , 166 in the latching members are in alignment with the front, rear, and center holes 130 , 132 , and 134 of the latching ends 114 and 120 . As such, the ends 114 and 120 abut the stop tabs 156 of their respective latching members and do not encroach into the eyelets 154 .
Four outside female fasteners 170 (FIGS. 7 through 10) include internally threaded sleeves 172 slideably fitted in the four pairs of aligned holes 130 through 162 and 132 through 164 and smooth heads 174 that are preferably received in countersunk recesses around the holes in the outer plates 148 . Four inside bolts 180 have threaded shanks 182 fitted in the holes and threaded into respective sleeves of the fasteners. The bolts also have slotted heads 184 preferably received in countersunk areas around the holes of the inner plates 146 . Thus, by tightening the four bolts, the upper and lower latching ends 120 and 114 are tightly sandwiched between the inner and outer plates 146 and 148 of the latching members 140 and 142 .
To further secure each latching member 140 and 142 to its respective latching-end portion 102 and 100 , a thong 190 (FIGS. 3, 4 , and 8 ), preferably of leather, is threaded through the pair of aligned center holes 134 through 166 in each latching member. Each thong is interwoven with the strands 108 of its latching-end portion and then wrapped at 192 and 194 around the upper and lower ends 110 and 118 (FIG. 3) and tied. As such, each latching member is dependably connected to its respective latching-end portion. Each latching member 140 and 142 is also provided with side walls 196 and an end wall 198 (FIG. 8 ), thereby to enclose the latching ends 114 and 120 within the latching members. These side and end walls are provided by applying a cold bonding material in paste form, such as Loctite Weld, stock number 19986, which hardens upon drying.
The latch 42 further includes a latch pin 200 (FIGS. 3 through 8) having an elongated shank 202 which in the disclosed embodiment is approximately two inches long and about one-quarter inch in diameter. The latch pin is made of a high-strength material such as steel or a high-strength plastic, steel being used in the disclosed embodiment. The shank has front and rear ends, and a spring-pressed detent 204 is fitted in the front end of the shank so that it is spring-urged outwardly slightly from the outer diameter of the shank. Furthermore, a ring 206 similar to a key ring is connected to a hole in the rear end of the shank.
With the eyelets 154 of the latching members 140 and 142 interfitted so that all four eyelets are aligned (FIGS. 3 through 7 ), the shank is slideably inserted into the eyelets until the detent is exposed at the front of the latch. The latch pin can be slid between this latching position that holds together the latching members and thus the upper and lower latching-end portions 100 and 102 of the latching section 82 , and a released position (FIG. 8) that allows these upper and lower latching end portions to be separated. The detent retracts to allow such movement between latching and unlatched positions of the latching pin but prevents the latch pin from simply falling out of its latched position.
A flexible pull strap 215 (FIGS. 1 and 3 through 5 ) of a suitable fabric or plastic material has a front end 218 that is looped around the ring 206 and a rear end 220 that extends freely from the ring. The pull strap has two functions; namely, to be grasped in order to pull the latch pin 200 from its latched position out of the latching members 140 and 142 , and secondly, to provide a place for selected indicia, as indicated by the number 222 in FIG. 5 . This indicia may include the name of the bull rider, awards or records of the rider, advertising material, or the like.
Upper and lower cover sleeves 230 (FIGS. 3 through 5) of a soft material, such as leather, are slideably fitted on the upper and lower latching-end portions 100 and 102 . These sleeves have dimensions sufficient to allow them to be slid over the latching members 140 and 142 so as to conceal these latching members and prevent their direct contact with the bull 20 or other animal on which the rope 40 is used. As further such protection, an inside cover flap 232 , also preferably of a soft material such as leather, has a neck 234 slideably received on the upper latching-end portion 100 above the upper cover sleeve 230 and a generally rectangular panel 236 that extends downwardly under both the latching members 140 and 142 so as to bridge the gap between these latching members and further to protect the latch from contacting the bull 40 .
OPERATION OF THE APPARATUS AND DESCRIPTION OF THE METHOD
The apparatus of the present invention is particularly suited for use in a bull rope as 40 that is used for riding bulls, as 20 , in a rodeo. Thus, initially and normally, the latch pin 200 is in its latching position (FIGS. 3 and 4) holding the separable ends 114 and 120 together so that the bull rope is intact in the usual way. That is, the latching members 140 and 142 are interfitted with the eyelets 154 aligned, and the latch pin is slideably fitted into the eyelets so as to releasably connect the latching members and thus the looped and latching sections 80 and 82 of the second-end portion 52 of the bull rope. In this condition, the bull rope is a continuous piece as a standard bull rope would be without the subject latch. The sleeves 230 and flap 232 are then slid into positions over the latching members and with the flap 232 bridging the two latching members. After the bull 20 is guided into the chute, the bull rope 40 is extended in a continuous and uninterrupted loop around the girth 30 of the bull (FIGS. 1 and 2) in the usual way so that the handle 54 is located behind the hump 36 on the back 24 of the bull and the latch 42 is disposed along one side of the bull (the bull's left side as illustrated, but it could be on the right side if desired).
As is normally done, the free end 60 (FIGS 1 through 3 ) of the first-end portion 50 of the bull rope 40 is extended through the looped end 88 of the second-end portion 52 of the rope and is pulled upwardly so as to cinch the rope around the bull. In this sense, the free end 60 and the looped end 88 may be referred to as cinching ends of the rope. With the bull rope thus around the bull, it is to be noted that the pull strap 215 extends freely rearwardly from the latch 42 and that the indicia 222 faces outwardly of the bull. It is also to be noted that the covers 230 and the flap 232 prevent direct contact between the latch and the bull and also conceal the latch.
The rider, not shown, then mounts the bull 20 in the usual manner. The rider places a glove 250 (FIG. 3) on his hand 252 that he will use to grip the bull rope 40 . As is well known, prior to wearing the glove, the glove is saturated in rosin to serve as a stiffener for the glove. When mounted on the bull, the rider grasps the free end 60 of the bull rope to pull it tight and also grasps the handle 54 , as shown in FIG. 3 . In order to maximize his grip, the rider will typically pound the finger of his gloved hand down tightly around the handle. The stiffened and pounded rosin-saturated glove tends to hold this pounded grip in place.
Cinching the bull rope 40 around the bull 20 in the usual manner as briefly discussed above is not affected in any way by the latch 42 since the latch pin 200 is in its latched condition thereby maintaining the continuity of the bull rope. However, cinching of the bull rope helps to tighten the latching members 140 and 142 against the latch pin which aids in maintaining the latch in latched condition. It is also to be noted that the indicia 222 on the outside of the pull strap 215 is clearly visible.
The chute, not shown, is then opened to allow the bull 20 to charge into the bull ring or arena whereupon the bull attempts to dislodge the rider, and the rider attempts to remain on the bull at least for the eight seconds required for a qualifying ride. During this time, the bull is bucking, spinning, twisting, bolting forwardly and then stopping abruptly, completely flying off the ground and slamming down hard, cocking his head and neck back and forth and from side to side thereby attempting to hook the rider with its horns, and also rolling fore and aft and from side to side, using every technique it can to throw the rider. The rider's only hold on the bull is by his gloved hand 252 holding the free end 60 and the handle 54 of the bull rope 40 . He is not allowed to touch the rope or the animal with his free hand or else he will be disqualified.
Because of the importance of the rider's grip on the bull rope 40 , a rider may wrap the free end of the rope too tightly around his hand 252 . Accordingly, if the rider is thrown from the bull, this free hand may remain caught in the bull rope so that the rider is not thrown clear of the bull.
If the rider is thrown from the bull 20 while his hand remains hung up on the bull rope 40 , the latch 42 of the present invention is used to rescue the rider. In this case, the latch pin 200 may be removed in one of two ways. If the rider is thrown from the bull 40 toward the side where the latch is located, the rider may be able to grasp the pull strap 215 and pull the latch pin 200 out of the latching members 140 and 142 . Alternatively, cowboys or so-called clowns rush toward the bull when the rider is thrown. One of the clowns will attempt to dislodge the rider's hand, but the other one will grasp the pull strap 215 and pull the latch pin out of the latching members.
In either event, the latch pin 200 is pulled so as to unlatch the latch 42 and separate the latching-end portions 100 and 102 of the latching section 82 of the second-end portion 52 of the bull rope 40 . Thus, the continuity of the bull rope when it is cinched about the bull 20 is broken. As such, it is then possible to separate the rider and the bull rope from the bull. Either the rider can himself pull away from the animal, or else the rider and the bull rope can be pulled away from the animal by the clowns.
The foregoing action is completed in a matter of seconds since every second counts in this very dangerous scenario. By nature, a bull has a predisposition to attack the rider. If the rider is down on the ground next to the bull, the bull will attempt to gore him or step on him, or otherwise assault him. If the rider is hung up as above described, it is very important to be able to very quickly break the bull rope by separating the separable end portions 100 and 102 . Then the rider can be freed from the bull and either run away of his own accord or be dragged away from the bull and avoid injury or further injury, and perhaps even to save his life.
Although the latch 42 of the subject invention has been described with regard to a bull rope and bull riding, it will be understood that it could be used in connection with riding any rough animal or even in riding any animal where a rigging is used to assist the rider in maintaining balance on the animal but which could be entangled with a limb of the rider in the event that the rider is thrown from the animal or falls from the animal and cannot easily be extricated from this situation.
Moreover, although a very specific modified construction of a standard bull rope has been described to incorporate the latch 42 , it will be understood that many variations of this construction may be employed without departing from the principles of the present invention. In essence, and in its broadest form, all that is required is that the rope or other rigging have separable ends, apart from the ends used to cinch the rigging, that are normally held together by a latch, and that this latch be located for ready access by the rider or an attendant. The rigging need not be a rope, nor a braided rope nor need it involve latch members or plates fastened to the strands of a rope. Simply to incorporate a latch in an animal rigging that holds when the rider is mounted but that can be released when the rider is thrown and hung up is all that is necessary.
It is also to be recognized that automatic and remote means could be used to retract or unlatch the latch 42 , such as, a solenoid-operated latch remotely operated by electronic means such as radio control. In this manner, the latch could be retracted even more quickly with the intervention of clowns or the rider.
Although a preferred embodiment of the present invention has been shown and described, and alternate embodiments of various features have been described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
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A latch inserted in an animal rigging and controllably releasable for quick unlatching. Such a rigging is normally cinched about the body of the animal for various purposes, but with the latch in the rigging, the rigging can be quickly released from the animal when desired. For a bull rigging, the latch is inserted in the rope that assists a rider in maintaining balance on the animal and allows the rider to be quickly separated from the animal if a limb of the rider becomes caught in the rope when the rider is thrown from the animal. The bull rigging includes a holder or handle interfittingly engaged by a limb of the rider while mounted on the animal to aid the rider in remaining balance on the animal. The inserted latch is normally closed but may be released, that is, unlatched, either by the rider if possible or by an attendant or otherwise if the limb of the rider is entangled with and caught in the rigging when the rider is thrown from the animal whereby the rider and the rigging can be pulled from or otherwise separated from the animal.
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CROSS REFERENCE TO RELATED APPLICATIONS
None.
BACKGROUND OF THE INVENTION
1. Field of Invention
A hydraulic tool for the installation of fencing T-posts into the ground without bending the T-post or causing damage or deformity to the top of the T-post, installs to the three point hitch of a tractor with hydraulic connections to the tractor hydraulic system, securing the post along its vertical length prior to insertion into the ground, the tool having an upper stationary bracket holding an upper section of the T-post within a T-post slot and a lower sliding ram bracket securing to a lower section of the post, the lower sliding ram bracket forcing the T-post into the ground by use of a hydraulic ram at a chosen depth.
2. Description of Prior Art
A preliminary review of prior art patents was conducted by the applicant which reveal prior art patents in a similar field or having similar use. However, the prior art inventions do not disclose the same or similar elements as the present T-post insertion tool, nor do they present the material components in a manner contemplated or anticipated in the prior art. They also, for the most part, address post insertion devices that push the post into the ground from the top of the post, unlike the lateral insertion means for the insertion of the present T-post installation tool, such top-of-the-post insertion increasing the chance of damage to the top of the post from impact and also the risk of bending the post during insertion.
A first set of post installation tools are found in multiple U.S. Patents, each of this patent applying a striking force on the top of the post being driven, in the same manner as a hammer strike to the top of the post. These striking force post driver patents include U.S. Pat. No. 2,844,006 to Lutz, U.S. Pat. No. 3,117,635 to Deerkoski, U.S. Pat. No. 5,494,117 to Aldridge, U.S. Pat. No. 6,889,777 to Boley, U.S. Pat. No. 7,296,636 to Vreeland, and U.S. Pat. No. 7,686,098 to Tyer. A manual hammer device slipping over the top of a post is shown in U.S. Pat. No. 3,712,389 to Smoak.
Another set of patent engage the top of the post being driven and force the post into the ground using a steady vertical force. These patent are identified in U.S. Pat. No. 6,591,919 to Herrmann and two patents to Reid, identified as U.S. Pat. Nos. 7,597,156 and 7,950,470. These patent employ the use of hydraulics to supply the driving force.
Post drivers have also disclosed guides of some nature to support a post during the installation process. In U.S. Pat. No. 2,378,131 to Dirkson, a pair of rollers are use for the smooth movement of the gear driven post long channel member. Another friction pulley is disclosed in U.S. Pat. No 2,348,820 to Jordan which provides engagement with the plate hammer of that driver which is further driven by a belt or chain and sprocket. A guide roller is supplied for contact and security of a post which is driven by the apparatus in the post driver safety latch shown in U.S. patent Publication No. 2006/0113444 to Parson. This latch has a lever which engages and disengages the rollers against the post.
A one person fence post driver is shown in U.S. Pat. No. 1,569,857 to Farb. In this patent, there are two parts which integrate to form the driving apparatus—a first tube section which is placed over the top of the T-post with a locking dog having a transversely extending head that engages the T-post on the surface having a plurality of projections between two of the projection which can be locked using a bolt. A second component slips over the first tube section and is slid up and down to drive the post into the ground until two hands can be used to complete the T-post installation. This was the only other patent found which has some engagement with the lateral surface of a T-post to avoid a direct and potentially deforming impact to the top of the T-post. It provides basically a type of impact hammering device, however and must be installed over the top of the T-post prior to the driving of the T-post using this manual device.
SUMMARY OF THE INVENTION
T-post fencing is currently the most expeditious and cost effective means of supplying fencing in the agricultural industry for containment of livestock using wire fencing. It is also used for roadside marking, for erection of snow fencing and for temporary confinement of animals in small areas using fencing panels. A common T-post, as referenced in the present application, is generally supplied in a length of six to seven feet, defines a T cross-section (hence the name “T-post) with a flat side having a plurality of wire supports (Reid '156 and '470), or flanges (T-post 17 in Herrmann '919) on the flat lateral side indicating the top of the “T” in the T-post cross section. These flanges are used to secure a vertically placed wire tied to the post from being raised or lowered along the vertical axis of the post once secured.
Of the prior art T-post installation tools, most of them involve an impact on the upper end of the T-post or they insert over the top of the T-post to engage some downward force on the top end of the post. These type forces pose two major potential issues during installation—deformation of the T-post and injury to the user. As to deformation, impact on the top of the T-post with some type of hammering tool can misshape the top of the T-post, bending the upper end or causing it to flare. Over time, this can cause to post to decay faster or split longitudinally. Impact removes the paint on the metal T-post and promotes rust build-up. Impact can also bend the T-post at some point between the upper and lower end when the T-post is installed in hard ground. As to the injury potential, there is always a chance for a user to get their hand between the driver and the T-post, to have the impact cause a lateral shift of the T-post while the post is being held, or to bend in the direction of the user's position during installation. There is also the risk of getting a hand or glove caught between the installation tool and the T-post in the devices that insert over the top of the T-post which could lead to a crushing type or pinching type injury to the user's hand.
It would therefore be preferred that the user is no exposed to impact or any requirement to actually hold the T-post during installation. It would also be preferred that the installation tool be presented in a manner that would cause little or no damage to the T-post, preserving the shape and integrity of the T-post.
DESCRIPTION OF THE DRAWINGS
The following drawings are submitted with this utility patent application.
FIG. 1 is a rear perspective view of the T-post installation tool with a T-post.
FIG. 2 is a side view of the T-post installation tool indicating the connecting components between the tower support member and the hydraulic ram assembly, with a T-post attached within upper stationary T-post latch assembly and the lower drive T-post latch assembly.
FIG. 3 is a rear view of the T-post installation tool with a T-post in a position to be driven.
FIG. 4 is a top view of the T-post installation tool demonstrating the insertion of a T-post.
FIG. 5 is a rear perspective view of the T-post installation tool attached to a three point hitch of a tractor.
FIG. 6 is an isolated view of the pivotal joint assembly of the tower support member between the horizontal support arm and the lower vertical insert section with the spring locking pin disengaged.
FIG. 7 is an upper perspective view of the hydraulic ram assembly in a raised position.
FIG. 8 is a rear view of the hydraulic ram assembly in a lowered position.
FIG. 9 is an exploded view of the T-post installation tool.
FIG. 10 is a top view of the upper stationary T-post latch assembly in a closed position.
FIG. 11 is a top view of the upper stationary T-post latch assembly in an open position.
FIG. 12 is a perspective view of the inner encasement ram bracket attached to the lower drive T-post latch assembly.
FIG. 13 is a cross-sectional view of the lower drive T-post latch assembly with the latch catch in a closed position showing a T-post.
FIG. 14 is a cross-sectional view of the lower drive T-post latch assembly with the latch catch in an open position showing a T-post.
FIG. 15 is a perspective partial cutaway view of the ram cylinder attached between the lower ram support in the upper end cap and the inner encasement ram bracket.
FIG. 16 is a perspective view of the upper end cap and lower drive T-post latch assembly with the hydraulic ram secured between the lower ram support and the rear bracket channel extension.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A T-post installation tool 10 , attaching to the rear end of a tractor having a three point hitch and having hydraulic line connections, shown in FIGS. 1-16 of the above drawing sheets, presents the tool for driving a T-post A into the ground without impact and with little or no potential for deformation to the T-post A, the tool 10 comprising a tower support member 20 attaching to the three point hitch of the tractor X, FIG. 5 , providing a locking ball hitch 65 pivotally engaging an upper hitch ball 124 suspending a hydraulic ram assembly 100 .
The T-post A intended for use with the tool 10 are referenced herein as a common “T-post”, shown in FIGS. 1-4 and 13-14 of the drawings, generally supplied in a length of six to seven feet, defining a “T” cross-section (hence the name “T-post) formed by two lateral side sections B, a rear section C and a flat front surface D having a plurality of wire supports (Reid '156 and '470), flanges (T-post #17 in Herrmann '919) or in the present specification, extending projections E, extending from the flat front surface D perpendicular to the two extending lateral sides B, a lower twist plate F and a top end G and bottom end H which is inserted into the ground along with the twist plate F. The extending projections E are used to secure a vertically placed wire tied to the post from being raised or lowered along the vertical axis of the T-post once secured. Relying on this definition, the T-post used in the drawings and Claims will be defined as the T-post above.
The tower support member 20 further comprises a hitch tower base 30 defining a pair of opposing lateral three point hitch supports 32 , a singular upper three point hitch support 34 , the three point hitch supports attaching to the supplied three point hitch of a tractor or other implement having a conventional hydraulic three point hitch using standard hitch pins, FIG. 5 , the hitch tower base 30 extending a base tower receiver 35 and providing a chain anchor bracket 37 directed towards the tractor or implement and optionally providing an accessory receiver hitch 36 , as shown in FIGS. 1-2 and 5 . The tower support member 30 further provides an upper tower assembly 40 including a lower vertical insert section 42 which is secured within the base tower receiver 35 and an upper pivot base plate 44 pivotally attaching to a pivotal locking gear 52 by a horizontal plane bearing 50 , the pivotal locking gear 52 being locked into a position by a spring locking pin 53 incorporated into the upper pivot base plate 44 in a position selected by the user, FIGS. 1-2 and 4-6 , the pivotal locking gear 52 further extending at least two horizontal support arm brackets 54 which support a horizontal support arm 60 at a bracket end 62 , the support arm 60 extending horizontally to a hitch end 64 , the hitch end 64 defining the locking ball hitch 65 .
The hydraulic ram assembly 100 further comprises a support encasement 110 defining an upper end 111 providing a plurality of axial end cap bolt holes 112 , a lower end 113 , a front surface 114 , a right side surface 115 , a left side surface 116 , a rear surface 117 includes a lower vertical slide channel 118 , the four side 114 - 117 , defining an inner vertical channel 119 from the upper end 111 to the lower end 113 , FIGS. 1, 3, and 7-9 . Within the upper end 111 , an upper end cap 120 is attached to the support encasement 110 by a plurality of anchor bolts 122 secured through the axial end cap bolt holes 112 , FIGS. 9 and 15 . The upper end cap 120 further defines the upper hitch ball 124 and provides a lower ram mounting support 126 , FIGS. 9 and 15 . The upper hitch ball 124 secures within the locking ball hitch 65 of the tower support member 20 in a pendulum-type engagement allowing the hydraulic ram assembly 100 to be positioned perpendicular to the ground for level placement of a T-post A into the ground.
Suspended from within the inner vertical channel 119 of the support encasement 110 by the lower hydraulic ram support 126 is an upper pin mount 132 of a hydraulic ram cylinder 130 , the upper pin mount 132 and the lower hydraulic ram support 126 connecting by a ram pin 128 , FIGS. 15-16 . The hydraulic ram cylinder 130 further defining a ram arm 134 having a lower pin mount 136 . The hydraulic ram cylinder 130 is attached through an upper hose outlet 146 and a lower hose outlet 148 by hydraulic cylinder hoses 144 attaching to a hydraulic valve controller 140 attaching to the front surface 114 of the support encasement 110 , the hydraulic valve controller 140 having an activation lever 145 to control the movement of the hydraulic ram cylinder 130 , the hydraulic valve controller 140 further connecting to the hydraulic connections of a tractor or implement by hydraulic connector lines 142 , FIGS. 1, 2 and 5 . The activation lever 145 of the hydraulic valve controller 140 is directed either to the right side surface 115 or to the left side surface 116 of the support encasement 110 on the front surface 114 , away from any moving components of the hydraulic ram assembly 110 later defined, FIG. 1 .
The hydraulic ram assembly 100 further defines an upper stationary T-post latch assembly 200 attached to the rear surface 117 of the support encasement 110 above the lower vertical slide channel 118 and a lower drive T-post latch assembly 300 attaching to the lower pin mount 136 of the ram cylinder 130 through the lower vertical support channel 118 , these two latch assemblies retaining a T-post A and providing the active driving means by which the T-post A is installed by force into the ground. The upper stationary T-post assembly 200 does not move in relation to the support encasement 110 , FIGS. 7-8 . The lower drive T-post latch assembly 300 moves in a vertical pathway within the lower vertical slide channel 118 as directed by the extension and retraction of the ram cylinder 130 as directed by the user having control of the activation lever 145 of the hydraulic valve controller 140 , FIGS. 7-8 .
The upper stationary T-post latch assembly 200 is attached to the rear surface 117 above the lower vertical slide channel 118 and further defines a latch base 204 forming a latch assembly grip post 202 extending laterally from the latch base 204 , the latch base 204 being welded to the rear surface 117 on an inner conforming margin 203 . The latch base 204 further defines an outer T-post slide channel 220 conforming to the profile of a vertical cross-section of a T-post A with an angular groove 222 accepting one of the laterals side sections B and a projection slide slot 224 which allows for the passage of the plurality of extending projections E of the captive T-post A, as indicated in FIGS. 1-4 . A latch member 210 is presented between the T-post slide channel 220 and the grip post 202 , the latch member 210 further defining a slide pin cylinder 214 attached to the latch base 204 , the slide pin cylinder 214 containing a slide pin 216 having a rotational slide pin lever 218 and projecting a latch catch 212 , the latch catch 212 spanning a portion of the T-post slide channel 220 in a closed position and fully clearing the T-post slide channel 220 in an open position, the latch catch extending towards the T-post A at the intersection of the rear section C and the lateral side section B away from the angular groove 222 , the selection of the open and closed position being determined by the position of the slide pin lever 218 , as seen in FIGS. 10-11 and 13-14 .
The lower drive T-post latch assembly 300 further comprises an inner encasement ram bracket 302 , conforming to the shape of the inner vertical channel 119 of the support encasement 110 to move freely up and down within the support encasement 110 , the inner encasement ram bracket 302 further providing an axial bore 304 through which a ram arm pin 305 attaches the inner encasement ram bracket 302 to the lower pin mount 136 of the ram cylinder 130 suspended within the inner vertical channel 119 . The inner encasement ram bracket 302 extends a rear bracket channel extension 306 through the lower vertical slide channel 118 beyond the rear surface 117 of the support encasement 110 , as shown in FIG. 12 . A latch base 308 is welded to the rear bracket channel extension 306 with the latch base 308 further defining a T-post drive channel 320 . The T-post drive channel 320 is distinguished from the T-post slide channel 220 of the upper stationary T-post latch assembly 200 , forming the same angular groove 322 , but without a projection slide slot 224 , instead forming a flat projection drive margin 324 presenting an upper edge 326 and a lower edge 325 . This T-post drive channel 320 will conform to the vertical cross-section of a T-post A, with a lateral side section B within and the rear section C against the T-post drive channel 320 , except the projection drive margin 324 will not allow the passage of the extending projections E of the T-post A, the projection drive margin 324 fitting between a selected pair of extending projections E against the flat front section D, the lower extending projections E below the projection drive margin 324 forced downward by the lower edge 325 of the projection drive margin 324 .
