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CROSS REFERENCE APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 12/071,445, filed Feb. 21, 2008, which claims priority under 35 U.S.C. 119 (e) of U.S. Provisional Application No. 60/996,895, filed Dec. 10, 2007, the entire contents of which are hereby incorporated by reference their entireties.
BACKGROUND
In conventional propulsion systems, propellers perform the work required to accelerate fluid molecules to a desired velocity, but the propellers are unable to operate further on the fluid molecules to follow up on the work that was expended to overcome the initial inertia. This is due to the fact that a fluid molecule at rest tends to remain at rest and thus once placed in motion, a relatively smaller amount of energy is required to further accelerate it. Additionally, parts in conventional propulsion systems are easily damaged by foreign objects and unprotected screw-type propulsion systems pose a danger to divers and other living systems which pass in the vicinity of the propulsion system.
Those skilled in the art relating to propulsion systems have found that the propulsion efficiency of a propeller may be increased by carefully channeling the fluid flow to a propeller and similarly directing the accelerated fluid flow efficiently as it leaves the back of the propeller. In the past, various types of conical enclosures or nozzles have been fashioned in an attempt to increase the performance of propellers.
Essentially, a conical enclosure or nozzle surrounds the propeller in a longitudinal direction and directs fluid flow exiting from the propeller blades. The principles of fluid dynamics dictate that the volume of water flowing into the propeller will equal the volume of water flowing out. As such, the diameter of the nozzle is reduced as the water flows rearward and out of the nozzle. Since the volume of water exiting must equal the volume that enters the nozzle, the water flow accelerates as it travels through the nozzle and thereby provides additional thrust which cannot be achieved by the propeller alone.
SUMMARY
An exemplary embodiment of a propulsion system may disclose a cylindrical support member and a tubular rotatable member rotatably mounted within the support member that may be adapted to permit fluid flow there through. The tubular rotatable member may extend past a down stream end of the support member. An exemplary embodiment of a propulsion system may also disclose a vane attached on an interior surface of the tubular member and may include a blade which extends in a direction toward a rotational axis of the rotatable member such that rotation of the tubular member and the vane attached thereon draws fluid into the tubular member to accelerate the fluid flow through the tubular member. Additionally, a nozzle may be attached to the down stream end of the support member and include a primary nozzle and a secondary nozzle within the primary nozzle. The secondary nozzle may be engaged with the primary nozzle by a stator.
Another exemplary embodiment can disclose a propulsion system which may include a nozzle attached to a down stream end of a support member. The nozzle may include a primary nozzle and a secondary nozzle within the primary nozzle. The secondary nozzle may be engaged with the primary nozzle by a stator. The primary nozzle may define first, second and third sections extending along a longitudinal direction of the primary nozzle. The first section may extend in a direction that is substantially parallel to a central longitudinal axis of the nozzle, the second section may taper inwardly in a direction toward the central longitudinal axis and the third section may extend in a direction that is substantially parallel to the central longitudinal axis. Primary and secondary nozzles may be arranged to receive and direct accelerated water leaving final impeller blades into a space between an interior surface of the primary nozzle and an external surface of the interior nozzle. Internal surfaces of secondary nozzle may be arranged to accept a combined volume of slower-moving water or fluid not directly accelerated by impeller blades, and comprising a mixture of water vapor, fluid/water, and/or air, and, in its first section, can represent a low-pressure expansion chamber followed by a constriction in the second section which, aided by pressure from forward movement accelerates this combined flow backward, contributing to thrust.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of embodiments of the propulsion system will be apparent from the following detailed description of the exemplary embodiments thereof, which description should be considered in conjunction with the accompanying drawings in which like numerals indicate like elements, in which:
FIG. 1 is an exemplary cross-sectional longitudinal view of an exemplary embodiment of a propulsion system.
FIG. 2 is an exemplary side view of an exemplary embodiment of a nozzle of a propulsion system.
FIG. 3 is another exemplary side view of an exemplary embodiment of a nozzle of a propulsion system.
FIG. 4 a is an exemplary downstream view of an exemplary embodiment of a nozzle of a propulsion system in an unengaged position.
FIG. 4 b is an exemplary downstream view of an exemplary embodiment of a nozzle of a propulsion system in a fully engaged position.
FIG. 5 is an exemplary side view of an exemplary embodiment of a propulsion system.
DETAILED DESCRIPTION
Aspects of the propulsion system are disclosed in the following description and related drawings directed to specific embodiments of the propulsion system. Alternate embodiments may be devised without departing from the spirit or the scope of propulsion system. Additionally, well-known elements of exemplary embodiments of the propulsion system will not be described in detail or will be omitted so as not to obscure the relevant details of the propulsion system. Further, to facilitate an understanding of the description, discussion of several terms used herein follows.
The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the terms “embodiments of the propulsion system,” or “exemplary embodiments,” do not require that all embodiments of the propulsion system include the discussed feature, advantage or mode of operation.
Other examples of the below-described exemplary embodiments may be used or adapted to be used with U.S. Pat. No. 5,383,802 which is hereby incorporated by reference in its entirety.
In an exemplary embodiment, as shown in FIG. 1 , a propulsion system 100 may include an outer shell 102 having bearings 106 for supporting a rotor 104 . Outer shell 102 may provide bearing support for rotor 104 and further provide ducting and streamlining for rotor 104 . Rotor 104 may be hollow with vanes 108 extending from an interior surface of rotor 104 in the direction of the rotational axis of rotor 104 . Rotor 104 may define first, second and third sections which may extend along a longitudinal direction of rotor 104 . The first section of rotor 104 , as seen in FIG. 1 beginning at the furthest up-stream location (the left-side as seen in FIG. 1 ), may be slightly tapered to provide a venturi effect so as to draw air into a fluid medium passing through rotor 104 . In an exemplary embodiment where the first section inwardly tapers, the second section may begin at a point along rotor 104 where further restriction by the tapering first section would inhibit the fluid flow, however, the point at which the second section begins may not be limited to this point and may depend on design considerations. The second section may extend outwardly to a third section which may gradually return to a surface which may be parallel to the axis of rotation of rotor 104 at the exit of rotor 104 , at a down-stream location.
Vanes 108 may extend from rotor 104 and the vane shapes when viewed in cross-section from a point perpendicular to the rotor's rotational axis may define an archimedes screw, but may change in angle of attack and loaded surface areas in proportions that roughly correspond to fluid speed and rotor diameter. The number of blade sections may depend on design considerations and can be less than or more than three.
The propulsion system may enhance efficiency due to air inducted into the fluid by natural venturi effects or vapor formed in areas of low pressure. The design may draw air and vapor into areas of low pressure that would normally allow vapor bubbles to form and collapse. In addition, energy lost due to turbulence at apices and trailing edges of vanes 108 may be decreased by dropping or holding a stream of entrained air and vapor in close proximity to (or impinging upon) areas of predicted low pressures. The rotor wall constriction in the first section rotor 104 may indirectly compress air and vapor admitted to high stress areas, effectively pre-loading higher-pressure air, gas or vapor into these regions. Consequently, potential regions of vapor formation and accumulation may be filled with gas, vapor, or air pockets. In typical operation, a low pressure area implies the expansion of gas or air to fill the anticipated vacuum, and, because low pressure phenomena may occur with steadily increasing frequency throughout the rear two thirds of the propulsion device, vapor tends to accumulate into even larger, stable, visible gas or air pockets suspended between the fast-moving outer ring of fluid that may be driven by vanes 108 and the slower moving inner core of fluid that may form around the axis of rotation of rotor 104 in the center area that may not be disturbed by vanes 108 due to increased pressure caused by flow constriction within the nozzle. This gaseous region may remain largely contained within the secondary nozzle 114 .
In another exemplary embodiment, propulsion system 100 may utilize water lubricated bearings 106 and drive systems that may require cooling or heat removal/transfer systems. A gap 116 between the end of rotor 104 and a primary nozzle 112 may be adapted to provide a means of escape for high pressure water from the interior of rotor 104 . This high pressure water may be directed through gap 116 into the space surrounding bearings 106 and could potentially surround components of a drive system or any other desired structure or components housed between outer shell 102 and rotor 104 . This may provide a positive pressurized flow between moving and static surfaces. Gap 116 may vary in size for example, 0.25 inches, or any other desired gap size. Additionally, gap 116 may be expanded to release additional pressurized water or other desired fluid for use in cooling, for example, electric drives, internal combustion engines, or any other desired system requiring pressurized fluid.
In another exemplary embodiment, as seen in FIG. 1 , ducts 110 may be formed in the side walls of rotor 104 at high and low pressure sides of vanes 108 . Ducts 110 may introduce high pressure water to water-lubricated bearing interfaces. The high pressure water may enter ducts 110 on the high pressure side of vanes 108 , cool and lubricate bearings 106 and then be reintroduced at the low pressure side of vanes 108 which may result in a closed loop cooling and lubrication system with substantially no volumetric loss of fluid passing through rotor 104 . The pressure differential between the two openings of ducts 110 may provide a current of pressurized fluid, such as water, to any desired location outside of rotor 104 . Ducts 110 may also be diverted to other desired tasks or locations which may result in a corresponding reduction of fluid pressure in the interior of rotor 104 . The positioning of ducts 110 can be in any desired location through the walls of rotor 104 and be of any desired shape or size.
A further exemplary embodiment of a propulsion system 100 , as seen in FIGS. 1-5 , may include a primary nozzle 112 , a secondary nozzle 114 and at least one stator 118 , but may include any desired number of stators 118 . Secondary nozzle 114 may be affixed within primary nozzle 112 by stators 118 .
Primary nozzle 112 may be placed at a point of largest diameter of the interior of rotor 104 and may be mounted to outer shell 102 , at a down-stream side, through welding or any other type of fastening mechanism that may provide a fluid tight seal between outer shell 102 and primary nozzle 112 . The interface created by the attachment of primary nozzle 112 and outer shell 102 may approximate a continuous static interior surface with vanes 108 extending from rotor 104 .
Down-stream from the attachment of primary nozzle 112 and outer shell 102 , the interior of primary nozzle 112 may reduce in diameter which may induce a constriction or reduced cross-sectional area. The reduction in diameter of primary nozzle 112 may vary according to desired vectoring of the fluid flow through primary nozzle 112 and the desired increase in flow acceleration, for example, the angle of curvature of the primary nozzle 112 and secondary nozzle 114 may be between 15 and 30 degrees or any other desired angle of curvature. The constriction caused by primary nozzle 112 may induce acceleration in fluid flow and an increase in pressure on the fluid from the point of exiting the rotor 104 to the terminating downstream end of primary nozzle 112 .
Secondary nozzle 114 may be positioned approximately at the apices of the inner edges of the furthest downstream vanes 108 and may also reduce in diameter at a rate of curvature equal or different than the rate of curvature of primary nozzle 112 . The inner walls of secondary nozzle 114 may generally follow the contours or the outer walls of secondary nozzle 114 and may be configured to reduce flow disruption between the up stream side of the primary nozzle 112 and secondary nozzle 114 and the down stream side of the primary nozzle 112 and secondary nozzle 114 . At least one stator 118 , but may be as many as desired, may be mounted between the inner surface of primary nozzle 112 and the outer surface of secondary nozzle 114 . Stator 118 may be used to maintain the spatial and static separation between primary nozzle 112 and secondary nozzle 114 .
The separation between primary nozzle 112 and secondary nozzle 114 may provide a channel which may facilitate a physical separation between inner and outer streams of fluid. In operation, as rotor 104 rotates, fluid may be forced through rotor 104 and into primary nozzle 112 and secondary nozzle 114 . As rotor 104 rotates the fluid, for example water, may be separated into a liquid outer stream and a vapor inner stream. The outer liquid stream may be naturally forced outward against the inner walls of primary nozzle 112 . Secondary nozzle 114 may be configured, as seen in FIG. 1 , to allow gaseous expansion from rotor 104 and vanes 108 at the upstream side and then facilitate acceleration of the vapor and gas by the reduction in diameter of secondary nozzle 114 at the downstream side. Thus the channel between primary nozzle 112 and secondary nozzle 114 may facilitate the flow of the liquid portion of the fluid flow and secondary nozzle 114 may facilitate the flow of the vapor portion of the fluid flow.
Stators 118 may impinge on fluid flow exiting rotor 104 and direct fluid flow downstream of primary nozzle 112 and secondary nozzle 114 . Stators 118 may be mounted at locations immediately downstream from vanes 108 and may be formed at the upstream side with an angle of attack that may approximate the angle of vanes 118 at the downstream side of rotor 104 . Stators 118 may gradually decrease in angle of attack, eventually aligning in parallel with the axis of rotation of rotor 104 and the longitudinal axis of primary nozzle 112 . This formation of stators 118 may aid in altering the velocity vector of the exiting fluid, forcing the fluid to exit the primary 112 and secondary nozzles 114 to exit parallel to the axis of rotation of rotor 104 , in such a way that may increase the potential and actual thrust of the overall propulsion system 100 .
The separation of the vapor and liquid flow by primary nozzle 112 and secondary nozzle 114 may attribute to an increased thrust of rotor 104 . Adding primary nozzle 112 and secondary nozzle 114 to rotor 104 may produce a 400 percent increase in thrust when compared to the thrust of rotor 104 alone. This increase in thrust may also be attributed to the containment of radially centrifuged high pressure liquid and the separation and pressurization of internally generated vapor flow. The percent increase in thrust may increase or decrease depending on, for example, the rate of curvature of primary nozzle 112 and secondary nozzle 114 .
In another exemplary embodiment, as seen in FIGS. 2-5 , primary nozzle 112 may include steering ports 201 and braking ports 207 , each of which creates an opening through the wall of primary nozzle 112 . Each steering port 201 may be coupled with a corresponding steering port flap 200 . Steering ports 201 may be located at any desired position on primary nozzle 112 and, for example, may be located on the first 20 percent of the upstream side of primary nozzle 112 . Additionally, steering ports 201 and corresponding steering port flaps 200 may, for example, be symmetrically or asymmetrically oriented around the periphery of primary nozzle and may be formed in any desirable shape or configuration. Steering ports 201 and corresponding steering port flaps 200 may also be located on the first 20% of the upstream portion of primary nozzle 112 , the first half of the upstream portion of the primary nozzle 112 or at any other desired location over the entire length of primary nozzle 112 .
Steering port flaps 200 may be formed to seal steering ports 201 when placed in a closed position. Steering port flaps 200 may have a hinge 202 or be otherwise attached at an upstream position with respect to primary nozzle 112 , as can be seen in FIG. 2 . The number of steering ports 201 and corresponding steering port flaps 200 may range from a single steering port 201 and corresponding steering port flap 200 to as many as desired.
In another exemplary embodiment, as seen in FIGS. 4 a - 5 , hinges 202 may facilitate opening steering port flaps 200 in such a way that fluid flow may exit primary nozzle 112 at an angle that may be less than or equal to 90 degrees from the direction of the downstream exit of primary nozzle 112 . Steering port flaps 200 may be incrementally opened, thus diverting select amounts of fluid flow from the inside of primary nozzle 112 through steering ports 201 . As fluid flow is diverted through selected steering ports 201 , the diverted flow may alter the velocity vector of the overall fluid exiting primary nozzle 112 , thus providing a means of adjusting the direction of the thrust of nozzle 112 .
In a further exemplary embodiment, as seen in FIG. 3 , each braking port 207 may be coupled with a corresponding braking port flap 206 . Braking ports 207 may be located at any desired position on primary nozzle 112 and, for example, may be located on the first 20 percent of the up stream side of primary nozzle 112 . Additionally, braking ports 207 and corresponding braking port flaps 206 may, for example, be symmetrically oriented around the periphery of primary nozzle and may be formed in any desired shape or configuration. Braking ports 207 and corresponding braking port flaps 206 may also be located on the first 20% of the upstream portion of primary nozzle 112 , the first half of the upstream portion of the primary nozzle 112 or at any other desired location over the entire length of primary nozzle 112 .
Braking port flaps 206 may be formed to seal braking ports 207 when placed in a closed position. Braking port flaps 206 may have a hinge 208 or be otherwise attached at a downstream position with respect to primary nozzle 112 , as can be seen in FIG. 3 . The number of braking ports 207 and corresponding braking port flaps 206 may range from a single braking port 207 and corresponding braking port flap 206 to as many as desired.
In a further exemplary embodiment, as seen in FIGS. 4 a - 5 , hinges 208 may facilitate opening braking port flaps 206 in such a way that an upstream portion of braking flap 206 may be opened externally to primary nozzle 112 and a downstream portion may extend internally into primary nozzle 112 . The downstream portion of braking flap 206 may act as a partial valve, restricting a portion of fluid flow from exiting primary nozzle 112 between secondary nozzle 114 and primary nozzle 112 . The upstream portion of braking port flap 206 may open from an upstream side of braking port 207 and may force a portion of the fluid flow from primary nozzle 112 to be diverted out of primary nozzle 112 at an angle that may be between 90 and 180 degrees from the direction of the downstream exit of primary nozzle 112 . Braking port flaps 206 may be incrementally opened, thus diverting a select amount of fluid flow from the inside of primary nozzle 112 through braking ports 207 .
As fluid flow is diverted through selected braking ports 207 , the diverted flow may be directed in a generally opposite direction of the overall fluid exiting primary nozzle 112 , thus reducing the velocity vector of the overall fluid exiting primary nozzle 112 , and acting as a braking mechanism for propulsion system 100 , during use. Additionally, the upstream portion of braking port flap 206 may act as a drag on propulsion system 100 when opened. The amount of drag created by the braking port flap 206 may be directly correlated to the amount braking port flap 206 is opened and may add to the braking ability of propulsion system 100 .
In another exemplary embodiment, steering port flaps 200 and braking port flaps 206 may be utilized in directional control of propulsion system 100 , as seen in FIGS. 2-5 . Any combination of opening and closing steering port flaps 200 may divert fluid flow and thrust away from the downstream side of primary nozzle 112 at different variable angles, which may be used to facilitate steering or adjusting the trim of the propulsion system 100 . Any combination of opening and closing braking port flaps 206 may divert fluid flow in an opposite direction from the fluid flow exiting the downstream side of secondary nozzle 114 , thus reducing or breaking the thrust vector of the fluid flow exiting the downstream side of secondary nozzle 114 . This braking system may, therefore, not necessitate closing off the downstream side of either the primary nozzle 112 or the secondary nozzle 114 . Hard or extreme steering may, for example, require a combination of opening and closing specific steering port flaps 200 and braking port flaps 206 .
In a further exemplary embodiment, opening and closing steering port flaps 200 and braking port flaps 206 may be accomplished by a mechanical release mechanism. For example, rod 204 may mate with a groove on steering flap 200 , as seen in FIG. 2 , and may be retracted in the direction of hinge 202 as a means of releasing steering flap 200 and allowing fluid flow from within nozzle 112 to escape through steering port 201 . This rod 104 and groove mechanism may be used to incrementally control the opening and closing of both steering port flaps 200 and braking port flaps 206 . Hinges 202 and 208 may also be spring loaded or otherwise biased toward an open or closed position as an additional means of facilitating the opening of both steering port flaps 200 and braking port flaps 206 .
Additionally, for example, opening and closing steering port flaps 200 and braking port flaps 206 may be accomplished via magnetic servos, control wires, piezoelectric mechanisms or any other mechanical, electrical or magnetic devices capable of incrementally opening and closing both steering port flaps 200 and braking port flaps 206 . Control systems may also be employed to communicate with and control the opening and closing devices, mentioned previously, in order to open or close steering port flaps 200 and braking port flaps 206 from a remote location.
The foregoing description and accompanying drawings illustrate the principles, preferred embodiments and modes of operation of the invention. However, the permit application and issuance system should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art.
Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the permit application and issuance system as defined by the following claims.
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A propulsion system may include a cylindrical support member and a tubular rotatable member rotatably mounted within the support member that may be adapted to permit fluid flow therethrough. The tubular rotatable member may extend past a down stream end of the support member. An exemplary embodiment of a propulsion system may also disclose a vane attached on an interior surface of the tubular member and may include a blade which extends in a direction toward a rotational axis of the rotatable member such that rotation of the tubular member and the vane attached thereon draws fluid into the tubular member to accelerate the fluid flow through the tubular member. Additionally, a nozzle may be attached to the down stream end of the support member and include a primary nozzle and a secondary nozzle within the primary nozzle. The secondary nozzle may be engaged with the primary nozzle by a stator.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims foreign priority to Japanese application no. 2001-197347 filed Jun. 28, 2001, the disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to power failure sensing devices and card reader devices.
BACKGROUND OF THE INVENTION
Generally, in various devices, a power failure sensing device is employed broadly. For example, in a power failure sensing device shown in FIG. 6 , an output voltage from an internal electrical power source 1 provided in a use apparatus is altered by a reference voltage by a regulator 2 and the reference voltage is outputted to a comparator 3 . Also, as the output voltage from the internal electrical power source 1 is altered a power failure sensing voltage is created by resistors R 1 , R 2 and the power failure sensing voltage is outputted to comparator 3 .
When the output voltage from the internal electrical power source 1 falls to less than a predetermined level, a power failure sensing signal (L signal) is generated. However, for example, as a card reader is used in a cash dispenser and the like, the card reader, a subordinate use apparatus, is controlled by the host external device. In the subordinate use apparatus, when a power failure occurred in a power source of the interior side of the subordinate use apparatus, the state of the power failure of the subordinate use apparatus can be detected by the power failure sensing device as described above.
It is problematic not to be able to detect the state of a power failure when an occurrence is detected in the host external device side. That is, even if a power failure does not occur in the use apparatus itself as a subordinate device, there may be cases where a power failure occurs in the host external device side. Thus, the state of the power failure of the external device side keeps the failure at the subordinate device not detected. As a result, when an operation of the use apparatus as a subordinate device is continued, drawbacks are given to an operation of the whole device.
Accordingly, it is a object of the present invention to provide a power failure sensing device which can detect well the state of a power failure of an external device side in addition to a power failure sensing of the interior side with a simple configuration and a card reader having the power failure sensing device.
SUMMARY OF THE INVENTION
In order to achieve the above purpose, a power failure sensing device according to the present invention has a power failure sensing circuit of a use apparatus and provides an outside signal input part receiving power failure signal from an external device is provided and a power failure signal output part. The power failure signal output part outputs a final power failure sensing signal based on at least one signal of two signals, that is, an outside power failure signal is generated from the external signal input part when the external device has a power failure and an interior power failure signal is generated when the use apparatus has a power failure. That is, according to the power failure sensing device having the configuration as described above, a final power failure sensing signal can be generated when at least one signal of the external device side and the use apparatus side controlled by the external device has the state of a power failure.
Further, in a card reader having a power failure sensing device according to the present invention a power failure sensing circuit of the card reader provides an outside signal input part receiving a power failure signal from a host external device and a power failure signal output part which outputs a final power failure sensing signal in response to at least one (signal) of an external power failure signal and an interior power failure signal. The outside power failure signal is generated from the outside signal input part when the host external device has a power failure, the interior power failure signal is generated when the card reader side has a power failure. That is, according to the card reader having the power failure sensing device having the configuration as described above, a final power failure sensing signal can be generated when at least one (signal) of the external device side and the use apparatus side controlled by the external device has the state of a power failure.
Moreover, a power failure sensing device or a card reader comprising power failure sensing device according to the present invention in a power failure signal output part has an open collector type output circuit so that a power failure signal output part can embody with a simple and cheap circuit.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram showing a circuit structure of a power failure sensing device of a card reader according to one embodiment of the present invention.
FIG. 2( a ) is a diagram showing the state of a power failure sensing of the card reader side.
FIG. 2( b ) is a diagram showing the state of a power failure sensing of the external device side,
FIG. 2( c ) is a diagram showing the state of a final power failure sensing.
FIG. 3 is a block diagram showing a circuit structure of a power failure sensing device of an another embodiment of the present invention.
FIG. 4 is a block diagram showing a circuit structure of a power failure sensing device of a further another embodiment of the present invention.
FIG. 5 is a block diagram showing a circuit structure of a power failure sensing device of a still further another embodiment of the present invention.
FIG. 6 is a block diagram showing a circuit structure of a power failure sensing device employed in a general card reader.
DETAILED DESCRIPTION OF THE INVENTION
A power failure sensing device in an embodiment shown in FIG. 1 applies the present invention to a card reader built in as a subordinate device in a cash dispenser as a host external device. The various operations that are carried out in the card reader of a use apparatus as the subordinate device is controlled based on command signals from the cash dispenser as the host external device and Interlocked operations carry out.
A power failure sensing device provided in the card reader provides a card reader power failure sensing circuit 12 to detect the state of a power failure in an internal electrical power source 11 provided for the card reader. Also, the main unit of the cash dispenser as the host external device provides a host device power failure sensing circuit to detect the state of a power failure of a power source with the main unit which omitted illustration.
In the card reader power failure sensing circuit 12 , at first, an output voltage (24V) from an internal electrical power source 11 for the card reader is altered to a reference voltage (5V) by a 3-terminal regulator 12 a . The reference voltage (5V) is inputted a minus side terminal of a comparator 12 b of an open collector output type through a resistor R 3 and a condenser C 2 which eliminate a noise and a voltage drop of a short time and prevent from a malfunction of the circuit.
The output voltage from the internal electrical power source 11 (24V) is altered to e.g. a power failure sensing voltage Vp (=5×(R 1 +R 2 )/R 2 =19V) by resistors R 1 , R 2 . The power failure sensing voltage (19V, for example) is inputted to a plus side terminal of the above-described comparator 12 b through a condenser C 1 that eliminates a noise and a voltage drop of a short time and prevents from a malfunction of the circuit.
By this time, the card reader power failure sensing circuit 12 sets up that an open collector output from the comparator 12 b is replaced with “L signal” when the internal electrical power source 11 for the card reader has a power failure. In addition, an interior power failure signal S 1 of the card reader side comprising the “L signal” is inputted to a power failure signal output part 13 .
The power failure signal output part 13 in the present embodiment is comprised an open collector type output circuit having a pull-up power 13 a and a resistor R 6 . Further, an external signal input portion 14 is connected with the power failure signal output part 13 between the main unit of the cash dispenser comprising the host outside device as described above. That is, a host power failure sensing signal (/PF) is inputted in the external signal input part 14 . The host power failure sensing signal (/PF) is generated by a power failure sensing circuit (not illustration) which is provided by the main unit of the cash dispenser as the host external device.
After the host power failure sensing signal (/PF) boosts to a constant voltage, the host power failure sensing signal (/PF) is inputted to an inverter 14 a . The inverter 14 a has a schmitt trigger circuit for chattering protection through a resistor R 5 and a condenser C 3 which eliminate a noise and a voltage drop of a short time and prevent from a malfunction of the circuit. Furthermore, an output of the inverter 14 a is altered to a signal inverted the logic and the signal is inputted to a base terminal of a NPN transistor 14 b with built-in resistor.
An output from a collector terminal of this transistor 14 b is set up to be replaced with “L signal” when the main unit of the cash dispenser as the host external device has a power failure. Additionally, an external power failure signal S 2 of the main unit of the cash dispenser side comprising the “L signal” is inputted to the above-described power failure signal output part 13 .
The power failure signal output part 13 comprising the open collector type output circuit as described above is generated both “L signal”, that is, the interior power failure signal of the card reader side and the external power failure signal of the main unit of the cash dispenser side, (which make) as a final power failure sensing signal S 3 . That is, according to the power failure sensing device of the card reader as described above, when at least one of the main unit of the cash dispenser side as the host external device and the card reader side controlled by the host outside device side has the state of a power failure, the power failure signal output part 13 is generated a final power failure sensing signal S 3 comprising “L signal”.
The state of a power failure of the main unit of the cash dispenser side as the host external device can be detected in addition to the state of a power failure of the card reader itself. For example, the state of a power failure of the internal electrical power source 11 of the card reader side, shown in FIG. 2( a ), occurs within the range of that is, a level of a power failure sensing voltage Vp or less.
When the state of a power failure of the main unit of the cash dispenser side as the host external device occurs with a low level, as shown in FIG. 2( b ), both the state of a power failure of the card reader side and the state of a power failure of the main unit of the cash dispenser side as the host external device are detected with a low level as shown in FIG. 2( c ), Namely, in state “1” shown in FIG. 2 , the internal electrical power source 11 of the card reader side holds a normal voltage, but the external power source of the host outside device side has the state of a power failure. Thus, a final power failure sensing signal S 3 is generated.
In state of “2”, both internal electrical power sources 11 of the card reader side and the external power source of the host outside device side hold a normal voltage so that a power failure sensing signal is not generated. Moreover, in state “3”, the internal electrical power source 11 of the card reader side has the state of a power failure so that a final power failure sensing signal S 3 is generated even if the external power source of the host outside device side holds a normal voltage. Also, in state of “4”, which is the same as the state of “3” as described above, both internal electrical power sources 11 of the card reader side and the external power source of the host outside device side hold a normal voltage. Thus, a power failure sensing signal is not generated. Lastly, in state of “5”, which is the same as the state of “3” as described above, the internal electrical power source 11 of the card reader side has the state of a power failure so that a final power failure sensing signal S 3 is generated even if the external power source of the host outside device side holds a normal voltage.
In a conventional device, when a power voltage suddenly fell, the time which can hold an output of a regulator (see reference number 2 in FIG. 6 ) after detecting a power failure is cut to correspond to the lower of the power voltage. In the present embodiment, to detect a power failure of the external device side can do (process) with speed so that the time which can hold an output of a regulator (see reference number 12 in FIG. 1 ) can be longer than that of the conventional device. Accordingly, It has enough execution (running) disposition time of various operations after a power failure so that it can afford to deal with processing operation after a power failure.
In the embodiment shown in FIG. 3 , the power failure sensing circuit 12 of the card reader side is applied to a comparator 12 b ′ of the positive type which is not an open collector output type. And, in correspondence with the comparator 12 b ′, an AND gate IC 23 a is employed for the power failure signal output part 23 .
Moreover, the embodiment shown in FIG. 4 employs an inverter IC 14 c in the external signal input part 14 for the transistor 14 b of the described above embodiment in addition to the embodiment of FIG. 3 as described above. Also, an embodiment shown in FIG. 5 employs separated CPUs of the power failure sensing circuit 12 side and the external signal input part 14 side, respectively. The separated CPU uses instead of the AND gate IC 23 a used in the power failure signal output part 23 in the above described each embodiment shown in FIG. 3 and FIG. 4 . An interior or outside power failure sensing signals which are inputted into each separated CPU are processed according to software using the same AND logic to detect a power failure which is the same as a described in the above embodiment.
A power failure sensing device according to the present invention, as described above, has a power failure sensing circuit of a use apparatus provides an outside signal input part receiving a power failure signal from an external device and a power failure signal output part, the power failure signal output part outputs a final power failure sensing signal based on at least one of two signals, that is, an outside power failure signal is generated from the external signal input part when the external device has a power failure and an interior power failure signal is generated when the use apparatus has a power failure.
The power failure sensing device generates a final power failure sensing signal when at least one of the external device side and the use apparatus side controlled by the external device has the state of a power failure. Accordingly, the state of a power failure of the external device side can be detected well with simple configuration in addition to detecting a power failure of the interior side of the use apparatus. And it can obtain the power failure sensing device with a high degree of reliability and inexpensively.
Further, a card reader having a power failure sensing device according to the present invention, as described above, includes a power failure sensing circuit of the card reader to provide an outside signal input part receiving a power failure signal from a host external device and a power failure signal output part, the power failure signal output part outputs a final power failure sensing signal based on at least one of two signals, that is, an outside power failure signal is generated from the external signal input part when the external device has a power failure and an interior power failure signal is generated when the card reader has a power failure.
Thus, the power failure sensing device generates a final power failure sensing signal when at least one of the external device side and the card reader side controlled by the external device has the state of a power failure. AS a result, the state of a power failure of the host external device side can be detected well with simple configuration in addition to detecting a power failure of the interior side of a card reader. Also, it can obtain a card reader having the power failure sensing device with a high degree of reliability and cheap.
Also, a power failure sensing device or a card reader having power failure sensing device according to present invention, in addition to the above, has a power failure signal output part which has an open collector type output circuit so that the power failure signal output part can embody with a simple and cheap circuit and it can make described above effect improve moreover.
It should be apparent to those skilled in the art that various modifications and variations may be made in apparatus and process of the present invention without departing from the spirit or scope of the invention. For example, each embodiment of the invention shown in FIGS. 3–5 have the same function and effect as described above. Further, the present invention is applied to a card reader in each embodiment described above, however, the present invention may be applied to other devices of various kinds in a similar manner.
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A power failure detection system for detecting power failures in a cash dispenser machine and in an associated card reader includes an external signal input part for receiving a power failure signal from a first power failure sensing circuit located in a host cash dispenser machine, a card reader associated with the cash dispenser; an internal power source located in the card reader, a second power failure sensing circuit located in the card reader; a power failure signal output part for receiving and processing power failure signals from the external signal input part and from the second power failure sensing circuit. The power failure signal output part contains a circuit to output a final power failure signal if either the card reader or the cash dispenser has a power failure wherein the shape of said final power failure signal indicates whether the card reader or the cash dispenser or both experience a power failure.
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The invention relates to unique polymeric bicomponent fibers and to the production of low cost tobacco smoke filters from bicomponent fibers comprising a core of a low cost, high strength, thermoplastic polymer, preferably polypropylene, and a bondable sheath of a material, preferably selected from plasticized cellulose acetate, ethylene-vinyl acetate copolymer, polyvinyl alcohol or ethylene-vinyl alcohol copolymer.
While bicomponent fibers comprising a sheath of each of these polymeric materials have unique properties and advantages particularly when used in tobacco smoke filters, they share several common attributes which are important to commercial application of the instant inventive concepts. Perhaps foremost to the smoking public, each of these sheath materials have been determined to have acceptable taste impact when used to filter tobacco smoke. Moreover, such bicomponent fibers may be melt blown to produce very fine fibers, on the order of about 10 microns or less in diameter, in order to obtain enhanced filtration. A further commercially important feature of these bicomponents fibers is that they can be produced continuously and converted simultaneously in a one step process into tobacco smoke filters. Thus, tobacco smoke filters formed from bicomponent fibers according to this invention can provide improved filtration efficiency and acceptable taste impact, at a substantially lower cost when used on cigarettes and other smoking articles.
BACKGROUND OF THE INVENTION
A wide variety of fibrous materials have been employed in tobacco smoke filter elements. However, the choice of materials for use in production of such filters has been limited because of the need to balance various commercial requirements. A very important property of a tobacco smoke filter is obviously its filtration efficiency, i.e., its ability to remove selected constituents from the tobacco smoke. However, the range of filtration efficiency has had to be compromised in order to satisfy other commercially important factors such as resistance to draw, hardness, impact on taste, and manufacturing costs.
Cellulose acetate has long been considered the material of choice in the production of tobacco smoke filters, primarily because of its ability to provide commercially acceptable filtration efficiency, on the order of about 50%, without significantly detracting from the tobacco taste, low resistance to draw, and filter hardness desired by the majority of smokers.
A significant component of the commercially desirable "taste" is provided by the standard plasticizers utilized in the production of filter elements from cellulose acetate fibers, usually triethylene glycol acetate or glycerol triacetate ("triacetin"). In conventional cigarette filter manufacturing, the plasticizer is commonly applied to the cellulose acetate fiber by spraying or wicking using art-recognized techniques. The tendency of the plasticizer to migrate toward the center of conventional cellulose acetate fibers reduces the level of plasticizer at the fiber surface, minimizing its taste-enhancing capability and limiting the shelf life of plasticized tow fibers before being processed into filter rods. The plasticizer is therefore usually added to the tow during the manufacture of the filter rods.
Cellulose acetate fiber plasticized in this manner and wrapped with paper into rod-like forms become bondable at the fiber contact points, enabling the formation of relative self-sustaining, elongated filter rods in two to four hours. This process can be accelerated by the application of gases at elevated temperatures simultaneously with the formation of the filter rod. Filter rods produced in this manner provide a tortuous path for the passage of tobacco smoke when discrete lengths of such material are utilized as tobacco smoke filter elements.
Filtration efficiency can be increased significantly through the use of small fibers which provide increased fiber surface area at the same weight of fiber. Solvent spun cellulose acetate fiber is commercially available only in fiber sizes down to 13 microns in diameter. To obtain finer cellulose acetate fiber, e.g., 10 microns or less, melt spinning of plasticized cellulose acetate resin would be required; however, the level of plasticizer necessary to directly spin such fine cellulose acetate fibers would render the resultant fibers very weak and commercially useless. Melt spun cellulose acetate of a larger diameter, which would require less plasticizer, would have to be drawn and crimped to produce such fine fibers for use in tobacco smoke filters. Unfortunately, melt spun cellulose acetate fibers can only be commercially drawn at relatively low draw ratios before the fibers break during processing. The inability to form and process very fine fibers of cellulose acetate places practical limits on the filtration efficiency capabilities of this material in the production of tobacco smoke filters.
Further, and very important commercially, by comparison with other polymeric materials such as the polyolefins, cellulose acetate is relatively expensive, costing, for example, on the order of more than three times as much as commercially available polypropylene in resin form. While attempts have been made to utilize other less expensive and more easily processed polymeric materials such as polypropylene in lieu of cellulose acetate in the manufacture of tobacco smoke filters, such efforts have been almost universally abandoned on a commercial level, primarily because of the undesirable impact of such materials on the taste properties of tobacco smoke. Also, such use is generally limited by the inability to easily bond the fibers in order to obtain the desired filter hardness at required resistance to draw.
Another problem with commercially available tobacco smoke filters, particularly cigarette filters, currently on the market is the difficulty in disposing of such materials after use. By bonding highly crimped cellulose acetate fibers at their contact points, conventional cigarette filters are designed to provide a significant volume of interstitial space for the passage of smoke. The bonded contact points of such filter elements degrade very slowly under normal environmental conditions resulting in high volume, long life, environmentally undesirable litter.
OBJECTS OF THE INVENTION
It is a primary object of this invention to provide unique polymeric bicomponent fiber materials which afford the advantages of cellulose acetate, particularly when used in the manufacture of tobacco smoke filters, while overcoming many of the aforementioned commercially recognized disadvantages of such material.
A further important object of the instant invention is to provide a tobacco smoke filter which affords the advantages of conventional cellulose acetate fiber filters at significantly lower cost.
Another object of this invention is to provide a sheath-core bicomponent fiber material, particularly for the use in the production of tobacco smoke filter elements, which combines the commercially desirable taste, hardness, and resistance to draw properties of cellulose acetate fiber filters with a low cost, high strength, polymeric material such as polypropylene.
A further object of the instant inventive concepts is to provide a tobacco smoke filter formed from sheath-core bicomponent fibers in which the sheath will rapidly degrade when subjected to environmental conditions, leaving only unbonded fine fibers which are of very low volume as compared to the filter element from which they came, and virtually unnoticeable.
A still further object of this invention is the provision of a bicomponent fiber which has been attenuated using melt blown fiber techniques resulting in very fine fibers having average diameters on the order of about 10 microns or less.
Yet another object of the instant invention is to provide very fine bicomponent fibers which can be used to form a tobacco smoke filter rod of high filtration efficiency while maintaining the structural integrity of the filter rod, thereby further reducing costs.
Still another object of the invention is to provide filter rods, filter elements, and filtered cigarettes and the like incorporating filter elements made from such melt blown, bicomponent fibers, which have commercially desirable taste properties, filtration efficiency, resistance to draw, and hardness properties, and methods of making such materials in a highly efficient and commercially acceptable manner.
Upon further study of the specification and the appended claims, additional objects and advantages of this invention will become apparent to those skilled in the art.
SUMMARY OF THE INVENTION
These and other objects of this invention are achieved by the provision of a bicomponent fiber which has preferably been melt blown, having a core of low cost, high strength polymeric material, preferably polypropylene, and a sheath of a bondable polymeric material preferably selected from plasticized cellulose acetate (CA), ethylene-vinyl acetate copolymer (EVA), polyvinyl alcohol (VAL), and ethylene-vinyl alcohol copolymer (EVAL), and the processing of such fibers to form relatively self-sustaining, elongated filter rods which may be subdivided to produce a multiplicity of filter elements for incorporation into filtered cigarettes or the like.
The term "bicomponent" as used herein refers to the use of two polymers of different chemical nature placed in discrete portions of a fiber structure. While other forms of bicomponent fibers are possible, the more common techniques produce either "side-by-side" or "sheath-core" relationships between the two polymers. The instant invention is concerned primarily with production of "sheath-core" bicomponent fibers where a bondable sheath polymer is spun to completely cover and encompass a core of relatively low cost, high strength polymeric material such as polypropylene, preferably using a "melt blown" fiber process to attenuate the fiber. With this construction, the core material may comprise at least about 50 weight %, and as much as about 90 weight % of the total fiber, providing high strength to the fiber at substantially less material cost than a fiber comprised entirely of cellulose acetate. With denser sheath materials, higher weight percentages of sheath material may be desirable, e.g., 40/60, sheath/core, to insure proper coverage for successful bonding and taste impact while still maintaining a majority of core material. Even lesser amounts of core material in the conjugate reduces the cost of the fiber and tobacco smoke filters made therefrom in a commercially significant manner.
When used in the production of a tobacco smoke filter, the sheaths of juxtaposed fibers in a tow formed of CA, EVA, VAL or EVAL, can be bonded at their contact points to form self-sustaining filter rods by the techniques described herein to provide a filtration efficiency, hardness, and resistance to draw similar to conventional cellulose acetate filters. Also, since only the surface sheath contacts the smoke, the highly desirable taste properties of the sheath polymer are realized and the undesirable impact on taste properties of the core material is avoided.
While bicomponent fibers are well known, certain sheath-core conjugates according to this invention are believed to be unique, having attributes that would not have been expected. For example, because of the difficulty in melt spinning CA and providing compatibility and attenuation of a composite formed with a thermoplastic such as polypropylene, bicomponent fibers of such materials formed by melt blowing of the conjugate according to this invention, are believed novel. Likewise, while side-by-side bicomponent fibers of EVA and a polyolefin have been suggested, primarily for use as a binder, in the production of tobacco smoke filters comprised principally of cellulose acetate staple fibers, the advantages of using continuous EVA sheath-core fibers to provide the major component, or the entirety, of such filter products has not been recognized. Moreover, the ability of a bicomponent fiber having a high strength, low cost, core such as polypropylene, and a sheath of VAL or EVAL, to form relatively stable and self-sustaining air-permeable, bonded rods which will function effectively as smoke filters, and yet, readily disintegrate when subjected to environmental conditions, is unexpected.
Bicomponent fibers of this nature, produced by conventional "melt blown" fiber spinning techniques, can be attenuated during extrusion to produce ultrafine fibers. Although cellulose acetate fibers on the order of about 11 microns are known, as indicated above, the smallest currently available commercial cellulose acetate fibers are generally about 13 microns or more in diameter. With the instant inventive concepts, bicomponent fibers of 10 microns and less, down to 5 and even about 1 micron, can be produced and incorporated into a tobacco smoke filter rod.
The sheath of CA, EVA, VAL, or EVAL polymer not only provides a resultant tobacco smoke filter with the commercially desirable taste properties demanded by the smoking public, but a tow or web comprising such fibers has the excellent bonding properties expected of such materials, and such fibers can be processed on suitably adapted commercial high speed filter rod manufacturing equipment commonly in use in the industry. Moreover, when heat-accelerated bonding is used, the core of polypropylene in such bicomponent fibers retains its strength during the heat processing of the tow, minimizing flattening and providing high loft. Also, with a polypropylene (or the like) core, the tendency of fibers made entirely of cellulose acetate to collapse when subjected to hot, moist tobacco smoke ("hot collapse"), resulting in smoke bypass, is obviated.
Bicomponent fibers according to this invention may be formed with a cylindrical core and surrounding sheath, but such materials may also be extruded through a melt blown fiber die that produces a non-round cross-section. For example, known techniques and equipment can be used for the production of trilobal or "Y" shaped fibers. Likewise, fibers of an "X" or other multi-legged extended cross-section fiber shape may be produced. In all such fibers, the sheath polymer should still completely cover the polypropylene core to provide the advantages referred to previously. However, the non-round cross-section is particularly advantageous in providing increased surface area for filtration purposes in the ultimate product.
Further, the production of fibers having non-round cross-section and, thus, increased surface area, also improves the effectiveness of the air used to attenuate the fibers in the melt blowing process, producing a higher loft in the resultant web. This is an important factor in that, with a melt blown product, crimp is not produced. Non-round cross-sections generally result in a reduction in the quantity of air required in the processing of the bicomponent fibers which further reduces the manufacturing cost, not only by reducing the cost of providing the compressed air, but also by minimizing the cost of dissipating the air when it has served its purpose.
With the use of bicomponent fibers according to this invention, particularly fibers with a CA, EVA, VAL or EVAL polymer in the sheath and polypropylene polymer in the core, tobacco smoke filters can be produced using conventional) commercially available equipment at a significant material cost savings, as high as 70%. Moreover, when very fine melt blown fibers are produced, filters with very high filtration efficiencies up to 80-95%, or more, can result at commercially acceptable pressure drops and at substantially less cost than prior art high filtration filters. Effectively, the filtration efficiency of tobacco smoke filters made according to this invention is at least comparable to prior art filters at a significant cost reduction resulting from the substitution of a lower cost core material for a major part of the fiber. Examples of filters made with various fiber compositions of this invention and related filter performance and cost values are summarized in Tables 1, 2, and 3, discussed hereinafter.
The use of bicomponent fibers in the production of tobacco smoke filters according to this invention in which the sheath comprises VAL or EVAL has the further advantage of improved biodegradability. Except for the conventional filter element, the remaining components of a filtered cigarette disintegrate relatively rapidly under normal environmental conditions, leaving little residue to mar the environment or take up valuable space in waste landfills. However, the highly crimped, bonded cellulose acetate filter elements commonly used in commercially available filtered cigarettes are difficult to destroy, resulting in unsightly and long-lasting, environmentally undesirable litter. VAL and EVAL copolymers readily soften or dissolve in the presence of water. Therefore, the bonded contact points forming tobacco smoke filters according to this invention, wherein the relatively self-sustaining, smoke-pervious filter element is formed by bonding bicomponent sheath-core fibers with a sheath of VAL or EVAL, will break down under normal environmental conditions, leaving behind nothing more than a multiplicity of almost unnoticeable, very fine fibers. Thus, while filter elements formed of such materials can withstand the relatively small quantities of moisture to which they are subjected for a short time during smoking, the bonded contact points will quickly disintegrate along with the remaining portions of the filtered cigarette after use, producing little environmentally undesirable residue. Even using a major proportion of such bicomponent fibers in the production of tobacco smoke filters in combination with other fiber materials, will result in a more readily biodegradable product.
While tobacco smoke filters formed entirely of bicomponent fibers such as described herein are unique and commercially desirable, such bicomponent fibers may be integrated with minor proportions of other polymeric fibers, including cellulose acetate homopolymer fibers, for special applications. However, the maximum cost advantages resulting from this invention are realized by the production of tobacco smoke filters formed entirely of the bicomponent melt blown fibers disclosed herein.
Various properties of such filters may be enhanced by the addition of granular solid or liquid additives. For example, fine activated charcoal particles may be added to a web or roving of such bicomponent fibers before gathering same into a filter rod to provide gas phase filtration characteristics in the resulting filter element as is commonly known by persons familiar with the art. Since conventional cellulose acetate plasticizers tend to "blind" or deactivate activated charcoal, the instant bicomponent fibers provide higher gas phase filtration efficiency due to the absence or reduced amount of plasticizer required. Therefore, a more effective filter can be provided at the same level of charcoal addition, or a lower cost filter will result at the same efficiency.
Likewise, liquid flavor-modifying materials or flavorants may be sprayed onto the fiber to modify or improve the flavor of smoke passing through a filter element made from such materials. For example, menthol is commonly added to tobacco and/or to filter materials in order to produce mentholated cigarettes. However, such materials are commonly absorbed by cellulose acetate fiber, reducing their effectiveness. Since the polypropylene core is non-absorbing and the sheath polymers have little or no absorption; with the instant bicomponent fibers, reduction of the amount of added flavorant necessary to achieve a desired taste effect is possible.
While the instant inventive concepts are useful in the production of bicomponent fibers comprising a CA, EVA, VAL or EVAL polymer sheath and a thermoplastic polymer core that may have utility in any application where fibers formed entirely of cellulose acetate (or, for bondability), have been used heretofore, the principal use that matter, any fiber requiring high strength and presently contemplated for such fibers is in the production of tobacco smoke filters. Likewise, while the tobacco smoke filters of this invention may be associated with cigarettes, cigars, or pipes, the primary commercial application of such filters relates to the use of filters for cigarettes. Therefore, these products will be described herein in detail as exemplary of the broader applications for this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention, as well as other objects, features and advantages thereof, will become apparent upon consideration of the detailed description herein, in connection with the accompanying drawings wherein:
FIG. 1 is an enlarged perspective view of one form of a "sheath-core" bicomponent fiber according to the instant invention;
FIG. 2 is an enlarged end elevation view of a trilobal or "Y" shaped bicomponent fiber according to this invention;
FIG. 3 is a similar view of an "X" or cross-shaped embodiment of the bicomponent fiber of this invention;
FIG. 4 is a schematic view of one form of a process line for producing tobacco smoke filter rods from the bicomponent fibers of this invention;
FIG. 5 is an enlarged schematic view of the sheath-core melt blown die portion of the processing line of FIG. 4;
FIG. 6 is an enlarged perspective view of a tobacco smoke filter rod produced from bicomponent fibers according to the instant invention concepts;
FIG. 7 is an enlarged perspective view of a cigarette including a filter element according to this invention; and
FIG. 8 is a graph showing the effect of plasticizer on flow characteristics of cellulose acetate resins.
DETAILED DESCRIPTION OF THE INVENTION
The instant inventive concepts are embodied in a bicomponent, sheath-core, melt blown fiber where the core is a low cost, high strength, thermoplastic polymer, preferably polypropylene, and the sheath is preferably cellulose acetate, ethylene-vinyl acetate copolymer, polyvinyl alcohol, or ethylene-vinyl alcohol copolymer, and tobacco smoke filters made therefrom.
The preferred cellulose acetate is cellulose acetate resin in chip form which has been compounded with a standard plasticizer such as triacetin. In order to obtain increasingly smaller melt blown, bicomponent fibers, the cellulose acetate resin must be more highly plasticized to lower its viscosity as is illustrated in FIG. 8. However, the polypropylene core provides structural strength to the fine fibers to assure processability into tobacco smoke filters. Also, with the use of a cellulose acetate resin properly compounded with plasticizer, it is not necessary to further add plasticizer during the manufacture of the bicomponent fiber or in the tobacco filter making process when heat-bonding techniques are applied. Preferably, the cellulose acetate resin will be at about the same acetylation level as the solvent spun cellulose acetate currently used for the commercial production of tobacco smoke filters, although significant variation is possible without major impact on the ultimate product.
When cellulose acetate is used for the sheath material, the preferred plasticizer is an acetic acid ester such as glycerol triacetate ("triacetin") or triethylene glycol diacetate; however, any plasticizer of cellulose acetate may be employed. Because the polypropylene core does not absorb the plasticizer, high quantities of plasticizer are retained on the surface of the bicomponent polymeric fibers which allows the fibers to be bonded solely with the addition of heat during the rod-forming processing. The surface plasticizer also contributes to the favorable taste impact of the fibers on the tobacco smoke. The lack of plasticizer absorption by the polypropylene core also allows the fibers to be stored in the form of fiber tow, web, or roving for a long period of time and subsequently processed into a filter rod using heat-bonding techniques.
Alternate sheath materials to cellulose acetate which have been found to provide good processability and bonding characteristics with acceptable impact on tobacco smoke taste include those polymers containing acetic acid esters and/or an abundance of hydroxyl groups. Polymers in this category include all polymers made by copolymerization of vinyl acetate and one or more other monomers, e.g., ethylene or propylene, preferably ethylene-vinyl acetate copolymers (EVA), as well as the totally or partially hydrolyzed products of the above, preferably polyvinyl alcohol (VAL) usually containing residual acetate groups and ethylene-vinyl alcohol copolymer (EVAL).
Low molecular weight resins are required to produce small diameter bicomponent fibers and in some cases plasticizer may be added to lower viscosity in a relationship similar to that illustrated for plasticized cellulose acetate in FIG. 8. The following examples A and B illustrate the effect of polymer molecular weight on fiber size capability of an EVA/polypropylene bicomponent melt blown fiber and the relationship between the molecular weight of the EVA polymer and its melt viscosity on the resulting fiber size.
______________________________________ Example A Example B______________________________________Sheath Polymer EVA EVAMolecular Weight (MW) 22,450 30,600Melt Flow Rate, g/m 550 115(ASTM 1238 -125° C./0:325 Kg)Melt Viscosity, cps 325 660at 250° F.Weight, % 30 30Core Polymer Polypropylene PolypropyleneMolecular Weight (MW) 88,400 88,400Melt Flow Rate 550 550Measured Fiber SizeAverage size in microns 6.7 10.9______________________________________
The melt viscosity can be modified by changing molecular weights through the polymerization process. Also, the blends of copolymers can be adjusted. For example, although the EVA referred to in the examples herein utilized a 20/80 weight % vinylacetate/ethylene blend, this ratio can be varied independently. Further, as mentioned, the use of a plasticizer specific to the sheath polymer at different levels will also modify the melt viscosity. Those skilled in this art can readily select the appropriate parameters to produce a fiber of the desired size and properties within the scope of the instant inventive concepts.
The method of manufacturing the specific polymers used in the production of the bicomponent fibers is not part of the instant invention. Processes for making these polymers are well known in the art and most commercially available CA, EVA, VAL, or EVAL materials can be used. While it is not necessary to utilize sheath and core materials having the same melt viscosity, as each polymer is prepared separately in the bicomponent melt blown fiber process, it may be desirable to select a core material, e.g. polypropylene, of a melt index similar to the melt index of the sheath polymer, or, if necessary, to modify the viscosity of the sheath polymer to be similar to that of the core material to insure compatibility in the melt extrusion process through the bicomponent die. Providing sheath-core components with compatible melt indices is not a significant problem to those skilled in this art with commercially available thermoplastic polymers and additives.
While polypropylene is the preferred core material, other thermoplastic polymeric materials, including polyamides such as nylon 6 and nylon 66, and polyesters such as polyethylene terephthalate, can be used. However, the polyolefins, including both low density and high density polyethylene, are preferred for cost reasons, and polypropylene has been found to be particularly useful in providing the strength needed for production of very fine fibers using melt blown techniques.
While other sheath or core materials may be utilized within the broadest concepts of the instant invention as defined herein and in the appended claims, the preferred sheath is formed either from a plasticized CA, EVA, VAL or EVAL, and the preferred core is formed from polypropylene. Therefore, reference will be made primarily to those materials hereafter.
A bicomponent fiber according to the instant inventive concepts is schematically shown at 10 in FIG. 1. Of course, the size of the fiber and the relative proportion of the sheath-core portions thereof have been greatly exaggerated for illustrative clarity. The fiber 10 is preferably comprised of a CA, EVA, VAL, or EVAL sheath 12 and a polypropylene core 14. The core material comprises at least 50%, and preferably about 80% or more by weight of the overall fiber content.
The bicomponent fiber shown in FIG. 1 is round in cross section. However, by selecting openings in the sheath-core extrusion die of an appropriate shape, the fiber may be provided with a non-round cross section to increase its surface area for improved filtration of the ultimate tobacco smoke filter, and to enhance the use of air when melt blowing techniques are used for attenuation of the fiber. A trilobal or "Y" shaped fiber 10a is shown in FIG. 2 comprising a sheath 12a and a core 14a. Similarly, a cross or "X" shaped bicomponent fiber as seen at 10b in FIG. 3, comprising a sheath 12b and a core 14b, is illustrative of many multi-legged fiber core sections possible. It will be seen that, in each instance, the sheath completely covers the core material. Failure to enclose any major portion of the core material minimizes or obviates many of the advantages of the instant invention discussed herein.
FIGS. 4 and 5 schematically illustrate preferred equipment used in making a bicomponent fiber according to the instant inventive concepts, and processing the same into filter rods that can be subsequently subdivided to form filter elements used in the production of filtered cigarettes or the like. The overall processing line is designated generally by the reference numeral 20 in FIG. 4. In the embodiment shown, the bicomponent fibers themselves are made in-line with the equipment utilized to process the fibers into tobacco smoke filter rods. Such an arrangement is practical with the melt blown techniques of this invention because of the small footprint of the equipment required for this procedure. While the in-line processing is unique and has obvious commercial advantages, it is to be understood that, in their broadest sense, the instant inventive concepts are not so limited, and bicomponent fibers according to this invention may be separately made and stored for extended periods of time.
Whether in-line or separate, the bicomponent fibers themselves can be made using standard fiber spinning techniques for forming bicomponent filaments as seen, for example, in Powell U.S. Pat. Nos. 3,176,345 or 3,192,562 or Hills U.S. Pat. No. 4,406,850. The subject matter of each of the foregoing patents is incorporated herein in its entirety by reference for exemplary information regarding common techniques for the production of bicomponent fibers including sheath-core fibers. Likewise, methods and apparatus for melt blowing of fibrous materials, whether they are bicomponent or not, are well known. For example, reference is made to Buntin U.S. Pat. Nos. 3,615,995 and 3,595,245, Schwarz U.S. Pat. Nos. 4,380,570 and 4,731,215, and Lohkamp et al, U.S. Pat. No. 3,825,379, the entire subject matter of each of which is incorporated herein by reference for further background in this technology. The foregoing references are to be considered to be illustrative of well known techniques and apparatus for forming of bicomponent fibers and melt blowing for attenuation that may be used according to the instant inventive concepts, and are not to be interpreted as limiting thereon.
In any event, one form of a sheath-core melt blown die is shown enlarged in FIG. 5 at 25. Molten sheath-forming polymer 26, and molten core-forming polymer 28 are fed into the die 25 and extruded therefrom through a pack of polymer distribution plates shown schematically at 30 which may be of the type shown in the aforementioned Hills U.S. Pat. No. 4,406,850.
As previously discussed, bicomponent fibers need not be melt blown in accordance with the broadest concept of this invention. Alternatively, the fibers could be collected in web form using techniques commonly referred to as "spun bonded" or "spun laced" (not shown). However, using melt blown techniques which extrude the molten fibers into a high velocity air stream such as provided through an air plate shown schematically at 32, attenuates and solidifies the fibers, enabling the production of ultrafine bicomponent fibers on the order of 10 microns or less. Such treatment produces a randomly dispersed entangled web or roving 34 (see FIG. 4) of the bicomponent fibers which is a form suitable for immediate processing without subsequent attenuation or crimp-inducing processing.
A layer of a particulate additive such as granular activated charcoal may be deposited on the tow 34 as shown schematically at 36. Alternatively, a liquid additive such as a flavorant or the like may be sprayed onto the tow 34 (not shown). A screen covered vacuum collection drum as shown schematically at 38 or similar device is used to separate the fibrous web or roving 34 from entrained air to facilitate further processing.
The remainder of the processing line seen in FIG. 4 is conventional, as shown and described in further detail in patents issued to the inventor hereof, Richard M. Berger, although modifications may be required to individual elements thereof in order to facilitate heat-bonding of the fibers. Exemplary Berger patents include U.S. Pat. Nos. 4,869,275, 4,355,995, and 3,637,447, the subject matter of each of which is incorporated herein in its entirety by reference. Such heat-bonding techniques are illustrated in FIG. 4 where a web or roving 34 of bicomponent fibers are produced using melt blowing techniques and continually passed through a conventional air jet at 40, bloomed as seen at 42 and gathered into a rod shape in a heated air or steam die 44 where the sheath of plasticized cellulose acetate or other suitable sheath polymer is activated to render the same bondable. Other heating techniques, such as dielectric heating, may be useful or desirable with selected sheath materials. In any event, the resultant material is cooled by air or the like in the die 46 to produce a relatively stable and self-sustaining rod-like fiber structure 48. The fiber rod 48 can be wrapped with paper or the like 50 (plugwrap) in a conventional manner to produce a continuously wrapped fiber rod 52. The continuously produced fiber rod 52, whether wrapped or not, may be passed through a standard cutter head 54 at which point it is cut into preselected tobacco filter rod lengths and deposited into an automatic packaging machine.
By subdividing the resultant filter rods in any well known manner, a multiplicity of discrete tobacco filter elements or plugs according to this invention are formed, one of which is illustrated schematically in FIG. 6 at 60. Each filter element 60 comprises an elongated air-permeable body of tobacco smoke filter material 62 encased in plugwrap 64. The filter material 62, according to this invention is comprised of a multiplicity of bicomponent fibers such as shown in 10 in FIG. 1, bonded at their contact points to define a tortuous interstitial path for passage of tobacco smoke in use.
It is to be understood that the filter rods produced in accordance with this invention need not be of uniform construction throughout as illustrated herein, but could have interior pockets, exterior grooves, crimped portions or other modifications as shown in the aforementioned prior patents to Berger, or others, without departing from the instant inventive concepts.
Portions of a conventional filtered cigarette are illustrated schematically at 65 in FIG. 7 as comprising a tobacco rod 66 covered by a conventional cigarette paper 68 and secured to a filter means comprising a discrete filter element 70, such as would result from further subdividing a filter rod on conventional cigarette manufacturing equipment (not shown). The filter element 70 comprises a body of filtering material 72 over-wrapped by plugwrap 74 and secured to the tobacco rod in a conventional manner as by standard tipping wrap 76.
The examples set forth in Tables 1, 2, and 3 provide further information regarding the instant inventive concepts. It is to be understood, however, that these examples are illustrative and the various materials and processing parameters may be varied within the skill of the art without departing from the instant inventive concepts.
TABLE 1______________________________________Example No. 1 2 3 4 5 6______________________________________Sheath Con- EVA Con- EVA VAL CAPolymer trol* trol*Core Same PP Same PP PP PPPolymerSheath/Core N/A 30/70 N/A 30/70 40/60 30/70RatioFilter 0.150 0.132 0.171 0.136 0.167 0.210Weight, g**Pressure 2.8 2.7 4.5 4.5 4.4 3.8Drop, incheswaterTotal 57 63 69 74 76 67ParticulateMatterRetention, %______________________________________ *Conventional Cellulose Acetate (CA) Fiber **27 mm Filter EVA: Ethylenevinyl acetate copolymer VAL: Polyvinyl alcohol PP: Polypropylene
TABLE 2______________________________________Example No. 7 8 9 10______________________________________Sheath Polymer Control* EVA EVA VALCore Polymer Same PP PP PPSheath/Core Ratio N/A 30/70 30/70 40/60Activated Charcoal, g** 0.066 0.050 0.050 0.033Fiber Weight, g** 0.127 0.095 0.095 0.145Pressure Drop, 4.2 4.2 3.4 3.4inches waterTotal Particulate 63 76 71 73Matter Retention, %Vapor Phase Retention, % 52 77 78 50______________________________________ *Conventional Cellulose Acetate Fiber **20 mm Filter EVA: Ethylenevinyl acetate copolymer VAL: Polyvinyl alcohol PP: Polypropylene
TABLE 3______________________________________Selective Comparison of Raw Material CostsExample Price Fiber Weight CostNo. Material $/lb % g/120 mm $/1000______________________________________1 (Control) Cellulose 1.63 100 0.667 2.39 Acetate Fiber2 PP 0.46 70 0.412 0.42 EVA 0.74 30 0.176 0.29 Total 100 0.588 0.713 (Control) Cellulose 1.63 100 0.762 2.74 Acetate Fiber4 PP 0.46 70 0.423 0.43 EVA 0.74 30 0.182 0.30 Total 100 0.605 0.735 PP 0.46 60 0.447 0.453 VAL 1.75 40 0.298 1.149 Total 100 0.745 1.6026 PP 0.46 70 0.63 0.638 CA Resin 1.86 30 0.27 1.106 Total 100 0.90 1.7447 (Control) Cellulose 1.63 65.5 0.76 2.729 Acetate Fiber Activated 1.74 34.5 0.40 1.533 Charcoal Total 100 1.16 4.2628/9 PP 0.46 46.0 0.40 0.405 EVA 0.74 19.5 0.17 0.277 Activated 1.74 34.5 0.30 1.150 Charcoal Total 100 0.87 1.83210 PP 0.46 48.6 0.52 0.527 VAL 1.75 32.7 0.35 1.349 Activated 1.74 18.7 0.20 0.767 Charcoal Total 100 1.07 2.643______________________________________
By comparison of the controls in Table 1 with filter elements formed according to this invention, it will be seen that improved filtration is possible with commercially acceptable pressure drops and reduced filter weight. More importantly, as seen from Table 3, the raw material costs are reduced dramatically, by as much as 70%. Similarly, in Table 2, when activated charcoal is added to the filter element, both solid and vapor phase filtration are improved, notwithstanding the significantly reduced raw material costs evidenced in Table 3. Cost and functional advantages comparable to those shown with VAL are expected with a sheath of EVAL.