A latch member 310 is presented between the T-post drive channel 320 on a margin opposite the T-post drive channel 320 from the attachment between the rear bracket channel extension 306 , the latch member 310 further defining a slide pin cylinder 314 attached to the latch base 308 , the slide pin cylinder 314 retaining a slide pin 316 having a rotational slide pin lever 318 and projecting a latch catch 312 . The latch catch 312 spans a portion of the T-post drive channel 320 in a closed position which intrudes into a portion of the T-post A, formed by the lateral side section B and the rear section C and fully clearing the T-post drive channel 320 in an open position, the selection of the open and closed position being determined by the position of the slide pin lever 318 , as seen in FIGS. 13-14 .
The T-post installation tool 10 can be used by a single user or by a user and a tractor driver as a team. Prior to attachment of the T-post installation tool 10 to a tractor, it is recommended that the tractor be turned off. Installation involves the steps commencing by connecting the tower support member 20 to the three point hitch and ensuring that all safety pins are engaged. The locking ball hitch 65 is opened and the hydraulic ram assembly 100 is placed in a vertical position with the upper hitch ball 124 up, the hitch ball 124 being installed within the locking ball hitch 65 , further engaging the locking ball hitch 65 to capture and secure the upper hitch ball 124 within the locking ball hitch 65 and further installing and securing any hitch pin to lock the locking ball hitch 65 in a closed position. The rear surface 117 of the hydraulic ram assembly 100 is directed away from the tractor and the front surface 114 of the hydraulic ram assembly 100 is directed towards the tractor. At this point, the hydraulic connector lines 142 are attached to the tractor hydraulic system. It is advisable at this point that the user directs the horizontal support arm 60 away from the tractor and that the spring locking pin 53 locks the support arm 60 in this position by engaging the spring lock pin 53 in the appropriate location within the pivotal locking gear 52 . At this point, the user may start the tractor. It may also be recommended that at this point that a chain be used to connect the optional chain anchor bracket 37 , where supplied, to a sturdy section of the tractor, perhaps an extending hitch plate on the tractor, to prevent the T-post installation tool 10 from sudden rise during the start up of the tractor, commonly resulting in an upward lurch of the three point hitch and/or pressure in the hydraulic lines that might present unintentional movement to the hydraulic ram assembly 100 . At this point, the T-post installation tool 10 is ready for use to install T-posts A. The chain may be left in place during use of the installation to retain the three point hitch at a certain level.
Installation of the T-post A using the T-post installation tool 10 requires a mere few steps. Caution should be taken in keeping hands away from any moving component during use of the tool 10 . A user will position the tractor and attached tool 10 at the location where the T-post A is to be installed, placing the lower end 113 of the hydraulic ram assembly 100 adjacent to a T-post insertion site. The lever 145 of the hydraulic valve controller 140 is elevated until the lower drive T-post latch assembly 300 is at the top of the lower vertical slide channel 118 , retracting the ram cylinder 130 to its most compressed state. A T-post A is then inserted into the T-post slide channel 220 and T-post drive channel 320 of respective upper stationary T-post latch assembly 200 and the lower drive T-post latch assembly 300 while each respective latch catch 212 , 312 , is in the open position, FIGS. 11 and 14 . The projection drive margin 324 must be between two extending projections E of the inserted T-post A. The slide pin levers 218 , 318 , are then rotated to close the latch catches 212 , 312 , FIGS. 10 and 13 . At this point, the user is to remove their hands from the rear surface area, especially away from the lower drive T-post latch assembly 300 and the lower vertical slide channel 118 . If needed, the user may grasp the latch assembly grip post 202 to steady the hydraulic ram assembly 100 and to maintain the level of the T-post A during installation. Using another hand, the user would maneuver the activation lever 145 of the hydraulic valve controller 140 to lower the lower drive T-post latch assembly 300 , driving the bottom end H and the twist plate F of the T-post A into the ground until the hydraulic ram cylinder 130 reaches its full extension or when the lower drive T-post latch assembly 300 is at the lower end 113 of the support encasement 110 . The latch catches 212 , 312 , are then released and the hydraulic ram assembly 100 is moved to release the T-post A from the respective T-post slide channel 220 and T-post drive channel 320 . The user then moves on to the next installation.
It is intended that the inner encasement ram bracket 302 is confined within the support encasement 110 at all times and that the design of the tool 10 be such that the return of the ram cylinder 130 be consistent with the length of the support encasement 110 so that the inner encasement ram bracket 302 is never completely pushed beyond the lower end 113 of the support encasement 110 . At full extension, if the T-post A requires further insertion, the T-post A would be released from both respective angular grooves 222 , 322 , by unlatching the latch members 210 , 310 , and maneuvering the hydraulic ram assembly 100 using the latch assembly grip post 202 to release the T-post A, retracting the ram cylinder 130 , reapplying the hydraulic ram assembly 100 to a higher point of the T-post A and repeat the driving of the T-post A until installed to the proper depth in the ground.
In addition to installation, the tool 10 may be used to remove a T-post A which is in the ground using the reverse installation steps, or by connecting a chain to the T-post A or any other post for that matter, further attaching the chain to a lateral slotted chain extension 328 , shown in FIGS. 1, 5, 7, 12-14 , and retracting the hydraulic ram 130 , elevating the lower drive T-post latch assembly 300 and pulling the post out of the ground.
While the T-post installation tool 10 has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that changes in form and detail may be made therein without departing from the spirit and scope of the invention.
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A hydraulic tool for the installation of fencing T-posts into the ground without bending the T-post or causing damage or deformity to the top of the T-post, installs to the three point hitch of a tractor with hydraulic connections to the tractor hydraulic system, securing the post along its vertical length prior to insertion into the ground, the tool having an upper stationary bracket holding an upper section of the T-post within a T-post slot and a lower sliding ram bracket securing to a lower section of the post, the lower sliding ram bracket forcing the T-post into the ground by use of a hydraulic ram at a chosen depth.
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FIELD OF THE INVENTION
This invention discloses a kind of casting type bandage, and more specifically, relates to a modified aqua-activated polyurethane orthopedic bandage used for orthopedia in the department of orthopedics and as a medicinal material for fixing of fractures. It can be stably stored.
BACKGROUND OF THE INVENTION
The gypsum bandage for fixing extremities has existed for a long time. This bandage is formed by sedimentation of gypsum powder onto a cotton gauze. It is cast and hardened after impregnating with water. However, there are a series of drawbacks existing in the plaster bandage, such as bulkiness, a tendency to crack, poor air permeability, softening or breaking by soaking in water, and poor penetration of X-rays. Furthermore, the X-ray examination is taken after the patient has been fitted with the plaster bandage, and so, the condition of the fracture can't be observed clearly.
In order to overcome these drawbacks of plaster bandages, bandages prepared from high-molecular weight synthetic materials instead of plaster have been used.
U.S. Pat. Nos. 3,421,501 and 3,881,473 disclose that the substrate of a bandage is made of soft fibers. It is impregnated with a type of light-sensitive resin on its surface which can be solidified by means of ultraviolet light. But bulky hardening equipment is required; the operation is very inconvenient; and at the same time, the time required for solidification and conforming the bandage to the body part is too long. These drawbacks are a large limitation to practical usage.
U.S. Pat. No. 4,105,025 discloses a kind of thermoplastic bandage composed of high molecular weight materials. When the bandage is heated above its melting point of 77°-82° C., it can be wound, thereby surrounding the therapeutic position of the patient, and then it can solidify after cooling. Of course, it can be seen that the patient's skin has to withstand this temperature during winding, and the burning of the skin can be very severe.
In recent times, U.S. Pat. Nos. 4,376,438; 4,502,479, 4,427,002 and Faming Zhuanli (Chinese Patent Applications) CN 89103603,2 disclose subsequently applying aqua-activated polyurethane prepolymer as the material for an orthopedic bandage. The major components of this prepolymer are the reaction products of isocyanate and polyhydric alcohol. The method for application of this bandage is the same as that of the plaster bandage.
It can be bandaged on a patient's extremity after it is impregnated with water. The prepolymer can be polymerized when combining with water, i.e., the polymer is solidified to a rigid state, thus fixing it to the patient. In order to make the bandage solidify or harden quickly in about 10 minutes, it is necessary to blend in a certain amount of catalyst.
U.S. Pat. No. 4,376,438 discloses that aminopolyhydric alcohol is used as a catalyst. U.S. Pat. No. 4,427,002 discloses A-99, i.e., bis-(2-dimethylamino ethyl) ether, as a catalyst for controlling the time of solidification. U.S. Pat. No. 4,502,479 discloses that DMEA (dimethyl ethanol amine) or the mixture of DMEA and A-99, i.e., bis-(2-dimethylamino ethyl) ether, can be used as catalyst. Faming Zhuanli CN 89103603,2 discloses a mixture of DMEA and anhydrous K 2 CO 3 can be used as a mixed catalytic system.
However, the tertiary amine catalyst presented within the polyurethane bandage as above incurs gelatinizing side reactions in the prepolymer. These side reactions may form biuret or ureido formate and a small amount of trimer of isocyanate. The gelatin caused by these side reactions can cause the bandage to solidify or harden prematurely before use. Thus, the storage period of the bandage is too short and its stability is poor. Generally, the storage period of the bandage is only about 12 months at ambient temperature (23° C.), and those bandages can't be made commercially available. Although many catalysts have been used to catalyze the reaction of the isocyanate moiety of polyurethane prepolymer with water, there is little use for them in the orthopedic bandage of the casting type because these catalysts can,t provide a long storage period for the orthopedic bandage.
U.S. Pat. No. 4,433,680 (Johnson & Johnson, Inc.) discloses the catalyst DMDEE, i.e., bis-(2-morpholino diethyl) ether, applied previously to the forming of polyurethane foams (U.S. Pat. No. 3,645,925) and to the forming of polyurethane injection molding elastomer (U.S. Pat. No. 4,273,885). It is used polyurethane prepolymer in the orthopedic bandage. Not only is the storage period of the bandage prolonged, but there is excellent time of solidification. Thus, this modification develops an excellent prospect for wide application of the aqua-activated polyurethane bandage.
Thereafter, U.S. Pat. No. 4,574,793 (Hexcel Co.) applied bis-(2,6-dimethylmorpholinoethyl) ether and U.S. Pat. No. 4,705,840 (3M & Co.) synthesized by itself MEMP, i.e., 4[2-methyl-2-(4-morpholino ethoxy)-ethane-] morpholine, and used it as the catalyst of the polyurethane prepolymer in the orthopedic bandage. The same effect occurred, i.e., the storage period was prolonged and satisfactory results were obtained.
OBJECT OF THE INVENTION
An object of the present invention is to provide a casting type bandage with excellent storage stability and aqua-activity.
SUMMARY OF THE INVENTION
In the present invention, a special catalyst has been used. The inventors have synthesized a novel compound with bismorpholine structure, specifically, LF-3, i.e., α-(morpholino polyethoxy)-β-morpholino ethane. The chemical structural formula is as follows: ##STR1## wherein n=2-8.
The present invention is further directed to a stable catalytic and aqua-activated polyurethane bandage comprising a woven glass fiber or synthetic fiber substrate coated with an aqua-activated polyurethane prepolymer, said prepolymer comprising an aromatic isocyante, a polyhydroxy compound, and a catalyst, wherein the equivalent ratio of NCO:OH in the prepolymer is from 3:1 to 9:1, and said catalyst is α-(morpholinopolyethoxy)-β-morpholinoethane or a mixture of α-(morpholinopolyethoxy)-β-morpholinoethane and a cocatalyst of bis-(2-dimethylaminoethyl) ether.
DETAILED DESCRIPTION OF THE INVENTION
LF-3 is used as the catalyst for the aqua-activated polyurethane prepolymer. The rate of formation of side reactions is quite lower than that of the application of tertiary amine catalyst.
Furthermore, a suitable amount of stabilizing agent, such as methane sulfonic acid, can be added into the prepolymer to form a stable complex with the catalyst LF-3. The storage period or storage stability of the bandage prepared from the stable catalytic polyurethane prepolymer of this invention can be increased from 1.5 to 2-fold over that of a bandage prepared by utilizing a tertiary amine as the catalytic system. But as for this premise, the solidification time required in clinics must be guaranteed.
The aromatic isocyanates in the stable catalytic and aqua-activated polyurethane prepolymer of this invention can be any kind of aromatic isocyanate described in polyurethane chemistry, e.g., as described by Chemistry and Technology of Polyurethane, published by Intersciences Co., 1962.
The aromatic isocyanates comprise toluene diisocyanate (TDI), diphenyl methane-diisocyanate (MDI) or carbodiimide [--C(═NH) 2 ]group-containing modified liquid MDI.
The polyhydroxy compound used in the polyurethane prepolymer of this invention is a mixture of dihydroxy polyether and trihydroxy polyether, with a mol. wt. of 400-2000. The equivalent ratio of the dihydroxy group to trihydroxy group is from 1:9 to 9:1, and the ratio of NCO:OH in the prepolymer is from 2:1 to 10:1 The NCO content is 5%-10%.
The content of LF-3, i.e., α-(morpholino polyethoxy)-β-morpholino ethane, catalyst in the stable catalytic and aqua-activated polyurethane prepolymer of this invention based on the total weight of the prepolymer is 0.1-10% preferably in the range of 1.0-10%, most preferably in the range of 1.0-4.0%. A small amount of cocatalyst A-99, i.e., bis-(2-dimethylaminoethyl) ether, may be utilized jointly with catalyst LF-3. Its content is 0.1% to 1.0%, more preferably 0.1 to 0.5%, by total weight of prepolymer.
The polyurethane prepolymer can otherwise comprise a small amount of a stabilizing agent of methane sulfonic acid in an amount of 0.01-0.5% and an anti-foam agent in an amount of 0.01-1.0%. All of the percentages are based upon the total weight of the prepolymer. Small amounts of a thixotropic agent, antioxidant, thermal stabilizing agent, etc. may also be present.
The thixotropic agent can be, for example, silica white, preferably in an amount from 0.5 to 4.0% based on the total weight of the polyurethane prepolymer. The antioxidant can be, for example 2,6-ditertiarybutyl-4-ethylphenol, preferably in an amount from 0.01 to 0.1% based on the total weight of the polyurethane prepolymer. The heat stabilizer can be, for example, calcium stearate, preferably in an amount from 0.1 to 2.0% based on the total weight of the polyurethane prepolymer. The antifoam agent can be, for example, antifoam silicone oil 201, preferably in an amount from 0.1 to 2.0% based on the total weight of the polyurethane prepolymer.
The following Example is given to show the preparation of the stable catalytic and aqua-activated polyurethane prepolymer A.
EXAMPLE
Into a 5 liter reaction vessel, which is equipped with a thermometer, mechanical stirrer, liquid feeding equipment and N gas inlet, 3400 g of carbodiimide-containing, diphenyl-methanediisocyanate (liquid MDI), 135 g of methane-sulfonic acid, 54 g of antifoam silicone oil, 108 g of silica white and 16.2 g of 2.6-ditert-butyl-4-methyl phenol are added. The mixture is heated to 55° C. 1200 g of dihydroxy polyether (OH═105) and 800 g of trihydroxypolyether (OH═86) as a mixed polyhydroxyl compound are added dropwise. The temperature is controlled at 60°-65° C. The reaction proceeds for 1-2 hrs. After cooling the material is drawn and is ready for use. The resultant prepolymer viscosity is 2800 centipoise and has an NCO content=14.8%. 1.5% (wt.) of LF-3 catalyst or 1.0% of LF-3, i.e., α-(morpholino ethoxy-ethoxy) -β-morpholinoethane, and 0.1% of A-99 are added to this polyurethane prepolymer. This material is coated onto the woven substrate. After it is impregnated in water for 15 sec., the bandage is wound around the affected region of the patient. The times of solidification are 9 min. and 7 min. for 1.5% LF-3 and 1.0% LF-3/0.1% A-99, respectively.
The testing of the storage stability is performed as directed by U.S. Pat. No. 4,433,680. It is a good method for detecting storage stability by means of maintaining the polyurethane prepolymer at a definite temperature for accelerating aging. After the test-sample has undergone a definite time for aging, its viscosity is determined. A lower prepolymer viscosity indicates a better storage stability or that it can be stored over a longer storage period.
In accordance with U.S. Pat. No. 4,574,793 (Hexcel Co.), the storage stability of the polyurethane prepolymer was determined with different catalytic systems at 80° C. after undergoing a definite time for thermal aging. The distribution of viscosity was measured.
Testing method
The sample of polyurethane prepolymer A prepared in the above example is accurately weighed. A definite amount of catalyst is added. They are placed into a dry bag of Al-plastic complex foil and put into a dry box with protection under N. It is sealed after thorough agitation. This sample is then placed into an oven at a constant temperature of 80° C.
The sample is taken out at 24-hr intervals to determine its viscosity after cooling down to 50° C. The total test period runs for 7 days. The test results regarding the influence of different catalytic systems DMEA, A-99, LF-3 and LP3+A-99 on storage stabilities of polyurethane prepolymer are shown below in Table 1.
TABLE 1__________________________________________________________________________Storage Stabilities of Polyurethane Prepolymer A(NCO 14.8%) with Different Catalytic Systems time to Viscosity in centipoise solidi- determined at 50° C.catalyst cation 80° C. thermal aging (days)No. (%) (min) 0 1 2 3 4 5 6 7__________________________________________________________________________1 not added 3200 3000 3300 3300 4200 4600 5100 60002 DMEA 9 4200 11000 20000 (1.5) par- tially harden3 A-99 8 3300 5700 12500 17000 22500 28500 harden (0.35)4 LF-3 9 3500 4600 7000 9500 12500 15600 19500 20500 (1.5)5 LF-3(1.0) 7 3600 3600 10500 14000 17500 20500 25600 A-99 (0.1) 26500__________________________________________________________________________
These data are plotted in FIG. 1 and indicate the distribution of viscosities during 80° C. thermal aging.
______________________________________curve 1 no catalyst is used.curve 2 DMEA 1.5%curve 3 A-99 0.35%curve 4 LF-3 1.5%curve 5 LF-3 1.0%; A-99 0.1%______________________________________
The polyurethane prepolymer with DMEA (1.5%) as catalyst has a storage period of about 12 months. We assumed the stability coefficient of the prepolymer with this catalyst system to be K=1, and then compared the stabilities of the prepolymers with other various catalystic systems. From FIG. 1, we can compute the days required for the viscosities of prepolymers with various catalytic systems to arrive at 15000 and 20000 centipoise respectively after an 80° C. thermal aging. These data are shown in tables 2 an d3, respectively.
TABLE 2______________________________________Time (days) Required for 80° C. Thermal Aging Whenthe Viscosity (50° C.) of Prepolymer A with Various CatalyticSystems Reached 15000 Centipoise time to days of storage solidifi- stability thermal period Catalyst cation coefficient aging at 23° C.No. (%) (min) (K) at 80° C. (months)______________________________________1 DMEA 9 1.0 1.5 ˜12 (1.5)2 A-99 8 1.33 2.0 ˜16 (0.35)3 LF-3 9 3.33 5.0 ˜40 (1.5)4 LF-3 (1.0) 7 2.33 3.5 ˜28 A-99 (0.1)______________________________________
TABLE 3______________________________________Time (days) Required for 80° C. Thermal Aging Whenthe Viscosity (50° C.) of Prepolymer A with Various CatalyticSystems Reached 20,000 Centipoise time to storage solidifi- stability days of period Catalyst cation coefficient thermal at 23° C.No. (%) (min) K aging (months)______________________________________1 DMEA 9 1.0 2.0 ˜12 (1.5)2 A-99 8 1.5 3.0 ˜18 (0.35)3 LF-3 9 3.5 7.0 ˜42 (1.5)4 LF-3 (1.0) 7 2.5 5.0 ˜30 A-99 (0.1)______________________________________
The above results indicate that when DMEA is used as the catalyst (its content is 1.5% of the total weigh of the prepolymer) in the polyurethane prepolymer A (NCO content=14.8%) prepared according to the Example above for this invention, the solidification time determined is 9 min. and the viscosity (50° C.) of the prepolymer reaches 15000 centipoise after 80° C. thermal aging for 1.5 days. We take the stability coefficient of K=1 as the storage stability index; that is, it is equivalent to a stable storage period at 23° C. of about 12 months.
If we take A-99 as the catalyst, wherein it: content is 0.35% of the total weight of the prepolymer, the solidification time determined is 8 min. and the viscosity of the prepolymer reaches 15000 centipoise after 80° C. thermal aging for 2. days. Its stability coefficient is K=3.33, which is equivalent to a stable storage period at 23° C. of about 16 months.
If we use the LF-3 of this invention as catalyst, wherein its content is 1.5% of the total weight of the prepolymer, the solidification time determined is 9 min. and the viscosity (50° C.) of the prepolymer reaches 15000 centipoise after 80° C. thermal aging for 5.0 days. Its stability coefficient i: K=3.33, which is equivalent to a stable storage period at ambient temp (23° C.) of 40 months. The storage stability is enhanced 2.3 fold as compared with that of the DMEA catalyzing system and is enhanced 1.5 fold as compared with the A-99 catalyzing system.
Furthermore, when the LF-3 catalyst and A-99 cocatalyst are used, their contents are 1.0% and 0.1% by total weight of the prepolymer, respectively. The solidification time determined is 7 min. and the viscosity (50° C.) of the prepolymer reaches 15000 centipoise after 80° C. thermal aging for 3.5 days. Its stability coefficient is K=2.33, which is equivalent to a stable storage period at ambient temp. (23° C.) of 28 months.
Similar results are shown in Table 3, wherein a prepolymer A with various catalytic systems is employed, but a viscosity (50° C.) of 20000 centipoise is used. The relation of time (days) for 80° C. thermal aging can be similarly measured as was done for Table 2.
Other features, advantages and embodiments of the invention disclosed herein will be readily apparent to those exercising ordinary skill after reading the foregoing disclosure. In this regard, while specific embodiments of the invention have been described in considerable detail, variations and modifications of these embodiments can be effected without departing from the spirit and scope of the invention as described and claimed herein.
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The invention is directed to a stable catalytic and aqua-activated polyurethane bandage used for orthopedic casting. The bandage has a substrate and an aqua-activated polyurethane prepolymer. The catalyst used to make the prepolymer is α-(morpholinopolyethoxy)-β-morpholinoethane or the mixture of α-(morpholinopolyethoxy)-β-morpholinoethane and cocatalyst bis-(2-dimethylaminoethyl) ether. The catalyst in this bandage can be optionally combined with a stabilizing agent, such as ethane-sulfonic acid to form a structurally stable complex. The catalyst of this invention provides an excellent solidification time and significantly prolongs the storage period of the bandage.
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BACKGROUND OF THE INVENTION
This invention relates to a cushion body, especially a seat cushion for a motor vehicle, consisting of a spring body which is deformable and at the same time air and moisture permeable in the loaded condition, as well as a buffer layer which has a substantial content of cellulose fibers, and is located intermediate the spring body and an air-permeable cover material. The cover material is stretched over the cushion body.
DE-GM No. 75 03 063 discloses a cushion body, which is stated to be suitable for use as a seat cushion for a motor vehicle. The spring body disclosed by that reference consists of a foam material block which has continuous openings, and is enclosed in a multilayer cover. The openings in the foam block serve to improve the air circulation in the foam block, and thereby to discharge moisture. This effect is aided by the cover material, which includes a layer of cellulose fibers, and is capable of absorbing accumulated moisture without becoming saturated. If a substantial amount of moisture is going to be accumulated during use, however, an absorbent layer of considerable thickness is required to absorb the excess moisture, and a long drying time between individual periods of use will be required. This is true because the relative size of the exchange surfaces bounding the openings in the foam block are too small relative to the area of the cover material, and because the volume of air contained in the pores of the foam block is renewed too slowly. Cushion bodies of this type are therefore considered only conditionally suitable for extended use.
It is an object of the present invention to provide a cushion body which is free of the disadvantages mentioned above, and which can be used without interruption, and without the danger that during use partial areas will occur on the cushion which feel wet.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the foregoing objectives, the cushion body of this invention employs a spring body consisting of fibers with hydrophilic properties, and a titer of about 3 to about 50 dtex, which fibers are combined to form a spatially oriented network, and are cemented together where the fibers intersect. When the spring body is comprised of natural and/or synthetic fibers, the spring body may have a thickness of about 5 to about 20 mm and a bulk weight of about 10 to about 100 kg/m 3 . A buffer layer having an area weight of about 150 g/m 2 to about 350 g/m 2 is disposed intermediate an air permeable surface covering for the cushion body and the spring body.