While preferred embodiments and processing parameters have been shown and described, it is to be understood that these examples are illustrative and can be varied within the skill of the art without departing from the instant inventive concepts.
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Sheath-core bicomponent fibers comprising a core of a low-cost, high strength, thermoplastic material, preferably polypropylene, completely covered with a sheath formed preferably of plasticized cellulose acetate, ethylene-vinyl acetate copolymer, polyvinyl alcohol or ethylene-vinyl alcohol copolymer, are produced, preferably melt blown to an average diameter of 10 microns or less, and formed into tobacco smoke filters. The resultant filters retain the desirable taste properties and processing capabilities of conventional cellulose acetate filter elements, but are substantially less expensive. Because the core material is non-absorbent, less plasticizer or additive is required for comparable properties, and a web, roving or filter made of such materials has a longer shelf-life. The very fine fibers can be formed of various cross-sections, providing higher surface area and requiring less air in the melt blowing and manufacturing processes. With sheaths of polyvinyl alcohol or ethylene-vinyl alcohol copolymer, the filter element readily disintegrates when subjected to environmental conditions leaving behind only a multiplicity of very fine, substantially unnoticeable, fibers as residue.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 60/406,245, filed on Aug. 27, 2002, all of which is incorporated by reference as if completely written herein.
TECHNICAL FIELD
[0002] The present invention relates to the field of hair care products, in particular, to a heat activated form fitting hair cap capable, among other uses, of promoting the retention of hair care products upon the hair.
BACKGROUND OF THE INVENTION
[0003] Hair care is in excess of a $100 billion (U.S.) dollar industry. A large percentage of this total is spent on hair care products, including hair conditioners, gels, oil, and other hair treatments. Since the earliest days of such treatments, consumers have faced an ongoing problem, the need to retain these products on their hair while the treatments work on the hair. Many unsatisfactory solutions have been attempted. The simplest of these is to apply some type of cap or head covering over the treated hair. Ideally, this head covering needs to be made of some non-absorbent material in order not to absorb the hair treatment away from the hair, thus defeating the purposes of the treatment. Plastic caps, often shower caps, are the prototypical hair covering in this class, but these caps have numerous drawbacks. They are loose fitting and can be easily dislodged by wind or touch. They are bulky and unsightly. They fit loosely, and therefore do not assist in distributing the hair treatment among the hair shafts. Lastly, their loose fit promotes the pooling of hair treatment products which are likely to then run out from under the cap, damaging or putting unsightly marks on clothing.
[0004] The art has developed various means of retaining hair care products within a cap-like device. For example, U.S. Pat. No. 5,265,278 to Watanabe utilizes a loose, bouffant style cap that contains a ceramic paper liner within layers of plastic material. The ceramic paper layer is designed to retain heat. Also, U.S. Pat. No. 5,850,636 to Reuven teaches a loose, bouffant style cap that contains a gel layer held in a space between two layers of plastic.
[0005] These devices share several common shortcomings that are addressed by the instant invention. First, the caps are loose, bouffant style caps that are not form fitted to the head. As a result, they are loose when worn, and are susceptible to being disturbed by wind or touch. Secondly, as they are not form fitted to the head, they are incapable of exerting any compressive force upon the hair. As a result, they are incapable of exerting any hydraulic pressure on hair care products that may have been applied to the hair. Further, hair care products would tend to pool along the elastic band line of these caps, and would not tend to be evenly distributed around the individual hair shafts. Additionally, application of one of the prior art caps will inevitably trap air beneath it, potentially interfering with the utility of various hair care products that may have been applied underneath.
[0006] Accordingly, the art has needed a means of providing a form fitted cap that, among other utilities, retains hair products and excludes air, and that is both comfortable and easy to apply. The instant invention provides for these needs.
SUMMARY OF INVENTION
[0007] In its most general configuration, the present invention advances the state of the art with a variety of new capabilities and overcomes many of the shortcomings of prior devices in new and novel ways. In its most general sense, the present invention overcomes the shortcomings and limitations of the prior art in any of a number of generally effective configurations. The instant invention demonstrates such capabilities and overcomes many of the shortcomings of prior methods in new and novel ways.
[0008] In one of the simplest configurations, the heat activated form fitting hair cap of the instant invention is utilized for substantially sealing an area of a body, such as the scalp, from the environment. The heat activated form fitting hair cap includes a heat activated shrinkable body having at least one layer of material generally sized to receive a portion of a human head. The cap is generally bounded substantially by a distal edge. Once the cap is placed on the head, the heat activated shrinkable body may be activated by exposure to a heat source, such as by way of example and not limitation, a hair dryer. Due to its material properties, the heat activated shrinkable body shrinks, thereby reducing the open interior volume, forming a tight fit around the area of the body that is to be enclosed.
[0009] The cap may also include at least one cap retention means located substantially near the distal edge for ensuring that the distal edge substantially conforms to the head prior to activation and that allows the cap to be adjusted to fit a wide range of head shapes and sizes prior to activation. The at least one cap retention means may include at least one elasticized band, at least one drawstring, or a plurality of ties. To further increase the adjustability of the cap, another embodiment may include a plurality of tear away stress lines that are substantially concentric with the distal edge, thereby imparting adjustability of the volume. In this embodiment, the user may tear away portions of the cap along any of the plurality of tear away stress lines, either before or after shrinking the cap, thereby achieving a custom fit.
[0010] One primary illustrative use for the cap is for applying hair/scalp care products to the head. As such, the material of the heat activated shrinkable body may be substantially moisture resistant and/or substantially gas impermeable to aid in the hair/scalp treatment. For example, a user may seek to infuse their hair and scalp with a conditioning treatment. The cap forces the treatment fluid deep into the hair and to the scalp while substantially isolating the treatment area from the surrounding environment.
[0011] The cap reduces the amount of heat transfer from the head to the surrounding atmosphere, thus increasing the effectiveness of the treatment. Variations of the cap may incorporate aspects to further retain the heat that is generally lost through the head, such as employing multiple layers of cap material. Such multilayer embodiments may include air spaces and/or infill material between the multiple layers to further reduce heat transfer.
[0012] The heat activated form fitting hair cap may incorporate virtually any thermally activated shrinking material. The simplest embodiments incorporate shrink films made essentially of PVC, polyolefin, polyethylene, polyester, nylon, or saran; however one with skill in the art can recognize a number of alternative materials. The activation temperature, thickness, and shrink rate of the material may be adjusted to the particular application.
[0013] Additional variations of the heat activated form fitting hair cap may further include methods of introducing treatment fluids directly from the cap, such as including at least one treatment pouch on the inside of the cap housing at least one treatment fluid. While the description herein focuses on the use of the heat activated form fitting hair cap for applying treatment to the hair/scalp, it may be equally effective in a number of other applications. Examples of such applications may include situations wherein it is desirable to keep the hair or scalp dry to reduce the chances of hypothermia, such as during swimming, watersports, or virtually any outdoor activity. Additionally, the cap may be used to protect the wearer from undesirable gripping of the hair or scalp during sporting activities such as wrestling. Further, the cap may be used as a hygienic measure to retain loose hair as may be desired in the medical professions and in the food service industry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Without limiting the scope of the present invention as claimed below and referring now to the drawings and figures:
[0015] [0015]FIG. 1 shows a heat activated form fitting hair cap of the present invention, in the shrunken state, on a human head in side elevation view, not to scale;
[0016] [0016]FIG. 2 shows the heat activated form fitting hair cap of FIG. 1 in front elevation view, not to scale;
[0017] [0017]FIG. 3 shows the heat activated form fitting hair cap of FIG. 1 in side elevation view, not to scale;
[0018] [0018]FIG. 4 shows a variation of the heat activated form fitting hair cap of FIG. 1 in side elevation view, not to scale;
[0019] [0019]FIG. 5 shows a variation of the heat activated form fitting hair cap of FIG. 1 in side elevation view, not to scale;
[0020] [0020]FIG. 6 shows a variation of the heat activated form fitting hair cap of FIG. 1 in bottom plan view, not to scale;
[0021] [0021]FIG. 7 shows a variation of the heat activated form fitting hair cap of FIG. 1 in side elevation view, not to scale;
[0022] [0022]FIG. 8 shows a variation of the heat activated form fitting hair cap of FIG. 1 in side elevation view, not to scale; and
[0023] [0023]FIG. 9 shows a variation of the heat activated form fitting hair cap of FIG. 1 in cross sectional view, not to scale.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The heat activated form fitting hair cap of the instant invention enables a significant advance in the state of the art. The preferred embodiments of the apparatus accomplish this by new and novel arrangements of elements and methods that are configured in unique and novel ways and which demonstrate previously unavailable but preferred and desirable capabilities.
[0025] The detailed description set forth below in connection with the drawings is intended merely as a description of the presently preferred embodiments of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the designs, functions, means, and methods of implementing the invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and features may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.
[0026] In its simplest form the heat activated form fitting hair cap 50 of the instant invention is utilized for substantially sealing an area of a body, generally an area having hair, such as the scalp, from the environment. The heat activated form fitting hair cap 50 includes a heat activated shrinkable body 100 having at least one layer of material wherein the body 100 is formed to define an open interior volume that is generally sized to receive a portion of a human head, as shown in FIG. 1. Each of the at least one layer of material has a distal edge 116 , an inner surface 112 , and an outer surface 114 , as shown in FIG. 2 and FIG. 3. The open interior volume is generally bounded substantially by the distal edge 116 . Furthermore, once the cap 50 is placed on the head, the heat activated shrinkable body 100 may be activated by exposure to a heat source producing a first predetermined activation temperature on the outer surface 114 of the heat activated shrinkable body 100 . Due to the material properties of the heat activated shrinkable body 100 ,it shrinks, thereby reducing the open interior volume, when exposed to the first predetermined activation temperature, forming a tight fit around the area of the body that is to be enclosed, as shown in FIG. 1.
[0027] The heat activated form fitting hair cap 50 may also include at least one cap retention means 200 located substantially near the distal edge 116 and thereby ensuring the distal edge 116 substantially conforms to the head prior to activation. The at least one cap retention means 200 allows the cap 50 to be adjusted to fit a wide range of head shapes and sizes prior to activation. The at least one cap retention means 200 may include a number of variations. For instance, the at least one cap retention means 200 may include at least one elasticized band 210 , as seen in FIG. 4. In an alternative embodiment seen in FIG. 5, the at least one cap retention means 200 may include at least one drawstring 220 . Furthermore, the at least one cap retention means 200 may include a plurality of ties 230 , as illustrated in FIG. 7. To further increase the adjustability of the cap 50 , another embodiment may include a plurality of tear away stress lines 140 , in the at least one layer of material, that are substantially concentric with the distal edge 116 thereby imparting adjustability of the volume, as seen in FIG. 8. In this embodiment, the user may tear away portions of the cap 50 along any of the plurality of tear away stress lines 140 , either before or after shrinking the cap 50 to conform to the head, thereby achieving a custom fit.
[0028] While the heat activated form fitting hair cap 50 of the instant invention has a number of uses, one primary illustrative use is for applying hair/scalp care products to the head. As such, the material of the heat activated shrinkable body 100 may be substantially moisture resistant and/or substantially gas impermeable to aide in the hair/scalp treatment. For example, in just one application, a user may seek to infuse the hair and scalp with a conditioning treatment. As such, the hair would generally be wetted and the conditioning treatment applied. Traditionally, a towel may be wrapped around the head in an effort to prevent the treatment from running out of the hair and into the user's eyes, or into other undesirable areas. Furthermore, since the hair and treatment is essentially exposed to the surrounding atmosphere it often quickly dries, thereby reducing the effectiveness of the treatment. It is widely known that creating a barrier between the treatment area and the surrounding environment increases the effectiveness of the treatment. The cap 50 of the instant invention forces the treatment fluid deep into the hair and to the scalp while substantially isolating the treatment area from the surrounding environment. Embodiments that include moisture barriers and gas barriers greatly slow the evaporation of the hair's moisture as well as the treatment fluid.
[0029] Furthermore, the cap 50 reduces the amount of heat transfer from the head to the surrounding atmosphere. This increased temperature in the treatment area further increases the effectiveness of the treatment. Variations of the cap 50 may incorporate aspects to further retain the heat that is generally lost through the head. For instance, the cap 50 may incorporate multiple layers of material. The embodiment illustrated in FIG. 9 shows a cap 50 wherein the at least one layer of material includes a first layer 110 and a second layer 120 joined at least in part along the distal edge 116 of each layer. One with skill in the art will appreciate that the multiple layers may be joined in any number of ways and at any number of locations. Such multilayer embodiments may include air spaces and/or infill material between the multiple layers to further reduce heat transfer.
[0030] The heat activated form fitting hair cap 50 may incorporate virtually any thermally activated shrinking material. The simplest embodiments incorporate shrink films made essentially of PVC, polyolefin, polyethylene, polyester, nylon, or saran; however one with skill in the art can recognize a number of alternative materials. In some embodiments, those directed toward home (non-professional) use, the materials of construction are selected such that the first predetermined activation temperature can be applied with a conventional hair dryer. As such, in this embodiment, the first predetermined activation temperature is between approximately 100 degrees Fahrenheit and 140 degrees Fahrenheit. Further, the material thickness of the heat activated shrinkable body 100 may vary greatly depending on the particular application. However, in the home (non-professional) use embodiments, the material thickness is between approximately 0.25 mil and approximately 8 mil. Additionally, the shrinkage rate of the heat activated form fitting hair cap 50 is dependent upon the material and the material thickness. The shrinkage rate for most home (non-professional) embodiments of the heat activated form fitting cap is between approximately 20 percent and approximately 85 percent. This range allows the creation of a cap 50 that may be effectively applied to a wide range of head sizes.
[0031] Additional variations of the heat activated form fitting hair cap 50 may further include methods of introducing treatment fluids directly from the cap 50 . One such variation, seen in FIG. 6, may include at least one treatment pouch 130 housing at least one treatment fluid. The at least one treatment pouch 130 may be constructed of the same heat activated shrinkable material as the body 100 . Further, the at least one treatment pouch 130 may include at least one egress point 132 that allows the discharge of the at least one treatment fluid when exposed to a predetermined pressure. Such predetermined pressure may be created by the shrinkage of the at least one treatment pouch 130 , by exertion of external forces, or by expansion of the at least one treatment fluid. In a further variation, the at least one treatment pouch 130 may be formed of a material having a second predetermined activation temperature that is different from the first predetermined activation temperature thereby permitting release of the at least one treatment fluid prior to reaching the first predetermined activation temperature, or retarding the release until after the first predetermined activation temperature has been exceeded.
[0032] While the description herein focuses on the use of the heat activated form fitting hair cap 50 for applying treatment to the hair/scalp, it may be equally effective in a number of other applications. Examples of such applications may include situations wherein it is desirable to keep the hair or scalp dry to reduce the chances of hypothermia, such as during swimming, water sports, or virtually any outdoor activity. Additionally, the cap may be used to protect the wearer from undesirable gripping of the hair or scalp during sporting activities such as wrestling. Further, the cap may be used as a hygienic measure to retain loose hair as may be desired in the medical professions and in the food service industry.
[0033] Numerous alterations, modifications, and variations of the preferred embodiments disclosed herein will be apparent to those skilled in the art and they are all anticipated and contemplated to be within the spirit and scope of the instant invention. For example, although specific embodiments have been described in detail, those with skill in the art will understand that the preceding embodiments and variations can be modified to incorporate various types of substitute and or additional or alternative materials, relative arrangement of elements, and dimensional configurations. Accordingly, even though only few variations of the present invention are described herein, it is to be understood that the practice of such additional modifications and variations and the equivalents thereof, are within the spirit and scope of the invention as defined in the following claims.
[0034] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or acts for performing the functions in combination with other claimed elements as specifically claimed.
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A heat activated form fitting hair cap to protect the hair and to retain hair products in close proximity to the hair. A loosely fitted hair cap is made from a heat activated shrink-wrap material that may be substantially moisture and gas resistant. The cap is placed over the hair, and optionally, secured with a variety of retention means such as elastic, drawstrings, or ties. Upon application of heat, normally from a hair dryer, at or slightly above the activation temperature of the plastic, the shrink-wrap material is activated and shrinks snugly about the hair. This effectuates both a protection of the hair, and a tendency to trap and retain hair treatment products that might have been applied to the hair. Options include pouches containing releasable hair treatment products on the inside of the cap and tear away areas to customize the size of the cap to the wearer.
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FIELD OF THE INVENTION
This invention is related to improvements in concrete floor sockets of the type facilitating a reinforced joint between adjacently cast slabs.
BACKGROUND OF THE INVENTION
In the construction of large concrete slabs for floors and the like, it is customary to first cast a slab of a size capable of being worked by concrete finishers and then cast further slabs in abutment thereto.
After preparing the ground surface, formwork defining the peripheral edges of the slab is erected and reinforcing mesh is positioned within the formwork surround and supported above the ground surface by spacers known as "bar chairs".
In order to maintain the upper surfaces of adjacent slabs in the same plane, steel reinforcing rods known as "dowel bars" are cast into the initial slab with a portion .projecting from the side walls of that slab. When an adjacent slab is poured, the projecting portion of the dowel bar is encapsulated within the adjacent slab to resist relative movement in an upright plane between the edges of adjacent slabs. As some horizontal movement between adjacent slabs is inevitable due to thermal expansion and contraction, the free end of the dowel bar extending from the edge of a slab is coated with oil or grease to prevent adhesion in the subsequently poured adjacent slab. By allowing the dowel bar to slide within one slab during expansion or contraction, edge fractures are thereby avoided.
Dowel bars for a floor slab construction typically comprise 300 mm to 600 mm lengths of 10 to 30 mm diameter round or square section steel bar arranged at about 600 mm intervals along the edge of a previously cast slab. The dowel bars extend into each adjacent slab from 150 mm to 300 mm.
Although the dowel bars are generally effective for their intended purpose, traditional methods employed for positioning the bars in the initial slab edge are far from satisfactory in that not only are they extremely time consuming and therefore costly. They can lead to considerable frustration on the part of those engaged in slab construction.
Typically, it was customary for specialized formwork erectors to erect a timber formwork surround for a slab to be cast and then to drill apertures for the dowel bars at approximately 300 mm to 600 mm intervals. The apertures provide a neat fit to avoid leakage of concrete through these apertures when the slab is cast Another team specialised in positioning the steel reinforcing mesh then set up the necessary reinforcing structure including the steel dowel bars which protrude outwardly from the apertures in the formwork surrounds.
The main problem associated with this technique is that it is practically impossible to position the dowel bars perfectly parallel in both the upright and horizontal planes. Accordingly. after the slab has cured, extreme difficulty is incurred in removal of the formwork (usually a long timber plank) as a consequence of the non parallel array of protruding ends. To avoid loosening the dowel bars cast into the slab and also to avoid damage to the edge of the slab by attempting to lever the formwork away from the slab, it has become customary to cut the formwork between adjacent dowel bars and slide each segment over the protruding portion of the dowel bar.
Apart from being a costly waste of time and materials. this procedure is frustrating and difficult in view of the fact that the formwork extends to the ground surface thus necessitating a hole to be dug into the ground to enable an electric saw to cut all the way through the formwork.
These prior art problems have been addressed in Australian Patent Application No. 21883/95 and U.S. Pat. Nos. 5005331, 5216862 and 5487249, all of which provide a moulded plastics tubular socket of circular cross section having a closed distal end and an open proximal end with an integral or separate mounting flange to permit attachment to slab casting formwork.
While generally effective for their purpose, the dowel bars socket of the above prior art references do not accommodate slab shrinkage in a transverse direction unless the dowel bar has a lesser diameter than the internal diameter of the dowel bar socket.
In many cases this clearance does not create a problem but in certain high specification applications, the clearance between the dowel bar and Its socket, while allowing transverse shrinkage movement, also allows an unacceptable vertical displacement between a previously cast and subsequently cast slab.
Typically, for injection moulded plastics sockets of say, 300 mm in length, it is necessary to form a divergent taper on both the interior and exterior walls from the closed distal end to the open proximal end to enable removal of the moulded socket from the injection moulding die.
Thus, for a 20 mm dowel bar the internal diameter of the socket bore at the distal end may be 20.0 mm to 20.5 mm whereas the inner bore diameter at the open proximal end will be typically of the order of 21.0 mm to 22.5 mm.
Accordingly unless dowel bars are centred in respective sockets they may be capable of shrinkage movement in a lateral direction of up to 2.5 mm and similarly up to 2.5 mm in a vertical direction.
Generally speaking the loose fit of the dowel bars at the proximal end of the sockets means that they are randomly arranged and substantial variations in movement capacity can exist between adjacent dowel bars. This uneven allowance for lateral shrinkage and unacceptable allowance of relative upright movement between adjacent slabs can give rise to cracking of slabs in the region of the dowel bar as they cure and even after curing if substantial movement is permitted between slabs.
SUMMARY OF THE INVENTION
It is an aim of the present invention to overcome or alleviate at least some of the prior art problems associated with dowel bar sockets for concrete slab casting purposes.
According to the invention there is provided a dowel bar socket for concrete slab constructions, said socket comprising: a
hollow elongate body having a closed distal end;
mounting means for attachment of said body to concrete slab formwork;
said socket characterised in that normally upper and lower wall portions of said body are substantially parallel and side wall portions taper divergently from said distal end towards a proximal end of said body.
Suitably said socket includes yieldable locating means associated with an inner wall surface of said body adjacent said proximal end to locate a dowel bar substantially centrally of said side wall portions.
If required said body may comprise an integral member.
Alternatively said body may comprise telescopically engageable members connecting intermediate the distal and proximal ends of the body.
Preferably the body has a closed proximal end.
Suitably the proximal end of the body is closed by a removable and/or pierceable closure member.
If required said mounting means may be integrally formed with a proximal end of said body.
Alternatively the mounting means may comprise a detachable mounting member.
Preferably the mounting member comprises a mounting flange and a hollow socket adapted to receive an open proximal end of said body.
Alternatively the mounting member comprises a mounting flange and a spigot engagable in an open proximal end of said body.
The mounting means suitably comprises at least one reinforcing web.
Preferably at least one reinforcing web includes an aperture to releasably retain a reinforcing member transverse to a longitudinal axis of said body.
BRIEF DESCRIPTION OF DRAWINGS
In order that the invention may be more fully understood and put into practical effect, reference will now be made to preferred embodiments illustrated in the accompanying drawings in which:
FIG. 1 illustrates a perspective view of one form of a socket according to the invention.
FIG. 2 illustrates a part longitudinal cross sectional view of an alternative embodiment of the invention.
FIG. 3 illustrates an end elevation of the embodiment of FIG. 1 with a rectangular cross section dowel bar.
FIG. 4 illustrates an end elevation of the embodiment of FIG. 1 with a circular cross section dowel bar.
FIG. 5 shows a particularly preferred embodiment of the invention.
FIG. 6 shows an end elevational view of the embodiment of FIG. 5.
FIG. 7 shows one embodiment of a detachable mounting means.
FIG. 8 shows another embodiment of a detachable mounting means.
DETAILED DESCRIPTION
In FIG. 1 the socket comprises a hollow rectangular body 1 tapering convergently from a proximal end 2 to a distal end 3 which includes an end wall 4.
At proximal end 2 is a mounting flange 5 having apertures 6 for insertion of fasteners such as nails or clouts (not shown).
Reinforcing webs 7 are provided between the mounting flange 5 and the upper and lower surfaces of the body 1.
A channel shaped recess 8 is provided in the upper and lower walls of body 1, the channel shaped recesses being aligned with apertures 9 in the upper and lower webs 7, the purpose of which apertures and recesses will be described later.
FIG. 2 shows schematically an alternative embodiment of the invention.
In FIG. 2, the socket comprises a proximal end comprising a hollow body portion 10, a mounting flange 11 and reinforcing webs 12 extending between the body portion 10 and flange 11.
A distal body portion 13 comprises a tubular member closed at its distal end 15 and frictionally engageable with proximal body portion 10 to form an elongate hollow cavity within which a dowel bar 16 may be received.
Extending transversely of body portion 10 is a channel shaped recess 17 which is aligned with an aperture 18 in reinforcing web 12. Channel shaped recess 17 defines a region 19 of reduced wall thickness in body 10.
Reinforcing means in the form of steel pegs 20 are transversely located in recesses 17 and apertures 18 to resist upright forces on the socket as a result of differential upright forces between adjacently cast concrete slabs (not shown) with which the socket/dowel bar assembly is associated.
FIG. 3 shows an end elevation of the socket of FIG. 1 in which a square dowel bar 21 is inserted.
Across the proximal end of the interior cavity 22 of body 23 is formed a membrane 24 to form a closure in mounting flange 25. Suitably membrane 24 comprises an integrally formed yieldable wall of reduced thickness in a moulded plastics socket. Alternatively the membrane 24 comprises a yieldable plastics or metal foil or a laminate thereof adhesively attached to mounting flange 25.
FIG. 4 shows a similar-arrangement of FIG. 3 except that a circular cross section dowel bar is inserted in the socket. For the sake of simplicity, the same reference numerals as FIG. 3 have been employed.
As shown in FIGS. 3 and 4, the thin yieldable membrane 24 associated with the mounting flange 25 permits the insertion of either a round or rectangular cross section dowel bar 21 while providing a sealable engagement with the surface of the bar 21 to prevent incursion of concrete during the pouring of an adjacent slab.
As the adjacent slab (not shown) shrinks transversely during curing, at least a limited amount of transverse movement is permitted in the dowel bar 21 without inducing stresses in the concrete surrounding the more recently poured slab which could lead to fracture. As the cavity 22 within the socket body 23 provides a neat fit of dowel bar 21 in an upright direction, relative movement between adjacent concrete slabs in an upright direction due to settling or the like is resisted.
For higher specification slabs, reinforcing means such as transverse steel bars 20 (as shown in FIG. 2), U-shaped loops or the like can be inserted in apertures 18 and cast into the initial slab as further reinforcement against upright movement.
FIG. 5 shows a particularly preferred form of the invention.
In FIG. 5, the socket comprises separate telescopically engagable body portions 30, 31 produced by an injection moulding process. One end of the body portion 30 locates in an enlarged portion 31a of body portion 31 and is retained therein by a projection engaging with aperture 31b in portion 31a.
The upper and lower wall portions of the assembled body 30, 31 are substantially parallel and snugly accommodate a dowel bar (not shown) therebetween.
The opposed side wall portions of the assembled body 30, 31 diverge from the closed distal end 32 to the proximal end 33 of the socket body to define an interior aperture of a generally oval cross section adjacent the proximal end.
A mounting flange 34 is integrally formed on the proximal end of body portion 31 and, if required, apertures 35 are provided for fasteners.
An integrally formed reinforcing web 36 extends between flange 34 and body portion 31 and includes a notched aperture 37 to receive a reinforcing member (not shown) extending transversely of the longitudinal axis of the body 30, 31.
FIG. 6 shows an end elevational view of proximal end 33 of the socket of FIG. 5.
The end wall of flange 34 includes a closure in the form of a thin membrane 38 formed over the cross sectionally oval shaped cavity 39 shown in phantom within body portion 31.
Adjacent the membrane 38 are ribs 40 formed on the inner wall of cavity 39 to centrally locate a dowel bar 41 within the cavity.
As both body portions 30 and 31 are formed by injection moulding, the membrane 38 is formed with a peripheral weakness whereby the membrane can be readily perforated by a dowel bar yet still act to prevent ingress of wet concrete.
The ribs 40 are sufficient to locate the dowel bar centrally of the aperture 39 during pouring of concrete. As the concrete slab shrinks during curing, the ribs to yield to lateral pressures applied on the dowel bar to enable lateral movement within cavity 39.
FIG. 7 shows a cross sectional view of an alternative mounting arrangement for dowel bar sockets according to the invention.
In this arrangement the mounting means 41 comprises a separately formed mounting flange 42 having a tubular socket 43 extending normally thereto to receive an open proximal end of a socket body 44.
An aperture 45 is provided in reinforcing web 46 to receive a transversely extending load bearing member (not shown).
Although as shown the mounting flange 42 is formed as a contiguous member, it could be formed with a perforable closure member or it could have an aperture formed therein.
In order to centrally locate the dowel bar in such an arrangement, small ribs 47 are formed on the inner wall of socket body 44.
FIG. 8 shows yet another alternative mounting means for sockets according to the invention.
In this arrangement mounting flange 48 has extending therefrom a spigot 49 adapted to engage the inner surface of a body 50. Spigot 49 may be a solid or tubular member.
The inner wall surface of body 50 has formed therein ribs 51 to centre a dowel bar and, if, required a projection 52 having a reinforcing bar locating aperture 53.
The mounting arrangement of FIG. 8 is adapted for mounting on either a front or rear side of slab formwork and if mounted on a front surface, spigot 49 is extended by an appropriate amount as shown in phantom.
Similarly, the mounting arrangement of any of the embodiments of FIGS. 1, 2, 5 and 7 could be adapted for mounting on either side of a formwork member either where the formwork is cast in situ or removed before pouring an adjacent slab. In this respect, the mounting means adapted for mounting on the front side of removable formwork are reusable.
The reinforcing means may comprise round bar sections in combination with round or square section dowel bars or for even higher specification slabs, square section transverse reinforcing bars may be used in combination with square section dowel bars for maximum load distribution.
It will be readily apparent to a skilled addressee that many modifications and variations may be made to the invention without departing from the spirit and scope thereof.
For example, the yieldable membrane closure in the proximal end may comprise a thin plerceable film or it may comprise regions of reduced thickness defining tearable circular and/or rectangular apertures.
Similarly, the apertures in the reinforcing web may each comprise a pierceable membrane or deformable aperture to firmly locate a circular or rectangular section reinforcing bar.
The socket according to the invention may also be adapted to accommodate a range of dowel bar diameters. For example the upright inner dimension of the socket body may be of 19-20 mm to accommodate a 19 mm bar.
In the event that a lower specification slab is desired with say, a 16 mm diameter bar, a larger transverse reinforcing bar may be used to cause the regions 19 of reduced thickness (FIG. 2) to deform inwardly to define a 16 mm upright internal cavity dimension.
Sockets according to the invention may be adapted to accommodate dowel bar insertion lengths of from 150-400 mm and diameters in the range 12 mm-35 mm.
The transverse dimensions of the proximal end of the body cavity may be adapted to allow a lateral clearance of from 2 mm-6 mm on each side of a centrally located dowel bar.
The reinforcing bars, whether circular or rectangular may have a diameter in the range of from 10-16 mm and be of any suitable length depending upon reinforcing requirements for the slab.
The sockets may be made by any suitable process such as injection moulding of plastics materials including polyolefins, nylons, ABS or the like. Suitably, the sockets are manufactured from reclaimed plastics for cost considerations.
The sockets may be separately formed as distal and proximal elements which are telescopically engageable and secured frictionally or by an adhesive or by fusion.
Alternatively the sockets may be formed with longitudinally extending joints engageable by socket and spigot means, fused wall joints or fused wall flanges.
The socket and spigot joints, wall flanges or the like may be shaped to provide a means for retention in an initially cast slab or the socket may include outwardly extending projections or inwardly extending cavities to resist withdrawal from a cast concrete slab.
Suitably the sockets are formed with longitudinally extending reinforcing webs extending over substantially the length of the socket.
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A dowel bar socket for concrete slab construction comprises a hollow elongate body (30, 31) having a mounting means (34) at a proximal end and a closed distal end (32). The socket is characterized in that the upper and lower portions of the body wall are parallel and provide a snug fit for a dowel bar to prevent movement in an upright direction. The hollow body tapers divergently from the distal end to the proximal end to permit limited lateral movement of a dowel bar as a curing concrete slab undergoes shrinking.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a National Stage of International patent application PCT/EP2012/069960, filed on Oct. 9, 2012, which claims priority to foreign French patent application No. FR 1103083, filed on Oct. 10, 2011, the disclosures of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
The subject of the present invention relates to a method and a system for the dynamic use of different modulation and coding schemes on n separate paths or channels in a wideband high frequency (HF) communication system.
BACKGROUND
In the present description, the words path or channel are used interchangeably to denote a channel for propagating and transmitting the data. These channels will be able to be accumulated to provide wideband communication.
HF links notably provide a capacity beyond the line of sight or BLOS that allows long or even very long haul communications to be implemented without requiring the use of a satellite.
The technical context of the present invention relates more particularly to the use of high speed HF links (for example bit rates>19.2 kb/s) as dealt with in the patent application filed by the applicant under the number FR 10/04650, which proposes considering the use of a plurality n of conventional channels or paths with a typical width of 3 kHz of passband.
The long haul communication capability (for BLOS) of the HF links is reliant on the reflection of the HF waves (which typically range from 2 to 30 MHz) on the layers of the ionosphere, layers that have qualities that are not stable in time and space, which leads to strong variations in the propagation channel. To this instability of the channel is also added the ever-possible presence of various intentional or unintentional sources of scrambling, particularly at night when the transmitting portion of the HF spectrum is not as great.
Despite its instability, this channel has the benefit of transmitting long haul communications without it being first of all necessary to deploy a complicated or expensive infrastructure, in contrast to satellite communications, for example. If its better stealth is likewise considered, this explains why professionals seek to increase the bit rates provided on the HF links. A solution has been proposed in the aforementioned patent application for considering the use of a plurality n of 3 kHz channels, which may or may not be contiguous, so as to go further and provide higher useful bit rates for users of the HF band.
The modulation and coding schemes used in some standards are of monocarrier modulation type using a modulation and coding scheme that is reliant on a given constellation, for example PSK (phase shift keying) or QAM (Quadrature Amplitude Modulation) modulation, and a given correction code, for example a convolutional code, which may or may not be punctured, defining a useful bit rate. In the case of extension with a lower side band or BLI, two paths share the same digital modulation, with an even bit/odd bit distribution on one or other path, and hence the same useful bit rate, the correction code being common.
It thus appears that when there are a plurality of available transmitting channels distributed over a relatively wide band, for example of 200 kHz, and wideband transmission allowing high bit rates, greater than 32 kb/s, to be reached is performed, the various paths distributed over this wide band will not be able to see the same imperfections in the propagation channel. Typically, fading will be different, and intentional or unintentional scrambling will differ.
The use of a single modulation and coding scheme, i.e. one and the same constellation and an identical or shared correction code, will not allow the best adaptation of capabilities of the transmission channel. In order to succeed in transmitting on a path that has a high level of fading, one solution involves reducing the useful bit rate on all of the paths, including those that do not have high levels of fading.
Moreover, the generalization of an approach such as the one reserved for BLI therefore does not allow effective combat of the loss of a path. The reason is that, for BLI, the sudden degradation of a path causes the system to fall back to communication in a mode with a single useful band (called upper side band mode BLU), which creates the problem of a strong reduction in bit rate.
The solutions that exist in the prior art or the immediate declension of said solutions in the case of n paths are of two types that are summarized below.
A first solution, shown schematically in FIG. 1 in the case in which the use of two channels simultaneously is considered, involves processing the bands separately, each one typically being provided with a dedicated modem implementing the current 3 kHz or 6 kHz standard, with a change to wideband processing solely at the level of the radio, by means of summation of the various carriers. The odd bits will be processed via the channel Ch 1 , chain 101 , and the even bits via the channel Ch 0 , chain 102 . Equally, at reception, two processing paths 103 and 104 will be used to process the even and odd data bits. This type of solution will not allow there to be a diversity gain, since each path will in fact be processed separately. In the case in which a single path is under consideration, with an approach of mono-carrier type, a single modulation and coding scheme is used, and it is management of link establishment/link maintenance (ALE/ALM) type that can introduce a dynamic character. The waveform under consideration is generally autobaud, which means that the waveform includes a specific transmission capability, commonly called separately decodable and demodulable autobaud field, which indicates the modulation and coding scheme used for the rest of the frame (or up until the next autobaud field), the change of bit rates being remotely controlled by the upper layers, typically by an ARQ controller.
In the description that follows, the processing chain being known to a person skilled in the art, the designations in the figures will be as follows:
for the transmission chain in FIGS. 1, 2 and 3 , FEC: the error correction code, I: the interleaving, SYM: the symbol formation, FR: the framing step, M: the modulation step; the step SC in the diagram for scrambling.
for the reception chain in FIGS. 1, 2 and 3 : g(t) the filtering, SYN: the synchronization, BDFE: the frame equalization step, SYNP: the prediction of the synchronization, DI: the deinterleaving, D: the decoding of the data.
This first type of solution (with coding and modulation processing separated on a path-by-path basis) does not allow full advantage to be drawn from the fact of using parallel paths, because such an approach does not bring about any diversity gain. It is moreover one of the reasons for which the BLI solution, combining two channels, as proposed in the MIL118-110B standard that is known to a person skilled in the art, introduces coding diversity by pooling the error correction coding and interleaving stage. However, this solution does not ensure the capability of easily operating with a blocked path (that is to say that the path is not transmitting, either on account of the propagation itself or because the channel is occupied by an intentional or unintentional source of scrambling) when the interleaving, bit rate, etc., or even number-of-paths information is variable because this information that is required for correctly decoding the frame is shared between the various paths. In the absence of appropriate signaling (typically in order to establish what has been lost), the result in the (conventional) case in which two paths are used is that the data transmitted on the two channels are lost when one is blocked because the standard approach uses the two paths in coupled fashion, by using the autobaud fields of the two paths to define the same and single modulation and coding scheme to be used on these two paths (the even bits traveling on channel 0 and the odd bits on channel 1).
A second solution, shown schematically in FIG. 2 , involves extending the principle of the BLI by pooling the FEC correction code 205 and the interleaver 206 with a plurality of paths Chi, at the processing chains 201 , 202 , in order to provide a coding diversity gain, and by using the same modulation parameters on the various modem paths, before the frequency transposition 209 and likewise the summation 210 of the various carriers in the wideband radio. As mentioned above, this solution will not allow adaptation to the propagation condition differences of each of the channels under consideration. On reception, the pooling will be found for all the paths Ch of the deinterleaver 207 and the decoding 208 . This second type of solution (extension of the BLI solution) which involves the use of the same modulation on each of the paths by sharing the correction code and the interleaver, will therefore allow a coding diversity gain, contrary to the first solution but on the other hand will render the system sensitive to the loss of one of the paths, as in the BLI solution with two combined paths. The reason is that, in the BLI solution, it will be noticed that the sharing of the autobaud information on the various paths (for BLI, channel 0 transmits the bit rate information, and channel 1 transmits the interleaver used), which is the information that allows the demodulator to know the mode that is used, risks making it impossible to use the various paths when one of them is lost completely, for example in the case of scrambling. This point, which was already a problem in BLI mode, and which had therefore led to the implementation of a mechanism for returning to the BLU monopath case in the event of a problem, becomes problematical in a context in which there is a change to n paths, since the probability of having a blocked channel increases greatly. Such a mechanism would therefore become very unstable and inefficient a priori.
None of the two approaches that have been set out above allows efficient use of the n paths in parallel, and combination of at least the various following advantages: improvement of the transmission owing to coding diversity, minimal protection of the autobaud information against the risk of blocked channels, capability of having different bit rates on the various paths, on the basis of the quality of the propagation channel under consideration.
The document by M. Jorgenson et al. entitled “Meeting military requirements for increased data rates at HF”, MILCOM 2000, 21st Century Military communications Conference Proceedings 22-25 Oct. 2000, PISCATAWAY, N.J., USA, IEEE, XP010532080 discloses the use of independent modulations on a plurality (n) of channels in one and the same system, with the same modulation parameters for each channel, and a correction code that is common to all channels.
The document by S. Trinder et al. entitled “Optimisation of the stanag 5066 ARQ Protocol to support high data rate HF communications”, MILCOM 2001, Proceedings. Communications for Network-Centric Operations: creating the information Force. XP010579059 discloses a system in which the addition of redundancy allows the success of reception of the information to be optimized.
One of the problems posed is therefore that of having, for one and the same communication, efficient transmission on n paths in parallel, each of these paths seeing a potentially different propagation channel, while ensuring that the loss of one of the paths or of a plurality of these paths does not destroy the whole communication.
SUMMARY OF THE INVENTION
To solve at least this problem, the method according to the invention is reliant notably on the implementation of a protocol for dynamic choice of the modulation and coding schemes (MCS) independently on a path-by-path basis within a context of multifrequency transmission that is suited to the HF medium.
The subject of the present invention relates to a method for communication in a wideband high frequency HF communication system comprising a transmitter for an HF signal and a receiver, at least n communication channels ch n , an FEC error correction code and an interleaver that are common to the n channels, a means allowing determination of the communication quality Qn provided by each of the n channels ch n , the data being transmitted in the form of a frame comprising an initial synchronization preamble and a standard autobaud followed by a block of data characterized in that it has at least the following steps, which are performed in order to allow the use of n channels in parallel, sharing one and the same coder and one and the same interleaver in order to benefit from frequency diversity protection, while allowing the use of different modulations on the n channels and providing redundancy on the information pertaining to coding, interleaving, modulation by channel, number of channels:
a step that involves introducing, into the structure of the frame of the data in the transmitted HF signal, an autobaud extension after the standard autobaud, said extension preamble having at least the following information:
a piece of information about the modulation used on each of the n channels ch 1 , . . . , ch n , a piece of information about the interleaver that is considered common to the n channels, the FEC correction code used, which is common to the n channels, the number of channels used (n), and for each the identifier id 1 , . . . , id n thereof that allows them to be ordered,
a step of choosing the modulation on a channel n on the basis of the link quality of said channel, a common coding and interleaving operation on the n channels, the transmission of the information introduced into the shared autobaud at the receiver.
By way of example, the method has a step that involves inserting the autobaud extension preamble after a standard autobaud that is itself regularly inserted into the data frame.
By way of example, said frame comprises a first standard portion composed of two tribits followed by a mini-probe and a second portion made up of n tribits followed by a mini-probe, with, by way of example, n equal to four tribits.
By way of example, the information on the modulation used is a piece of bit rate information.
A propagation channel ch k may carry the bit rate information for the communication channels ch k and ch k+1 [n].
By way of example, the choice of modulation used on the channel is made by taking into account the quality Q n of the communication channel ch n .
By way of example, the link quality of a communication channel is estimated by executing at least one of the following steps:
measurement of power of the received signal, in the absence of communication, in each channel considered by the system, attribution of a quality grade to each of said channels by comparing the value measured for the power with one or more threshold values, selection of the n channels having the highest grade values.
The width of a channel may be 3 kHz or, more generally, t kHz, t being a given real number.
According to an implementation variant, the frame structure is defined in the ST4539 standard or the MIL 188-110B standard and the method uses the value ‘111’ of the first tribit of the autobaud in order to signal extended autobaud operation to the receiver and in the course of the method four additional tribits are defined, or eight symbols for forming an autobaud of 137 symbols and thus constituting the extended autobaud, said tribits being protected by a correction code.
It is possible to use various modulations, possibly coded, on the various channels under consideration.
The invention also relates to a wideband high frequency communication system having at least one HF transmitter and at least one HF receiver that are suited to transmitting and receiving a signal having an HF waveform, characterized in that:
said HF receiver has means for determining n frequency channels, on which it will transmit an HF signal, said receiver has means for evaluating the transmission quality Qn of a channel, said HF transmitter moreover has means allowing the generation of an extended and shared autobaud comprising at least the following information:
a piece of information about the modulation used on each of the n channels ch 1 , . . . , ch n , a piece of information about the interleaver that is considered common to the n channels, the FEC correction code used, which is common to the n channels, the number of channels used (n), and for each the identifier idn thereof that allows them to be ordered,
the system comprising a return path allowing the information about the quality of the channel to be sent back up to the HF transmitter.
It is likewise possible to have a means for measuring the quality of the communication channels at the transmitter so as to choose as preferred channels those that are of good quality for the transmitter and the receiver. At the transmitter end, this measurement can be effected by measuring the power of the signal received at the transmitter, in the absence of communication, in each channel under consideration by the system, or in the event of the system operating in duplex mode, by using quality levels measured when the transmitter was in reception mode. In the case of half-duplex use as often occurs in HF, it is possible to take the information that is present at reception in order to use it for transmission as well.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the device according to the invention will become more apparent on reading the following description of an exemplary embodiment given as an illustrative and nonlimiting implementation example with appended figures, in which:
FIG. 1 shows an architecture example for a system for transmission and reception according to the prior art,
FIG. 2 shows a second implementation example of the prior art,
FIG. 3 shows a solution example implementing the method according to the invention comprising n paths with different and independent modulation and coding schemes,
FIGS. 4A and 4B show a frame structure according to the prior art and a frame structure integrating the method according to the invention, and
FIG. 5 shows a composition example for the fields of the autobaud for two low bit rate modes.
DETAILED DESCRIPTION
The method and system proposed in the present invention are based on the assumption that there is a set of n channels of conventional HF type, for example 3 kHz channels (which may or may not be contiguous) and a return path that is capable of informing the system of the quality Q of the propagation channel for each of the channels.
These conditions are satisfied, by way of example, if following the approach described in the Thales invention proposal entitled “Method and system for adaptive HF band communications”, filed under the number FR10/04650. The method described in this patent application notably allows dynamic selection of a set of frequency bands on the basis of the quality, at a given instant, of the transmission on these frequency bands. The bands are not necessarily contiguous but are taken from all of the frequencies allocated to a user. Any other method that allows there to be n channels may also be used. In order to obtain a piece of information about the quality Q of the propagation channel, it is possible, by way of example, to use the technique described in the aforementioned patent application. Thus, it is possible to obtain quality information corresponding to a noise power or to a signal-to-noise ratio that is transmitted by the receiver to the transmitter, from measurements performed at reception, either on the signal-to-noise ratio estimated on pilot symbols of the received frame, for example, or for the channels in which there is no traffic, by integrating the noise on the sub-band under consideration. In practice, these measured values will be converted into a discrete value taken from a predefined set S of values that qualify the link. By way of example, the power of the received signal is measured, in the absence of transmission in each channel. This measurement is carried out by the receiver using an analog-to-digital converter with known dynamics and saturation values, which is not shown, because it is not part of the subject matter of the present invention. The grade for the quality of the transmission can likewise take into account an average power value for the signal in the course of a period of time in the past. This average power can be used only if measured over a period of time for which the transmission and reception conditions are comparable to those observed for the measurement of the instantaneous power of the signal. It is also possible to weight the measurement of the instantaneous power of the signal, by means of preferential allocations to various services. By way of example, if there are frequencies attributed for exclusive use and others for shared access, it will be possible to favor the use of exclusive frequencies. Finally, if there is likewise a means for measuring the quality of the communication channels at the transmitter, it will be possible to take into account the quality measurements of the transmitter, in order to favor the channels that are likewise the best at the transmitter. This is notably beneficial when the system is operated in half-duplex mode, that is to say that the link is used alternately for transmission/reception between two sites, then for reception/transmission between these same two sites.
Once the quality of the transmission in each channel has been established, the method will fix one or more comparison threshold values to this quality grade, beyond which the channel is considered to be perturbed and therefore not available.
The example that will be given in order to illustrate the technical features implemented by the invention relates to two standards that exist for HF communications, namely the Stanag 4539 standard and the MIL STD 110-118B standard.
The implementation of the present invention notably allows the obtainment of complete interoperability with existing narrowband equipment in a BLU or BLI mode of operation. The frame format will be preserved and compatibility with the existing autobaud fields will be observed.
FIG. 3 schematically shows a communication system example according to the invention comprising:
at the transmitter portion 300 , binary data of the user {0, 1} pass first into an FEC correction module 301 , then into an interleaver 302 before being demultiplexed 303 . The demultiplexed data are then transmitted on n channels in parallel. The n channels or n paths ch 1 . . . ch n are, by way of example, channels having a width of 3 kHz that may or may not be contiguous.
The data following processing in the transmission chain 304 comprising means known to a person skilled in the art, for example, a symbol formation means, sampling means, followed by modulation means, will then be subjected to frequency transposition, the transposition frequency Tfn being associated with a channel ch n , and then will be summed 305 . The resulting sum will be transmitted and the signal will be propagated 306 there by the transmission channel before being received on the receiver portion 320 .
At the receiver portion 320 , the received signal is firstly subjected to frequency transposition T′fi, which allows separation of the data on the n channels ch n , and then the data are transmitted in a processing chain 307 that processes the data on n paths in parallel before reassembling them at a series parallel buffer 308 , then transmitting the set to a deinterleaver 309 that balances the interleaver of the transmitter portion. Following deinterleaving, the data are transmitted to a correction decoding module 310 that provides binary data. The binary data thus received are then delivered to the receiver 311 .
The system also has a return path 312 and a means 313 allowing determination of the quality Qi of a propagation channel for the various channels chi that are possible for transmission. The return path retransmits the quality Q of each of the n propagation channels ch n to the transmitter.
The very principle of separation into n paths or channels that are subject to different and independent propagation channels gives rise to the possibility of observing different and independent bit rates on the n channels, these bit rates therefore not being equal or fixed.
On the aforementioned assumption of the presence of n channels and the quality Q of the n propagation channels, the method proposes, in the example given below, guaranteeing the protection of the autobaud in the event of loss of a path, in order to avoid generating redundancy that is too expensive.
By using, as shown by FIG. 3 , independent modulations 304 mn on the n paths ( 304 m 1 for the channel ch 1 , . . . 304 mn for the channel ch n ), but by sharing the correction coding stage 301 and the interleaving 302 , the method introduces coding diversity, which will allow better resistance to the imperfections of the channel (errors, losses, intentional or unintentional sources of scrambling), and will likewise allow better adaptation of the resistance and the efficiency of the modulation used to the quality of each of the paths used for the transmission.
The example given by way of illustration is restricted to application of a single correction code that is common to the various paths in order to guarantee coding diversity. Without departing from the scope of the invention, it is, however, envisageable to take into account various correction codes as will be explained further on in the description.
One of the technical features used by the method according to the invention is the presence of an extended autobaud at the frame of the data, with redundancy capability, which will allow the necessary signaling to be provided: it is owing to this extended autobaud that it will be possible to correctly reconstitute the missing information in the event of a loss of the elements of a path, the corresponding unreceived data then being input as erased upstream of the deinterleaver 309 , so as to be deinterleaved and then decoded by the correction code, which, within the limits of its correction capability, will be able to correctly decode the received signal. This therefore requires the extended autobaud to transmit the information listed below in a redundant manner:
information about the modulation on each path or channel ch n , the information being able to be the bit rate used, for example, the interleaver under consideration, which is common to the n channels, the correction code used, which is common to the n channels, the number of paths or channels used (n), and for each the identifier idn thereof that allows them to be ordered.
More information is introduced into the autobaud by, for example, introducing an extension into the existing autobaud, as shown in FIGS. 4A and 4B .
Once formed in this way, the frame therefore provides the following features:
it is recognized by a station according to the prior art as a standard frame that it is not capable of decoding. The standard station will therefore continue to scan the stream in search of a decodable solution without the risk of moving into error, it is recognized as a frame in an extended format for stations that incorporate the capability, with indication of the choices made in terms of modulation by channel, interleaving and type of correction code for the frame, and number of channels under consideration, and the numbering of these channels.
With such information, a station that incorporates the new capability is capable of decoding channels with different modulations on the various channels, is able to adapt itself on the fly to modification of the modulations used on all or some of the channels, and is able to adapt itself on the fly to a reduction in the number of channels or to modification of the order of the channels.
By way of example given in nonlimiting fashion, within the framework of the sought compatibility with the ST4539/MIL 188-110B standard, for bit rates higher than 3200 b/s, the value ‘111’ of the first tribit (set of three bits) will be used in order to signal to the receiver or the transmitter of the system that operation has changed to extended autobaud mode. Consequently, a standard transmitter/receiver station will detect an unknown mode and will seek to synchronize itself to the next preamble, whereas a wide band station will know that it needs to change to extended mode and therefore to interpret the extended autobaud field.
FIG. 4A schematically shows the format of a frame structure 400 in the compatible format of the ST4539/MIL 188-110B standard.
The frame comprises a first portion 401 a , 401 b that respectively corresponds to an initial synchronization preamble and a standard autobaud, for example with 287 symbols, followed by a data block 402 with 256 symbols, by a mini-probe 403 with 31 symbols and by a standard autobaud 404 inserted regularly into the frame of 103 symbols.
FIG. 4B schematically shows an autobaud extension example according to the invention that involves, by way of example, inserting a preamble 405 , in this example made up of 157 symbols, the preamble 405 being inserted, by way of example, into the portion at the synchronization preamble ( 401 a , 401 b ). The frame extended in this manner keeps the conventional format. According to another variant implementation, the preamble 405 constituting the autobaud extension can be inserted after the standard autobaud 404 .
The extended autobaud according to the present invention is divided into two portions; the first in accordance with current standards has, by way of example, two tribits followed by their mini-probe, which ensures that it can be demodulated by conventional systems, followed by a second portion made up of n tribits, followed by a mini-probe, with n being equal to four new tribits, for example. This second portion is demodulated by the conventional BDFE equalizer relying on the introduction of a final mini-probe that is identical to that of the conventional autobaud (31 symbols). The change to extended mode is signaled in this example by the first tribit positioned at the value “111” in the standard autobaud.
Thus, a station compatible with the extension of the autobaud, when receiving a signal, will look for the rest of the autobaud and interpret it. A standard station that is not equipped to recognize the extended autobaud will detect a mode that is not known to it and will seek to get hold of the next preamble regularly inserted that it is capable of recognizing.
FIG. 5 shows an embodiment of the method according to the invention that is compatible with the aforementioned current standards:
The method will therefore transmit on each path or channel ch n :
the modulation (homogeneous with the bit rate information in the current standards), and a second piece of modulation information, corresponding to the one employed on another path. In order to be able to provide at least ten modulation values, this information is coded over 4 bits: d 0 d 1 d 2 d 3 for the modulation of the path, and d 4 d 5 d 6 d 7 for the modulation of the second path (repetition of the initial information transmitted on the path in question), the identifier of the channel under consideration, coded over 3 bits: n 0 n 1 n 2 .
The method likewise has the following redundant information, for example at least once on all of the n channels:
the interleaver used, which involves interleavers from the aforementioned standards or new interleavers obtained using methods known to a person skilled in the art, for example, the correction code employed, FEC, whether involving correction codes from the aforementioned standards or new coders obtained using methods that are known to a person skilled in the art, for example, the value of the total number of channels (n) used for transmitting the signal.
For these three pieces of information, one way of proceeding involves the use of 4 bits: i 0 i 1 i 2 i 3 and alternating once in three times, for the transmission of the interleaver information, with the value of n, and with FEC code, that is to say:
If channel ch k =0[3], i0 i1 i2 i 3→number of channels used (n)
If channel ch k =1[3], i0 i1 i2→interleaver under consideration
If channel ch k =2[3], i0 i1 i2→correction code under consideration
As far as the duplication of the bit rate information is concerned, it is possible, by way of example, to have the channel c k carry the bit rate information of the channels ch k and ch k+1 [n].
This therefore leads to the following autobaud format:
111 d 0 d 1 d 2 d 3 +n 0 n 1 n 2 i 0 i 1 i 2 i 3 d 4 d 5 d 6 d 7 ,
that is to say to the definition of four additional tribits (or eight symbols D3, D4, D5, D6, D7, D8 protected by the Barker code known to a person skilled in the art, for example), in order to form an extended autobaud having a size of 1+8*13+1+31=137 symbols.
This results in the new modulations that are presented in the tables below, by way of example:
Modulation
4 bits mapping
illegal
0000
illegal
0001
reserved
0010
reserved
0011
BPSK
0100
QPSK
0101
8-PSK
0110
illegal
0111
illegal
1000
16-QAM
1001
32-QAM
1010
64-QAM
1011
128-QAM
1100
256-QAM
1101
illegal
1110
illegal
1111
Channel under consideration
3 bits mapping
1
000
2
001
3
010
4
011
5
100
6
101
7
110
8
111
Number of channels
4 bits mapping
illegal
0000
illegal
0001
1
0010
2
0011
3
0100
4
0101
5
0110
6
0111
7
1000
8
1001
reserved
1010
reserved
1011
reserved
1100
reserved
1101
illegal
1110
illegal
1111
Interleaver
3 bits mapping
illegal
000
1 frame (US)
001
3 frames (VS)
010
9 frames (S)
011
18 frames (M)
100
36 frames (L)
101
72 frames (VL)
110
illegal
111
FEC
3 bits mapping
illegal
000
perforated ½ CC: Y = ¾
001
unperforated ½ CC
010
reserved
011
reserved
100
reserved
101
reserved
110
illegal
111
It will be noted that some values in the tables provided are declared illegal in order to avoid any risk of confusion with the mini-probe motif, in the same way as some values are prohibited in the reference standard for the tribits for definition of the interleaver in BLU mode. Other values are presented as reserved in this case for attributions to be defined on the basis of needs.
According to the method, owing to the provided possibility of changing FEC error correction code, and not using just the ½ convolutional code punctured to a ¾ yield in the BLI version, for example, it is therefore effectively proposed that the modulation information used be conveyed on the paths, instead of the useful bit rate traditionally transmitted in the extended autobaud. This is because this modulation will moreover possibly be able to be coded, which means that it can have a repetition or coding capability to reinforce its resistance, or will simply be able to be used with the common FEC correction code, with an equal or different yield from the standard BLI yield.
The example explained above can, without departing from the scope of the invention, be implemented in any communication system that has a plurality of paths, n channels, a means allowing knowledge of the quality of the communication channels, and a frame structure comprising a set of unused bits in order to introduce at least the following information:
the bit rate used on each channel ch 1 , . . . , ch n , the interleaver under consideration, which is common to the n channels, the correction code used, which is common to the n channels, the number of channels used (n), and for each the identifier id 1 , . . . , id n thereof that allows them to be ordered.
More generally, the implementation of the method according to the invention is aimed at a frame structure composed of a first portion 401 = 401 a , 401 b comprising synchronization and autobaud information, followed by a data block 402 , then a portion 403 comprising the error correction code.
The extended autobaud involves the introduction, at the portion 401 a , 401 b comprising synchronization information, of a set of information 405 corresponding to a number of symbols, this second portion being demodulated by the conventional BDFE equalizer relying on the introduction of a final mini-probe that is identical to that of the conventional autobaud (31 symbols). The extended autobaud according to the present invention can be regarded as a standard autobaud and an extension 405 .
The invention notably exhibits the following advantages. It allows independent management of the various paths and thus improvement of the probability of having adapted the modulation and the coding to the conditions of the propagation channel. This makes it possible to obtain a scope and a probability of setup of the communication that are desired according to the communication system.
The extended autobaud proposal according to the invention therefore allows current stations not to be perturbed, but also the introduction of a redundancy capability in order to allow successful decoding of the frame itself in the event of loss of a channel (or a plurality of noncontiguous channels), but also allows the use of different modulations according to the channels.
The method according to the invention makes it possible to benefit from coding diversity owing to the use of a single correction code and interleaving stage between the various paths, to be able to resist at least one blocked channel owing to the specific redundancy introduced into the extended shared autobaud mechanism, and it therefore makes it possible to avoid the break in communication in the event of rapid deterioration (fading, scrambling) of one or more channels owing to the sharing of the information on all of the paths.
The method makes it possible to vary the (possibly coded) modulation on each of the paths, and thus to propose more adaptation flexibility or to provide a different point of operation for the various paths of the communication system.
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A method and system of communication in a wide band high frequency HF communication system is disclosed. The system includes at least n communication channels, an interleaver common to the n communication channels, a means for determining the quality of communication of each of the n communication channels. At least the following information is introduced into the structure of the frame of the data at the level of an autobaud: an item of information about the modulation employed on each of the n communication channels ch n , an item of information about the interlever common to the n communication channels, the corrector code FEC employed, the number of communication channels employed (n) as well as for each one its identifier id n . The modulation is chosen on channel n, a common coding and interleaving are operated on the n channels, and the information introduced in the shared autobaud is transmitted.
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FIELD OF THE INVENTION
[0001] The invention relates to an improved handle for ramrods of the type as used with firearms of the muzzle-loading type.
BACKGROUND OF THE INVENTION
[0002] With muzzle-loading firearms, a ramrod is provided comprising a cylindrical tool having a diameter substantially similar to the bore of the barrel of the firearm. In use, the ramrod is inserted into the open end or muzzle of the barrel of the firearm for several purposes such as: tamping powder and a bullet previously inserted into the barrel; or, with the addition of appropriate removal means, removing a bullet or other unwanted material lodged in the barrel; or, with the addition of appropriate cleaning means, cleaning the bore of the barrel.
[0003] In view of the relatively small diameter of most ramrods, a handle for ramrod manipulation is a virtual necessity for accomplishing either the tamping function, or the removal function, or the cleaning function.
[0004] A wide variety of ramrod handles is disclosed in the prior art. However, most are either permanently affixed to the ramrod or, if removable therefrom, must be stored separately from the firearm, such as in a pouch or the like.
[0005] In addition, many prior art handles can function only with a particular ramrod or weapon and are not universally adaptable for use with a wide variety of ramrods or weapons.
[0006] Accordingly, a need exists for a ramrod handle, which is easily removable from and attachable to the ramrod, is readily storable upon the weapon with which the ramrod is used, and is universally adaptable for use with a wide variety of ramrods or weapons.
SUMMARY OF THE INVENTION
[0007] Among the objects of the invention is the provision of a ramrod handle which is easily removable from and attachable to the ramrod, can be readily stored upon the weapon with which the ramrod is used, and is universally adaptable for use with a wide variety of ramrods or weapons.
[0008] Another object is the provision of a handle, which may be releasably locked to the ramrod and, in a storage mode, to the barrel of the firearm.
[0009] A still further object is to provide a handle, which is so constructed that when it and a ramrod are locked in a storage mode relative to the barrel of a firearm, unwanted rattling of the ramrod against the barrel is precluded.
[0010] An additional object is to provide a handle which is so constructed that when it and a ramrod are locked in a storage mode relative to the barrel of a firearm, the interior of the handle is protected from becoming fouled by muzzle debris, while accidental movement of the handle to an open position, wherein it is disposed in front of the firearm muzzle, is also precluded.
[0011] The storage mode of the handle of the invention and a ramrod relative to a firearm is achieved as follows:
a. the handle is positioned adjacent the end of the ramrod and disposed in parallel relation thereto; b. the handle is snapped onto the ramrod to bring the two members into a coaxial relationship; c. the ramrod is threadedly engaged with a connector means which is sleeved by the handle and mounted for sliding rectilinear movement relative to an interior bore within the handle; d. the connector means and attached ramrod are slid rectilinearly inwardly relative to the interior bore in the handle to a locked position wherein pivotal swinging movement between the handle and ramrod is blocked; and e. the ramrod, and the attached handle, are slid rectilinearly inwardly relative to a storage means provided on the firearm barrel until an end of the ramrod bottoms relative to the storage means, with the handle now being in contact with an adjacent surface of the barrel of the firearm.