BRIEF DESCRIPTION OF THE FIGURE
This invention will be described in detail with reference to appended FIG. I, which provides a cut-away view of the present cushion invention.
DETAILED DESCRIPTION OF THE INVENTION
The spring body employed in the cushion body of this invention is very thin, for example, a thickness of only about 5 to about 20, or about 8 to about 15 mm. If natural and/or synthetic threads are used in the fabrication of the spring body, the preferred bulk weight of the spring body is about 50 kg/m 3 .
The spring body consists of relatively coarse fibers with hydrophilic properties, which are combined to form a spatially oriented network, and are cemented together where the fibers of the fiber network intersect.
During use, local compression of the spring body preferably by about 20% to about 60% is obtained in the area of greatest load, and a corresponding reduction occurs in the volume of the hollow spaces defined by the fiber network of the spring body. Normally, during use, this volume reduction is not constant but changes depending on any change in the sitting position or, if the cushion body is used as a seat cushion in a motor vehicle, depending on any swing of the vehicle. Therefore, an airflow develops in between the interior zones of the fiber network which bear different loads. This airflow occurs parallel to the surface of the cushion. In addition, the airflow is continuously reversed, and the circulating air with the spring body contacts areas which are subjected to different degrees of moisture.
The spring body network consists of fibers with hydrophilic properties, which are in contact with a buffer layer of cellulose fibers and form, together with the latter, a closed unit with respect of the absorption and desorption properties.
More specifically, the moisture absorbed by portions of the buffer layer is transported into the hydrophilic fibers of the spring body network, before the buffer layer becomes saturated. Thereby, the moisture is distributed, in the process, over an exchange area which is several times larger than the moisture loaded area of the buffer layer. The moisture can thereby be absorbed more easily by the air flowing through the spring body network, and transported into regions of the spring body which are ess heavily loaded. There, the moisture is precipitated, preferably again in the hydrophilic fibers of the network, for eventual discharge into the buffer layer, and for evaporation over the surface of the cushion during use. There is no longer any danger of a moisture backup, even if moisture is loaded over an extended period of time, as the result of an unchanged sitting position.
The area weight of the buffer layer is about 150 to about 350 g/m 2 . If the area weight of the buffer layer is lower than this, the result can be insufficient distribution of the moisture absorbed by the buffer layer to as many fibers of the spring body network as possible. If the area weight of the buffer layer is higher than about 150 to about 350 g/m 2 , the result is unsatisfactory desorption behavior in the non-loaded areas if the cushion is loaded by a sitting person of average weight under extreme conditions, for instance, during a long automobile trip in summer. In such a case, a backup of moisture in the area of the loaded zone can occur.
The dry feel of the surface of the cushion can be aided by applying a layer of hydrophobic fibers on the surface of the buffer layer. This layer must be sufficiently air permeable, and must not impair the absorption and desorption behavior of the buffer layer to an appreciable degree. Woven and knitted materials, as well as velour and terry cloth materials with an area weight of about 100 to about 500 g/m 2 comprised of polypropylene and/or polyester fibers have proven themselves. However, any conventional cushion covering material can be used if the above-mentioned requirements are met.
The use properties of the cushion body depend substantially on the constant elasticity of the network. Natural fibers with a coarse titer can be used without difficulty. However, the use of synthetically produced fibers of hydrophobic materials which have a surface coating of a hydrophilic material is preferred. For the purpose of transporting the moisture from and into the buffer layer, only the cross-sectional area of the coating of hydrophilic material is available. However, the cross-sectional area is entirely sufficient in view of the multiplicity of the fibers combined in the network. Moreover, moisture exchange occurs between the hydrophilic surface of the fibers, the buffer layer and the passing air.
Contrary to cushions of the type described in DE-GM No. 7503063, practically the entire underside of the buffer layer of the cushion of this invention is available for moisture exchange between the flowing air and the buffer layer, and, additionally, the entire surface of each individual fiber of the spring body is also available for moisture exchange.
The hydrophobic fibers which comprise the spring body may consist of metal and/or of plastic. Among the metals, corrosion-resistant materials are preferred; particularly preferred are brass fibers and suitable grades of steel fibers. Of the plastics, those with low water absorption are preferred, particularly polypropylene and polyester. Moreover, preferably crinkled fibers are employed in order to provide an open structure, and good spring elasticity in the network. The number of crinkled arcs per centimeter may be about 5 to about 40. The fibers are durably cemented to each other, so that there is no danger that the bonds may come loose during use. Preferably, chemically cross-linked bonding agents are used, for instance, those bonding agents having a rubber or plastic base.
The spring body network may also be a textured fabric of at least one endless thread. Depending on the fixation and mutual relationship of the individual meshes, the air flowing through the network during use is canalized, and through the use of such a textured fabric, a particularly advantageous ventilation effect is obtained. On the other hand, embodiments in which the network consists of fibers combined in accordance with a nonwoven fabric technology have the advantage of better fiber separation and, therefore, improved moisture exchange.
The present invention will be illustrated further with reference to FIG. I, which discloses an embodiment of the present invention suitable for use as an automobile seat.
The shape of the automobile seat is essentially determined by the shape of the foam material body (4) which is substantially impervious to air and consists of a soft polyurethane foam with a bulk weight of about 35 kg/m 3 .
The spring body (1) is connected to the topside of the foam material body (4). The spring body consists of a mixture of the fibers defined in detail as follows:
______________________________________Type of Titer Staple Length Crinkle Content inFiber (dtex) mm (arcs/cm) Mixture______________________________________PES 45 80 5 to 6 20%PES 22 50 5 to 6 60%CV 9 75 smooth 20%______________________________________
The fibers were intimately mixed, randomly deposited, and further densified by a needling process applied to the fabric obtained. Subsequently, impregnation with a hydrophilic bonding agent of the following composition was performed:
A mixture is prepared of:
1. An aqueous dispersion of a copolymerisate with a base of butadiene/acrylonitrile with self-crosslinking groups,
2. A Lewis acid, for instance, ammonium chloride as a catalyst for the crosslinking reaction, and
3. Emulsifiers in order to increase the hydrophilic action of the bonding agent film, for instance, polyethylene oxide siloxane.
The bonding agent was deposited as a continuous layer on the surface of the fibers of the fabric and, after drying and subsequent crosslinking, the bonding agent causes the fibers to be mutually cemented together at points of intersection. The weight percentage of bonding agent is 70%, and the thickness of the spring body is 15 mm with an area weight of 600 g/m 2 .
A buffer layer of a fabric obtained by a wet process is applied to the top side of the spring body. The fiber mixture consists of a mixture of the following fibers:
______________________________________Type of Titer Staple Length Content inFiber (dtex) mm Crinkle Mixture______________________________________CV 17 18 smooth 20%PES 3.3 18 smooth 10%PES 6.8 12 smooth 10%Cellulose Pinewood sulfate bleach, 60% with high alpha-cellulose content______________________________________
The fiber fabric, prepared from the mixture described above, is solidified with a bonding agent mixture which is composed of:
1. An aqueous dispersion of a copolymerisate with a base of butadiene/acrylonitrile with self-crosslinking groups,
2. A Lewis acid, for instance, ammonium chloride, and
3. Emulsifiers, for instance, polyethylene oxide siloxane.
After drying and subsequent crosslinking, this bonding agent causes the fibers to be cemented together. The weight content of the binding agent in the buffer layer is about 20%. The buffer layer has a thickness of 1.5 mm with an area weight of 250 g/m 2 .
The cover material (2) may consist of a highly air-permeable knitted fabric of polyamide fibers, having, for example, an area weight of about 400 g/m 2 . The cover layer is cut and sewed together in such a manner that the unit consisting of the foam material body, the spring body and the buffer layer is enclosed on all sides by the cover layer.
While specific embodiments of the invention have been described with particularity herein, it should be understood that this invention is intended to cover all changes and modifications of the embodiments of the invention chosen for purposes of illustration which do not constitute departures from the spirit and scope of the present invention.
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The invention of this application relates to a cushion body, well suited for use as a seat cushion of a motor vehicle, consisting of a spring body which is deformable under a load, and is air and mositure permeable. The cushion also employs an air permeable cover material which is stretched over the cushion and is underlaid with a buffer layer which has a substantial content of cellulose fibers. The spring body consists of fibers with hydrophilic properties and a titer of 3 to 50 dtex, which fibers are combined to form a spatially oriented network, and are cemented together where they intersect.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a tool for preparing a cigar for smoking, and particularly to a tool that removes the cap-end of a cigar without disturbing the area of the cigar surrounding the cap-end or the cigar filler material within the cigar.
2. Description of the Prior Art
The customary and conventional method of preparing a cigar for smoking has been to bite off the end of the cigar intended to be placed in the mouth, or cutting off the end of the cigar with the blade of a pocket knife or other sharp blade. In either case, the smoker is usually left with a frayed cigar end to place in the mouth, and possibly, in some cases, risking ingestion of the leafy tobacco material from the cigar. Connoisseurs of fine cigars smoke cigars, among other reasons, because they like the "feel" of the end of the cigar in the mouth. Having a frayed end of a cigar in the mouth lessens the pleasure derived from the "feel" sought by the cigar smoker. The conventional or customary methods described above are for that and other reasons unacceptable to the connoisseur of fine cigars.
Accordingly, one of the important objects of the present invention is to provide a tool to be used by the cigar smoker that will cleanly remove the central portion of a cigar-cap, leaving the remaining portion of the cigar-cap intact so as to prevent fraying of the leafy cigar wrapper.
Another object of the invention is the provision of a tool that is compact and unobtrusive so that it may conveniently be carried in a pocket.
Still another object of the invention is the provision of a tool equipped with a sharp circular cutting edge that easily and smoothly penetrates the central portion of the cap-end of the cigar without disturbing the surrounding area.
Yet another object of the invention is the provision of a tool that not only cuts and extracts a centrally located portion from the cap-end of the cigar, but which may be easily manipulated to expel from the tool the extracted portion of cigar.
A still further object of the invention is the provision of a cigar cutting tool having a recess with sharpened edges for cutting into the cap-end of the cigar, and which includes means for conveniently ejecting from the tool the portion of the cigar cut therefrom.
A still further object of the invention is the provision of a tool of the type herein described which is fabricated from durable material that effectively withstands innumerable cigar cap cutting operations without need of resharpening.
The invention possesses other objects and features of advantage, some of which, with the foregoing, will be apparent from the following description and the drawings. It is to be understood however that the invention is not limited to the embodiment illustrated and described since it may be embodied in various forms within the scope of the appended claims.
SUMMARY OF THE INVENTION
In terms of broad inclusion, the cigar cutting tool of the invention comprises a generally cylindrical housing tube one end of which is provided with a very sharp circular cutting edge susceptible of being pressed into the cap-end of a cigar to thereby define the configuration of the central cigar portion to be cut from and withdrawn from the cigar by the housing tube. Plunger means are provided within the housing tube, manipulable from the end opposite the circular cutting edge for ejecting the cut central portion of cigar from within the housing tube.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a horizontal cross-sectional view of the tool, shown approximately two and one-half times actual size, taken along its longitudinal axis, and shown with the circular cutting edge in penetrating position in relation to the cap-end of the cigar, and with the plunger retracted.
FIG. 2 is a horizontal cross-sectional view similar to FIG. 1, but illustrating the sharp circular cutting edge of the tool removed from the associated end of a cigar and the plunger deployed to eject the cut portion of the cigar from the tool.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In terms of greater detail, the tool forming the subject of the present invention is designated generally by the numeral 2, and comprises an outer metallic tubular housing portion designated generally by the numeral 3. Because the tool is intended to be carried in a pocket so as to be readily available, and because when in use it is visible to observation by others, and further because the tool will frequently be handled by fingers that may be wet with perspiration, the tubular housing is preferalby fabricated from stainless steel of sufficient thickness as to not crush easily, or be damaged by other articles carried in the pocket such as keys or a pocket knife, and the outer surface 4 of the tubular housing is preferably polished to a mirror-finish.
As illustrated in the drawings, the circular sharpened end edge 6 defines the full diameter of the tubular housing, and is formed by grinding and/or honing the interior end surface portion 7 into a conical configuration that tapers outwardly from the inner peripheral surface 8 of the tubular housing. At its opposite end, the tubular housing is provided with a mounting portion 9 terminating in end edge 12. The mounting portion 9, as shown, is fixedly embedded in a cylindrical bearing insert designated generally by the numeral 13, including an exterior flange portion 14 that is press-fitted or otherwise fixed permanently in overlapping relationship onto the exterior end surface portion of the mounting portion 9 of the tubular housing.
The exterior flange portion 14 of the bearing insert 13 is integral with a cylindrical elongated interior plug portion 16 that is conveniently press-fitted into the open end of the tubular housing, conforms to inner surface 8 thereof, and extends into the tubular housing just short of half the length of the tubular housing to provide an end surface 17 that functions as a stop or abutment for a purpose which will hereinafter be explained. In like manner, the opposite end surface 18 of the bearing insert 13 functions as a stop or abutment in a manner and for a purpose hereinafter explained. The bearing insert 13 is preferably fabricated from an appropriate synthetic resinous material, either by machining, or by injection molding.
Interiorly, the bearing insert 13 is provided with a first bore or cavity 19 defined by a cylindrical surface 20 that is symmetrical about the longitudinal axis 21 of the tool, and which is concentrically related to the inner periphery 8 of the tubular housing 3. At its outer end the first bore 19 and surface 20 are intercepted by the end surface 18, while at its opposite end the first bore 19 and surface 20 are intercepted by a first annular shoulder 22 that extends transversely of the longitudinal axis to be intercepted by the inner periphery of a second bore 23 of smaller diameter than the first bore 19. The second bore 23 extends axially toward the sharpened end edge 6, and terminates in a second annular shoulder 24 that also extends transversely of the longitudinal axis, and which is itself intercepted by the third bore 26 formed in the bearing insert. The third bore 26 is defined at one end by the transverse annular shoulder 24 and at its other end by the stop or abutment surface 17.
While I have described the bearing insert 13 as being press-fitted onto the tubular housing 3, it should be understood that the interengagement of the tubular housing 3 and bearing insert 13 may also be effected by a snug fit between these parts, with an appropriate adhesive applied to retain the parts permanently attached one to the other.
Slidably mounted within the bore 19 of the bearing insert 13, more specifically slidably disposed on and in relation to the surface 20 of bore 19, there is provided a plunger designated generally by the numeral 27. The plunger is preferably fabricated from a suitable synthetic resinous material, such as those sold under the trademarks "Teflon" or "Delrin", and includes a head portion 28, formed integrally by machining or by injection molding, with a cylindrical guide portion 29 having a cylindrical cavity 30 therein concentrically disposed in relation to the central axis and defined by the inner peripheral wall surface 31, and a cylindrical outer bearing surface 32 that is slidably disposed in relation to the inner peripheral surface 20 of the bearing insert 13.
As illustrated in the drawings, the head portion 28 is provided with an under surface 33 that functions as a stop or abutment as will hereinafter be described. Additionally, the length of the guide portion 29 of the plunger 27 is dimensioned so that when the plunger 27 is fully deployed as illustrated in FIG. 2, the under surface 33 of the head portion 28 abuts against the end surface 18 of the bearing insert 13, while the interior end surface 34 of the plunger guide portion 29 abuts against the first annular shoulder 22. The outer cylindrical bearing surface 32 of the plunger 27 slidably guides on the inner peripheral surface 20 of the bearing insert 13. Thus axial displacement of the plunger 27 in the direction of deployment is limited by both abutment surfaces 18 and 22.
Mounted within the cavities or bores 23 and 30 is a coil compression spring 36. The spring at one end 37 bears against the annular transverse shoulder 24, while at its opposite end 38 the spring 36 abuts against the annular transverse shoulder 39 that defines one end of the bore or cavity 30. The length of the spring and the axial dimensions of the cavities 23 and 30 are such that when the plunger 27 is in its retracted position as illustrated in FIG. 1, the spring 36 is only slightly compressed so as to continually exert a resilient biasing force on the plunger 27, tending to push it out of the open end of the bearing insert 13.
To prevent the plunger 27 from being pushed out of the bearing insert 13, and to provide a means of ejecting from the tubular housing 3 the cut portion of the cigar, there is mounted on the plunger 27 an elongated ejection and stop rod designated generally by the numeral 41. The ejection and stop rod 41 is preferably fabricated from the same material as the bearing insert 13 and plunger 27. One end portion 42 of the rod 41 is embedded in the plunger guide portion 29 beyond the shoulder 39 and continues into the head 28 where it is secured either by press-fitting into an appropriate bore 43 that receives the end portion or is adhesively permanently secured therein.
Intermediate the ends of the ejection/stop rod 41 there is provided an integral annular abutment 44 that is positioned along the length of the ejection/stop rod 41 so that its annular transverse side surface 46 lies parallel with the end surface 17 of the bearing insert 13. When the spring 36 normally resiliently biases the plunger 27 into its retracted position as illustrated in FIG. 1, the transverse annular surface 46 comes into abutting contact with the end surface 17, thus limiting the axial translation of the plunger 27 to the right as seen in FIG. 1.
In this retracted position of the plunger, the ejection head 47, which is formed integrally on the end of the axially aligned ejection/stop rod 41 remote from the head portion 28 of the plunger, lies within the interior of the outer metallic housing portion 3, spaced sufficiently from the sharpened end edge 6 to enable penetration of the end edge 6 into the cap end 48 of the cigar 49 shown in broken lines in the drawings. Penetration is effected by grasping the cigar with the fingers of one hand, say the left hand, while grasping the tool in the fingers of the right hand, aligning the axis of the tool with the long axis of the cigar, and placing the sharpened circular end edge 6 against the cap end 48 of the cigar 49 while pressing the tool into the cigar with a slight rotational movement.
The sharpened circular end edge 6 of the tool will cut cleanly through the cap leaf of tobacco, and penetrate the cigar until the end of the cigar abuts the outer face 51 of the ejection head 47. At this point, all that is required to detach the cigar cap end portion 52 from the remainder of the cigar is that a slight laterally reciprocating displacement be effected to the opposite end of the tool, whereupon the filler tobacco within the cap end of the cigar is broken away, leaving the now detached cap end portion 52 within the end of the tubular metallic housing portion 3, and leaving a recess 53 in the end of the cigar that permits smoke to be easily and conveniently drawn through the cigar from the lighted end thereof.
To eject the detached cap end portion 52 from within the tubular metallic housing, the head 28 of the plunger is depressed against the resilient bias of the spring 36 while holding the tubular metallic housing portion 3 stationary. This causes the ejection head 47 to be displaced to the left as viewed in FIG. 2, driving the detached cap end portion 52 out of the tool housing as illustrated in FIG. 2.
Having thus described the invention, what is believed to be new and novel and sought to be protected by letters patent of the United States is as follows.
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Presented is a cigar cap-cutting and ejection tool provided with a very sharp circular cutting edge susceptible of being pressed into the cap-end of a cigar to thereby define the configuration of the central cigar cap-end portion to be cut from and withdrawn from the cigar by the tool. Plunger members are provided in the tool manipulable from the end opposite the circular cutting edge for ejecting the cut central cap-end portion of cigar from within the tool.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the priority of U.S. Provisional Application No. 60/643,701 entitled “Rocket Propelled Grenade, Variant II” filed Jan. 13, 2005, the contents of which are incorporated herein by reference in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
This invention was made with Government support under Contract N61339-00-D-0001 with the Department of the Navy. The Government has certain rights in this invention.
FIELD OF THE INVENTION
Embodiments of the invention generally relate to devices, systems, and methods for simulating the operation and effect of various weapons, especially explosive weapons, during military training exercises. More particularly, the invention relates to devices, systems and methods for simulating the operation and effect of weapons such as rocket propelled grenades (RPG's) in a laser-based battle simulation environment
BACKGROUND OF THE INVENTION
At present, in live battlefield military operations in areas such as the Middle East, opposing forces using weapons such as the rocket-propelled-grenade (RPG) are presenting a significant threat to U.S. military forces stationed there. In an RPG weapon, a relatively small rocket charge is mounted in a tube, together with a grenade, which can then be aimed and launched at a target. One example of a commercially available RPG device is the RPG-7, which has been manufactured in a number of countries, including Russia and various Eastern European countries such as Romania, over its forty-plus year history. FIG. 1 is an illustration showing a prior art Russian-made RPG-7 antitank grenade launcher 2 (“RPG 2”). The RPG 2 is a recoilless, shoulder-fired, muzzle-loaded, reloadable weapon, capable of firing an 85-mm (PG-7) or 70-mm (PG-7M) rocket-assisted High Explosive Anti Tank (HEAT) grenade from a 40-mm smoothbore launcher tube. Features of the RPG 2 include a flared blast shield 3 (which also serves as the breech through which the charge can be loaded). The charge is provided to initially launch the grenade assembly from the firing tube. 3 , a telescope optical sight 4 , an iron sight 5 , a heat shield 6 (which in this illustration is made of an insulating material such as wood), a trigger 7 , a grenade 8 , such as the PG-7VM grenade, and include a pair of hand grips 9 A, 9 B. The RPG 2 is light enough (around 15 pounds) to be carried and fired by one person.
With the RPG 2, launch of the grenade 8 is typically via a gunpowder booster charge (not visible in FIG. 1 ) at about 115 m/s, and this launch creates a cloud of light bluish grey smoke (which typically puffs out in the vicinity of the blast shield 3 . It is the sight of this smoke that is often the only warning (i.e., a visual indicator) that a potential target has alerting the target that the RPG 2 has been fired. After the grenade 8 such as the 70 mm PG-7M is fired from the RPG 2, the PG-7M's internal rocket motor will ignite after the grenade 8 has traveled about 10-11 meters, giving the grenade 8 higher velocity, a relatively flat trajectory, and better accuracy. In addition, when the grenade round exits the tube of the RPG 2, several sets of fins 8 A at the rear of the grenade round 8 unfold, to maintain direction and induce rotation. The maximum effective range of the RPG 2 is about 500 meters for stationary targets and 300 meters for moving targets, with a maximum overall range of about 920-1100 meters, at which point the grenade 8 will self destruct (typically about 4-5 seconds after it was launched). The fuse sets the maximum range of the grenade 8 . One way the timed detonation of the RPG 2 has been used is to create rough proximity airbursts against targets such as helicopters once the targets have passed the preferred 100 meter “head-on attack” zone. In addition, some grenades used with the RPG 2 can penetrate armor up to 330 millimeters.
Although the RPG 2 generally won't travel as far as a larger rocket, the RPG 2 is far more portable (it can be held over a shoulder), lightweight, simple to use (literally “point and shoot”) and, unlike indirect weapons such as mortar, can be more directly aimed at a target, to produce damage essentially equivalent to a stick of dynamite detonated at the target location. Further, because the blast radius of anti-armor round fired by an RPG 2 is around 4 to 8 meters, personnel and/or equipment in proximity to an RPG blast will still experience significant negative effects from it. For example, personnel may experience effects such as temporary deafness and blindness from an RPG blast even if such persons are not permanently harmed or killed by the blast.
Because the RPG 2 is so simple to use, effective, damaging, and widely available, it has become the weapon of choice for many forces around the world, including many guerilla armies and insurgents hostile to U.S. interests. Consequently, the U.S. military has great interest in training its personnel to deal with military combat situations in which RPGs may be used.
One way that the U.S. military trains its forces to deal with various military combat situations is using laser-based combat simulation systems. Such laser-based systems have been developed to simulate military combat situations without actually having to fire live ammunition. These systems use relatively low power lasers and matched detectors for indicating when a “hit” has occurred. One such system is the Multiple Integrated Laser Engagement Systems, referred to as the MILES system. Military forces in the U.S. and around the world have found MILES to be an important tool to help soldiers and others learn combat survival skills and evaluate battle outcomes, and MILES training has been proven to dramatically increase the combat readiness and fighting effectiveness of military forces.
An illustrative implementation of MILES uses so-called eye-safe “laser bullets,” combined with the use of laser sensitive detectors, to simulate battlefield situations. Each individual and vehicle in the training exercise has a detection system to sense hits and perform casualty assessment. For example, as part of an exemplary MILES event, some soldiers are equipped with one or more laser detectors (e.g., an optical detector) capable of receiving a coded laser signal or pulse that has been fired, and these laser detectors can be attached to the soldier himself, to a vehicle the solder is riding on or in, or to any other location proximate to a target of interest. Other soldiers are equipped with laser transmitters capable of “shooting” coded laser signals and/or pulses of infrared energy. These laser transmitters can be readily attached to and detached from any location, person, or thing (e.g., vehicle mounted weapons, hand carried weapons, vehicles, tanks, etc.). In some implementations, one or more of the coded laser signals and/or pulses are modulated to indicate the type of weapon that is the source of the laser beam; and a soldier identification number may also be included in the transmitted signal.
When the laser sensitive detectors receive the coded laser signal/pulse(s), one or more MILES decoders determine whether the target was hit and, if so, whether the “laser bullet” was accurate enough to cause damage (e.g., a casualty). This determination can be made in various ways, such as by whether the coded signals/pulses exceed a threshold, whether the coded signals/pulses actually hit its intended target, and the like. In some implementations, the target (and/or the shooter) can be made aware almost instantly of the accuracy of a simulated shot, such as by audible alarms, visible displays, pyrotechnics, and the like, where these indicators can designate a hit or near miss and also help to provide realism for the soldiers.
In more recent implementations of MILES, all action by shooters and targets (deemed “players”) is recorded during a simulated event, so that a so-called After Action Review (AAR) can occur later, to review the effectiveness of the weapons and/or of the defenses against them. For example, one implementation of AAR allows commanders to process, format and view engagement data collected during an exercise, for review after the exercise. In addition, exercise data can be archived for future use, such as to provide additional training for military forces.
SUMMARY OF THE INVENTION
The following presents a simplified summary in order to provide a basic understanding of one or more aspects of the invention. This summary is not an extensive overview of the invention, and is neither intended to identify key or critical elements of the invention, nor to delineate the scope thereof. Rather, the primary purpose of the summary is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
In one embodiment, to help mitigate the threat of devices such as RPGs, the invention provides a surrogate training device simulating an RPG, where the training device is usable with a laser-based system such as the MILES system. The surrogate training device, which simulates the RPG (minus the launch of an actual grenade at a target) provides a simulation of predetermined characteristics of the RPG, such as the aesthetics (e.g., “look and feel”), weight, appearance, and physical features, such as the muzzle flash (e.g., an incandescent flash at a weapon muzzle following departure of the arms being used, which can be caused be the ignition of oxygen, the expulsion of burning powder grains and the expansion of powder gasses), smoke trail and sounds that occur when a grenade is launched from an actual RPG.
In one embodiment, the invention provides a rocket propelled grenade (RPG) simulation device usable with a laser detector, the RPG simulation device comprising a laser transmitter, a switch, a controller, and a housing. The laser transmitter is capable of directing a laser signal to the laser detector, the laser signal comprising information readable by the laser detector, to simulate a launch of a rocket propelled grenade from the RPG simulation device to the laser detector. The switch permits a user to trigger a laser signal from the laser transmitter. The controller is in operable communication with the laser transmitter and the switch, and the controller is operable to respond to triggering of the switch and to simulate the launch of a rocket propelled grenade by directing the laser transmitter to generate and transmit a laser signal. The housing simulates at least one predetermined characteristic of an actual RPG device. The housing is constructed and arranged to house at least one element selected from the group consisting of the laser transmitter, the switch, and the controller.
The laser signal can comprise a pulse of laser energy. The RPG simulation device can further comprise an anti-tank weapons effect systems simulator (ATWESS) in operable communication with the controller, the ATWESS generating an indicator replicating a physical effect that occurs when an RPG launches a grenade. When the switch is triggered, the controller can command the ATWESS to generate the indicator replicating the physical effect. For example, the indicator can comprise at least one physical effect selected from the group consisting of a noise, a visual effect, a gaseous effect, muzzle flash, smoke, an audible effect, and a blast sound.
The RPG simulation device can further comprise a display in communication with the controller, wherein the display is constructed and arranged to display information related to operation of the RPG to an operator of the RPG. For example, the displayed information can comprise at least one piece of information selected from the group consisting of round count, player identification number, laser power level, rounds remaining, weapon type, and battery level. In addition, the RPG simulation device can include indicators capable of indicating to a user that a laser signal has been transmitted and/or capable of enabling alignment of the laser transmitter.
In one embodiment, the laser transmitter can transmit a laser signal encoded with a MILES code, such as a code recognizable by a MILES-type detector. In one embodiment, the controller can perform additional operations, such as one or more of tracking number of rounds fired; tracking a player identification number, tracking a power level of a laser signal emitted by the laser transmitter; tracking a battery level; generating a programmable hit and near miss word, adjusting a power level of the laser signal emitted by the laser transmitter; adjusting an alignment of the laser signal emitted by the laser transmitter; generating a signal to control the laser signal where the laser signal further comprises a MILES code; tracking MILES code related information in a laser signal that comprises a MILES code; receiving an instruction from an external system via a USB port; providing data to an external system via a USB port; providing information to a display; providing reverse voltage protection; responding to a controller key; responding to a push to read switch; responding to a magnetic switch; responding to a trigger switch; and responding to a safety switch.
In another embodiment, the invention provides a method for simulating operation of a rocket propelled grenade (RPG). A physical structure having at least one predetermined characteristic in common with an actual RPG is provided. A laser transmitter is coupled to the physical structure, the laser transmitter operable to direct a laser signal to a laser detector. A user-accessible control is provided on the physical structure. The laser transmitter is coupled to the user-accessible control so as to enable a user to transmit a laser signal towards a target to simulate launching an RPG at that target. In a further aspect, an anti-tank weapons effect system simulator (ATWESS) is provided, where the ATWESS is capable of generating an indicator simulating a physical effect that occurs when an actual RPG launches a grenade. In still a further aspect, the laser signal can be encoded with a MILES code.
In one aspect, a physical effect is generated when the laser signal is transmitted, the physical effect comprising at least one physical effect selected from the group consisting of sound, muzzle flash, smoke, visual effect, audio effect, and gaseous effect.
In another embodiment, the invention provides a system usable with a detector responsive to a laser signal for simulating the operation of a rocket propelled grenade (RPG) device. The system comprises means for enabling a user to trigger a simulated launch of a grenade from the RPG device; means for directing a laser signal to the detector in response to the simulated launch trigger; and means for generating a physical indicator of the launch. In a further embodiment, the system further comprises means for simulating at least one predetermined characteristic associated with the operation of the RPG device, the at least one predetermined characteristic selected from the group consisting of sound, muzzle flash, smoke, weight, color, shape, housing material, length, range, visual effect occurring when weapon is fired, audio effect occurring when weapon is fired, and gaseous effect occurring when the weapon is fired.
Details relating to this and other embodiments of the invention are described more fully herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and aspects of the present invention will be more fully understood in conjunction with the following detailed description and accompanying drawings, wherein:
FIG. 1 is a prior art image of a rocket-propelled grenade (RPG) launcher and its grenade, as viewed from the right side;
FIG. 2 is a perspective view of a rocket propelled grenade (RPG) simulation device, without the sighting attachment, as viewed from the left side, in accordance with one embodiment of the invention;
FIG. 3A is a left side view of the RPG simulation device of FIG. 2 ;
FIG. 3B is a bottom side view of the RPG simulation device of FIG. 2 ;
FIG. 4 is a first exploded perspective view of the RPG simulation device of FIG. 2 , as viewed from the right side;
FIG. 5 is a second exploded perspective view of the RPG simulation device of FIG. 2 , as viewed from the left side and also including the sighting attachment;
FIG. 6A is an enlarged perspective view of the grenade portion of the RPG simulation device of FIG. 2 ;
FIG. 6B is an enlarged exploded view of the grenade portion of the RPG simulation device of FIG. 2 ;
FIG. 7 is partial cross-sectional enlarged view of the grenade portion of the RPG simulation device of FIG. 2 , showing the grenade mounting and circuit card assembly (CCA) housing cover;
FIG. 8 is an enlarged view of the CCC housing assembly of the RPG simulation device of FIG. 2 ;
FIG. 9A is a first enlarged view showing the mounting of the CCA housing to the front tube, for the RPG simulation device of FIG. 2 ;
FIG. 9B is a second enlarged view showing the mounting of the CCA housing to the front tube, for the RPG simulation device of FIG. 2 ;
FIG. 10 is a perspective view showing the front and rear tubes of the RPG simulation device of FIG. 2 ;
FIG. 11A is an enlarged perspective view showing the rear tube and its blast shield mounting holes, for the RPG simulation device of FIG. 2 ;
FIG. 11B is an enlarged perspective view showing the ATWESS assembly and blast shield mounted to the rear tube, for the RPG simulation device of FIG. 2 ;
FIG. 12A is an enlarged perspective view showing the front grip assembly, including finger guard, for the RGP simulation device of FIG. 2 ;
FIG. 12B is an enlarged side view of the front grip assembly of FIG. 11A , without the finger guard;
FIG. 13 is an enlarged perspective view of the rear grip assembly of the RPG simulation device of FIG. 2 ;
FIG. 14A is an enlarged exploded perspective view of the liquid crystal display (LCD) housing assembly for the RPG simulation device of FIG. 2 ;
FIG. 14B is an enlarged cross-sectional view of the controller key receptacle switch for the RPG simulation device of FIG. 2 ;
FIG. 15 is a wiring harness interconnection diagram for the RPG simulation device of FIG. 2 ;
FIG. 16 is a functional block diagram of the CCA inputs and outputs, used with the RPG simulation device of FIG. 2 ;
FIGS. 17A and 17B are front and side views, respectively, of the dual function laser tube used with the RPG simulation device of FIG. 2 ; and
FIGS. 17C and 17D are front and side views, respectively of a the first laser tube used with the dual function laser tube of FIGS. 17A and 17B ; and
FIGS. 17E and 17F are front and side views, respectively, of the second laser tube used with the dual function laser tube of FIGS. 17A and 17B .
In the drawings, like reference numbers indicate like elements. The drawings are not to scale, emphasis instead being on illustrating the principles of the invention.
DETAILED DESCRIPTION
Throughout this document, the term “rocket propelled grenade” (RPG) is used to describe a particular type of weapon being simulated. However, those of skill in the art will recognize that at least some embodiments of the invention are equally applicable to weapons such as rifle-propelled grenades, light anti-tank weapons (LAWs), artillery, mortar, grenades, and rockets. For example, the physical appearance of the RPG simulation device can readily be adapted to match the physical appearance of a weapon such as rifle propelled grenade, light anti-tank weapon, etc., and the physical effects (e.g., sights and sounds) that occur when the respective weapon is used can also be incorporated as part of the simulation device. In addition, note that the term “rocket propelled grenade” is a term of art that refers at least to a weapon that launches a grenade using a rocket, and not merely to the grenade itself that is being launched.
FIG. 2 is a perspective view of a rocket propelled grenade (RPG) simulation device 10 as viewed from the left side, in accordance with one embodiment of the invention. FIGS. 3A-5 provide additional views of the RPG simulation device 10 , including a left side view ( FIG. 3A ), a bottom side view ( FIG. 3B ), a first, exploded, right perspective view ( FIG. 4 ), and a second, exploded, left perspective view ( FIG. 5 ), the latter of which also shows an optional field viewing scope 19 . In one embodiment, the field viewing scope 19 is a Model Red Dot 30, from BSA Optics, Inc. of Ft. Lauderdale, Fla. Because the Picatinny mounting rail 70 (described further herein) is used as the mounting bracket for the field viewing scope 19 , a variety of different scopes may be mounted, if desired.
Referring now to FIGS. 2-5 , the RPG simulation device 10 has aesthetics (e.g., the look and feel) designed to closely simulate an actual RPG, such as the RPG 2 of FIG. 1 . The RPG simulation device 10 also includes MILES technology that enables it to produce a MILES signal 11 usable in a MILES environment to enable, for example, instrumented training events for After Action Review (AAR) training at both military home stations and at combat training centers. The RPG simulation device 10 , in one embodiment, weighs approximately fifteen (15) pounds and has a length of about fifty-one (51) inches. The RPG simulation device 10 is constructed to be water-resistant and has an effective range of 300 to 1000 meters. The RPG simulation device 10 is capable of firing signals that include one or more of selectable MILES codes, a word count, and a player identification number or code. In addition, the RPG simulation device 10 provides a programmable rounds count.
Referring still to FIGS. 2-5 , the RPG simulation device 10 includes a simulated grenade 12 , a circuit card assembly (CCA) housing assembly 14 (which is not visible in FIG. 2 , but is shown in FIGS. 4-9A , 15 , and 16 ), and a trigger switch 34 . The CCA housing assembly 14 itself contains the circuit card assembly (CCA) 80 , which is described and illustrated further herein in connection with FIGS. 15 and 16 . In addition, the CCA housing assembly 14 includes a dual-function laser tube 120 (not visible in FIG. 2 ) that can generate one or more MILES or ALIGN signals 11 , as shown in FIG. 2 , the dual-function laser tube is illustrated and discussed further herein in connection with FIGS. 15-17F . The embodiment of the RPG simulation device 10 as shown in FIGS. 2-5 also includes a housing implemented via the CCA housing assembly 14 , a rear tube assembly 20 , a front tube assembly 16 , a front grip assembly 28 , rear grip assembly 30 , an LCD assembly 32 , field viewing scope 19 and sighting attachment mounting rail 70 , safety switch 53 , an anti-tank weapons effect system simulator (ATWESS) assembly 24 , a blast shield 26 , and a shoulder stop bracket 22 . Each of these elements is described further herein.
As those of skill in the art will appreciate, a housing for the RPG simulation device 10 can be implemented in many different ways. For example, it could be made using a single tube, rather than front and back tubes, with multiple tubes, in fewer or more pieces than illustrated, etc.
FIG. 6A is an enlarged perspective view of the simulated grenade 12 of the RPG simulation device 10 of FIG. 2 , and FIG. 6B is an enlarged exploded view of the simulated grenade 12 , showing where the CCA 80 is disposed (the CCA 80 is disposed within the tubular CCA housing assembly 14 shown in the figure). In one embodiment, the simulated grenade 12 is formed from two symmetrical pieces 12 A, 12 B of a substantially rigid and rugged material, such as polypropylene thermal plastic, and has a color (e.g., olive drab) to mimic the color of an actual grenade. As those of skill in the art will appreciate, however, the simulated grenade 12 can be formed of virtually any material (e.g., metals, composite, plastics, etc.), in any color, which is able to be formed into a grenade-like shape (or the shape of any other warhead being simulated) and able to withstand the rigors of the application and environment where the RPG simulation device 10 is being used, such as operation in an environment with temperatures that can range from 35° C. (−31° F.) to 62° C. (144° F.)
The simulated grenade 12 includes one or more ribs 12 C that help to strengthen the structure of the simulated grenade 12 and to also conform around the CCA housing assembly 14 portion of the RPG simulation device of FIG. 6B . In addition, the simulated grenade 12 includes a plurality of fins 12 D to help mimic the appearance of the actual grenade.
FIG. 7 is partial cross-sectional enlarged view of the simulated grenade 12 of the RPG simulation device 10 of FIG. 2 , showing the simulated grenade mounting and circuit card assembly (CCA) housing cover 18 . In this embodiment, the CCA housing cover 18 is mounted to the CCA housing 14 using four hex socket head screws 17 , and the simulated grenade 12 is secured to the CCA housing assembly 14 using eight Philips screws 21 . The method of mounting, as well as the particular configuration and arrangement of mounting screws is merely illustrative and not intended as limiting. Using screws helps to enable the simulated grenade 12 and/or the CCA 80 (contained within the CCA housing 14 ) to be more easily serviceable. The CCA housing assembly 14 also includes a groove 29 that cooperates with the alignment screw 23 (see FIG. 8 ) to help orient the CCA housing assembly 14 within the front tube 16 .
FIG. 8 is an enlarged view of the CCA housing assembly 14 of the RPG simulation device 10 of FIG. 2 , FIG. 9A is a first enlarged view showing the mounting of the CCA housing to the front tube 16 , for the RPG simulation device of FIG. 2 , and FIG. 9B is a second enlarged view showing the mounting of the CCA housing 14 to the front tube 16 , for the RPG simulation device 10 of FIG. 2 . Referring to FIGS. 8-9B , the CCA housing assembly 14 is constructed of a substantially rigid material, such as aluminum 6061-T6 material, and has an appearance and color (e.g., anodized olive drab) to further mimic the appearance of an actual RPG. The CCA housing assembly 14 is shaped so as to house the CCA 80 ( FIG. 15 and FIG. 16 ) and also a laser tube assembly 120 ( FIG. 17 ), and includes an opening 15 in which the CCA 80 is mounted, as well as a CCA housing cover 18 . The CCA housing assembly 14 is secured to the front tube 16 with six screws 21 . In addition, an alignment screw 23 (which helps serve as an alignment indicator) is used for orientation, and alignment screw 23 is coupled through slot 29 (see FIGS. 7 , 8 ) to help to ensure that the CCA housing assembly 14 is installed into the front tube 16 in the same orientation both during production and in later follow on field repairs.
FIG. 10 is a perspective view showing the front and rear tubes 16 , 20 , respectively, of the RPG simulation device 10 of FIG. 2 , coupled together. The front tube 16 and rear tube 20 are each made of a substantially rigid material, such as aluminum 6061-T6. The front tube 16 is inserted into the rear tube 20 and secured by six screws. To simulate the appearance of an actual RPG, the front tube 16 is anodized black and the rear tube 20 is anodized brown. The shoulder stop bracket 22 can be provided in various ways. In one embodiment, the shoulder stop bracket 22 is molded out of a substantially rigid material, such as brown polycarbonate plastic or anodized brown metal and secured to the rear tube 20 , such as by screws, welding, soldering, adhesives, or any other attachment method. In another embodiment, the shoulder stop bracket 22 can be formed integrally with the rear tube 20 .
FIG. 11A is an enlarged perspective view showing the rear tube 20 and its blast shield mounting holes 25 , for the RPG simulation device 10 of FIG. 2 , and FIG. 11B is an enlarged perspective view showing the ATWESS assembly 24 and blast shield 26 mounted to the rear tube 20 , for the RPG simulation device of FIG. 2 . The ATWESS assembly 24 uses an ATWESS cartridge (not shown) and is able to provide one or more indicators or physical effects, such as a realistic weapon signature, including muzzle flash, noise, and backblast smoke, appropriate for the simulation of a grenade launched from an RPG. The ATWESS breech lock lever 49 locks the ATWESS cartridge into place.
ATWESS simulation devices are available from various vendors, including Cubic Defense Systems of San Diego, Calif. In one embodiment, the ATWESS assembly 24 and blast shield 26 are substantially the same as those used on the simulated VIPER device used with the MILES system.
The ATWESS assembly 24 includes an ATWESS breech lock lever 49 (to lock the ATWESS cartridge cover) and an ATWESS safety lever 46 that must be pulled to arm the ATWESS. The blast shield 26 is provided to protect the operator and to collimate the blast from the ATWESS assembly 24 to reduce the likelihood injury to nearby personnel.
FIG. 12A is an enlarged perspective view showing the front grip assembly 28 for the RPG simulation device 10 of FIG. 2 , with the finger guard 50 , and FIG. 12B is an enlarged side view of the front grip assembly 28 of FIG. 11A , without the finger guard 50 . The front grip assembly 28 includes several user accessible controls, including a trigger switch 34 , as well as an internal magnetic switch 47 (not visible in the figures). The magnetic switch 47 communicates with the CCA 80 to activate a Helium Neon Laser Tube located within a so-called dual function laser tube 120 ( FIG. 15 ) that also is in communication with the CCA 80 for alignment purposes. Placing a magnet near the bottom of the front grip assembly 28 can trigger the magnetic switch 47 . The front grip assembly 28 can include a removable finger guard 50 and a cover 51 . To help simulate the appearance of an actual RPG, the front grip assembly 28 is anodized black and the cover 51 is anodized brown and mounted to the rest of the front grip assembly 28 via four counter-sunk screws. The front grip assembly 28 couples to the front tube 16 via screws mounted through a plurality of screw holes 53 .
FIG. 13 is an enlarged perspective view of the rear grip assembly 30 of the RPG simulation device of FIG. 2 . The rear grip assembly 30 houses a battery 65 (e.g., a 9 volt battery) (not visible in this Figure) that is held in place via battery door 64 and battery door knob 66 , which advantageously has a low profile. The rear grip assembly 30 includes a user accessible control, such as the safety switch 42 . During operation, in one embodiment, the safety switch 42 must be engaged prior to engaging the trigger switch 34 . The rear grip assembly 30 , like the front grip assembly 28 , is anodized black, with a brown cover 60 , to simulate the appearance of an actual RPG. The cover 60 is mounted to the rear grip assembly 30 using four counter-sunk screws, and the rear grip assembly couples to the front tube 16 via screws mounted through a plurality of screw holes 63 .
Although the functions of the front grip assembly 28 and rear grip assembly 30 could be implemented in a single grip, it is advantageous if they are provided as part two separate grips to ensure that an operator has both hands on the RPG simulation device 10 when using it, to improve safe use of the RPG simulation device 10 .
FIG. 14A is an enlarged exploded perspective view of the liquid crystal display (LCD) housing assembly 32 for the RPG simulation device of FIG. 2 . The LCD housing assembly 32 includes a liquid crystal display (LCD) 78 , an indicator LED 81 (which illuminates when the RPG simulation device 10 is fired), a reset push button switch 82 (used to reset the RPG simulation device 10 , reset round count, etc.), an LCD housing assembly cover 74 , and LCD cover 76 , and a controller key receptacle switch 36 (also referred to herein as a weapon switch), which is usable with a controller key switch, explained further herein.
In at least some embodiments, the LCD housing assembly 32 includes a so-called Picatinny mounting rail 70 (i.e., a bracket used on some firearms to provide a standardized mounting for accessories such as the field viewing scope 19 ; such a bracket can be provided in accordance with MIL-STD-1913, first published by the U.S. Picatinny Arsenal). Picatinny rails are available from numerous suppliers, including Centurion Tactical Systems of Layton Utah.
FIG. 14B is a cross sectional view of the controller key receptacle switch 36 . As FIG. 14B illustrates, the controller key receptacle switch 36 has four positions and is used to set the RPG simulation device 10 in one of several operating modes. In at least one embodiment, a controlling operator has a first key (i.e., a so-called “green” master key) capable of putting the RPG simulation device 10 into either a so-called “Dry Fire” mode (a mode with no ATWESS, e.g., no smoke) or an ATWESS mode (a mode in which an ATWESS cartridge is used as part of the simulation), and the RPG simulation device operator has a second key (i.e., a so-called “yellow” weapon key).
The following modes of operation are provided by way of example and are not limiting.
To put the RPG simulation device 10 in “Dry Fire” mode, assuming a battery 65 is installed into the rear grip 30 , the green master key is then inserted into the controller key receptacle switch 36 and turned to the “set” position 36 A, and then the green master key is then turned to position 3 ( 36 B in FIG. 14B ). The green master key is then removed from controller key receptacle switch 36 , and the RPG simulation device 10 will be in “Dry Fire mode”. The operator of the RPG simulation device 10 can then press the push to read switch 82 to see an indication of the “Rounds Remaining” on the LCD display 78 (e.g., four rounds remaining). To fire the RPG simulation device 10 , an operator inserts his yellow operator key into the controller key receptacle switch 36 , presses the safety switch 42 ( FIG. 13 ), then the trigger switch 34 ( FIG. 12 ), and the LED 81 illuminates when the laser signal 11 is emitted, when the laser transmitter 206 ( FIG. 16 ) is fired by the trigger switch 34 . The laser transmitter 206 sends a laser signal, such as a pulse of laser energy and/or eye-safe, invisible laser (light) beams, toward the target. If the laser beam hits the target, detector assemblies on the target sense the beam and cause an alarm to sound. In addition, if the target is a vehicle, an externally-mounted light on the vehicle will flash.
Optionally, the operator of the RPG simulator device 10 may wear a harness or vest equipped with a laser detector assembly and alarm and which also includes a similar controller key receptacle switch 36 . The laser detector can, for example, be a detector usable with a MILES-type of system. If a MILES-equipped weapon fires a laser signal at the operator of the RPG simulator device 10 , one of two results may occur: if it is a “near miss” the alarm on the harness sounds for one second; if it is a “hit”, the alarm sounds continuously and the operator has been “killed”. The operator's yellow weapon key can be removed from the RPG simulator device 10 and inserted into the controller key receptacle switch 36 (on the harness) to shut off the alarm. In one embodiment, only the green master key can perform a system reset on the RPG simulator device 10 (which provides for a new set of rounds).
To put the RPG simulation device 10 in “ATWESS” mode, assuming a battery 65 is installed in the rear grip 30 , the green master key is then inserted into the controller key receptacle switch 36 and turned to the “set” position 36 A, and then the green master key is then turned to position 4 ( 36 C in FIG. 14B ). The green master key is then removed from controller key receptacle switch 36 , and the RPG simulation device 10 will be in “ATWESS Mode.” The operator of the RPG simulation device 10 can then press the push to read switch 82 to see an indication of the “Rounds Remaining” on the LCD display 78 (e.g., four rounds remaining).