[0017] The use mode of the handle and ramrod relative to a firearm is achieved as follows:
a. the handle is grasped and, with the ramrod, is slid rectilinearly outwardly relative to the firearm whereby the ramrod is removed from the storage means and the handle is removed from contact with the barrel of the firearm; b. the connector member and attached ramrod are slid rectilinearly outwardly relative to the handle to an unlocked position wherein pivotal swinging movement between the handle and ramrod may be effected; and c. the handle is swung 90 degrees from its coaxial position relative to the ramrod to a position wherein it is perpendicular to the ramrod and ready for use by insertion of the ramrod into the bore of the barrel of the firearm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a front elevational view of a handle embodying a preferred form of the invention;
[0022] FIG. 2 is a rear elevational view thereof;
[0023] FIG. 3 is a top plan view thereof;
[0024] FIG. 4 is a bottom plan view thereof;
[0025] FIG. 5 is an end elevational view thereof on an enlarged scale;
[0026] FIG. 6 is a front elevational view on an enlarged scale of the connector means of the handle of FIG. 1 ;
[0027] FIG. 7 is an exploded perspective view of the handle of the invention, a ramrod and a rifle barrel;
[0028] FIG. 8 is a perspective view of the handle of the invention following its attachment to a ramrod and its engagement with a rifle barrel in a storage mode; and
[0029] FIG. 9 is a perspective view of the handle of the invention following removal of the ramrod from the storage mode of FIG. 8 to a use mode, with one end of the ramrod now being positioned in the bore of the rifle barrel, and the handle having been swung 90 degrees relative to the opposite end of the ramrod to a position wherein it is perpendicular thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Referring first to FIGS. 7-9 , a handle embodying a preferred form of the invention is generally indicated by 10 ; a ramrod, shown fragmentarily, is generally indicated by 12 ; and a firearm, also shown fragmentarily, is generally indicated by 14 .
[0031] Firearm 14 includes a barrel 16 having a bore 18 which terminates at an outer free end in a muzzle 20 , the barrel having a storage sleeve 22 formed integrally therewith.
[0032] Storage sleeve 22 is spaced rearwardly of muzzle 20 , and is disposed in parallel relationship to bore 18 of barrel 16 for receiving and storing ramrod 12 therein, in a manner as shown in FIG. 8 .
[0033] Ramrod 12 , which is of cylindrical cross section and has a diameter substantially similar to that of bore 18 of firearm 14 , is fabricated from thermoplastic, or metal, or wood, or composite material.
[0034] Handle 10 is fabricated from thermoplastic, or metal, or wood, or composite material, is substantially cylindrical in cross-section, and is of appropriate size as to be grasped readily by hand, as shown in FIG. 9 .
[0035] As best seen in FIG. 4 , handle 10 has an open end 23 and a closed end 25 and is provided on its central longitudinal axis with an interior bore 26 of circular cross section which has an open outer end 28 and a closed inner end 30 .
[0036] A primary slot 32 is provided in a lower face 34 of handle 10 and is of appropriate width as to receive ramrod 12 therein in the manner of a press or snap fit.
[0037] Primary slot 32 communicates with interior bore 26 and extends longitudinally from handle open end 23 for approximately one half the length of the handle and terminates in a closed inner end 36 .
[0038] Referring now to FIGS. 1 and 2 , a pair of spaced, parallel, secondary slots 38 and 38 ′ is provided in handle 10 , with slot 38 being disposed in a side wall 40 of the handle and slot 38 ′ being disposed in a side wall 40 ′ of the handle.
[0039] Each slot 38 and 38 ′is positioned adjacent closed end 25 of handle 10 and communicates with bore 26 .
[0040] Secondary slots 38 and 38 ′ each extend along the approximate central longitudinal axis of the handle for approximately one-half the length of the handle with each slot having opposite, closed inner and outer ends 42 and 44 , respectively.
[0041] As best seen in FIGS. 1-6 , a connector means, generally indicated by 24 , is mounted for rectilinear sliding movement in interior bore 26 of handle 10 and includes a semi-circular head 46 having a pin 48 extending transversely therethrough and outwardly from each side thereof on its approximate central transverse axis and a flat base 50 having a threaded stem 52 formed integrally therewith which extends outwardly therefrom on the central longitudinal axis of the connector means.
[0042] Pin 48 of connector means 24 is of appropriate size and configuration as to be receivable for sliding rectilinear movement in and relative to slots 38 and 38 ′ in side walls 40 and 40 ′ respectively of handle 10 , with pin 48 serving the dual functions of capturing the connector within handle 10 while limiting sliding movement of the connector relative to the handle.
[0043] Ramrod 12 is provided on one of its ends with a threaded bore 54 of appropriate size to accept therein threaded stem 52 of connector means 24 .
[0044] Stem 52 is of such size and thread design as to be receivable in the threaded bore provided in the ends of virtually all standard ramrods, whereby handle 10 is appropriate for use with a wide range of ramrods.
[0045] Handle 10 and ramrod 12 are joined by snapping the ramrod through primary slot 34 of the handle into interior bore 26 so that the handle and the ramrod are co-axially aligned, whereby stem 52 of connector means 24 may be threadedly engaged in bore 54 of the ramrod
[0046] Connector means 24 and ramrod 12 can now be slid axially relative to interior bore 26 of the handle, with pin 48 of the connector means sliding relative to secondary slots 38 and 38 ′ until head 46 of the connector means contacts closed inner end 30 of interior bore 26 and pin 48 contacts closed outer ends 44 of secondary slots 38 and 38 ′.
[0047] Closed inner end 30 of interior bore 26 and closed outer ends 44 of secondary slots 38 and 38 ′ together form stop means which limit the extent of axial movement of connector means 24 and ramrod 12 relative to handle 10 , with the handle and ramrod now being locked in co-axial alignment, while lower wall 34 of the handle blocks any swinging clockwise pivotal movement of the connector means and the ramrod relative to interior bore 26 of the handle.
[0048] Thus, when handle 10 and ramrod 12 are in a storage mode on firearm barrel 16 , accidental swinging movement of the handle to an open position in front of firearm muzzle 20 is precluded.
[0049] Following removal of handle 10 and ramrod 12 from a storage mode on firearm barrel 16 , the co-axial alignment of handle 10 relative to ramrod 12 can be changed simply by sliding the ramrod and connector means 24 axially relative to interior bore 26 of the handle until pin 48 of the connector means contacts closed inner ends 42 of secondary slots 38 and 38 ′ of the handle, with the connector means now being in the position as shown in FIG. 4 , wherein it is clear of lower wall 34 of the handle and positioned immediately adjacent and clear of first slot 32
[0050] Connector means 24 and ramrod 12 now may be swung downwardly in a clockwise direction, with the ramrod snapping into and through first slot 32 and pin 48 pivoting relative to slots 38 and 38 ′ of handle 10 . The ramrod is now in a position wherein it is perpendicular to the handle, with one of its side faces contacting closed end 36 of first slot 32 , thereby effectively precluding further clockwise swinging motion of the connector means and the ramrod
[0051] Thus, closed inner end 36 of first slot 32 serves as a stop, which limits the range of clockwise swinging movement of the ramrod past 90 degrees.
[0052] To return the ramrod to a coaxial position relative to the handle, the operation is reversed, with the ramrod first being swung in a counterclockwise direction relative to the handle.
[0053] An upper face 56 of handle 10 is provided with an arcuate depression 58 which extends longitudinally for the length of the handle, with the depression permitting the engagement or marriage of the handle with gun barrel 16 of firearm 14 , as will appear.
[0054] Depression 58 is provided with a pair of spaced, parallel, upstanding, inwardly inclined ribs 60 and 62 , each of which extends longitudinally for the length of the depression in closely spaced parallelism to an adjacent side edge of the depression.
[0055] Ribs 60 and 62 permit the handle to seat relative to firearm barrel 16 , regardless of the cross-sectional shape of the barrel, be it round, hexagonal, oval or other shape, when handle 10 and ramrod 12 are placed in a storage mode on the firearm barrel.
[0056] For example, were ribs 60 and 56 not present, arcuate depression 58 of handle 10 would not seat properly relative to a firearm barrel of hexagonal cross-section.
[0057] In addition, when handle 10 and ramrod 12 are placed in a storage mode on firearm barrel 16 , ribs 60 and 62 preclude unwanted rattling of the ramrod relative to the barrel.
[0058] When the handle is in a storage mode as seen in FIG. 8 , its closed end 25 is facing the muzzle end of the barrel, thereby effectively protecting interior bore 26 and connector means 24 from being fouled by debris which may be emitted from muzzle 20 when the firearm is fired.
[0059] Further, when handle 10 and ramrod 12 are in a storage mode on the firearm barrel, accidental swinging movement of the handle to a position in front of the muzzle, is precluded.
[0060] Based on the foregoing, it will be readily apparent to those skilled in the art that the handle of the invention is easily removable from and attachable to a ramrod, is readily stowable upon the weapon with which the ramrod is used, and is universally adaptable for use with a variety of ramrods and weapons.
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A handle for the ramrod of a muzzle loading firearm which has storage means for the ramrod on its barrel is releasably attached to the ramrod and movable between a first locked position wherein it is coaxial with the ramrod and a second locked position wherein it is perpendicular to the ramrod, the handle having a seating surface which allows it to be stored on the firearm barrel regardless of the cross sectional shape of the firearm barrel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/477,571, filed on Jun. 11, 2003. The disclosure of the above application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a fall protection system and more specifically to a rappelling mechanism for controlled descent.
BACKGROUND OF THE INVENTION
[0003] People working from heights have been known to fall from workstations and hunters in trees have fallen out of tree stands. Today there are many types of fall protection systems intended to arrest the fall of a person. One of these mechanisms is a life line that is connected to a harness worn by the user and connected to a stationary object. Also there exists mechanisms that allow a person to control their descent as they rappel. Conventional rappelling devices generally require that the user has specialized knowledge or training in the use of the devices. Additionally, these devices are sometimes bulky, heavy and expensive. Many conventional rappelling mechanisms are not self locking and require the user to actuate the rappelling mechanism in order to stop or slow the rate of descent. What is needed is a fall protection system that will restrain the fall of an individual and also provide a rappelling mechanism that is less complicated and easier to use.
SUMMARY OF THE INVENTION
[0004] In accordance with the teachings of the present invention, a fall protection system with a rappelling mechanism is disclosed. In one form, the present invention provides a fall protection system that incorporates a harness with a rappelling mechanism and a pouch for storing a length of webbing. In another form, the present invention provides a rappelling mechanism including a pair of lock plates, a pair of release plates, a release pin, a pair of short pins, and a pivot pin. Additional advantages and features for the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0006] FIG. 1 is a front view of the controlled descent mechanism in accordance with the present invention;
[0007] FIG. 2 is a sectional view taken along line 2 , 2 of FIG. 1 ;
[0008] FIG. 3 is a perspective view of a fall protection system in accordance with the teachings of the present invention;
[0009] FIG. 4 is a perspective view of the pouch of FIG. 3 showing a top portion;
[0010] FIG. 5 is a perspective view of a release plate of the mechanism of FIG. 1 ;
[0011] FIG. 6 is a perspective view of a locking plate of the mechanism of FIG. 1 ; and
[0012] FIGS. 7 and 8 represent front and side views of an alternate rappelling mechanism according to the teachings of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0014] The following description of embodiments of a fall protection system and controlled descent mechanism are exemplary in nature and in no way intended to limit the invention, its applications or uses. Moreover, while the present invention is described in detail with reference to fall protection, it will be appreciated by those skilled in the art that the present invention is not limited to a fall, but may also be used wherever a controlled descent mechanism would be required.
[0015] The rappelling mechanism 10 functions to selectively control the movement of the webbing 42 through the mechanism 10 . To this end, by coupling a harness 52 to the mechanism 10 , a user can selectively release or lock the harness to the webbing 42 . As shown in FIG. 1 , the locking plates 12 and 14 are held together in a generally parallel configuration by the pins 26 , 28 , and 30 . Additionally disposed between the locking plates 12 and 14 is the pivot pin.
[0016] Similarly, the release plates 16 and 18 are parallelly configured and held together by pins 20 and 24 . As described below, the lock plates 12 and 14 are rotationally coupled to the pin 26 . Rotation of the release plates 16 and 18 with respect to the locking plates moves the locking pin 24 with respect to the short pins 20 , 24 .
[0017] With reference to FIGS. 1 and 2 , a controlled descent or rappelling mechanism in accordance with the teachings of the present invention is generally illustrated as reference numeral 10 . Mechanism 10 includes a pair of lock plates 12 , 14 , a pair of release plates 16 , 18 , a pair of short pins 20 , 22 , a locking pin 24 , a pivot pin 26 , a release pin 28 , an attachment pin 30 , and a cover 32 . Mechanism 10 is illustrated with a belt 40 inserted therein. An attachment webbing 42 is secured to attachment pin 30 and a release strap 44 is secured to release pin 28 .
[0018] FIG. 3 illustrates a fall protection system 50 to include a harness 52 having a D-ring 54 attached thereto and a pouch 56 mounted thereon. Pouch 56 can be attached to harness 52 with a conventional hook and loop closure attachment. Harness 52 includes straps 60 with adjustment portions 62 and a locking mechanism 64 attached thereto. Adjustment portions 62 are provided with straps 60 to adjust the length of straps 60 when fitting harness 52 to a user. Locking mechanism 64 are adjustable with respect to straps 60 and lock onto straps 60 in order to form the harness 52 that can be secured to the torso of an individual. When harness 52 is strapped on an individual, D-ring 54 is preferably mounted in the back just above pouch 56 as best seen in FIG. 3 . Attachment webbing 42 is secured to D-ring 54 of harness 52 . While harness 52 is illustrated as multiple straps 60 , it is also anticipated that the harness of the present invention could be a vest with straps 60 attached thereto to provide the same function as harness 52 .
[0019] FIG. 4 illustrates pouch 56 including belt 40 folded therein. Pouch 56 is intended to enclose a predetermined length of belt 40 in order to allow an individual that has fallen to rappel safely to the ground as described below. Belt 40 is shown in FIG. 4 to be folded and overlaid within pouch 56 in order to allow belt 40 to self feed from pouch 56 during operation of fall protection system 50 .
[0020] With reference to FIG. 5 , release plate 18 is shown in greater detail. Release plate 18 is identical to release plate 16 and is shown to include a locking pin aperture 124 , a pivot pin aperture 26 , a release pin aperture 128 , and an attachment pin aperture 130 . FIG. 6 illustrates locking plate 14 to include short pin apertures 220 and 222 , a locking pin slot 224 , and a pivot pin aperture 226 .
[0021] When assembled, pivot pin 26 is shown in FIGS. 1 and 2 to be interposed through pivot apertures 126 of pivot plates 16 , 18 , and pivot apertures 226 of locking plates 12 , 14 . Pivot pin 26 is interposed through apertures 126 , 226 in such a manner as to allow locking plates 12 , 14 , to rotate relative release plates 16 , 18 . Short pin 20 is interposed within short pin apertures 220 and short pin 22 is interposed within short pin apertures 222 . Locking pin 24 is shown interposed through locking pin apertures 124 and locking pin slots 224 . Thus provided, locking pin 24 translates within locking pin slots 224 as lock plates 12 , 14 rotate with respect to release plates 16 , 18 . Belt 40 is positioned within mechanism 10 such that belt 40 threads through a space between short pins 20 , 22 , around locking pin 24 , and back through the space between short pins 20 , 22 . Attachment pin 30 is interposed within attachment pin apertures 130 and release pin 28 is interposed within release pin apertures 128 and secured therein. Locking pin 24 , release pin 28 , and attachment pin 30 are securely attached to release plates 16 , 18 , thereby forming a rigid mechanism 10 . This attachment can be accomplished by an interference fit between release plates 16 , 18 and locking pin 24 , release pin 28 , and attachment pin 30 wherein the ends of locking pin 24 , release pin 28 , and attachment pin 30 are splined, or by any other suitable means. Cover 32 is superposed about the moveable components of mechanism 10 . As presently preferred, cover 32 is constructed of injection molded plastic belt 40 is a seat belt webbing, and all other components of mechanism 10 are constructed of 4130 cold rolled steel.
[0022] As best seen in FIGS. 2, 5 and 6 , as release plates 16 , 18 rotate counterclockwise with respect to locking plates 12 , 14 , the locking pin 24 translates within locking pin slots 224 toward short pins 20 , 22 . As locking pin 24 translates in this direction, belt 40 is cinched between the surfaces of locking pin 24 and short pins 22 and/or 20 . In this manner, counterclockwise rotation of release plates 16 , 18 (see FIG. 2 ), will cause locking pin 24 to tighten belt 40 against short pins 20 , 22 . This prevents relative movement between belt 40 and locking pin 24 . As release plates 16 , 18 are counter-rotated or rotated in a clockwise direction, the locking pin 24 rotates away from short pins 20 , 22 , thereby unlocking belt 40 . This allows the belt 40 to travel through rappelling mechanism 10 . This clockwise rotation is accomplished by pulling on release strap 44 thereby exerting a force on release plates 16 , 18 via release pin 28 in a downward direction with respect to FIG. 2 . The amount of force required to release belt 40 is approximately 25% of the individuals body weight.
[0023] In operation, the weight of a user will provide a downward reactive force W on attachment pin 28 , generally in the direction of arrow D. This force will rotate locking plates 16 , 18 counter clockwise thereby locking belt 40 between locking pin 24 and short pins 20 , 22 . Thus provided, belt 40 is self-locked after a user falls. To descend, the user pulls release strap 44 thereby moving locking pin 24 away from short pins 20 , 22 . This permits the belt 40 to travel through the rappelling mechanism 10 . The amount of force applied by the user to release pin 28 has a component of force P in the direction of arrow D. As belt 40 travels through rappelling mechanism 10 , friction between belt 40 and pins 20 , 22 , and 24 counter acts some of the downward reactive force W, thereby slowing the rate of descent and inhibiting a free fall of the user. The amount of force P applied by the user varies the amount of friction between belt 40 and pins 20 , 22 , and 24 which, in turn, varies the rate of descent. Thus provided, a user can control the rate of travel of belt 40 through mechanism 10 by selectively regulating the amount of force P applied to release pin 28 . It would be appreciated by one skilled in the art that pins 20 , 22 , and 24 could be provided with a frictional surface, and that belt 40 can be selected to provide a desired coefficient of static and/or dynamic friction during operation of fall protection system 50 .
[0024] When a fall protection system is desired, an individual is secured within harness 52 such that pouch 56 is located adjacent the individuals rear torso region. Attachment webbing 42 is secured to D-ring 54 thereby providing a positive attachment between rappelling mechanism 10 and harness 52 . Pouch 56 is preferably located on a portion of harness 52 that is below rappelling mechanism 10 , as seen in FIG. 3 . Straps 60 are securely tightened around the person's torso and leg regions using lock mechanisms 64 and adjustment portions 62 . In the event of a fall, the weight of an individual is translated through D-ring 54 and attachment webbing 42 to attachment pin 30 . This downward force on attachment pin 30 as seen in FIG. 2 , causes locking pin 24 to rotate counterclockwise towards short pins 20 , 22 thereby locking the rappelling mechanism 10 . With rappelling mechanism 10 locked, belt 40 will not translate therethrough, thereby arresting the user's fall. For a controlled descent to the ground or other recovery location, release strap 44 is pulled such that locking pin 24 is moved away from short pins 20 , 22 and belt 40 is allowed to slowly translate between locking pin 24 and short pins 20 , 22 . The rate of descent is controlled by the amount of downward force P exerted on release pin 28 via release strap 44 , as discussed above. During descent, the rate of descent can be lowered by exerting less force P on release pin 28 . Thus provided, fall protection system 50 allows an individual to control their rate of descent after a fall.
[0025] With reference to FIGS. 7 and 8 , an alternate rappelling mechanism 70 according to the teachings of the present invention is disclosed. The rappelling mechanism 70 is configured to releasably engage a flat webbing 72 as previously described. The rappelling mechanism 70 has a walking pin support frame 74 which is configured to align three walking locking pins 76 , 78 , and 80 . Coupled to the center locking pin 80 is a release arm 82 . The rappelling mechanism 70 is configured to be positioned along a length of webbing 72 and further fixaby coupled the harness 52 . In this regard, the rappelling mechanism 70 is disposed between the harness 52 and a fixed point so as to allow a user to manually adjust the distance between the harness 52 and the fixed point along the webbing 72 .
[0026] The locking pin support frame 74 has a pair of generally parallel lock pin support bars 84 and 86 . The lock pin support bars 84 and 86 slidably receive the three walking locking pins 76 , 78 , and 80 . As best seen in FIG. 8 , the webbing 72 is serpentinely fed about locking pins 78 and 80 . Further, the webbing 72 is fed between the interfacing surfaces of locking pins 76 and 80 . It should be noted that the locking pins 76 , 78 , and 80 are slidable along the locking pin support bars.
[0027] The orientation of the locking pins in conjunction with the webbing 72 locks the webbing 72 and prevents relative movement of the webbing with respect to the locking pins 76 , 78 , and 80 . The locking pins 76 , 78 and 80 are generally cylindrical and can have an outer surface with a constant radius. Disposed transversely through each pin is a pair of holes which slidably accept the lock pin support bars 84 and 86 . It is envisioned the rappelling mechanism 70 can further have a suitable injection molded plastic housing and at least one web guide 71 to maintain the mechanism 70 in a preferred orientation.
[0028] The lever release arm 82 has a handle portion 90 and a camming portion 92 . The camming portion 92 , which is formed of two parallel members 91 , has first and second bearing surfaces 94 and 96 which contact locking pins 76 and 78 . Members 91 define a through hole 93 that rotatably interfaces with the outer surface 95 of locking pin 80 . Rotation of the lever release arm 82 rotates the camming portion 92 with respect to the locking pin 80 and causes the first and second bearing surfaces to apply pressure to surfaces of locking pins 76 and 80 . This pressure causes the locking pins 78 and 80 to translate and separate from locking pin 76 along the locking pin support bars. In this regard, while locking pin 76 is pressed against the stop by the lock pin support bar's formed end or stop 98 and 100 , locking pins 78 and 80 translate along the locking in support bars. The mechanism is configured so the amount of separation of the locking pins 76 , 78 and 80 is proportional to the angle of rotation of the release lever. Upon the loading of the webbing 72 from a user's weight, the webbing 72 pulls the three locking pins 76 , 78 , and 80 into engagement with the pair of stop members 98 and 100 formed on the locking pin support bars. Specifically, in loading the lock pin support bar toward locking pin 78 , the webbing 72 forces lock pin 78 into the center locking pin 80 which in turn forces and traps the webbing 72 into lock pin 76 . Lock pin 76 is stopped and held in position by the lock pin support bar's formed end or stop 98 and 100 . In this position, the mechanism 70 is in a locked condition and will not payout any webbing 72 until the release lever is pulled.
[0029] The speed of the decent is controlled by the magnitude of the forces on release arm 82 . To descend slowly, a small rotation is applied to the release arm 82 . To descend faster, forces to cause more rotation of the release arm 82 are applied. The removal of forces to the release arm 82 will cause the mechanism 70 to be again put into the locked condition.
[0030] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A controlled descent mechanism with a self locking feature. The mechanism includes a belt with an end for attaching to a higher elevation and a free end. The belt is routed between moveable pins within the mechanism and slides across the pins as it moves through the mechanism. The pins can be moved toward one another to induce a dynamic friction within the mechanism to slow the rate of belt movement. The mechanism includes an attachment location for a user harness, and can be used to lower the user while controlling the rate of descent. The mechanism includes a self locking feature to automatically arrest the descent of the user.
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RELATED APPLICATION
This Application claims priority and is entitled to the filing date of U.S. Provisional Application Ser. No. 60/205,972 filed May 19, 2000, and entitled “METHOD ALLOWING PERSISTENT LINKS TO WEB-PAGES”, the contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
The present invention is generally related to an Internet addressing system and, more particularly, to a system and method that maintains linkage between Internet addresses and the ultimate web page locations of those addresses, even where links in the Internet addresses have been broken, altered or modified.
Much of the flexibility and interconnectedness provided by the Internet and the World Wide Web is due to the extensive links that exist between webpages. Each link is the address of another webpage (or image, or sound file, or cgi-script, or other object, all of which will be referred to herein as webpages), which may reside on a different website (i.e. a different host domain) than the page containing the link, or may be contained within the same website.
The Web contains hundreds of millions of webpages, and billions of links. But as any web surfer knows, many of those links are “broken”, pointing to nowhere because the page they once pointed to no longer exists at that address.
Webpages are typically accessed through use of a web browser, though other software programs, such as Internet search utilities, may do so as well, as may a variety of built-in functions of other software products. (As used herein, the term “web browser” is meant to encompass all these means of accessing URLs.) Links may be either “absolute” or “relative”. An absolute link consists of a webpage address in the form of a Uniform Resource Locator (URL), which has the format:
http://host.domain/path/filename
Where:
“host” is, typically, www “domain” is (for IBM's website) ibm.com “path” is the fully qualified path-address of the file denoted by “filename”, comprising the target webpage, reflecting the file's location within the hierarchical directory structure of the computer on which the file resides. For example, if on the IBM website there is a sub-directory of the root directory with the name “products”, and if the “products” directory contains a further sub-directory called “hardware”, and if the “hardware” directory contains a further sub-directory called “servers”, and if the “servers” directory contains a further sub-directory called “aix”, and if the “aix” directory contained a file called “howtobuy.htm”, the path-address of “howtobuy.htm” would be: /products/hardware/servers/aix/howtobuy.htm
and the URL comprising an absolute link would be:
http://www.ibm.com/products/hardware/servers/aix/howtobuy.h tm
By default, a URL points to the beginning of a webpage, as does the above example. However, if the creator of the webpage has named any internal sections of the webpage, it then is possible to link to those sections directly. For example, the section dealing with payment terms within the “howtobuy.htm” webpage could be given the name “PT” by using the following HTML tag, positioned at the beginning of the applicable text:
<A NAME=“PT”>
The following URL could then be used to link to the specific text dealing with payment terms:
http://www.ibm.com/products/hardware/servers/aix/howtobuy.h tm#PT
Often, the filename itself may be omitted from a URL. Many web servers adopt a convention that if a filename is absent, a specific filename is assumed, often “index.htm” or “index.html”. For example, if the “howtobuy.htm” file were renamed “index.htm”, the following URL would link to it, even without supplying the filename explicitly:
http://www.ibm.com/products/hardware/servers/aix
Relative links consist of the relative path from the current webpage to the linked-to webpage. For example, if there was a webpage on IBM's website named “hwlist.htm” in the /products/hardware/ directory, it would have a URL of http://www.ibm.com/products/hardware/hwlist.htm. The hwlist.htm webpage might contain a number of links to other pages, including a link to the howtobuy.htm file described above. Instead of using the absolute link described above, a relative link could be used, which would be:
/servers/aix/howtobuy.htm
Web browsers form absolute links from relative links by combining the relative link with the path of the current webpage. They do this by concatenating the relative link together with the full path of the current webpage to form the full URL of the linked-to page, which is then used to access the linked-to page. In the example given above, when the relative link (/servers/aix/howtobuy.htm) is concatenated with the path of the hwlist.htm webpage itself (http://www.ibm.com/products/hardware) the result (http://www.ibm.com/products/hardware/servers/aix/howtobuy. htm) is the absolute URL of the linked-to page.
An advantage of using relative links when constructing webpages is that that if a webpage and all its direct or indirect sub-pages are severed from their existing location and moved to another location in the webpage tree, the relative links, which give the path information of the desired target webpage relative to the current location, continue to operate in the desired manner without modification.
A webpage may link to another, target, webpage by embedding within its HTML the address, in the form of the URL, of the target webpage. A particular URL uniquely identifies a particular webpage. For example, www.ibm.com is the URL of IBM's home page. Pages within IBM's website have URL-addresses that reflect their hierarchical location on the computer hosting the website. The page devoted to servers has a URL of www.ibm.com/servers, the page describing a particular server, the AIX computer, has a URL of www.ibm.com/servers/aix, and the page describing how to buy an AIX computer has the URL of www.ibm.com/servers/aix/howtobuy.htm. Someone wishing to, let's say, create a directory-webpage comprising a list of available computer equipment could point into the IBM website, perhaps linking to the AIX product-description at www.ibm.com/servers/aix, and the purchasing information at www.ibm.com/servers/aix/howtobuy.htm. These URLs may be manually transcribed into the HTML of the directory webpage, or they may be quasi-automatically captured while viewing the applicable page with a browser (such as Microsoft Internet Explorer or Netscape Navigator) by saving a bookmark or copying the current-URL line, then pasting this data into the HTML.
But, if IBM subsequently changes the structure of its website, any URLs previously gathered may no longer be valid. For example, if the page on servers became subordinate to a page devoted to “hardware” the server-page might have a new URL of www.ibm.com/hardware/servers and the AIX-page would have a new URL of www.ibm.com/hardware/servers/aix. Or, the IBM website might be changed from a static structure, with each page predefined, to a dynamic structure where certain pages are generated on-the-fly by a program operating on the server. For example, the URL www.ibm.com/aw-cgi/ibmISAPI.dll?ViewItem&item=259 might invoke a cgi-script named ibmISAPI, which would expect to receive an item-code corresponding to the product in question, in this example 259, corresponding to AIX. The cgi-script would use the item-code to access a database, retrieve information about the product, and build the webpage to be displayed. Or, IBM could consolidate all the information from a variety of servers, including AIX, on a single page with the URL www.ibm.com/hardware/allservers, in which case the AIX information would be embedded somewhere within this composite page.
If the prior AIX-related URLs (www.ibm.com/servers and www.ibm.com/servers/aix) had been used in any other pages as links, they would no longer work, even though the information—the content—of the pages they originally linked to still exists, though not at the same location as previously. (Note that this is fundamentally unlike certain other situations causing broken links in which the content is simply gone, such as a deleted website, an out-dated news article, or a discontinued product.) The Webmaster of the directory-webpage would not be alerted to the fact that IBM had changed the structure of their website, causing some of the links in the directory-webpage to become broken, and could only determine this fact by constant checking. In fact, there are products like Xenu's Link Sleuth or services like LinkAlarm that are specifically directed at finding and reporting on broken links by constantly or periodically monitoring the website containing them. Some websites even ask visitors to fill out a form, reporting on any broken links they may have encountered.
But however a broken link may be discovered, it usually must be fixed manually. To fix the links broken by IBM's hypothetical reorganization of its website, the webmaster of the directory-website would typically have to visit the IBM website, find the new locations of the pages that the links used to point to, copy their present URLs, and recreate the links.
A similar situation exists for those individuals who create bookmarks or favorites, which are essentially identical to links, and can be broken in the same way.
And broken links can also occur within the restructured website itself, not just externally. It's very common for the pages of a website to cross-link to one another, to allow the user to navigate to anywhere, from anywhere, and some of these links can break whenever any restructuring takes place. And relative links, which are extensively used to link within a website, though insensitive to changes to the path that occur “above” the page containing the relative link, are readily broken by any changes in the path “below” the containing page.
The author or Webmaster of the IBM website could attempt to avoid the problem of broken links by providing “redirect” instructions to the web server serving the IBM website domain. These “redirect” instructions specify both the old URL (the one that no longer exists) and the new URL that accesses to the old URL should be directed to instead. For example, accesses to the first version of the AIX page www.ibm.com/servers/aix, in this example now defunct, could be redirected to the second version at www.ibm.com/hardware/servers/aix. The web server typically effects the redirection by returning the new URL to the browser, along with an appropriate indicator; the browser then simply reprocesses the URL in the usual manner, thereby accessing the new webpage. As an alternative, a web server may itself access the new webpage and return it to the browser in response to the original request (the “old” URL), however in this instance the web server must still supply back to the browser the new URL. (Note that this is required because web browsers, as described previously, process relative links by concatenating them with the absolute URL of the page containing the relative link. Therefore, if redirection occurs, in order to be able to process relative links if any are encountered, the web browser must be informed by the web server as to the actual URL of the page that the original request was redirected to, and which was returned to the web browser for display. In the present example, though the browser may have requested www.ibm.com/servers/aix, the page actually returned to the browser has the URL www.ibm.com/hardware/servers/aix, and the browser would receive this updated URL from the server.) But, if the IBM website is restructured again, the redirection instruction might have to be changed so that accesses to the first AIX page, www.ibm.com/servers/aix, are now redirected to the third version at www.ibm.com/aw-cgi/ibmISAPI.dll?ViewItem&item=259. Moreover, since there will also continue to be accesses to the second version, another redirection instruction would have to be created so that accesses to the second version, www.ibm.com/hardware/servers/aix, are also redirected to the third version, www.ibm.com/aw-cgi/ibmISAPI.dll?ViewItem&item=259. This procedure illustrates the deficiencies of the redirection technique, which requires that each earlier version of a webpage be redirected to the current version of that webpage, and that each of these redirection instructions remain in place indefinitely, all of which is cumbersome, burdensome, and error-prone.
In addition to being used as links, URL addresses are often simply typed into the browser by the computer user. But URLs are often difficult if not impossible to remember (in one of the prior examples, the user would have to remember that www.ibm.com/aw-cgi/ibmISAPI.dll?ViewItem&item=259 is the URL for the AIX page), laborious to type, and subject to being broken or outdated in the same way as URLs used as links.
In response to these deficiencies, several firms, including Netword Inc. and RealNames Corporation, have devised systems in which users can type easy-to-remember keywords into their browsers in place of URLs. (Netword Inc. is the holder of U.S. Pat. No. 5,764,906: “Universal electronic resource denotation, request and delivery system”.) For example, if “AIX” had been established as such a keyword, a user could simply type “AIX” into his browser and be taken to the current appropriate webpage, such as www.ibm.com/aw-gi/ibmISAPI.dll?ViewItem&item=259. This is accomplished through use of a central database maintained by the proprietors (such as Netword or RealNames) of the keyword system that correlates each keyword with the applicable URL. When a user types something that looks like a keyword into a browser, the browser uses it to access the keyword database. If it's a defined keyword, the database returns the corresponding URL to the browser, which then processes that URL as if the user had typed it in. The responsibility typically rests with the webmasters of each participating website to use the facilities of the keyword system to assign the keywords, associate the appropriate URL, and update the database whenever restructuring of their website causes changes to any of the URLs associated with keywords.
A problem with keyword systems is that there is no single central keyword database: both Netword and RealNames maintain their own databases. Particular keywords might be defined in one system but not the other, or might be defined in both, but conflict with one-another. For example, the IBM webmaster might register “AIX” as a Netword keyword, and associate it with a page on the IBM website, but some other webmaster, perhaps associated with a company selling AIX-related software, or the Allied Insurance Exchange, may have previously registered “AIX” with RealNames. In this example, for a user who types in a keyword of “AIX”, the webpage that the user is eventually taken to will depend on which database the keyword is looked up in. Keywords, being short, provide a limited name-space that will inevitably lead to conflicts and collisions. For example, consider that “Explorer” is the name of a browser (from Microsoft), a sport-utility vehicle (from Ford) and the name of a Boy Scout program. Each of these organizations might wish to use “Explorer” as a keyword tied to a URL within their website. Further contributing to erratic results is the fact that different browsers give precedence to different keyword systems. For example, Microsoft Internet Explorer looks keywords up in the RealNames database, but does not consult Netword. Netscape Navigator does not use RealNames (perhaps because RealNames is partially owned by Microsoft), but can readily be customized to consult Netword. And AOL has its own system of keywords, unrelated to RealNames or Netword, that only functions for users of the AOL online service. Moreover, creating keywords can be expensive. RealNames charges an annual fee of $100 per keyword (which is greater than the annual fee to keep a domain name active) and many organizations might wish to maintain dozens or even hundreds of keywords.
Another deficiency associated with the use of keywords is that since the browser immediately translates each keyword to its associated URL and then uses that URL for further processing, if the person using the browser bookmarks (or copies, either manually or programmatically) that URL, or the URL of any subsequent webpage that the initial page might directly or indirectly link to, whether absolutely or relatively, that bookmarked or copied URL is fully vulnerable to being broken in the future, just as if a keyword had never been initially employed.
In summary, URLs are hard to remember and, when used as links, are fragile and easily broken. The process of discovering and repairing broken links is unsystematic and extremely laborious. Keyword aliases for URLs are expensive, unreliable and inconsistent, discouraging website owners from creating and publicizing them. The present invention describes several methods, which would greatly minimize the incidence of broken links, while also providing easily remembered or inferred URLs that would behave in a reliable, predictable fashion.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a system and method that allows creation of URL addresses in which the path information is partially or entirely symbolic.
It is another object of the invention to provide a system and method for Internet addressing that is more adaptable to addressing changes.
Still another object of the invention is to provide a system and method for Internet addressing which is more versatile and tolerant to revisions or modifications.
The foregoing and other objects of the invention are realized by the system and method of the present invention which is to be known as the Symbolic Addressing System (SAS) and which creates URL addresses in which the path information is partially or entirely symbolic. In accordance with several embodiments of the invention, a web site can receive and process URL addresses which are constituted partially or wholly by path information that is symbolic. A URL Resolution Database (URD) helps convert the symbolic path information to conventional physical path information that allows the web server at the web page to properly direct web information requests and to provide web content even where web page reorganizations have altered the physical location of web pages. (As used herein, the term “physical” means the structure of folders and subfolders, typically residing on a hard disk, which are used to contain the files, images, and other elements of a website.)
Preferably, the URD operates in conjunction with Correlation Records (CRs), and with a URL Correlation Tool and a SPI Correlation Tool that operate with the symbolic path information.
Alternatively, the invention operates with Augmented Web Browsers (AWBs) that consult an SPI Conversion Server (SCS) that is Internet accessible and which serves to obtain physical path information, prior to the transmission of the physical path information to the conventional web servers.
Other features and advantages of the present invention will become apparent from the following description of the invention which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram and layout of the first embodiment of the invention.
FIG. 2 is a block diagram of a second embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
It is the object of the invention, which is to be known as the Symbolic Addressing System (SAS), to provide a system to create URL addresses in which the path information is partially or entirely symbolic. Unlike the physical path information (PPI) in URLs or in absolute or relative links, which is tied to the physical structure of a website, and becomes inaccurate whenever that structure changes, symbolic path information (SPI) is largely or completely independent of the physical structure. SPIs are composed, in part, of assigned, arbitrary names that refer to particular content or subject matter, and which are associated to the appropriate, applicable PPI at the time the URL or link containing the SPI is accessed. URLs or links employing SPIs thus remain valid and unbroken so long as the same or equivalent content continues to exist somewhere within the website, and the association between SPI and PPI has been updated and kept current, which may be done by the webmaster, or through other means.
As stated above, URLs have the format:
http://host.domain/PPI-path/filename A PPI-path contains one or more directories, and can therefore be considered to consist of one or more physical path segments (PPSs), each of which also consists of one or more directories, as follows: http://host.domain/“path-segment” “path-segment” . . . . “path-segment”/filename For example the PPI /products/hardware/servers/aix may be divided into PPSs in a number of ways, including: /products/hardware/servers/aix /products & /hardware/servers/aix /products/hardware & /servers/aix /products & /hardware/servers & /aix etc. SAS allows one or more PPSs to be replaced by SPIs, with each SPI correlated to the applicable PPS through use of a database. For example, the URL www.ibm.com/products/hardware/servers/aix could be expressed, using an SPI arbitrarily named “aixinfo”, as www.ibm.com/aixinfo (the PPS corresponding to the “aixinfo” SPI is /products/hardware/servers/aix) As another example, the URL www.ibm.com/products/hardware/servers/aix/aixpage.htm could be expressed, using an SPI of “aixstuff”, as www.ibm.com/aixstuff (the PPS corresponding to the “aixstuff” SPI is /products/hardware/servers/aix/aixpage.htm) Or the same URL could be expressed, again using an SPI of “aixstuff”, as www.ibm.com/aixstuff/aixpage.htm (the PPS corresponding to the “aixstuff” SPI is /products/hardware/servers/aix/) Or multiple SPIs may be used together. For example, the same URL as used in the above two examples could be expressed, using two SPIs, as www.ibm.com/hardinfo/aixstuff (the PPS corresponding to the “hardinfo” SPI is /products/hardware and the PPS corresponding to the “aixstuff” SPI is /servers/aix/aixpage.htm).
One aspect of the SAS consists of a URL Resolution Database (URD). The URD contains Correlation Records (CRs) each of which correlates an SPI to a PPS. Each CR is assigned an access-key composed of the SPI and the host and domain name. Inclusion of the host and domain name allows a single URD to serve multiple domains without risk that SPIs applicable to one domain will conflict with those from another. The host and domain may be omitted from the key if the URD will only contain information applicable to a single domain.
The URL that is known to the web browser (and displayed to the user, and used for bookmarks, etc.) will be referred to as the “apparent” URL, or AU. The URL that is ultimately used by the web server to access the associated data will be referred to as the “effective” URL, or EU. The AU and the EU may often be identical. However, as will be seen, SAS allows the EU to be arrived at by decoding or transforming a AU that contains SPI data. Note that an EU is not merely some internal representation of a URL, or some set of parameters. An EU is a properly formed URL that could be used, unmodified, as an AU.
Another aspect of SAS consists of an Augmented Web Server (AWS). When processing URLs sent to it by a web browser, the AWS assumes that any directory name or filename that cannot be matched (which would ordinarily result in a “not found” condition) might be an SPI, and therefore uses it to access the URD database (see below). Actual SPIs will be matched in the URD. If no match is obtained, the normal “not found” processing is followed.
Though the above method of SPI detection is preferred, an alternative method is for the AWS to assume that every directory name or filename might be a SPI, and to use the name to try to access the URD before determining if the name is in fact a directory name or filename.
Another alternative method is to use an explicit tag to indicate the presence of a SPI, for example by preceding each SPI with a unique identifier-character (or string) such as “>” or “>#”.
Whichever technique may be used to recognize the SPI, the AWS employs the URD to correlate the SPI- to a PPS. If the URD contains a CR matching the supplied key, it returns the corresponding PPS to the AWS. The AWS then modifies the URL by replacing the SPI with the PPS. If there are additional SPIs in the current URL, the AWS follows the described procedure for each of them.
When all SPIs have been processed, the resultant, possibly modified, URL constitutes the EU, which the AWS processes in the usual manner and serves back the appropriate data to the web browser that transmitted the original URL. Note that if the AWS passes back to the originating browser any updated URL information (for example, as a result of redirection, or the inclusion of a default filename) the AWS does not pass back the new, modified URL containing PPSs, but instead passes back the symbolic URL, with SPIs intact, augmented, if appropriate, by including a defaulted filename. The web browser therefore will continue to use as the AU the symbolic URL (including the one or more SPIs), which will therefore be used when creating bookmarks, and as the base-URL when processing relative links. The web browser will also display the AU to the user, so that if the user copies the AU, whether using the computer or manually, any subsequent use will employ the symbolic URL. This ensures that all external URL references continue to be symbolic, with all translation to physical URLs occurring solely within the AWS.
Another aspect of the invention consists of the URL Correlation Tool (UCT). The UCT allows a Webmaster or other authorized user to create CRs within the URD correlating SPIs with their associated PPSs. The user may manually supply the SPI. The PPS may also be manually supplied, or, optionally, the UCT browses the indicated website and, while displaying a particular page, at the direction of the user, use all or a portion of the PPI from the page's URL as the PPS.
Other UCT functions allow existing CRs to be modified (for example to change the PPS associated with a particular symbolic name to a new PPS), and to delete CRs.
Another aspect of the invention consists of the SPI Correlation Tool (SCT). One of the functions of the SCT allows a Webmaster or other authorized user to incorporate into the HTML of a webpage an SPI-tag that contains the SPI associated with that webpage. A number of different conventions may be adopted for the format and placement of the SPI-tag, so long as the SPI-tag, while being intelligible to the SCT, will be ignored by web browsers. Anything contained between “<!” and “>” will be treated by a browser as a comment so, as an example, the SPI-tag might take the form of an HTLM-comment of a particular defined format, such as <! #+SPI=aixinfo>. (Or, as an alternative, the specification of the HTML language might be expanded to formally define the SPI-tag as a recognized construct.) Once inserted into the HTML by the SCT, the SPI-tag persists until intentionally removed, even if the webpage containing it were to be renamed and/or moved to a different location in the website's directory structure.
Following use of the SCT to create SPI-tags, another function of the SCT performs automatic regeneration of CRs. The SCT does this by inspecting all the pages of the website and detecting all the embedded SPI-tags. For each such tag, the SCT creates a CR correlating the indicated SPI with a PPS consisting of the entire PPI of the webpage.
For example, if the SCT was used to insert into the webpage named “aixpage.htm” a SPI-tag of <! #+SPI =aixinfo>, and if the PPI of the webpage is:
/products/hardware/servers/aix/aixpage.htm the SCT, after scanning the aixpage.htm page-file and discovering the embedded SPI-tag, creates a CR correlating “aixinfo” (the SPI) with /products/hardware/servers/aix/aixpage.htm (the PPI, used as the PPS).
As a further enhancement to this process, if one or more specific sections of the webpage have been named, by use of a “NAME=” tag, as described earlier, the SCT optimally also provides the ability to associate SPI-tags with those names. The SCT accomplishes this by using a convention based on the placement within the webpage of the SPI-tag such that SPI-tags will be associated with the previous named section or, if there is no previous named section, with the beginning of the webpage. Alternatively, or in addition, a special location-independent SPI-tag may be used that specifies the name of the section with which it should be associated. For example the tag <! #+SPI#PT=aixinfo> would associate the “aixinfo” SPI with the section of the current webpage named “PT”.
As an alternative to the AWS, the process of recognizing SPIs and converting them to PPSs may be performed by an Augmented Web Browser (AWB) rather than by the web server. The AWB (which does not have direct access to the file system of the website being accessed by a URL, and therefore cannot verify whether a seeming directory does or does not exist) assumes that any directory name contained within a URL might be a SPI, and uses that name (combined with the domain-name of the associated website) to try the hypothesis by using the presumed SPI to access the URD. Note that since most directory names would not be SPIs, this would result in a great deal of unproductive overhead, so in an embodiment using an AWB it is preferable for SPIs to be explicitly tagged, as described previously.
The URD may exist on a separate computer from the AWB, accessible via the Internet, or on the same computer. There may be a single URD, performing all SPI-resolution services for the entire Internet, or there may be multiple URDs, each containing the SPI data applicable to a distinct (or overlapping) set of domains. When processing a URL, the AWB may determine which URD to use by consulting a master server (similar to a domain-name server) that correlates domains with the applicable URD-server. The AWB converts symbolic URLs containing SPIs to physical URLs in the same manner as was described for the AWS, and retains the symbolic URL as the AU, thereby ensuring, as described above, that any bookmarks and other copies of the initial URL, or of any URLs subsequently constructed via relative links from the initial URL, record the symbolic form of that URL.
As another alternative, the AWB either sends all URLs, or only those determined to contain one or more SPIs, to another server for processing. This server, the SPI Conversion Server (SCS) performs the remainder of the processing previously described as being performed by the AWB.
Note that the information in the URD may be stored therein using a variety of expediences. These include manual entry of information, automatic gathering of information specifying relationships between symbolic path information and physical path information by automatic scanners that scan web pages and cull from it the relationships, or by communications initiated by the web servers which send to the URD which may exist on the Internet or at other locations, the correlations that pertain to them.
The various facilities, systems, subsystems, process steps, etc. described above are further elucidated by reference to FIGS. 1 and 2 , in which FIG. 1 illustrates a typical web page processing that uses the Symbolic Addressing System (SAS) 10 of the present invention, depicting a web browser 30 that receives requests to access URLs from an Internet user 32 , such requests being communicated via the Internet 34 .
The SAS 10 incorporates the web server 12 which communicates with the URD 14 and which, in turn, accesses or contains within the Correlation Records (CRs) 16 . As already described, the URL Correlation Tool (UCT) 18 is interfaced so as to be able to create various Correlation Records 16 . The functions of the SPI Correlation Tool (SCT) 20 is to insert SPI tags into the Correlation Records 16 and/or to automatically regenerate various Correlation Records as already described. The overall SAS 10 is under the control of a web site operator 36 .
With reference to FIG. 2 , instead of providing the URL translation functionality at the web server 12 , an Augmented Web Browser (AWB) 40 receives URL addresses containing symbolic path information and consults the SPI Conversion Server (SCS) 42 (which can be located on the Internet or locally) to carry out the appropriate conversions that are then communicated via the Internet to a web servers. Accordingly, in the present invention, the web browser user interface operates so that users continue to see the same apparent URLs that they are familiar with or which they have bookmarked or the like, regardless of changes, modifications, alterations, etc. in the effective URLs.
As described above, the present invention has no need to resort to or consult proprietary “key word” translating systems, as in the prior art. Rather, the web site itself provides the functionality that allows the use of symbolic path information simplifying web page addressing and providing the other benefits described above. Alternatively, the requesting web browser is augmented to provide the necessary translation, either directly or through the SPI Conversion Server, in a manner which consistently converts symbolic path information into physical path information.
Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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A system that enables creation of URL addresses in which the path information is partially or entirely symbolic. The symbolic path information is maintained even after the physical path information is altered, whereby users do not have to learn or provide constantly changing URL addresses to accommodate changes in the organization and presentation of evolving or changing web sites. To this end, web servers interface with a URL resolution database tool that contains information that enable the conversion of the symbolic path information to physical path information. Alternatively, the conversion from symbolic to physical path information is carried by augmented web browsers which have access to symbolic path information conversion servers located on the Internet at a centrally distributed location, or even locally, so that web servers receive only physical path information.
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CLAIM OF PRIORITY OR CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority to Provisional Patent Application Ser. No. 61/416,570, filed Nov. 23, 2010, the contents of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to an offshore floating platform for the drilling and production of oil and gas. Specifically, the invention relates to a circular cylindrical semi-submersible platform (C-Semi) for offshore drilling and production.
BACKGROUND OF THE INVENTION
[0003] Floating structures used for offshore oil and gas drilling and production are known. One such floating structure is conventional semi-submersible hulls. A conventional semi-submersible hull has a square pontoon structure. The square pontoon structure is coupled to four square shaped columns placed at the four corners of the pontoon structure. Therefore, the pontoon section length is the same as the length separating the columns.
[0004] In a conventional semi-submersible hull, the columns do not have strakes. Each column is connected to a deck structure to support topside facilities. A spread mooring or dynamic positioning system is used for station keeping.
[0005] Conventional semi-submersible hulls have several limitations. They are subject to large heave, roll and pitch motions. A conventional semi-submersible hull is unable to support steel catenary risers in extreme weather conditions. These steel catenary risers also have fatigue problems in long term operating conditions. Furthermore, a conventional semi-submersible hull is unable to be used for dry tree production applications while undergoing these motions.
[0006] There are also known variants of this structure that alter the draft and the column distance of the floating platform. In traditional structures, the length of the pontoon structure is considerably larger than the draft. In an attempt to reduce the effects of motions experienced in extreme and operating weather conditions, structures were developed with an increased draft and/or modified column distance. However, these deep draft variants are still operationally limited.
[0007] Another type of known floating structure is an extendable draft platform (EDP). An EDP structure includes a buoyant equipment deck. The buoyant equipment deck is either rectangular or triangular. Column wells are coupled to each corner of the buoyant equipment. On an opposite end, the columns are coupled to a heave plate. In an EDP structure, each of the columns has an upper portion with a diameter that is different from that of a lower portion, which is usually smaller. The columns can move vertically in the column well to adjust the draft.
[0008] EDP structures have several limitations. EDP structures are difficult to manufacture and maintain because they use complex, large moving components. Additionally, strong sub-surface currents can cause vortex-induced vibrations (VIV). A structure that has prolonged exposure to VIV can experience fatigue damage to components and is subject to structural failure.
[0009] A dual column semi-submersible hull is a known floating structure as well. A dual column semi-submersible hull has a deck structure that is supported by vertical columns arranged in pairs. In these structures, one set of the paired columns is displaced a distance outward from the other set of paired columns. The other set of paired columns is in line with a pontoon structure. The lower ends of this set of vertical columns are connected to the pontoon structures.
[0010] The dual column semi-submersible hull, at a much deeper draft, has better performance than a conventional semi-submersible hull at a much shallower draft. However, at the same draft, the dual column semi-submersible hull only marginally improves the motions of a conventional semi-submersible hull. In addition, the dual columns complicate design, fabrication and operation.
[0011] There is also a central pontoon semi-submersible floating platform. The central pontoon structure is disposed inboard of the columns, with each of said vertical support columns having a transverse cross sectional shape with a horizontal major axis oriented radially outward from a center point of said hull. However, the vertical wave force on the central pontoon not substantially cancelled by the forces on the columns. This arrangement has adverse effects, and can result in worse vertical motions than a conventional semi-submersible hull at the same draft.
[0012] The other known semi-submersible is octabuoy. The draft of octabuoy is substantially greater than the distance between the columns' central axes. The columns have quite large diameter relative to the length of pontoon section, and the pontoon section length is around 2 times column diameter. As a result, the column displacement is a few times greater than the pontoon displacement, and the wave forces on the columns will make a greater contribution than the force on the pontoon. The most preferred draft of octabuoy is at least 60 meters, and the most preferred ratio of draft to the distance between central axes of columns is 1.3 to 1.35. The substantially deep draft required makes it cannot integrate topsides at quaysides because of water depth limitations. Additionally, float over operations near the shore are required. The nonlinear shape and variant cross section of columns also increases fabrication complexity.
[0013] Therefore, for the drilling and production of offshore oil and gas, there is a need for a simple floating structure that is subject to minimized environmental forces and platform motions compared with known semi-submersibles.
SUMMARY OF THE INVENTION
[0014] According to an embodiment of the present invention, a C-Semi floating platform for offshore production and drilling includes a generally circular toroidal, hollow pontoon, a plurality of columns, a deck structure, and topside facilities. The circular cylindrical pontoon can be comprised of straight and curved sections. The diameter from a center of the radial width of the pontoon is larger than the distance from one column center to an adjacent column center. At the intersection points of columns and pontoon, the cross-sectional area of columns is generally greater than, but can be equal to or less than, the corresponding area of pontoon. The columns have a cross section that is either circular or square with rounded corners. If desired, each column can be provided with overlapping helical strakes, which extend across the entirety of the column perimeter below the waterline.
[0015] In one embodiment of the present invention, the offshore floating structure for the drilling and production of oil and gas includes a generally circular toroidal, hollow pontoon of substantially the same radial width throughout a perimeter of the pontoon. The offshore floating structure includes a plurality of columns of substantially a same cross-sectional area, each coupled at a coupling point, on a bottom end thereof to the pontoon at an equidistant point along the perimeter of the pontoon, and adapted to be coupled on a top end to a deck structure. The diameter from a center of the radial width of the pontoon is greater than a distance from a center of one column to a center of an adjacent column.
[0016] According to another embodiment of the present invention, the offshore floating structure is a hollow, oval toroidal pontoon of substantially a same radial width throughout the perimeter of the pontoon. The offshore floating structure includes four large columns of substantially a same cross-sectional area, each coupled on a bottom end thereof to the pontoon at an equidistant point along the perimeter of the pontoon forming two non-shortest diameters. Each large column is also adapted to be coupled on a top end to a deck structure. The offshore drilling structure also includes two small columns of substantially a same cross-sectional area, each coupled on a bottom end thereof to the pontoon at an equidistant point along the perimeter of the pontoon forming the shortest diameter. Each small column is also adapted to be coupled on a top end to a deck structure.
[0017] According to another embodiment of the present invention, the offshore floating structure is a hollow, rectangular cuboid pontoon of substantially a same radial width throughout a perimeter of the pontoon. The offshore floating structure includes four columns of substantially a same cross-sectional area, each coupled on a bottom end thereof to the pontoon at the center of each side of the pontoon. Each column is also adapted to be coupled on a top end to a deck structure.
[0018] The present invention offers utility for semi-submersible drilling and production units including wet trees with steel catenary risers (SCR) and/or dry trees with top tensioned risers (TTR). Additionally, the C-Semi hull is applicable for Tension Leg Platforms (TLPs).
[0019] The C-Semi offers several advantages, including minimized wave, current and vortex induced motions, and structural forces. These advantages significantly improve hull, mooring and riser system performance. Additionally, the present invention reduces the costs and risks typically in offshore oil and gas field development.
[0020] Further features and advantages of the present invention shall be understood in view of the following description with reference to the drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] While the present invention may be embodied in many different forms, a number of illustrative embodiments are described herein with reference to the accompanying figures. The skilled person should understand that the present disclosure is to be considered as providing examples of the principles of the invention, and such examples are not intended to limit the invention to the preferred embodiment described herein and/or illustrated herein.
[0022] FIG. 1 is a plan view of a C-Semi, according to an embodiment of the present invention.
[0023] FIG. 2 is an elevation view of a C-Semi, according to an embodiment of the present invention.
[0024] FIG. 3 is a perspective view of a C-semi, according to an embodiment of the present invention.
[0025] FIG. 4 is a detailed view of an individual column with strakes, according to another embodiment of the present invention.
[0026] FIG. 5 is a plan view of a C-Semi with the pontoon offset to the outside, according to another embodiment of the present invention.
[0027] FIG. 6 is a plan view of a C-Semi with the pontoon offset to the inside, according to another embodiment of the present invention.
[0028] FIG. 7 is a plan view of a C-Semi with square columns, according to another embodiment of the present invention.
[0029] FIG. 8 is a plan view of a C-Semi with six columns, according to another embodiment of the present invention.
[0030] FIG. 9 is a plan view of a C-Semi with straight pontoon middle sections and circular columns, according to another embodiment of the present invention.
[0031] FIG. 10 is a plan view of a C-Semi with straight pontoon middle sections and square columns, according to another embodiment of the present invention.
[0032] FIG. 11 is a perspective view of a C-Semi with straight pontoon middle sections and square columns, according to another embodiment of the present invention.
[0033] FIG. 12 is a plan view of a C-Semi with a square pontoon and circular columns, according to another embodiment of the present invention.
[0034] FIG. 13 is a graph displaying the heave response amplitude operators (RAO) for a C-Semi (as embodied in FIG. 3 ) and conventional semi-submersible hull both at the same draft.
[0035] FIG. 14 is a graph displaying the heave response amplitude operators (RAO) around wave peak period for a C-Semi (as embodied in FIG. 3 ) and conventional semi-submersible hull both at the same draft.
[0036] FIG. 15 is a graph displaying the wave exciting forces on the pontoon and columns in the vertical direction for a C-Semi (as embodied in FIG. 3 ) and a conventional semi-submersible hull both at the same draft.
DETAILED DESCRIPTION OF THE INVENTION
[0037] FIG. 1 is a plan view of a C-semi 10 with a circular cylindrical pontoon 11 according to an embodiment of the present invention. As shown, the four circular cylindrical columns 12 are coupled to the pontoon 11 at points along the perimeter of the pontoon 11 equidistant from each other. While the pontoon 11 may be a single structure or several separate structures, for ease in description, the pontoon 11 will be referred to as having four sections or quadrants 19 a , 19 b , 19 c and 19 d ; each section is coupled to and positioned between two adjacent columns 12 . The pontoon 11 is a circular, hollow toroid with an interior edge 11 a and an exterior edge 11 b . The pontoon can be filled with buoyant material such as air, or ballast such as water.
[0038] In this embodiment, parts of each column 12 can extend radially beyond the interior and exterior edges of the pontoon 11 . The maximum width (in this case the diameter) 13 of the columns 12 is larger than the radial width 16 of the pontoon 11 . Therefore, at the point where the column 12 intersects the pontoon 11 , the cross-sectional area of each column 12 is greater than the corresponding area of the pontoon 11 . The diameter from the center of the radial width of one pontoon section 17 to the center of the radial width of an opposite pontoon section 17 is larger than the distance from the center of one column 18 to the center of an adjacent column 18 . A spread mooring (not shown) can be used for station keeping of the C-Semi.
[0039] FIG. 2 is an elevation view of the C-Semi 10 with a circular cylindrical pontoon 11 according to this embodiment of the present invention. A deck structure 13 can be connected to the top end of columns 12 . Strakes 14 can be provided on the exterior of the columns 12 below the mean waterline 15 to mitigate vortex induced motions. The columns 12 can be attached to the pontoon 11 on the end opposite the deck structure 13 .
[0040] The pontoon sections are positioned radially outward relative to the columns. The diameter 23 from the center of the radial width of one pontoon section 17 to the center of the radial width of an opposite pontoon section 17 is preferably between 1.2 to 1.5 times the distance 21 from the center of one column 18 to the center of an adjacent column 18 . The pontoon sections are substantially longer relative to the column width 13 , and the distance 21 between central axes of adjacent columns is preferably 3.5 to 4 times the column width 13 . The preferred draft 20 is generally between 20 to 50 meters. The draft is between 0.3 and 1 times the distance 21 from the center of one column 18 to the center of an adjacent column 18 . The draft is also typically much less than the distance 21 between central axes of adjacent columns. The pontoon width 16 varies from 0.6 to 1 times the column width 13 . The preferred pontoon height 22 is in the range of 0.4 to 0.8 times the pontoon width 16 . The column displacement is between 0.8 to 2 times the pontoon displacement. The wave forces on the columns contribute less than the force on the pontoon for most wave periods.
[0041] FIG. 3 is a perspective view of the C-semi 10 with a circular cylindrical pontoon 11 according to this embodiment of the present invention. As shown, the four circular cylindrical columns 12 can be coupled to the pontoon 11 at equidistant points along the pontoon 11 .
[0042] FIG. 4 is a plan view of an individual column 12 according to another embodiment of the present invention. The exterior of each column can be provided with three overlapping helical strakes 14 a , 14 b and 14 c , which fully cover the column 12 perimeter below the waterline.
[0043] FIG. 5 is a plan view of a C-Semi 50 with a circular cylindrical pontoon 51 according to another embodiment of the present invention. As shown, the four circular cylindrical columns 52 can be coupled to the pontoon 51 at points along the perimeter of the pontoon 51 equidistant from each other. The pontoon 51 is a is a circular, hollow toroid with an interior edge 51 a and an exterior edge 51 b.
[0044] While the pontoon 51 may be a single structure or several separate structures, for ease in description, the pontoon 51 will be referred to as having four sections or quadrants 59 a , 59 b , 59 c and 59 d ; each section is coupled to two adjacent columns 58 . As shown, the maximum width (in this case the diameter) 53 of the columns 52 is larger than the radial width 54 of the pontoon 51 . Therefore, at the point where the column 52 intersects the pontoon 51 , the cross-sectional area of each column 52 is greater than the corresponding area of the pontoon 51 . In this embodiment, as shown, parts of each column 52 extend radially beyond only the interior edge 51 a of the pontoon 51 . The edge of a column 52 can be in line with the outer circumferential edge of the pontoon 51 . The diameter from the center of the radial width of one pontoon section 57 to the center of the radial width of an opposite pontoon section 57 is larger than the distance from the center of one column 58 to the center of an adjacent column 58 .
[0045] FIG. 6 is a plan view of a C-Semi 60 with a circular cylindrical pontoon 61 according to another embodiment of the present invention. As shown, the four circular cylindrical columns 62 can be coupled to the pontoon 61 at points along the perimeter of the pontoon 61 equidistant from each other. The pontoon 61 is a circular, hollow toroid with an interior edge 61 a and an exterior edge 61 b.
[0046] While the pontoon 61 may be a single structure or several separate structures, for ease in description, the pontoon 61 will be referred to as having four sections or quadrants 69 a , 69 b , 69 c and 69 d ; each section is coupled to two adjacent columns 68 . The maximum width (in this case the diameter) 63 of the columns 62 is larger than the radial width 64 of the pontoon 61 . Therefore, at the point where the column 62 intersects the pontoon 61 , the cross-sectional area of each column 62 is greater than the corresponding area of the pontoon 61 . In this embodiment, as shown, parts of each column 62 extend radially beyond only the exterior edge 61 b of the pontoon 61 . The diameter from the center of the radial width of one pontoon section 67 to the center of the radial width of an opposite pontoon section 67 is larger than the distance from the center of one column 68 to the center of an adjacent column 68 .
[0047] FIG. 7 is a plan view of a C-Semi 70 with a circular cylindrical pontoon 71 according to another embodiment of the present invention. As shown, the four square cylindrical columns 72 with round corners can be coupled to the pontoon 71 at points along the perimeter of the pontoon 71 equidistant from each other. The pontoon 71 is a circular, hollow toroid with an interior edge 71 a and an exterior edge 71 b.
[0048] While the pontoon 71 may be a single structure or several separate structures, for ease in description, the pontoon 71 will be referred to as having four sections or quadrants 79 a , 79 b , 79 c and 79 d ; each section is coupled to two adjacent columns 78 . The maximum width 73 of the columns 72 is larger than the radial width 74 of the pontoon 71 . Therefore, at the point where the column 72 intersects the pontoon 71 , the cross-sectional area of each column 72 is greater than the corresponding area of the pontoon 71 . In this embodiment, as shown, parts of each column 72 extend radially beyond only the exterior edge 71 b of the pontoon 71 . The diameter from the center of the radial width of one pontoon section 77 to the center of the radial width of an opposite pontoon section 77 is larger than the distance from the center of one column 78 to the center of an adjacent column 78 .
[0049] The pontoon sections are positioned radially outward relative to the columns. The diameter 76 from the center of the radial width of one pontoon section 77 to the center of the radial width of an opposite pontoon section 77 is preferably between 1.2 to 1.5 times the distance 75 from the center of one column 78 to the center of an adjacent column 78 . The pontoon sections are substantially longer relative to the column width 73 , and the distance 75 between central axes of adjacent columns is preferably 3.5 to 4 times the column width 73 . The preferred draft is generally between 20 to 50 meters. The draft is between 0.3 and 1 times the distance 75 from the center of one column 18 to the center of an adjacent column 78 . The draft is also typically much less than the distance 75 between central axes of adjacent columns. The pontoon width 74 varies from 0.6 to 1 times the column width 73 . The preferred pontoon height is in the range of 0.4 to 0.8 times the pontoon width 74 . The column displacement is between 0.8 to 2 times the pontoon displacement. The wave forces on the columns contribute less than the force on the pontoon for most wave periods.
[0050] FIG. 8 is a plan view of a C-Semi 80 according to another embodiment of the present invention. The pontoon is an oval, hollow toroid with an interior edge 81 a and an exterior edge 81 b . As shown, two small cylindrical columns 83 can be coupled to the pontoon 81 such that the distance between the coupling points of the columns and the interior of the pontoon forms the shortest diameter 85 of the oval pontoon 81 . The two small cylindrical columns 83 can have a maximum width 87 that is equal to the radial distance 86 from the interior edge 81 a to the exterior edge 81 b of the pontoon 81 . The other four large columns 82 can be coupled to the oval pontoon 81 at opposite ends of two diameters that do not comprise the shortest diameter of the oval.
[0051] The four large columns 82 can have a maximum width 84 that is larger than the radial width 86 of the pontoon 81 . Therefore, at the point where these four columns 82 intersect the pontoon 81 , the cross-sectional area of each column 82 is greater than the corresponding area of the pontoon 81 . In this embodiment, as shown, parts of each column 82 extend radially beyond both the interior edge 81 a and exterior edge 81 b of the pontoon 81 .
[0052] FIG. 9 is a plan view of a C-semi 90 according to another embodiment of the present invention. As shown, the four circular cylindrical columns 97 can be coupled to the pontoon 91 at points along the perimeter of the pontoon 91 equidistant from each other.
[0053] While the pontoon 91 may be a single structure or several separate structures, for ease in description, the pontoon 91 will be referred to as having four sections or quadrants 99 a , 99 b , 99 c and 99 d ; each section is coupled to two adjacent columns. The pontoon 91 is generally in the shape of a circular, hollow toroid with an interior edge 91 a and an exterior edge 91 b . However, each pontoon section or quadrant 99 a , 99 b , 99 c and 99 d can have linear portions 93 and non-linear portions 94 . The linear portions 93 can comprise the center of each pontoon section 99 a , 99 b , 99 c and 99 d , while the non-linear portions 94 can be nearest to the coupling points of the columns 97 and pontoon 91 . The maximum width (in this case the diameter) 98 of the columns 97 is larger than the radial width 95 of the pontoon 91 . Therefore, at the point where the column 92 intersects the pontoon 91 , the cross-sectional area of each column 92 is greater than the corresponding area of the pontoon 91 . In this embodiment, as shown, parts of each column 92 extend radially beyond the interior edge 91 a and exterior edge 91 b.
[0054] The pontoon sections are positioned radially outward relative to the columns. The diameter 96 from the center of the radial width of one pontoon section 93 to the center of the radial width of an opposite pontoon section 93 is preferably between 1.2 to 1.5 times the distance 95 from the center of one column 97 to the center of an adjacent column 97 . The pontoon sections are substantially longer relative to the column width 98 , and the distance 95 between central axes of adjacent columns is preferably 3.5 to 4 times the column width 98 . The preferred draft is generally between 20 to 50 meters. The draft is between 0.3 and 1 times the distance 95 from the center of one column 98 to the center of an adjacent column 98 . The draft is also typically much less than the distance 95 between central axes of adjacent columns. The pontoon width 92 varies from 0.6 to 1 times the column width 98 . The preferred pontoon height is in the range of 0.4 to 0.8 times the pontoon width 92 . The column displacement is between 0.8 to 2 times the pontoon displacement. The wave forces on the columns contribute less than the force on the pontoon for most wave periods.
[0055] FIG. 10 is a plan view of a C-semi 100 according to another embodiment of the present invention. As shown, the four square cylindrical columns 102 with round corners can be coupled to the pontoon 101 at points along the perimeter of the pontoon 101 equidistant from each other.
[0056] In this embodiment, each of the four columns can be positioned to face the center of the interior of the pontoon structure. While the pontoon 101 may be a single structure or several separate structures, for ease in description, the pontoon 101 will be referred to as having four sections or quadrants 109 a , 109 b , 109 c and 109 d ; each section is coupled to two adjacent columns 102 . The pontoon 101 is generally in the shape of a circular, hollow toroid with an interior edge 101 a and an exterior edge 101 b . However, each pontoon section 109 a , 109 b , 109 c and 109 d can have linear portions 103 at the center and non-linear portions 104 nearest to the coupling points of the columns 102 and pontoon 101 . The maximum width 106 of the columns 102 is larger than the radial width 105 of the pontoon 101 . Therefore, at the point where the column 102 intersects the pontoon 101 , the cross-sectional area of each column 102 is greater than the corresponding area of the pontoon 101 . In this embodiment, as shown, parts of each column 102 extend radially to flush the interior edge 101 a and exterior edge 101 b.
[0057] FIG. 11 is an elevation perspective view of a C-semi 100 according to this embodiment of the present invention. As shown, the four square cylindrical columns 102 with round corners can be coupled to the pontoon 101 at points along the perimeter of the pontoon 101 equidistant from each other.
[0058] FIG. 12 is a plan view of a C-Semi 120 according to another embodiment of the present invention. As shown, the four circular columns 122 can be coupled to the pontoon 121 at the center of each side of the pontoon 121 . The pontoon 121 is a hollow rectangular cuboid with an interior edge 121 a and an exterior edge 121 b.
[0059] While the pontoon 121 may be a single structure or several separate structures, for ease in description, the pontoon 121 will be referred to as having four sections or quadrants 129 a , 129 b , 129 c and 129 d ; each section is coupled to two adjacent columns 122 . The maximum width (in this case the diameter) of the columns 122 is larger than the width 125 of the pontoon 121 . Therefore, at the point where the column 122 intersects the pontoon 121 , the cross-sectional area of each column 122 is greater than the corresponding area of the pontoon 121 . In this embodiment, as shown, parts of each column 122 extend radially beyond the interior edge 121 a and exterior edge 121 b.
[0060] The pontoon sections are positioned radially outward relative to the columns. The diameter 126 from the center of the radial width of one pontoon section 129 a to the center of the radial width of an opposite pontoon section 129 c is preferably between 1.2 to 1.5 times the distance 123 from the center of one column 127 to the center of an adjacent column 127 . The pontoon sections are substantially longer relative to the column width 124 , and the distance 123 between central axes of adjacent columns is preferably 3.5 to 4 times the column width 124 . The preferred draft is generally between 20 to 50 meters. The draft is between 0.3 and 1 times the distance 123 from the center of one column 122 to the center of an adjacent column 122 . The draft is also typically much less than the distance 123 between central axes of adjacent columns. The pontoon width 125 varies from 0.6 to 1 times the column width 124 . The preferred pontoon height is in the range of 0.4 to 0.8 times the pontoon width 125 . The column displacement is between 0.8 to 2 times the pontoon displacement. The wave forces on the columns contribute less than the force on the pontoon for most wave periods.
[0061] A C-Semi with a circular cylindrical ring pontoon and straked columns is beneficial because the structure minimizes hydrodynamic and structural forces. FIG. 13 is a graph of heave response amplitude operators for a C-Semi according to the embodiment shown in FIG. 3 and a conventional semi-submersible hull at the same draft. FIG. 14 is a graph showing a detailed view around the wave peak period (Tp) in FIG. 13 . The graphs show that the C-Semi minimizes hydrodynamic loading around both the wave peak period and the natural period through cancellation and redistribution of wave excitation forces on pontoon and columns. Specifically, the C-Semi reduces heave motions by 20% to 30% in extreme hurricane conditions when compared to a conventional semi-submersible hull at the same draft. The C-Semi reduces heave motions by 40% to 50% in fatigue sea states.
[0062] FIG. 15 is a graph of wave exciting forces on the pontoon and columns in the vertical direction corresponding to FIG. 14 . The C-Semi and conventional semi-submersible hulls have the same draft, column width, and distance between central axes of adjacent columns, and thus the same wave exciting force on columns, A. According to preferred embodiments of the present invention, the wave exciting force on the C-Semi pontoon, C, is noticeably less than the wave exciting force of the conventional semi-submersible pontoon, B, for a dominant wave peak period. Since the wave forces on the pontoon and columns act in the opposite direction, the total force on the C-Semi, C-A, is more significantly reduced than the conventional semi-submersible, B-A.
[0063] A C-Semi also minimizes vortex induced motion (VIM) by mitigating current flows through strakes. In comparison to a conventional semi-submersible hull, the C-Semi reduces VIM amplitude by 50% or more and riser fatigue damage by 80% in current sea states. The C-Semi structure also reduces VIM induced mooring and riser tension and fatigue damage. The C-Semi structure may offer additional benefits by minimizing current forces.
[0064] Furthermore, the C-Semi minimizes structural forces. In comparison to a conventional semi-submersible hull, the C-Semi reduces structural forces and stress concentrations by eliminating the sharp corners between the pontoon sections.
[0065] Thus, the preferred embodiments have been fully described above. Although the invention has been described based upon these preferred embodiments, it would be apparent to those of skill in the art that certain combinations, modifications, variations, and alternative constructions could be made to the described embodiments within the spirit and scope of the invention.
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An offshore floating structure ( 10 ) for the drilling and production of oil and gas includes a generally circular toroidal, hollow pontoon ( 11 ) of substantially the same radial width throughout a perimeter of the pontoon. The offshore floating structure includes a plurality of columns ( 12 ) of substantially a same cross-sectional area, each coupled at a coupling point, on a bottom end thereof to the pontoon at an equidistant point along the perimeter of the pontoon, and adapted to be coupled on a top end to a deck structure. The diameter ( 23 ) from a center of the radial width of the pontoon is greater than a distance ( 21 ) from a center of one column to a center of an adjacent column.
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BACKGROUND
Timed location sharing is a process for providing location sharing among approved users. In some situations, users may wish to share their location with others, such as friends, family, and/or co-workers. For example, co-workers may wish to keep track of each other during a conference weekend. Thus, the conventional strategy is to keep in touch with each other using mobile devices such as cellular telephones. This often causes problems because the conventional strategy requires users to proactively and continuously send each other messages. For example, users may need to make several calls and/or send several messages every time they move to keep others apprised of their location. Other conventional systems may broadcast a user's location, but may have no limitations as to duration, distance, identity, and/or other factors, thus raising privacy concerns.
SUMMARY
Timed location sharing may be provided. 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 this Summary intended to be used to limit the claimed subject matter's scope.
Rule-based location sharing may be provided. A location determining device, such as a Global Positioning System (GPS) enabled device, may receive a request to share the location. A rule may be used to determine whether to share the location with the requestor. If the rule allows the location to be shared, the location may be sent to the requestor. The location may be relayed through a third party server, which may be operative to evaluate the rule before sharing the location with the requestor.
Both the foregoing general description and the following detailed description provide examples and are explanatory only. Accordingly, the foregoing general description and the following detailed description should not be considered to be restrictive. Further, features or variations may be provided in addition to those set forth herein. For example, embodiments may be directed to various feature combinations and sub-combinations described in the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate various embodiments of the present invention. In the drawings:
FIG. 1 is a block diagram of a user interface;
FIG. 2 is an illustration of an operating environment;
FIG. 3 is a flow chart of a method for providing timed location sharing; and
FIG. 4 is a block diagram of a system including a computing device.
DETAILED DESCRIPTION
The following detailed description refers to the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While embodiments of the invention may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting, reordering, or adding stages to the disclosed methods. Accordingly, the following detailed description does not limit the invention. Instead, the proper scope of the invention is defined by the appended claims.
Rule-based location sharing may be provided. Consistent with embodiments of the present invention, a user may choose to share their location with another individual, group, organization, and/or business. In order to alleviate privacy concerns with unlimited sharing, rules may be used to limit the location sharing according to various criteria such as duration and/or proximity. For example, a user may set up a rule to share their location with selected contacts for a particular duration, such as an hour.
FIG. 1 is a block diagram of a user interface (UI) 100 for providing rules-based location sharing. UI 100 may comprise an information bar 105 that may comprise, for example, a current time 110 and a battery status indicator 115 . UI 100 may further comprise a main display area 120 and a rule UI 125 . Rule UI 125 may comprise a menu 130 and a drop-down icon 135 . UI 100 may further comprise a contact information area 140 .
FIG. 2 is an illustration of an operating environment 200 for providing rules-based location sharing. Operating environment 200 may comprise a plurality of user devices each operative to determine their current geographic location. Such user devices may include, for example, a first tablet computer 205 , a second tablet computer 210 , a laptop 215 and a cellular telephone 220 . Consistent with embodiments of the invention, each of the plurality of user devices may be operative to send and/or receive a location for at least one of the other user devices. For example, first tablet computer 205 may be operative to determine its current location and may share that current location with second tablet computer 210 . The user devices may be equipped with modules for determining location, such as a Radio Frequency Identification (RFID) tag, a Global Positioning System (GPS) or a cellular location system.
Radio-frequency identification (RFID) may comprise the use of an object applied to and/or incorporated into a product, animal, and/or person for the purpose of identification and tracking using radio waves. Some tags may be read from several meters away and beyond the line of sight of the reader. RFID tags may comprise an integrated circuit for storing and processing information, modulating and demodulating a radio-frequency (RF) signal, and other specialized functions. RFID tags may also comprise an antenna for receiving and transmitting the signal. RFID tags may comprise active RFID tags, which may comprise a battery and may transmit signals autonomously, and passive RFID tags, which have no battery and may require an external source to provoke signal transmission.
GPS is a global navigation satellite system (GNSS) developed by the United States Department of Defense and managed by the United States Air Force. It may be used freely, and may be used by civilians for navigation purposes. A GPS navigation device may comprise a device that receives GPS signals for determining a present position. The GPS navigation device may calculate its position by precisely timing the signals sent by the GPS satellites high above the Earth. Each satellite continually transmits messages containing the time the message was sent, precise orbital information, and the general system health and rough orbits of all GPS satellites. The GPS navigation device may measure the transit time of each message and may compute the distance to each satellite. Geometric trilateration may be used to combine these distances with the location of the satellites to determine the device's location.
Cellular location systems may include systems operative to locate a device comprising a cellular radio based on a communication with a cellular network antenna. The communication can be analyzed according to various algorithms such as time difference of arrival (TDOA), time of arrival (TOA), and/or angle of arrival (AOA). In the TDOA algorithm, the network may determine the time difference and therefore the distance from each base station to a mobile phone. The TOA algorithm may use the absolute time of arrival at a certain base station rather than the difference between two stations. The AOA algorithm may locate the device at the point where the lines along the angles from multiple base stations intersect. Cell of Origin (COO) positioning may determine a device's location according to the location of a base station that receives an outgoing communication from the device.
The plurality of devices may be operative to share their identified location with at least one other of the plurality of user devices. Consistent with embodiments of the invention, each of the plurality of user devices may be operative to send its location to a server operative to relay that location to one and/or more of the other devices. For example, first tablet computer 205 and second tablet computer 210 may each send their identified location to laptop 215 . Laptop 215 may then send the location of first tablet computer 205 to second tablet computer 210 and/or cellular telephone 220 . Consistent with further embodiments of the invention, a user device may be operative to send its location to other user devices within a given range. For example, first tablet computer 205 may establish a five mile radius 230 centered on the device and may send its location to second tablet computer 210 and laptop 215 within radius 230 . Second tablet computer 210 may establish a five mile radius 240 centered on the device and may send its location to first tablet computer 205 , laptop 215 and cellular telephone 220 . Second tablet computer 210 may relay a location received from first tablet computer 205 to a device outside of radius 230 , such as cellular telephone 220 .
FIG. 3 is a flow chart setting forth the general stages involved in a method 300 consistent with an embodiment of the invention for providing rule-based location sharing. Method 300 may be implemented using a computing device 400 as described in more detail below with respect to FIG. 4 . Ways to implement the stages of method 300 will be described in greater detail below. Method 300 may begin at starting block 305 and proceed to stage 310 where computing device 400 may create a rule. For example, a user may select a contact via UI 100 with whom to share their location for a certain restricted duration, such as 15 minutes. Consistent with embodiments of the invention, the user may create a rule allowing their location to be shared with any and/or all contacts, such as all members of a group of contacts, employees of a company, or contacts affiliated with an organization. The rule may comprise, for example, a parameter restricting sharing of the user's information according to a time duration, a distance and/or proximity to another user, and/or a distance and/or proximity to another location.
From stage 310 , where computing device 400 created the rule, method 300 may advance to stage 320 where computing device 400 may receive information about the user. For example, cellular telephone 220 may receive a current location from a GPS component of cellular telephone 220 . Consistent with embodiments of the invention, a device such as laptop 215 may receive information, such as a location for cellular telephone 220 , from a user.
Once computing device 400 receives the user information in stage 320 , method 300 may continue to stage 330 where computing device 400 may determine whether to share the information according to the rule. For example, the rule may comprise a parameter allowing the user's location to be shared for fifteen minutes. Information received within that fifteen minute window may be shared while information received after that window may not be shared. Consistent with embodiments of the invention, a user may be notified when a rule allowing information to be shared is about to expire. For example, one minute before a fifteen minute sharing rule expires, the user may be notified via a message on the device. Further consistent with embodiments of the invention, the notification may comprise a request to extend and/or modify the rule. For example, a user may be provided with the option to renew the location sharing rule for another fifteen minutes.
If, at stage 330 , computing device 400 determines that the information should not be shared, method 300 may end at stage 365 . Otherwise, method 300 may advance to stage 340 where the information may be shared. For example, cellular telephone 220 may send its location to second tablet computer 210 . Second tablet computer 210 may receive the information and display it to a user, such as by displaying a map with an icon indicating the location of cellular telephone 220 .
After computing device 400 shares the information in stage 330 , method 300 may proceed to stage 350 where computing device 400 may determine whether an event associated with the rule and/or a user should be modified according to the received information. For example, the location sharing rule may be associated with a scheduled occurrence that may be modified according to a user's shared location. For example, a rule may be created to share the location of a plurality of meeting attendees with each other. The attendees' locations may be received by computing device 400 and evaluated to determine whether a parameter of the event, such as a start time, a meeting location, and/or an attendee list, should be modified based on the user's location.
If, at stage 350 , computing device 400 determines that the event should not be modified, method 300 may end at stage 365 . Otherwise, method 300 may advance to stage 360 where computing device 300 may modify a parameter associated with the event. For example, a meeting start time may be changed if one and/or more attendees have not arrived at the meeting location by the scheduled start time. For another example, a meeting location may be relocated to a new location more convenient to at least one attendee's current location. For yet another example, a meeting attendee list may be updated, such as by marking an attendee as absent based on their received location during the meeting time.
Once computing device 400 modifies the event parameter in stage 340 , method 300 may then end at stage 350 .
A rule may restrict sharing of the user's information to a current location and/or a previous location. For example, the user's device may allow the calculation of a route from a first location to a second location and the rule may share the user's progress along the route comprising previous locations along the route and/or the user's present location. Consistent with embodiments of the invention, the projected future route may also be shared. The rule may restrict sharing such that the user's location is only shared while within a certain proximity of the projected route. For example, the user's location may only be shared while the user is within a mile of the route, but may stop sharing if the user deviates from the route by more than a mile. The rule may restrict location sharing until the user arrives at the endpoint of the route; once the user arrives, location sharing may cease. Alternately, the rule may not allow location sharing until after the user arrives at a location, such as the route's endpoint.
The user's device, such as cellular telephone 220 , may be operative to determine a distance between the device's current location and a second location and calculate a travel time for the device to arrive at the second location. The calculation may be based, for example, on an average speed of the device's movement and/or a baseline average, such as 3 miles per hour for a person on foot or 60 miles per hour for a car traveling on a highway.
Any number of rules may be created a proximity to a person or location. For example, a user device associated with a child may give the child freedom to roam within a certain radius, such as a neighborhood, of a second user device associated with a parent. If the child leaves that proximity, the child's device may provide an indicator disclosing sharing and/or privacy options such as informing the child that if they proceed, their information may be shared with their parent. Once outside the radius, location sharing may cease according to a rule, such as if the child arrives at a known location (e.g. a relative's house).
Further consistent with embodiments of the invention, rules may be created that restrict sharing of a user's location if the user is within a certain proximity of another user and/or another location. For example, an attendee at a meeting may create a rule operative to share their location with other attendees of the meeting while the attendee is within a geographic boundary comprising an office building. The shared location may comprise the attendees physical location and may be shared by indicating that location on a map display provided by a device used by one of the other attendees. The sharing attendee's location may also be provided to recipients in the form of an estimated time of arrival at a particular location, such as a recipient's current location and/or a location for the meeting, such as a conference room. The rule may disable sharing of the attendee's location if they are in proximity to certain other locations, such as a restroom. Alternately, an estimated time of travel between the attendee's location and a second location and/or an estimated time of arrival may be shared while in proximity to such a location.
Rules may be created by a user on a device associated with the user. For example, a user may use UI 100 to create a location sharing rule on cellular telephone 220 . Consistent with embodiments of the invention, rules may be created on a separate device, such as laptop 215 and/or another computing device, and transmitted to a user's device. The user's device may then be operative to determine its location and whether or not to share its location according to the received rule. For example, a server computer used by a restaurant may create a rule for a diner who makes a reservation that shares the diner's location until the reservation time arrives, the diner arrives, and/or the reservation is canceled. The rule may be transmitted to the diner's device, such as cellular telephone 220 , and the device may request permission from the diner to enable the location sharing rule.
An embodiment consistent with the invention may comprise a system for providing rule-based location sharing. The system may comprise a memory storage and a processing unit coupled to the memory storage. The processing unit may be operative to receive a request to share a location of a device operative to determine a geographic location, associate at least one restriction with the request to share the location, determine whether the at least one restriction is satisfied, and in response to determining that the at least one restriction is satisfied, share the location of the device.
Another embodiment consistent with the invention may comprise a system for providing rule-based location sharing. The system may comprise a memory storage and a processing unit coupled to the memory storage. The processing unit may be operative to create a rule associated with a first user, receive a location associated with the first user, determine whether the location associated with the first user should be shared with at least one second user according to the rule, and in response to determining that the location associated with the first user should be shared with at least one second user according to the rule, share the location with the at least one second user.
Yet another embodiment consistent with the invention may comprise a system for providing rule-based location sharing. The system may comprise a memory storage and a processing unit coupled to the memory storage. The processing unit may be operative to create a rule associated with a first user, receive information associated with the first user, determine whether to share the information associated with the first user with at least one second user according to the rule associated with the first user, share the location with the at least one second user, determine whether to modify the scheduled event according to the information associated with the first user; and modify at least one parameter of the scheduled event, wherein the at least one parameter comprises at least one of the following: a time of the scheduled event, a location of the scheduled event, and an attendee list of the scheduled event.
The rule may comprise at least one parameter comprising at least one of the following: a duration, a distance from at least one other user, and a distance from at least one other location. The information may comprise at least one of the following: a location of the first user, a distance of the location of the first user from the at least one other location, an estimated time of arrival of the first user at the at least one other location, and a proximity of the first user to the at least one other user.
FIG. 4 is a block diagram of a system including computing device 400 . Consistent with an embodiment of the invention, the aforementioned memory storage and processing unit may be implemented in a computing device, such as computing device 400 of FIG. 4 . Any suitable combination of hardware, software, or firmware may be used to implement the memory storage and processing unit. For example, the memory storage and processing unit may be implemented with computing device 400 or any of other computing devices 418 , in combination with computing device 400 . The aforementioned system, device, and processors are examples and other systems, devices, and processors may comprise the aforementioned memory storage and processing unit, consistent with embodiments of the invention. Furthermore, computing device 400 may comprise an operating environment for system 100 as described above. System 100 may operate in other environments and is not limited to computing device 400 .
With reference to FIG. 4 , a system consistent with an embodiment of the invention may include a computing device, such as computing device 400 . In a basic configuration, computing device 400 may include at least one processing unit 402 and a system memory 404 . Depending on the configuration and type of computing device, system memory 404 may comprise, but is not limited to, volatile (e.g. random access memory (RAM)), non-volatile (e.g. read-only memory (ROM)), flash memory, or any combination. System memory 404 may include operating system 405 , one or more programming modules 406 , and may include a GPS/Navigation application 420 . Operating system 405 , for example, may be suitable for controlling computing device 400 's operation. In one embodiment, programming modules 406 may include GPS/Navigation application 420 operative to communicate with a location-determining module 419 . Furthermore, embodiments of the invention may be practiced in conjunction with a graphics library, other operating systems, or any other application program and is not limited to any particular application or system. This basic configuration is illustrated in FIG. 4 by those components within a dashed line 408 .
Computing device 400 may have additional features or functionality. For example, computing device 400 may also include additional data storage devices (removable and/or non-removable) such as, for example, magnetic disks, optical disks, or tape. Such additional storage is illustrated in FIG. 4 by a removable storage 409 and a non-removable storage 410 . Computer storage media may include volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information, such as computer readable instructions, data structures, program modules, or other data. System memory 404 , removable storage 409 , and non-removable storage 410 are all computer storage media examples (i.e memory storage.) Computer storage media may include, but is not limited to, RAM, ROM, electrically erasable read-only memory (EEPROM), flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store information and which can be accessed by computing device 400 . Any such computer storage media may be part of device 400 . Computing device 400 may also have input device(s) 412 such as a keyboard, a mouse, a pen, a sound input device, a touch input device, etc. Output device(s) 414 such as a display, speakers, a printer, etc. may also be included. The aforementioned devices are examples and others may be used.
Computing device 400 may also contain a communication connection 416 that may allow device 400 to communicate with other computing devices 418 , such as over a network in a distributed computing environment, for example, an intranet or the Internet. Communication connection 416 is one example of communication media. Communication media may typically be embodied by computer readable instructions, data structures, program modules, or other data in a modulated data signal, such as a carrier wave or other transport mechanism, and includes any information delivery media. The term “modulated data signal” may describe a signal that has one or more characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media may include wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, radio frequency (RF), infrared, and other wireless media. The term computer readable media as used herein may include both storage media and communication media.
As stated above, a number of program modules and data files may be stored in system memory 404 , including operating system 405 . While executing on processing unit 402 , programming modules 406 (e.g. GPS/Navigation application 420 ) may perform processes including, for example, at least one of method 300 's stages as described above. The aforementioned process is an example, and processing unit 402 may perform other processes. Other programming modules that may be used in accordance with embodiments of the present invention may include electronic mail and contacts applications, word processing applications, spreadsheet applications, database applications, slide presentation applications, drawing or computer-aided application programs, etc.
Generally, consistent with embodiments of the invention, program modules may include routines, programs, components, data structures, and other types of structures that may perform particular tasks or that may implement particular abstract data types. Moreover, embodiments of the invention may be practiced with other computer system configurations, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers, and the like. Embodiments of the invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
Furthermore, embodiments of the invention may be practiced in an electrical circuit comprising discrete electronic elements, packaged or integrated electronic chips containing logic gates, a circuit utilizing a microprocessor, or on a single chip containing electronic elements or microprocessors. Embodiments of the invention may also be practiced using other technologies capable of performing logical operations such as, for example, AND, OR, and NOT, including but not limited to mechanical, optical, fluidic, and quantum technologies. In addition, embodiments of the invention may be practiced within a general purpose computer or in any other circuits or systems.
Embodiments of the invention, for example, may be implemented as a computer process (method), a computing system, or as an article of manufacture, such as a computer program product or computer readable media. The computer program product may be a computer storage media readable by a computer system and encoding a computer program of instructions for executing a computer process. The computer program product may also be a propagated signal on a carrier readable by a computing system and encoding a computer program of instructions for executing a computer process. Accordingly, the present invention may be embodied in hardware and/or in software (including firmware, resident software, micro-code, etc.). In other words, embodiments of the present invention may take the form of a computer program product on a computer-usable or computer-readable storage medium having computer-usable or computer-readable program code embodied in the medium for use by or in connection with an instruction execution system. A computer-usable or computer-readable medium may be any medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device.
The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific computer-readable medium examples (a non-exhaustive list), the computer-readable medium may include the following: an electrical connection having one or more wires, a portable computer diskette, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, and a portable compact disc read-only memory (CD-ROM). Note that the computer-usable or computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory.
Embodiments of the present invention, for example, are described above with reference to block diagrams and/or operational illustrations of methods, systems, and computer program products according to embodiments of the invention. The functions/acts noted in the blocks may occur out of the order as shown in any flowchart. For example, two blocks shown in succession may in fact be executed substantially concurrently or the blocks may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
While certain embodiments of the invention have been described, other embodiments may exist. Furthermore, although embodiments of the present invention have been described as being associated with data stored in memory and other storage mediums, data can also be stored on or read from other types of computer-readable media, such as secondary storage devices, like hard disks, floppy disks, or a CD-ROM, a carrier wave from the Internet, or other forms of RAM or ROM. Further, the disclosed methods' stages may be modified in any manner, including by reordering stages and/or inserting or deleting stages, without departing from the invention.
All rights including copyrights in the code included herein are vested in and the property of the Applicant. The Applicant retains and reserves all rights in the code included herein, and grants permission to reproduce the material only in connection with reproduction of the granted patent and for no other purpose.
While the specification includes examples, the invention's scope is indicated by the following claims. Furthermore, while the specification has been described in language specific to structural features and/or methodological acts, the claims are not limited to the features or acts described above. Rather, the specific features and acts described above are disclosed as example for embodiments of the invention.
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Rule-based location sharing may be provided. A location determining device, such as a Global Positioning System (GPS) enabled device, may receive a request to share the location. A rule may be used to determine whether to share the location with the requestor. If the rule allows the location to be shared, the location may be sent to the requestor. The location may be relayed through a third party server, which may be operative to evaluate the rule before sharing the location with the requestor.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a transmission lever unit for vehicle (defined as a transmission lever unit in a broad sense, including a lever mechanism for switching between “forward” and “reverse” and “2WD” and “4WD” for operating a transmission (defined as a transmission in a broad sense, including a mechanism for switching between “forward” and “reverse” and between “2WD” and “4WD”) of a vehicle such as a three-wheeled or four-wheeled utility (working) vehicle, a three-wheeled or four-wheeled leisure vehicle (hereinafter referred to as a small vehicle) enabling the operation by a driver seated on a driver's seat that is apart from the transmission, and a mounting structure of a coil spring suitable for use in the transmission lever unit.
[0003] 2. Description of the Related Art
[0004] In the case of small vehicles, e.g., all-terrain vehicles including leisure and utility vehicles, a transmission has gear trains for a plurality of different systems, e.g., a gear train for changing a gear ratio (high-speed gear and low-speed gear), a gear train for switching between “forward” and “reverse”, and a gear train for switching between “2WD” and “4WD”.
[0005] In conventional all-terrain vehicles, operation levers are provided in the vicinity of a driver's seat for the respective gear trains for the plurality of systems.
[0006] When the operation levers are thus provided, the constitution around the driver's seat is complicated and the transmission lever unit for vehicle is correspondingly complicated.
[0007] Under the circumstances, Publication of Unexamined Patent Application No. Hei. 8-337131 discloses an operation lever unit in which the use of one operation lever enables the operations of connecting means, e.g., push-pull cables and connecting rods, for two systems.
[0008] This operation lever unit is constituted such that, while shifting operation for one of the systems is conducted by using one of the connecting means, the connecting means in the other system is free. In other words, while the switching operation between “forward” and “reverse” is being performed, the force of this operation does not act to maintain the current condition (e.g., high-speed gear) of the system for changing the gear ratio. Accordingly, it is necessary to increase a detent force of the operation lever unit for the purpose of maintaining the current condition of the gear train for the system which should not be operated. In that case, however, the lever needs to be operated by a force exceeding the detent force, so that a great force is required to operate the lever. As a result, operation of the operation lever feels heavy to the operator. In addition, in this constitution, high rigidity and precision are needed in respective members. This results in a heavyweight and expensive lever unit.
SUMMARY OF THE INVENTION
[0009] The present invention addresses the above-described conditions, and an object of the present invention is to provide a lightweight transmission lever unit for a vehicle that can be operated without an increase in an operation force and need not increase the rigidity of respective members. Another object of the present invention is to provide a mounting structure of a coil spring suitable for use in the transmission lever unit.
[0010] According to the present invention, there is provided a transmission lever unit for vehicle comprising: a single transmission lever for operating the transmission unit; a first lever member swingable around a first pivot and having a second pivot; and a second lever member integrally attached to a base end portion of the transmission lever and swingable around the second pivot orthogonal to the first pivot, the transmission lever unit being adapted to select a desired combination of gear trains of first and second systems of the transmission through independent connecting means of the first and second systems by operation of the transmission lever, wherein the first connecting means is adapted to operate by a swing operation of the transmission lever around the first pivot, and the second connecting means is adapted to operate by swing operation of the transmission lever around the second pivot.
[0011] In accordance with the transmission lever unit so constituted, the gear trains of the two systems can be independently operated by using one transmission (or operation) lever, and the shifting operation for one of the gear trains does not affect the shifting operation of the other gear train. Therefore, it is not necessary to increase an operation force applied to the operation lever and increase the rigidity of the respective members. This results in a lightweight transmission lever unit for a vehicle. More specifically, the operation lever is swung around the first pivot to cause the first connecting means to operate, thereby operating the first gear train of the transmission, while the operation lever is swung around the second pivot to cause the second connecting means to operate, thereby operating the other gear train of the transmission. So, during the swing operation around either the first pivot or the second pivot, the position of the other pivot side can be maintained as it is. Therefore, it is not necessary to provide a detent mechanism with a large detent force for maintaining the current condition on the first pivot side and the second pivot side. The use of this lever unit can reduce the operation force exerted by the operator for swinging the target side. As a result, it is not necessary to increase the rigidity of the respective members of the transmission lever unit for a vehicle, and a lever unit that could be lightweight and manufactured at a low cost is achieved. In addition, the swing operation around the second pivot does not affect the swing operation around the first pivot.
[0012] It is preferable that in the transmission lever unit for a vehicle, the second pivot is provided at a tip end of the first lever member, because this provides rational placement.
[0013] It is preferable that the transmission lever unit for a vehicle further comprises a third lever member swingable around a third pivot provided in a unit frame in parallel with the second pivot, the third lever member and the second lever member being connected by means of a connecting member, and the second connecting means is adapted to operate via the third lever member by swing operation of the operation lever around the second pivot. Thereby, the tip end of the second connecting means can be easily positioned in the vicinity of the first pivot and the second connecting means is hardly affected by the swing operation around the first pivot.
[0014] It is preferable that in the transmission lever unit for a vehicle, a tip end portion of the first connecting means is connected to a portion of the first lever member that is apart from the first pivot and a tip end portion of the second connecting means is connected to a portion of the third lever member that is apart from the third pivot. Thereby, the constitution enabling the shifting operation is attained.
[0015] It is preferable that in the transmission lever unit for a vehicle, the connecting member is comprised of a rigid member, and connecting elements having three degrees of freedom are respectively disposed at a connected portion of the connecting member and the third lever member and at a connected portion of the connecting member and the second member. Thereby, the third lever member is hardly affected by the swing operation of the first lever member around the first pivot.
[0016] It is preferable that in the transmission lever unit for a vehicle, the connecting elements are a ball-joint mechanism. Thereby, the power can be smoothly transmitted with three degrees of freedom.
[0017] It is preferable that in the transmission lever unit for a vehicle, the first pivot is provided substantially vertically and the second pivot is substantially horizontal.
[0018] It is preferable that in the transmission lever unit for a vehicle, at least one of the first lever member, the second lever member, and the third lever member, is comprised of two members coupled to each other by means of elastic means. Thereby, shocking force caused by the transmitting operation is alleviated by the elastic means, to and therefore, the operator can smoothly operate the lever.
[0019] It is preferable that in the transmission lever unit for a vehicle, the first system is a system for changing a gear ratio and the second system is a system for switching between forward and reverse.
[0020] It is preferable that in the transmission lever unit for a vehicle, at least one of the first lever member, the second member, and the third lever member includes a first plate member and a second plate member respectively provided with openings overlapping with each other as seen from one direction, and the elastic means is formed by disposing a spring in the openings. Thereby, sufficient elastic function is obtained with a simple constitution and a lightweight constitution is obtained.
[0021] It is preferable that in the transmission lever unit for a vehicle, the openings of the first plate member and the second plate member have substantially equal length. This constitution allows the deformation of the entire spring, e.g., the entire coil spring to be fully utilized for elastic function.
[0022] It is preferable that in the transmission lever unit for a vehicle, the spring is a coil spring, a convex portion for prevention of disengagement of the spring toward an opposite side of the second plate member is provided at a portion of the opening of the first plate member so as to extend toward the opposite side of the second plate member and a convex portion for prevention of disengagement of the spring toward an opposite side of the first plate member is provided at a portion of the opening of the second plate member so as to extend toward the opposite side of the first plate member. Thereby, the coil spring can be reliably held in the openings.
[0023] It is preferable that the convex portion is formed by two opposed bent portions.
[0024] It is preferable that in the transmission lever unit, the coil spring is held from its outer periphery by the convex portions provided at the openings of the first plate member and the second plate member. Thereby, the coil spring can be reliably and stably held in the openings from its outer periphery.
[0025] According to the present invention, there is also provided a mounting structure of a coil spring held by two members disposed such that at least part of the members are substantially parallel to each other, for elastically connecting the two members via the coil spring, the structure having openings at parts of the members which are substantially parallel to each other so as to overlap with each other as seen from one direction, and the coil spring disposed in the openings.
[0026] In accordance with the mounting structure of the coil spring, it is possible to realize the mounting structure of the coil spring capable of holding the coil spring simply and reliably by the two members that are substantially parallel to each other.
[0027] It is preferable that in the mounting structure of the coil spring, the two members are first and second plate members, the openings of the first plate member and the second plate member have substantially equal length, a convex portion for prevention of disengagement of the spring toward an opposite side of the second plate member is provided at a portion of the opening of the first plate member, so as to extend toward the opposite side of the second plate member and a convex portion for prevention of disengagement of the spring toward an opposite side of the first plate member is provided at a portion of the opening of the second plate member, so as to extend toward the opposite side of the first plate member. In this mounting structure, the coil spring can be reliably held in the openings in a simple manner.
[0028] It is preferable that in the mounting structure of a coil spring, the coil spring is held from its outer periphery by the convex portions provided at the openings of the first plate member and the second plate member. The coil spring can be reliably and stably held in the openings from its outer periphery.
[0029] It is preferable that in the mounting structure of a coil spring, the openings and the convex portions are formed by one pressing operation. Thereby, these portions can be formed speedily and at a low cost.
[0030] The above and further objects and features of the invention will more fully be apparent from the following detailed description with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] [0031]FIG. 1 is a perspective view seen from an oblique front direction, showing an entire constitution of a small four-wheeled utility vehicle according to an embodiment of the present invention;
[0032] [0032]FIG. 2 is a side view showing the small four-wheeled utility vehicle of FIG. 1 in which rear wheels are represented by two-dot chain lines;
[0033] [0033]FIG. 3 is a plan view showing an entire constitution of the small four-wheeled utility vehicle in which a luggage deck of the vehicle of FIG. 1 is removed therefrom and an upper half portion of a cover of a belt converter is illustrated to be cut away;
[0034] [0034]FIG. 4 is a side view partially showing a transmission lever unit for vehicle which is mounted in the small four-wheeled utility vehicle of FIGS. 1 - 3 ;
[0035] [0035]FIG. 5 is a cross-sectional view taken in the direction of arrows substantially along line V-V of FIG. 4;
[0036] [0036]FIG. 6 is a plan view taken in the direction of arrows substantially along line VI-VI of FIG. 4;
[0037] [0037]FIG. 7A is a plan view showing a constitution of a first lever member of the transmission lever unit of FIG. 4;
[0038] [0038]FIG. 7B is a side view showing the constitution of a first lever member of the transmission lever unit for vehicle of FIG. 4;
[0039] [0039]FIG. 7C is a view taken in the direction of arrows substantially along line c-c of FIG. 7A, and showing the constitution of the first lever member of the transmission lever unit for vehicle of FIG.4;
[0040] [0040]FIG. 7D is a side view showing a constitution of the first lever member of the transmission lever unit for vehicle of FIG. 4, and partially showing a spring mounting portion;
[0041] [0041]FIG. 7E is a cross-sectional view taken in the direction of arrows substantially along line e-e of FIG. 7D;
[0042] [0042]FIG. 8A is a plan view showing a first member of the first lever member of FIGS. 7 A- 7 E;
[0043] [0043]FIG. 8B is a side view showing the first member of the first lever member of FIGS. 7 A- 7 E;
[0044] [0044]FIG. 8C is a view taken in the direction of arrows substantially along line c-c of FIG. 8A and showing the first member of the first lever member of FIGS. 7 A- 7 E;
[0045] [0045]FIG. 9A is a plan view showing a second member of the first lever member of FIGS. 7 A- 7 E;
[0046] [0046]FIG. 9B is a side view showing the second member of the first lever member of FIGS. 7 A- 7 E;
[0047] [0047]FIG. 9C is a view taken in the direction of arrows substantially along line c-c of FIG. 9A and showing the second member of the first lever member of FIGS. 7 A- 7 E;
[0048] [0048]FIG. 10A is a plan view showing the second lever member of FIGS. 4 - 6 , with a tip portion of a transmission lever portion omitted;
[0049] [0049]FIG. 10B is a side view showing the second lever member of FIGS. 4 - 6 , with the tip portion of the transmission lever portion omitted;
[0050] [0050]FIG. 11A is a side view showing a first member of a third lever member of FIGS. 4 - 6 ;
[0051] [0051]FIG. 11B is a view taken in the direction of arrows substantially along line b-b of FIG. 11A and showing the first member of the third lever member of FIGS. 4 - 6 ;
[0052] [0052]FIG. 12A is a side view showing a second member of the third lever member of FIGS. 4 - 6 ;
[0053] [0053]FIG. 12B is a view taken in the direction of arrows substantially along line b-b of FIG. 12A and showing the second member of the third lever member of FIGS. 4 - 6 ;
[0054] [0054]FIG. 13A is a plan view showing a unit frame of FIGS. 4 - 6 ;
[0055] [0055]FIG. 13B is a side view showing the unit frame of FIGS. 4 - 6 ;
[0056] [0056]FIG. 13C is a view taken in the direction of arrows substantially along line c-c of FIG. 13B;
[0057] [0057]FIG. 13D is a view taken in the direction of arrows substantially along line d-d of FIG. 13B and showing the unit frame of FIGS. 4 - 6 ;
[0058] [0058]FIG. 14 is a side view showing the entire transmission lever unit of FIGS. 4 - 6 with the transmission lever and wires attached thereto;
[0059] [0059]FIG. 15 is a view showing a plate provided with a gate pattern of the transmission lever unit of FIG. 14, seen from a driver's seat; and
[0060] [0060]FIG. 16 is a plan view schematically showing a constitution of a power train of a vehicle comprising the transmission lever unit of FIGS. 4 - 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] Hereinafter, a transmission lever unit for a vehicle according to an embodiment of the present invention will be described. By way of example, a transmission lever unit mounted in a small four-wheeled utility (working) vehicle as a small vehicle will be described in detail with reference to drawings.
[0062] Referring now to FIGS. 1 - 3 , there is shown a small four-wheeled utility vehicle V. In vehicle V, power from an engine E placed behind a seat S and beneath a luggage deck is changed to have a desired speed by a belt converter B placed on the left side of the engine E (left side in the traveling direction) and a transmission Tm, and rear wheels Hr are driven via a differential gear DG and right and left drive shaft DS. Since the vehicle V is of a 4WD type, front wheels Hf can be also driven via a propeller shaft Ps (see FIGS. 3, 16) extended forwardly from the transmission Tm.
[0063] As shown in FIGS. 2, 3, the transmission Tm is remotely operated by a transmission lever unit Dm provided in the vicinity of a handle Hd of the driver's seat Dd. The transmission lever unit Dm is provided with a transmission lever Ls protruded from a dash board Db in front of the driver's seat Db in this embodiment, for being operated by an operator (driver) Or. A body portion of the transmission lever unit Dm is provided at the base end side of the transmission lever Ls, i.e., inside of the dash board Db.
[0064] The operator Or uses the transmission lever unit Dm to select a gear train of the transmission Tm at the rear side of the vehicle via a push-pull wire (“connecting means”) Wp 1 or Wp 2 (see FIG. 16). Specifically, the gear ratio (“high-speed gear” or “low-speed gear”), and “forward” or “reverse” is selected. The transmission lever unit Dm is constituted as described below.
[0065] Specifically, as shown in FIGS. 4 - 6 , the transmission lever unit Dm comprises a unit frame Fd that is formed by pressing a plated-steel thin plate with a sheet metal press, and that is fixed to a vehicle body Fr (see FIGS. 2, 3). Transmission lever unit Dm further includes a first plated-steel lever member Lm 1 , a second plated-steel lever member Lm 2 , a third plated-steel lever member Lm 3 , a plated-steel tie rod Tr, a first pivot Ss 1 , a second pivot Ss 2 , and a third pivot Ss 3 , which are all mounted on the unit frame Fd. The first lever member Lm 1 is swingable around the first pivot Ss 1 comprised of a vertical shaft. The second lever member Lm 2 is swingable around the second pivot Ss 2 comprised of a horizontal shaft orthogonal to the first lever member Lm 1 . The third lever member Lm 3 is swingable around the third pivot Ss 3 located in parallel with the second pivot Ss 2 at a neutral position (home position). The tie rod Tr is comprised of a rigid body connecting the third lever member Lm 3 and the second lever member Lm 2 . As shown in FIG. 6, when no tensile force from the wire Wp 1 is applied to the first lever member Lm 1 , the first lever member Lm 1 is pulled to the right side of FIG. 6 by a spring St engaged at one end with the unit frame Fd so that a predetermined condition (e.g., high-speed gear) is maintained.
[0066] In this embodiment, the first lever member Lm 1 of FIGS. 7 A- 7 C comprises a first member Lm 1 a L-shaped in a plan view of FIGS. 8 A- 8 C, and a second member Lm 1 b of FIGS. 9 A- 9 C provided so as to overlap with part of the first member Lm 1 a substantially in a surface contacting relationship. As shown in FIG. 7A, the second member Lm 1 b is engaged with the first member Lm 1 a by means of an engagement portion Lmt and the first pivot Ss 1 such that it is relatively movable (swingable) toward the direction indicated by an arrow Y of FIG. 7A. In the placement state of FIGS. 7 A- 7 C, the first member Lm 1 a and the second plate member Lm 1 b are respectively provided with openings Op overlapping with each other as seen in a plan view. A coil spring Sc is disposed in the openings Op to bias the two members so as to be swingable toward the direction indicated by an arrow Y. The coil spring Sc is held from its outer periphery by means of a convex portion Lm 13 and a convex portion Lm 14 formed to provide openings Op.
[0067] As shown in FIGS. 7A, 7C, an attaching pin Lm 1 e is integrally provided on an upper surface of a tip end of the second member Lm 1 b to attach the wire Wp 1 to the second member Lm 1 b.
[0068] A pipe member Lm 5 is integrally provided on the side of the first member Lm 1 a which does not overlap with the second member Lm 1 b , to pivotally mount the second pivot Ss 2 of the second lever member Lm 2 .
[0069] As shown in FIGS. 10A, 10B, a base end portion of the operation lever Ls is integrally welded to a tip end side (right side in FIGS. 10A, 10B) of the second lever member Lm 2 . A portion Lm 2 b at the base end side of the second lever member Lm 2 (attaching side to the first member Lm 1 a ) is two-forked. This two-forked portion Lm 2 b is provided with mounting holes Lm 2 h to connect the pipe member Lm 5 (see FIG. 7A) of the first member Lm 1 a side to be pivotally mounted. The two-forked portion Lm 2 b is further provided with a mounting hole Lm 2 d at a base end side closer to a base end than the mounting holes Lm 2 h on the second lever member Lm 2 , to allow a lower end portion of the tie rod Tr (see FIG. 4) to be pivotally mounted. As shown in FIG. 4, in this embodiment, ball joints Bj are respectively provided at the lower end portion and an upper end portion of the tie rod Tr respectively connected to the third lever member Lm 3 and the second lever member Lm 2 so as to have mechanically three-degree freedom.
[0070] Also, as shown in FIGS. 10A, 10B, the upper end Lme and the lower end Lme at the base end portion of the second lever member Lm 2 are bent at a right angle with respect to the base portion Lm 2 c of the second lever member Lm 2 without interference with the tie rod Tr for the purpose of rigidity.
[0071] In this embodiment, the third lever member Lm 3 comprises a first member Lm 3 a “inverted-L” shaped by providing a pipe member Lm 3 ap pivotally attached to the third pivot Ss 3 and a plate member Lm 3 an vertically extending from a right end of the pipe member Lm 3 ap , as shown in FIGS. 11A, 11B, and a second member Lm 3 b of the third lever member Lm 3 comprised of a bent portion Lm 3 bu provided so as to partially hold the first member Lm 3 a in such a manner that the bent portion Lm 3 bu and the plate member Lm 3 an of the first member Lm 3 a are in surface contact with each other, and a pipe member Lm 3 br pivotally attached to the third pivot Ss 3 at a lower end of the second member Lm 3 b , as shown in FIGS. 12 (A), 12 (B). The second member Lm 3 b is engaged with the first member Lm 3 a by means of engagement at the bent portion Lm 3 bu provided at the second member Lm 3 b and the third pivot Ss 3 such that it is relatively movable (swingable) toward the direction indicated by an arrow X of FIG. 4. Similarly to the constitution of the first lever member Lm 1 , the coil spring Sc is held by the first member Lm 3 a and the second member Lm 3 b . More specifically, in the placement of FIGS. 4 - 6 , the first member Lm 3 a and the second member Lm 3 b (see FIG. 11A, 11B, 12 A, 12 B) are respectively provided with openings Op overlapping with each other as seen in a side view. The coil spring Sc is disposed in the openings Op to bias these two members to cause the openings Op to overlap with each other. The coil spring Sc is held from its outer periphery by means of a convex portion Lm 7 and a convex portion Lm 8 formed for provision of the opening Op.
[0072] An attaching pin Lm 3 e is, as shown in FIGS. 12A, 12B, integrally provided at an upper end portion of the second member Lm 3 b to attach the wire Wp 2 to the second member Lm 3 b.
[0073] The unit frame Fd is, as shown in FIGS. 13A, 13B, provided with an attaching hole 9 for attaching an attaching pin 6 (see FIGS. 4 - 6 ) as the first pivot Ss 1 and an attaching hole 10 for attaching an attaching pin 8 (see FIGS. 4 - 6 ) as the third pivot Ss 3 . These attaching holes 9 , 10 are orthogonal to each other. The unit frame Fd is further provided with concave portions 11 , 12 to which tip end portions of cable sheaths of the wires Wp 1 , Wp 2 are fixed.
[0074] As shown in FIG. 14, mounting holes 13 , 14 and mounting nuts 15 , 16 are provided at one end face of the unit frame Fd, for mounting of the unit frame Fd to the rear face of the dashboard Db.
[0075] A plate provided with a gate pattern (groove conforming to a pattern of a shifting operation) shown in FIG. 15 is attached to the front surface of the dashboard Dc. In FIG. 15, Ls represents a shaft cross-section of the transmission lever Ls.
[0076] Subsequently, the function of the transmission lever unit Dm will be described in greater detail below.
[0077] As shown in FIG. 2, operator Or seated on driver's seat Dd holds the handle Hd with the left hand and operates lever Ls according to the gate pattern 16 of FIG. 15 with the right hand, thereby selecting “forward” or “reverse” and the gear ratio (“high-speed gear” or “low-speed gear”). More specifically, according to the gate pattern 16 , operator Or shifts lever Ls from a neutral position N laterally provided at the center in the vertical direction, to the left-end side, and further upwardly, thereby selecting “forward F and high-speed gear Hi”, while operator Or shifts lever Ls from the neutral position N, to the rightend side, and further upwardly, thereby selecting “forward F and low-speed gear Lw”. Also, operator Or shifts lever Ls from the left side to the right side while downwardly pressing lever Ls, thereby selecting “reverse Rv”.
[0078] By shifting lever Ls to select “forward F and high-speed gear Hi”, in the transmission lever unit Dm, the first lever member Lm 1 is swung clockwise around the first pivot Ss 1 in FIG. 6 and then, the second lever member Lm 2 is swung counterclockwise around the second pivot Ss 2 in FIG. 4. Thereby, the third lever member Lm 3 connected to the second lever member Lm 2 by means of the tie rod Tr is swung counterclockwise around the third pivot Ss 3 in FIG. 4. As a result, the wire Wp 1 for selecting the “high-speed gear” or “the low-speed gear” is pulled (to the right side in FIG. 4) to allow the “high-speed gear” to be selected and the wire Wp 2 for by selecting “forward” or “reverse” is pushed (to the left side in FIG. 4) to allow “forward gear” to be selected.
[0079] Meanwhile, by shifting the lever Ls to select the “forward and low-speed gear”, in the transmission lever unit Dm, the first lever member Lm 1 is swung counterclockwise around the first pivot Ss 1 in FIG. 6, and then second lever member Lm 2 is swung counterclockwise around the second pivot Ss 2 in FIG. 4. Thereby, the third lever member Lm 3 connected to the second lever member Lm 2 by means of the tie rod Tr is swung counterclockwise around the third pivot Ss 3 in FIG. 4. As a result, the wire Wp 1 is pushed to allow “low-speed gear” to be selected and the wire Wp 2 is pushed to allow “forward gear” to be selected.
[0080] Further, by shifting the lever Ls to select “reverse”, in the transmission lever unit Dm, the first lever member Lm 1 is swung counterclockwise around the first pivot in FIG. 6, and then the second lever member Lm 2 is swung clockwise around the second pivot Ss 2 in FIG. 4. Thereby, the third lever member Lm 3 connected to the second lever member Lm 2 by means of the tie rod Tr, is swung clockwise around the third pivot Ss 3 in FIG. 4. As a result, the wire Wp 1 is pulled to allow “low-speed gear” to be selected and the wire Wp 2 is pulled to allow “reverse gear” to be selected. In case of the transmission of this embodiment, the gear train for selecting “forward” or “reverse” and the gear train for selecting “high-speed gear” or “low-speed gear” are comprised of independent gear trains, and therefore, when “reverse” is selected, this operation for selecting the reverse gear does not affect the already selected high-speed or low-speed gear.
[0081] In the above-identified shifting operation in the transmission lever unit Dm of this embodiment, because the connected portion of the second lever member Lm 2 and the tie rod Tr is located in the vicinity of the first pivot Ss 1 , the wire Wp 2 is maintained at a predetermined condition during the operation for selecting “high-speed gear” or “low-speed gear”.
[0082] In addition, because the second lever member Lm 2 and the third lever member Lm 3 are connected by means of the tie rod Tr comprising the ball joint mechanisms Bj at both ends. Therefore, without a need for connecting structure having so-called “play”, the lever member Lm 2 and the third lever member Lm 3 can be smoothly operated even if the attaching positions at both ends three-dimensionally vary.
[0083] In this embodiment, since the first lever member Lm 1 and the third lever member Lm 3 are each comprised of two members and the coil spring Sc is interposed between these two members, the shifting operation makes the operator Or feel good.
[0084] In the “mounting structure of the coil spring Sc” employed in the embodiment, the members between which an elastic member (coil spring Sc) is interposed are simply provided with the openings OP and the convex portions for prevention of the disengagement of the coil spring Sc are provided at the outer periphery of the openings Op. Thus, the mounting structure reliably holding the coil spring Sc, can be attained in a very simple manner. The openings and the convex portions can be simply pressed by one pressing. While the convex portion is formed by the two opposed bent portions, their tip end portions may be integrally connected to each other.
[0085] The “mounting structure of the coil spring sc” is not limited to the mounting structure applied to the transmission lever unit, but can be, as a matter of course, employed in mounting structures of coils of another units. Also, the members are not limited to the aforesaid two plate members but any other types of two members may be employed provided that these members are substantially parallel to each other.
[0086] Subsequently, the schematic constitution of the small four-wheeled utility vehicle V of FIG. 1 comprising the above-mentioned transmission lever unit will be described with reference to FIGS. 2 - 3 . The periphery except beneath seat S located at the front of vehicle V is surrounded by pipe frame 53 . The pipe frame 53 is comprised of a pipe 53 a and a pipe 53 b . The pipe 53 a located behind the seat S and vertically provided on the left side is connected to an intake port 13 provided in a cover C of the belt converter B by means of a connecting tube or the like (not shown), for supplying air containing little dust. The pipe 53 b located behind the seat S and vertically provided on the right side is connected to an air-intake port of a carburetor (not shown) of the engine E via an air cleaner and a connecting tube 54 a placed beneath the seat S.
[0087] A luggage deck 56 to be loaded with luggage is provided behind the seat S and swingable around a swing shaft 56 a of FIG. 2 as indicated by an arrow R to damp the luggage.
[0088] The engine E integrally provided with the belt converter B is mounted below a floor face F of the luggage deck 56 . The transmission Tm is placed behind the engine E and a muffler M is provided behind the transmission Tm. The muffler M is connected to an exhaust port of the engine E by means of an exhaust pipe 59 , for muffling an exhaust gas from the engine E and discharging the resulting gas to the outside.
[0089] While description has been given of the transmission lever unit applied to the small four-wheeled utility vehicle of FIGS. 1 - 3 , this unit may be, as a matter of course, applied to various types of vehicles, e.g., a straddle-type small four-wheeled leisure vehicle. In that case, the same functions and effects are attained.
[0090] Also, the description has been given exclusively of the transmission lever unit comprising the gear train of “forward” and “rearward” and the gear train of “high-speed gear” and “low-speed gear” which is independent of the former gear train. Alternatively, a gear train of “forward” and “reverse” (or a gear train of “high-speed gear” and “low-speed gear”) and a gear train of “4WD” and “2WD,” which is independent of the former gear train, may be adopted.
[0091] Numerous modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, the description is to be construed as illustrative only, and is provided for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the structure and/or function may be varied substantially without departing from the spirit of the invention and all modifications which come within the scope of the appended claims are reserved.
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Disclosed are a transmission lever unit for vehicle comprising: a single transmission lever for operating the transmission unit; a first lever member swingable around a first pivot and having a second pivot; and a second lever member integrally attached to a base end portion of the transmission lever and swingable around the second pivot orthogonal to the first pivot, the transmission lever unit being adapted to select a desired combination of gear trains of first and second systems of the transmission through independent connecting means of the first and second systems by an operation of the lever, wherein the first connecting means is adapted to operate by swing operation of the transmission lever around the first pivot, and the second connecting means is adapted to operate by swing operation of the transmission lever around the second pivot, and a mounting structure of a coil spring held by two members disposed such that at least part of the members are substantially parallel to each other, for elastically connecting the two members via the coil spring, the structure having openings at parts of the members which are substantially parallel to each other so as to overlap with each other as seen from one direction, and the coil spring disposed in the openings.
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This is a continuation of application Ser. No. 07/730,203, filed Jul. 15, 1991.
BACKGROUND OF THE INVENTION
The present invention relates to cleaning devices, and particularly cleaning devices which apply a cleaning solution to a surface to be cleaned and then use a source of suction to remove the cleaning solution, and any dirt mixed therein, from the surface to be cleaned.
Commonly assigned U.S. Pat. No. 4,558,484, the entire disclosure of which is hereby incorporated by reference, describes a cleaning device having a main housing, a suction nozzle at the lower end of the housing, a handle at the upper end of the housing and a pair of wheels attached near the lower end of the housing by means of struts. A reservoir of cleaning fluid detachably connects to a port on the main housing. A pair of tanks are removably mounted to the lower end of the housing. One of the tanks includes a supply of clean water; the other tank receives the dirty mixture of water and cleaning fluid that is vacuumed from the surface being cleaned.
In the cleaning device described in above-incorporated U.S. Pat. No. 4,558,484, a blower which provides the suction is located in the main housing, near its upper end. Directly above the blower is an electric motor which powers the blower. Beneath the blower is an air/liquid separator which separates the air from the mixture of air and dirty cleaning solution. The dirty solution passes by a conduit into the dirty water reservoir.
In the cleaning device described in above-incorporated U.S. Pat. No. 4,558,484, positive pressure from the blower is directed into the cleaning fluid bottle and clean water tank through inlet openings in the bottle and tank. This forces cleaning fluid and water out of outlets in the bottle and tank, respectively into separate conduits. After the cleaning fluid is mixed with the water, the mixed solution passes through a flexible conduit to a manifold on the underside of the main housing. The air exhausted by the blower is also directed into the manifold, so that the air being exhausted draws the water and cleaning fluid mixture out of the manifold and onto the surface to be cleaned. A pinch valve mechanism operated by a trigger on the handle is spring biased to crush the flexible conduit leading to the manifold to allow the user to control the application of the cleaning fluid/water mixture to the surface to be cleaned with the trigger.
While the cleaner described in above-incorporated U.S. Pat. No. 4,558,484 is versatile and effective for cleaning carpets and floors, it is not as well-suited for above-the-floor cleaning (i.e., cleaning upholstery, draperies, etc.) as the cleaner of the present invention. And, although some cleaners do exist which can perform above-the-floor cleaning by spraying a cleaning fluid on a surface and then vacuuming up the fluid, such systems have been bulky and inconvenient to use, and have usually been expensive to manufacture.
Accordingly, there is a need for an inexpensive, mobile cleaner which can spray a cleaning fluid on both floor and above-the-floor surfaces to be cleaned, and then vacuum the surface to remove the cleaning fluid and dirt.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an inexpensive, mobile cleaner which can effectively spray a cleaning fluid on both floor and above-the-floor surfaces to be cleaned, and then vacuum the surface to remove the cleaning fluid and dirt.
It is also an object of this invention to provide an inexpensive and reliable upholstery or hand tool for a cleaner, wherein the upholstery tool includes a means for spraying a cleaning fluid on a surface to be cleaned, valve means for controlling the means for spraying, wherein the hand tool can be connected to a source of pressurized cleaning fluid and a source of suction air for vacuuming the mixture of dirt and cleaning fluid from the surface to be cleaned.
It is a further object of this invention to provide a one-step connection for coupling two parallel fluid lines.
It is another object of this invention to provide a detachable squeegee which can be easily clipped onto and removed from a suction nozzle.
In accordance with this invention, a cleaner for controllably spraying a cleaning fluid on both floor and above-the-floor surfaces to be cleaned, and then vacuuming the surface, is provided. The cleaner includes a cleaning fluid pump for drawing cleaning fluid from a cleaning fluid supply means. The output of the pump is attached to a nipple connector extending beside and parallel to the suction line connector of the cleaner. A floor nozzle can be detachably connected to the nipple connector and suction line connector, and a trigger means can be used to spray cleaning fluid on the surface to be cleaned through a spray nozzle attached to the floor nozzle and connected to the nipple connector. The floor nozzle can be replaced by a hand tool which also connects to the nipple connector and the suction line connector. When the hand tool is used, a trigger lock is provided to lock the trigger means in a position to keep the pump on, and the application of cleaning fluid is controlled by a pinch valve mechanism in the hand tool.