Operation of the RPG simulator device 10 in ATWESS mode is similar to operation in DRY FIRE mode, except that in ATWESS mode, an operator cannot fire the laser transmitter unless an ATWESS cartridge is loaded and the ATWESS safety lever 46 is in the ARMED position. The operator ensures that the backblast area near the blast shield 26 is clear, and centers the target (e.g. via field viewing scope 19 ). The target is tracked, and the operator then fires at the target, pressing and holding the safety switch 42 first and then the pressing the trigger switch 34 . In one embodiment, the operator can fire a round every 10 seconds, for up to four rounds, with each round using its own ATWESS cartridge. After the firing, an operator can check the “Rounds Remaining” by depressing the push to read switch 82 , and a displayed rounds counter will show rounds remaining. When the round is fired, the ATWESS provides an audible sound equivalent to the sound a real round would make, as well as a blast of smoke similar to that produced during the firing of a “real” rocket propelled grenade.
FIG. 15 is a wiring harness interconnection diagram for the RPG simulation device 10 , of FIG. 2 , showing internal interconnections amongst some of the elements shown in FIGS. 2-14 . All of the components shown in FIG. 15 are interconnected to at least the CCA 80 of FIG. 16 , which is disposed within the CCA housing 14 of FIG. 15 , but is not itself visible in FIG. 15 . In at least one embodiment, the CCA 80 acts as a controller for one or more functions of the RPG simulation device 10 . The CCA 80 couples to a laser tube 120 (which contains one or more lasers, such as a 904 nm Infrared wavelength laser tube, to generate, direct, and control the MILES laser signals that are emitted by the RPG simulation device 10 and to also control the laser alignment signal 11 B (which helps serve as an alignment indicator) used to align the MILES laser signals 11 ( FIG. 2 ) emitted by the RPG simulation device 10 . The laser alignment signal 11 B is activated via a magnetic switch (not visible in FIG. 15 ) that is switched when a magnet is placed in proximity to the bottom 28 A of the front grip assembly 28 .
The CCA 80 is further interconnected with (and responsive to) the trigger switch 34 on the front grip assembly 28 , as well as to a safety switch 42 on the rear grip assembly 30 . The trigger switch 34 and safety switch 42 can be used independently of each other or in conjunction with each other, depending on the mode of operation of the RPG simulation device 10 , as described above. In one embodiment, the RPG simulation device 10 will only fire (in either mode) if the safety switch 42 is pressed and held first and then the trigger switch 34 is pressed. The mode of operation of the RPG simulation device 10 is set via the weapon switch 36 , which, in one embodiment, can be controlled or set via a removable weapon switch key 36 A (e.g., the controller green key described previously). The CCA 80 communicates with and controls the ATWESS assembly 24 , in response to inputs at the trigger switch 34 and safety switch 42 .
The CCA 80 monitors the terminals 44 of battery 65 , to monitor the battery voltage and provide a “low battery” indicator on LCD display 78 of the LCD assembly 32 . The CCA 80 is responsive to the push to read switch 82 and provides a signal to the LED indicator 81 .
FIG. 16 is functional block diagram of the CCA 80 and its inputs and outputs, as used with the RPG simulation device 10 of FIG. 2 . In one embodiment, the CCA 80 is sized to fit in the opening 15 on the CCA housing assembly 14 and is about 3.5 inches by 1 inch in size. The inputs to the CCA 80 include the settings of/signals from the safety switch 42 and main trigger switch 34 , signals monitoring the power/voltage level of the battery 65 , the setting of the controller key receptacle switch 36 , the setting of the push to read switch 82 , the setting of the magnetic switch 47 , the setting of the ATWESS safety arming switch 46 , and inputs from a USB programming interface 55 (USB port).
The outputs of the CCA 80 include a signal controlling the ATWESS 24 , signals to the display 80 and the LED fire indicator 81 , data to the USB port 55 , and the signals directed to the dual function laser tube 120 to energize a laser diode (not visible in the Figure) in the dual function laser tube 120 , so as to cause the RPG simulation device 10 to emit a laser beam (either the MILES laser 106 or an alignment laser 114 ) towards a given target.
The CCA 80 itself includes functionality providing weapons effect simulation control 200 (to control the ATWESS 24 ), weapon round count 202 (where the round count can relate to a specific weapon type via the weapon type control 204 ), signals to control the laser diode 206 , signals to control the laser power level adjustment 208 (including hit and near miss laser power level adjustment), signals to control alignment 210 , signals to control the display 212 (including display of PID, rounds remaining, weapon type, and battery low indicators), capability to track up to 5280 player identification codes (PID) (e.g., Enhanced MILES PID), encoding all existing MILES codes 216 , providing reverse voltage protection 216 , monitoring battery power 220 , and tracking player identification (PID) (e.g., via a 5280 Enhanced PID).
FIGS. 17A and 17B are front and side views, respectively, of the dual function laser tube 120 used with the RPG simulation device of FIG. 2 . FIGS. 17C and 17D are front and side views, respectively of a first laser tube 100 used with the dual function laser tube of FIGS. 17A and 17B . FIGS. 17E and 17F are front and side views, respectively, of the second laser tube 110 used with the dual function laser tube of FIGS. 17A and 17B . As FIG. 17 illustrates, both the MILES laser tube 110 and the alignment laser tube 110 are disposed within the dual function laser tube 120 .
The first laser tube 100 is the MILES laser tube and includes laser transmitter/laser diode that emits a laser beam when energized (such as when an operator presses the trigger switch 34 to cause the CCA 80 to generate a signal to energize the laser transmitter). In one embodiment, the laser transmitter uses a so-called MOCVD (metal organic chemical vapor deposition) type of laser, which is an infra-red, non-visible laser, available from Laser Diode, Inc., of Edison, N.J.
The second laser tube 110 includes a laser transmitter (not visible in FIG. 18 ) capable of generating a read laser “pointer” type beam for alignment purposes.
In describing the embodiments of the invention illustrated in the figures, specific terminology (e.g., language, phrases, product brands names, etc.) is used for the sake of clarity. These names are provided by way of example only and are not limiting. The invention is not limited to the specific terminology so selected, and each specific term at least includes all grammatical, literal, scientific, technical, and functional equivalents, as well as anything else that operates in a similar manner to accomplish a similar purpose. For example, although particular materials (e.g., aluminum, polycarbonate, etc.) are described as being used in various embodiments to construct aspects of the RPG simulation device, those of skill in the art will recognize that numerous other materials could work equally well. Furthermore, in the illustrations, Figures, and text, specific names may be given to specific features, processes, military programs, etc. Such terminology used herein, however, is for the purpose of description and not limitation.
Although the invention has been described and pictured in a preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form, has been made only by way of example, and that numerous changes in the details of construction and combination and arrangement of parts may be made without departing from the spirit and scope of the invention.
In the Figures of this application, in some instances, a plurality of system elements may be shown as illustrative of a particular system element, and a single system element or may be shown as illustrative of a plurality of a particular system elements. It should be understood that showing a plurality of a particular element is not intended to imply that a system or method implemented in accordance with the invention must comprise more than one of that element, nor is it intended by illustrating a single element that the invention is limited to embodiments having only a single one of that respective elements. In addition, the total number of elements shown for a particular system element is not intended to be limiting; those skilled in the art can recognize that the number of a particular system element can, in some instances, be selected to accommodate the particular user needs.
In addition, those of ordinary skill in the art will appreciate that the embodiments of the invention described herein can be modified to accommodate and/or comply with changes and improvements in the applicable technology and standards referred to herein. Variations, modifications, and other implementations of what is described herein can occur to those of ordinary skill in the art without departing from the spirit and the scope of the invention as claimed.
The particular combinations of elements and features in the above-detailed embodiments are exemplary only; the interchanging and substitution of these teachings with other teachings in this and the referenced patents/applications are also expressly contemplated. As those skilled in the art will recognize, variations, modifications, and other implementations of what is described herein can occur to those of ordinary skill in the art without departing from the spirit and the scope of the invention as claimed. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention's scope is defined in the following claims and the equivalents thereto.
Having described and illustrated the principles of the technology with reference to specific implementations, it will be recognized that the technology can be implemented in many other, different, forms, and in many different environments. The technology disclosed herein can be used in combination with other technologies. Having described the preferred embodiments of the invention, it will now become apparent to one of ordinary skill in the art that other embodiments incorporating their concepts may be used. These embodiments should not be limited to the disclosed embodiments, but rather should be limited only by the spirit and scope of the appended claims.
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A rocket propelled grenade (RPG) simulation device usable with a laser detector is provided. The RPG simulation device comprises a laser transmitter, a switch, a controller, and a housing. The laser transmitter is capable of directing a laser signal to the laser detector, the laser signal comprising information readable by the laser detector, to simulate a launch of a rocket propelled grenade from the RPG simulation device to the laser detector. The switch permits a user to trigger a laser signal from the laser transmitter. The controller is in operable communication with the laser transmitter and the switch, and the controller is operable to respond to triggering of the switch and to simulate the launch of a rocket propelled grenade by directing the laser transmitter to generate and transmit a laser signal. The RPG simulation device can further comprise an anti-tank weapons effect systems simulator (ATWESS) in operable communication with the controller, the ATWESS generating an indicator replicating a physical effect (such as noise, a visual effect, a gaseous effect, muzzle flash, smoke, an audible effect, and/or a blast sound) that occurs when an RPG launches a grenade.
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This application is a continuation, of application Ser. No. 563,806, filed Dec. 21, 1983, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to automated systems for storing and retrieving containers. More specifically, the present invention relates to such systems wherein a particular container can be selectively stored and retrieved from an isolated storage chamber such as a refrigerated or fire proof room.
In many storage systems wherein a lot of articles or containers having articles are stored in an isolated room, or chamber, for example, a tightly sealed room such as a refrigerating room, a thermostically controlled room, a fire-proof room, a safe room or the like, and a secret room for storing secret or important articles, it is often desired that a desired article or container can be retrieved from the room and again stored therein automatically.
It is undesirable that a person goes in and out of such a tightly sealed room for storing and retrieving articles, because the internal condition such as temperature, pressure, cleanliness or others is changed thereby. In some instances anyone wishing to enter such a room must put on a special or exclusive apparel such as a suit, jacket or the like. This is inconvenient for the person. In another case, a man who goes in the room may be in danger.
In connection with secret room storing secret articles, it is undesired for protection of secrecy that a person or persons can go in the room every time when desiring a stored article or articles.
In rental safe deposit box system, those boxes are stored in a fire-proof safe room in a bank. When a hirer or a contractor desires to use his box, he must usually ask to a clerk to bring his box. However, it is desired for protecting privacy of the contractor that he can perform retrieval and return of his box without handle and observation by other persons.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a system wherein a lot of articles are stored in an isolated room having a tightly closed opening by a door and a desired one of the articles can automatically be retrieved to a location separated from the room through the opening and again stored into the room automatically.
It is another object of this invention to provide the system wherein all data in connection with every retrievals can be recorded.
It is still another object of this invention to provide the system wherein only predetermined persons permitted can perform retrieval of articles stored in the room.
It is yet another object of this invention to provide the system wherein each one of the predetermined persons can retrieve predetermined one of the articles stored in the room but cannot obtain the other articles than the predetermined one.
It is a special object of this invention to provide an automatic rental safe-deposit box system wherein a lot of safe-deposit boxes are stored in a fire-proof safe room having a fire-proof door in a bank and anyone of hirers or contractors can automatically retrieve his own box in a private room separated from the safe room, can handle the box in the private room and can again store the box into the safe room automatically, without intermediation of other persons nor observed by others.
According to an aspect of this invention, a system for automatically retrieving articles from, and storing the articles into, an isolated room, can be obtained. The system comprises an automatic article retrieval and storage unit constructed in the isolated room, the unit comprising article storing shelf means having a plurality of article storage locations arranged in a matrix-like form, an article delivery and return station provided at an end of the shelf means, a transporting platform means being disposed to be movable along a front surface of the shelf means and transporting an article from one of the article delivery and return station and a selected one of the article storage locations, an article delivering means being mounted on the platform means and for effecting the article delivery from one of the platform means and the article storage location selected to the other and from one of the platform means and the delivery and return station to the other. An opening is formed in a wall defining the isolated room and for permitting articles to pass therethrough. A door means is provided to automatically close and open the wall opening. Internal transporting means is provided for transporting articles between the article delivery and return station and the wall opening. At least one article handling table is disposed outside the isolated room. External transporting means is provided for transporting articles between the wall opening and the at least one article handling means. A movable portion of one of the internal and external transporting means is made to be automatically moved apart from the wall opening at a time when the door means is closed, while being moved to the wall opening at another time when the door means is opened. Data input terminal means is provided at the at least one article handling table for inputting information data in connection with article retrieval or storage and an article storing location. Electric control means is connected to the data input terminal means and controls operations of the automatic article retrieval and storage unit, the internal and external transporting means, the automatically opening and closing door means, and the movable portion.
According to another aspect of this invention, an automatic rental safe-deposit box system for automatically retrieving a rental safe-deposit box belonging to a user as requested by the user from a safe room storing a lot of boxes belonging to respective users, can be obtained. The system comprises an automatic box retrieval and storage unit constructed in said safe room, the unit comprising box storing shelf means having a plurality of box storage locations arranged in a matrix-like form, a box delivery and return station provided at an end of the shelf means, a transporting platform means being disposed to be movable along a front surface of the shelf means and transporting a box from one of the box delivery and return station and a selected one of the box storage locations, a box delivering means being mounted on the platform means and for effecting the body delivery from one of the platform means and the article box storage location selected to the other and from one of the platform means and the delivery and return station to the other. An opening is formed in a fire-proof wall containing the safe room for permitting boxes to pass therethrough. A plurality of private compartments are disposed separately from the safe room, each for permitting each user to privately handle his own rental box therein. Data input terminal means is disposed within each compartment and permits a user to input information data required for retrieving his own rental box and to input a storage command after his use of the rental box. Transporting means comprise a single main transporting means extending from the box delivery and return station to vicinities of the plurality of private compartments through the wall opening, and a plurality of sub-transporting means connecting the single main transporting means and respective private compartments. The transporting means are for transporting a rental box from one of the box delivery and return station and a selected one of the plurality of private compartments. Box displacing means are provided at cross positions between the single main transporting means and respective sub-transporting means, and displace a box on the single main transporting means to one of the sub-transporting means corresponding to the selected one of the private compartments. Electric control means is connected to the data input terminal means and controls operations of the automatic box retrieval and storage unit, the transporting means and the box displacing means, whereby a user can automatically obtain, and again store, his own rental box only by operating the data input terminal within one of the private compartment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rear perspective view schematically illustrating a construction of an embodiment of this invention;
FIG. 2 is a front perspective view schematically illustrating the embodiment;
FIG. 3 is a view illustrating a block diagram of a control circuit in the embodiment; and
FIG. 4 is a perspective view illustrating an example of the system layout.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
An embodiment of this invention will be described in connection with an automatic rental safe-deposit box system with reference to the drawings.
Referring to FIGS. 1 and 2, the system shown therein comprises a safe room 2 for storing rental safe-deposit boxes therein and being enclosed by a wall 1 (only a portion thereof is shown) such as a fire-proof or refractory wall, and a plurality of private rooms (two rooms 3a and 3b are shown) for clients' or hirers' privately handling their own safe-deposit boxes and being located apart from safe room 2. The safe room 2 is provided with a fire-proof door 4 in the wall 1 for permitting the safe-deposit boxes to pass therethrough.
Within safe room 2, an automatic box storage and retrieval unit 5 for storing the safe-deposit boxes at predetermined locations in a shelf or a rack is established wherein a desired one of the stored boxes can be automatically taken out of the unit and automatically returned to the predetermined location in the shelf. Well-known automatic object storage and retrieval apparatus, as described in U.S. Pat. No. 3,526,326 and others, are conventionally used for such an automatic box storage and retrieval unit. Namely, this unit is provided with storage shelves 6 (confronting two shelves are shown) each of which has a plurality of box storing locations 7 arranged into a matrix-like form, a transportation platform 9 which conveys a box between each storing location 7 and a delivery and return station 8 provided to one end of the confronting storage shelves, a box gripping means 10 used for transferring a box between transportation platform 9 and a storing location 7 or delivery and return station 8, and a control circuit (not shown in the drawings).
When the control circuit receives a code indicating a storing location of a box to be retrieved and a take-out command, transportation platform 9 moves and reaches the inputted receiving location, and box gripping means 10 is actuated to take out the storage box onto transportation platform 9. Then, platform 9 moves to delivery and return station 8, where gripping means 10 is again actuated to transfer the box to the station 8.
For return and storage actions, a code indicating the storing location of the box to be returned and a return command are inputted to the control circuit. Then, transportation platform 9 moves to delivery and return station 8, and gripping means 10 transfers the box onto transportation platform 8, which, in turn, moves to the storing location inputted. Then, gripping means 10 is actuated to transfer the box onto the corresponding storing location.
The detailed construction and the functions of the automatic box storage and retrieved units are well-known in the prior art, and therefore, are not described further.
In safe room 2, there is a transporting device 12 connecting the safe room entrance 11 closed by door 4 with delivery and return station 8. In the embodiment shown, the transporting device 12 comprises a horizontal conveyor 12a, an elevator 12b vertically connecting the delivery and return station 8 with one end of horizontal conveyor 12a, and another conveyor 12c feeding a box into elevator 12b from delivery and return station 8.
Each private room of 3a and 3b is provided with a handling table 13, and an operating console containing keyboards for inputting information such as a number or a storing location code of a box desired, the retrieved or storage command, etc., a card reading device for an ID card, and displays, within the room. The back wall of each private room of 3a and 3b is provided with a box passing gate 15. A transporting device 16 extends through gate 15 to connect safe room entrance 11 with the handling table 13. The transporting device 16 comprises a movable conveyor 16a which moves away from entrance 11 when door 4 is closed and approaches it when door 4 is opened so as to be connected with inside conveyor 12a, and a main conveyor 16b connected with movable conveyor 16a, and sub-conveyors 16c and 16d which are branched from the main conveyor 16b and extended to handling tables 13 of respective rooms 3a and 3b through respective gates 15. The movable conveyor 16 a is shown in the embodiment as a swing-up type conveyor, namely, pivoted to be rotatable up and down at one end of the main conveyor 16b and driven by a motor (not shown).
Now referring to FIG. 3, a control circuit of the system will be described. In the figure, consoles 14 of respective private rooms 3a and 3b are connected to a main control device 17, which generates control signals to control operations of storage and retrieval unit 5, door 4, and transporting devices 12 and 16 in response to information inputted from each console 14. Moreover, a control circuit 18 of storage and retrieval unit 5, a control circuit 19 of door 4, and a control circuit 20 of transporting devices 12 and 16 are connected to main control device 17.
The main control device 17 is also provided with a memory device 21 which stores recognition codes representing respective users or contractors recorded on ID cards delivered to them, recitation numbers or private numbers of the contractors, and box storing addresses in the storage and retrieval unit.
On the other hand, the main control device 17 is connected with a service input device 22 and a recording device 25 which are positioned on a control table 24. The service input device 22 commands input or placement of the recognition codes and the recitation numbers into memory device 21, and controls establishment of the initial state and stop of the system at start and termination of daily service, respectively. The recording device 23 records service data of the system such as the service date (year, month, day and hour), retrieval storage history of the boxes, and the like.
For starting the safe-box service, predetermined items such as date, hour, operator code and the recognition code assigned to the operator are inputted via the service input device 22. This information is sent to main control device 17, and if there is no discrepancy with the contents in memory device 21, main control device 17 sends command signals for setting control circuits 18, 19 and 20 into their initial states, respectively.
When receiving the initial state setting signal, the control circuit 18 of the automatic storage and retrieval unit 5 controls respective driving parts (as represented by 25) of the transportation platform 9 and the gripping means 10 in such a way that they can be moved to their predetermined initial positions, respectively, and then sends a termination signal of the initial state setting to main control device 17.
On the other hand, the door control circuit 19 actuates a driving motor 26 to open door 4 in response to the initial state setting signal. After opening door 4, the door control circuit 19 sends a door-open signal to main control device 17.
When receiving the door-open signal, main control device 17 sends a signal (a connecting signal) for commanding movement of movable conveyor 16a to entrance 11, as the initial state setting signal, to the control circuit 20 of the transporting device. Accordingly, motor 27 is driven and movable conveyor 16a moves to entrance 11, whereby the inside and outside conveyors 12a and 16b are connected to one another through the movable conveyor 16a. When this operation is completed, a complete signal is sent from the conveyor control circuit 20 to main control device 17.
When receiving both of the complete signal and the above-mentioned signal from the unit control circuit 18, main control device 17 activates an indicator on service input device 22 to display completion of the initial state setting, and at the same time, activates recording device 23 to record the inputted data on a predetermined format. Thus, the system is put in the waiting condition for a requirement of safe-deposit box retrieval.
After starting the service, a hirer, who visits to use his box, enters a vacant one of the private rooms 3a and 3b. For example, in private room 3a, the user inserts his ID card into card reading device 28 (FIG. 3) on console 14, and inputs his recitation number by keyboard 30 (FIG. 3) checking indicator 29 (FIG. 3). The main control device 17 compares a combination of the information signals from reading device 28 and from keyboard 30 with the content of memory device 21. If there is no coincidence between the combination and the memory content, the main control device 17 commands indicator 29 to display an invalid access for a certain time period and stops the proceeding operations. If they coincide with one another, main control device 17 commands indicator 29 to display the transport operation start and at the same time sends a code representing the storing location of the box belonging to the user and a retrieval command to control circuit 18 of the unit 5. Upon receiving the retrieval command signal and the storing location code, the unit control circuit 18 controls the respective driving parts 25 of transportation platform 9 and gripping means 10 in such a way that the take-out operation of the required box onto delivery and return station 8 is performed, after which a take-out complete signal is sent to main control device 17.
The main control device 17, then, generates a command signal to conveyor control circuit 20 to begin transport operation. The control circuit 20 starts and controls operation of the transporting devices 12 and 16, namely, puts a driving motor 31 (FIG. 3) of conveyor 12c on delivery and return station 8 in motion to feed the box to the elevator 12b, makes elevator 12b descend by a driving motor 32 (FIG. 3) so as to place the box on the horizontal conveyor 12a, puts the respective driving motors (represented as 33) of horizontal conveyor 12a, movable conveyor 16a, main conveyor 16b, and sub-conveyors 16c in motion to feed box 40 onto handling table 13 in the private room 3a. When these operations are completed, a transport complete signal is sent to main control device 17 from the control circuit 20.
The main control device 17, then, commands the retrieval operations of a box requested from a different private room 3b, or storage operation (described later) thereof, if there is such a request.
In the system, as there are multiple private rooms (two in this embodiment), a stopper plate that moves up and down, an object detecting means, and object displacing means are located at each of the crossing points between the main conveyor and the respective sub-conveyors, so that the object can be displaced on a sub-conveyor corresponding to a requesting private room. Namely, each crossing point is provided with a stopper plate 34 which projects over the main conveyor part 16b in order to stop transportation of the object moving in the direction of the main conveyor part 16b, and a belt conveyor 36 which runs in a direction perpendicular to the conveyor roller of the main conveyor part and elevated from below over the conveyor roller surface, as shown at the crossing point between main conveyor 16b and sub-conveyor 16c in FIG. 1, and further provided with a detector 37 (for example, a microswitch, a photoelectric switch, etc.) for detecting the presence of the object thereon, as also shown at the crossing point between the main conveyor part 16b and the subconveyor part 16d. The ones 34, 36 and 37 located at the crossing point with the sub-conveyor part 16c corresponding to the private room 3a are designated with suffix "A", while those to the private room 3b with suffix "B".
The up and down motion of stopper plate 34 and the up and down motion and transport operation of the belt conveyor 36 are carried out under control of main control device 17. The output of the detector 37 is also connected with main control device 17 and used for controlling belt conveyor 36. Namely, referring to FIG. 3, if a retrieval is demanded from private room 3a, in addition to the retrieval operation as mentioned above, a driving motor 38a for stopper plate 34a at the crossing point between sub-conveyor 16c corresponding to said private room 3a and main conveyor part 16b is driven to elevate the stopper plate 34a. Thereafter, when there is a detection output of detector 37a, an up and down motion motor and a driving motor for transportation of belt conveyor 36a (both are represented as 39a) are activated by main control device 17 to elevate the belt conveyor 36a and start the transporting action. Thereby, the box located at the crossing point is displaced from main conveyor 16b to sub-conveyor 16c and sent out on handling table 13 in the requesting private room 3a through sub-conveyor part 16c. When the transporting action is finished, the motors 38a and 39a are driven in reverse to lower stopper plate 34a and the belt conveyor 36a. When retrieval is requested from another private room 3b, another stopper plate 34b and another belt conveyor 36b at the crossing point with sub-conveyor 16d are driven similarly. These driving motors are shown at 38b and 39b in FIG. 3.
For storing the box retrieval, the storing action is initiated by operation of the keyboard 30 in, for example, private room 3a to input the return command signal and, if necessary, the storing code.