Also provided is a hand or upholstery tool for use with a cleaner which applies a cleaning fluid to a surface to be cleaned and then vacuums up the cleaning fluid. The hand tool comprises a unitary housing having a cylindrical main body, a rear nozzle wall, a nozzle base, and a pair of downwardly extending, parallel side walls. A face plate comprising a front nozzle wall and two nozzle side walls is adhered to the rear nozzle wall and the nozzle base to form the nozzle. A trigger mechanism and a spray nozzle attach to the underside of the hand tool between the parallel side walls. The trigger mechanism controls a hammer which is spring biased to crush a flexible conduit supplying cleaning fluid against the main body of the hand tool unless the rear end of the trigger is drawn toward the main body of the hand tool. The flexible conduit carries pressurized cleaning fluid to the spray nozzle.
A coupling arrangement for detachably coupling both suction and cleaning fluid lines from a hose assembly to a cleaning appliance is also provided. A tubular suction line coupling part and a cleaning fluid nipple on the cleaning appliance are coupled to a hose assembly by a coupling collar which fits over the suction line coupling part, with the cleaning fluid nipple fitting in a bore in a projection on the coupling collar.
A squeegee which can be clipped onto and easily removed from a floor nozzle is also provided. The squeegee mounting clip positions the squeegee blade low enough so as to raise the floor nozzle brush off the floor.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
FIG. 1 is a perspective view of the main unit of a cleaner in accordance with the present invention;
FIG. 2 is side view of the main unit of a cleaner in accordance with the present invention, with the floor nozzle removed;
FIG. 3 is a front view of the upper portion of a cleaner of the type of the present invention, with the upper housing removed;
FIG. 4 is a rear view of the lower portion of a cleaner in accordance with the present invention, with the rear cover removed;
FIG. 4A is a view of the pump switch assembly employed in one embodiment of the present invention;
FIG. 5 is a cross-sectional view of a handle of a cleaner in accordance with the present invention;
FIG. 5A is an exploded view of the handle, trigger and trigger lock assembly of a cleaner in accordance with the present invention;
FIG. 6 is a perspective view of the tank unit of the cleaner in accordance with the present invention;
FIG. 6A is cross-sectional view of the tank unit shown in FIG. 6;
FIG. 7 is a rear view of the floor nozzle shown in FIG. 1;
FIG. 7A is a side view of the floor nozzle shown in FIG. 1;
FIG. 8 is a perspective view of a hand tool and hose assembly in accordance with the present invention;
FIG. 9 is bottom view of the hand tool and a portion of hose assembly shown in FIG. 8;
FIG. 10 is a cross-sectional view of the hand tool and a portion of hose assembly shown in FIG. 8;
FIG. 11 is a view of a portion of the bottom of the hand tool shown in FIG. 8, with the trigger and spray tip removed;
FIG. 12 is a cross-sectional view of the hose assembly shown in FIG. 8;
FIG. 13 is an end view of the connector on the hose assembly shown in FIG. 8 which joins the hose assembly to the hand tool;
FIG. 14 is an end view of the connector on the hose assembly shown in FIG. 8 which joins the hose assembly to the cleaner shown in FIGS. 1 and 2;
FIG. 15 is a cross-sectional view of the connection between the hose assembly and the cleaner shown in FIGS. 1 and 2;
FIG. 16 is a view of the ring lock in the suction line coupling of the cleaner of the present invention;
FIG. 17 is a side view of the ring lock in the suction line coupling of the cleaner of the present invention;
FIG. 18 is a cross-sectional view of the floor nozzle spray tip shown in FIG. 7;
FIG. 19 is a cross-sectional view of the hand tool spray tip shown in FIGS. 9 through 11;
FIG. 20 is a diagram showing a fluid circuit for use with the cleaner of the present invention;
FIG. 21 is a front view of a squeegee and squeegee mounting bracket in accordance with the cleaner of the present invention;
FIG. 22 is a cross-sectional view of the squeegee and squeegee mounting bracket mounted on a vacuum floor nozzle in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is an improved cleaner of the type shown and described in above-incorporated U.S. Pat. No. 4,558,484. As shown in FIGS. 1 and 2 of the present application, main cleaner unit 10 includes an upper housing 12, a rear housing 13 and a rear cover 11. Handle 14, and rear housing 13 are attached to main frame 17 (shown in FIGS. 3 and 4). Upper housing 12 is attached to rear housing 13. Leverage-assist pad 15 is an integral part of handle 14.
A pair of struts 20 (only one of which is shown in FIGS. 1 and 2) attaches wheels 18 to main frame 17. Wheels 18 may optionally include rubber tires 19. Floor nozzle 16 attaches to main unit suction connector 40. Frame stand 22 attaches to the underside of the main frame 17. Frame stand 22 is raised slightly off the floor when floor nozzle 16 is attached to the main unit, as shown in FIG. 1.
Tank unit 34 includes clean water tank 35 and dirty solution tank 36. Water is added to clean water tank 35 in the opening normally covered by tank cap 37. Tank unit 34, which can be removed to fill clean water tank 35 or empty dirty solution tank 36, is held in position by cam latch 38 as described in above-incorporated U.S. Pat. No. 4,558,484.
Cleaning fluid bottle 26, which contains concentrated cleaning fluid, is removably attached to cleaner 10 at cleaning fluid port 28. The docking port connection with cleaning fluid bottle 26 is described in above-incorporated U.S. Pat. No. 4,558,484.
Upper housing 12 may have a window 30 such as is shown in FIG. 1 so that air/liquid separator 32 can be seen through window 30.
FIG. 2 is a side view of cleaner 10, but with floor nozzle 16 removed. As shown in FIG. 2, cleaning solution nipple connector 42 is located directly under main housing suction connector 40. Conduit 44 provides pressurized cleaning solution to nipple connector 42 from pump 104 (not shown in FIG. 2) which is located between main frame 17 and rear cover 11.
FIG. 2 also shows trigger 48 in handle 14. Directly in front of trigger 48 is trigger lock 50. Power switch 54 controls power to the cleaner 10. Power switch 54 can be a two-position (on/off) switch, or it may have more positions if the motor for the blower is to be operated at more than one speed. A power line cord (not shown) enters rear housing 13 on the side opposite power switch 54.
FIG. 2 also shows cleaner 10 standing on wheels 18 and frame stand 22, as floor nozzle 16 has been removed.
FIG. 3 shows the motor 60, blower 66, air/liquid separator 32 and tank block 74 in rear housing 13. The motor 60, which may have one or more speeds, is powered by power line cord 55 via switch 54. The motor shaft drives blower 66 in blower chamber 64.
Air/liquid separator 32 is preferably transparent, as shown in FIG. 3. The mixture of dirty air and liquid from the suction nozzle travels through suction conduit 76 and enters air/liquid separator 32 through an opening 67 in the back of separator 32. As described and shown more fully in above-incorporated U.S. Pat. No. 4,558,484, air in separator 32 is drawn up through the open bottom of conical shroud 33 and into blower chamber 64 through an opening at the top of conical shroud 33. From blower chamber 64, the air is exhausted via exhaust conduit 78, which leads down to the bottom of the cleaner housing, where the air is exhausted from the cleaner 10. Liquid and dirt mixed therein entering separator 32 are drawn by gravity down to the open end 71 of separator 32. Tank unit 34 (not shown in FIG. 3) sealingly connects to the open end 71 of separator 32, with gasket 70 sealing the connection.
The motor 60, blower chamber 64, air/liquid separator 32, and tank block 74, which are mounted to main frame 17 by conventional means, are not discussed in great detail here as they are known to those skilled in the art and as they are described in above-incorporated U.S. Pat. No. 4,558,484.
FIG. 3 also shows the upper end of the cleaning fluid port 28, cleaning fluid bottle bleed connector 94 and cleaning fluid line connector 96. Thin conduit 80 connects cleaning fluid bottle bleed connector 94 to a first connector 90 on the lower side of blower chamber 64. Similarly, a second connector 92 on blower chamber 64 is connected by thin conduit 82 to water tank bleed connector 98 on tank block 74. The thin conduits preferably comprise PVC tubing, the ends of which are stretched tightly over the connectors to seal the connection.
Tank block 74, which is attached to separator 32, also has a water line connector 100, which is located directly behind water tank bleed connector 90 as shown in FIG. 3. Water conduit 86 connects water line connector 100 to a first connector 103 on "T" connector 101, which is shown through transparent separator 32 in FIG. 3. "T" connector 101 is shown more clearly in FIG. 20. Similarly, cleaning fluid conduit 84 connects cleaning fluid line connector 96 to a second connector 105 on the "T" connector 101 shown in detail in FIG. 20. Water conduit 86 and cleaning fluid conduit 84 are preferably transparent PVC tubing having respective inner diameters of about 0.187 and 0.156 inches, respectively. The three passageways in "T" connector 101 all have the same inner diameters, preferably about 0.120 inches.
While the embodiment of the invention described herein employs "T" connector 101 as a mixing manifold, it will be understood this is but one of a multitude of manifolds which can be used for this purpose.
While a number of different cleaning fluids may be employed in the present invention, the preferred cleaning fluids are Regina® STEEMER® Carpet Shampoo and Regina® STEEMER® Upholstery Shampoo.
FIG. 4 shows cleaning solution pump 104, which is preferably a 120V electric oscillating pump, such as Eaton Controls Mod. No. CP5. Pump 104, which includes input connector 108 and output connector 110, is mounted on two mounting brackets 112 and 114, each of which includes a semi-circular opening. Input connector 108 and output connector 110 have grooves 111 and 113, respectively, which fit into the semicircular-thin openings of mounting brackets 112 and 114. The inside of rear cover 11 also includes a similar pair of mounting brackets (not shown) having semicircular-openings to hold pump 104 in place when the rear cover is attached to main frame 17.
Input connector 108 is connected via pump input conduit 120 to the third connector 107 of "T" connector 101 shown in FIG. 20 (and FIGS. 3 and 4). Pump input conduit 120 has a preferred interior diameter of about 0.187 inches. Pump input connector 120 passes through opening 122 in main frame 17 into rear housing 13, in which "T" connector 101 is located (See FIGS. 3, 4 and 20).
Output connector 110 is connected via pump output conduit 44 to the input 512 of cleaning solution nipple connector 42, shown in FIG. 15. Pump output conduit 44 has a preferred interior diameter of about 0.156 inches.
The switch 128 for pump 104, which is shown in FIG. 4A, is attached to main frame 17 inside rear housing 13 by conventional means, such as the screws shown in FIG. 4A. Pump switch 128, which is preferably a switch such as part No. DSB-1106-R-DS-02 made by Defond North America, Inc. of Raleigh, North Carolina, is a spring biased momentary contact switch which is normally biased to the "Off" position. Lower handle wire 129 is attached to the switch by a hook 134 in the wire 129 which passes through a hole 138 bored in switch actuator 136. A loop 130 is formed at the other end of lower handle wire 129. Loop 130 protrudes out of rear housing 13 at the recess 132 where handle 14 is joined to main frame 17.
Handle 14 is shown in detail in FIGS. 5 and 5A. Trigger 48 and trigger lock 50 are both pivotally mounted in handle 14 about respective pivots 146 and 148 as shown in FIG. 5. Upper handle wire 144 is attached to trigger 48 at post 145, around which loop 147 is placed (See FIG. 5A). Hook 150 is formed at the other end of upper handle wire 144. When the handle 14 is attached to cleaner 10, hook 150 is connected to loop 130 of lower handle wire 129. Alternatively, a single wire, or any other mechanical actuation means could be used. As shown in FIG. 5, the trigger 48 is locked in the "on" position, with ridge 152 on trigger 48 engaged in indentation 154 formed at the end of trigger lock 50. Because pump switch 128 is spring biased to the "off" position, tension in upper and lower handle wires 144 and 129 forces ridge 152 into indentation 154, which prevents trigger 48 from pivoting counter-clockwise to allow pump switch to be turned off. If trigger 48 is pulled back (clockwise) slightly from the locked position shown in FIG. 5, trigger lock 50 will fall away and hang down, as shown in FIG. 2. Then trigger 48, when released by the user will be urged forward by the tension in upper and lower handle wires 144 and 129 from spring biased pump switch 128, and will return to the "off" position shown in FIG. 2.
Handle halves 149 and 151, which are preferably ultrasonically welded together, are shown separated in the exploded view of FIG. 5A. Handle 14 is joined to main frame 17 by conventional means, such as screws.
The electrical wiring of pump 104 and motor 60 is not shown in detail, as it will be evident to those of ordinary skill in the art. Power switch 54 controls power to the entire cleaner 10, while pump switch 128 controls only pump 104. Thus motor 60 is turned on if switch 54 is "on", while pump 104 is on only if both switches, 54 and 128, are "on". If switch 54 is a three-position switch having two positions in which it is "on", pump 104 is on if switch 54 is in either of its "on" positions and if switch 128 is also "on".
In contrast to the cleaner described in above-incorporated U.S. Pat. No. 4,558,484, the cleaner of the present invention includes one-piece tank unit 34, which is show in FIG. 6. Tank unit 34 includes a top 160 having a circular ridge 162 and an insert 164 therein. Insert 164 includes outer water line nipple connector 166 and an outer bleed line nipple connector 168.
As best shown in FIGS. 6 and 6A, the large opening in the top 160 of tank unit 34 leads to dirty solution tank 36 via funnel 170 and conduit 172. Conduit 172 is a circular conduit which passes through middle of clean water tank 35. Water tube 174, which extends to the bottom of clean water tank 35, is connected to inner water line connector 178, so that water can be drawn from clean water tank 35, through insert 164 via a bore (not shown) connecting inner water line connector 178 and outer water line nipple connector 166 into the water port opening of tank block 74 as described in above-incorporated U.S. Pat. No. 4,558,484.
Inner bleed opening 176, which is connected to outer bleed line connector 168 via a second bore in insert 164, permits air from the bleed line port of tank block 74 to enter clean water tank 35 as water is withdrawn via water tube 174. The connection of outer bleed line connector 168 to the bleed line port of tank block 74 is also described in above-incorporated U.S. Pat. No. 4,558,484.
The bottom of separator 32 connects to the top 160 of tank unit 34 as described in above-incorporated U.S. Pat. No. 4,558,484.
FIGS. 7 and 7A show transparent floor nozzle 16 in accordance with the present invention. Floor nozzle spray tip 182 is mounted to floor nozzle 16 by welding mount 189 by ultrasonically welding mount 189 to the collar 184 of floor nozzle 16. Collar 184 also includes a keyway 186 which conforms to a key 506 on main housing suction connector 40 as shown in FIG. 15. Keyway 186 ensures that collar 184 is properly aligned with main housing suction connector 40 so that cleaning solution nipple connector 42 fits tightly into the bore 188 in the end of floor nozzle spray tip 182, with "O"-ring 425 (shown in FIG. 15) on nipple connector 42 sealing the connection. Collar 184 also includes a circular opening 185 on one side thereof (the right side in FIG. 7, in which opening 185 is not shown). Locking pin 516 of ring lock 514 (shown in FIGS. 16 and 17) fits in opening 185 to lock floor nozzle 16 onto main housing suction connector 40.
Floor nozzle brush 190 comprises bristles 192 which are embedded in brush frame 194. Brush frame 194 includes angled tabs 196 having holes therein so that brush 190 can be mounted to nozzle 16 by screws 198 which are also used to hold the front and back floor nozzle halves together. As shown in FIG. 7A, brush 190 is mounted behind the suction opening 199 formed between the two housing halves.
Hand tool 210 and hose assembly 400, which are shown in FIGS. 8 through 10, will now be described. As will be discussed in more detail below, floor nozzle 16 may be removed from the improved cleaner of the present invention and replaced with hand tool 210 by connecting hose-to-cleaner connector 402 of hose assembly 400 to main housing suction connector 40.
Hand tool 210 includes hand tool housing 211, transparent face plate 212, brush 214 and hand tool trigger 216. Hand tool housing 211 is a single molded component including a generally cylindrical main body 220, a rear nozzle wall 222, a nozzle base 226 and two side walls 228 and 230 which extend down from the sides of the main body 220.
Face plate 212 is ultrasonically welded onto a rear nozzle wall 222 and nozzle base 226 to form the nozzle of hand tool 210. Nozzle base 226 includes a front portion 232 having a flat surface 233 along its bottom and a rear portion 234 having a series of ridges 236 across its bottom. Front and rear portions 232 and 234 are joined along the bottom of hand tool 210 by structural supports 238, 240 and 242. Suction openings 244 and 246 are defined by supports 238, 240 and 242 and front and rear portions 232 and 234.
Brush 214 comprises bristles 250 embedded in brush frame 252. Brush frame 252 includes two ends 254 and 256 having a trapezoidal shape; the ends 254 and 256 of the brush frame 252 are mounted in two similarly shaped openings 258 (only one of which is shown in FIG. 8) in tabs 262 and 264 which extend from rear nozzle wall 222.
Suction conduit 268 extends from the top of the nozzle through hand tool housing 211 and through cylindrical flange 272 which fits into collar 430 of hose-to-hand tool connector 408 of hose assembly 400. Annular wall 271 at the base of circular flange 272 abuts the end of collar 430 of hose-to-hand tool connector 408.
The end of inner (cleaning solution) hose 406 extending out of hose-to-hand tool connector 408 is tightly stretched over one end of tubular connector 276. One end of hand tool pinch tubing 278 is tightly stretched over the other end of tubular connector 276. The other end of hand tool pinch tubing 278 is stretched over the cleaning fluid connector 286 of hand tool spray tip 282. The pinch tubing 278 extending from tubular connector up to about the middle of hand tool trigger 216 is recessed in channel 290 (shown in FIGS. 9 and 11), which is formed by walls 292 and 294. Bridge 296 extends below pinch tubing 278 and channel 290 near tubular connector 276.
Hand tool pinch tubing is preferably 68 durometer Shore A transparent vinyl (PVC) tubing such as part number 01PV121V of Ark-Plas Products, Inc. of Flippin, Ark. or the equivalent.
Hand tool trigger 216 is pivotally mounted beneath hand tool housing 211 by means of pivots 302 and 304, which are best shown in FIG. 11. Pivots 302 and 304 are mounted in openings in side walls 228 and 230; only one of these openings 306 is shown (FIG. 8). Ramped slots 307 and 308 in side walls 228 and 230 permit the pivots to be snapped into these openings.
Hand spray tip 282 which is located below square-shaped mount 310 has tabs 311 and 312 which fit in another set of openings in side walls 228 and 230; only one of these openings 314 is shown (FIG. 8). Ramped slots 318 and 319 in side walls 228 and 230 permit tabs 311 and 312 to be snapped into these openings. When tabs 311 and 312 are set in their respective openings, hand spay tip is prevented from pivoting by ribs 320 and 321 which abut the ends of square-shaped mount 310.
Spring 322 normally biases hammer 324 of hand tool trigger 216 against anvil 326 to crush pinch tubing 278 and thereby prevent any cleaning solution from reaching hand tool spray tip 282. Spring 322 is attached to hand tool trigger 216 by a projection 328 on the inside of the hand tool trigger which may be in the form of a raised cross around which the base of the spring rests. The other end of spring 322 extends slightly into channel 290 in arcuate recesses 330 and 331 in walls 294 and 292, respectively. Recesses 330 and 331 are only about 3/32 of an inch deep--a sufficient depth so as to provide a stable base for spring 322. Spring 322 must be strong enough to allow hammer 324 to hold back the pressure in pinch tubing 278 when pump 104 is turned on.
When the free end of hand tool trigger 216 is pulled toward hand tool housing 211, hammer 324 pivots away from anvil 326 so that pinch tubing 278 is no longer crushed. Pressurized cleaning solution then flows through pinch tubing 278 to hand tool spray tip 282, which sprays the cleaning solution on the surface to be cleaned behind suction openings 244 and 246.
The cleaning solution is under pressure provided that cleaning fluid pump 104 is turned on. In the normal mode of operation, the user locks trigger 48 in handle 14 in the "on" position using trigger lock 50 as described above, after attaching hand tool 210 via hose assembly 400 to main housing suction connector 40 and cleaning solution nipple connector 42. Thus hand tool trigger 216 then controls the flow of cleaning solution to hand tool spray tip 282 by means of the pinch valve formed by hammer 324, anvil 326 and pinch tubing 278.
Pump 104 supplies pressurized cleaning fluid to hand tool spray tip 282 even if hand tool 210 is several feet above cleaner 10. Pump 104 develops a pressure of about 45 psi at its output. Hose assembly 400 is preferably about 7 to 10 feet in length.
Hose assembly 400, which is shown in FIGS. 8-10 and 12-15, will now be described. Hose assembly 400 includes hose-to-cleaner connector 402, hose-to-tool connector 408, suction hose 404 and inner hose 406. Outer suction hose 404 is a reinforced hose of conventional design which is extruded over reinforcing coil 410. Inner hose 406 is embedded in connectors 402 and 408 in a manner known in the art.
Hose-to-cleaner connector 402 includes keyway 414 formed by raised side wall 415, suction coupling collar 416, and cleaning solution passageway 418 formed in a cylindrical portion of hose-to-cleaner connector 402 located below suction collar 416. Annular wall 422 divides passageway 418 into a bore 424 for receiving cleaning solution nipple connector 42 and a passageway for inner hose 406. The side walls of suction coupling collar 416 are not joined directly to suction hose 404, but rather are separated from suction hose 404 by second annular wall 428.
FIG. 15 shows hose-to-cleaner connector 402 joined to main housing suction connector 40 and cleaning solution nipple connector 42. As shown in FIG. 15, suction connector 40 fits inside suction coupling collar 416, with the end wall 504 of suction connector 40 abutting the second annular wall 428 of hose-to-cleaner connector 402. Key 506 fits snugly in keyway 414 formed by raised side wall 415. Cleaning solution nipple connector 42 fits in bore 424, with "O"-ring 425 on nipple connector 42 sealing the connection. Circular opening 510 in suction connector 40 is normally occupied by locking pin 516 of ring lock 514, which is not shown in FIG. 15. A similarly shaped opening (not shown) is cut in suction coupling collar 416 so as to be aligned with opening 510 when suction connector 40 is fitted in hose-to-cleaner connector 402 as shown in FIG. 15. Thus locking pin 516 of ring lock 514 protrudes through opening 510 of suction connector 40 and through the opening (not shown) in hose-to-cleaner connector 402 to lock the coupling together.
Ring lock 514, which is shown in FIGS. 16 and 17 comprises a locking pin 516 mounted on a spring base 518. Ring lock 514 is mounted in suction connector 40 so that locking pin 516 is protruding through opening 510 and the curved sides of spring base 518 are in contact with the curved inner walls of suction connector 40. Thus locking pin 516 can be urged inward, back into suction connector 40 to allow the floor nozzle 16 or hose assembly 402 to be put on or removed from connector 40; but once the external pressure on locking pin 516 is removed, resilient spring base 518 biases locking pin 516 outward, back through opening 510.
Hose-to-hand tool connector 408 will now be described. Hose-to-hand tool connector 408 includes collar 430 and a generally cylindrical projection 432, extending below collar 430. Inner hose 406 extends from the inside of suction hose 404 through and out of the end of projection 432, with inner hose 406 ending short of the end of hose-to-hand tool connector 408. Collar 430 includes circular opening 434 at the end of slot 436. Annular wall 438 is located at the inner end of collar 430. As shown in FIG. 10, circular flange 272 of hand tool 210 fits inside collar 430, with the end of flange 272 abutting annular wall 438. As discussed in connection with hand tool 210, inner hose 406 is connected to one end of tubular connector 276.
Circular flange 272 of hand tool 210 includes a circular projection (not shown) which slides in slot 436 and locks in opening 434, to lock hand tool 210 to hose assembly 400.
FIGS. 18 and 19 show cross-sectional views of floor nozzle spray tip 182 and hand tool spray tip 282, respectively.
FIG. 20 shows an overview diagram of the fluid circuit employed in one embodiment of the present invention.
Clip-on squeegee 600 is shown in FIGS. 21 and 22. Clip-on squeegee 600 comprises a rear frame 601 having a handle 602 attached thereto. Squeegee blade 603 is ultrasonically welded between rear frame 601 and front frame 604 as shown in FIG. 22.
Rear frame 601 includes a pair of spring clips 606 at the ends thereof, as shown in FIG. 21. As shown in FIG. 22, spring clips 606 clip on to floor nozzle 16, with the bottom 608 of spring clips 606 covering a portion of the nozzle suction opening. When squeegee 600 is attached to floor nozzle 16, brush 192 is raised slightly off the floor by squeegee blade 603. This prevents fluid on the surface being cleaned from being driven away from the suction opening in floor nozzle 16 by brush 192 when floor nozzle 16 is moved rearwardly.
Spring clips 606 include resilient ends 610 which grasp floor nozzle 16 firmly when squeegee 600 is attached thereto. Squeegee 600 can be easily placed on and removed from floor nozzle 16 by sliding spring clips 606 on and off of floor nozzle 16.
It will be appreciated that the component parts shown herein can be attached by any conventional means. Because the housing components are preferably made of high impact polystyrene plastic, screws are the preferred fastening means.
One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for the purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow.
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An improved cleaning system of the type which applies a cleaning fluid to a surface to be cleaned and then vacuums the dirty cleaning fluid from said surface is provided. The system includes a cleaning fluid pump for delivering pressurized cleaning fluid to spray nozzles attached to either a floor nozzle or a hand tool. Both the floor nozzle and the hand tool are connected to the suction and cleaning fluid connectors of the main cleaner unit by a one-step connection which connects both fluid and suction lines in a single motion. The hand tool, which is attached to the main unit by a hose assembly, has its own pinch valve for controlling the application of cleaning fluid to the surface to be cleaned. When the hand tool is being used the trigger which actuates the pump may be locked in the "on" position.
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[0001] This application claims benefit of U.S. Provisional Application No. 60/215,228, filed Jun. 30, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates generally to processes for the preparation of pyrimidinediones. In particular, it pertains to single vessel processes for preparing 1-substituted-3-(substituted phenyl)-pyrimidinediones from the appropriate carbamates or isocyanates.
BACKGROUND OF THE INVENTION
[0003] It is known in the art that 1-substituted-3-(substituted phenyl)-pyrmidinediones are useful in the preparation of certain pesticides. For example, the use of 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione as an intermediate to prepare herbicides is disclosed in U.S. Pat. Nos. 5,344,812, 5,399,543, 5,674,810 (issued to FMC Corportation on Sep. 6, 1994, Mar. 21, 1995, and Oct. 7, 1997, respectively); the use of 1-methyl-6-trifluoromethyl-3-(4-chloro-6-fluoro-3-methoxy-2-nitrophenyl)-2,4(1H,3H)-pyrimidinedione as an intermediate to prepare herbicides is disclosed in WO patent application 99/21837 (published on May 6, 1999 in the name of ISK Americas Incorporated); and the use of 1-methyl-6-trifluoromethyl-3-(4-chloro-2,6-difluorophenyl)-2,4(1H,3H)-pyrimidinedione as an intermediate to prepare herbicides is disclosed in WO patent application 00/28822 (published on May 25, 2000 in the name of BASF Aktiengesellschaft). In U.S. Pat. Nos. 5,344,812, 5,399,543, 5,674,810, the 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione is prepared by reacting the corresponding phenylisocyanate with 3-amino-4,4,4-trifluorocrotonate, sodium hydride, and methyl iodide. Similar to the processes set forth in U.S. Pat. Nos. 5,344,812, 5,399,543, 5,674,810, in WO patent application 99/21837, the 1-methyl-6-trifluoromethyl-3-(4-chloro-6-fluoro-3-methoxy-2-nitrophenyl)-2,4(1H,3H)-pyrimidinedione is prepared by reacting the corresponding phenylisocyanate with ethyl-3-amino-4,4,4-trifluorocrotonate, sodium hydride, and methyl iodide. Similar to the processes set forth in U.S. Pat. Nos. 5,344,812, 5,399,543, 5,674,810 and WO patent application 99/21837, in WO patent application 00/28822, the 1-methyl-6-trifluoromethyl-3-(4-chloro-2,6-difluorophenyl)-2,4(1H,3H)-pyrimidinedione is prepared by reacting the corresponding phenylisocyanate with ethyl-3-amino-4,4,4-trifluorocrotonate and sodium hydride to form 6-trifluoromethyl-3-(4-chloro-2,6-difluorophenyl)-2,4(1H,3H)-pyrimidinedione that, in turn, is reacted with methyl iodide to form the 1-methyl-6-trifluoromethyl-3-(4-chloro-2,6-difluorophenyl)-2,4(1H,3H)-pyrimidinedione. These processes result in low yields of product and as such are not commercially viable. Accordingly, there exists a need for further processes for preparing 1-substituted-3-(substituted phenyl)-pyrimidinediones.
SUMMARY OF THE INVENTION
[0004] The present invention describes processes for preparing pyrimidinediones from carbamates or isocyanates, often in near quantitative yields.
[0005] One aspect of the present invention involves processes of preparing pyrimidinediones of formula I:
[0006] wherein V, W, X, Y, and Z are each independently selected from hydrogen, halogen, cyano, nitro, alkyl, alkoxyalkyl, phenylalkyl, alkenyl, alkenyloxyalkyl, alkynyl, alkynyloxyalkyl, haloalkyl, haloalkenyl, haloalkynyl, alkylthioalkyl, alkenylthioalkyl, alkynylthioalkyl, alkylsulfinylalkyl, alkenylsulfinylalkyl, alkynylsulfinylalkyl, alkylsulfonylalkyl, alkenylsulfonylalkyl, alkynylsulfonylalkyl, phenoxyalkyl, phenylthioalkyl, phenylsulfinylalkyl, phenylsulfonylalkyl, hydroxy, alkoxy, cyanoalkoxy, alkoxyalkoxy, alkenyloxy, alkynyloxy, haloalkoxy, haloalkenyloxy, haloalkynyloxy, alkoxycarbonylalkoxy, amino, dialkylamino, dialkoxyamino, carboxy, alkoxycarbonyl, alkylthiocarbonyl, alkoxyalkoxycarbonyl, aminoacarbonyl, dialkylaminocarbonyl, and dialkoxyaminocarbonyl, wherein phenyl is optionally substituted with halogen, alkyl, or haloalkyl; and
[0007] R is selected from the group consisting of alkyl, amino, haloalkyl, alkylnitrilyl, aryl, allyl, alkylalkoxy, alkylcarboxyl, or propargyl;
[0008] by reacting under basic conditions a carbamate of formula B:
[0009] wherein R 1 is selected from the group consisting of hydrogen, alkyl, haloalkyl, aryloxy, substituted or unsubstituted aryl, substituted or unsubstituted heterocyclyl, the substituents of said substituted aryl or heterocyclyl comprising one or more members selected from the group consisting of halo, C 1-20 alkyl or alkoxy, nitro, amino, amido, alkylthio, aryl, arylthio, aryloxy, alkylsulfonyl, and arylsulfonyl;
[0010] with an alkenoate of formula D:
[0011] wherein R 2 is alkoxy;
[0012] to form a 1-unsubstituted pyrimidinedione of formula A:
[0013] and reacting the unsubstituted pyrimidinedione A with an adduct forming agent selected from the group consisting of alkylating, aminating, haloalkylating, alkylnitrilating, arylating, allylating, alkylalkoxylating, alkylcarboxylating, and propargylatings agents to form the pyrmidinedione of formula I.
[0014] Another aspect of the present invention involves processes of preparing the pyrmidinediones of formula I by reacting under basic conditions an isocyanate of formula C:
[0015] with the alkenoate of formula D to form the 1-unsubstituted pyrimidinedione of formula A and reacting the unsubstituted pyrimidinedione A with the adduct forming agent to form the pyrmidinedione of formula I.
[0016] Also provided in accordance with the present invention is a process for preparing 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione by reacting ethyl 4-methoxyphenylcarbamate with ethyl 3-amino-4,4,4-trifluoro-2-butenoate under basic conditions to form 6trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione and then reacting the 6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione with a methyl halide to form the 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In one aspect of the present invention, a process is provided for preparing a pyrimidinedione of formula I, preferably in near quantitative yields. The process comprises the steps of:
[0018] forming a 1-unsubstituted pyrimidinedione of formula A:
[0019] by reacting under basic conditions a carbamate of formula B:
[0020] wherein R 1 is as defined above;
[0021] with an alkenoate of formula D:
[0022] wherein R 2 is as defined above; and
[0023] forming a compound of formula I by reacting said unsubstituted pyrimidinedione A with an adduct forming agent selected from the group consisting of alkylating, aminating, haloalkylating, alkylnitrilating, arylating, allylating, alkylalkoxylating, alkylcarboxylating, and propargylating agents;
[0024] wherein said reactions are carried out within a single reaction vessel.
[0025] Preferred processes are those in which V, W, X, Y, and Z are each independently selected from hydrogen, halogen, alkyl, nitro, haloalkyl, and alkoxy; R is alkyl or amino; R 1 is alkyl; and R 2 is ethoxy.
[0026] Particularly preferred processes are those in which V, W, Y and Z are hydrogen; X is alkoxy; R is alkyl; and R 1 is ethyl. An even more preferred process is that in which X is methoxy and R is methyl.
[0027] Suitable bases that may used are those substances that have the ability to react with an acid to form a salt without hydrolyzing the alkenoate D. Examples of bases that can be used include, but are not limited to, sodium hydride, sodium methoxide, potassium methoxide, potassium carbonate, sodium carbonate, cesium carbonate, lithium carbonate, and ammonium carbonate. Preferred bases that can be used include sodium hydride, sodium methoxide, and potassium carbonate. A particularly preferred base is potassium carbonate.
[0028] Suitable alkylating, aminating, haloalkylating, alkylnitrilating, arylating, allylating, alkylalkoxylating, alkylcarboxylating, or propargylating agents that can be used as adduct forming agents are those agents that have the ability to attach an alkyl, amino, haloalkyl, alkylnitrilyl, aryl, allyl, alkylalkoxy, alkylcarboxyl, or propargyl moiety, respectively, at the 1-position of the unsubstituted pyrimdinedione A. Examples of such agents that can be used include, but are not limited to, methyl iodide, methyl chloride, methyl bromide, 1-aminooxysulfonyl-2,4,6-trimethylbenzene, O-(2,4-dinitrophenyl)hydroxylamine, hydroxylamine-O-sulfonic acid, allyl bromide, propargyl bromide, methoxymethyl bromide, benzyl chloride, and ethyl chloroacetate. Preferred agents that can used are methyl iodide, methyl bromide, 1-aminooxysulfonyl-2,4,6-trimethylbenzene, and hydroxylamine-O-sulfonic acid.
[0029] In the present invention, the reaction of the carbamate B with the alkenoate D to form the unsubstituted pyrimidinedione A is preferably carried out at elevated temperature, such as from about 70° C. to about 170° C., more preferably from about 100° C. to about 160° C., preferably for about three to about 24 hours, more preferably for about five to about 18 hours. The reaction can be run at lower temperatures, but generally will require an appreciably longer time to complete. In addition, the reaction may be run at atmospheric or increased pressure.
[0030] One molar equivalent of alkenoate D can be reacted with about 0.01 to about 5 molar equivalents, preferably about 0.5 to about 3 molar equivalents, of carbamate B and about 0.5 to about 10 molar equivalents, preferably about 1 to about 5 molar equivalents, of base.
[0031] The reaction of the carbamate B with the alkenoate D to form the unsubstituted pyrimidinedione A can be carried out neat or in a suitable organic solvent. Preferred organic solvents, both polar and apolar, useful in the context of the present invention include halogenated solvents, for example, without limitation, chlorobenzene, carbon tetrachloride, bromodichloromethane, dibromochloromethane, bromoform, chloroform, bromochloromethane, butyl chloride, dichloromethane, tetrachloroethylene, trichloroethylene, 1,1,1-trichloroethane, 1,1,2-trichloroethane, 1,1-dichloroethane, 2-chloropropane, hexafluorobenzene, 1,2,4-trichlorobenzene, 1,2-dichlorobenzene, fluorobenzene and other halogenated solvents known in the art.
[0032] Preferred polar organic solvents include ethers, for example, without limitation, dimethoxymethane, tetrahydrofuran (THF), 1,3-dioxane, 1,4-dioxane, furan, diethyl ether, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, triethylene glycol dimethyl ether, tert.-butyl ethyl ether, tert.-butyl methyl ether and other ether solvents known in the art. Other polar organic solvents useful in the context of the present invention include, for example, without limitation, propionitrile, ethyl formate, methyl acetate, hexachloroacetone, acetone, ethyl methyl ketone, ethyl acetate, nitromethane, nitrobenzene, glymes, and other polar solvents known in the art.
[0033] Other organic solvents useful herein include polar aprotic solvents, for example, without limitation, N,N-dimethylformamide (DMF), dimethylacetamide (DMAC), 1,3-dimethyl-3,4,5,6-tetrahydro-2(1H)-pyrimidinone (DMPU), 1,3-dimethyl-2-imidazolidinone (DMI), N-methylpyrrolidinone (NMP), formamide, N-methylacetamide, N-methylformamide, acetonitrile, dimethyl sulfoxide, sulfolane, N,N-dimethylpropionamide, tetramethylurea, hexamethylphosphoramide and other polar aprotic solvents known in the art.
[0034] Yet other organic solvents useful for implementation of the present invention include protic solvents, for example, without limitation, water, methanol, ethanol, 2-nitroethanol, 2-fluoroethanol, 2,2,2-trifluoroethanol, ethylene glycol, 1-propanol, 2-propanol, 2-methoxyethanol, 1-butanol, 2-butanol, isobutanol, tert.-butanol, 2-ethoxyethanol, diethylene glycol, 1-, 2-, or 3-pentanol, 2,2-dimethyl-1-propanol, tert.-pentanol, cyclohexanol, anisole, benzyl alcohol, glycerol and other protic solvents known in the art.
[0035] Further organic solvents useful in the context of the present invention include: acidic solvents, for example, without limitation, trifluoroacetic acid, acetic acid, formic acid and other acidic solvents known in the art; basic solvents, for example, without limitation, 2-, 3-, or 4-picoline, pyrrole, pyrrolidine, morpholine, pyridine, piperidine, triethylamine and other basic solvents known in the art; and hydrocarbon solvents, for example, without limitation, benzene, cyclohexane, pentane, hexane, toluene, cycloheptane, methylcyclohexane, heptane, ethylbenzene, ortho-, meta-, or para-xylene, octane, indane, nonane, naphthaline and other hydrocarbon solvents known in the art.
[0036] Organic solvents particularly suitable for forming the unsubstituted pyrimidinedione A are those that are low in cost, enhance the solubility of the starting materials to promote rate of reaction, and offer minimum solvent decomposition. Preferred organic solvents include DMF, DMAC, DMPU, DMI, NMP, formamide, N-methylacetamide, N-methylformamide, acetonitrile, dimethyl sulfoxide, sulfolane, N,N-dimethylpropionamide, tetramethylurea, hexamethylphosphoramide. More preferred solvents include DMF, DMAC, acetonitrile, and dimethyl sulfoxide. A particularly preferred organic solvent in which to conduct the formation of the unsubstituted pyrimidinedione A is DMF.
[0037] In the course of conducting chemical reactions, especially large scale organic chemical reactions yielding commercial quantities of desired product, a balance must be met between having to handle too much solvent yet providing sufficient solvent to afford optimum reaction conditions. A useful ratio of solvent to alkenoate D to afford optimum reaction conditions is generally in the range of about 2.5/1 to about 40/1 wt/wt, preferably about 3/1 to about 20/1.
[0038] The reaction of the unsubstituted pyrimidinedione A with the adduct forming agent to form the pyrimidinedione of formula I is generally carried out at about 0° C. to about 80° C., preferably about 0° C. to about 40° C., for at least 30 minutes, preferably for about one to about eight hours. Similar to above, the reaction of unsubstituted pyrimidinedione A with the adduct forming agent can be carried out at atmospheric or increased pressure.
[0039] The reaction of unsubstituted pyrimidinedione A with the adduct forming agent can be carried out by combining one molar equivalent of the unsubstituted pyrimidinedione A with about 0.01 to about 10 molar equivalents, preferably about 1 to about 4 molar equivalents, of the adduct forming agent.
[0040] Similar to the reaction of the carbamate B with alkenoate D to form the unsubstituted pyrimidinedione A, the reaction of unsubstituted pyrimidinedione A with the adduct forming agent can be carried out neat or in a suitable organic solvent. The organic solvents and ratios disclosed above can also be used in the reaction of the unsubstituted pyrimidinedione A with the adduct forming agent. Preferred organic solvents that may be used in the reaction of the unsubstituted pyrimidinedione A with the adduct forming agent are DMF, DMAC, acetonitrile, and dimethyl sulfoxide. The particularly preferred organic solvent in which to conduct the formation of the pyrimidinedione I is DMF.
[0041] In another aspect of the present invention, a process is provided for the preparing a pyrimidinedione of formula I, as set forth above and wherein V, W, X, Y, Z, R are as defined above with the proviso that X is not alkoxy, (preferably in near quantitative yields), which process comprising the steps of:
[0042] forming a 1-unsubstituted pyrimidinedione of formula A, as set forth above, by reacting under basic conditions an isocyanate of formula C:
[0043] with an alkenoate of formula D, as set forth above and wherein R 2 is as defined above, and
[0044] forming a compound of formula I by reacting said unsubstituted pyrimidinedione A with an adduct forming agent selected from the group consisting of alkylating, aminating, haloalkylating, alkylnitrilating, arylating, allylating, alkylalkoxylating, alkylcarboxylating, and propargylating agents; wherein said reactions are carried out within a single reaction vessel.
[0045] The bases set forth above may also be used when the isocyanate C is reacted with the alkenoate D to form the unsubstituted pyrimdinedione A. Preferred bases that can be used in the reaction of the isocyanate C with the alkenoate D to form the unsubstituted pyrimdinedione A include sodium hydride, sodium methoxide, and potassium carbonate. A particularly preferred base is potassium carbonate.
[0046] The alkylating, aminating, haloalkylating, alkylnitrilating, arylating, allylating, alkylalkoxylating, alkylcarboxylating, or propargylating agents set forth above can be used as adduct forming agents in conjunction the isocyanate C. Preferred agents that can used in the conjunction with the isocyanate C are methyl iodide, methyl bromide, 1-aminooxysulfonyl-2,4,6-trimethylbenzene, and hydroxylamine-O-sulfonic acid.
[0047] The reaction of the isocyanate C with the alkenoate D to form the unsubstituted pyrimidinedione A is preferably carried out at elevated temperature, such as from about 70° C. to about 170° C., more preferably from about 100° C. to about 160° C., preferably for about three to about 24 hours, more preferably for about five to about 18 hours. The reaction can be run at lower temperatures, but generally will require an appreciably longer time to complete. In addition, the reaction may be run at atmospheric or increased pressure.
[0048] One molar equivalent of alkenoate D can be reacted with about 0.01 to about 5 molar equivalents, preferably about 0.5 to about 3 molar equivalents, of isocyanate C and about 0.5 to about 10 molar equivalents, preferably about 1 to about 5 molar equivalents, of base.
[0049] The reaction of the isocyante C with the alkenoate D to form the unsubstituted pyrimidinedione A can be carried out neat or in a suitable organic solvent. The organic solvents and ratios set forth above, including, but not limited to, the preferred solvents and ratios, can also be used in carrying out the reaction of the isocyante C with the alkenoate D to form the unsubstituted pyrimidinedione A.
[0050] The unsubstituted pyrimidinedione A can be reacted with the adduct forming agent at about 0° C. to about 80° C., preferably about 0° C. to about 40° C., for at least 30 minutes, preferably for about one to about eight hours, to form the pyrimidinedione of formula I. The reaction of unsubstituted pyrimidinedione A with the adduct forming agent can be carried out at atmospheric or increased pressure.
[0051] The reaction of unsubstituted pyrimidinedione A with the adduct forming agent can be carried out by combining one molar equivalent of the unsubstituted pyrimidinedione A with about 0.01 to about 10 molar equivalents, preferably about 1 to about 4 molar equivalents, of the adduct forming agent.
[0052] The reaction of the unsubstituted pyrimidinedione A with the adduct forming can be carried out neat or in a suitable organic solvent. The organic solvents and ratios disclosed above can also be used in conjunction with the reaction of unsubstituted pyrimidinedione A with the adduct forming agent. Preferred organic solvents that may be used in conjunction with the reaction of unsubstituted pyrimidinedione A with the adduct forming agent are DMF, DMAC, acetonitrile, and dimethyl sulfoxide. The particularly preferred organic solvent in which to conduct the formation of the pyrimidinedione I is DMF.
[0053] In yet another aspect of the present invention, 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione can be prepared (preferably in near quantitative yields in a single reaction vessel) by reacting ethyl 4-methoxyphenylcarbamate with ethyl 3-amino-4,4,4-trifluoro-2-butenoate under basic conditions to form 6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione and then methylating the 6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione in the 1-position with a methyl halide, such as methyl iodide or bromide, to form the 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione.
[0054] As used in this specification and unless otherwise indicated the substituent terms “alkyl”, “cycloalkyl”, “alkoxy”, “aryloxy”, and “alkoxyarylamino”, used alone or as part of a larger moiety, include straight or branched chains of at least one or two carbon atoms, as appropriate to the substituent, and preferably up to 20 carbon atoms, more preferably up to ten carbon atoms, even more preferably up to seven carbon atoms. “Halogen” or “halo” refers to fluorine, bromine, iodine, or chlorine. “Aryl” refers to an aromatic ring structure having 5 to 10 carbon atoms. “Heteroaryl” refers to an aromatic ring structure having 1 to 4 nitrogen, sulfur, or oxygen atoms or a combination thereof as hetero ring components, with the balance being carbon atoms. The term “ambient temperature” as utilized herein shall mean any suitable temperature found in a laboratory or other working quarter, and is generally not below about 15° C. nor above about 30° C.
[0055] The processes of the present invention are typically safer and more efficient than existing methods to the extent they reduce the risk of chemical exposure resulting from the transfer of chemicals from one reaction vessel to another, the reagents used are cheaper, and the time of the reaction is reduced. In addition to these advantages, the processes of the present invention generally convert in excess of 70%, often in excess of 90%, of the starting material to the pyrimidinedione I.
[0056] The present invention is now described in more detail by reference to the following examples, but it should be understood that the invention is not construed as being limited thereto.
EXAMPLE 1
[0057] This example illustrates one protocol for the preparation of 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione using methyl iodide as the alkylating agent.
[0058] To a 100 mL roundbottom flask equipped with a mechanical stirrer and thermometer was added 23.1 grams (0.118 mole-0.94 equiv.) of 99% pure ethyl 4-methoxyphenylcarbamate, 23 grams (0.125 mole-1 equiv.) of ethyl 3-amino-4,4,4-trifluoro-2-butenoate (available from Aldrich Chemical Company, Milwaukee, Wis.), 21.9 grams (0.159 mole-1.3 equiv.) of 98% pure potassium carbonate (available from Aldrich Chemical Company), and 125 mL (% wt/wt. butenoate to solvent-18.4%) of DMF (available from J. T. Baker Inc., Phillipsburg, N.J.). The reaction mixture was heated at reflux for six hours. After this time, the reaction mixture was allowed to cool to 38° C. and then 19.7 grams (0.138 moles-1.1 equiv.) of methyl iodide (available from Aldrich Chemical Company) was added dropwise during a 15 minute period. Upon completion of addition, the reaction mixture was heated to 80° C. and stirred at that temperature for two hours. At the conclusion of this period, the DMF was removed under reduced pressure at 100° C. and 125 mL of water was added. Upon completion of addition, the resulting mixture was allowed to cool to ambient temperature during a one hour period. The resulting precipitate was collected by filtration and dried in an oven at 60° C. for four hours, yielding 32.2 grams (88.4%) of 97.3% pure 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione. The NMR spectrum was consistent with the proposed structure.
EXAMPLE 2
[0059] This example illustrates one protocol for the preparation of 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione using methyl bromide as the alkylating agent.
[0060] To a two liter three-necked flask equipped with a thermocouple, Dean-Stark trap, nitrogen inlet, a mechanical stirrer and a thermometer was added one liter of DMF, 200 grams (1.0 mole-0.91 equiv.) of 96% pure ethyl 4-methoxyphenylcarbamate, 199 grams (1.1 moles-1 equiv.) of 97% pure ethyl 3-amino-4,4,4-trifluorobutenoate (% wt/wt. butenoate to solvetnt-19.9%) and 190 grams (1.4 moles-1.3 equiv.) of potassium carbonate. The reaction mixture was heated to reflux where it stirred for eight hours. After this time, the DMF was removed by distillation and the reaction mixture was analyzed by Gas Chromatography (GC), which indicated the formation of the 1-unsubstituted pyrimidinedione. The reaction mixture was cooled to ambient temperature and a solution of 107 grams (1.13 moles-1.02 equiv.) of methyl bromide (available from Aldrich Chemical Company) and 190 grams (1.4 moles-1.3 equiv.) of potassium carbonate in one liter (% wt/wt. butenoate to solvent-19.9%) of DMF was added. Upon completion of addition, the reaction mixture was stirred at ambient temperature for one hour and the resulting precipitate was collected by filtration. The filter cake was washed with two 100 mL portions of distilled water, air-dried for two hours, and then concentrated under reduced pressure, yielding 286 grams (91% yield) of 97% pure 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione. The NMR spectrum was consistent with the proposed structure.
EXAMPLE 3
[0061] This example illustrates one protocol for the preparation of l-amino-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione using hydroxylamine-O-sulfonic acid as the aminating agent.
[0062] To a 100 mL roundbottom flask equipped with a mechanical stirrer and thermometer is added 23.1 grams (0.118 mole-0.94 equiv.) of ethyl 4-methoxyphenylcarbamate, 23 grams (0.125 mole-1 equiv.) of ethyl 3-amino-4,4,4-trifluoro-2-butenoate, 21.9 grams (0.159 mole-1.3 equiv.) of potassium carbonate, and 125 mL (% wt/wt. butenoate to solvent-18.4%) of DMF. The reaction mixture is heated at reflux for eight hours. After this time, the reaction mixture is cooled to ambient temperature and then 15.6 grams (0.138 moles-1.1 equiv.) of hydroxylamine-O-sulfonic acid (available from Aldrich Chemical Company) is added. Upon completion of addition, the reaction mixture is heated to 80° C. where it is stirred for two hours. At the conclusion of this period, the DMF is removed under reduced pressure and 125 mL of water is added. Upon completion of addition, the resulting mixture is allowed to cool to ambient temperature. The resulting precipitate is collected by filtration and dried to yield 1-amino-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione.
EXAMPLE 4
[0063] This example illustrates one protocol for the preparation of 1-methyl-6-trifluoromethyl-3-(4-chloro-2-fluorophenyl)-2,4(1H,3H)-pyrimidinedione using methyl iodide as the alkylating agent.
[0064] To a 500 mL roundbottom flask equipped with a thermometer, condenser, and an overhead stirrer was added 18.9 grams (0.1 mole-1.0 equiv.) of 97% pure ethyl 3-amino-4,4,4-trifluoro-2-butenoate, 13.8 grams (0.1 mole-1.0 equiv.) of potassium carbonate, and 100 mL (% wt/wt. butenoate to solvent-18.9%) of DMF. The reaction mixture was heated to reflux and a solution of 24.6 grams (0.11 mole-1.1 equiv.) of 97% pure ethyl (4-chloro-2-fluorophenyl)carbamate in 50 mL of DMF (% wt/wt. butenoate to solvent-37.8%) was added dropwise. Upon completion of addition, the reaction mixture was heated at reflux for 7.5 hours. After this time, the reaction mixture was cooled to ambient temperature where it was allowed to stand for about 18 hours. At the conclusion of this period, 21.4 grams (0.151 mole-1.5 equiv.) of methyl iodide was added dropwise. Upon completion of addition, the reaction mixture was heated to 95° C. where it stirred for 24 hours. After this time, the reaction mixture was again cooled to ambient temperature and the mixture was concentrated under reduced pressure to yield a gummy brown solid. To the brown solid was added 100-110 mL of water. The resulting mixture was stirred for about one hour. The resulting precipitate was collected by filtration, placed in a crystallizing dish, and dried at 60° C. for about 18 hours. The resulting solid was washed with diethyl ether and then purified by chromatographic techniques to yield 1-methyl-6-trifluoromethyl-3-(4-chloro-2-fluorophenyl)-2,4(1H,3H)-pyrimidinedione.
EXAMPLE 5
[0065] This example illustrates one protocol for the preparation of 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione using 4-methoxyphenylisocyanate as the starting material.
[0066] A stirred mixture of 3.0 grams (0.02 mole-1.0 equiv.) of 99% pure ethyl 4-methoxyphenylisocyanate (available from Aldrich Chemical Company), 3.8 grams (0.02 mole-1.0 equiv.) of 97% pure ethyl 3-amino-4,4,4-trifluoro-2-butenoate, 2.8 grams (0.02 mole-1.0 equiv.) of potassium carbonate, and 20 mL (% wt/wt. butenoate to solvent-19%) of DMF was heated to 140° C. for one hour. At the conclusion of this period, the reaction mixture was analyzed by GC, which indicated the reaction was complete. The reaction mixture was allowed to cool to ambient temperature and 6.6 grams (0.047 mole-2.4 equiv.) of 99.5% pure methyl iodide was added. Upon completion of addition, the reaction mixture was heated to 80° C. where it stirred for one hour. After this time, the reaction mixture was allowed to cool to ambient temperature. Once at the prescribed temperature, the reaction mixture was concentrated under reduced pressure to yield a residue. To the residue was added 40 mL of water followed by 80 mL of ethyl acetate. The pH of the resulting solution was adjusted to a pH of 7 with concentrated hydrochloric acid. The organic layer was separated and concentrated under reduced pressure to yield 4.7 grams of a solid. The solid was concentrated under reduced pressure to yield 4.2 grams (70% yield) of 94.3% pure 1-methyl-6-trifluoromethyl-3-(4-methoxyphenyl)-2,4(1H,3H)-pyrimidinedione. The NMR spectrum was consistent with the proposed structure.
[0067] While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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A process for the preparation of a compound of formula I
comprising the steps of forming an 1-unsubstituted pyrimidinedione by reacting under basic conditions either a carbamate or an isocyanate with an alkenoate and forming a compound of formula I by alkylating, aminating, haloalkylating, alkylnitrilating, arylating, allylating, alkylalkoxylating, alkylcarboxylating, or propargylating the 1-position of said unsubstituted pyrimidinedione by adding an adduct forming agent selected from the group consisting of alkylating, aminating, haloalkylating, alkylnitrilating, arylating, allylating, alkylalkoxylating, alkylcarboxylating, and propargylating agents; where the 1-unsubstituted pyrimidinedione, the carbamate, the isocyanate, the alkenoate, and substituents V, W, X, Y, Z, and R are described herein. The reactions as described herein are carried out in a single reaction vessel and often produce the pyrimidindione of formula I in near quantitative yields. It is emphasized that his abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims (see 37 C.F.R. 1.72(b)).
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This application is a continuation-in-part of application Ser. No. 07/981,048, filed Nov. 24, 1992, now abandoned.
FIELD OF THE INVENTION
The invention is related to a novel biologically pure Bacillus thuringiensis (B.t.) isolate which solely produces a CryIA(a)-like crystal delta-endotoxin having a molecular weight of about 130,000 daltons and activity against lepidopteran pests as well as a spore, crystal delta-endotoxin and/or mutant thereof. The invention also relates to insecticidal compositions obtainable therefrom. The invention further relates to methods of using the insecticidal compositions to control an insect pest(s) from the order Lepidoptera.
BACKGROUND OF THE INVENTION
Every year, significant portions of the world's commercially important agricultural crops, including foods, textiles, and various domestic plants are lost to pest infestation, resulting in losses in the millions of dollars. Various strategies have been used in attempting to control such pests.
One strategy is the use of chemical insecticides with a broad range of activity. However, there are a number of disadvantages to using such chemical insecticides. Specifically, because of their broad spectrum of activity, these insecticides may destroy non-target organisms such as beneficial insects and parasites of destructive pests. Additionally, these chemical insecticides are frequently toxic to animals and humans, and targeted pests frequently develop resistance when repeatedly exposed to such substances.
Another strategy has involved the use of biopesticides, which make use of naturally occurring pathogens to control insect, fungal and weed infestations of crops. Biopesticides comprise a bacterium which produces a toxin, a substance toxic to the pest. Biopesticides are generally less harmful to non-target organisms and the environment as a whole than chemical pesticides. The most widely used biopesticide is Bacillus thuringiensis (B.t.). B.t. is a widely distributed, rod shaped, aerobic and spore forming microorganism.
During its sporulation cycle, B.t. produces an alkali soluble protein(s) in crystal form known as a crystal delta-endotoxin(s) having a molecular weight ranging from 27-140 kd, which upon ingestion kills insect larvae. Toxic activity may reside in one or more of such crystal proteins in a given B.t. strain. Most delta-endotoxins are protoxins that are proteolytically converted into smaller toxic (truncated) polypeptides in the target insect midgut (H6fte and Whiteley, 1989, Microbiol. Rev. 53:242-255). The delta-endotoxins are encoded by cry (crystal protein) genes. The cry genes have been divided into six classes and several subclasses based on structural similarities and pesticidal specificity. The major classes are Lepidoptera-specific (cryI); Lepidoptera-and Diptera-specific (cryII); Coleoptera-specific (cryIII); Diptera-specific (cryIV) (H ofte and Whiteley, 1989, Microbiol. Rev. 53:242-255); Coleoptera- and Lepidoptera-specific (referred to as cryV by Tailor et al., 1992, Mol. Microbiol. 6:1211-1217); and Nematode-specific (referred to as cryV and cryVI by Feitelson et al., 1992, Bio/Technology 10:271-275).
Six cryI genes have been identified: cryIA(a), cryIA(b), cryIA(c), cryIB, cryIC, and cryID (H ofte and Whiteley, 1989, Microbiol. Rev. 53:242-255). Since cryIA(a), cryIA(b), and cryIA(c) show more than 80% amino acid identity, they are considered to be part of the cryIA group.
A number of B.t. strains have been isolated that have been found to be active against insect pests of the order Lepidoptera. B.t. subsp. kurstaki HD-1 produces bipyramidal and cuboidal crystal proteins in each cell during sporulation (L uthy et al., in Microbial and Viral Pesticides, ed. E. Kurstak, Marcel Dekker, New York, 1982, pp.35-74); the bipyramidal crystal was found to be encoded by various cryIA genes (Aronson et al., 1986, Microbiol. Rev. 50:1-50). B.t. subsp. kurstaki HD-73 contains the cryIA(c) gene for its crystal delta-endotoxin (Adang et al., 1985, Gene 36:289-300). B.t. subsp. dendrolimus HD-7 and HD-37 contain a CryIA and a CryII protein; B.t. subsp. sotto contains an alkaline soluble protein that differs from the holotype CryIA(a) protein by 24 amino acids; B.t. subsp. subtoxicus HD-10 contains CryIA and CryIB proteins; B.t. subsp. tolworthi HD-121 contains CryIA and CryII proteins; B.t. subsp. entomocidus HD-110, 4448 contains CryIA, CryIB, and CryIB proteins; and B.t. subsp. aizawai HD-68 contains CryIA proteins (H ofte and Whiteley, 1989, Microbiol. Reviews 53:242-255). Bt. subsp. aizawai HD-11 contains a Cry IA protein as well as a P 2 crystal (Hofte and whiteley, 1989, Microbiol. Rev. 53:242-255). Padua, 1990, Microbiol. Lett. 66:257-262, discloses the isolation of two mutants containing two crystal delta-endotoxins, a 144 kD protein having activity against a lepidopteran pest and a 66 kD protein having activity against mosquitoes. Payne, U.S. Pat. No. 4,990,332, issued Feb. 5, 1993, discloses an isolate of B.t. PS85A1 and a mutant of the isolate, PS85A1 which both have activity against Plutella xylostella, a Lepidopteran pest and produce alkali soluble proteins having a molecular weight of 130,000 and 60,000 daltons. Payne, U.S. Pat. No. 5,045,469, issued Sep. 3, 1991 discloses a B.t. isolate designated PS81F which also produces alkali soluble proteins having a molecular weight of 130,000 and 60,000 daltons and has activity against Spodoptera exigua and T. ni; the toxin gene from PS81F appears to have little homology to the toxin gene from B.t. subsp. kurstaki HD-1. Payne, U.S. Pat. No. 5,206,166, filed Jun. 25, 1992, issued Apr. 27, 1993, discloses B.t. isolates PS81A2 and PS81RR1 which produce 133,601 and 133,367 dalton alkali-soluble proteins; both have activity against Trichoplusia ni, Spodoptera exigua and Plutella xylostella and are different from B.t subsp kurstaki HD-1 and other B.t. isolates. Payne, U.S. Pat. No. 5,169,629, filed Nov. 1, 1988, issued Dec. 2, 1992, discloses B.t. isolate PS81GG active against lepidopteran pests and which produces a bipyramidal (130,000 daltons) and a cuboidal (60,000 daltons) crystal delta-endotoxin. Payne, U.S. Pat. No. 5,188,960, filed Dec. 14, 1989, issued Feb. 23, 1993, discloses B.t. PS81I which produces a 130,000 dalton alkali soluble protein having a flagellar serotype of 7, aizawai which can be distinguished from HD-1 and is active against Spodoptera exigua, Plutella xylostella, and Choristoneura occidentalis. Bernier et al., U.S. Pat. No. 5,061,489 and WO 90/03434 discloses strain A20 producing a delta-endotoxin encoded by at least three genes: 6.6-, 5.3-, and 4.5-type genes (CryIA(a)-like, cryIA(b), and cryIA(c)). Bradfish et al., U.S. Pat. No. 5,208,017, discloses B.t. isolates PS86A1 and PS86Q3 which respectively produce alkali-soluble proteins having a molecular weight of 58,000 and 45,000 daltons and 155,000, 135,000, 98,000, 62,000, and 58,000 daltons respectively and which have activity against lepidopteran and coleopteran pests.
It is advantageous to isolate new strains of Bacillus thuringiensis so that there exists a wider spectrum of biopesticides for any given insect pest.
SUMMARY OF THE INVENTION
The invention is related to a novel biologically pure Bacillus thuringiensis strain(s) or a spore(s) or mutant (s) thereof which strain or mutant in contrast to B.t. strains disclosed in the prior art, solely produces a CryIA(a)-like crystal delta-endotoxin having activity against an insect pest of the order Lepidoptera and a molecular weight of about 130,000 daltons. As defined herein, a "biologically pure" B.t. strain is a strain essentially free of microbial contaminants. In a specific embodiment of the invention, the thuringiensis strains of the present invention are EMCC-0073 and EMCC-0074 having all of the identifying characteristics of NRRL B-21014 and NRRL B-21015 respectively.
As defined herein, a CryIA(a)-like crystal delta-endotoxin is a protein in crystalline form substantially homologous to a CryIA(a) protein which is immunologically reactive with antibodies to the CryIA(a) protein and has essentially the same insecticidal activity as a CryIA(a) protein. Preferably, the CryIA(a)-like protein has at least 90% homology to the CryIA(a) protein; more preferably at least 95% homology and most preferably at least 99% homology.
As detailed above, the prior art strains produce crystal delta-endotoxins encoded not only by the cryIA(a) gene, but by other genes as well. The CryIA(a)-like crystal delta-endotoxin is encoded by at least one copy of a cryIA(a)-like gene. As defined herein, a "cryIA(a)-like gene" is a DNA sequence encoding a CryIA(a)-like crystal delta-endotoxin defined above. In a specific embodiment, the cryIA(a)-like gene has at least 90% homology to the cryIA(a) gene, preferably at least 95% homolgy to the cryIA(a) gene and most preferably at least 99% homolgy to the cryIA(a) gene.
The invention is also related to a substantially pure crystal delta-endotoxin. As definded herein, a "substantially pure" crystal delta-endotoxin is substantially free (>95%) of other proteins and/or other contaminants. As will be detailed in Section 5, infra, the crystal delta-endotoxin of the present invention is obtainable from the strains of the present invention.