Receiving the code and the return command, and the storing code if inputted, from the console 14, main control device 17 sends a return-operation command signal to conveyor control circuit 20. Namely, the conveyor control circuit 20 actuates elevator driving motor 32 to lower elevator 12b, and also rotates the respective driving motors 33 of sub-conveyor 16c, main conveyor 16b, the movable conveyor 16a, and horizontal conveyor 12a in order to feed the box from the handling table 13 onto the descended elevator 12b. Then, elevator driving motor 32 is driven to elevate elevator 12b. When the elevator 12b arrives at delivery and return station 8, driving motor 31 of conveyor 12c is driven to take out the box from the inside of elevator 12b and place it on the station 8. The conveyor control circuit 20 then sends a signal to main control device 17, which transmits the storing location code and the storage command signal to the unit control circuit 18. Then, the control circuit 18 actuates driving motors 25, etc. to start the storage action of transportation platform 9 and gripping means 10, so that the box on the delivery and return station 8 can be returned to the storing location on the shelf designated by the storing code. When the return action is completed, unit control circuit 18 sends a signal to main control device 17, whereby the system is in a condition awaiting a new request from a private room, or starts the operation already requested from a private room.
At the end of a day's service, the person in charge inputs the information necessary to stop the service operation of the system from the service input device in the similar manner as in the service start. If there is no abnormality in the information inputted, main control device 17 sends a recovery signal to conveyor control circuit 20, which thereupon rotates motor 27 reversely to turn movable conveyor 16a upwards. When the upward motion of the conveyor 16a is completed, a conveyor motion complete signal is sent to main control device 17, which, in turn, sends a door closing signal to door control circuit 19 to drive motor 26 reversely in order to close door 4. When door 4 is closed, a door closed signal is sent to main control device 17 and the system stops.
FIG. 4 is a perspective view showing an outline of the system layout, wherein various paths of safe-deposit boxes, such as box 40, are designated by thick solid arrows, while signals by broken lines.
In the above embodiment, gate 15 to each private room 3 is maintained open. However, it is preferable to use a refractory door (represented at 41 in FIG. 4), such as an iron door, which is mounted at gate 15 to be slidable upwards and downwards and to open only for passing the box therethrough. A motor can be installed for this purpose. The motor is activated by an output of a detector, such as a microswitch, for detecting the transportation of a box onto, for example, sub-conveyor 16c corresponding to private room 3a, and thus, door 41 is opened. Then, when the box is displaced onto handling table 13, door 14 is closed by the transport complete signal as described above. For returning the storage box, the motor is activated by the above-described return command to open door 41, and is driven reversely by the aforementioned detector output when the box is transferred from handling table 13 onto sub-conveyor 16c. All of these door motions may be controlled by main control device 17.
As clearly understood from the above description, a construction space and expenditures for transportation of boxes are saved, because the traverse motion of a single transportation line (excluding the sub-conveyors) between the storage unit 5 and each private room 3 can serve for all take-out and take-in actions of boxes.
Meanwhile, when the inputs from multiple private rooms interferes, the priority is given to the earlier input, while the main control device 17 holds the later input until the preceding actions are finished. For the storage commands, however, main control device 17 can be made to carry out displacement of the box onto sub-conveyor 16c or 16d, independently of inputs from other private rooms, and keeps the box in waiting on the sub-conveyor until the actions corresponding to the earlier input are finished, thereby preventing the client requesting the storage from waiting for a long and uncomfortable period.
The above-mentioned embodiments are directed to an automatic rental safe-deposit box system wherein the boxes stored in the storage unit belong to predetermined users. Therefore, the storing location codes of respective users' boxes are stored in the memory together with information representing respective users. Accordingly, anyone of users can access his own boxes by setting his ID card and inputting his recitation number at the consoles without inputting the storing location codes of his box, but he cannot obtain other boxes' than one belonging to him. Accordingly, the system of the above-mentioned embodiments cannot be applied to a system wherein articles can be automatically retrieved and stored as desired in an isolated chamber such as a fire-proof room, a refrigerating room, a thermostat room, a secret room or the like. However, it will be easily understood by those skilled in the art from the description of the above-described embodiments that the system shown in FIGS. 1-4 would be used to such an application by modifying the control circuit of the system. In that case, an isolated room is represented by room 1 in FIGS. 1 and 2.
Referring to FIG. 3, in a modification, the storing location codes of boxes are not stored in memory device 21 and main control device 17 is modified to transfer storing location information inputted by keyboard 30 to unit control circuit 18. In the case, a user can obtain boxes as desired by inputting the storing location code of the box as desired after coincidence of the combination inputted by his ID card and the keyboard with the content in the memory device.
Door 4 is usually closed and is opened at each time of the retrieval and storage commands from console 14 by modifying main control device 17 to send the door opening signal to door control circuit 19 in response to each retrieval or storage command from the console, and the door closing signal in response to the transportation complete signal from conveyor control circuit 20.
In cases where it is not required to use either one of the recitation number and the ID card, the other ones of the recitation numbers and the recognition codes of the users are registered in the memory device 21. Then, the user can inputs his code by operating either one of ID card or keyboard.
In order to permit anyone to use the system, the memory device 21 is not necessary but is omitted. The memory device is modified to send information data inputted by keyboard 30 to unit control circuit 18 as a storing location code.
If service input device 24 is not required, it can, of course, be omitted, and the main control device 17 is simplified by omitting the function responding to the service input device 24.
In the embodiments and modifications as described above, two private rooms are provided in the system. However, it will be apparent to those skilled in the art how to make those systems with more or less rooms.
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A system wherein a contractor of a rental safe-deposit box can privately obtain, handle and restore his own box in the fire-proof safe room. The system includes an automatic article retrieval and storage unit located within the safe room and having contractors' safe-deposit boxes. A plurality of private compartments for contractors' use are disposed separately from the safe room and are connected to the retrieval and storage unit by conveyor devices extending through a safe room wall opening having a fire-proof door. Each private room includes a data input terminal device and a handling table. When a contractor operates the terminal device to input his identification code, his own rental safe-deposit box is automatically extracted onto the handling table from the safe room.
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BACKGROUND OF THE INVENTION
[0001] This invention concerns automated arrangements for stacking items onto a pallet, and is more particularly concerned with apparatus for palletizing bags or sacks of loose articles, such as ice cubes. In particular, the invention is concerned with machines that line up the bags of ice cubes or similar articles into rows of bags in predetermined patterns, and that move the rows of bags onto the pallet, and then after each layer or tier is completed, move the pallet down for stacking the next layer or tier.
[0002] The invention is also concerned with technology for lining up and turning the bags as need be so that the bags will be placed in a row pattern onto an indexing conveyor or collation conveyor, and is concerned in particular with technology that employs vacuum systems capable of achieving a desired stacking pattern by control of the various vacuum pickups and conveyors. The invention concerns pallet stacking apparatus that employs a vacuum pickup device which picks up a number of bags of articles at one time, i.e., a row of the bags, and positions them onto a pallet. The invention here relates also to vacuum pickups having special vacuum cups adapted to work with bags of products that might be lumpy or prone to shifting, such as ice cubes.
[0003] The present invention also concerns technology that can be employed as pallet counterbalance systems that increases in force as the pallet is loaded and is moved down.
[0004] Moreover, the invention concerns arrangements in which a pallet loader may be situated between two pallet holders, so the bags can be stacked onto one pallet while, on the other side, a full pallet can be taken away and replaced with an empty pallet.
[0005] The current method of palletizing bags of ice cubes requires stacking them manually onto a pallet. This involves having an individual assigned to a pallet station near an ice bagging machine. The machine inserts ice cubes into a polyethylene bag, seals the bag, and transports the bags to the pallet station at a rate of about 30 to 40 bags per minute. The bags are lifted by hand and placed on the pallet in alternating patterns so that the bags in each tier interlock with the bags in the tier beneath. This is difficult and strenuous work, and it is often difficult to find and keep reliable employees willing to do this.
[0006] There have been a number of examples of automated palletizing equipment proposed, for such items as boxes or cartons, of for bags of more or less granular material such as sand or concrete mix. However, because ice cubes are lumpy and create an irregular top surface of the bag, those previously proposed systems do not offer a palletizing solution for automatically stacking bags of ice cubes.
[0007] One example of bag palletizing equipment is provided in Marth et al. U.S. Pat. No. 4,024,965. That equipment is relevant to the general concept of orienting and stacking bags to form layers or tiers on a pallet in a pallet elevator. There is an infeed conveyor, and an intermediate conveyor at a bag diverting station, and a row-forming station which is comprises a plurality of rollers. Marth et al. employs a sweep bar assembly for moving the bags onto a pallet in a pallet elevator.
[0008] There are examples of equipment that employ vacuum lifting devices for moving or orienting bags or cartons of product. Typical vacuum lifting features are shown in Goodman U.S. Pat. No. 6,003,296, which has a vacuum pick-and-place feature that can change the orientation of a bag. Thibault U.S. Pat. No. 4,242,025 employs a rotatable sucker head on a horizontally movable carriage. Padgin et al. U.S. Pat. No. 2,841,433 and Wahl et al. U.S. Pat. No. 2,716,497 show mechanisms for orienting articles on a pallet, and stacking two pallets alternately. Sheehan U.S. Pat. No. 3,921,825 shows a mechanism for bag turning using vacuum cups. However, none of these prior proposals address the problem of lifting and turning bags of lumpy, shifting articles, nor of transporting such bags from a row forming position to a position on a pallet.
[0009] As for the general concept of orienting items for the purpose of stacking them on a pallet, Bon U.S. Pat. No. 4,984,963 shows a stacker that is programmable for article orientation, and which employs a drop-down pallet elevator using pneumatic cylinders. Pearce et al. U.S. Pat. No. 4,753,564 relates to a device that stacks tiers of articles onto pallets, employing a mechanism for feeding fresh pallets and also having a vertical pallet elevator mechanism with chain drive.
[0010] Jones U.S. Pat. No. 3,780,884 employs a pallet holder that retracts as it is loaded. Miller, Jr. U.S. Pat. No. 3,164,080 shows a drop-down pallet elevator, with a bag orienting and stacking feature.
[0011] The current state of the art does not provide orienting, lifting, transporting, or stacking equipment that can accommodate the articles in the nature of bags of ice cubes. The state of the art does not provide vacuum heads that are adapted for picking up and maintaining a vacuum on bags of lumpy shifting product. The state of the art lacks a combination of a primary or infeed conveyor and a staging or collating conveyor, and lacks an effective pick-and-turn mechanism, i.e., lift mechanism for turning either 90 or 180 degrees, so as to orient the bags properly and in an appropriate pattern for stacking. The state of the art lacks a torsion-spring-based counterbalance for the pallet elevator which increases in spring force with the increasing weight of the pallet as it is filled. The state of the art does not suggest a convenient, small-footprint solution for an automated ice-bag pallet stacker, and does not suggest apparatus that is especially adapted for automatically stacking bags of ice cubes.
OBJECTS AND SUMMARY OF THE INVENTION
[0012] Accordingly, it is an object of the present invention to provide apparatus for stacking bags of ice cubes or other like product and which overcomes the drawbacks of the prior art.
[0013] It is another object to provide an ice bag palletizer that arranges the incoming bags into rows of predetermined patterns, and then transports the rows of bags onto the pallet to form layers or tiers of bags, and then continues to arrange the bags into rows and to transport them such that the successive tiers of bags on the pallet interlock one another.
[0014] It is a further object to provide a vacuum lift mechanism with vacuum lift heads that conform to the irregular surfaces of the bags of ice cubes.
[0015] A still further object is to provide the palletizer equipment with a pallet lift mechanism that increases in lift force as the pallet is filled, with the weight of the pallet being shared between a spring mechanism and a motor drive mechanism.
[0016] Yet another object is to provide apparatus that permits continuous operation with one pallet being stacked while another is removed and replaced with a fresh pallet.
[0017] In accordance with one aspect of the present invention, pallet stacking apparatus are provided for automatically stacking bags filled with solid objects, which may have an irregular, lumpy, shape and may be shifting in nature, such as bags of ice. These filled bags are stacked automatically onto a pallet in layers or tiers of predetermined patterns of rows. In the apparatus, a pallet holder e.g., a pallet lift or elevator, holds a pallet at a predetermined position. A collating conveyor, i.e., an indexing or staging conveyor, is situated adjacent the pallet holder. An infeed conveyor receives the filled bags from a source, i.e., an ice bagging machine, and carries these bags towards the staging conveyor. Above the staging conveyor there is a pick-and-turn mechanism, i.e., an orienting mechanism that is adapted to pick up the bags of ice cubes and rotate them selectively for ninety degrees (to orient the bags into a transverse position) or for one-hundred eighty degrees (to displace the bags by the width of the bag). This is operated under control of a process controller so that the filled bags will form the rows with a predetermined row geometry when the bags collect on the staging conveyor. This ensures the bags of ice will be in the proper orientation when they are positioned onto the pallet for each given layer or tier on the pallet.
[0018] The collating or staging conveyor collects the bags to form each row. The bags are blocked or barred at the end of the conveyor with the bags being held in place until a complete row has been accumulated or collected on the staging conveyor. A bag transport mechanism, i.e., a vacuum head shuttle or gantry, picks up each complete row of filled bags from the staging conveyor when the row is complete, and transfers the row to a predetermined position on the pallet.
[0019] The pallet lift or elevator holds the pallet at a predetermined elevated position adjacent the staging conveyor, and incorporates a mechanism for lowering the pallet incrementally as each layer of bags is completed. Favorably, this mechanism includes a torsion spring mechanism such that the spring force on the pallet increases with each increment that the pallet is lowered. The pallet holder also has a motor drive for raising and lowering the pallet, with the load being shared by the torsion spring and the motor.
[0020] In one preferred version, the conveyors are belt conveyors, and the staging or collating conveyor has a belt with a low-friction surface that permits sliding of the bags.
[0021] The orienting mechanism or pick-and-turn device can be a rotary vacuum arrangement, in which a rotary arm or frame is positioned over the infeed conveyor, and has a pair of vacuum heads attached onto it. The rotary arm and vacuum heads can be raised and lowered for picking up the bags, and can be selectively rotated through either 90 degrees or 180 degrees for changing the orientation of the bags. A presence sensor can detect when a bag of ice is under the pick-and-turn device, and interrupts motion of the infeed conveyor belt while the device acts to change the orientation of the ice bag.
[0022] Favorably, the vacuum heads can be formed with a rigid cap portion and an annular skirt or side wall that is attached onto the cap portion and extends down from it. The skirt may be formed of a flexible resilient material, e.g., a closed-cell foam elastomer, so that the skirt deflects to conform with irregularities in the top surface of the bags. This enables the vacuum head to maintain vacuum despite the irregular and shifting nature of the ice cubes or other items in the plastic bags.
[0023] A bag transport mechanism lifts and carries completed rows of bags from the staging conveyor to the pallet. This may comprise a set of rails that are situated above the pallet holder and span across pallet and the staging conveyor. A shuttle or gantry, i.e., a transport assembly, is mounted to travel along the set of rails. The transport assembly has an array of vacuum heads disposed on it and adapted to pick up the row of filled bags. These vacuum heads hold the bags while the transport assembly travels to a position over the pallet, and then release the ice bags onto the pallet. In one favorable implementation, the bag transport mechanism includes twelve heads arranged in two rows of six heads. The raising and lowering of the heads and the application of suction are controlled by the system controller, and that vacuum can be applied selectively either to only one of the two rows of heads or to both of the rows of heads. This permits the rows of bags to be configured and transported as a row of three bags end to end, a row of six bags arranged transversely, or a row of bags of mixed orientation.
[0024] As in the pick and turn device, the transport mechanism vacuum heads are favorably each formed with a rigid cap portion and an annular skirt or side wall that depends from the cap portion with the skirt member being formed of a flexible resilient elastomer, such as a rubber-like closed-cell foam that conforms to irregularities in the upper surface of the bags.
[0025] The above and many other objects, features, and advantages of this invention will be more fully appreciated from the ensuing description of a preferred embodiment, which is to be read in conjunction with the accompanying Drawing.
BRIEF DESCRIPTION OF THE DRAWING
[0026] FIG. 1 is a schematic side elevation of the ice bag palletizer according to one preferred embodiment of this invention.
[0027] FIG. 2 is a schematic front elevation of this embodiment.
[0028] FIG. 3 is a perspective view of this embodiment.
[0029] FIG. 4 is a perspective view of another embodiment.
[0030] FIG. 5 is an assembly view of a vacuum head employed in these embodiments.
[0031] FIG. 6 is a sectional view of the vacuum head.
[0032] FIG. 7 is a sectional view of the gantry and vacuum heads of the foregoing embodiment(s) shown lifting bags of ice cubes or the like.
[0033] FIG. 8 illustrates the stacking scheme carried out by these embodiments in achieving interlocking tiers or layers of the ice cube bags stacked onto the pallet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] With reference now to the Drawing, and initially to FIGS. 1 , 2 and 3 , an ice bag palletizer arrangement 10 according to the present invention is shown adjacent an ice cube bagging machine 12 , which here can be for example a Hamer ice packaging form fill and seal machine in any of various models. In FIG. 3 , some of the structure is omitted. In this example, the ice cube bags and seals the ice cubes into polyethylene bags at a rate of about 40 bags per minute, with each bag being 7 to 8 pounds of ice and having length and width dimensions of about sixteen by nine inches. The bags of ice cubes drop down to a discharge conveyor 14 that carries the filled bags to an incline conveyor 16 , which carries the bags up to an elevation of about six feet, to feed them to the ice palletizing arrangement 10 .
[0035] An infeed conveyor 18 receives the ice cube bags, and is in the form of a low profile belt conveyor, 48 inches in length and 24 inches in width, with a belt formed of a polyurethane-coated canvas. This belt can be a cleated belt with quarter-inch cleats on three-inch centers for a good coefficient of friction. The infeed conveyor has a belt speed of about 167 feet per minute, to provide adequate gap or spacing between successive bags, so the bags can be picked and placed, as described shortly.
[0036] A sensor 20 , here in the form of a cantilevered sensor arm and SPST switch, is placed at the top side of the infeed conveyor 18 to detect when a bag is present. This sensor 20 is coupled to a programmed logic controller or PLC that is located in a controller cabinet 22 ( FIG. 2 ), and the PLC will interrupt movement of the infeed conveyor belt to permit a pick and place operation, after which the belt will resume action.
[0037] A pick-and-rotate device 24 is situated above the infeed conveyor 18 for picking up the ice cube bags and rotating them either 90 degrees or 180 degrees on the infeed conveyor. The device has a pair of vacuum heads 26 , i.e., vacuum cups, mounted on a rotatable frame. There is an associated centrifugal regenerative blower 28 to provide vacuum to these vacuum heads 26 , with a valve 30 , controlled by the PLC, to switch between atmospheric pressure and suction, and a vacuum hose or conduit 32 linking the valve 30 to the vacuum heads or cups 26 . The device may also be configured to pick up and displace the bags linearly, rather than rotate them through 180°, i.e., to side-shift the bags.
[0038] When the sensor 20 detects that a bag is present, but belt of the conveyor 18 stops momentarily; the pick-and-rotate device descends and picks up the bag, and then rotates through either ninety or one-hundred-eighty degrees, as determined by a program in the PLC. Some of the bags are permitted to pass through without being picked up or rotated. The bags are initially presented on the infeed conveyor belt in a lengthwise fashion, i.e., with the shorter ends front and back, and to one side of the centerline of the belt. The pick and rotate device 24 turns the bags ninety degrees to orient them in a transverse fashion, i.e., with the shorter sides to right and left of the belt, and rotates them one-hundred-eighty degrees to locate them in a straight on or lengthwise fashion, but oriented to the other side of the belt centerline. Alternately, the pick and rotate device 24 can side shift the bags or displace them laterally. The action of the device 24 allows the bags to be lined up into rows of three bags end-to-end lengthwise, six bags transversely side-by-side, or six bags with a mixed orientation, so that the bags can be placed into tiers on the pallet with the bags of each tier interlocking with the bags in the tier beneath.
[0039] After the bag is released from the device 24 , the bag travels to the next stage, which is a collation conveyor 38 or indexing conveyor.
[0040] The collation conveyor 38 here is a low profile belt conveyor, also 48 inches in length and 24 inches in width, similar to the infeed conveyor, but the belt here contains polyester-impregnated fibers. This belt may also be a cleated belt with one-quarter inch cleats on thirty-six inch centers.
[0041] A photosensor 40 detects when each bag has been transferred to the collation conveyor 38 . This is used to control the advancing of the conveyor 38 , to advance the bags after they have passed the pick and turn station. There is a barrier 42 at the far or distal end of the belt of the conveyor 38 , so that the bags are held on the collation conveyor until a full row has been formed. That is, the collation conveyor 38 indexes the bags until the full row (three bags or six bags) has been collected. In this embodiment, the pattern for each row, as aforesaid, can be three bags end-to-end, six bags side-by-side, or six bags mixed orientation. This will be described in detail later on.
[0042] A linear motion gantry 50 is situated above the collation conveyor 38 and is in the form of a frame that is mounted to travel upon a pair of transverse tracks 52 (see FIG. 3 ). The gantry 50 is movable from the position over the conveyor 38 to positions over a pallet holder 54 , which in this embodiment, is situated immediately adjacent the conveyor 38 . The gantry carries a plurality of vacuum heads or vacuum cups 56 , which are of similar construction to the vacuum heads 26 described earlier. Here there are twelve vacuum heads 56 arranged in two rows of six heads each. In this arrangement, two heads 56 are positioned over each bag for lifting and carrying the rows of bags. There is a regenerative blower 58 to provide suction to the vacuum heads of the gantry 50 , a suction line 60 , and dual valves 62 , one of which is switched between atmosphere and suction, and the other of with selects between applying suction to just one of the two rows of heads or to both rows of heads, depending on whether the row of bags consists of three or six bags.
[0043] It should be mentioned here that there are air cylinders to move the gantry up and down and transport motors to drive the gantry transversely, but these are not shown specifically here so as to avoid some drawing clutter. Likewise, the air cylinders and motors associated with the pick and turn device 24 are omitted from the drawing.
[0044] The pallet holder 54 is here in the form of a vertical, four-sided enclosure, and this holds a standard pallet 64 on which bags 66 of ice cubes are stacked. The pallet 54 is somewhat oblong, and so the bags 66 fit five across in one direction, and six across in the other direction. This means that in this example the bags 66 of seven to eight pounds of ice cubes are stacked in tiers of two rows of six and one row of three, i.e., fifteen bags per tier, and the pallet 54 holds twenty tiers. The tiers are stacked in successive patterns that alternate from one tier to another so that the bags of each tier overlap and interlock the bags of the other tiers so that the bags 66 remain securely in place on the pallet 64 .
[0045] The pallet holder 54 contains a pallet lift or elevator 68 for raising the pallet and then lowering the pallet as the bags 66 are stacked onto it. There are chain drives 70 located within corner posts 72 of the pallet holder, and a torsion spring 74 coupled to these chain drives. The torsion spring charges when the pallet drops down, so that its spring force increases as the pallet 64 is filled and drops down. The torsion spring balances about fifty percent of the weight of the pallet as the ice cube bags 66 are stacked onto it. Also, a motor drive 76 is coupled with the pallet lift to provide the remainder of the force necessary to raise and lower the pallet 64 . The motor drive is controlled by the PLC in the control cabinet 22 . When the pallet is empty (e.g., when it is loaded into the pallet holder) the torsion spring will lift the empty pallet to the top. The pallet 64 then drops down incrementally as it is loaded until it is finally situated at the bottom of the pallet holder 54 (as shown in FIG. 2 ). An access door 78 is provided on the forward side of the pallet holder to permit the loaded pallet to be removed and replaced with a fresh pallet. This door 78 is provided with interlocks and safety features such as a flashing lamp to indicate locked and open states of the door. The PLC will interrupt operation of the bag machine 12 and the palletizing arrangement 10 until the door 78 is closed and latched and the fresh pallet 64 is brought to the top position to receive the bags.
[0046] FIG. 4 shows an alternative embodiment, in which the infeed conveyor 18 and collation conveyor 38 are situated between a pair of pallet holders, including a first pallet holder 54 on the right and a second pallet holder 154 on the left. The gantry 50 here is situated upon a pair of extended tracks so that the gantry can travel from the home position over the conveyor 38 to positions over either of the two pallet holders 54 , 154 . The bags 66 are loaded alternately into the pallets in the two pallet holders, first loading bags 66 onto the pallet 64 in the one holder 54 and then loading onto the pallet in the second pallet holder 154 . In this arrangement, the bags of ice cubes 66 are loaded continuously, i.e., without interruption, with the loaded pallet being removed from the one pallet holder and replaced with fresh pallet while the ice cube bags are being loaded and stacked onto the pallet in the other pallet holder. In this arrangement, there is no need to interrupt the bagging and stacking operations when the operator is removing the full pallet and then replacing it with a fresh, empty pallet.