The novel Bacillus thuringiensis strains, spores, mutants or crystal delta-endotoxins may within the scope of this invention be formulated into an insecticidal composition. In one embodiment, the strain, spores, mutant or crystal delta-endotoxin may be combined with an insecticidal carrier. The insecticidal composition may be used to control an insect pest from the order Lepidoptera, particularly Spodoptera exigua, Heliothis zea, and Heliothis virescens in a method comprising exposing the pest to an insect-controlling effective amount of such an insecticidal composition.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows the results of PCR analysis of Bacillus thuringiensis strains for cryIAgenes by agarose gel electrophoresis. Lanes 1 and 14 show molecular weight markers (1 kb ladder, Bethesda Research Laboratories). Lanes 2-4 show analysis of strain EMCC-0073 with cryIA(a), cryIA(b), and cryIA(c) oligonucleotide primers respectively; lanes 5-7 shows analysis of strain EMCC-0074 with cryIA(a), cryIA(b), and cryIA(c) oligonucleotide primers respectively; lanes 8-10 shows analysis of strain EMCC-0086 with cryIA(a), cryIA(b), and cryIA(c) oligonucleotide primers respectively; and lanes 11-13 shows analysis of a Bacillus thuringiensis subsp. tenebrionis strain containing only cryIIIA gene with cryIA(a), cryIA(b), and cryIA(c) oligonucleotide primers respectively. EMCC-0086 is a Bacillus thuringiensis subsp. kurstaki HD-1 strain containing all three cryIA genes.
DETAILED DESCRIPTION OF THE INVENTION
The spores and crystal delta-endotoxin of the present invention are obtainable from the strains of the present invention. The strains of the present invention may be cultured using media and fermentation techniques known in the art (see, for example, Rogoff et al., 1969, J. Invertebrate Path. 14:122-129; Dulmage et al., 1971, J. Invertebrate Path. 18:353-358; Dulmage et al., in Microbial Control of Pests and Plant Diseases, H. D. Burges, ed., Academic Press, N.Y., 1980 ). Upon completion of the fermentation cycle, the bacteria can be harvested by separating B.t. spores and crystal delta-endotoxin from the fermentation broth by means well known in the art, e. g. centrifugation. The spores and crystal proteins are contained in the pellet.
Purification of the crystal delta-endotoxin can be carried out by various procedures known in the art, including but not limited to chromatography (e.g. ion exchange, affinity, hydrophobic and size exclusion), further centrifugation, electrophoretic procedures, differential solubility, or any other standard technique for the purification of proteins.
The invention is also directed to a mutant B.t. strain which produces a larger amount of and/or a larger crystal of CryIA(a)-like crystal delta-endotoxin than the parental strain. A "parental strain" as defined herein is the original Bacillus strain before mutagenesis. In a specific embodiment, the mutant contains more than one copy of the CryIA(a)-like gene.
To obtain such mutants, the parental strain may, for example, be treated with a mutagen by chemical means such as N-methyl-N'-nitro-N-nitrosoguanidine or ethyl methanesulfonate, gamma-irradiation, X-ray or UV-irradiation. Specifically, in one method of mutating Bacillus strains and selecting such mutants the parental strain is:
i) treated with a mutagen;
ii) the thus treated mutants are grown in a medium suitable for the selection of a mutant strain;
iii) selection of a mutant strain.
According to a preferred embodiment of this method, the selected colonies are grown in a normal production medium, and a final selection for strains capable of increased CryIA(a)-like protein production is performed.
Alternatively, the mutant may be obtained used recombinant DNA methods known in the art. For example, a DNA sequence containing two or more copies of the CryIA(a)-like gene may be inserted into an appropriate expression vector and subsequently introduced into the parental strain using procedures known in the art.
The activity of the B.t. strains of the present invention or a spore(s), mutant(s) or crystal delta-endotoxin thereof against various insect pests may be assayed using procedures known in the art, such as an artificial insect diet incorporation assay, artificial diet overlay, leaf painting, leaf dip, and foliar spray. Specific examples of such assays are given in Section 6, infra.
COMPOSITIONS
The strain, spore(s), crystal delta-endotoxin, or mutant(s) of the present invention described supra can be formulated with an acceptable carrier into an insecticidal composition(s) that is for example, a suspension, a solution, an emulsion, a dusting powder, a dispersible granule, a wettable powder, an emulsifiable concentrate, an aerosol or impregnated granule.
Such compositions disclosed above may be obtained by the addition of a surface active agent, an inert carrier, a preservative, a humectant, a feeding stimulant, an attractant, an encapsulating agent, a binder, an emulsifier, a dye, a U.V. protectant, a buffer, a flow agent, or other component to facilitate product handling and application for particular target pests.
Suitable surface-active agents include but are not limited to anionic compounds such as a carboxylate, for example, a metal. carboxylate of a long chain fatty acid; an N-acylsarcosinate; mono or di-esters of phosphoric acid with fatty alcohol ethoxylates or salts of such esters; fatty alcohol sulphates such as sodium dodecyl sulphate, sodium octadecyl sulphate or sodium cetyl sulphate; ethoxylated fatty alcohol sulphates; ethoxylated alkylphenol sulphates; lignin sulphonates; petroleum sulphonates; alkyl aryl sulphonates such as alkyl-benzene sulphonates or lower alkylnaphthalene sulphonates, e.g. butyl-naphthalene sulphonate; salts of sulphonated naphthalene-formaldehyde condensates; salts of sulphonated phenol-formaldehyde condensates; or more complex sulphonates such as the amide sulphonates, e.g. the sulphonated condensation product of oleic acid and N-methyl taurine or the dialkyl sulphosuccinates, e.g. the sodium sulphonate or dioctyl succinate. Non-ionic agents include condensation products of fatty acid esters, fatty alcohols, fatty acid amides or fatty-alkyl- or alkenyl-substituted phenols with ethylene oxide, fatty esters of polyhydric alcohol ethers, e.g. sorbitan fatty acid esters, condensation products of such esters with ethylene oxide, e.g. polyoxyethylene sorbitar fatty acid esters, block copolymers of ethylene oxide and propylene oxide, acetylenic glycols such as 2,4,7,9-tetraethyl-5-decyn-4,7-diol, or ethoxylated acetylenic glycols. Examples of a cationic surface-active agent include, for instance, an aliphatic mono-, di-, or polyamine as an acetate, naphthenate or oleate; an oxygen-containing amine such as an amine oxide of polyoxyethylene alkylamine; an amide-linked amine prepared by the condensation of a carboxylic acid with a di- or polyamine; or a quaternary ammonium salt.
Examples of inert materials include but are not limited to inorganic minerals such as kaolin, phyllosilicates, carbonates, sulfates, phosphates or botanical materials such as cork, powdered corncobs, peanut hulls, rice hulls, and walnut shells.
The compositions of the present invention can be in a suitable form for direct application or as a concentrate or primary composition which requires dilution with a suitable quantity of water or other diluent before application. The insecticidal concentration will vary depending upon the nature of the particular formulation, specifically, whether it is a concentrate or to be used directly. The composition contains 1 to 98% of a solid or liquid inert carrier, and 0 to 50%, preferably 0.1 to 50% of a surfactant. These compositions will be administered at the labeled rate for the commercial product, preferably about 0.01 lb-5.0 lb per acre when in dry form and at about 0.01 pts-10 pts per acre when in liquid form.
In a further embodiment, the strain, spore, crystal delta-endotoxin or mutant of the present invention can be treated prior to formulation to prolong the pesticidal activity when applied to the environment of a target pest as long as the pretreatment is not deleterious to the crystal delta-endotoxin. Such treatment can be by chemical and/or physical means as long as the treatment does not deleteriously affect the properties of the composition(s). Examples of chemical reagents include but are not limited to halogenating agents; aldehydes such as formaldehyde and glutaraldehyde; anti-infectives, such as zephiran chloride; alcohols, such as isopropranol and ethanol; and histological fixatives, such as Bouin's fixative and Helly's fixative (see, for example, Humason, Animal Tissue Techniques, W.H. Freeman and Co., 1967).
The compositions of the invention can be applied directly to the plant by, for example, spraying or dusting at the time when the pest has begun to appear on the plant or before the appearance of pests as a protective measure. Plants to be protected within the scope of the present invention include but are not limited to cereals (wheat, barley, rye, oats, rice, sorghum and related crops), beets (sugar beet and fodder beet), drupes, pomes and soft fruit (apples, pears, plums, peaches, almonds, cherries, strawberries, raspberries, and blackberries), leguminous plants (alfalfa, beans, lentils, peas, soybeans), oil plants (rape, mustard, poppy, olives, sunflowers, coconuts, castor oil plants, cocoa beans, groundnuts), cucumber plants (cucumber, marrows, melons), fibre plants (cotton, flax, hemp, jute), citrus fruit (oranges, lemons, grapefruit, mandarins), vegetables (spinach, lettuce, asparagus, cabbages and other brassicae, carrots, onions, tomatoes, potatoes, paprika), lauraceae (avocados, cinnamon, camphor), deciduous trees and conifers (e.g. linden-trees, yew-trees, oak-trees, alders, poplars, birch-trees, firs, larches, pines), or plants such as maize, turf plants, tobacco, nuts, coffee, sugar cane, tea, vines hops, bananas and natural rubber plants, as well as ornamentals. In both cases, the preferred mode of application is by foliar spraying. It is generally important to obtain good control of pests in the early stages of plant growth as this is the time when the plant can be most severely damaged. The spray or dust can conveniently contain another pesticide if this is thought necessary. In a preferred embodiment, the composition of the invention is applied directly to the plant.
The compositions of the present invention may be effective against pests including but not limited to pests of the order Lepidoptera, e.g. Achroia grisella, Acleris gloverana, Acleris variana, Adoxophyes orana, Agrotis ipsilon, Alabama argillacea, Alsophila pometaria, Amyelois transitella, Anagasta kuehniella, Anarsia lineatella, Anisota senatoria, Antheraea pernyi, Anticarsia gemmatalis, Archips sp., Argyrotaenia sp., Athetis mindara, Bombyx mori, Bucculatrix thurberiella, Cadra cautella, Choristoneura sp., Cochylls hospes, Colias eurytheme, Corcyra cephalonica, Cydia latiferreanus, Cydia pomonella, Datana integerrima, Dendrolimus sibericus, Desmia funeralis, Diaphania hyalinata, Diaphania nitidalis, Diatraea grandiosella, Diatraea saccharalis, Ennomos subsignaria, Eoreuma loftini, Ephestia elutella, Erannis tilaria, Estigmene acrea, Eulia salubricola, Eupocoellia ambiguella, Eupoecilia ambiguella, Euproctis chrysorrhoea, Euxoa messoria, Galleria mellonella, Grapholita molesta, Harrisina americana, Helicoverpa subflexa, Helicoverpa zea, Hellothis virescens, Hemileuca oliviae, Homoeosoma electellum, Hyphantria cunea, Keiferia lycopersicella, Lambdina fiscellaria fiscellaria, Lambdina fiscellaria lugubrosa, Leucoma salicis, Lobesia botrana, Loxostege sticticalis, Lymantria dispar, Macalla thyrsisalis, Malacosoma sp., Mamestra brassicae, Mamestra configurata, Manduca quinquemaculata, Manduca sexta, Maruca testulalis, Melanchra picta, Operophtera brumata, Orgyia sp., Ostrinia nubilalis, Paleacrita vernata, Papilio cresphontes, Pectinophora gossypiella, Phryganidia californica, Phyllonorycter blancardella, Pieris napi, Pieris rapae, Plathypena scabra, Platynota flouendana, Platynota stultana, Platyptilia carduidactyla, Plodia interpunctella, Plutella xylostella, Pontia protodice, Pseudaletia unipuncta, Pseudoplasia includens, Sabulodes aegrotata, Schizura concinna, Sitotroga cerealella, Spilonota ocellana, Spodoptera sp., Thaurnstopoea pityocampa, Tinsola bisselliella, Trichoplusia hi, Udea rubigalis, Xylomyges curiails, and Yponomeuta padella.
The following examples are presented by way of illustration, not by way of limitation.
EXAMPLES
CULTURING OF B.t. STRAINS EMCC-0073 AND EMCC-0074
A subculture of EMCC-0073 and EMCC-0074, maintained on a Nutrient Broth Agar slant is used to inoculate a 250 ml baffle shake flask containing 50 ml of medium with the following composition.
______________________________________Corn Steep liquor 15 g/l100 (malodextrin) 40 g/lPotato Starch 30 g/lKH.sub.2 PO.sub.4 1.77 g/lK.sub.2 HPO.sub.4 4.53 g/l______________________________________
The pH of the medium is adjusted to 7.0 using 10 N NaOH.
After inoculation, shake flasks are incubated at 30° C. on a rotary shaker with 250 rpm shaking for 72 hours. The B.t. crystals and spores, obtained in the above fermentation are recovered by centrifugation at 15,000 rpm for 15 minutes using a Sorvall RC-5B centrifuge.
INSECTICIDAL ACTIVITY OF EMCC-0073 AND EMCC-0074
EMCC-0073 and EMCC-0074 are cultivated in shake flasks as described in Section 6.1., supra. A 1:50 dilution of culture broth was made. 5 ml of such diluted culture broth is transferred into a 50 ml propylene centrifuge tube. 20 ml of artificial insect diet containing antibiotics is added into the centrifuge tube. The mixture is subsequently dispensed into bioassay trays. Three to six eggs each of beet armyworm (Spodoptera exigua), corn earworm (Hellothis zea) and tobacco budworm (Heliothis virescens) are applied on the surface of the "diet". Mylar is ironed onto the bioassay trays and the trays were incubated at 28° C. without photoperiod. Scoring is carried out at 7 and 11 days.
At the dosage tested, EMCC-0073 and EMCC-0074 stunted Spodoptera exigua and Heliothis zea. After seven days incubation, both Spodoptera exigua and Heliothis zea only grows to less than 25% of the size of the control larvae. At the same dosage, EMCC-0073 and EMCC-0074 kills 50% and 70% respectively, of the testing population of Heliothis virescens. In Table I, the bioactivity of EMCC-0073 and EMCC-0074 towards Spodoptera exigua and Hellothis zea is expressed in terms of stunt score (SS). The stunt score is determined after incubating the trays for 7 days. In this system, 4=full size larvae (control larvae); 3= 3/4 size of control larvae; 2= 1/2 size of control larvae; and 1= 1/4 size of control larvae. The smaller the number, the higher the B.t. activity. The bioactivity of EMCC-0073 and EMCC-0074 towards Heliothis virescens is determined in terms of % mortality and the live larvae (survivors) were scored by stunt score (SS) for their size.
TABLE I______________________________________ Spodoptera Heliothis Heliothis exigua zea virescens % Mort. SS % Mort. SS % Mort. SS______________________________________EMCC-0073 0 1.0 0 0.8 50 0.5EMCC-0074 0 0.9 0 1.0 70 0.3Control (H.sub.2 O) 0 4.0 0 4.0 0 4.0______________________________________
CRY GENE PROFILE FOR EMCC-0073 AND EMCC-0074
The cry gene profile for EMCC-0073 and EMCC-0074 is determined by using the PCR method which is described in the Perkin Elmer Cetus Gene Amp® PCR Reagent Kit literature with AmpliTaq® DNA Polymerase. The double-stranded DNA is heat-denatured and the two oligonucleotides of cryIA(a) (SEQ ID NO:i and SEQ ID NO:2), cryIA(b) (SEQ ID NO:3 and SEQ ID NO:4), or cryIA(c) (SEQ ID NO:5 and SEQ ID NO:6) are annealed at low temperature and then extended at an intermediate temperature.
The results from the PCR analysis are shown in FIG. 1 and indicate that B.t. strains EMCC-0073 and EMCC-0074 contain the cryIA(a), but not the cryIA(b) nor the cryIA(c) genes. Therefore, the crystal delta-endotoxin of B.t. strains EMCC-0073 and EMCC-0074 is encoded only by the cryIA(a) gene.
Oligonucleotide primers for Polymerase Chain Reaction (PCR) amplification of the entire cryIA(a)-like gene of EMCC-0073 were designed based on the sequence of the holotype cryIA(a) gene cloned from Bacillus thuringiensis subsp. kurstaki HD-1 (Schnepf et al., 1985, J. Biol. Chem. 260:6264-6272). The primers are shown in the Sequence Listing as SEQ ID NO:7 and SEQ ID NO:8. Fragments bearing the cryIA(a)-like gene of EMCC-0073 (corresponding to nucleotides 380 to 4205 of the sequence reported by Schnepf et al., 1985, J. Biol. Chem. 260:6264-6272) were cloned from two separate PCRs were cloned in pCR™II (Invitrogen Corporation) or pBCSK+ (Stratagene Cloning Systems) from two separate PCRs. DNA sequencing was performed on the two clones using the Applied Biosystems 373A DNA Sequencer and PRISM Ready Reaction DyeDeoxy Terminator Cycle Sequencing Kit with synthetic oligonucleotides based on the sequence of the holotype cryIA(a) gene. The clones shared two nucleotide differences relative to the holotype cryIA(a) gene (C to T at nt 756 and C to G at nt 3551, according to the numbering of Schnepf et al., 1985, J. Biol. Chem. 260:6264-6272), which corresponded to two amino acid changes relative to the holotype CryIA(a) protoxin (Pro to Leu at residue 77 and Leu to Val at residue 1009). The nucleotide sequence is shown in the Sequence Listing as SEQ ID NO:9 and the amino acid sequence is shown in the Sequence Listing as SEQ ID NO:10.
INSECTICIDAL ACTIVITY OF PURIFIED SPORES FROM EMCC-0073
The B.t. culture obtained from Section 6.1., supra is transferred into sterile 250 ml centrifuge bottles and centrifuged at 10,000 rpm in a Sorvall RC-5B centrifuge for 30 minutes at 5° C. to collect crystals and spores. Pellets are then washed three times with sterile, de-ionized water. The pellets are resuspended into deionized water to i g. wet weight per 10 ml followed by sonicating the suspension on ice to disrupt any clumping. Each 10 ml suspension is further diluted to 33.2 ml with deionized water. 10 ml 3M NaCl, 23.4 ml 20% polyethylene glycol, and 33.4 ml 20% sodium dextran sulfate are all added and mixed well in a separatory funnel with the previously diluted suspension (33.2 ml). An additional 100 ml 20% polyethylene glycol is then added to the separatory funnel and the mixture is shaken vigorously to mix the phases. The phase separation of the mixture is achieved by gravity at room temperature for 30 minutes. The upper phase consists of large quantities of spores which could be removed by pipetting.
Purified spores are then bioassayed against Spodoptera exigua, by using the diet incorporation bioassay described in Section 6.2., supra. The results are shown in Table II. 48 second instar larvae are used for each point. Mortality is recorded on the seventh day post-treatment.
TABLE II______________________________________ % Mortalityμg/g of Diet EMCC-0073 EMCC-0086______________________________________83.3 48 2755.6 21 1735.7 28 822.7 10 7______________________________________
The spores from EMCC-0073 has significantly higher activity against Spodoptera exigua than spores from the B.t.k. type of reference strain (EMCC-0086).
DEPOSIT OF MICROORGANISMS
The following strains of Bacillus thuringiensis have been deposited in the Agricultural Research Service Patent Culture Collection (NRRL), Northern Regional Research Center, 1815 University Street, Peoria, Ill., 61604, USA.
______________________________________Strain Accession Number Deposit Date______________________________________EMCC-0073 NRRL B-21014 November 16, 1992EMCC-0074 NRRL B-21015 November 16, 1992______________________________________
The strains have been deposited under conditions that assure that access to the culture will be available during the pendency of this patent application to one determined by the Commissioner of Patents and Trademarks to be entitled thereto under 37 C.F.R. §1.14 and 35 U.S.C. §122 and under conditions of the Budapest Treaty. The deposit represents a biologically pure culture of each deposited strain. The deposit is available as required by foreign patent laws in countries wherein counterparts of the subject application, or its progeny are filed. However, it should be understood that the availability of a deposit does not constitute a license to practice the subject invention in derogation of patent rights granted by governmental action.
The invention described and claimed herein is not to be limited in scope by the specific embodiments herein disclosed, since these embodiments are intended as illustrations of several aspects of the invention. Any equivalent embodiments are intended to be within the scope of this invention. Indeed, various modifications of the invention in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims.
Various references are cited herein, the disclosures of which are incorporated by reference in their entireties.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 11(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:CTGCTCCAGCTGCTTGGCTC20(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 20 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:CTGCTCCAGCTGCTTGGCTC20(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:GAATTATACTTGGTTCAGGCCC22(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 22 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:GCACACCTTACATTTTAAAGCA22(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 27 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:AGATTACAAGCGGATACCAACATCGCG27(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 21 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:TGGCACTTTCAAAATAACCAA21(2) INFORMATION FOR SEQ ID NO:7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 25 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:GCATCGGATAGTATTACTCAATCCC25(2) INFORMATION FOR SEQ ID NO:8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 39 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:8:CGGGATCCTGGGTCAAAAATTGATATTTAGTAAAATTAG39(2) INFORMATION FOR SEQ ID NO:9:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 43 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:9:CCTGTCGACTAGAAAATAACATAGTAAAACGGACATCACTCCG43(2) INFORMATION FOR SEQ ID NO:10:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 3826 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:10:CCTGGGTCAAAAATTGATATTTAGTAAAATTAGTTGCACTTTGTGCATTTTTTCATAAGA60TGAGTCATATGTTTTAAATTGTAGTAATGAAAAACAGTATTATATCATAATGAATTGGTA120TCTTAATAAAAGAGATGGAGGTAACTTATGGATAACAATCCGAACATCAATGAATGCATT180CCTTATAATTGTTTAAGTAACCCTGAAGTAGAAGTATTAGGTGGAGAAAGAATAGAAACT240GGTTACACCCCAATCGATATTTCCTTGTCGCTAACGCAATTTCTTTTGAGTGAATTTGTT300CCCGGTGCTGGATTTGTGTTAGGACTAGTTGATATAATATGGGGAATTTTTGGTCCCTCT360CAATGGGACGCATTTCTTGTACAAATTGAACAGTTAATTAACCAAAGAATAGAAGAATTC420GCTAGGAACCAAGCCATTTCTAGATTAGAAGGACTAAGCAATCTTTATCAAATTTACGCA480GAATCTTTTAGAGAGTGGGAAGCAGATCCTACTAATCCAGCATTAAGAGAAGAGATGCGT540ATTCAATTCAATGACATGAACAGTGCCCTTACAACCGCTATTCCTCTTTTGGCAGTTCAA600AATTATCAAGTTCCTCTTTTATCAGTATATGTTCAAGCTGCAAATTTACATTTATCAGTT660TTGAGAGATGTTTCAGTGTTTGGACAAAGGTGGGGATTTGATGCCGCGACTATCAATAGT720CGTTATAATGATTTAACTAGGCTTATTGGCAACTATACAGATTATGCTGTGCGCTGGTAC780AATACGGGATTAGAGCGTGTATGGGGACCGGATTCTAGAGATTGGGTAAGGTATAATCAA840TTTAGAAGAGAGCTAACACTTACTGTATTAGATATCGTTGCTCTATTCTCAAATTATGAT900AGTCGAAGGTATCCAATTCGAACAGTTTCCCAATTAACAAGAGAAATTTATACGAACCCA960GTATTAGAAAATTTTGATGGTAGTTTTCGTGGAATGGCTCAGAGAATAGAACAGAATATT1020AGGCAACCACATCTTATGGATATCCTTAATAGTATAACCATTTATACTGATGTGCATAGA1080GGCTTTAATTATTGGTCAGGGCATCAAATAACAGCTTCTCCTGTAGGGTTTTCAGGACCA1140GAATTCGCATTCCCTTTATTTGGGAATGCGGGGAATGCAGCTCCACCCGTACTTGTCTCA1200TTAACTGGTTTGGGGATTTTTAGAACATTATCTTCACCTTTATATAGAAGAATTATACTT1260GGTTCAGGCCCAAATAATCAGGAACTGTTTGTCCTTGATGGAACGGAGTTTTCTTTTGCC1320TCCCTAACGACCAACTTGCCTTCCACTATATATAGACAAAGGGGTACAGTCGATTCACTA1380GATGTAATACCGCCACAGGATAATAGTGTACCACCTCGTGCGGGATTTAGCCATCGATTG1440AGTCATGTTACAATGCTGAGCCAAGCAGCTGGAGCAGTTTACACCTTGAGAGCTCCAACG1500TTTTCTTGGCAGCATCGCAGTGCTGAATTTAATAATATAATTCCTTCATCACAAATTACA1560CAAATACCTTTAACAAAATCTACTAATCTTGGCTCTGGAACTTCTGTCGTTAAAGGACCA1620GGATTTACAGGAGGAGATATTCTTCGAAGAACTTCACCTGGCCAGATTTCAACCTTAAGA1680GTAAATATTACTGCACCATTATCACAAAGATATCGGGTAAGAATTCGCTACGCTTCTACT1740ACAAATTTACAATTCCATACATCAATTGACGGAAGACCTATTAATCAGGGTAATTTTTCA1800GCAACTATGAGTAGTGGGAGTAATTTACAGTCCGGAAGCTTTAGGACTGTAGGTTTTACT1860ACTCCGTTTAACTTTTCAAATGGATCAAGTGTATTTACGTTAAGTGCTCATGTCTTCAAT1920TCAGGCAATGAAGTTTATATAGATCGAATTGAATTTGTTCCGGCAGAAGTAACCTTTGAG1980GCAGAATATGATTTAGAAAGAGCACAAAAGGCGGTGAATGAGCTGTTTACTTCTTCCAAT2040CAAATCGGGTTAAAAACAGATGTGACGGATTATCATATTGATCAAGTATCCAATTTAGTT2100GAGTGTTTATCAGATGAATTTTGTCTGGATGAAAAACAAGAATTGTCCGAGAAAGTCAAA2160CATGCGAAGCGACTTAGTGATGAGCGGAATTTACTTCAAGATCCAAACTTCAGAGGGATC2220AATAGACAACTAGACCGTGGCTGGAGAGGAAGTACGGATATTACCATCCAAGGAGGCGAT2280GACGTATTCAAAGAGAATTACGTTACGCTATTGGGTACCTTTGATGAGTGCTATCCAACG2340TATTTATATCAAAAAATAGATGAGTCGAAATTAAAAGCCTATACCCGTTATCAATTAAGA2400GGGTATATCGAAGATAGTCAAGACTTAGAAATCTATTTAATTCGCTACAATGCAAAACAT2460GAAACAGTAAATGTGCCAGGTACGGGTTCCTTATGGCCGCTTTCAGCCCAAAGTCCAATC2520GGAAAGTGTGGAGAGCCGAATCGATGCGCGCCACACCTTGAATGGAATCCTGACTTAGAT2580TGTTCGTGTAGGGATGGAGAAAAGTGTGCCCATCATTCGCATCATTTCTCCTTAGACATT2640GATGTAGGATGTACAGACTTAAATGAGGACCTAGGTGTATGGGTGATCTTTAAGATTAAG2700ACGCAAGATGGGCACGCAAGACTAGGGAATCTAGAGTTTCTCGAAGAGAAACCATTAGTA2760GGAGAAGCGCTAGCTCGTGTGAAAAGAGCGGAGAAAAAATGGAGAGACAAACGTGAAAAA2820TTGGAATGGGAAACAAATATCGTTTATAAAGAGGCAAAAGAATCTGTAGATGCTTTATTT2880GTAAACTCTCAATATGATCAATTACAAGCGGATACGAATATTGCCATGATTCATGCGGCA2940GATAAACGTGTTCATAGCATTCGAGAAGCTTATCTGCCTGAGCTGTCTGTGATTCCGGGT3000GTCAATGCGGCTATTTTTGAAGAATTAGAAGGGCGTATTTTCACTGCATTCTCCCTATAT3060GATGCGAGAAATGTCATTAAAAATGGTGATTTTAATAATGGCTTATCCTGCTGGAACGTG3120AAAGGGCATGTAGATGTAGAAGAACAAAACAACCAACGTTCGGTCCTTGTTGTTCCGGAA3180TGGGAAGCAGAAGTGTCACAAGAAGTTCGTGTCTGTCCGGGTCGTGGCTATATCCTTCGT3240GTCACAGCGTACAAGGAGGGATATGGAGAAGGTTGCGTAACCATTCATGAGATCGAGAAC3300AATACAGACGAACTGAAGTTTAGCAACTGCGTAGAAGAGGAAATCTATCCAAATAACACG3360GTAACGTGTAATGATTATACTGTAAATCAAGAAGAATACGGAGGTGCGTACACTTCTCGT3420AATCGAGGATATAACGAAGCTCCTTCCGTACCAGCTGATTATGCGTCAGTCTATGAAGAA3480AAATCGTATACAGATGGACGAAGAGAGAATCCTTGTGAATTTAACAGAGGGTATAGGGAT3540TACACGCCACTACCAGTTGGTTATGTGACAAAAGAATTAGAATACTTCCCAGAAACCGAT3600AAGGTATGGATTGAGATTGGAGAAACGGAAGGAACATTTATCGTGGACAGCGTGGAATTA3660CTCCTTATGGAGGAATAGTCTCATGCAAACTCAGGTTTAAATATCGTTTTCAAATCAATT3720GTCCAAGAGCAGCATTACAAATAGATAAGTAATTTGTTGTAATGAAAAACGGACATCACC3780TCCATTGAAACGGAGTGATGTCCGTTTTACTATGTTATTTTCTAGT3826(2) INFORMATION FOR SEQ ID NO:11:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 1176 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: protein(xi) SEQUENCE DESCRIPTION: SEQ ID NO:11:MetAspAsnAsnProAsnIleAsnGluCysIleProTyrAsnCysLeu151015SerAsnProGluValGluValLeuGlyGlyGluArgIleGluThrGly202530TyrThrProIleAspIleSerLeuSerLeuThrGlnPheLeuLeuSer354045GluPheValProGlyAlaGlyPheValLeuGlyLeuValAspIleIle505560TrpGlyIlePheGlyProSerGlnTrpAspAlaPheLeuValGlnIle65707580GluGlnLeuIleAsnGlnArgIleGluGluPheAlaArgAsnGlnAla859095IleSerArgLeuGluGlyLeuSerAsnLeuTyrGlnIleTyrAlaGlu100105110SerPheArgGluTrpGluAlaAspProThrAsnProAlaLeuArgGlu115120125GluMetArgIleGlnPheAsnAspMetAsnSerAlaLeuThrThrAla130135140IleProLeuLeuAlaValGlnAsnTyrGlnValProLeuLeuSerVal145150155160TyrValGlnAlaAlaAsnLeuHisLeuSerValLeuArgAspValSer165170175ValPheGlyGlnArgTrpGlyPheAspAlaAlaThrIleAsnSerArg180185190TyrAsnAspLeuThrArgLeuIleGlyAsnTyrThrAspTyrAlaVal195200205ArgTrpTyrAsnThrGlyLeuGluArgValTrpGlyProAspSerArg210215220AspTrpValArgTyrAsnGlnPheArgArgGluLeuThrLeuThrVal225230235240LeuAspIleValAlaLeuPheSerAsnTyrAspSerArgArgTyrPro245250255IleArgThrValSerGlnLeuThrArgGluIleTyrThrAsnProVal260265270LeuGluAsnPheAspGlySerPheArgGlyMetAlaGlnArgIleGlu275280285GlnAsnIleArgGlnProHisLeuMetAspIleLeuAsnSerIleThr290295300IleTyrThrAspValHisArgGlyPheAsnTyrTrpSerGlyHisGln305310315320IleThrAlaSerProValGlyPheSerGlyProGluPheAlaPhePro325330335LeuPheGlyAsnAlaGlyAsnAlaAlaProProValLeuValSerLeu340345350ThrGlyLeuGlyIlePheArgThrLeuSerSerProLeuTyrArgArg355360365IleIleLeuGlySerGlyProAsnAsnGlnGluLeuPheValLeuAsp370375380GlyThrGluPheSerPheAlaSerLeuThrThrAsnLeuProSerThr385390395400IleTyrArgGlnArgGlyThrValAspSerLeuAspValIleProPro405410415GlnAspAsnSerValProProArgAlaGlyPheSerHisArgLeuSer420425430HisValThrMetLeuSerGlnAlaAlaGlyAlaValTyrThrLeuArg435440445AlaProThrPheSerTrpGlnHisArgSerAlaGluPheAsnAsnIle450455460IleProSerSerGlnIleThrGlnIleProLeuThrLysSerThrAsn465470475480LeuGlySerGlyThrSerValValLysGlyProGlyPheThrGlyGly485490495AspIleLeuArgArgThrSerProGlyGlnIleSerThrLeuArgVal500505510AsnIleThrAlaProLeuSerGlnArgTyrArgValArgIleArgTyr515520525AlaSerThrThrAsnLeuGlnPheHisThrSerIleAspGlyArgPro530535540IleAsnGlnGlyAsnPheSerAlaThrMetSerSerGlySerAsnLeu545550555560GlnSerGlySerPheArgThrValGlyPheThrThrProPheAsnPhe565570575SerAsnGlySerSerValPheThrLeuSerAlaHisValPheAsnSer580585590GlyAsnGluValTyrIleAspArgIleGluPheValProAlaGluVal595600605ThrPheGluAlaGluTyrAspLeuGluArgAlaGlnLysAlaValAsn610615620GluLeuPheThrSerSerAsnGlnIleGlyLeuLysThrAspValThr625630635640AspTyrHisIleAspGlnValSerAsnLeuValGluCysLeuSerAsp645650655GluPheCysLeuAspGluLysGlnGluLeuSerGluLysValLysHis660665670AlaLysArgLeuSerAspGluArgAsnLeuLeuGlnAspProAsnPhe675680685ArgGlyIleAsnArgGlnLeuAspArgGlyTrpArgGlySerThrAsp690695700IleThrIleGlnGlyGlyAspAspValPheLysGluAsnTyrValThr705710715720LeuLeuGlyThrPheAspGluCysTyrProThrTyrLeuTyrGlnLys725730735IleAspGluSerLysLeuLysAlaTyrThrArgTyrGlnLeuArgGly740745750TyrIleGluAspSerGlnAspLeuGluIleTyrLeuIleArgTyrAsn755760765AlaLysHisGluThrValAsnValProGlyThrGlySerLeuTrpPro770775780LeuSerAlaGlnSerProIleGlyLysCysGlyGluProAsnArgCys785790795800AlaProHisLeuGluTrpAsnProAspLeuAspCysSerCysArgAsp805810815GlyGluLysCysAlaHisHisSerHisHisPheSerLeuAspIleAsp820825830ValGlyCysThrAspLeuAsnGluAspLeuGlyValTrpValIlePhe835840845LysIleLysThrGlnAspGlyHisAlaArgLeuGlyAsnLeuGluPhe850855860LeuGluGluLysProLeuValGlyGluAlaLeuAlaArgValLysArg865870875880AlaGluLysLysTrpArgAspLysArgGluLysLeuGluTrpGluThr885890895AsnIleValTyrLysGluAlaLysGluSerValAspAlaLeuPheVal900905910AsnSerGlnTyrAspGlnLeuGlnAlaAspThrAsnIleAlaMetIle915920925HisAlaAlaAspLysArgValHisSerIleArgGluAlaTyrLeuPro930935940GluLeuSerValIleProGlyValAsnAlaAlaIlePheGluGluLeu945950955960GluGlyArgIlePheThrAlaPheSerLeuTyrAspAlaArgAsnVal965970975IleLysAsnGlyAspPheAsnAsnGlyLeuSerCysTrpAsnValLys980985990GlyHisValAspValGluGluGlnAsnAsnGlnArgSerValLeuVal99510001005ValProGluTrpGluAlaGluValSerGlnGluValArgValCysPro101010151020GlyArgGlyTyrIleLeuArgValThrAlaTyrLysGluGlyTyrGly1025103010351040GluGlyCysValThrIleHisGluIleGluAsnAsnThrAspGluLeu104510501055LysPheSerAsnCysValGluGluGluIleTyrProAsnAsnThrVal106010651070ThrCysAsnAspTyrThrValAsnGlnGluGluTyrGlyGlyAlaTyr107510801085ThrSerArgAsnArgGlyTyrAsnGluAlaProSerValProAlaAsp109010951100TyrAlaSerValTyrGluGluLysSerTyrThrAspGlyArgArgGlu1105111011151120AsnProCysGluPheAsnArgGlyTyrArgAspTyrThrProLeuPro112511301135ValGlyTyrValThrLysGluLeuGluTyrPheProGluThrAspLys114011451150ValTrpIleGluIleGlyGluThrGluGlyThrPheIleValAspSer115511601165ValGluLeuLeuLeuMetGluGlu11701175__________________________________________________________________________
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The invention relates to a Bacillus thuringiensis strain(s) which solely produces a CryIA(a) crystal delta-endotoxin having a molecular weight of 130,000 daltons and is active against lepidopteran pests. The invention is also related to a spore(s), mutant(s), or crystal delta-endotoxin obtainable therefrom. Furthermore, the invention relates to insecticidal compositions comprising the B.t. strain, spore, mutant or crystal delta-endotoxin of the present invention. The invention further relates to methods of using the insecticidal compositions to control an insect pest(s) of the order Lepidoptera.
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CROSS REFERENCE TO RELATED APPLICATION
This is a divisional application of U.S. patent application Ser. No. 13/522,067, filed Jul. 13, 2012, which is a national phase of International Application No. PCT/SE2011/050058 filed Jan. 19, 2011, which claims priority to U.S. 61/296,161 filed Jan. 19, 2010.
FIELD OF INVENTION
The present invention relates to a highly modular method for heterogeneous modification of polysaccharide-based materials in native solid state by the reaction between a sulfide and an alkene or an alkyne.
BACKGROUND
The development of polymeric materials with tailored surface properties plays an important role in today's society. Essential all devices and carriers contain different materials that have to be compatible with their surroundings. In addition, there is a need to develop chemistry that is based on renewable resources. Polysaccharides are a natural and renewable resource and a desirable raw material for sustainable chemistry applications. Chemical modifications of polysaccharides are often an important step to change its chemistry or structure in order to design properties needed for specific applications. [1,2] Esterification and etherification are among the most commonly used derivatizations of polysaccharides. There is much use of, and many reports on, efficient and homogenous derivatization of dissolved polysaccharides, but less on solid polysaccharides, such as cellulose. There are different technically viable approaches for cellulose modifications using, for example, acid chlorides, anhydrides and heavy metal based catalyst or nucleophilic substitutions. However, direct, inexpensive, technically simple, environmentally friendly and modular modifications of solid carbohydrates are of great interest to many industries utilizing natural fibers, but it is a challenging task due to the low reactivity of the solid surface of native cellulose and polysaccharide-based materials. [3] So called “Click” chemistry, [5] (copper(I)-catalyzed Huisgen 1,3-dipolar cycloaddition between azides and terminal alkynes) [6] have been applied to polysaccharides and allow for chemoselective and highly modular route to cellulose modifications. [7,8] The reaction of a thiol with an un-activated double bond has been used in various applications to crosslink polymers and has recently emerged as a new thiol-ene based “click” chemistry coupling reaction providing for chemo-selective bio-conjugations and polymerizations. [9-11] The thiol-ene “click” reaction does not require the need for a metal catalyst as compared with for example the copper(I)-mediated azide/alkyne click chemistry. Thiol-ene coupling also benefits from that it can be activated both thermally or photochemically and, depending on substrates, performed without solvents allowing for green and efficient reaction conditions. [12]
This invention provides the first example of the environmentally benign heterogeneous modification of polysaccharide-based materials in its native solid state by thiol-ene “click chemistry”. This “organoclick” methodology is highly modular and completely metal-free.
OBJECT OF THE INVENTION
It is an object of the invention to provide a highly modular method for the heterogeneous modification of polysaccharide-based materials (plant material or plant derived-fibers, solid-(ligno)cellulose, hemicellulose, starch or any solid state polysaccharide-containing polymer alone or within a matrix) in native solid state by the reaction of a thiol with a double or triple bond by thiol-ene and thiol-enyne click modification.
Another object of the invention is to provide a highly modular method for the heterogeneous modification of polysaccharide-based materials comprising or substantially consisting of cellulose fiber in native solid state by the reaction of a thiol with a double or triple bond by thiol-ene and thiol-enyne click modification.
Another object of the invention is to attach a small molecule (e.g. fluorophores, UV active molecules, drug, amino acid, catalyst) by the method of the invention.
An additional object is to attach a large molecule (e.g. polymer, peptide, polymer) by the method of the invention.
A still further object of the method is to provide a method of the aforementioned kind that is advantageous from an environmental and health standpoint.
Even more objectives will become evident from a study of the summary of the invention, a number of preferred embodiments illustrated in a drawing, and the appended claims.
DESCRIPTION OF THE SCHEMES AND FIGURES
Scheme 1 is a picture illustrating the “thiol-ene” reaction or “thiol-enyne” reaction between a heterogeneous polysaccharide with thiol groups and an alkene or an alkyne, respectively.
Scheme 2 is a picture illustrating the “thiol-ene” reaction or “thiol-enyne” reaction between a heterogeneous polysaccharide with alkene or alkyne groups with a thiol, respectively.
Scheme 3 is a picture illustrating examples of molecules that were attached to cellulose modified with alkenes.
FIG. 1 shows the fluorescence of cellulose 2a, cellulose 4aa and cellulose were the fluorescent molecule has been removed by hydrolysis.
FIG. 2 shows the IR spectra of cellulose (blank), cellulose 2a and cellulose 4ab.
SUMMARY OF THE INVENTION
The invention is based on the use of heat or light as activation agents for the conjunction of a solid polysaccharide-based material carrying a terminal thiol-group with another molecule (monomer, oligomer or polymer) containing a terminal unsaturated double or triple bond via a thiol-ene click-chemistry type reaction. And the reverse case also apply, with a solid polysaccharide-based material carrying an alkene or alkyne hydrocarbon bond reacting with a molecule (monomer, oligomer, protein, biotine, peptide, amino acid, small molecule, drug or polymer) containing a terminal thiol-group via a thiol-ene click-chemistry type reaction.
One aspect of the invention is that a solid polysaccharide-based material ((plant material or plant derived-fibers, solid-(ligno)cellulose, hemicellulose, starch or any solid state polysaccharide-containing polymer alone or within a matrix)) with a terminal thiol group reacts with another molecule (monomer, oligomer or polymer) carrying a terminal unsaturated (double or triple) hydrocarbon bond using either photon irradiation or heat, or in combination, as catalyst obtaining the corresponding thiol-ene linked modified products (according to Scheme 1).
Another aspect of the invention is that a solid polysaccharide-based material ((plant material or plant derived-fibers, solid-(ligno)cellulose, hemicellulose, starch or any solid state polysaccharide-containing polymer alone or within a matrix)) with a terminal unsaturated (double or triple) hydrocarbon bond reacts with another molecule (monomer, oligomer or polymer) carrying terminal thiol group using either photon irradiation or heat, or in combination, as catalyst obtaining the corresponding thiol-ene linked modified products (according to Scheme 2).
Another aspect of the invention is that all the previously described transformations can be and are performed with an enantiomerically pure reactants yielding enantiomerically pure products.
Another aspect of the invention is that polysaccharide-based fiber material initially without thiol- or olefinic groups may be substituted with an terminal thiol-or olefinic containing molecule by organocatalytic derivatization of polysaccharide-based fiber material using small organic acids as catalysts according a previous patent (International Patent WO 2006068611 A1 20060629 “Direct Homogeneous and Heterogeneous Organic Acid and Amino Acid-Catalyzed Modification of Amines and Alcohols”). Thereby, a completely metal-free, environmentally friendly and highly modular modification of any solid polysaccharide-based fibrous material may be achieved.
Another aspect of the invention is that polysaccharide-based fiber material initially without olefinic groups may be substituted with a terminal olefinic containing molecule by derivatization of polysaccharide-based fiber material using acrylic and methacrylic anhydrides with or without a nucleophilic catalyst. Thereby, a completely metal-free, environmentally friendly and highly modular modification of any solid polysaccharide-based fibrous material may be achieved.
The method of the invention is composed of two steps in which the heterogeneous polysaccharide is modified under environmentally benign conditions. In one embodiment of the invention the method comprises the steps of:
i) Providing a heterogeneous polysaccharide ii) Chemically modify said polysaccharide with a molecule containing an alkene or alkyne group by a suitable modification method. iii) To the alkene or alkyne group on the modified heterogeneous polysaccharide attach a thiol-containing functional molecule by using thiol-ene and thiol-enyne click modification, respectively, using UV irradiation, heat or a Michael conjugate addition.
In another embodiment of the invention the method comprises the steps of:
iv) Providing a heterogeneous polysaccharide v) Chemically modify said polysaccharide with a molecule containing a thiol group by a suitable modification method. vi) To the thiol group on the modified heterogeneous polysaccharide attach an alkene- or alkyne-containing functional molecule by using thiol-ene and thiol-enyne click modification, respectively, using UV irradiation, heat or a Michael conjugate addition.
Suitable reactive molecules that may be used in order to attach the alkene, alkyne, or thiol group to the heterogeneous polysaccharide in the second step of the invention include acids, alkyl ketene dimmers, acid chlorides, epoxides, akoxysilanes, chlorosilanes, anhydrides, or other reactive molecules containing the alkene, alkyne or thiol functionality. The modification may be performed in a water based solution, in an organic solvent or neat. The modification may be performed with or without a catalyst. Suitable catalysts, depending on the nature of the reactive molecule, may be an acid catalyst, or a nucleophilic catalyst. The nature of the catalyst for the specific reactive molecule may be determined by a person skilled in the art.
In the third step of the invention, a thiol-, alkene-, or alkyne-containing molecule is linked to the previously attached thiol, alkene- or alkyne containing molecule used in step two of the invention by thiol-ene and thiol-enyne click modification, respectively, using UV irradiation, heat or a Michael conjugate addition as previously described.
Heterogeneous polysaccharides modified by using the method of the invention may be for example modified cellulosic fibres, modified starches, or modified hemicelluloses. The materials may be polymers or individual fibres, but may also be in form or a matrix or web such as for example a paper based material, cotton based textile, nonwoven textile, or wood based material, such as for example particle board, MDF-board, or solid wood.
DETAILED DESCRIPTION
Thiol-Ene Click Derivatization of Cellulose
To a solution of a thiol ((with 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %)) around 30 mg cellulose (containing terminal olefinic groups) was added (see Scheme 3). Then the reaction was irradiated with a UV lamp (UV-B bulb, TL20W/12, 20 W) for 1 h. After that, the cellulose was taken out and purified by soxhlet extraction. After drying the thiol-ene click modified cellulose was obtained. The cellulose was modified with polyesters, aliphatic and aryl groups. The cellulose was also modified with the amino acid cystein.
Sample Analyses
The cellulose samples derivatized by polyesters or hydrocarbons were analyzed using FT-IR, directly without further sample handling, using a Perkin-Elmer Spectrum One FT-IR spectrophotometer. Each sample was subject to 32 averaged scans. Fluorescence of benzyl-derivatized cellulose samples were analyzed using a Leica fluorescence microscope with an excitation/emission filter cub (filter cub A); excitation (λ ex )=340-380 nm and emission (λ ex )=>425 nm using 10× objective lens.
The present invention will now be described by reference to a number of preferred embodiments illustrated in the following Examples.
Example 1
The filter paper (around 30 mg) was dipped into a mixture of 9-decenoic acid (1 g) and
(S)-tartaric acid (5 mol %). Then the reaction was heated to 110° C. and kept for 8 hours. After that, the filter paper was taken out and extracted by soxhlet. After drying the modified filter paper 2a (Scheme 3) was obtained.
Example 2
The filter paper (around 30 mg) was dipped into a mixture of hex-5-ynoic acid (1 g) and (S)-tartaric acid (5 mol %). Then the reaction was heated to 110° C. and kept for 8 hours. After that, the filter paper was taken out and extracted by soxhlet. After drying the modified filter paper 2b was obtained.
Example 3
The filter paper (around 30 mg) was dipped into a mixture of 2-(oct-7-enyl)oxirane (1 g) and (S)-tartaric acid (5 mol %). Then the reaction was heated to 110° C. and kept for 1 hour. After that, the filter paper was taken out and extracted by soxhlet. After drying the modified filter paper 2c (Scheme 3) was obtained.
Example 4
To a mixture of the 9-decenoic acid (340 mg, 2 mmol) and octane-1-thiol (292 mg, 2 mmol) was added 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %). Then the reaction mixture was irradiated with UV lamp (UV-B bulb, TL20W/12, 20 W) for 1 h. The product was formed as a white solid and checked by 1 H NMR.
10-(Octylthio)decanoic acid: 1 H NMR (400 MHz, CDCl3) δ 2.51 (t, J=6.0 Hz, 4H), 2.36 (t, J=6.0 Hz, 2H), 1.66-1.56 (m, 6H), 1.38-1.29 (m, 20H), 0.89 (t, J=5.6 Hz, 3H); 1 3 C NMR (100 MHz, CDCl3) δ 180.6, 34.2, 32.3, 32.2, 31.9, 29.82, 29.78, 29.4, 29.32, 29.29, 29.13, 29.08, 29.0, 28.5, 24.7, 22.8, 14.2.
Example 5
To a solution of the benzylthiol with 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %) the modified cellulose 2a (around 30 mg) was added. Then the reaction was irradiated with a UV lamp (UV-B bulb, TL20W/12, 20 W) for 1 h. After that, the cellulose was taken out and purified by soxhlet. After drying the modified cellulose 4aa was obtained. The cellulose 4aa exhibited fluorescence, which is in agreement with the attachment of the benzyl thiol to the cellulose FIG. 1 .
FIG. 1 . The fluorescence of 9-decenoic acid modified cellulose 2a (a), fluorescent-labeled cellulose 4aa (b), and sample 4aa after deesterification (NaOH) and subsequent extraction to remove the released molecules (c).
Example 6
To a bulk solution of the polymer (poly(ε-caprolactone (PCL)) with a thiol end-group and 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %) the modified cellulose 2a (around 30 mg) was added. Then the reaction was irradiated with a UV lamp (UV-B bulb, TL20W/12, 20 W) for 1 h. After that, the cellulose was taken out and purified by soxhlet. After drying the polymer-modified cellulose 4ab was obtained. The cellulose 4ab was analyzed by IR ( FIG. 2 ).
FIG. 2 . FT-IR spectra: the top line is the IR of the modified cellulose 4ab, the middle one is the IR spectrum of 2a, the lowest line is the IR of the blank. The ester carbonyl (C═O) absorbs at 1730 cm −1 .
Example 7
To a solution of the octane thiol with 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %) the modified cellulose 2a (around 30 mg) was added. Then the reaction was irradiated with a UV lamp (UV-B bulb, TL20 W/12, 20 W) for 1 h. After that, the cellulose was taken out and purified by soxhlet. After drying the modified cellulose 4ac was obtained.
Example 8
To a solution of the benzylthiol with 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %) the modified cellulose 2c (around 30 mg) was added. Then the reaction was irradiated with a UV lamp (UV-B bulb, TL20W/12, 20 W) for 1 h. After that, the cellulose was taken out and purified by soxhlet. After drying the modified cellulose was obtained. The cellulose exhibited fluorescence, which is in agreement with the attachment of the benzyl thiol.
Example 9
To a bulk solution of the polymer (poly(ε-caprolactone (PCL)) with a thiol end-group and 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %) the modified cellulose 2c (around 30 mg) was added. Then the reaction was irradiated with a UV lamp (UV-B bulb, TL20W/12, 20 W) for 1 h. After that, the cellulose was taken out and purified by soxhlet. After drying the polymer-modified cellulose 4bb was obtained.
Example 10
To a solution of the octane thiol with 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %) the modified cellulose 2c (around 30 mg) was added. Then the reaction was irradiated with a UV lamp (UV-B bulb, TL20W/12, 20 W) for 1 h. After that, the cellulose was taken out and purified by soxhlet. After drying the modified cellulose 4bc was obtained.
Example 11
To a bulk solution of the polymer (poly(ε-caprolactone (PCL)) with a thiol end-group and 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %) the modified cellulose 2c (around 30 mg) was added. Then the reaction was heated at 80° C. for 16 h. After that, the cellulose was taken out and purified by soxhlet. After drying the polymer-modified cellulose 4bb was obtained.
Example 12
To a bulk solution of the polymer (poly(ε-caprolactone (PCL)) with a thiol end-group and 2,2-dimethoxy-2-phenylacetophenone (DMPA) (1 wt %) the modified cellulose 2b (around 30 mg) was added. Then the reaction was irradiated with a UV lamp (UV-B bulb, TL20W/12, 20 W) for 1 h. After that, the cellulose was taken out and purified by soxhlet. After drying the polymer-modified cellulose 4cc was obtained.
REFERENCES
[1] D. K. Klemm, B. Heublein, H. P. Fink, A. Bohn, Angew. Chem. Int. Ed. 2005, 44, 3358 and references therein.
[2] [2a] J. Huang, I. Ichinose, T. Kunitake, Angew. Chem. Int. Ed. 2006, 118, 2949; [2b] R. A. Caruso, Angew. Chem, Int. Ed. Ed. 2004, 43, 2746; [2c] J. Huang, T. Kunitake, J. Am. Chem. Soc. 2003, 125, 11834; [dc] T. Liebert, S. Hornig, S. Hesse, T. Heinze, J. Am. Chem. Soc. 2005, 127, 10484.
[3] [3a] J. Jagur-Grodzinski, “Heterogeneous modification of polymers”, J. Wiley & Sons, New York 1997, p. 64; [3b] R. D. Gilbert, J. F. Kadla, “Polysaccharides-Cellulose”, in: Biopolymers from renewable resources, D. L. Kaplan, Eds., Springer Verlag, New York 1998, p. 47.
[4] [4a] J. Hafrén, A. Córdova, Macromol. Rapid Commun. 2005, 26, 82; [4b] A. Córdova, J. Hafrén, Nordic Pulp Paper Res. J. 2005, 20, 477; [4c] J. Hafrén, A. Córdova, Nordic Pulp Paper Res. J. 2007, 22, 184.
[5] H. C. Kolb, M. G. Finn, K. B. Sharpless, Angew. Chem. Int. Ed. 2001, 40, 2004.
[6] [6a] V. V. Rostovsev, L. G. Green, V. V. Fokin, K. B. Sharpless, Angew. Chem. Int. Ed. 2002, 41, 2596; [6b] W. G. Lewis, L. G. Green, F. Grynszpan, Z. Radic, P. R. Carlier, P. Taylor, M. G. Green, V. V. Fokin, K. B. Sharpless, Angew. Chem. Int. Ed. 2002, 41, 1053; [6c] S. Punna, E. Kaltgrad, M. G. Finn, Bioconjugate Chem. 2005, 16, 1536; [6d] P. Wu, A. K. Feldman, A. K. Nugent, C. J. Hawker, A. Scheel, B. Voit, J. Pyun, J. M. J. Frechet, K. B. Sharpless, V. V. Fokin, Angew. Chem. Int. Ed. 2004, 43, 3863; [6e] D. B. Ramachary, C. F. Barbas III, Chem. Eur. J. 2004, 10, 5323; [6f] C. W. Tornoe, C. Christensen, M. Meldal, J. Org. Chem. 2002, 67, 3057.
[7] T. Liebert, C. Hänsch, T. Heinze, Macromol. Rapid Commun. 2006, 27, 208.
[8] J. Hafrén, W. Zou, A. Córdova, Macromol. Rapid Commun. 2006, 27, 1362.
[9] [9a] C. E. Hoyle, T. Y. Lee, T. Roger, J. Polym. Sci. Part A: Polym. Chem. 2004, 42, 5301; [9b] J. A. Carioscia, L. Schneidewind, C. O'Brien, R. Ely, C. Feeser, N. Cramer, C. N. Bowman, J. Polym. Sci. Part A: Polym. Chem. 2007, 45, 5686; [9c] Q. Li, H. Zhou, D. A. Wicks, C. E. Hoyle, J. Polym. Sci. Part A: Polym. Chem. 2007, 45, 5103.
[10] [10a] J. A. Carioscia, H. Lu, J. W. Stanbury, C. N. Bowman, Dent. Mater. 2005, 21, 1137; [10b] C. N. Salinas, B. B. Cole, A. M. Kasko, K. S. Anseth, Tissue Eng. 2007, 13, 1025. [10c] A. E. Rydholm, C. N. Bowman, K. S. Anseth, Biomaterials 2005, 26, 4495.
[11] [11a] P. Wu, A. K. Feldman, A. K. Nugent, C. J. Hawker, A. Scheel, B. Voit, J. Pyun, J. M. J. Fréchet, K. B. Sharpless, V. V. Fokin, Angew. Chem. Int. Ed. 2004, 43, 3928; [11b] C. Nilsson, N. Simpson, M. Malkoch, M. Johansson, E. Malmström, J. Polym. Sci Part A: Polym. Chem. 2008, 46, 1339.
[12] [12a] K. L. Killops, L. M. Campos, C. J. Hawker, J. Am. Chem. Soc. 2008, 130, 5062; [12b] L. M. Campos, K. L. Killops, R. Sakai, J. M. J. Paulesse, D. Damiron, E. Drockenmuller, B. W. Messmore, C. J. Hawker, Macromol. 2008, 41, 7063.
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This invention concerns the first environmentally benign heterogeneous modification of polysaccharide-based material in native solid state by thiol-ene “click chemistry”. The direct reaction of a thiol with an un-activated double or triple bond by thiol-ene and thiol-enyne click modification is thermally or photochemically catalyzed and is completely metal-free and allows for a highly modular approach to modifications of fibers and fiber-based materials.
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This invention relates to a utility basket which serves to hold tools, materials and supplies while the basket is supported at the top of a stepladder, and is particularly directed to a bracket or hanger which is mounted at an exterior of the basket for also supporting tools, materials or supplies. The application is based on U.S. Provisional Patent Application Ser. No. 60/017,209, filed May 13, 1996.
BACKGROUND OF THE INVENTION
Suspension brackets, even of the shape illustrated, have been known and used in this particular environment. They are typically mounted with conventional screws to the relatively thin vertical side walls of the basket, often putting severe strain on the fasteners whenever a heavy load such as a gallon can of paint is hung from the bracket.
SUMMARY OF THE INVENTION
A suspending system for supporting one or more brackets from a utility basket includes a pair of conventional, vertically-aligned keyhole slots in a side wall of the basket, but further utilizes a slot in an adjacent horizontal lip of the basket to add rigidity to the basket as well as support for the bracket after installation. The use of the keyhole slots enables a bracket to be installed or removed quickly if desired, without requiring tools for the installation or removal. This permits easy relocation of the bracket in the event a particular job being performed is best facilitated by repositioning a bracket to a different side or end of the basket other than the one where it had been located previously.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a stepladder containing a utility basket having the novel bracket support of my invention.
FIG. 2 is a cross-sectional, fragmentary elevational view of the prior art type of bracket support used in this environment.
FIG. 3 a cross-sectional, fragmentary elevational view of the bracket of my invention during the initial part of its installation to the basket.
FIG. 4 is a cross-sectional, fragmentary elevational view of the bracket in its final, installed position, looking in the direction of the lines 4--4 of FIG. 5.
FIG. 5 is a fragmentary elevational view of the bracket mounted on the utility basket, looking in the direction of lines 5--5 of FIG. 4, from the inside of the basket.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A stepladder 10 is positioned in a location to perform a task such as changing fluorescent lighting tubes, painting a wall, ceiling or trim, washing windows or a large variety of other tasks. Mounted atop the stepladder is a utility basket 12 having a bail 14 which pivots over the top of the stepladder and holds the basket within easy reach of a person standing on ladder steps. The utility basket 12 typically has a carrying handle 16, a plurality of compartments 18 and 20, a bottom wall 22, a pair of side walls 24, a pair of end walls 26 and an outer lip 28 or ledge surrounding the tipper edges of the side and end walls 24 and 26. The lip 28 provides stability to the side and end walls 24 and 26. The basket 12 is produced from any of several different kinds of thermoplastics, and the walls are relatively thin for cost-saving purposes, on the order of three-sixteenths of an inch in thickness. The portion of the basket constituting the lip 28 is formed in an inverted U-shape to add further strength to the basket, as seen in FIGS. 3-5.
As noted in FIG. 1, vertically-aligned pairs of keyhole slots 30 are provided in one or more of the side and end walls 24, and 26. The slots 30 cannot be seen in the left side wall 24 of FIG. 1, where they are spaced apart horizontally and capable of suspending a pair of U-shaped brackets 32 for supporting elongated objects such as fluorescent lamps. As will be apparent, the brackets 32 may be repositioned from one of the side walls 26 by disassembling them from the left side wall 24 and placing them or one of them on an end wall 26. If both side and end walls are to be used for mounting brackets, it is preferred that all slots 30 be in the walls surrounding compartment 18. This allows compartments 20 to be kept watertight for containing liquid, if desired. Regardless of which wall a bracket is on, it may also be used to support things such as the bail of a paint can, a washing rag or rags, a tool having a support ring which can be placed over the outer end of a bracket, and has many other uses, as well. The purpose is to provide as much flexibility to use of the basket 12 as possible, with minimum trips up and down the stepladder to perform the intended task.
Prior to development of the bracket-mounting design depicted in FIGS. 3-5, brackets had been fastened by self-threading screws 34 threaded into a thin wall of the basket as shown in prior art FIG. 2. Depending on the screws used, only a few threads in the wall could normally hold the screws and bracket in place. It was not intended that the brackets of the prior art FIG. 2 design ever be removed once installed at manufacture, and thus they were adequate to perform their intend function. When a heavy object was suspended from the bracket of FIG. 2, however, the wall could deflect outwardly somewhat since the strain was borne primarily at the upper screw 34. The lip 28A offered no resistance to the cantilevered force affecting the bracket, since it provided no support for the bracket. Additionally, the screws 34 extended inwardly of the compartment 18, possibly scratching material held therein or the user's fingers or hands. Of some slight concern, however, was the lack of sufficient strength to enable carrying a heavy object. Furthermore, the cost of production of the FIG. 2 design is greater than what will be disclosed hereinafter, because of the time required to install the brackets. The prior art design did not readily allow the brackets to be repositioned during use for the convenience of the user, since repositioning would gradually adversely affect the screw threads created in the plastic walls in the basket at the time of manufacture.
The improved bracket support is shown in FIGS. 3-5, where FIG. 3 shows the bracket as it appears is an initial stage of its installation, and FIGS. 4 and 5 show the bracket fully installed, from two different positions. Only a part of one bracket 32 is shown, it being understood that they are preferably provided with the basket as a pair, as shown in FIG. 1. The bracket 32 is metal and has a pair of attaching buttons 36 which are simply illustrated as screws threaded perpendicularly into a vertical portion of the bracket. The buttons 36 may also be rivets or other means, all within the scope of the invention. Each button 36 has a head 38 and a necked-down portion 40. Referring to FIG. 5, the buttons are positioned and mounted in conventional fashion in the keyhole slots 30. The slots 30 each have a vertical portion 44 slightly larger than the necked-down portion 40 and an upper hole 46 exceeding the diameter of a head 38 by a small amount to permit the head 38 to pass through its hole.
During installation of a bracket 32 to a wall 24 or 26 of the basket 12, the bracket is first brought angularly as shown in FIG. 3 and pushed upwardly through a rectangular hole 48 at the upper surface of the lip 28. Four such holes 48 are shown in FIG. 1. When the bracket is raised to the level of FIG. 3, the heads 38 align with the holes 46 of the keyhole slots 30. The bracket is then pivoted about the lip hole 48 in the direction of arrow 50 until the heads 38 pass through the holes 46. The bracket is next moved downwardly in the direction of arrow 52 of FIG. 4 until the necked-down portions 40 bottom in vertical portions 44 of the keyhole slots 30. It can be seen from FIGS. 4 and 5 that the top or distal end of the bracket is flush with the top surface of the lip 28 at that time. This additional support by the lip 28 provides a stronger mounting of the bracket to the wall, relieving leftward force on the button heads 38 as viewed in FIG. 4. The design also allows easy removal of a bracket by reversing the steps of installation, if desired. Neither installing nor removing a bracket requires use of tools, and either can be done quickly by the user if, for example, he or she wishes to position a pail of water, paint or some other item at an end rather than the far side of the basket when mounted on a stepladder as in FIG. 1. Obviously, the item supported should be removed from a bracket before a bracket is relocated.
Various chances may be made in the design without departing from the spirit and scope of the claims, including making bracket 32, button 36 and necked-down portion 40 integral and of an appropriate injection-molded plastic.
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A suspending system for supporting one or more brackets from a utility basket includes a pair of conventional, vertically-aligned keyhole slots in a side wall of the basket, but further utilizes a slot in an adjacent horizontal lip of the basket to add rigidity to the basket as well as support for the bracket after installation. The use of the keyhole slots enables a bracket to be installed or removed quickly if desired, without requiring tools for the installation or removal.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
None.
BACKGROUND OF THE INVENTION
The present invention relates to a fishing lure. In particular, the present invention is a crankbait which carries a tubular insert (such as a chemiluminescent or colored tube) element which is exposed below and on both sides of the crankbait body.
Fishing is among the most popular recreational sports. Anglers are of all ages and from virtually all walks of life. In the United States, it is estimated that between 40 and 60 million people go fishing every year.
There is a never ending quest for more effective fishing lures. Lures of all shapes, colors, and sizes have been used in attempts to attract fish and increase fishing success. Fish can be attracted by the sight, sound, and smell of lures.
In the past, various attempts have been made to develop a lighted lure which would be useful in attracting fish during low-light conditions. These conditions may occur during evening hours, during overcast days, and even on brightly lit days when water clarity is low. Examples of lighted fishing lures include the following patents: Bercz, et al. U.S. Pat. No. 3,708,903; Murphy U.S. Pat. No. Des. 381,734; Northcutt U.S. Pat. No. 3,940,868; Kulak U.S. Pat. No. 4,437,256; Malphrus U.S. Pat. No. 4,516,350; Cota, et al. U.S. Pat. No. 4,741,120; Douglas, Jr. U.S. Pat. No. 4,888,904; Kaplan U.S. Pat. No. 5,043,851; Ladyjensky U.S. Pat. No. 5,067,051; Livingston U.S. Pat. No. 5,157,857; Troescher U.S. Pat. No. 5,195,266; Giglia U.S. Pat. No. 5,213,405; Steiger, et al. U.S. Pat. No. 5,446,629; Hunt U.S. Pat. No. 5,495,690; and Ladyjensky U.S. Pat. No. 5,552,968.
BRIEF SUMMARY OF THE INVENTION
The fishing lure of the present invention is a crankbait which includes a crankbait body having a cavity in its lower surface. A elongated insert (such as a chemiluminescent element or a colored tube) is positioned in the cavity so that the insert is exposed below it on both sides of the crankbait body.
The insert is releaseably held in place in the cavity. In preferred embodiments, the element is held in place by a bias spring, by a loop located near a forward end of the cavity, or by flexing the element so that it is captured by recesses at the front and rear ends of the cavity.
In another embodiment of the present invention, the fishing lure is part of a kit which includes a crankbait body and a set of inserts. The inserts can include chemiluminescent tubes, as well as inserts which are not light emitting, but which have different colors. As a result, the same crankbait body can be modified to present different appearances, including those which are light emitting in order to attract fish or trigger striking of the lure under a variety of different conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of one embodiment of the fishing lure of the present invention.
FIG. 2 is a cross sectional view of the fishing lure of FIG. 1 taken along section 2--2 of FIG. 3.
FIG. 3 is a cross sectional view of the fishing lure of FIGS. 1 and 2 taken along section 3--3 of FIG. 2.
FIG. 4 is a side elevational view of a second embodiment of the fishing lure of the present invention.
FIG. 5 is a bottom view of the fishing lure of FIG. 4.
FIG. 6 is an exploded view of a third embodiment of the fishing lure of the present invention.
FIG. 7 is a fishing lure kit which includes a crankbait and a set of tubular inserts.
FIG. 8 is an exploded view of another embodiment of the fishing lure of the present invention.
FIG. 9 is an assembled view of the fishing lure of FIG. 8.
DETAILED DESCRIPTION
FIGS. 1-3 show a first embodiment of the present invention. Fishing lure 10 includes crankbait body 12, treble hooks 14 and 16, and chemiluminescent light source tube 18. Crankbait body 12 includes bill 20, front eyelet 22, bottom eyelet 24, and rear eyelet 26. On the underside or belly of crankbait body 12 is a longitudinal cavity 28. Bias spring 30 is positioned in forward end pocket 28F of cavity 28.
When chemiluminescent tube 18 is positioned within cavity 28, the rear end of tube 18 is received in rear end pocket 28R of cavity 28. The front end of tube 18 presses against bias spring 30, and is captured within forward end pocket 28F of cavity 28. Cavity 28 is shaped so that tube 18 is exposed on both sides and the bottom of crankbait body 12.
Front eyelet 22 is connected to a fishing line either directly by tying, or through a connector such as a snap or snap swivel.
Treble hook 14 is connected to lower eyelet 24 by split ring 32. Similarly, rear treble hook 16 is connected to rear eyelet 26 by split ring 34.
Chemiluminescent tubes are available from several sources and are available in different sizes and different colors. Typically, the chemiluminescent tube is activated by bending the tube until a snapping sound is heard, which breaks a seal separating two substances within the tube. The chemicals within the tube are then mixed by shaking the tube. Once activated, tube 18 is inserted within cavity 28. One form of chemiluminescent tube which has been used with the present invention is Cyalume® lightstick from Omniglow Corporation. Cyalume® is a registered trademark of American Cynamid Company. Cyalume® lightsticks are available in 1.5 inch (0.25 ml fluid) sizes in a number of different colors (including red and yellow). They are also available in a larger 7.5 mm ×75 mm size, which is used with larger crankbaits.
Another chemiluminescent tube which can be used with the present invention is the Firefly Lightstick from Bandi Co., Ltd. Seoul, Korea.
Light emitted from chemiluminescent tube 18 provides additional color or flash to the lure, and is particularly advantageous in low light conditions caused either by lack of water clarity, weather conditions, or the time of day.
Other colored tubes, which are not chemiluminescent, can also be inserted into cavity 28. For example, under certain conditions a red, orange, chartreuse, silver, or copper colored tube can provide additional color to lure 10 which may attract fish or trigger strikes. The present invention provides the flexibility of presenting different appearances with the same lure.
FIGS. 4 and 5 show another embodiment of the present invention. Lure 50 includes crankbait body 52, treble hooks 54 and 56, and tube 58 (which may be chemiluminescent or plain colored, as desired by the angler.
Crankbait body 52 includes bill 60, front eyelet 62, bottom eyelet 64, and rear eyelet 66. Longitudinal cavity 68 has a rear end 68R for capturing the rear end of tube 58. The forward end of tube 58 is captured and held in place by eyelet 70.
FIG. 5 shows cavity 68 with tube 58 removed. Treble hook 54 is also not shown in FIG. 5 for clarity.
As shown in FIG. 4, tube 58 is slightly flexed as it is held in place.
The Firefly Lightstick from Bandi Co., Ltd. has been found to have sufficient flexibility to allow it to perform while in a slightly flexed condition.
FIG. 6 shows still another embodiment of the present invention. Lure 80 is shown in an exploded view. Crankbait 82 carries a pair of treble hooks 84 and 86. A tubular insert 88, which may be a chemiluminescent tube or a tube of a selected color, is carried within crankbait body 82, with the sides and bottom of tube 88 exposed.
Crankbait body 82 has bill 90, front eyelet 92, lower eyelet 94, rear eyelet 96, and cavity 98. Positioned within cavity 98 are cavity liner 100 and bias spring 102. Liner 100 is preferably formed from a metal or plastic tube which is shaped to match the contour of the outer edge of cavity 98. Tube 88 is inserted into cavity 98 and into liner 100. Bias spring 102 acts on the forward end of tube 88 to hold the rear end of tube 88 within the rear portion of liner 100. In embodiments where crankbait body 82 is molded plastic, liner 100 is preferably inserted in a mold and crankbait body 82 is molded around it.
FIG. 7 shows an embodiment of the present invention which is in the form of a fishing lure kit 120. The kit includes container 122 with foam liner 124, which has cutout sections 126, 128, and 130.
Crankbait 140, which for example may be any one of the forms illustrated in FIGS. 1-6 (or the form illustrated in FIGS. 8 and 9) is positioned within cutout 126. Cutout 128 contains a number of different colored tubes 150. The tubes may be, for example, chartreuse, copper, red, yellow, and silver, as illustrated in FIG. 7, or may be a wide variety of other colors. Cutout 130 provides a storage space for sealed packages 160 which contain chemiluminescent tubes.
FIGS. 8 and 9 show another embodiment of the present invention. Lure 170 is shown in an exploded view in FIG. 8 and an assembled view in FIG. 9.
Lure 170 includes crankbait body 172, which carries a pair of treble hooks 174 and 176. Insert 178, which may be a chemiluminescent tube or a tube of a selected color, is carried within crankbait body 172, with the sides and bottom of insert 178 exposed.
Crankbait body 172 has bill 180, front eyelet 182, lower eyelet 184, and rear eyelet 186. Cavity 188, with front end pocket 188F and rear end pocket 188R, is located in the bottom surface of crankbait body 172. Insert 178 is inserted into cavity 188 by flexing tube 178 slightly so that it is arched as shown in FIG. 9. The forward end of insert 178 is located in and captured by front end pocket 188F. The rear end of insert 178 is located in and captured by rear end pocket 188R.
In the embodiment shown in FIGS. 8 and 9, the natural resiliency of tubular insert 178 facilitates its insertion into cavity 188, and its retention within cavity 188, during use of lure 170. Insert 178 can be removed simply by pulling downward on it so that one or both ends pop out of pockets 188F and 188R.
In each of the embodiments illustrated in FIGS. 1-9, the crankbait body has had the same general shape and hook configuration. It is well known that crankbaits come in a wide variety of different sizes and shapes, with varying numbers of hooks. Some crankbaits have bills and others do not. The location of the front eyelet can vary considerably. In some lures, the eyelet is located on the bill, while in others the eyelet is located on a top surface of the crankbait body.
The present invention is applicable to any of these crankbait configurations. The location of the insert may differ depending upon the specific shape of the crankbait. Although all of the embodiments illustrated have shown the cavity located in a lower surface of the crankbait body, the cavity can, alternatively, be located in an upper surface. In still other embodiments, more than one cavity can be located in the crankbait, such as on each side or on both top and bottom.
The present invention provides a simple and effective way to vary the appearance of a crankbait as needed and dictated by different fishing conditions. Different colors of inserts can provide a different appearance which may more closely match the appearance of bait fish in the body of water being fished, or may provide a color which triggers a strike because of lighting and water clarity conditions. The color choices can include an insert which is the same as the crankbait body. Similarly, the use of chemiluminescent tube inserts can provide for an increased visibility or flash to the crankbait in low light or poor water clarity conditions. Changes to the crankbait are made quickly and easily using the inserts, without the need to retie a new lure.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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A fishing lure which includes a crankbait body has a cavity in the lower surface of the body. An elongated insert (which may be a chemiluminescent tube or a colored tube) is positioned in the cavity so that the element is exposed below and on both sides of the crankbait body. The chemiluminescent element is releaseably held in place by a bias spring, a loop located near the forward end of the cavity, or by flexing the element so that it is captured by recesses at the front and rear ends of the cavity.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a technology for manipulating water-flow in the pipe, and more particularly to an intoxication-free inner lining of the ball valve structure.
[0003] 2. Related Art
[0004] Our everyday drinking water is usually transported by water pipe, therefore the material of water pipe has to conform the national standards or regulations for safety and health. Ordinary water pipe also provides plurality of switches for controlling the water flow, so-called “valve”, and controlling the inter-pipe water flow in order to proceed some indispensable maintenances and replacements. Conventionally, an ordinary ball valve provides a rotational ball element in a valve base; an aperture is opened through the center of the ball element to form a path with the flow tunnel of the valve base. With this mechanism, people can manipulate water flows on/off with the shielding effect caused by the control of ball element's rotation.
[0005] However in the prior art, the valve base is made by forging or sand casting with bronze zinc alloy (59% of red bronze, zinc and lead for the rest composition. And lead takes more than 1% of total.), so it can be cut or manufactured easier, and the ball element is made in the same way. The water contacts with alloy contained with lead when passing through the valve base, causing the lead being dissolved in drinking water greatly. After drinking the water described above, lead ions that the water contained react with carbon dioxide in human bodies and are transferred to lead carbonates. Moreover, it further generates replacement reaction with calcium in one's frame and will cause chronic diseases. Furthermore, lead holds a strong affinity to neural system, so that lead does stronger toxicity to children in development phase than grownups during. For this reason, a national standard or regulation suggests that the lead's quantity ratio in the drinking water shall be lower than 0.25% after passing through the ball valve(s) for ensuring the health of nationals.
SUMMARY OF THE INVENTION
[0006] In view of the defects of the conventional art, the present invention is directed to a ball valve which lowers the lead content in water after passing through water pipe.
[0007] In order to achieve the above object, the present invention contains a valve base, a ball element, a valve shaft, a handle and a locking element. Wherein, a flow tunnel goes through the valve base interiorly, and a containing space is formed in the flow tunnel. The inner wall of the containing space and part of the flow tunnel is provided with a first inner lining, and an aperture is perpendicularly disposed above the containing space. A penetrative aperture is centrally provided in the ball element and a valve shaft aperture is provided on the top of the ball element, the valve shaft pierces through the penetrative aperture. One end of the handle is connected with one end of the valve shaft jointly. A second inner lining is provided on the inner wall of the locking element, and a second thread portion is provided on the outer wall of one end for threading into a first thread portion provided in the valve base near the containing space.
[0008] Compare to the conventional art, the present invention provides numerous inner linings, so that when the water flows among the ball element and the inner linings, the present invention prevents the water from being contacted with the metal material of valve base (mainly lead). In addition, the ball element in the present invention is made of stainless steel, so as to avoid the contamination of metal material and ensure the safety of drinking water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will become more fully understood from the detailed description given below and the figures for illustration only. The figures are not limited to the present invention, wherein:
[0010] FIG. 1 is a solid exploded schematic view of preferred embodiment of present invention;
[0011] FIG. 2 is a combinative schematic view of preferred embodiment of present invention;
[0012] FIG. 3 is a solid combinative schematic view of preferred embodiment of present invention;
[0013] FIG. 4 is a first schematic view of using preferred embodiment of present invention; and
[0014] FIG. 5 is a second schematic exploded view of preferred embodiment of present invention;
DETAILED DESCRIPTION OF THE INVENTION
[0015] The implementation of the present invention is described with specific detailed embodiments as following, and those of ordinary skill in the art may easily understand other advantages and efficacies of the present invention from the content of the specification.
[0016] FIGS. 1-3 are schematic views of preferred embodiment of present invention, mainly comprising: a valve 1 which is in a tube shape, a flow tunnel 11 running centrally through the interior of the valve base 1 , a containing space 12 formed on one side of the flow tunnel 11 . The inner wall of the containing space 12 and part of the flow tunnel 11 is provided with a first inner lining 13 . The first inner lining 13 is made of toxicity-free plastic material such as HDPE (High Density Polyethylene), POM (Polyoxymethylene) and LLDPE . . . etc. A first anti-leaking ring 14 is set on an aperture of one end of the flow tunnel 11 . An inclined plane is provided on one side of the first anti-leaking ring 14 . A first thread portion 15 is provided on each end of the flow tunnel 11 , and is partially formed on the first inner lining 13 . This combination keeps isolation from drinking water to contact with metal material when a pipe 5 is threaded. Besides, an aperture 16 is perpendicularly disposed above the containing space 12 , and at least one stopper portion 17 is provided on the wall of the aperture 16 .
[0017] In this embodiment, a ball element 2 is provided in the containing space 12 of the valve base 1 movably, and a penetrative aperture 21 is centrally provided therein. A valve shaft aperture 22 is provided on the top of the ball element 2 . As shown in FIGs, the valve shaft aperture 22 is a strip-shaped aperture, and a valve shaft 23 is disposed within the valve shaft aperture 22 . One end of the valve shaft 23 pierces out of the aperture 16 of the valve base 1 , and the valve shaft 23 connects with the ball element 2 . Further, a second anti-leaking ring 24 is disposed between the valve shaft 23 and the aperture 16 .
[0018] In this embodiment, one end of a handle 3 is connected with one end of the valve shaft 23 , so as to make the ball element 2 and the handle 3 move simultaneously. A curvature portion 31 is provided in the center of the handle 3 . A protective suit 32 is covered on the surface of the curvature portion 31 . The stopper portion 17 on the outer wall of the aperture 16 is used to restrict the movement of handle 3 for meeting the purpose of manipulating the rotation angle of the ball element 2 .
[0019] A locking element 4 is provided in this embodiment, and a second inner lining 41 is provided on its inner wall. The second inner lining 41 is similarly made of toxicity-free plastic material. A second thread portion 42 is provided on the outer wall of one end of the locking element 4 , for threading into the first thread portion 15 provided on the valve base 1 near the containing space 12 . A third thread portion 43 is provided on the inner wall of the other side of the locking element 4 , and partially provided on the second inner lining 41 . A third anti-leaking ring 44 is disposed on the inner wall of the licking element 4 . An inclined surface is provided on one side of the third anti-leaking ring 44 . When the present invention is assembled, the first anti-leaking ring 14 of the valve base 1 and the third anti-leaking ring 44 of the locking element 4 both attach to the surface of the ball element 2 firmly, so as to prevent the water flow from being leaked out. Furthermore, a fourth anti-leaking ring 45 is disposed between the valve base 1 and the locking element 4 , so as to fill the gap where the locking element 4 is threaded into the valve base 1 , and to prevent the water flow from being leaked out.
[0020] FIG. 4-5 shows the fabrication of present invention, in this embodiment, a fourth thread portion 51 is provided on the outer wall of one end of the pipe 5 in order to assemble the present invention among two pipes 5 . Both ends of the pipe 5 are threaded into the first thread portion 15 of the valve base 1 and the second thread portion 43 of the locking element 4 respectively. The first inner lining 13 and the second inner lining 41 are provided in the valve base 1 and the locking element 4 respectively. When a user wants to switch the water flow on/off, revolve the handle 3 to correspondingly revolve the ball element 2 , so as to adjust the included angle of the penetrative aperture 21 and the flow tunnel 11 . Water flows when the included angle is less than 90 degree. Contrarily, when the included angle equals to 90 degree where the handle 3 is stopped by the stopper portion 17 , the penetrative aperture 21 is blocked by the valve base 1 , and water flow stops. And more, when the drinking water flows through the valve base 1 , the drinking water merely flow through the penetrative aperture 21 , the first inner lining 13 and the second inner lining 41 of the ball element 2 made of stainless steel without contacting with the metal material constructing the valve base 1 . With those lead-free elements, the present provides an intoxication-free mechanism.
[0021] To sum up, as mentioned above and shown in FIG. 1-5 , the present invention separates water from metal material to prevent water from being contaminated during passing through the ball valve 2 , so as to lower the lead content in drinking water and ensure the safety of drinking water.
[0022] The above embodiments are merely intended to illustrate the principles and efficacies of the present invention, but not to limit the present invention. The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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The present invention provides a ball valve, comprising a valve base, a ball element, a valve shaft and a locking element. The valve base has a containing space opening inside for containing the ball element, and having a lining layer on its inner wall. The locking element is threaded onto one side of the valve base, and correspondingly having a lining layer on its inner wall to separate water and metal materials (mainly refers to lead), in order to prevent contamination from metal material to water.
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This application claims benefit of Provisional Applications Ser. No. 60/239,111 filed Oct. 11, 2000, and Ser. No. 60/284,947 filed Apr. 13, 2001.
FIELD OF INVENTION
This invention relates to an apparatus and method for rendering sanitary (i.e. germ-free) a contact surface, such as a door handle, on a continuous basis.
BACKGROUND OF THE INVENTION
For safety and sanitary reasons, hospitals, laboratories and commercial establishments are increasingly in need of means for maintaining sanitary certain facilities within their premises such as kitchen and washroom areas. Typically, a form of soap and hand drying method is provided within such facilities but it is known that a percentage of the population does not adhere to effective hand washing following consumption of food and/or using washroom facilities, or following the handling of chemicals, reagents, etc. within a hospital or laboratory, and this results in the transfer of germs, bacteria and/or viruses to surface areas which come into contact with individuals. Moreover, the provision of a soap and hand drying facility is relatively expensive because it requires labour to maintain and may also involve energy costs and wastage costs.
A lesser known means of protecting contact surfaces against the spread of germs is disclosed in published Canadian Patent Application No. 2,296,152 in the name of Lane Kendall Herman which appears to have been filed Jan. 12, 2000 and published on Jun. 20, 2000. That application discloses a sanitation system for dispensing an alcohol-based sanitiser over a surface (such as a door handle) by using touch controlled external or internal nozzles to spray the handle after it has been used and sensors to sense when the handle is being touched. The apparatus and method therein disclosed deposits (but does not retain) a sanitiser onto a contact surface and, thus, requires that the sanitiser be a highly volatile chemical (i.e. alcohol) in order that it evaporate quickly so as to leave the handle relatively dry soon after it is treated. Such fluids are not desirable for general use due to their relatively high flammable nature. The apparatus and method therein disclosed also undesirably uses a touch flow control system, for controlling the flow of the volatile fluid based on touch, and such flow systems are not desirable because they typically provide uneven coverage of the fluid due to the non-porous nature of the surface areas typically contemplated and the low viscosity of a nozzle-sprayed alcohol-based fluid. Additionally, a touch-activated flow control system is subject to cause flooding of the handle, and dripping of fluid onto the floor, if used repetitively.
Therefore, it is desirable to provide an improved and cost-effective means for providing a sanitising, safe material to a surface contact area. It is further desirable to provide means for evenly controlling and distributing such a sanitiser.
SUMMARY OF THE INVENTION
In accordance with the invention there is provided an apparatus and method for providing a contact surface which is continuously sanitized with a sanitizing fluid. A reservoir contains the sanitizing fluid. A contact material having a porous contact surface is in fluid communication with the reservoir. A moisture control and fluid distribution system determines the moisture level of the porous surface and, upon determining that the moisture level thereof has reached a predetermined level, causes a flow of the sanitizing fluid from the reservoir to the contact material. The contact material comprises a durable, porous outer layer configured for evenly distributing the sanitizing fluid, which is relatively non-flammable and may be chlorine-based, to the contact surface and a backing layer bonded to the outer layer to provide a seal there between.
In use, the contact material may be formed as desired to cover any surface area, such as a door handle, to provide a continuously sanitized surface therefore. Optionally, the contact material may be integrated within an object to provide such object with a continuously sanitized surface therefore. The moisture control and fluid distribution system preferably comprises a fluid flow control circuit and a flow controller for controlling the flow of fluid from the reservoir to the contact material in response to an output from the fluid control circuit. At least one transducer is preferably installed at the contact surface to produce a signal correlated to the moisture level at the contact surface for input to the fluid flow control circuit.
DESCRIPTION OF THE DRAWINGS
The present invention is described in detail below with reference to the following drawings in which like reference numerals refer throughout to like elements:
FIG. 1 is a front view of a door equipped with a sanitary contact surface apparatus in accordance with the present invention, the contact surface covering an extended longitudinal door handle;
FIG. 2 is a side view of the door of FIG. 1 showing a cross-section view of the sanitary contact surface apparatus installed therein;
FIG. 3 is a side view of a door equipped with an alternate embodiment of the sanitory contact surface apparatus of the present invention, wherein a flush-mounted contact surface is provided on the left side of the door and an extended contacted surface, covering a longitudinal door handle, is provide on the right side of the door;
FIG. 4 is a cross-sectional view of a preferred contact material used for the sanitary contact surface apparatus of the invention, the contact material having a backing layer and a porous outer layer which distributes a sanitizing fluid across the contact surface and provides a durable contact surface;
FIG. 5 shows the contact material of FIG. 4 formed as sleeve which can be slid over a door knob or handle;
FIG. 6 is a cross-sectional view of the sleeve of FIG. 5 taken at section C—C; and,
FIG. 7 is a schematic block diagram illustrating the combination of components of a sanitary contact surface apparatus in accordance with the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 of the drawings illustrates a front view of a door 5 equipped with a sanitary contact surface apparatus in accordance with the present invention, wherein the sanitized contact surface covers an outwardly extended longitudinal door handle, and FIG. 2 illustrates a side view of this embodiment. In this embodiment a sanitizing fluid reservoir 40 , a moisture control and fluid distribution system (see components 120 , 121 , 30 and 130 of FIG. 7) and a contact material 20 are produced as a single unit and inlaid into the door 5 to provide an installation which is integral to the door and does not significantly alter the appearance of the door. In the embodiment illustrated by FIGS. 1 and 2 an outwardly extended handle is covered with a contact material 20 . If desired, for an alternate embodiment, a push pad flush with the door surface could instead be used and covered with a like contact material. The contact material 20 comprises a durable, porous surface which distributes, over the surface, a non-flammable sanitizing fluid delivered from the reservoir 40 to the body of the contact material 20 . The delivery and flow of the sanitizing fluid is controlled by a fluid flow control circuit (see component 120 of FIG. 7) and a transducer (see probe 121 of FIG. 7) which detects the moisture level of the surface 85 of the contact material 20 .
The sanitizing fluid selected for the preferred embodiment is a chlorine-based chemical solution as this provides a relatively non-flammable fluid (as compared to an alcohol-based solution) and also provides the required germicide function. However, It is to be understood that the term “sanitizing fluid” used herein is not intended to be limited to any particular type of chemical solution or fluid and the scope and meaning of this term includes any suitable fluid which acts as a germicide. Optionally, a scent additive may be included in the fluid in order that the sanitizing fluid may function also as an air freshener.
With reference to FIG. 1, a reservoir sight level window 60 is preferably included to enable the user to monitor the fluid level of the reservoir 40 and a fluid fill aperture 50 is provided to fill the reservoir with sanitizing fluid. A battery charge indicator 70 is also preferably included to indicate the charge remaining on a battery which powers the moisture transducer (sensor) and fluid flow control circuit of the moisture control and fluid distribution system.
FIG. 3 illustrates an alternate embodiment of the sanitory contact surface apparatus of the present invention in which the fluid reservoir 40 is mounted externally to the door 5 , rather than integrally within the door 5 and, thus, the appearance of the door 5 is changed by the installation of the apparatus. As shown, for this illustrated embodiment a flush-mounted contact surface is provided on the left side of the door 5 and an extended contacted surface, in the form of a longitudinal door handle, is provide on the right side of the door 5 .
FIG. 4 shows a cross-sectional view of the contact material 20 of the apparatus of FIGS. 1-3. A backing layer 90 is bonded to an outer porous layer 80 and seals the material so that sanitizing fluid within the body of the contact material 20 does not leak or come into contact with the surface over which the contact material 20 is installed (for example, the metal or wooden surface of a door handle). The backing layer 90 may be comprised of a foam rubber or neoprene, for example, or any other suitable material. The outer layer 80 is made of a durable, porous material chosen such that it will evenly distribute the sanitizing fluid across the contact surface 85 provided by the contact material. The outer layer 80 is, in the preferred embodiment, comprised of a nylon which serves as a tough fabric layer. However, for an alternate embodiment any other porous material which is suitable to render the surface 85 sufficiently durable to withstand both the wear of usage and continuous saturation by the sanitizing fluid could be used. An inner absorbent layer 100 , such as a sponge layer, is optionally included to provide an inner material for retaining and holding the sanitizing fluid close to the surface 85 . Further, It is to be noted that a backing layer sealed to the porous contact surface may not be desired if the surface of the object over which it is installed is such that it will not be damaged by contact with the sanitizing fluid. For such an alternate embodiment, the contact material may consist solely of a fabric (e.g. nylon) which is suitable for distributing the fluid throughout itself using capillary action.
The contact material 20 may be manufactured in many shapes or as sleeves (see FIGS. 5 and 6 ). The outer covering 80 may be a heat shrinkable fabric (such as aircraft covering dacron) which can be mass produced and fitted tightly to handles, knobs or any other contact surface of various shapes. The material 20 may be provided as a removable outer cover over a door or window handle, or other contact surface, or may be integrally incorporated into a handle or other contact surface at the time of manufacture of such items. Optionally, the contact material 20 may be formed with inner distribution channels to transfer the sanitizing fluid to different areas of the surface 85 thereof.
The sanitizing fluid at the surface 85 of the contact material 20 is constantly removed through evaporation and items coming into contact with the surface such as persons' hands. Therefore, it is necessary that the apparatus be able to provide a fresh supply of the sanitizing fluid to the contact material 20 on a continuing and controlled basis.
FIG. 7 illustrates, in block diagram form, the interaction of the components of the sanitary contact surface apparatus of the present invention. The sanitizing fluid reservoir 40 holds a supply of the sanitizing fluid. The flow of the sanitizing fluid from the reservoir 40 to the contact material 20 and contact surface 85 is controlled by a flow controller 30 , being a pump or solenoid valve. A suitable fluid flow control circuit (with a power supply) 120 controls the flow controller 30 on the basis of control signals it receives from one or more transducers (i.e. moisture sensors) 121 at the surface 85 of the contact material 20 . When the contact surface 85 reaches a predetermined level of dryness the circuitry 120 is triggered to activate the flow controller 30 and cause it to allow more sanitizing fluid to flow through a manifold 130 to the contact material 20 .
Moisture/fluid flow control circuits are well-known and readily available in the marketplace and no claim is made herein to the fluid flow control circuit itself. For example, for information concerning suitable circuits, the reader is referred to the publication entitled The Encyclopedia of Electronic Circuits, FIG. 56-3, “Automatic Plant Waterer”, and Section 56, “Moisture and Rain detectors”, 1985, Tab Books Inc., Blue Ridge Summit, Pa. 17214. For the sanitary contact surface apparatus of the present invention, a suitable moisture/fluid flow control circuit with moisture transducer(s) is provided to maintain a predetermined (selected) moisture level at the surface 85 of the contact material 20 . Such circuits typically operate on the principal that as the contact surface dries, the resistance between two spaced apart probes positioned on the surface will increase. The probes may be provided externally to the contact material 20 or, instead, may be formed as conductive fibers woven into the contact material.
It is to be understood that the specific types, configurations and components of the contact material, reservoir, moisture control and fluid distribution system described herein with reference to the illustrated embodiments are not intended to limit the invention; for example, the invention is not intended to be limited to any specific configuration for the contact area, for which various alternative embodiments may be determined by one skilled in the art based upon the teachings herein and the particular application. Further, it is to be recognized that the moisture control and fluid distribution system disclosed herein is not limited to any particular type of system and alternative systems utilizing mechanical moisture valves and/or optical control sensing and/or other sensing and control means might instead be selected and/or the viscosity of the sanitizing fluid itself to achieve flow control. Further the apparatus claimed herein is not limited for use on any particular type of object or in any particular installation.
In accordance with a different aspect of the invention a continuously sanitized contact surface is provided by a solidified sanitizing material configured to form a coating layer over a surface which, through the wear of usage, is depleted over time. A preferred embodiment of this aspect of the invention provides continuous sanitization to a contact surface by means of the coating layer only.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention, is therefore, defined by the appended claims, and not by the foregoing description. All variations and equivalents coming within the meaning of the appended claims are intended to be embraced within the scope of the present invention.
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An apparatus and method for providing a contact surface which is continuously sanitized with a sanitizing fluid. A reservoir contains the sanitizing fluid. A contact material has a porous contact surface in fluid communication with the reservoir. A moisture control and fluid distribution system determines the moisture level of the porous surface and, upon determining that the moisture level thereof has reached a predetermined level, causes a flow of the sanitizing fluid from the reservoir to the contact material. The contact material comprises a durable, porous outer layer configured for evenly distributing the sanitizing fluid to the contact surface and a backing layer bonded to the outer layer to provide a seal there between.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 60/319,057 filed Jan. 10, 2002.
BACKGROUND OF INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to an optical detector arrangement for detecting and registering incident ultraviolet (UV) radiation and characteristics of a protective agent applied thereon.
[0004] 2. Background Information
[0005] A sunburn or a tan can be considered attractive at the same time that the exposure to too much ultraviolet radiation may cause skin cancer, such as malignant melanoma, and also early skin aging.
[0006] The ultraviolet radiation is generally classified into substantially three different wavelength areas, i.e. ultraviolet radiation, type A (UVA), ultraviolet radiation, type B (UVB) and ultraviolet radiation, type C (UVC). The UVA, and especially the UVB radiation are injurious for the skin, while the UVC radiation hardly hits the surface of the earth at all. The UVA radiation is relatively constant over the entire surface of the earth, while the UVB radiation varies considerably depending on the time of the day, the position on the earth and the thickness of the ozone layer. It should also be appreciated that the ultraviolet radiation of solariums is also mainly of the UVA-type. The UVA radiation substantially comprises wavelengths in the ultraviolet radiation region of about 400-320 nm. The UVB-radiation substantially comprises wavelengths in the ultra violet radiation region of about 320-280 nm. Finally, the UVC-radiation substantially comprises wavelengths in the ultra violet radiation region of about 280-200 nm.
[0007] It is, however, possible to protect oneself against ultraviolet radiation with sun control inhibitors or sun cream comprising a sun protection factor (SPC). Unfortunately, the SPC system is only valid for UVB radiation; that is, there is no method of measuring the UVA radiation, but the sun cream in itself does actually protect against both the UVA and UVB radiation. Moreover, the SPC factor, in most investigations, is only calculated for an application amount of SPC being considerably larger than the application amount of SPC that most people use, for instance when sun bathing.
[0008] Still further, the SPC degenerates over the course of time. Thus, the protection against UVA-radiation strongly decreases over the course of time for the sun protection creams available on the market. After a day in the sun, the absorbent effect of SPC reduces considerably. The absorption spectra of the SPC are then transferred to the UVC-region, where the SPC is not useful for protecting the user anymore.
[0009] Several arrangements have earlier been proposed to measure the ultraviolet radiation of the sun, especially for sun bathing.
[0010] U.S. Pat. No. 5,986,273 shows an ultraviolet radiation sensor that includes a thin, transparent semi-permeable membrane and an indicator means. The membrane is adhesive and may be worn on the skin to indicate the exposure of ultraviolet radiation and comprises ink that changes color gradually. This ultraviolet radiator sensor shows the user, such as a sunbather, when the exposure to sunlight should be terminated and/or when additional sunscreen should be applied. Further, this sensor may also be provided with a means to receive and absorb a sun screen preparation such that the user knows when to re-apply additional sun screen. Consequently, the sensor exhibits the absorbent characteristics of the sunscreen preparations on human skin by means of emulating the manner in which the sunscreen is absorbed by the human skin. As the general degeneration by solar radiation increases, the sun screen preparation will slowly become less and less effective in preventing the transmission of ultraviolet through the membrane to the indicator means of the sensor. Eventually, the membrane gradually will change the color to indicate that more sunscreen should be applied. In summary, this ultraviolet radiation sensor is only pre-set to different levels of radiation.
[0011] U.S. Pat. No. 4,985,632 shows an electronic watch having a photo diode for detecting skin damaging UVB ultraviolet tanning radiation. Some of the members of the watch interact so that the intensity of the UVB radiation presently incident on the detector gives an instantaneous value of the UVB radiation detected, but this arrangement will not measure the UVA and the UVC radiation. Moreover, the watch also presents the maximum time a user can be safely exposed to the UVB radiation, which is however initially calculated, preferably by a computer. The effect of any sun screening agents is not considered.
[0012] U.S. Pat. No. 5,008,548 shows a miniaturized portable battery operated with a combined power and energy radiometer, which provides a means to determine the direction of the maximum radiant UV power and also the measurement of total experienced energy over time, i.e. a received dosage. The miniaturized portable battery produces an alarm upon the attainment of a predetermined dosage level set by the user. Again, the effect of the sun screening agents is not considered.
[0013] U.S. Pat. No. 5,365,068 shows a portable device for calculating an optimal safe SPF lotion to be applied by the user under local ambient conditions. The user inputs his or her skin type and the amount of time that he or she wishes to spend in the sun. The device includes a photovoltaic (PV) cell for self-power having a battery back up.
[0014] Swedish Patent Application Patent No. 0102226-8, by the same Applicant, shows a UV detection sensor for detecting and registering incident ultraviolet radiation, a protective agent such as a SPC, and the degeneration of the SPC; this patent application is expressly incorporated herein by reference.
SUMMARY OF INVENTION
[0015] The present invention provides an optical detector arrangement for detecting and registering incident ultraviolet radiation, allowing detection of the quality of protective agents.
[0016] Accordingly, the optical detector arrangement of the present invention includes at least two sensors, each connected to electrical circuitry for generating a detection signal. One of the two sensors is arranged as a reference sensor and the other of the two sensors is arranged as a detector sensor to be applied with a protective agent. The electrical circuitry is arranged to compare signals from the reference and indicator sensors and to output a signal corresponding to changes in the characteristics of the protective agent. The characteristics include at least one of efficiency or degeneration of said protective agent.
[0017] The arrangement also has a covering that covers the sensors. The covering includes filters that have an area that is transparent to ultraviolet radiation allowing its passage therethrough. The filters are arranged to exhibit characteristics similar to human skin with respect to absorbency, transparency, thickness, and the like. The arrangement further quantifies and indicates the amount of ultraviolet radiation. This characteristic is optionally provided as a value of the accumulated total dose of ultraviolet radiation and/or as a real-time value of ultraviolet radiation being experienced.
[0018] The sensors can be provided with optical filters so that the incident UV radiation passing through the filters initially hits the optical filters and subsequently hits the sensors. The active elements are photo diodes. The optical filters are arranged for at least one of UVA and UVB radiation. The reference diode is blocked to the incident UV radiation.
[0019] The UVA radiation has a wavelength of about 400 to about 320 nm, and the UVB radiation has a wavelength of about 320 to about 280 nm.
[0020] The electrical circuitry includes amplifiers, ADC, an integrator, a resetting unit, calculating units an oscillator, a memory unit driving elements and display units. The optical detector arrangement also has data representing different skin types. The protective agent is a sun protective means such as a sun checking inhibitor, sun screen inhibitor, or the like. The efficiency of the protective agent is constituted as a SPC. The sensor is adjustable for different skin types and it can be provided with an alarm unit. Preferably, the sensor is waterproof and the sensor is powered by solar cells.
[0021] The presently disclosed invention(s) also relate to a method of detecting and registering incident ultraviolet (UV) radiation and characteristics of a protective agent applied on a detector arrangement. The method includes providing the arrangement with at least two sensors, each connected to electrical circuitry for generating a detection signal. One of the sensors is arranged as a reference sensor and the other as a detector sensor to be applied with the protective agent. The electrical circuitry is also arranged to compare signals from the reference and indicator sensors and output an signal corresponding to characteristics of the involved protective agent.
BRIEF DESCRIPTION OF DRAWINGS
[0022] In the following, the invention will be described in more detail and in a non-limiting way with reference to the accompanying drawings, in which:
[0023] [0023]FIG. 1 is an exploded perspective view of a preferred embodiment of the present invention;
[0024] [0024]FIG. 2 shows a schematic cross-sectional view of a UV detector configured according to the invention, including representations of the active elements according to a preferred embodiment of the invention; and
[0025] [0025]FIG. 3 graphically shows an exemplary wiring diagram of a sensor arranged as shown in FIG. 2.
DETAILED DESCRIPTION
[0026] In a preferred embodiment of the invention, as exemplarily illustrated in FIGS. 1 and 2, an optical detector arrangement 10 includes five active elements 11 , 12 , 13 , 14 and 22 that are arranged on a carrier 15 placed under a covering 23 . Active elements 11 and 13 are arranged with optical filters 16 and 18 , such that the incident ultraviolet radiation passes through the optical filters 16 and 18 and hits the active elements 11 and 13 . The optical filters 16 and 18 are intended for UVB radiation and therefore have a bandpass filter for UVB radiation centered around approximately 300 nm and having a full width at half maximum of approximately 30 nm. Active elements 12 and 14 are arranged with optical filters 17 and 19 , such that the incident ultraviolet radiation passes through the optical filters 17 and 19 and hits the active elements 12 and 14 . The optical filters 17 and 19 are intended for UVA radiation and therefore have a bandpass filter for UVA radiation centered around about 360 nm having a full width at half maximum of approximately 80 nm. The element 22 is a reference diode and is also arranged on the carrier 15 .
[0027] The UV detection sensor arrangement 10 includes members 20 and 21 , which are applicable with a protective agent, such as a sun protective means, sun checking inhibitor or sunscreen. The members 20 , 21 are transparent for UV radiation, and consequently serve as a window for the UV radiation. The windows 20 and 21 are arranged in connection with the active elements 11 and 12 , and 13 and 14 , respectively at locations between the incident ultraviolet radiation and the optical filters 16 , 17 , 18 and 19 . The arrangement is such that the incident ultraviolet radiation passes through the windows 20 and 21 , and thereafter hits the optical filters 16 , 17 , 18 and 19 , but not the reference diode 22 .
[0028] Additionally, the windows 20 and 21 show substantially the same characteristics as human skin, for instance with respect to absorption and transparency of ultraviolet radiation via thickness of the windows 20 and 21 , and the like.
[0029] The wiring diagram for an electrical arrangement of an UV detection sensor configured according to FIG. 2 is exemplarily illustrated in FIG. 3. In this embodiment, the active elements 11 , 12 , 13 and 14 as well as the reference diode 22 are initially connected to signal amplifiers 61 , 62 , 63 , 64 and 65 respectively. Preferably, the active elements 11 , 12 , 13 and 14 and the reference diode 22 are connected to operation amplifiers 66 , 67 , 68 and 69 . The operational amplifiers 66 , 67 , 68 and 69 are in turn connected to an ADC 70 , which in turn is connected to an integrator 71 and a calculating unit 76 .
[0030] Except for the operation amplifiers 66 , 67 , 68 and 69 , the signal units connected to the integrator 71 are preferably a driver element 73 and a resetting unit 74 . An oscillator is in turn connected to the driver element 73 .
[0031] Further, the integrator 71 is connected to a calculating unit 75 . The calculating unit 75 is connected to a driver element 81 , which in turn is connected to a display unit 82 . Moreover, a memory unit 78 is connected to the first calculating unit 75 . Further, an input unit 79 is connected to the memory unit 78 .
[0032] Furthermore, the ADC 70 is connected to a second calculating unit 76 , which is in the same way as the first calculating unit 75 is connected to a second driver element 83 , which in turn in connected to a display unit 84 . The calculating units 75 and 76 are also connected to a memory unit 77 .
[0033] The UV detection sensor 10 is adjustable for different skin types in one embodiment of the invention; that is, the sensor 10 includes the data unit 78 having data representing some different skin types (mJ/cm 2 ), and also the input unit 79 for choosing the required individual skin type with regard to the maximum ultraviolet radiation dose (mJ/cm 2 ). In one alternative embodiment, different UV detector sensor units 10 can be arranged for different skin types with regard to the ultraviolet radiation dose (mJ/cm 2 ).
[0034] The UV detection sensor 10 can be arranged with an alarm unit that goes off when the maximum dose of ultraviolet radiation is obtained. The UV detection sensor 10 can also be arranged with a RF unit 85 for wireless communication of stored data with an external computer/display unit.
[0035] The UV detection sensor 10 adapted according to the teachings of the present invention operates in the following way. Initially, the UV detection sensor 10 is set for the desired skin type, if necessary. Subsequently, the UV detection sensor 10 is reset. The user, such as a sunbather, applies a protective agent such as suntan lotion to his or her body, as well as to one of the windows 20 of the UV detection sensor 10 .
[0036] The display unit 82 of the sensor 10 , on a substantially instantaneous basis, continuously indicates the total accumulated dose of the UVA and UVB radiation by means of the integrator 71 and the calculating unit 75 . This is possible because the measured UVA and UVB radiation of the active elements 11 and 12 is an instantaneous measurement of the accumulated dose of the total UVA and UVB radiation is collected. The total dose of UVA and UVB-radiation is presented compared to the total dose for the actual skin type chosen. However, it is also possible to show the UVA and UVB radiation as a measurement in real-time; that is, it is possible to display how the incoming UV radiation varies in time.
[0037] Secondly, the display unit 84 of the sensor 10 substantially instantaneously and continuously indicates the relation between the element 11 (UVB) and element 13 (UVB), respectively with respect to element 12 (UVA) and element 14 (UVA) by means of the calculating unit 76 , a relationship that is a measurement of the sun protection factor. In this way, the window 20 that has been applied with a protective agent is compared to the window 21 not applied with the protective agent. The degeneration of the protective agent can also be obtained in this way, as a total value or in real-time.
[0038] An alarm signal can be generated when the maximum dose of UVA and UVB radiation is obtained for a chosen skin type. In one embodiment, the alarm unit alarms when a predetermined value of degeneration of SPC is obtained.
[0039] The optical detectors arrangement in the preferred embodiment can be arranged as a part of a membrane, a watch, a button, a sticker, or the like that can be worn by an individual such as a sunbather.
[0040] The active elements 11 , 12 , 13 , 14 and 22 are UV indicating means such as photo detectors or photo diodes operating in the ultraviolet radiation region. The filters 16 , 17 , 18 , and 19 are preferably optical filters, which substantially only transmit specified wavelengths.
[0041] The UV detection sensor 10 is preferably waterproof so that they can be used when swimming, which also can degenerate the sun protection agent.
[0042] Appropriate wiring diagrams are not limited to the illustrated examples. The type and connection of components can be varied in many ways, within the knowledge of a skilled person, as long as the function of the circuits are according to the teachings of the invention.
[0043] Still further, the invention is not limited to the embodiments shown, but can be varied in a number of different ways, for instance by combination of two or more of the embodiments shown, without departing from the scope of the appended claims, and the arrangement and the method can be implemented in a number of ways depending on application, functional units, needs and requirements and the like.
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Method and arrangement for an optical detector arrangement for detecting and registering incident ultraviolet (UV) radiation and characteristics of a protective agent applied thereon. The arrangement includes at least two sensors each connected to electrical circuitry for generating a detection signal, one of the at least two sensors is arranged as a reference sensor and the other one as a detector sensor to be applied with a protective agent. The electrical circuitry is arranged to compare signals from the reference and indicator sensors and output an signal corresponding to the characteristics of the protective agent.
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This application is a continuation-in-part of my copending application Ser. No. 68,209, filed Aug. 20, 1979, now abandoned, which in turn is a continuation-in-part of my application Ser. No. 922,748, filed July 7, 1978, and now abandoned.
BACKGROUND OF THE PRIOR ART
In recent years, there has been an upsurge of interest in so-called renewable energy resources, particularly carbohydrates. Carbohydrates can be converted to liquid organic fuels in a number of different ways. For example, simple sugars have been fermented to produce ethyl alcohol since ancient times. If liquid organic fuels obtained from carbohydrates are to be economically competitive with other energy sources, however, it is likely that starting materials for the fermentation or other microbiologically or enzymatically catalyzed syntheses will have to be selected from more complex carbohydrates or carbohydrate-containing materials, particularly materials of a cellulosic nature.
Enzymes and microorganisms capable of breaking down cellulose and hemicelluloses into mono- and oligosaccharides are known. In some instances, the same microorganism culture which breaks down the cellulose will ferment the simple sugar intermediates, thereby providing an essentially one-step conversion of cellulose to liquid organic solvents or fuels. (In actuality, of course, enzymatically or microbiologically catalyzed hydrolysis of cellulose and fermentation of the resulting simple sugars to alcohols, ketones, and the like is an extremely complex series of reactions involving many intermediates, but some of these intermediates or theoretically postulated intermediates, e.g. glyceraldehyde have only a short-term existence and do not show up in the ultimately obtained fermentation products.)
The scientific literature dealing with the utilization of cellulosic materials by microorganisms is very large. According to one study, cellulose-decomposing bacteria can be divided into three groups: (a) aerobic, (b) anaerobic, and (c) thermophilic. Very few aerobic bacteria have been used successfully for the purpose of deriving fuels or solvents from a cellulosic raw material. According to Porter, Bacterial Chemistry and Physiology, Wiley and Sons, Inc., New York, N.Y., 1946, page 822, "Aerobic bacteria and fungi usually bring about complete destruction of cellulose, without leaving much in the form of intermediate products; hence they have little to offer for the production of industrially valuable products." A disadvantage with thermophilic bacteria is that they tend to be inefficient or even ineffective at normal ambient or modestly elevated temperatures. In short, the use of thermophilic bacteria for decomposition of cellulose actually involves a significant energy input beyond the nutrients or nutrient sources which all microorganisms utilize for energy. Accordingly, anaerobic bacteria are typically the organisms of choice in microbiological processes for decomposing cellulose. The use of anaerobic organisms, however, has its own set of problems.
First, many anaerobic organisms have minimal aerotolerance. That is, not only are these organisms unable to make use of atmospheric oxygen as a hydrogen acceptor, they are also highly sensitive to the presence of oxygen and may even be poisoned by it. In a large industrial operation, it is generally possible to maintain strict anaerobic conditions to protect against this lack of aerotolerance. However, maintaining these conditions may be expensive and difficult, even in these large operations. Fermentation tanks typically must be purged with inert gases and sealed off from the atmosphere. The carbon dioxide generated during fermentation typically is vented through one-way valves or the like.
Second, not all cellulose-decomposing anaerobes are capable of converting the starting material to liquid organic fuels and solvents in accordance with the "one-step" procedure described previously. Typically, the action of the organism is cellulolytic in nature, the resulting hydrolyzate being a monosaccharide such as glucose, a disaccharide such as cellobiose, or the like. A further microbiological system has to be introduced into the fermentation process in order to convert the sugars into aldehydes, ketones, alcohols, and other desired fuels and solvents.
Third, not all anaerobic bacteria have sufficient nitrogen-fixing capabilities to provide a non-distillable residue which has utility as a fertilizer.
Fourth, careful control over temperature and pH conditions may be required to insure maximum efficiency. Excessively low or high temperatures or pH's may either inactivate or kill the organisms.
Fifth, the very specificity of the microorganism or its enzymes (oftentimes an advantage in some contexts) may be a disadvantage when the nature and quality of the raw material is poorly controlled. For example, if the raw material were a mixture of agricultural wastes, waste paper, municipal sewage or garbage, or other materials equally variable in content, it is possible that not all glycosides will be broken down into simple sugars. Specificity in the ultimate products of the fermentation can also be a disadvantage if the fermentation product is essentially ethyl alcohol or a mixture containing ethyl alcohol which is easily distilled to provide the pure water-alcohol azeotrope (190 proof alcohol). This water-alcohol azeotrope is subject to heavy taxation unless it is denatured in accordance with one of the accepted denaturing formulas. Even the production and sale of denatured alcohol entails involvement in a complicated regulatory scheme which may be burdensome for the solvent or fuel manufacturer, particularly when the manufacture is being carried out on a small scale or low-volume basis.
Finally, and perhaps most important, even if the cellulose can be converted to simple liquid organic chemicals in accordance with the aforementioned "one-step" approach, the resulting products may be mixtures with little industrial utility. In the field of solvents, there is ordinarily a much greater demand for single-solvent systems which can be blended to suit the particular application. A mixture of, say, 1-butanol and acetic acid in some ratio which is arbitrarily determined by the microbiological system might be totally unsuited to most solvent applications, and separation of the alcohol from the acid might be uneconomical. In the field of fuels, the chemical identity and ratios of the components of the fuel may be less critical, provided that the overall heat of combustion is substantial, e.g. above 4 Kg-cal/g. Even in the case of relatively sensitive use of fuels (e.g. motor fuels), a mixture of various oxo- or oxy-aliphatics (including cyclo-aliphatics) can perform very adequately, provided certain volatility and antiknock requirements are met. (Ever since the internal combustion engine was invented, oxo- and oxy-aliphatics have been used successfully--the essentially pure hydrocarbon character of modern gasoline results from the ready availability of hydrocarbon fuels rather than the inability to adapt alcohols, ketones, etc. to this use.)
That is not to say that any oxo- or oxy-aliphatic mixture obtained by fermentation of cellulose can be used as a fuel. Major fermentation products may be objectionable because they are corrosive, lacking in antiknock properties, too low in volatility, unpleasant in odor, or too low in energy content, e.g. below about 4 Kg-cal/g. From the standpoint of lack of volatility, higher molecular weight aliphatic carboxylic acids, polyhydric alcohols, and mixed functional group compounds (e.g. alpha-hydroxy carboxylic acids)--all known to be products of various anaerobic fermentations--are perhaps the primary offenders. Some of these compounds are solids at room temperature. Others boil at temperatures above 200° C., even though they may be liquids under normal ambient conditions. In addition, the C 3 -C 6 aliphatic carboxylic acids can be highly objectionable because of odor and corrosion problems.
The lower carboxylic acids, particularly formic acetic acids are objectionable for a variety of reasons. Their odors are strong, their boiling points are relatively high compared to other C 1 and C 2 compounds (such as the alcohols and carbonyl compounds), they are corrosive, and their energy content is well below, for example, ethyl alcohol. Yet many of the cellulolytic anaerobes produce significant amounts of carboxylic acids. Indeed, lower carboxylic acid and alpha-hydroxy carboxylic acid production are common applications of anaerobic fermentation technology.
SUMMARY OF THE INVENTION
It has now been found that a deliberate combination of microorganisms of the genus Clostridium (or the enzymes produced thereby) can be utilized to convert cellulose directly to a liquid organic fuel or relatively high energy (e.g. above 4 KG-cal/g when anhydrous). It has been found that at least two Clostridium species (or their enzymes) should be used in combination to achieve this result. Both species are preferably somewhat aerotolerant, and both should be carbohydrase-producing. One of the two species should be capable of producing cellulase, and other species preferably produces cellobiase, glucosidase, and/or glucase. Typical of such combinations would be Cl. cellobioparum with a saccharase-producing organism such as Cl. acetobutylicum. The enzymes produced by these organisms can be used without associated live cellular material, with some advantages, particularly with respect to sensitivity toward air, temperature changes, pH shifts, and the like. It is well known in the art of microbiology that, whenever two cultures are combined with the objective of adding together their functions, the results are essentially empirical and must typically be determined by experiment. It can often happen that microbiological cultures work in opposition to each other rather than in cooperation. However, not only do the Clostridium species used in this invention cooperate, the resulting suppression of carboxylic acid formation is believed to be truly suprising.
The deliberate combination of Clostridium organisms (or their enzymes) is effective for a variety of substrates, including commonly occurring cellulosic materials (agricultural wastes, municipal sewage, waste paper, and other inexpensive sources of cellulose and hemicelluloses). Although ratios of the deliberately combined organism populations (or enzyme activity) used in this invention can range from about 1:9 to 9:1 with respect to the two Clostridium species, it is preferred to maximize alcohol/ketone production and minimize carboxylic acid production, which objective appears to be obtained most effectively with at least 40% (by weight or activity or population) of the cellulase system or cellulase-producing organism, more preferably 50-80%. The preferred fermentation agent or fermenting organisms have at least some aerotolerance. The nitrogen-fixing capabilities of the preferred combinations of microorganisms are adequate to provide a non-volatile residue with properties making it useful as a fertilizer. Fermentation can proceed under normal ambient or moderately elevated temperatures, e.g. 30°-40° C. The preferred pH in the fermentation zone ranges from about 3 to about 7, more preferably at least 3.8, the optimum pH range being 5.8-6.4. The fuel obtained from a cellulose decomposition process of this invention is non-potable, relatively high energy, volatile (typically boiling within the range of 20° to 200° C.), and typically high in antiknock properties. High yields of this fuel are obtained in an efficient manner. Indeed, the efficiencies and the economies of the process of this invention are sufficient to permit small scale, low volume production--as low as a few gallons per week for the small farmer.
To sum up the key aspects of the process:
(a) Water, a cellulose- or hemicellulose-containing particulate mass, and a fermentation agent of this invention are blended to form a fermentation medium. The fermentation agent comprises the combination of Clostridium organisms described previously (or their enzymes).
(b) The particulate mass is permitted to ferment until fermentation products are produced.
(c) The resulting non-potable hydrocarbon oxidate fuel is then recovered from the fermentation medium by conventional means. The most commonly used conventional means is distillation; however, it is also known to utilize the principles of fractional crystallization, solvent extraction with gasoline (see U.S. Pat. No. 3,711,392 [Metzger], issued Jan. 16, 1973, column 15, line 5 et seq), and any other practical means for separating water from lower aliphatic fuels such as aldehydes, ketones, and alcohols.
Although the process of this invention most likely goes through at least two distinct stages and may involve a number of intermediates, changing of the fermentation medium is not required and can be undesirable, particularly in small scale operations. The most probable first stage of the reaction involves swelling of the particles with water for a period of time typically lasting about 12 to 48 hours and can proceed at normal ambient to moderately elevated temperatures. The most probable second stage of the process which typically lasts another 12 to 48 hours apparently involves both hydrolysis of cellulose and of oligosaccharides, along with fermentation of simple sugars to C 1 -C 6 (more typically C 1 -C 4 or C 5 ) oxo- or oxyaliphatics such as alcohols, aldehydes, and ketones.
DETAILED DESCRIPTION
The exact nature of the cellulosic starting material used in the process of this invention is not critical. Virtually any organic material containing cellulose or hemicellulose can be used. Representative materials include agricultural wastes (cornstalks, corn cobs, potatoes, grassy plants, straw, weeds, etc.), sewage, manner, waste paper, wood waste, pulp (sulphite pulp, kraft pulp, soda pulp, etc.), food wastes, waste liquors from pulp mills, and the like. Thus, the starting material can contain non-cellulosic materials such as lignin, pectin, protopectin, proteins and other polypeptides, and various types of glycosides. The glycosides can even contribute to the yield of useful products. The proteins and other nitrogen-containing compounds can contribute to the value of the residue as fertilizer. Another particularly useful ingredient in the raw material is starch. Starch is generally much easier to hydrolyze than cellulose, and any of a variety of amylase enzymes or amylase-secreting organisms will typically break the starch down into single glucose units which serve as an excellent substrate for fermentation.
Despite the inherent utility of these non-cellulosic materials which may be included with the cellulose, it is generally preferred to expose the cellulose to enzymatic action. For example, it is desirable to strip away lignin or pectinaceous sheaves or coverings which may impede hydrolysis of cellulose. Cellulose can be better exposed to enzymatic hydrolysis through bacterial action (e.g. by treatment of the cellulosic raw material with a suitable Bacillus culture), but the preferred approach is mechanical in nature, e.g. pulverizing the starting material to provide a particulate mass which will pass a 50 U.S. mesh screen, more preferably a 100 mesh screen. Conventional grinders, homogenizers, and the like are suitable for this purpose. Grinding or shredding of the raw material apparently helps to liberate some of the cellulose and speed up the hydrolysis.
The resulting particulate mass is blended with water to provide a slurry-like mass which is preferably pumpable. Pumping of this slurry-like mass becomes extremely difficult as the solids level approaches 50% by weight. On the other hand, a practical, high level of solids content is desirable to facilitate separation of the fermentation products from water at or near the conclusion of the process. From 5 to 10% solids is a typical practical lower limit, but, theoretically at least, the slurry could be far more dilute. The optimum solids level appears to be somewhere within the range of 15 to 35% by weight. Substantially the balance of the fermentation medium (with the exception of the fermentation agent) can be ordinary tap water. Distilled or deionized water can be used but is by no means essential to the effectiveness of any hydroysis or fermentation which occurs in the fermentation medium.
The fermentation agent comprises the aforementioned Clostridium organisms (in combination) or their enzymes. Although this invention is not bound by any theory, it is presently believed that the enzymes provided by preferred fermentation agents of this invention include a variety of carbohydrases including cellulase and one or more saccharases. In addition, proteases, amylases, and lipases are believed to be present; the proteases and lipases are believed to make a contribution to the liberation of the cellulose from outer coverings of non-cellulosic materials. Other carbohydrases believed to be present include cellobiase and/or glucosidase and/or glucase. All of these enzymes can be utilized without associated live cellular material in accordance with principles known in the art. For example, it is known that enzymes can be obtained from natural sources in more or less pure form. The isolation of enzymes is relatively simple when the organism or natural source produces (e.g. secretes) the enzyme extracellularly. Techniques are also known for isolating intracellularly produced enzymes, e.g. ultrasonic destruction of the cellular material followed by various chemical and/or physical separation steps.
Among the known methods of obtaining concentrated enzyme preparations is the so-called adsorption method, introduced by early workers and further improved by Willstaetter et al. It is based on the separation of the enzyme from extraneous matter by adsorption on a suitable colloid, such as kaolin, certain aluminum hydroxides, or other gels, and the subsequent freeing or elution of enzyme from the adsorbent. This method of purification is based on the greater affinities of the adsorbent for the enzyme than for the impurities; by repeating the procedure several times a concentration of the enzyme is obtained. Another technique involves dissolving the enzymes in a suitable solvent and precipitating them with various reagents or by electrophoretic methods. Changes in pH and temperature, dialysis, and other measures are often employed to remove impurities or concentrate or crystallize the enzyme. Additional methods are known. For example, if the association between the enzyme and the cellular material is not detrimental to enzyme activity, a microbiological culture can simply be killed, dried, and ground into a powder--the powder being a reasonably potent source of the enzyme. See U.S. Pat. No. 3,824,184 (Hatcher et al.), issued July 16, 1974, which describes a very simple technique for isolating the enzyme levan hydrolase. Finally, chemical synthesis techniques can be used to link amino acids or polypeptides or purine or pyrimidine bases or ribose units or the like into enzyme-like structures.
In the case of the organism Clostridium cellobioparum, the preferred cellulose-decomposing organism of this invention, it has been reported that profuse growth occurs in the presence of fermentable carbohydrate. Such profuse growth has been observed in practice. Accordingly, attainment of enzyme concentrates from a fermentation broth or production medium appears to be economically practical. Similar profuse growth has been obtained with other Clostridia.
Many Clostridia have poor aerotolerance. Ideally, these organisms are grown under strictly anaerobic conditions at a pH ranging from 5.8 to 6.4 and at an ambient temperature of about 35°-38° C. Some improvements in aerotolerance appear to be obtained by transferring the anaerobically grown colonies to a new growth zone which is not sealed off from the atmosphere. This transfer procedure can be repeated 5 to 8 times (always under aerobic conditions) to continue the trend toward improved aerotolerance. Following this procedure, hearty cultures can be obtained, at least about 10% of which can survive aerobic conditions and produce useful fermentation products. If the enzyme concentrate preparation procedure is followed, the resulting concentrates are highly advantageous in terms of far less sensitivity to air, pH shifts, and temperature changes.
For example, there appears to be very little in the way of a spontaneous pH shift when enzyme concentrates are used to ferment the cellulosic starting material. (with the live organisms, on the other hand, there is some danger that the pH will spontaneously shift downward toward 3.0 or even lower, resulting in a fast kill rate for the organisms.) With little or no pH manipulation, the enzyme-catalyzed processes of this invention tend to remain approximately in the 5 to 7 pH range. Enzymes can be deactivated by high temperatures, e.g. above 65° C., but temperatures on the order of 40 or even 50° C. appear to have very little adverse effect. No adverse effect has presently been observed at temperatures below 45° C. Furthermore, the enzymes appear to be active at normal ambient or room temperatures, e.g. 20°-25° C., and activity at temperatures as low as 5° or 10° C. has been observed. (With live clostridia, on the other hand, the 30°-40° C. range is preferred; although some clostridia are effective at lower and higher temperatures, the greatly preferred Cl. cellobioparum appears to be most effective in this range.)
In addition to the carbohydrase enzymes described previously, other useful enzymes are believed to include cellobiohydrolase or cellobiase and hemicellulase. Although Cl. cellobioparum is the clearly preferred cellulase-producing microorganism, other closteridia are known to have cellulolytic properties. According to Porter, Bacterial Chemistry and Physiology, cited previously, at page 821, anaerobic bacteria said to have these properties are called Cl. cellulosae-dissolvens, Cl. cellulosolvens, and Cl. cellulolyticum. A thermophile that digests cellulose is Cl. thermocellum, which occurs in human and animal feces; however, it should be noted that fermentation products for this organism are reported to include formic, acetic, lactic, and succinic acids.