[0047] Details of the vacuum heads or cups 26 or 56 are shown in FIGS. 5 and 6 . Here each vacuum head is formed of a rigid cap 80 or top in the form of a round or circular member, e.g., a disk or dome. This may favorably be formed of a PVC or other durable rigid or semirigid plastic resin. An opening or socket 82 is formed centrally on the cap 80 , which serves for mounting the vacuum head onto the associated gantry or pick and turn device, and also for communicating with the associated suction conduits to supply suction to the vacuum head(s). Affixed onto the outer rim of the cap 80 is a skirt 84 or side wall formed of a durable but soft, flexible closed cell foam polymer, i.e., a foam rubber. This foam material will deflect and conform to the irregular shape of the top surfaces of the ice cube bags 66 , so that the vacuum cups will maintain continuous suction onto the bags during the pick and turn operation and during gantry transport. The foam material of the vacuum head sidewalls 84 accommodates the general lumpiness of the contents of the bags 66 as well as the tendency of the contents to shift when the bags are being moved. This material maintains suction even under the reduced temperature condition associated with the making, bagging, and stacking of ice. As shown in FIG. 7 , a pair of the vacuum heads 56 of the gantry 50 are shown, each lifting an end of a respective ice cube bag 66 . In this embodiment, the cap 80 is about three inches in diameter, and the closed cell foam rubber sleeve or sidewall 84 is about three inches in height with a wall thickness of about one inch.
[0048] FIG. 8 illustrates generally the row forming and stacking procedure according to one embodiment of the invention, where the bags 66 proceed (i.e., along the conveyor 18 ), are picked up and turned by the pick and turn device 24 , and are either rotated ninety degrees, rotated one-hundred-eighty degrees, side-shifted, or not turned, as programmed in the programmable logic controller.
[0049] In this example, a row 90 is formed of six bags 66 in a pattern of mixed orientation, i.e., two end bags placed transversely and the middle four bags arranged in pairs oriented longitudinally. This row 90 is then picked up by the gantry 50 and transported (to the right in this view) and placed in the position shown in ghost lines to form a tier of bags indicated as 96 a . Here, there are already two previously formed rows 92 and 94 , respectively of three bags arranged longitudinally, and of six bags arranged transversely. Below this tier of fifteen bags there is an earlier formed tier 96 b where the three respective rows of bags 90 , 92 , and 94 are in a different order of row patterns, and below that another tier of bags 96 c with the bags in a different order of row patterns 92 , 94 , 90 . The bags 66 are thus stacked so that the bags in each tier overlap the bags in the tier beneath, and interlock with them to create stability in the stack on the pallet. Other patterns could be used for this purpose, and where the bags are of a different size, i.e., for ten pound bags or twenty pound bags, the rows can be formed in different arrangements as well.
[0050] The palletizing arrangement of this invention has a relatively small footprint, of about five feet by five feet, and seven and a half feet in height. One attendant can operate more than one of these palletizing machines, and in addition can attend to moving the full pallets into the ice warehouse and loading the fresh pallets. No human lifting is needed in stacking the ice bags 66 . The count of bags on each pallet is consistent, and the pallets of bags have an improved integrity over hand-stacked ice bags.
[0051] In addition to the ice bag palletizer(s) as discussed above, principles of this invention can be used favorably for stacking other packages onto pallets or carriers, e.g., bags of crushed rock or other irregular items. In some cases, the gantry and pallet holder can be arranged for movement of the rows of bags in the distal direction rather than transversely as in the above-described embodiments. The row patterns can be changed as needed depending on bag size, pallet size, and other factors. In some embodiments, the gantry can be configured for swing motion rather than only linear motion.
[0052] Although the preferred embodiment has been employed in connection with automated stacking of bags of ice cubes in predetermined patterns onto a pallet, it is possible to employ the principles of this invention in other environments. The pallets can be stacked automatically where the product handling generates airborne particulates which could create a health hazard for a human attendant doing hand stacking.
[0053] While the invention has been described with reference to a specific preferred embodiment, the invention is certainly not limited to that precise embodiment. Rather, many modifications and variations will become apparent to persons of skill in the art without departure from the scope and spirit of this invention, as defined in the appended claims.
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An automatic pallet stacking machine for loading bags of ice cubes onto a pallet has a first infeed conveyor with a pick and turn device for orienting the bags, and a collating conveyor adjacent a pallet holder or pallet elevator where the bags are accumulated until a row of bags is formed. Then a gantry picks up the bags and places transports the row to the pallet. The pick and turn device and the gantry employ vacuum heads that have closed cell foam side walls to accommodate the lumpy and shifting nature of the bag contents. A programmable controller ensures that the bags rows are formed in appropriate patterns so that the bags in each tier interlock with the bags in the tier beneath.
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This application is a continuation of U.S. patent application Ser No. 09/534,224, U.S. Pat. No. 6,426,289, entitled METHOD OF FABRICATING A BARRIER LAYER ASSOCIATED WITH A CONDUCTOR LAYER IN DAMASCENE STRUCTURES, filed Mar. 24, 2000, the entirety of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of fabricating a barrier layer and more particularly to a method of fabricating a barrier layer on top surfaces of metals in damascene structures utilizing ion implantation.
2. Description of the Related Art
As the demand increases for cheaper, faster, less power consuming yet more powerful integrated circuits, such as microprocessors and memory devices, the transistor packing density of the integrated circuit must be similarly increased. Very large scale integration (VLSI) techniques are very common place and yet the demand for even more reduced scale devices is ever present. All aspects of the integrated circuit must be scaled down to fully minimize the device dimensions. In addition to minimizing transistor dimensions, one must minimize the dimensions of the electrical interconnections which connect the transistors together on a microchip to form a complete circuit.
Currently, metals such as copper, aluminum, gold and silver, as well as others, are used as conductive materials for electrical interconnections in a VLSI integrated circuit. However, aluminum alloys are most commonly used and its alloys have been fully explored and characterized for use as an electrical interconnection in an integrated circuit, and much technology has been developed to aid in the formation of aluminum interconnections. Aluminum has very attractive features for use as an integrated circuit electrical interconnection, such as low electrical resistivity and strong adhesion to silicon dioxide. However, as VLSI dimensions move into the deep-sub micron Ultra Large Scale Integration (ULSI) arena, the deficiencies of aluminum and its alloys become limiting factors in achieving superior performance. For example, as the width of electrical interconnections becomes narrower, even the low resistance of aluminum becomes non-negligible and begins to slow down the signal speed. Hence, barrier layers are necessary due to decreasing dimensions and design rules become increasingly restricted by aluminum interconnection reliability concerns such as electromigration, stress-induced void formation, hillock suppression, and current density limitations.
Also, the microelectronics industry has recently migrated towards the investigation of more robust and conductive metals for use in interconnection technology, such as Copper (Cu). Cu is approximately 40% lower in resistivity than Al and is much more resistant to reliability problems such as electromigration. Unfortunately, Cu has been known to cause other reliability problems associated with the high rate of Cu diffusion through silicon substrates and dielectric films. One such problem is electrical shorting, wherein the Cu from one Cu interconnect line diffuses into an adjacent dielectric region, forming a conductive path to another Cu interconnect line. Another problem is transistor poisoning, wherein Cu diffuses into the underlying silicon substrate and causes junction leakage along with reduced channel mobility in the transistor, thereby destroying the device. Thus, to implement Cu as an interconnect material it has become necessary to develop methods for preventing Cu from diffusing through layers of a semiconductor device. Hence, various means have been suggested to deal with the problem of copper diffusion into integrated circuit material. Several materials, especially metallic ones, have been suggested for use as barriers to prevent the copper diffusion process. Tungsten, molybdenum, and titanium nitride (TiN) have all been suggested for use as copper diffusion barriers.
However, barriers for these conductive metals cannot be deposited onto substrates, or into vias, using conventional metal deposition processes, such as sputtering, since the geometries of the selected IC features are small. It is impractical to sputter metal to fill small diameter vias, since the gap filling capability is poor. Thus, new deposition processes such as CVD, have been developed for use with these barrier materials in the lines and interconnects of an IC interlevel dielectric. In a typical CVD process, the barrier material is combined with a ligand, or organic compound, to make the barrier material volatile. That is, the barrier material is vaporized into a gas and the metal is exposed to the barrier material gas in an elevated temperature environment. When the barrier material gas compound decomposes, the barrier is left behind on the metal surface.
However, CVD involves considerable process complexity, particularly in the fabrication process for the provision of a barrier layer on top surfaces of metals in damascene structures. Hence, what is needed is a method of fabricating a barrier layer which does not employ CVD and which is cost effective and involves less complexity.
SUMMARY OF THE INVENTION
The present invention is directed to a simplified, CVD-less method of forming a barrier layer for a metal layer which prevents metal contamination in an integrated circuit. The invention utilizes a sacrificial multilayer dielectric structure and selective etching to form the barrier layer. An opening is etched in the structure and a plating layer is deposited in the opening. A first unneeded portion of the structure along with an unneeded portion of the plating layer is removed utilizing an etchant that is selective for the first unneeded structural portion. A metal layer is deposited and implanted with barrier material to form the top barrier layer. A second unneeded portion of the structure along with an unneeded portion of the top barrier layer is removed utilizing an etchant that is selective for the second unneeded structural portion.
The resulting structure is a metal interconnect structure having an overlying top barrier layer which is produced without using CVD techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other advantages and features of the invention will become more apparent from the detailed description of preferred embodiments of the invention given below with reference to the accompanying drawings in which:
FIGS. 1-6 are cross-sectional views of a structure under fabrication illustrating the process sequences of fabricating a barrier layer in accordance with a first embodiment of the present invention; and
FIGS. 7-12 are cross-sectional views of a structure under fabrication illustrating the process sequences of fabricating a barrier layer in accordance with a second embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following detailed description, reference is made to various exemplary embodiments for practicing the invention. These embodiments are described with sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be employed, and that changes and substitutions may be made without departing from the spirit or scope of the present invention.
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.
A first embodiment of the invention will now be described with reference to FIGS. 1-6. FIG. 1 illustrates a portion of a semiconductor device under fabrication. A conductive layer 1 to which a metal conductor, preferably Cu, is to connect is provided over a substrate 200 which may include a base substrate or a substrate having one or more material layers formed on a base substrate. A first dielectric layer 7 is applied over conductive layer 1 and cured. A preferable first dielectric layer is a polymer. The polymer can be a polyimide or a foamed polyimide. Other dielectric materials may also be used. A second dielectric layer 5 is deposited on top of the first dielectric layer 7 . Preferably, the second dielectric layer is silicon dioxide deposited to a thickness of about 500 A. Other dielectric materials may also be used for layer 5 . A third dielectric layer 3 is deposited on top of the second dielectric layer 5 . The third dielectric layer 3 is preferably silicon nitride and is deposited to a thickness of about 500 A. Once again, other dielectric materials may also be used for layer 3 .
Referring to FIG. 2, a layer of resist 9 is applied, patterned and developed and an opening 2 is etched in the third dielectric layer 3 and second dielectric layer 5 to provide an area for forming a damascene structure. An O 2 RIE etch is next used to define an opening in the first dielectric layer 7 down to conductive layer 1 . This processing sequence will remove the resist 9 as well.
In FIG. 3, the resist layer 9 of FIG. 2 has been removed and the opening 2 has been etched all the way down to conductive layer 1 . A plating layer 11 is next deposited in the opening 2 as well as on top of the third dielectric layer 3 for the electroless deposition of the metal, preferably Cu. The plating layer 11 further comprises a first barrier layer 10 and a seed layer 12 . The seed layer 12 advantageously serves as a catalyst or base metal for subsequent electroless plating or electroplating of the metal and as an adhesion layer preventing delamination of subsequently electrolessly deposited or electroplated metal. In forming the seed layer of the present invention, any of various refractory metals can be employed, such as tantalum, tungsten, molybdenum, hafnium, niobium, rhenium, osmium, ruthenium, zirconium, titanium, vanadium, chromium and manganese. Preferably, a Cu seed layer is utilized if the metal conductor is copper. Also, in forming the first barrier layer 10 of the present invention, any of various refractory metals can be employed, such as tantalum, tungsten, molybdenum, hafnium, niobium, rhenium, osmium, ruthenium, zirconium, titanium, vanadium, chromium and manganese. It has been found particularly advantageous to employ alloys of Ta or W with N or with certain polyimides, especially those formed from the ester of Zr, TI or Hf.
In FIG. 4, the third dielectric layer 3 is removed utilizing an etchant, such as hot phosphoric acid (H 3 PO 4 ) at a temperature of about 180° C. and at a etch rate of about 80 A/min., that has a negligible attack on the second dielectric layer 5 . Thus, removing the unwanted plating layer 11 from where it was deposited on the third dielectric layer 3 and leaving plating layer 11 extending into the opening 2 up to the top of the second dielectric layer 5 .
Referring to FIG. 5, a metal layer 13 is next electrolessly plated in opening 2 to a thickness which causes the metal layer 13 to extend to about the level of the top surface of the first dielectric layer 7 . Electroless metal deposition is attractive due to low processing costs and high quality metal deposits. In addition, equipment for performing electroless metal deposition is relatively inexpensive compared to other semiconductor processing equipment for depositing metals. Electroless deposition also offers the advantageous opportunity for batch processing of wafers, thereby further reducing the cost of electroless deposition and increasing production throughput.
The surface of the metal layer 13 is then implanted with dopant 15 to form a top barrier layer 13 a to prevent metal contamination. The dopant 15 can be chosen from the group consisting of aluminum, boron, chromium, molybdenum, tungsten, titanium, zirconium, hafnium, magnesium, vanadium, columbium, tantalum or oxides or nitrides of these elements. In one exemplary embodiment, the metal is copper and the dopant is zirconium. The zirconium is implanted at an energy level of about 0.125 keV to 2.0 keV and at a dopant concentration of about 1.25×10 16 ions/cm 2 to 2.0×10 17 ions/cm2. Preferably, the zirconium is implanted at an energy of about 0.5 keV and at a concentration of about 5×10 16 ions/cm 2 . For the other possible dopants, the implant energy and the concentration can be about 0.125 to about 2.0 keV and about 1.25×10 16 to about 2.0×10 17 ions/cm 2 , respectively without deviating significantly from the spirit of the invention. Preferably, top barrier layer 13 a is about 5 A to 40 A thick and more preferably around 20 A thick. The second dielectric layer 5 is next removed by an etchant, such as a mixture of hydroflouric acid (HF) and ammonium fluoride (NH 4 F) (1:8) at room temperature and at a rate of 700 A/min., which selectively removes the second dielectric layer 5 but not the first dielectric layer 7 , as illustrated in FIG. 6 . Thus, any dopant, e.g. zirconium, which was implanted into the second dielectric layer 5 during the implant is removed leaving first dielectric layer 7 free of impurities (e.g. zirconium). The resulting top barrier layer 13 a can be utilized in an interconnect system for an integrated circuit coupling passive and/or active components such as capacitors, transistors and various memory devices.
Hence, according to the first exemplary embodiment of the present invention, a top barrier layer 13 a is formed over a metal layer 13 utilizing a sacrificial multilayer dielectric structure ( 3 , 5 ) and selective etching of the multilayer structure, plating layer 11 and top barrier layer 13 a to remove any unneeded portions.
A second embodiment of the invention is illustrated in FIGS. 7-12. In this embodiment, first dielectric layer 19 is deposited over conductive layer 1 in FIG. 7. A preferable first dielectric layer is a silicon dioxide. A second dielectric layer 17 is deposited on top of the first dielectric layer 19 . Preferably, the second dielectric layer is silicon nitride and is deposited to a thickness of about 500 A. In FIG. 8, a layer of resist 21 is applied, patterned and developed and an opening 2 is etched in the second dielectric layer 17 and first dielectric layer 19 down to conductive layer 1 to form an opening to produce a damascene structure. In FIG. 9, the resist layer 21 is maintained in place and a plating layer 23 is deposited in the opening 2 as well as on top of the resist layer 21 . The plating layer 23 further comprises a first barrier layer 24 and a seed layer 26 . The seed layer 26 advantageously serves as a catalyst or base metal for subsequent electroless plating or electroplating of the metal and as an adhesion layer preventing delamination of subsequently electrolessly deposited or electroplated metal. In forming the seed layer of the present invention, any of various refractory metals can be employed, such as tantalum, tungsten, molybdenum, hafnium, niobium, rhenium, osmium, ruthenium, zirconium, titanium, vanadium, chromium and manganese. Preferably, a Cu seed layer is utilized if the metal conductor is copper. Also, in forming the first barrier layer 24 of the present invention, any of various refractory metals can be employed, such as tantalum, tungsten, molybdenum, hafnium, niobium, rhenium, osmium, ruthenium, zirconium, titanium, vanadium, chromium and manganese. It has been found particularly advantageous to employ alloys of Ta or W with N, when silicon dioxide is used as a insulator.
As shown in FIG. 10, the resist layer 21 is next removed utilizing an etchant, such as a mixture of hydroflouric acid (HF) and ammonium fluoride (NH 4 F) (1:8) at room temperature and at a rate of 700 A/min., that has a negligible attack on the second dielectric layer 17 . This removes portions of plating layer 23 from where it was deposited on the resist layer 21 , leaving plating layer 23 extending only in the opening 2 up to approximately the level of the top surface of second dielectric layer 17 .
Referring next to FIG. 11, a metal layer 13 is electrolessly plated in opening 2 up to the thickness corresponding to approximately the level of the first dielectric layer 19 . The surface of the metal is then implanted with dopant 25 . The dopant 25 can be chosen from the group consisting of aluminum, boron, chromium, molybdenum, tungsten, titanium, zirconium, hafnium, magnesium, vanadium, columbium, tantalum or oxides or nitrides of these elements. In one exemplary embodiment, the metal is Cu and the dopant is TaN. The Ta is implanted at a concentration of about 2.5×10 16 ions/cm 2 to 4×10 17 ions/cm 2 and an energy level of about 025 keV to 0.4 keV and N is implanted at a concentration of about 2×10 16 to 3.2×10 17 ions/cm 2 and an energy level of about 0.175 keV to 2.8 keV. Preferably, the Ta is implanted at a concentration of about 10 17 ions/cm 2 and energy level of about at 0.1 keV and the N implanted at a concentration of about 8×10 16 ions/cm 2 and an energy level of about 0.7 keV. For the other possible dopants, the implant energy and the concentration can be about 0.125 to about 2.0 keV and about 1.25×10 16 to about 2.0×10 17 ions/cm 2 , respectively without deviating significantly from the spirit of the invention. The product of the Ta and N implants forms a TaN barrier layer 13 b , shown in FIG. 12 . Preferably, top barrier layer 13 a is about 5 A to 40 A thick and more preferably about 20 A thick. The second dielectric layer 17 is next removed by an etchant, such as hot phosphoric acid (H 3 PO 4 ) at a temperature of about 180° C. and at a etch rate of about 80 A/min., which selectively attacks the second dielectric layer and not the first dielectric layer as illustrated in FIG. 12 . Thus, any TaN dopants which were implanted into the second dielectric layer 17 are removed leaving first dielectric layer 19 free of impurities (i.e. TaN). Also, the remaining part of the plating layer 23 is removed along with the removal of the second dielectric layer 17 . The resulting top barrier layer 13 a can be utilized in an interconnect system for an integrated circuit coupling passive and/or active components such as capacitors, transistors and various memory devices.
Hence, according to the second embodiment of the present invention, a top barrier layer 13 a is formed over a copper plug 13 utilizing a sacrificial multilayer dielectric structure and selective etching of the structure, plating layer and the top barrier layer to remove any unneeded portions. A top barrier layer for a metal conductor is formed in accordance with the invention without the need for CVD or CMP processing steps.
While certain embodiments of the invention have been described and illustrated above, the invention is not limited to these specific embodiments as numerous modifications, changes and substitutions of equivalent elements can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the present invention is not to be considered as limited by the specifics of the particular methods which have been described and illustrated, but is only limited by the scope of the appended claims.
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The present invention is directed to a simplified, CVD-less method of forming a barrier layer for a metal layer which prevents metal contamination in an integrated circuit. The invention utilizes a sacrificial multilayer dielectric structure and selective etching to form the top barrier layer. An opening is etched in the structure and a plating layer is deposited in the opening. A first unneeded portion of the structure along with an unneeded portion of the plating layer is removed utilizing an etchant that is selective for the first unneeded structural portion. A Cu layer is deposited and implanted with barrier material to form the top barrier layer. A second unneeded portion of the structure along with an unneeded portion of the top barrier layer is removed utilizing an etchant that is selective for the second unneeded structural portion. The resulting structure is a metal interconnect structure having an overlying top barrier layer which is produced without using CVD techniques.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of copending International Application PCT/EP97/03911, filed Jul. 21, 1997 now EP914617A1, which designated the United States.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The present invention relates to a test procedure for carrying out a series of measurements on a large number of identical products after they have been manufactured, as well as to a test station for carrying out the test procedure.
When products have been manufactured, in particular semiconductor products, the quality of the final product must be checked continuously in order to ensure a high product quality standard. In this case, the accuracy and the reliability of the test apparatus plays a major role. In order to identify various discrepancies in the test apparatus early, the test apparatuses are checked at specific time intervals using previously characterized reference products.
Such diagnostic procedures and calibration routines are generally carried out by hand. This not only takes an extremely long time, but is also linked to high costs, since the test apparatus cannot be used productively during the diagnostic or calibration process. In consequence, some insidious discrepancies are frequently identified too late, which can lead to costly reworking and testing of the products.
Since every individual measurement is also subject to errors, specific measurement tolerances must also be introduced during the development of the test routines. The manufacturer's details relating to the test equipment are normally taken into account in this case. These details are generally not checked, or are too complex, and this is generally inconsistent with guaranteeing that the manufactured products have a high standard of quality (fault rate<1 ppm).
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a test procedure and a test station for carrying out the test procedure which overcome the above-mentioned disadvantages of the prior art methods and devices of this general type.
With the foregoing and other objects in view there is provided, in accordance with the invention, a test procedure for carrying out a series of measurements on a large number of identical products after they have been manufactured, which includes: a) testing a parameter of a product under test with a first test apparatus using a first input signal for producing a first test result; b) testing the parameter of the product under test with a second test apparatus using a second input signal independent of the first input signal for producing a second test result independent of the first test result; c) calculating a value of a difference between the first test result and the second test result; d) evaluating statistically and with the aid of a computer the first test result, the second test result and the value of the difference with earlier determined data determined in an identical series of measurements on products tested earlier; e) outputting a fault message if the value of the difference is outside a tolerance interval; and f) repeating steps a) and e) for at least one other parameter.
The object of the present invention is thus to specify a test procedure and a test station for carrying out a series of measurements on a large number of identical products after they have been manufactured. The aim with the test procedure and test station according to the invention is to allow semiconductor components to be tested correctly taking account of system-dependent measurement errors, as well as to carry out a stability check of the test apparatus required for this purpose.
The procedure according to the invention, in the case of a test system linked to a production line, allows a discrepancy in the test system to be identified early during production, that is to say during operation of the production line.
The test result determined by the test apparatuses is compared with the previously defined upper and lower test limits, by which product faults are identified, and faulty products can thus be filtered out correctly, taking account of test equipment errors. In order to filter out any discrepancy in accuracy or reliability present in the test apparatus, a further test result is determined in the same test apparatus using current sources or voltage sources and test paths that are different than those used for the first test.
Since present-day test apparatuses are equipped with a number of identical current sources or voltage sources, the procedure can be used universally and without any additional cost.
In a development, the second test process is carried out by the second reference test apparatus, only on one sample. It is thus possible to assume with high probability that, for example, a "critical" or "insidious" discrepancy in one of the test apparatuses will be identified early. The size of the sample can be varied or adapted automatically, for example by software control, based on the discrepancies found by the procedure according to the invention.
In a development, automatic recalibration of the test apparatus can also be carried out by the status values of the test apparatus determined by the procedure according to the invention.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a test procedure and a test station for carrying out the test procedure, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic block circuit diagram of a basic configuration of a test station according to the invention;
FIG. 2 is a graph of calculations of upper and lower nominal limits, which also show measurement tolerances;
FIG. 3 is a block diagram of the basic configuration of the test station; and
FIG. 4 is a flowchart for a test procedure in the test station.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case. Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a power semiconductor 1 which is to be tested and is connected via an appropriate non-illustrated supply device and via a sampling device 6 to a first test apparatus 2. Any other desired products whose characteristics are intended to be tested on the basis of one or more parameters can, of course, be used here.
A first test apparatus 2 determines a first parameter, after which the power semiconductor 1 which is to be tested is connected to a second test apparatus 3, for example a reference, by a changeover device of the sampling device 6. The second test apparatus 3 determines the same parameter, for example using a second test source that is identical to the first, and transmits the test result to an evaluation unit 4. The test results determined by the two test apparatuses 2, 3 are subtracted from one another in the evaluation unit 4 and the value of a difference δ determined in this way is passed to a decision unit 5.
The decision unit 5 produces control signals, for example a signal N, causing a diagnosis or a recalibration process of the test apparatuses 2, 3, or produces a clearance signal J, if a predetermined critical value is not violated. A computation unit, which is not illustrated in any more detail, can evaluate all the gathered data statistically and initiate the diagnosis/recalibration mentioned above just on the basis of the specific statistical values.
The entire test procedure takes place as follows. The completed product, in the present case the power semiconductor 1, is electrically connected to the first test apparatus 2 of a test station. The test apparatus 2 has a first test source which, for example in the case of a semiconductor, may be a current source which can be used to determine the forward resistance. The test station has the second test apparatus 3, of identical construction, as a reference which, in the illustrated example, is likewise a current source, in which case this current source is once again independent of the first current source. The corresponding paths to the module may likewise be duplicated.
Instead of the two test apparatuses 2, 3, a single test apparatus having two current sources that may be connected as alternatives can also be provided. In order to use the procedure according to the invention for early identification of fault sources which can occur within the test apparatuses 2, 3 it makes sense to provide two identical test apparatuses 2, 3, which are separate from one another, with the respective cable paths, changeover relays, etc. In the illustrated example, the forward resistance is now determined in two runs, separately from one another, by the two test apparatuses 2, 3. The evaluation unit 4 then determines the value of the difference δ between the tested parameters. In the present example, this is the forward resistance. Instead of using a current source as a reference, it is, of course, also feasible to use a voltage source or the like for this purpose.
Normally, that is to say when the test station is in the ideal state, both of the test apparatuses 2, 3 determine exactly the same forward resistance, as a result of which the evaluation unit 4 determines a difference value δ=0. If the test station has been in use for a relatively long time, it is possible that the nominal output range of one of the test sources may fluctuate, for example owing to temperature fluctuations, usage or the like. However, from experience, the two test apparatuses 2, 3 do not drift in the same direction. The value of a difference d can thus be used to determine quickly whether the test apparatuses 2, 3 are still operating within a predetermined tolerance band. If the determined value of the difference δ is outside the predetermined tolerance band, then the decision unit 5 outputs a fault signal N. If the determined value of the difference d is within the predetermined tolerance band, then the decision unit outputs a clearance signal J.
In order to avoid an identical fault occurring in both of the test apparatuses 2, 3, only the first test apparatus 2 is fed with all the components to be tested. The second test apparatus 3 then receives only a selected sample, that is to say, for example, every tenth component is tested. This provides greater confidence of avoiding an identical malfunction in the test apparatuses 2, 3 owing to usage, temperature influences or the like.
FIG. 2 is a graph showing a typical normal distribution of the discrepancies in the values of the difference from the test results. In addition, FIG. 2 shows the calculation of the upper and lower nominal limits, with the corresponding measurement tolerances.
In this case, F indicates a distribution of parameters of the measured value from the two test results. F is a measure of a product scatter in this case. The distribution F is disposed symmetrically about zero in the present example. However, this is not necessarily the case. Appropriate limits are shown as the critical limit for the decision unit 5, in which case LNL denotes the lower nominal limit and UNL denotes the upper nominal limit.
During the product test, it is necessary to check whether the values X i measured in the test apparatuses 2, 3 satisfy the rule, that is to say:
LNL≦X.sub.i ≦UNL
However, since every measurement is also subject to errors, it is necessary to introduce certain measurement tolerances V. Manufacturer's details relating to the test equipment are normally taken into account for this purpose. The procedure according to the invention takes account of the distribution F, determined from the measured values, of the test procedure and of the quality aims in the statistical determination of the measurement tolerances. The distribution F of the test procedure is also referred to in the following text as the capability of the test procedure. In this case, it is necessary to check whether the following condition is satisfied:
LNL+V≦X.sub.i ≦UNL-V
If the measurement error X i has a normal distribution and the quality aim is for a maximum error element P max (for example 1 ppm) or else a proportion exceeding a limit, then the measurement tolerance V results from the quantile of the standard normal distribution:
V=σ.sub.M ·|Φ.sup.-1 (0.5·P.sub.max)|
FIG. 2 therefore shows another distribution F.sub.δ, which indicates the scatter of the measurement process of the test apparatuses 2, 3. The measurement tolerance V can be determined from the scatter of the measurement process F.sub.δ.
σ M is obtained from special test equipment investigations or from the Delta control card, and is calculated from the standard deviation.
If a Delta control card is used for stability monitoring, the test result determined by the test apparatus is now compared with the test limits LNL+V and UNL-V defined in advance, by which product faults can be identified, and faulty products can thus be filtered out correctly, taking account of the test equipment errors. At this stage, it is not known whether there is a reliability or accuracy discrepancy in the test apparatuses. For this reason, a further test result is determined with the same test apparatus using current sources or voltage sources and test paths that are different than those for the first test. A fault in the product or a discrepancy in the test apparatus can then be clearly identified by comparing the two test results.
Since present-day test apparatuses 2, 3 are equipped with a number of identical electrical voltage sources, the procedure can be used universally and without any additional cost.
The test apparatuses 2, 3 may have appropriate automatic calibration devices, which are activated by the signal N from the decision unit 5. Alternatively, the signal N from the decision unit 5 can also be activated when, for example, a specific number of fault messages have occurred, that is to say difference values δ which are above the test limit UNL+V or below the test limit LNL-V. The downstream statistical evaluation apparatus 4 may be, for example, a microprocessor. Such a calibration process can be activated, for example, after a number n≧1.
FIG. 3 shows a detailed block diagram of the basic configuration of a test station according to the invention. Identical and functionally identical elements are provided with the same reference symbols as in FIG. 1.
FIG. 3 shows the semiconductor component 1 which is to be tested and is connected to the test station via an appropriate non-illustrated supply device and via a non-illustrated sampling device. Any other desired products whose characteristics are intended to be tested on the basis of one or more parameters can, of course, be used here instead of the semiconductor component 1.
The test station includes a driver unit A1 and a measurement unit A2. The driver unit A1 includes two drivers A1-1, A1-2. The measurement unit A2 includes two test sets A2-1, A2-2. The driver unit A1-1 and the test set A2-1 in this case form the first test apparatus 2 mentioned initially. The driver unit A1-2 and the test set A2-2 form the second test apparatus 3. It would also be feasible to use more than two drivers, with the same number of test sets.
The semiconductor component 1 is initialized via the driver A1-1, outputting a first input signal In1. A first output signal X1 is produced at the output of the semiconductor component, and is read out via the appropriate test set A2-1, and is declared a test result X1. The second driver A1-2 of the driver unit A1 outputs a second input signal In2 to initialize the semiconductor component 1 in an analogous manner to the first driver A1-1, and in this way produces a test result X2 that is read out via the second test set A2-2 of the measurement unit A2.
An essential feature of the invention here is that the injected input signals In1, In2 are independent of one another. Two mutually independent output signals, X1, X2 can thus be output as the measurement signals.
The test process can be repeated by a changeover routine. In this way, other parameters can also be tested by appropriate measurements on other connections of the semiconductor component 1.
FIG. 4 shows the flowchart in the test station according to the invention and corresponding to FIG. 3. The driver A1-2 as well as the test set A2-2 are used for this purpose in the flowchart in FIG. 4.
The test results determined by the two test sets are subtracted from one another. The value of the difference δ=X1-X2 determined in this way is checked against critical control limits including lower control limits LCL, and upper control limits UCL via a decision routine.
If the control limits LCL, UCL are undershot or exceeded, it is reported to the system, and defined correction actions are initiated.
This can, for example, result in a diagnosis or a recalibration of the driver unit A1 and of the measurement unit A2, or may result in the product test being continued. A computer unit, which is not illustrated, can evaluate the gathered data statistically (stability monitoring by Delta control cards), and can initiate the diagnosis or recalibration mentioned above only on the basis of specific statistical values.
A sequence of k measurements is required to produce the statistical control limits:
δ.sub.1 =X.sub.11 -X.sub.21 ; δ.sub.2 =X.sub.12 -X.sub.22 ; . . . ; δ.sub.k
In this case δ x =X 1x -X 2x (where x=1 to k) is the value of the difference between the two measurements. δ denotes both the random variable with the distribution function F.sub.δ and its implementation.
In the case of a normal distribution:
δ˜N(μ.sub.δ ;σ.sub.δ),
while the parameters μ.sub.δ and ε.sub.δ respectively correspond to the arithmetic mean and the standard deviation, and are estimated.
In addition to the capability of the measurement procedure it is also possible to monitor the stability of the test procedure on-line.
This test procedure is no longer stable if at least one of the following criteria is satisfied. In practice, it is necessary to check on a case-by-case basis which criteria are applicable.
a) The system is unstable if the value of the difference δ is less than a lower control limit LCL or is greater than an upper control limit UCL, that is to say δ is less than LCL or δ is greater than UCL.
The control limits LCL and UCL are defined by the inverse distribution function F.sub.δ, which is a function of the error probability α. The control limits LCL and UCL, respectively, are defined by:
LCL=F.sub.δ.sup.-1 (α/2)
UCL=F.sub.δ.sup.-1 (1-α/2)
b) The system is unstable if m successive difference values δ occur on one side of the center line, even if there is no value beyond the control limits LCL, UCL (so-called RUN). In this case, m can be defined from:
2*0.5.sup.m ≦α
c) The system is unstable if a trend is present. There are two alternative possibilities here:
First, m successive difference values δ rise or fall continuously. m is then given by: ##EQU1##
Second, the linear regression line defined by m successive points is determined and is checked to see whether the gradients differ significantly from 0 (statistical test).
If one of the above-mentioned conditions is satisfied, a sequence of corrective measures can be initiated, such as calibration or diagnosis of the test system, which is initiated automatically by the test system.
The procedure according to the invention is carried out for all the parameters to be tested. The test station must therefore be configured to be duplicated for each parameter to be tested. The following characteristic values Ckg, Cg, which may be calculated, can be used to determine the statistical values which are critical to the quality of the test apparatuses 2, 3. The two characteristic values Cg and Cgk represent the capability of the overall test station.
Let us assume that χ=1-χ with different δ 1 =X 11 -X 21 ; δ 2 =X 12 -X 22 ; . . . ; δ.sub.χ in a batch or reporting time period. This is used to determine the distribution function F.sub.δ. The two following characteristics for the capability (gauge capability) Cg and Cgk can be determined from this: ##EQU2##
C.sub.gk =minimum(C.sub.go ;C.sub.gu)
where Δ=0.25 and α=0.0027. Cgo and Cgu are given by ##EQU3##
The capability values must in this case satisfy the quality aims of the corresponding process capability values Cg and Cgk.
The test procedure according to the invention is due to determine the nominal limits, so that the proportion of faulty components which are found to be good and are delivered on the basis of the test accuracy does not exceed a predetermined quality aim.
Conventional methods, such as calibrating a test system at specific time intervals, give an indication of the test equipment capability at only one point in time. This never makes it possible to preclude the tester operating outside the specific range between these time intervals. Repeated testing of products tested provisionally as scrap is likewise prevented by the procedure according to the invention, as is the delivery of faulty components which, under some circumstances, were classified as being serviceable within the system-dependent measurement error. The quality aims can thus be guaranteed, and costly remeasurement and recall actions can be prevented from the start. The test times are also shortened, and the test costs are reduced. Furthermore, the test capacity of the test system is considerably increased.
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A test procedure or test station for testing products, especially products completed on an assembly line type production process, performing the following steps: First, testing a parameter of a product with a first testing device using a first input signal to produce a first test result. Second, testing the same parameter of the product with a second testing device using a second input signal that is independent of the first input signal to produce a second test result. Third, deriving a differential value from the test results obtained by the testing devices. Fourth, determining the conformance of the testing station from the differential value and outputting an error message when the differential value deviates from a predetermined range. Fifth, repeating above steps for at least one other parameter.
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BACKGROUND OF THE INVENTION
The present invention pertains generally to high-temperature resins and in particular to cyano-addition resins from oxyarylbisorthodinitriles.
It is known that certain bisorthodinitriles polymerize to form strong, high-temperature thermosetting resins. Examples of bisorthodinitriles suitable for producing these resins are disclosed in U.S. Pat. Nos. 4,056,560; 4,057,569; 4,116,945; and 4,136,107 by James R. Griffith amd Jacque G. O'Rear.
The structure of these resins is not completely known. For the following reasons, the principal mechanism of formation is theorized to be phthalocyanine nucleation. As the bisorthodinitriles polymerize, the color becomes progressively darker green in the manner similar to phthalocyanines. The polymerization is difficult to initiate and promote which indicates the formation of a large and complex nucleus such as the phthalocyanine nucleus by a charge end group such as the phthalonitrile group.
The resins have properties that make them exceptionally suitable for structural resins. They have a structural strength comparable to that of epoxy and polyimide resins and have many advantages over these resins. They have a maximum temperature stability in an oxygen-containing atmosphere of about 230° C. which represents a significant improvement over epoxy resins and their water resistance, as measured by the water-soak method, is better than that for epoxy resins. These resins have many advantages over polyimides due to the absence of solvents, being less hydroscopic, and not being thermoplastic with a low glass transition temperature. Thus, polyphthalocyanine resins promise to be an important new class of structural resins.
Much interest has been shown in improving the adhesive strength of polyphthalocyanine resins in order to obtain an adhesive with the exceptional properties of polyphthalocyanines and to improve the toughness of polyphthalocyanine composites.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a polyphthalocyanine resin having a water repellancy greater than existing polyphthalocyanine resins without fluorine atoms.
Another object is to provide a resin which is thermally stable in an oxidative atmosphere at a temperature up to about 300° C.
Another object of this invention is to provide a resin which is self-extinguishing and gives a high char yield upon burning.
Yet another object of this invention is to provide a resin which is more resistant to oxidative attack than epoxies and polyphthalocyanine resins prepared from amide-bridged bisorthodinitriles.
A still further object of this invention is to obtain a polyphthalocyanine resin with greater adhesive strength.
These and other objects are achieved by heating a bisorthodinitrile having phenoxy and carbonyl or sulfonyl moieties in the bridge in order to effect a polymerization by a cyclic addition reaction without forming volatile by-products and thereby forming a solid, void-free product.
DETAILED DESCRIPTION OF THE INVENTION
The bisorthodinitriles which are heated to form the polyphthalocyanine resins of the present invention have the general formula: ##STR3## where R is ##STR4## The polymerization of these bisorthodinitriles is believed to be a phthalocyanine formation for following reason. As the resins of this invention are formed, the green color becomes progressively darker in the same manner as phthalocyanines and polyphthalocyanines do. Other cyano-addition reactions may also be present; however, the resulting resin is a three-dimensional network polymer with exceptional uniformity in properties.
The resin with phthalocyanine nuclei has a structural formula: ##STR5## where n is any number, R is either ##STR6## represents a phthalocyanine nucleus which has the formula: ##STR7## If the phthalocyanine has been coordinated by a metal or salt, the phthalocyanine nucleus is represented by ##STR8## and the formula is: ##STR9## wherein M is a metal and MX is a metallic salt. Hereinafter, the resins of this invention are designated as: (PcO 4 R 2 Ph 4 ) n if neat, as (M.PcO 4 R 2 Ph 4 ) n if coordinated with a metal, and as (MX.PcO 4 R 2 Ph 4 ) n if coordinated with a metallic salt.
The preferred metals are copper, iron, zinc, and nickel on account of their enhancement of thermal stability over other metals at temperatures in excess of 250° C. Examples of other metals which may be used are chromium, molybdenum, vanadium, beryllium, silver, mercury, tin, lead, antimony, calcium, barium, manganese, magnesium, cobalt, palladium and platinum. The preferred metallic salt is stannous chloride. This salt increases the reaction rate more than metals or other salts and has the least trouble with poor dispersion and voids caused by entrapped gas. These advantages occur only if the stannous chloride is dispersed by the method described hereinafter. Other suitable metallic salts include cuprous bromide, cuprous cyanide, cuprous ferricyanide, zinc chloride, zinc bromide, zinc iodide, zinc ferrocyanide, zinc acetate, zinc sulfide, silver chloride, ferrous chloride, ferric chloride, ferrous ferricyanide, ferrous chloroplatinate, ferrous fluoride, ferrous sulfate, cobaltous chloride, cobaltic sulfate, cobaltous cyanide, nickel chloride, nickel cyanide, nickel sulfate, nickel carbonate, stannic chloride, stannous chloride hydrate, a complex of triphenylphosphine oxide and mixtures thereof. Additional examples of metals and salts are found in Mosher, Frank H. and Thomas, Arthur L. Phthalocyanine Compounds, N.Y. Reinhold, 1963, pp. 104-41.
The present bisorthodinitriles can polymerizes to the polyphthalocyanines of the subject invention at their melting point, but the reaction is slow. Consequently, it is preferred that the bisorthodinitriles are heated to about 15° C. above their melting points in order to have the polymerization completed within a reasonable time. The atmosphere can be oxygen-containing, inert, or a vacuum. The heating is continued until the melt solidifies to an extremely hard material. The preferred method of preparation comprises heating a phthaloninitrile to a temperature from about 15° to 20° C. above the melting point thereof until the visosity of the melt begins to increase due to the onset of phthalocyanine formation which is called the B-stage. At the B-stage, the material can be cooled to a frangible solid and can be stored indefinitely without further reaction. The C-stage is obtained from the B-stage resin by melting the resin and heating the resin at a temperature from about 25° C. above the melting point thereof to about the decomposition temperature of the resulting resin. The B-stage resin can also be broken up, processed into a desired formed, and then heated in the above manner. The preferred temperature range for obtaining the C-stage resin is from about 25° C. above the melting point to about the decomposition temperature. The optimum cure for any particular resin at a particular temperature is determined empirically by testing the structural strength of samples over a range of cure times.
In adding a metal or salt to co-ordinate the phthalocyanine nuclei, the metal or salt is added in a stoichiometric amount while the bisorthodinitrile is molten or powdered. If the amount of the metal or salt is less than stoichiometric, i.e., less than one equivalent per two equivalents of the phthalonitrile monomer, the resulting resin is not completely coordinated with a salt or metal. An amount in excess of stoichiometry would cause the resin to have unreacted metal or salt in it. Avoiding the presence of any unreacted salt or metal is particularly important with the synthesis of the present resins on account of the high temperature needed for polymerization.
High temperatures further require a high degree of purity on account of the increased reactivity of all species present including the impurities. For example, metal oxides at temperatures above 280° C. can attack the benzene-ring structure. The preferred amounts of impurities are less than 100 ppm. Impurities can be present in amounts up to 300 ppm without noticeably affecting the quality of the final resin.
As with previous polyphthalocyanine resins, the dispersion of the salt ot metal is affected by the particle size. Since the resin is formed at such high temperatures, dispersion becomes particularly critical. Consequently, particle sizes up to 100 micrometers are preferred.
If stannous chloride is used to co-ordinate the resin, the stannous chloride must be introduced into the melt as stannous chloride dihydrate by the following method. The stannous chloride dihydrate (SnCl 2 .2H 2 O) is introduced either as a melt or powder. If the bisorthodinitrile is a powder, the mixture is heated, while being stirred, to a temperature from the melting point to about 20° C. in excess thereof until all water is expelled from the mixture; and if the phthalonitrile is molten, then the mixture is kept at the melt temperature until all water is expelled. The mixture is then reacted either to the B-stage or C-stage in the manner previously described.
The effect of including a metal or salt is the promotion of the polymerization. Inclusion of a salt or metal permits a large reduction in the polymerization temperatures without greatly affecting the reaction rate or causes the reaction to significantly speed up at any given temperature. This promotion effect is especially present with the inclusion of stannous chloride. With that salt, the polymerization can occur at the melting point of the bisorthodinitrile with an extremely fast polymerization rate.
The bisorthodinitriles used to produce the polyphthalocyanines of this invention are prepared by a nucleophilic substitution of the nitrosubstituent, which has been activated by cyano groups on the aromatic ring of 4-nitrophthalonitrile with a bisphenol. The reaction is shown by the following schematic: ##STR10## wherein R represents ##STR11##
Examples of the preparation of the bisorthodinitriles and polyphthalocyanines of the invention are herein given. These examples are given by way of explanation and are not meant to limit the disclosure or the claims to follow in any manner.
EXAMPLE 1
Synthesis of Bis(3,4-Dicyanophenyl) Ether of Bisphenol S
A mixture of 51 g (0.2 mol) of bisphenol S, 16.4 g (0.4 mol) of 50% aqueous sodium hydroxide, 450 ml of dimethyl sulfoxide and 100 ml of benzene was stirred at reflux for 6 hours. The water and benzene were removed with a Dean-Stark trap. The reaction content was cooled to room temperature and 69.4 g (0.4 mol) of 4-nitrophthalonitrile was added in one sum. The resulting mixture was stirred for 12 hours at room temperature under a nitrogen atmosphere and then poured into 1500 ml of cold water. The slightly colored solid which separated was collected by suction filtration, washed with water and dried. The product was then washed with 400 ml of hot ethanol to afford 99 g (98%) of product, m.p. 231°-233° C.
A second mixture containing 5.1 g (0.02) of bisphenol S, 10.2 g (0.04 mol) of 4-nitrophthalonitrile, 10.1 g (0.08 mol) of anhydrous potassium carbonate and 40 ml of dry dimethyl sulfoxide was stirred under a nitrogen atmosphere at 70°-80° C. for 6 hours. The cooled product mixture was poured into 300 ml of cold dilute hydrochloric acid. The slightly colored crystalline material was collected by suction filtration and washed with water until the filtrate was neutral. Recrystallization from acetonitrile afforded 8.7 (85%) of the desired product, m.p. 230°-233° C.
EXAMPLE 2
Synthesis of Bis(3,4-Dicyanophenyl) Ester of 4,4'-Dihydroxybenzophenone.
A mixture containing 3.0 g (0.014 mol) of 4,4'-dihydroxybenzophenone, 1.2 g (0.03 mol) of 50% aqueous sodium hydroxide solution, 25 ml of dimethyl sulfoxide and 25 ml of benzene was heated at reflux for 12 hours under a nitrogen atmosphere. The water and then the benzene were removed by a Dean-Stark trap. To the cooled reaction content was added 4.8 g (0.028 mol) of 4-nitrophthalonitrile, and the resulting black mixture was stirred at room temperature for 18 hours. The product mixture was then poured into 150 ml of water. The white solid which separated was collected by suction filtration. The crude product was washed with hot ethanol to afford 6.1 g (94%) of product, m.p. 216°-218° C.
EXAMPLE 3
Polymerization of Bis(3,4-Dicyanophenyl) Ether of Bisphenol S.
Samples (1-2 g) of the monomer were placed in planchets and heated at 280° C. for 4 days. Gelation had occurred after 24 hours and the sample was postcured 3 additional days to toughen the polymer. The cured polyphthalocyanine was bonded to an aluminum planchet. Additional samples of cured polymers were isolated by spraying other planchets with an anti-sticking reagent.
Another sample (1.5 g, 0.003 mol) of the monomer and a stoichiometric amount (0.32 g, 0.0014 mol) of stannous chloride dihydrate was heated at 240° C. for 24 hours. After the monomer melted, the sample quickly turned green along with an immediate dissolution of the salt. The viscosity increased rapidly with gelation occurring in 5 minutes.
EXAMPLE 4
Polymerization of Bis(3,4-Dicyanophenyl) Ester of 4,4'-Dihydroxybenzophenone.
A sample (0.4 g) of the monomer was placed in a small test tube and heated at 280° C. for 36 hours. Gelation had occurred after 18 hours. Upon slowly cooling, the polymer contracted and the wall of the test tube shattered due to the adhesion of the polymer with the glass.
Another sample (0.6 g, 0.0013 mol) of the monomer and a stoichiometric amount (0.13 g, 0.0006 col) of stannous chloride dihydrate were thoroughly mixed, placed in a test tube and heated at 225° C. for 36 hours. The monomer melted at 215°-220° C., and the salt dissolved almost immediately at this temperature. Gelation had occurred after 10 minutes. The polymer again adhered to the wall of the test tube as determined by its breakage on cooling.
Samples prepared by methods similar to Examples 3 and 4 showed high thermal and oxidative stability when heated at 280° C. for over 100 days in air. After 75 days of continuous heating, the weight loss was about two percent of the original total weight. Exposure and removal of samples of these polymers from a high temperature flame demonstrated that these polymers are self-extinguishing.
Other samples prepared by methods similar to Examples 3 and 4 were tested by the water-soak test which comprises submerging a sample in water and periodically weighting the sample. Both polyphthalocyanines which contain polar moieties, e.g., SO 2 , CO, showed a maximum water absorptivity of 3.5 weight percent which occurred after 66 days. In contrast, amide-bridged polyphthalocyanines have a maximum water absorptivity of slightly over 6 percent, and epoxies have a maximum water absorptivity of at least 10 percent.
As these tests domonstrate, the resins of this invention with a bridge having a polar and phenoxy moieties have exceptional thermal and oxidative stability along with a low water absorptivity.
Another important feature of these polymers compared to the other polyphthalocyanines is their enhanced adhesive properties (see Examples 3 and 4). This phenomenon is apparently attributed to the polar moieties on the linking structure between the phthalocyanine nuclei.
Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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Polyphthalocyanine resins are obtained by heating one or more bisorthodiniles of the general formula: ##STR1## wherein R represents ##STR2## at temperature at or above the melting point thereof. The resins are useful in high-temperature structural composites and adhesives.
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