According to Bergey's Manual, Cl. cellobioparum is said to produce from cellulose a set of fermentation products including acetic acid. (This organism has been found in rumen contents.) Suprisingly, however, this tendency to produce acetic acid appears to be somewhat suppressed or overshadowed when the process of this invention is properly practiced.
The genus Clostridium has been divided into four groups. Cl. cellobioparum is included in Group III. Other preferred organisms from Group III include Cl. sphenoides and Cl. indolis, despite the poor aerotolerance of these species. These species are of interest for their ability to ferment glucose, cellobiose, and other mono- and poly-saccarides. A typical combination of organisms in accorcance with this invention (or combinations of the enzymes thereof) typically involves selection of the second clostridium species from Group I or Group II. The preferred Group I species is Cl. butyricum, and the preferred Group II species are Cl. felsineum and acetobutylicum. The last of these (Cl. acetobutylicum) is reported to have very little activity toward cellobiose, but good activity toward glucose, fructose, starch, sucrose, mannose, maltose, lactose, and other sugars of this type. Accordingly, it presently appears that Cl. acetobutylicum is not useful in itself in this invention, but rather in combination with other organisms such as Cl. cellobioparum. On the other hand, the use of Cl. cellobioparum by itself can result in the production of excessive amounts of acetic acid, which is not desired in the context of this invention.
As noted previously, the process of this invention can be carried out without change of fermentation medium or broth, even though the series of reactions occurring in the broth or medium appears to proceed in fairly definite stages. The primary objective in the early stages of the process is to bring the cellulosic material into maximum contact with water, swelling the material and improving the efficency of the hydrolysis which follows. The hydrolysis of cellulose and the fermentation of cellulose and simple sugars to the desired oxo or oxy aliphatic fuel is undoubtedly a multistage process in itself, although the entire series of reactions could reasonably be summed up with the single term "fermentation." Agitation of the fermentation medium is desirable but not essential. When agitation is used, it is not necessary to employ stirrers, mixers, or the like. It can be sufficient to simply pump the slurry-like medium from one tank to another, using conventional pumping equipment. Mixers, homogenizers, grinders, and the like can be placed in-line with the pumping equipment, thereby further improving the uniformity of the slurry-like mass.
As noted previously, recovery of the non-potable oxy or oxo aliphatic fuel from the fermentation products produced by the fermentation medium can be carried out by a variety of conventional means. For fuels used in simple combustion processes (and even, to some extent for motor fuels) conventional distillation and refluxing is sufficient, despite the presence of water in the distillate. If desired, the distillate can be made anhydrous by known techniques, e.g. addition of calcium oxide, hydrocarbon entrainers, or other dehydrating agents.
Enzyme-catalyzed decomposition of mono- and poly saccarides is known to produce a variety of oxygen-containing organic liquids, including cycloaliphatics (such as furfural, furfuryl alcohol, etc.), unsaturated aliphatics (such as the enol form of pyruvic acid), and saturated aliphatics, particularly the lower aliphatics (i.e. those having six carbons or less). When the cellulosic material includes lignin or other complex non-cellulosic material, some aromatics can be obtained (e.g. benzaldehyde, cinnamaldehyde, anisealdehyde, and the like). Undesired organic and inorganic products, if present, can be eliminated by techniques known in the art.
Some gases can be produced, principally carbondioxide, hydrogen, and methane.
The lower aliphatics are of primary interest with respect to liquid organic fuels. The preferred lower aliphatics are in the C 1 and C 5 range, optimally the C 1 -C 4 range. Foremost among these are the carbonyl compounds (particularly aldehydes and ketones) and the monohydric alcohols such as the lower alkanols. As noted previously, C 1 through C 6 carboxylic acids (including alph-hydroxy carboxylic acids) have been reported to occur in the fermentation products, but an objective of this invention is to minimize production of these acids.
From the standpoint of motor fuel production, the most desirable alcohols and carbonyl compounds are the C 1 -C 4 alcohols and acetone. The amyl alcohols are also suitable for motor fuel use, but their higher boiling points can be a disadvantage where highly volatile motor fuel is desired. The antiknock properties of methyl alcohol, ethyl alcohol, and acetone are so outstanding that these compounds can be considered to have value as antiknock additives. The "blending octane value" of methyl alcohol has been reported to be as high as approximately 130, and that of ethyl alcohol reported to be only a few numbers lower. As anhydrous organic liquids, they make outstanding additives for conventional modern gasolines, and they are also excellent motor fuels in themselves. Methanol/ethanol blends are desirable in that the ethanol component is, in effect, denatured by the methanol, which cannot be readily removed by distillation. For this reason, methanol is an accepted denaturent. Fermentation products other than ethanol and methanol have similar denaturing effects, causing the fuels produced in accordance with this invention to be non-potable.
Not only are the preferred fuels of this invention relatively free of acetic acid (e.g., less than 15%, preferably less than 5% by weight on an anhydrous basis) essentially no formic or butyric acid has been detected in these preferred fuels. This suppression of carboxylic acid formation is not presently understood. These preferred fuels boil within the range of 50°-140° C. (more preferably below 100° C.) and have a heat of combustion in excess of 4 Kg-cal/g, more typically above 5 Kg-cal/g.
The residue from the process of this invention is useful as fertilizer. More than 250 Kg of fertilizer per metric ton (1,000 Kg) of starting material can be obtained in accordance with the process. Typically, the amount of fertilizer produced is 900-1,100 lbs. per ton of cellulosic starting material (approximately 400-500 Kg per metric ton).
Although various mixtures of cellulase-producing (e.g. Cl. cellobioparum) and saccharase-producting (e.g. Cl. acetobutylicum) Clostridia organisms or their enzymes will be effective for the production of lower alcohols and ketones, alkanol/ketone production is apparently maximized and most efficient with mixtures containing at least 40% (by weight, by units of enzyme activity, by microorganism population, etc.) of the cellulase or cellulase-producing organism, more preferably a major amount of this component. When enzymes are used, ratios or percentages of the two active components of the mixture can be determined, for example, on an enzyme-activity-units-per-gram basis. When live organisms are used, organism density (number of live organisms per cubic centimeter) can be determined spectrophotometrically using a suitable wavelength (e.g. 650 nm) or by some similar method, and each component can be diluted to the desired density and blended or shipped in separate containers in pre-measured amounts and then combined before use. As the mixture or organisms or enzymes approaches 90% Cl. acetobutylicum, acetone becomes a more predominant product and sugar buildup can reach levels which may inhibit reaction rates. Unless a high proportion of acetone is desired, the proportion of Cl. acetobutylicum or other sugar-fermenting organism (or enzyme) is preferably kept below 60%, e.g. 20-50%. For a high energy, efficiently produced lower alkanol fuel from corn plant waste (stalks, cobs, etc.) of very modest acetone content, 60-70% Cl. cellobioparum and 30-40% Cl. acetobutylicum appears to be an optimum mixture.
Typical fermentation beers contain about 3-20% by weight of organic liquids (preferably 5-15%), the most typical organic liquids being ethyl alcohol, n-propyl alcohol, butyl alcohol, amyl alcohol, acetone, and, in very minor amounts, acetic acid.
Through simple manipulations of conditions well within the skill of the art, fuels made according to this invention can be shifted from the motor fuel category into fuels suitable for cooking, space heating, heating of steam boilers or hot water heaters, heating of themo elements, driving of heat-operated machines utilizing the refrigeration cycle, and a variety of other uses known to those skilled in the art.
The principle and practice of this invention is illustrated in the following Example.
EXAMPLE I
The following fermentation was carried out with no attempt to maintain strictly anaerobic conditions, using surviving cultures of Cl. acetobutylicum and Cl. cellobioparum which had been grown initially under anaerobic conditions, using boiled calf liver and cellulosic material as a growth medium and a 90:10 N 2 :CO 2 gas purge, then transferred eight times to eight different vessels under aerobic conditions.
A sample of agricultural waste consisting essentially of cornstalks was ground up into a minus 50 U.S. mesh particulate mass and then pulverized further in a blender to minus 100 mesh. The -100 mesh cornstalk particles were mixed with tap water in the ratio (by weight) of 3:1 water:cornstalk to provide a 25 weight-% solids, slurry-like mass. This 25% solids medium was placed in an enclosed (but not sealed or purged) fermentation vessel. The aforementioned surviving Cl. cellobioparum and Cl. acetobutylicum cultures were added to complete the formation of the fermentation medium. The fermentation vessel was kept at normal ambient temperatures (20°-25° C.) for 24 hours and was then placed in a heated room kept at a temperature within the range of 35°-38° C. The pH of the fermentation medium in the vessel was monitored (using a conventional electrical pH meter) and kept generally within the range of 5 to 6.5. During the next 24-hour period (while the fermentation vessel was kept at 35°-38° C.), gas bubbles formed, liquids formed and rose to the tope of the medium, and particulate matter settled. The liquid mixture in the fermentation zone was analyzed using a hydrometer and found to contain slightly less than 8.5 vol.-% lower aliphatic compounds, essentially the balance of the liquid being water. On an anhydrous basis, the predominantly-occurring lower aliphatic compounds were present in generally the following ratio: 1.85:1.15:1.00 (by weight or volume) 1-propanol:ethanol:methanol. Traces of acetone, butyl alcohol, and acetic acid were detected. According to published data, this fuel (tested on an anhydrous basis) would have a heat of combustion in excess of 5.3 Kg-cal/g. The BOV (blending octane value) would be in excess of 100, for a 20% addition to 85-octane gasoline.
Similar results were also obtained with dried enzyme from the Clostridium organisms, except that the enzymes were fully effective at 21°-25° C. The pH remained stable without manipulation.
Similar results were also obtained using grass clippings and waste paper instead of cornstalks. Variable results were obtained with more highly nitrogenous starting materials such as manure. Hog manure provided alcohols, but cow manure did form a significant amount of acetic acid. A sample of municipal sewage (3% by weight solids) gave a butyl alcohol:ethyl alcohol:methyl alcohol mixture in the ratio of 1.2:2:2.6. Thus, sewage, plant (particularly leafy) materials, and non-ruminant manure all appeared to provide reliable sources of C 1 -C 4 non-carboxylic oxo- or oxy-aliphatic fuels. Yields were generally good, e.g. 40 to 50 wt.-%, based on solid cellulosic starting material.
EXAMPLE II
Live Cl. cellobioparum and Cl. acetobutylicum organisms in growth media were diluted to a convenient number of organisms per cubic centimeters, as determined by a 650 nanometer-line spectrophotometer. With roughly equal populations per cm 3 established, volumes of diluted growth media were combined to provide a 65/35 Cl. cellobioparum/Cl. acetobutylicum organism population ratio. The initial growth medium contained, per liter of distilled water:
______________________________________NaCl: 6g.MgSO.sub.4 : 0.1 g.(NH.sub.4).sub.2 SO.sub.4 1.0 g.KH.sub.2 PO.sub.4 : 0.5 g.CaCl.sub.2 : 0.1 g.Yeast extract: 1.0 g.Cellulose: 5.0 g.______________________________________
The organisms were grown under anerobic conditions in previously-autoclaved, sealed containers which were purged with 90% N 2 /10% CO 2 .
The agricultural waste introduced into the fermentation vessel was again corncobs and cornstalks, ground as in Example I. The bacteria growth medium formed 4 to 6% of the fermentation tank volume. The fermentation tank was not purged with inert gases, but it was heated to 100° F. (38° C.) before the Clostridia were added.
After the fermentation was completed, the beer was concentrated to a 20% water/80% organic liquid mixture using a so-called "stripper" device supplied by Ferguson PO-W-ER Fuel, Inc. of Dunreith, Ind. The fuel sample was analyzed and found to contain 5% acetone, 11% ethyl alcohol, 14% n-butyl alcohol, 41% n-propyl alcohol, 8% n-amyl alcohol, and only 1% acetic acid, the balance being water. The heating value of this fuel was 13,412 BTU/lb or about 7.5 kg-cal/g. The octain rating of the fuel was 114, and under pressure combustion there was an 82.4% recovery from theoretical. The open flame temperature was 1460° F. (793° C.). The very high proportion of n-propyl alcohol was considered advantages.
EXAMPLE III
The procedure of Example II was repeated exactly except for the Cl. cellobioparum/Cl. acetobutylicum ratio, which was 50/50 instead of 65/35. This 50/50 fermentation agent produced a fuel which, concentrated to 69% organics, was found to contain
______________________________________25% acetone22% n-butyl alcohol12% n-propyl alcohol10% acetic acid31% water.______________________________________
This fuel had a heating value of 11,910 BTU/lb. (about 6.6 Kg-cal/g) and readily supported combustion.
It should be understood that the 65/35 ratio of Example II and the 50/50 ratio of this Example is the initial population ratio. The two species may multiply at different rates, and the ratio may change continually during the fermentation.
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In the disclosed cellulase-catalyzed fermentation process for converting a cellulose- or hemicellulose-containing starting material to an organic fuel, the fermentation medium contains an efficient combination of Clostridium organisms or their enzymes. One preferred combination of organisms includes Cl. cellobioparum and Cl. acetobutylicum. Conversion of the cellulose to a liquid hydrocarbon oxidate proceeds in good yield with relativey minimal carboxylic acid production. The nondistillable residue is suitable for use as a fertilizer.
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This is a continuation of U.S. application Ser. No. 07/983,579 filed Feb. 4, 1993 which was abandoned upon the filing hereof.
BACKGROUND OF THE INVENTION
The instant invention relates to a regulated drawing frame of the textile industry, i.e. a drawing frame in which draft is controlled or controllably adjustable. The concept of control comprises in this case the application of controls or of a multi-looped control system.
In this invention fiber slivers are processed and the thickness of the end-product must be uniform. It is the task of the control system to recognize a change in fiber sliver thickness and to bring it to the desired uniform thickness by drafting.
The thickness signals are detected at the measuring station before the inlet of the drawing frame. All along the subsequent course taken by the measured points in the fiber sliver, and up to the place where drafting occurs, the appertaining measuring signal is buffer-stored with a delay time. At the end of this delay time the control system intervenes immediately as a function of the deviation of the fiber sliver thickness. This onset of this control application is called the regulation onset point.
The problem in this case is that the regulation onset point must occur neither too early nor too late with respect to the onset of drafting because this would result in faulty drafting. Similarly, the intensity of regulation, i.e. the amplification, may be neither too low nor too high.
In practice, influences attributable to the machine or environmental influences are the cause that the drafting point cannot be determined precisely, and therefore errors occur in determining the regulation onset point and the intensity of regulation.
When erratic fluctuations of fiber sliver thickness occur, for example as a result of needle impulses exceeding the tolerance limits, the mechanical components are unable to follow quickly enough in driving the drawing frame rollers because of their inertia. Complete compensation for the variations in thickness is hardly possible in this case. The problem is aggravated by the existing need to increase the speed of the fiber sliver from an average of 500 m per minute to 800 m per minute and more.
Thickness fluctuations which increase very slowly over time are yet another extreme case. Here the reaction of regulation is also insufficient.
DE-OS 36 19 248 proposes that a correction value be determined for the delay period as a function of the steepness or the relative magnitude of mass fluctuation. The result is a shorting of the delay time as a function of the steepness and magnitude of the mass fluctuation. This solution has the disadvantage that the result of regulation cannot be checked. This is a disadvantage insofar as the correction made can be subject to influences attributable to the machine or by environmental influences.
The solution according to EP 412 448 proposes the utilization of a multi-looped control system on the drawing frame, whereby the measuring signal is detected and evaluated after the drawing frame output. The proposed solution here is to ascertain the result of controlled drafting change through supervision along the drawing frame course, to re-enter it into the same control system and to evaluate it in an optimization process broken down into low-frequency and high-frequency portions. The setting magnitude Y which is optimized by the main control is thus used as a setting value for the controller 8.2 of the drive of the main drafting zone 12 (EP 412 488, page 12, lines 12 -15). This solution is mainly based on the utilization of the measured values in order to always optimize the setting value. The clear drawback in this method is the fact that correction values to be used to set the setting values are not processed independently by the control system, and are therefore not free from influences.
To be able to detect changes in the regulation with certainty and independently of the regulation, the "sliver test" was conducted in the past. The "sliver test" is conducted by spot-checking and manually determining the correct levelling out of fluctuations in fiber sliver thickness. A test sliver is produced. The operator adds an individual sliver segment to the presented slivers or produces a limited sliver interruption through sliver breakage. The length of this created fiber sliver is cut out and its actual sliver thickness is determined by weighing (see instruction manual of the RIETER Spinning Systems, drawing frame RSB 851, SB 851, point 4.5.6, edition 8/1990). It is thus impossible to avoid an interruption of production counted in minutes. This is a considerable disadvantage in continuous production at high production speeds.
OBJECTS AND SUMMARY OF THE INVENTION
It is the object of the instant invention to create a process and a device which improves the correction of the regulation onset point and of the intensity of regulation in regulating the drawing frame. Additional objects and advantages of the invention will be set forth in part in the following description, or will be obvious from the description, or may be learned by practice of the invention.
Contrary to existing control methods utilizing the FFT analysis to obtain correction values, the method according to the invention has as one of its characteristics the selection of merely individual occurrences of fiber thickness in order to start the process which functions independently of the existing control system in order to determine and to carry out necessary corrections of the control system (i.e. correction of the regulation onset point or of regulating intensity) within a predetermined time span. The process according to the invention is therefore not constantly in operation. The process is started up only when a special signal is detected and is stopped after a predetermined time span.
This process does not involve a feedback of the control magnitude in the sense of a closed control circuit or of an interference magnitude lock-on.
The process consists in obtaining a transient signal of the fiber sliver thickness at the measuring station. The transient signal must possess high amplitude so that it is evident during a sufficiently long period of time that the fiber thickness is exceeding tolerance limits. At the same time, this amplitude must be steep enough to differentiate from a constantly increasing fiber thickness, but be less steep than for a needle impulse.
This signal must resemble a surge signal. This surge signal is transmitted to the control system and is utilized at the same time to start the correction process of the regulation onset point and of the intensity of regulation. The response signal is detected as an impulse diagram at the drawing frame output independently of current regulation and its deviation from the surge signal is evaluated in order to correct the regulation onset point and the intensity of regulation. The process is terminated after a defined time span.
Parallel to the existing control system, component groups are installed in the device which make it possible to recognize a transient signal as well as to evaluate the response signal with respect to the regulation onset point and to the regulating intensity.
The advantage of the process consists in the fact that it functions independently and is therefore free of influences from an existing regulation. The correction value is thus defined more precisely, since internal machine influences and environmental influences upon the drafting point can be taken into account with greater precision. Linked to this advantage is the further advantage of partial automation of the "sliver test" , in that a test sliver is produced automatically without interruption of the production process.
Since the process requires the targeted selection of a random individual occurrence of abnormal fiber sliver thickness, the process requires no constant operating mode.
The functioning of the process and its interaction with a known regulating system is described below through figures in an embodiment of the invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a modular mimic display depicting the process and the device of the invention;
FIG. 2a is a representation of a surge signal;
FIG. 2b is a representation of reply signal wherein regulation onset is premature;
FIG. 2c is a representation of a reply signal wherein regulation onset is too late;
FIG. 2d is a representation of response signal wherein regulation onset is premature and amplification is excessive;
FIG. 2e is a representation of a response signal wherein regulation onset is premature and amplification is insufficient; and
FIG. 3 is a representation of modular mimic display depicting the process and the device without reserve sliver feed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. The numbering of components in the drawings is consistent throughout the application, with the same components having the same number in each of the drawings.
FIG. 1 shows the modular mimic display pertaining to the process according to the invention with the essential characteristics of the device. The fiber sliver 5 runs through a measuring station 1. This measuring station 1 can be a mechanical pair of scanning rollers, for example. The draw-in rollers of reserve sliver feed 3 together with reserve sliver 4 are shown upstream of the measuring station 1. The fiber sliver is drafted in drawing frame 6. At the output of the drawing frame a measuring station 2 is provided. The conventional regulating system 7 receives the measuring signals from measuring station 1. These measuring signals are stored in a measured-value memory 7.1 with an appropriate delay time and are then transmitted to an amplifier 7.2, with the signal being transmitted from the output of the amplifier 7.2 to an adjusting element 7.3. The adjusting element 7.3 changes the rotational speed of a pair of rollers in the drawing frame 6 so that drafting is changed.
A component group 8 was installed in the device to implement this described regulating system 7. This component group 8 of the process according to the invention functions parallel to and independently of the conventional control regulating system 7. Shown in the component group 8 are a regulating circuit 8.1, a measured-value evaluating unit 8.2, a counting and evaluating unit 8.3 and a mean-value former 8.4, a buffer memory 8.5 and a comparator 8.6.
It is the task of a reserve sliver feed system to avoid production stoppages caused by fiber sliver breakage or by sliver ends in a can. The function of the reserve sliver feed system 3 is transferred to another area of application for the purpose of the invention. The reserve sliver feed system 3 is used in double function as part of a device to carry out the process.
One of the ways to start the process is for the regulating circuit 8.1 to transmit a starting signal to the reserve sliver feed system 3. At the end of a defined period of reserve sliver feeding, the reserve sliver feed system 3 is stopped. The length of that period is equal to the time required for the process.
Another way to start the process is provided by the presented slivers themselves. This possibility is shown in FIG. 3.
The presented slivers themselves can produce a transient signal at the measuring station 1 upstream of drawing frame 6 through a random deviation in fiber thickness. For this it is necessary that the transient signal possess high amplitude. The amplitude must differ by approx. 10% from the mean value and a time span (at least three clocking impulses of the measuring impulse) must be present. This signal must be recognized. For this purpose a measured-value analysis system 8.0 is installed between the measuring station 1 and the regulating circuit 8.1 (FIG. 3). A comparison value is defined by the mean of the measured-value analysis system 8.0 by constituting long-term mean values of the measured values. When the comparison value is exceeded by at least 10%, this is recorded as a threshold excess by the measured-value analysis system 8.0. The amplitude in this case must last for at least three clocking impulses. Parallel to the detection of amplitude, its steepness is detected. When its steepness is at the same time increasing in surges, the required transient signal has been found. The detection of such a signal starts the process. The process is terminated after a predetermined number of clocking impulses. The number of clocking impulses corresponds to at least the time it takes to go from measuring station 1 to measuring station 2.
The process functions parallel to and independently of the existing control system. By connecting the reserve sliver 4, or as a result of random deviation of the fiber sliver thickness, a defined surge signal (represented in an idealized form) according to FIG. 2a is triggered. This surge signal is transmitted to measuring station 1 and the course of the output signal over time is detected by means of measuring station 2 at the output of the drawing frame 6. The output signal may for example take on idealized forms as shown in FIGS. 2b, 2c, 2d or 2e. The measured-values evaluating unit 8.2 which follows the measuring station 2 has two paths in its output, one path for the control of the regulation onset point, and another path for the control of regulating intensity.
Two amplitudes are detected (FIG. 2d) in the processing arm for the control of the regulation onset point in function of the impulse diagram of the response signal of two amplitudes, whereby the first amplitude in progression and phase position is generally used for evaluation. According to FIG. 2 the delay t and the difference -f (t) between the background level of control and the background level of the response signal are evaluated. These values are referred to in the result of the evaluation in component group 8 to rate the effectiveness of regulation. According to FIG. 1 these values are introduced as signals into the measured-values memory 7.1 or into the amplifier 7.2 of the existing regulating system 7 and thus make it possible to correct the parameters in the control system.
The following explanations concerning the feeding of the reserve sliver are given to further facilitate the understanding of the process. With the feeding of the reserve sliver 4, the measuring station 1 registers a sudden increase in fiber sliver thickness. This corresponds to the surge signal. As the leaping signal is detected at the measuring station 1, the regulating circuit 8.1 receives the information on the start of the process. At the same time the measured-value evaluating unit 8.2 starts the mean-value former 8.4. The latter detects first the signals which come into measured-value evaluating unit 8.2 at the measuring station 2 until the arrival of the response signal, i.e. of the corrected sliver. These constituted mean values are stored in the buffer memory 8.5.
As the first flanks of the response signal arrive, the mean value former 8.4 will again form mean values for the period of the response signal's passing. These mean values are however transmitted directly to the comparator 8.6 which now also receives the values from the buffer memory 8.5. The amount difference between the background signal level at the start of the reserve sliver and the background signal level delivered with the response signal is determined in the comparator 8.6. A possible difference found in this comparison corresponds to a measure of regulation intensity. The output of the comparator 8.6 is connected to an amplifier 7.2 which determines the intensity of amplification as a function of the amount difference and its polarity.
Together with the arrival of the flank of the first impulse of the response signal at the measuring station 2, the counting and evaluating unit 8.3 is started through the measured-value evaluating unit 8.2. After the passage of the first impulse of the response signal the counting and evaluating unit 8.3 is again stopped. This result is delivered into the measured-values buffer memory 7.1. The number of time pulses of the first impulse of the response signal supplies the characteristic for the magnitude of the wrong control setting. The phase position (polarity) gives an indication on the direction of the wrong setting, i.e. the onset point of control is too slow with a positive phase position, and too rapid with a negative phase position. The last impulse of the response signal is not taken into consideration. It is always a trailing impulse with a polarity contrary to the first one. The simplicity of this process step consists in the fact that the length of this counted impulse is already a measure for the control application onset point. This characteristic is transmitted to the measured-values memory 7.1 which simultaneously corrects the control application point in function of the characteristic.
It is characteristic for the counting and evaluating unit 8.3 that it is started and stopped by the measured-value evaluating unit 8.2 and that it functions according to a machine-dependent measuring phase 7.4. The machine-dependent setting of the phase 7.4 is synchronized with the fiber sliver speed so that the evaluation of the impulse diagram takes place at the correct moments.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents.
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A process and a device for the correction of the regulation onset point and of the intensity of regulation relate to a regulated drawing frame of the textile industry, i.e. a drawing frame in which drafting can be regulated or can be changed in a controlled manner. A selected transient signal of the fiber sliver thickness starts the process for a limited time span so that, independently of the existing regulation, the response signal is detected at the drawing frame output and its difference with the input signal is evaluated in order to correct the regulation onset point and/or the intensity of regulation.
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BACKGROUND OF INVENTION
This invention relates generally to a timing apparatus and more particularly to a water-based timing apparatus whereby aquatic sports and pleasure activities such as sailboarding, yachting, motorboating and swimming may be timed and otherwise supervised.
In most water-based sports and the like, the critical points of a race such as the start, finish and completion of legs or laps, are generally determined by the passage of the participants through a reference line. The timing of such passage is usually recorded by the use of either hand-held stopwatches or some form of computer controlled timing system, either of which are activiated by an individual actually observing the passage of each participant through the reference line.
The timing of water-based sports and the like is complicated by the fact that participants are often staggered or vying closely for position as they pass through the reference line. Moreover, because the start, completion of laps or legs, and finish of such races are determined for each participant by physically eyeing the point at which that participant crosses the starting line, timing may be further complicated by the angle of view, the degree to which the participant is obscured by other objects, including other participants, and human error generally.
Further problems are presented by the so-called "flying start", in which it is the object of each participant to remain as close as possible to other participants in proceeding through the reference line, while not crossing the line before a starting signal is given. Because of the rapid motion of participants in events such as motorboating, it is often extremely difficult to determine by direct observation which participants should be disqualified for crossing the starting line prior to the official start of the race. Moreover, because such a start is presently judged by the use of a photograph to determine any disqualification, one must therefore wait until such photograph is developed to make rulings. Accordingly, races are well under way or are completed before a restart may be ordered, and often, as a result, participants can afford but one mistake in running such a race.
As a result of such complications, supervision and timing of aquatic races requires close scrutiny and is often subject to substantial error. Since such races are often determined in seconds or fractions of seconds, this error can be crucial indeed.
It is accordingly an object of the present invention to provide an improved means for judging the start, finish and completion of laps or legs of a timed aquatic event such as a sailboat, motorboat or yacht race.
It is a further object of the invention to provide an improved means whereby the time at which participants in an aquatic sport and the like pass through a reference line may be more accurately determined.
It is another object of the invention to provide a water-based apparatus whereby participants may pass between two sensing means contained thereon to actually record the occurrence and time of such passage during an aquatic race.
It is still a further object of the invention to provide a water-based apparatus which is stabilized such that its position in the water is relatively constant thereby allowing for the improved recording of data therefrom pertinent to position and timing of objects passing therethrough.
It is a further object of the invention to provide a stable and torsionally rigid floating apparatus to act as a base for a transmitter/receiver package adapted to detect the presence of an object passing between such transmitter and receiver contained thereon.
SUMMARY OF THE INVENTION
In accomplishing these and other objects there is provided, according to one aspect of the present invention, an apparatus comprising substantially horizontally disposed support means; at least two substantially vertical members attached to the support means and extending upwardly therefrom; sensing means disposed on the vertical members to detect the passage of an object between two of the vertical members; flotation means coupled to at least one of the vertical members or support means; and anchoring means for coupling at least one of the vertical members or support means to a substantially stationary object.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood as reference is made to the following specification read in conjunction with the drawings wherein;
FIG. 1 is a frontal view of the apparatus;
FIG. 2 is a top plane view of the apparatus; and
FIG. 3 is a side view of the apparatus taken along line 3--3 of FIG. 2 showing a single vertical member with flotation means and sensing means coupled thereto.
DETAILED DESCRIPTION
In the description of the present invention that follows, it is to be noted that like parts are designated by like reference numerals throughout the several views of the accompanying drawings. It is further to be noted that, for the sake of brevity, the present invention will be hereinafter described in conjunction with its use in a sailboat race.
According to the embodiment of the invention shown generally in FIG. 1, two substantially vertical members 12 and 14 are attached at opposite ends of a substantially horizontal support means 10 and extend upwardly therefrom. Flotation means 22 and 24 are attached to said vertical members 12 and 14 by means of extension bars 26 and 28 which may be movably adjusted along the height of said vertical members 12 and 14. Note that the degree of flotation (i.e., the buoyancy) of the flotation means 22 and 24 and the weight of the remainder of the apparatus (the support means and the vertical members) must be chosen with due regard to each other such that the support means 10 remains submerged and the vertical members 12 and 14 are kept substantially erect when the apparatus is placed in water. Transmitting means 32 and receiving means 34 (hereinafter referred to collectively as sensing means 35) may be disposed at the upper ends of said vertical members 14 and 12, respectively, such that a signal from transmitting means 32 to receiving means 34 will be interrupted by the passage of an object therebetween. Alternatively, the sensing means can comprise transmitter/receiver means disposed at the upper end of one vertical member and reflecting means disposed at the upper end of the other vertical member. In such case, a signal from the transmitter/receiving means to the reflecting means and back will be interrupted by the passage of an object therebetween.
Rigid cross bars 42 and 44, preferably of metal or plastic composite material, may be provided as structural stiffeners between each vertical member 12 and 14 and the horizontal support means 10 to provide for structural integrity and resistance to torsional twist of the upright segments of the vertical members 12 and 14 from the plane established by the overall apparatus. Rigid plates 46 and 48, preferably of metal or composite material, may be disposed between cross bars 42 and 44, respectively, and the vertical members 12 and 14 and the support means 10 connected by said cross bars, respectively, to further provide in-water stability on the vertical plane of the apparatus against currents and other natural movement of the water.
In operation, the apparatus is placed in water and will come to rest at the level of the flotation means 22 and 24. FIG. 2 illustrates that the vertical members 12 and 14 may be rigged with two or more flotation means 22 and 24 each. As mentioned above, the flotation means 22 and 24 may be adjustably secured at various heights along the vertical members 12 and 14 in order to displace the apparatus at selected depths in the water. As depicted in FIGS. 1-3, the flotation means 22 and 24 may be secured to the vertical members 12 and 14 by means of extension bars 26 and 28, and the disposition of such flotation means at angles away from the vertical axis defined by the horizontal support means 10 and vertical members 12 and 14 adds to the stability of the apparatus against the natural movement of the water. Naturally, other means, such as securing straps, may be used to secure the flotation means 22 and 24 to the vertical members 12 and 14.
Once displaced in the water, the apparatus may be secured to the water bed or other substantially stationary object by means of cable or the like attached to an eyelet 50 shown in FIGS. 1 and 2. The eyelet 50 can also be a hook or similar means on the apparatus. To ensure further stability in the water, the horizontal support means 10, the plates 46 and 48, the cross bars 42 and 44, and those portions of the vertical members 12 and 14 which will be disposed underwater may be made of porous material or may otherwise be fitted with holes and shall be of suitable weight to provide negative buoyancy for the portion of the structure below water. Consequently, the natural movement of water is prevented from exerting any upward force on the underwater portions to cause the apparatus to capsize.
Once the apparatus is secured in place, the vertical members 12 and 14 serve as a gate between which the participants of the sailboat race must pass. The reference line between the vertical members may naturally serve as a starting, finishing, or intermediate line for such a race, and, indeed, the apparatus in question may be placed wherever desired along the course of the race.
Upon passage of a participant between the vertical members 12 and 14, the sensing means 35 disposed on such vertical members may be used to electronically trigger the timing device utilized at that point in the race. Accordingly, in addition to accurately determining the point in time in which the participant passes through the gate, it is also possible to determine premature starts and the like.
As should be evident from the foregoing, the present invention allows for the accurate timing of water-based sports and eliminates the errors associated with timing of such sports by eye. This apparatus further eliminates human observation errors associated with the presence of other objects in the vicinity of a timing reference line and difficulties associated with angles of view of the reference line.
Naturally, various sensing means 35 may be utilized for a multitude of timing and management aspects of such races. Among these are means sensitive to various methods of coding the participants, such as color-sensing or signal-sensing means, to ensure that specific participants pass through appropriate gates at appropriate times as well as means sensitive to such variables as size, velocity, or heat to ensure that a gate's timing device is only triggered by appropriate participants in the race, rather than any object passing through the vertical members. Examples of different sensing means are infra-red sensing means which detect the heat given off by the engine of a motorboat passing therethrough and color-sensing means as disclosed in U.S. Pat. No. 3,890,463.
Other modifications and uses of and departures from the specific embodiments described herein may be practiced by those skilled in the art without departing from the inventive concepts. Consequently, the invention is to be construed as embracing each and every novel feature and novel combination of features present and possessed by the apparatus and techniques herein disclosed and limited solely by the spirit and scope of the appended claims.
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An apparatus for timing of water-based activities or events, such as, sailboarding, yachting, motorboating and swimming. The apparatus comprises a rigid horizontal support bar, two vertical members attached to the ends of the support bar, buoyant floats attached to the vertical members and a transmitter/receiver package disposed on the vertical members. The apparatus acts as a gate which individuals or water-vehicles passing therethrough are detected or timed by the transmitter/receiver package contained thereon. The apparatus is kept stabilized by being secured to any nearby stationary object and by adapting the submerged portion of the apparatus to provide negative buoyancy.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to European patent application No. 03077819.5, filed Sep. 8, 2003, which is hereby incorporated by reference as if fully disclosed herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a covering for an architectural opening, such as a roller shade for a window, having one or more, vertically-extending parallel layers of shade material. This invention especially relates to a roller shade, to which front and rear layers of a shade material are attached, so that the layers can be moved parallel to one another to open and close the shade to light.
[0004] 2. Description of the Relevant Art
[0005] Architectural coverings are known with two vertically-extending parallel sheet layers, which are disposed one in front of the other and each of which has an array of elongated, longitudinally-extending, vertically-alternating transparent and opaque stripes. When the transparent stripes of one layer have been in vertical alignment with the transparent stripes of the other layer, light has been transmitted through the coverings, but when the opaque stripes of one layer have been vertically aligned with the transparent stripes of the other layer, these coverings have blocked light. See GB 926 663, GB 1 227 619, U.S. Pat. No. 2,029,675, FR 1 366 224, DE 2 326 438, NL 7209084 and U.S. Pat. No. 6,189,592.
[0006] The two vertically-extending layers of such coverings have been made of fabric, plastic or the like and have been connected at their top and/or bottom ends by top and/or bottom bars. A special fabric, very suitable for such coverings, has been described in EP 1 088 920 and EP 1 241 318. This fabric is a two layer woven fabric having one or more binder threads connecting the layers, so that one layer could slide along the binder threads and along the other layer.
[0007] Such double layer architectural coverings have been made as roller shades, having a roller to which the layers of shade materials have been attached at radially different locations of the roller, so that partial rotation of the roller has displaced the layers relative to each other and continued rotation has wound the layers about the roller. The layers of shade materials of roller shades have generally been attached to their rollers by folding each layer over an attachment member or rod and then sliding or pushing the attachment member with the layer folded over it into a groove or slit of the roller. See GB 19 499 and DE 25 19 365.
[0008] However, the use of an attachment member has proven unsatisfactory for attaching a layer of a shade material to a roller. If the shade material has not been well aligned with the roller when folded over its attachment member, the shade has not hung straight down from the roller and has not operated well. Also, the layer folded over the attachment member has sometimes tended to get out of alignment during assembly of the roller shade which has been hard to correct afterwards. With two layer roller shades, it has been particularly difficult to align the complementary patterns, typically stripes of the front and rear layers, using such attachment members. Also, the layers have tended to become skewed, relative to one another, when wound about the roller if both layers have not been perfectly aligned with the roller. When the layers have not been perfectly aligned, light has shone through gaps between the stripes, and the patterns have no longer appeared to be complimentary.
SUMMARY OF THE INVENTION
[0009] In accordance with this invention, an architectural covering, such as a roller shade, is provided which includes a vertically-extending layer of a shade material between an elongated longitudinally-extending roller and an elongated longitudinally-extending bar; an elongated groove extending longitudinally along the length of the outer surface of the roller; a top portion of the layer of shade material being attached to an elongated longitudinally-extending top attachment member in the groove; the layer of shade material extending longitudinally along the roller, so that partial rotation of the roller causes the layer to move vertically and continued rotation of the roller winds the layer around the roller, and wherein:
the outer surface of the top attachment member has at least two peaks along its length such that when the upper portion of the layer of the shade material is attached to the attachment member, the peaks extend through the upper portion of the layer, preferably through an open structured section of the top portion of the layer.
Advantageously, the shade material comprises a plurality of vertically-extending layers, especially front and rear layers, the outer surface of the roller comprises a plurality of radially spaced apart grooves, and a top portion of each layer is attached to a different attachment member in a different groove, especially front or rear groove. Also advantageously, a bottom portion of each layer of the shade material is also attached to an elongated longitudinally-extending bottom attachment member in an elongated longitudinally-extending slit in the bar; the outer surface of the bottom attachment member having at least two peaks along its length such that when the bottom portion of the layer of shade material is attached to the bottom attachment member, the peaks extend through the bottom portion of the layer, preferably through an open structured section of the bottom portion of the layer. It is particularly advantageous that the shade material comprises front and rear layers, each with an array of elongated, longitudinally-extending, vertically-alternating transparent and opaque stripes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Further aspects of the invention will be apparent from the detailed description below of particular embodiments and the drawings thereof, in which:
[0013] FIG. 1 is a schematic perspective view of a roller shade with a double layer shade material extending between an elongated roller and an elongated bottom bar;
[0014] FIG. 2 is a cross-section of the shade of FIG. 1 , showing the attachment of the shade material to the roller and bottom bar;
[0015] FIG. 3A-3D is a schematic representation of the attachment of a first embodiment of an elongated attachment member to one of the layers of a woven fabric shade material and the subsequent attachment of the attachment member to an elongated groove in the roller;
[0016] FIGS. 4A-4C is a schematic representation of the attachment of two layers of the woven fabric shade material together to the first embodiment of the attachment member prior to attaching the attachment member to the bottom bar;
[0017] FIGS. 5A-5E are schematic perspective views of alternative embodiments of the attachment members; and
[0018] FIGS. 6A-6C are schematic perspective views, like FIGS. 3A-3C , of the attachment of the attachment member of FIG. 5D to a non-woven shade material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] FIGS. 1 and 2 show a roller shade or blind 1 of the invention having an elongated longitudinally-extending roller 3 at its top, a two-layer vertically-extending shade material or covering 5 , an elongated longitudinally-extending bar or rail 7 at its bottom and means 9 for rotating the roller 3 to raise and lower the shade material and the bar to open and close the shade (e.g., a conventional manually operated ball-chain or endless cord). The roller 3 is preferably a conventional hollow tube-like profile extending between a left end 11 and a right end 13 . The outer surface 3 A of the roller has and an elongated longitudinally-extending front groove 15 and an elongated longitudinally-extending rear groove 17 . The front and rear grooves 15 , 17 are radially spaced apart along the outer surface 3 A of the roller and are preferably undercut grooves. In this regard, each groove 15 , 17 has a longitudinally-extending top slit 19 , 21 in communication with a laterally larger, interior top pocket 19 A, 21 A. The top pocket 19 A, 21 A of each groove 15 , 17 can hold an elongate, longitudinally-extending top attachment member 23 , 25 , so that the top attachment members cannot fall out through the top slits 19 , 21 while the shade material 5 , attached to the top attachment members, extends downwards from the grooves.
[0020] The shade material 5 includes a vertically-extending front layer 27 and a vertically-extending rear layer 29 . When the shade material 5 is assembled to the roller 3 , the front layer 27 extends downwardly from the slit 19 of the front groove 15 , and the rear layer 29 extends downwardly from the slit 21 of the rear groove 17 . The front layer 27 has a plurality of elongate longitudinally-extending parallel rectangular stripes 31 , 33 . Relatively opaque stripes 31 alternate with relative translucent stripes 33 . The rear layer 29 also has a plurality of elongate longitudinally-extending parallel rectangular stripes 35 , 37 which are alternating relatively opaque stripes 35 and relatively translucent stripes 37 . The rear layer 29 can be moved vertically relative to the front layer 27 , so that the opaque stripes 31 , 35 of both layers can be aligned with each other or with the translucent stripes 33 , 37 of the opposite layer. Such movement of one layer relative to the other can be used to control and vary the light-transmitting properties of the shade 1 .
[0021] The top portions 39 , 41 of the front and rear layer 27 , 29 of the shade material 5 are attached to the front and rear top grooves 15 , 17 of the roller 3 , using the front and rear, top attachment members 23 , 25 . The manner of attaching the layers to the top attachment members is described below in relation to FIGS. 3 and 4 .
[0022] The bar 7 is preferably a generally U-shaped profile extending between a left end 43 and a right end 45 . The bar ( 7 ) has a front wall 47 , a rear wall 49 and a bottom wall 51 with an upwardly open, elongate, longitudinally-extending bottom slit 53 that opens into an interior space 55 in the bar. The bottom slit 53 extends along the entire length of the bar 7 , and the shade material 5 is attached to the bar 7 and extends upwardly from the bottom slit 53 towards the roller 3 . At the top of the front wall 47 of the bar 7 is an elongate longitudinally-extending interior undercut bottom pocket 57 , adjacent the bottom slit 53 . The bottom pocket 57 has a downwardly open, elongate, longitudinally-extending mouth 59 which is laterally smaller than the bottom pocket. Preferably, the bottom pocket 57 is integrally formed with the front wall 47 of the bar 7 . The layers 27 , 29 of the shade material 5 , mounted on the bar 7 , extend downwardly from the mouth 59 of the bottom pocket 57 into the interior space 55 of the bar and then upwardly through the bottom slit 53 towards the roller 3 .
[0023] As best shown in FIG. 2 , the top portion 39 of the front layer 27 of the shade material 5 is held by the front top attachment member 23 in the top pocket 19 A of the front top groove 15 of the roller 3 , and the top portion 41 of the rear layer 29 of the shade material is held by the rear top attachment member 25 in the top pocket 21 A of the rear top groove 17 of the roller. Also, front and rear bottom portions 61 , 63 of the front and rear layers 27 , 29 of the shade material 5 are attached to a bottom attachment member 65 in the bottom pocket 57 in the bar 7 . Preferably, the rear layer 29 of the shade material is longer than the front layer 27 , and when the bottom portions 61 , 63 of the two layers are mounted in the bottom pocket 57 , a loop 67 is formed in the rear layer 29 in the interior space 55 of the bar to serve as a hammock for a ballast rod 69 . The ballast rod 69 serves to pull the shade material taut and to help keep its layers aligned during operation of the shade 1 .
[0024] The top and bottom attachment members 21 , 23 , 65 with the shade material 5 attached to them are preferably slid into the top and bottom pockets pockets 19 A, 21 A, 57 from the right or left ends 11 , 13 , 43 , 45 of the roller 3 and bar 7 . The left and right ends of the roller and bar can then be closed by a suitable end cap (not shown).
[0025] Partial clockwise rotation of the roller 3 , as shown in FIG. 2 , by the operating means 9 , will move the front and rear layers 27 , 29 relative to each other, for example, to align either the opaque stripes of both layers, or the opaque stripes of each layer with the translucent stripes of the opposite layer. The front and rear top grooves 15 , 17 will move clockwise, and the rear layer 29 will be lifted a small distance, causing the loop 67 in the rear layer to move upwards within interior space 55 of bar 7 with ballast rod 69 . The small distance can be the vertical height of a stripe 35 , 37 of the rear layer 29 , thereby causing the opaque stripes 31 , 35 of both layers 27 , 29 to align or the opaque stripes 35 of the rear layer 29 to align with the translucent stripes 33 of the front layer. Continued clockwise rotation of the roller 3 will further lift the loop 67 and ballast rod 69 into abutment with the front and rear walls 47 , 49 of the bar 7 , near the bottom slit 53 . If such clockwise rotation is continued, the front and rear layers 27 , 29 of the shade material 5 will be wound about the roller 3 , thereby lifting the bar 7 upwardly. Thereafter, counter clock wise rotation will move the front and rear top grooves counter clockwise, causing the shade material to be unwound and the bar to be lowered. When the shade material is unwound and the counter clockwise rotation continues, the rear layer 29 will move again relative to the front layer 27 . Continued counter clockwise rotation after the ballast rod 69 has reached its lowest point will again cause the shade material to be wound around the roller and the bar to be lifted.
[0026] The depth of the interior space 55 of the bar 7 is preferably at least twice the height of a stripe 31 , 33 , 35 , 37 of the shade material 5 . This ensures that there is enough space for the rear layer 29 to move relative to the front layer 27 between the closed position of the shade 1 when the opaque stripes 31 , 35 of one layer are aligned with the translucent stripes 33 , 37 of the opposite layer and the open position of the shade when the opaque stripes of both layers are aligned.
[0027] FIGS. 3A-3D show the assembly of the top portion 39 , 41 of either the front or rear layer 27 , 29 of a woven shade material 5 to the front or rear, top attachment member 23 , 25 and then to the front or rear top groove 15 , 17 of the roller 3 . The assembly will be explained using the front layer 27 and the front top attachment member 23 as an example, but it is identical for the rear layer 29 . In FIG. 3A the front layer 27 and front top attachment member are ready to be assembled, in FIG. 3B they are in a first stage of assembly, in FIG. 3C they are completely assembled and ready for insertion into the front to groove 15 , and in FIG. 3D the front top attachment member 23 with the front layer 27 are in the front top groove 15 .
[0028] As shown in FIG. 3A , it is preferred that the top-most translucent stripe 33 A in the top portion 39 of the front layer 27 is an open-structured stripe 71 which includes top and bottom, continuous, longitudinally-extending border lines 73 , 75 along neighboring top and bottom opaque stripes 31 A, 31 B. The top attachment member 23 has a left end 77 , a right end 79 and main body 81 in between. The main body 81 includes a plurality of alternating generally outwardly—or upwardly—extending peaks or protuberances 83 and generally inwardly—or downwardly—extending valleys or depressions 85 along its length. When the open-structured stripe 71 of the front layer 27 is lowered onto the top attachment member 23 , the peaks 83 extend through the open-structure of the stripe 71 and outwardly of the front layer. This is shown in FIG. 3B . The front layer is then folded around the top attachment member to keep the peaks 83 extending through, and outwardly away, from the front layer. This is shown in FIG. 3C . Thereby, the attachment member 23 abuts against the top border line 73 of the open-structured stripe 71 , adjacent to the top opaque stripe 31 A. Since the top attachment member 23 abuts against the top opaque stripe 31 A, there is an automatic horizontal alignment of the front layer 27 . If necessary, the top border line 73 can be pulled into abutment with the top attachment member after the front layer 27 , with front top attachment member 23 is inserted into the front groove 15 of the roller 3 as shown in FIG. 3D . Once the shade 1 is completely assembled and ballast rod 69 is inserted in hammock-like loop 67 of the rear layer 29 as shown in FIG. 2 , the weight of the ballast rod will ensure alignment of the front and rear layers.
[0029] FIG. 4A-4C show the attachment of the front and rear layers 27 , 29 of the shade material 5 to the bottom attachment member 65 . The bottom attachment member 65 is preferably identical to the front and rear top attachment members 23 , 25 . Preferably, the bottom-most translucent stripes 33 B, 37 B of the bottom sections 61 , 63 of the front and rear layers 27 and 29 are open-structured stripes 71 ″ and 71 ′″, respectively. As described above, each open structured stripe 71 ″, 71 ′″ includes top and bottom, continuous, longitudinally-extending border lines 73 ″, 75 ″ and 73 ′″, 75 ′″ along neighboring top and bottom opaque stripes 31 C, 31 D and 35 C, 35 D of the front and rear layers. The bottom attachment member 65 has a left end 77 ″, a right end 79 ″ and a main body 81 ″. The main body 81 ″ includes a plurality of alternating generally upwardly-extending peaks 83 ″ and downwardly-extending valleys 85 ″ along its length. Preferably, the bottom open-structured stripes 71 ″, 71 ′″ of the front and rear layers 27 , 29 are aligned one on top of the other when they are lowered onto the bottom attachment member 65 . The peaks 83 ″ of the bottom attachment member 65 will then extend through the open-structured stripes 71 ″, 71 ′″ of both layers. This is shown in FIG. 4B . The two layers can then be folded around the bottom attachment member 65 to keep the peaks 83 ″ of the bottom attachment member extending outwardly of the layers and extending away from the front layer 27 as shown in FIG. 4C . The attachment member then abuts against the bottom closed border lines 75 ″, 75 ′″ of the open structured stripes 71 ″ and 71 ′″.
[0030] The attachment members 23 , 25 , 65 are preferably in the shape of helically wound wires, such as helical springs (e.g., steel springs). Such helical windings can provide the needed peaks and valleys to the attachment members. However, other forms of attachment member can be used, so long as they have a plurality of alternating peaks and valleys along the length of the attachment member.
[0031] FIG. 5 shows five alternative embodiments 123 , 223 , 323 , 423 , 523 of attachment members which are similar to the attachment member 23 of FIGS. 3 and 4 and for which corresponding reference numerals (greater by 100, 200 or 300) are used below for describing the same parts or corresponding parts. In FIG. 5A , an attachment member 123 is an elongated rod-like structure 181 , along the axis of which, wheel-like portions or peaks 183 of greater radius alternate with wheel-like portions or valleys 185 of smaller radius. In FIGS. 5B and 5C , comb-like attachment members 223 , 323 each have an elongated body 281 , 381 with teeth or peaks 283 , 383 alternating with openings or valleys 285 , 385 . In FIGS. 5D and 5E , comb-like attachment members 423 , 523 each have an elongated body 481 , 581 with a pair of teeth or peaks 483 , 583 alternating with openings or valleys 485 , 585 . In FIG. 5D , each peak 483 is a substantially round disk, and in FIG. 5E , each peak 583 is wedge-shaped.
[0032] The top and bottom open-structured stripes 71 , 71 ″ and 71 ′″ of the front and rear layers 27 , 29 of the sheet material 5 can be any type of open-structured material. It is preferred that each stripe 71 , 71 ″ and 71 ′″ includes a plurality of vertically-extending bridging members 87 between its top and bottom border lines 73 , 73 ″, 73 ′″, 75 , 75 ″, 75 ′″. These bridging members 87 are preferably distributed along the longitudinal length of each open-structured stripe. The bridging members can be formed by cutting away material from the front and rear layers 27 , 29 in their top-most and bottom-most translucent stripes. When the front and rear layers are assembled with the attachment members 23 , 25 , 65 , 123 , 223 , 323 , 423 , 523 each peak 83 , 183 , 283 , 383 , 483 , 583 of an attachment member extends through an open-structured stripe 71 , 71 ″, 71 ′″ between, and outwardly of, a pair of adjacent bridging members 87 of the layers. Preferably, the double-layer fabric shade material 5 is woven with its open-structured stripes being formed by omitting warp or weft threads of the fabric, thereby forming the bridging members 87 as weft or warp threads.
[0033] It is not necessary that the number of peaks 83 , 183 , 283 , 383 , 483 , 583 on the attachment members 23 , 25 , 65 , 123 , 223 , 383 , 483 , 583 and the number of bridging members 87 in the open-structured stripes 71 , 71 ″ and 71 ′″ are equal. For a minimal alignment of the shade material 5 with the roller 3 , only about two peaks on each attachment member are needed. See FIGS. 5D and 5E . The longitudinal spacing between adjacent bridging members 87 is not considered critical, so long as at least two peaks extend between adjacent pairs of bridging members.
[0034] FIG. 6 shows an alternative embodiment of a layer 627 of a two-layer shade material 605 of the invention which is similar to the front layer 27 of the shade material 5 FIGS. 3 and 4 and for which corresponding reference numerals (greater by 600) are used below for describing the same parts or corresponding parts.
[0035] Shown in FIGS. 6A-6C , the layer 627 of the two-layer shade material 605 is a non-woven material. Which can be a non-woven fabric but can also be a plastic sheet material or the like. A plurality of longitudinally-adjacent open-structured stripes 671 are cut into the top-most translucent stripe 633 A in the top portion 639 of the layer 627 and bridging members 687 are left between the open-structured stripes 671 . Each open-structured stripe 671 includes top and bottom, closed longitudinally-extending border lines 673 , 675 along neighboring top and bottom opaque stripes 631 A, 631 B. FIG. 6A shows the layer 627 and a front attachment member 423 of FIG. 5D prior to being assembled. FIG. 6B shows the layer 627 positioned over the front attachment member 423 with its peaks 483 directly underneath the open-structured stripes 671 of the layer. FIG. 6C shows the peaks 483 of the front attachment member 423 inserted into the open-structured stripes 671 of the layer 627 , between its bridging members 687 and the layer then folded around the attachment member, with the peaks 483 outside of, and extending away from the layer, so that the attachment member can then be inserted into the front groove 15 of the roller 3 of the shade 1 .
[0036] In FIG. 6 , the bridging member 687 are shown as relatively wide, and the Spacings between them are relatively narrow. However, this is not necessary. Likewise, the attachment member 423 is shown with two peaks 483 , but it could have more peaks.
[0037] This invention is, of course, not limited to the above-described embodiments which may be modified without departing from the scope of the invention or sacrificing all of its advantages. In this regard, the terms in the foregoing description and the following claims, such as “longitudinal”, “vertical”, “horizontal”, “top”, “bottom”, “radial”, “clockwise”, “counter-clockwise”, “right” and “left”, have been used only as relative terms to describe the relationships of the various elements of this invention for architectural coverings.
[0038] For example, the layers of the shade material 5 of the roller shade 1 can be fabric, preferably a woven or knit fabric (as shown in FIGS. 3 and 4 ), or a non-woven fabric or perforated plastic sheet (as shown in FIG. 6 ). However, with a non-woven fabric, separate border lines 673 , 675 are preferably provided, for example by providing a line of adhesive or an adhesively-attached reinforcing strip along the top and bottom borders of the open-structured stripes 671 .
[0039] Moreover, the roller 3 can be at the bottom of the shade 1 and the bar 7 can be at the top of the shade.
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A system for attaching a shade material to a roller having recesses in its surface includes inserting portions of the shade material into an associated elongated recess and retaining the material in the recess with an attachment member having peaks and valleys along its length for intermittent engagement with the material within the recess.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part, filed under 35 USC 120, of International Patent Application No. PCT/EP2007/001775 filed Mar. 1, 2007 which in turn claims the benefit of priority of U.S. Provisional Patent Application No. 60/777,788 filed Mar. 1, 2006 and UK Patent Application No. 0604089.3 filed Mar. 1, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates to an apparatus and method for the extraction of material from wild-type or recombinant arthropod glands.
DESCRIPTION OF THE RELATED PRIOR ART
[0003] Inoue et al in Eur. J. Biochem. 2004, 271, 356-366, described the secretion of native silk fibroin of Bombyx mori from the posterior silk gland as a 2.3 MDa elementary unit (hereinafter termed EU) which consists of six sets of a disulfide-linked heavy chain-light chain fibroin heterodimer and one molecule of P25.
[0004] Currently, solutions of silk proteins (such as fibroin and other proteins) are made as regenerated silk solutions out of cocoons or silk threads which are dissolved in solubilisation agents (e.g. lithium bromide) and refolded through dialysis or other buffer exchange techniques (see, for example, Altmann et al., Biomaterials 2003, 24, 401-416). Given the known challenges in producing active proteins through refolding after solubilisation in protein folding/chaotropic agents (Vallejo and Rinas, Microbial Cell Factories, 2004, doi:10.1186/1475-2859-3-11), a person skilled in the art will appreciate the technical hurdles which have to be solved in order to produce correctly folded, native fibroin EUs from regenerated silk solutions. It is therefore not surprising that there has been no report to date on the successful production of high molecular weight fibroin assembled in EU conformation out of regenerated silk solutions.
[0005] The differences between the native silk proteins as produced and stored in the glands of arthropods, such as silkworms, (i.e. in their high molecular weigh EU conformation) and the regenerated silk proteins (disclosed above) are such that the regenerated silk proteins produced by current techniques have at most “native-like” features, i.e. the regenerated silk proteins have some properties in common but cannot be said to be identical or substantially identical with the native silk proteins. The native silk proteins are defined as those proteins found in their native protein conformation, i.e. with the primary, secondary, tertiary and quaternary folding structures similar or essentially similar to the wild type protein (Thomas E. Creighton, Proteins, Second Edition, 1993, 232-236, ISBN 0-7167-2317-4). The differences of regenerated silk proteins in their protein folding pattern, especially for their tertiary and quaternary folding compared to native silk proteins have apparently no negative impact on their use as cosmetic or pharmaceutical ingredients (as described, for example, by Tsubouchi et al. in international patent application PCT/JP01/02250). However, for more demanding applications, such as the production of mechanically strong films, coatings and moulded objects or the biomimetic spinning of silks (as described by Vollrath and Knight in European Patent 1244828, assigned to Spintec Engineering GmbH), the correct folding and self-assembly of the silk proteins used for production of said materials plays a role in determining the mechanical strength and functional features of the formed materials. Due to the differences between the regenerated silk proteins and the native silk proteins noted above, the quality of regenerated silks has not been sufficient for the production of high quality silk materials through moulding, coating or biomimetic spinning as described in the above mentioned European patent 1244828. For example, Huemmerich et al. reported in Appl. Phys. A 2006, 82, 219-222 that cast silk membranes made out of regenerated artificial silk peptides had to be treated with potassium phosphate or methanol in order to improve the physical strength of the membranes and convert them from water soluble to water resistant membranes.
[0006] Another example is provided in international patent application number WO 2004/000915 which describes regenerated silk membranes which require cross-linking with alcohols to improve the inferior mechanical properties of the cast silk films.
[0007] In international patent application number WO 2005/012606, the chemicals PEG or PEO are used in an effort improve the known brittleness of regenerated silk protein membranes. A further example for using physico-chemical treatments to improve regenerated silk protein membranes is the use of a cross-linking agent followed by a freeze-drying method as described by Li et al. in Biomaterials 2003, 24: 357-365.
[0008] European Patent Application No 1241178 (assigned to the National Institute of Agrobiological Sciences and Kowa Co) teaches a method for the production of silk fibroin by dissolving cocoons in an aqueous alkaline solution or an aqueous urea solution. The aqueous alkaline solution described in the examples of the '178 patent application is sodium carbonate or lithium thiocyanate at a pH of 7. Subsequently acetone or alcohol is added to the aqueous alkaline solution to precipitate the fibroin. The results shown in the patent application do not indicate that high molecular weight silk proteins exhibiting native tertiary and quaternary protein folding conformations were produced. The '178 patent application reports (paragraph 18) also a method in which the silk gland is extracted from the body of a silkworm followed by extraction of the protein from a silk gland lumen. The disclosure suggests, however, that the process is not suitable for industrial production because the fibroin obtained contains impurities such as silkworm humor and silkworm gland cells.
[0009] A method for the extraction of native silk proteins from silkworm glands has been described in U.S. Pat. No. 7,041,797 (Vollrath, assigned to Spintec Engineering GmbH). The '797 patent describes an approach in which the silk glands are removed from the body of the silkworm followed by removal of an epithelial layer of the silk glands. The method works well for the manual extraction from individual ones of the silk glands. However, it is tedious and time consuming if a larger number of the silk glands need to be extracted. It is thus impracticable as a production method for the native proteins from the silk glands on a large industrial scale. The inventor of the '797 patent has also not detailed a method or an apparatus which allows for the efficient and homogeneous mixing and pooling of proteins extracted from the silk glands as well as for the incorporation of additives in the extracted content from the silk gland.
[0010] Similarly Japanese Patent Application JP-A-2268693 (Asahi) teaches a method of cultivating a silk gland obtained from silkworms (such as from Bombyx mori ) and using a culture medium. The culture medium is removed using dialysis to obtain an aqueous solution of the silk fibroin. However, the inventors in the '693 patent application did not consider how to incorporate additives homogenously into the highly viscous content of the silk gland.
[0011] A cruder method for obtaining fibroin protein is disclosed in Japanese Patent Application JP-A-3209399 (Terumo) in which the heads are cut off of grown silkworms. The fibroin protein is then harvested by pressing the abdomen of the silkworm to extract the fibroin protein. Sericin is removed from the resulting protein mixture by treating the protein mixture with a weak alkali, such as Na 2 CO 3 . The inventors of the '399 patent application did not teach how to include additives in the protein mixtures. Further the method of the '399 patent application has the disadvantage that incorporation of impurities from the silkworm body is not easily avoided. These impurities have to be removed or they may affect the properties of biomimetically spun fibres or of coated or moulded objects produced with said protein mixtures.
[0012] A disadvantage when using non-native, regenerated silk fibroin as feedstock for casting silk membranes is due to the presence of a distinct granular or globular morphology (a so-called “ultrastructure”) when analysed by SEM (scanning electron microscopy). As reported by Jin and Kaplan in Nature, 2003, Vol 424, 1057-1061). This SEM ultrastructure is caused by the aggregation of individual silk fibroin micelles during the drying process of the cast silk fibroin solution. According to Jin and Kaplan, those micelles can also give rise to larger globular structures with diameters of up to 15 μm (see also Nazarov et al. Biomacromolecules 2004, 5, 718-726). Micellar-like morphology has also been demonstrated at high resolution SEM (2 μm scale) by Jin and Kaplan to occur in methanol treated, natural silk protein isolated from the silk glands of Bombyx mori silkworms (Nature, 2003). The fibroin micelles have also been reported by G. Freddi et al. in Int J Biomacromolecules 1999, 24: 251-263 as densely packed, roundish particles with diameters of around 200 nm. Because of the granular ultrastructure of regenerated silk membranes, it has not been possible yet to manufacture mechanically strong, regenerated silk membranes with pore sizes below 0.2 μm which are required in medical applications as effective physical barrier against antimicrobial and antiviral contamination. In addition, the aggregated fibroin micelles in regenerated silk membrane hinder development of advanced optical and electronics applications which require non-granular ultrastructural morphologies.
SUMMARY OF THE INVENTION
[0013] There is therefore a need for a method and apparatus to efficiently extract native proteins from arthropod glands.
[0014] There is furthermore a need to incorporate additives into said arthropod gland proteins.
[0015] There is furthermore a need to homogenously mix arthropod gland proteins extracted from more than one arthropod.
[0016] There is furthermore a need to obtain a strong silk protein membrane which has pore sizes smaller than 200 nm for the protection against microbial and viral contamination.
[0017] These and other objects are solved by an apparatus for the extraction of material from a gland of an arthropod (such as a silkworm) comprising a holding device by which at least part of the gland is held. A buffer solution at least partially (but not necessarily completely) immerses the gland. The material is released from the gland into the buffer solution.
[0018] The material is ultimately sedimented in a collection area at the bottom of the apparatus.
[0019] The apparatus ensures that material from the two or more silkworm glands from one or more arthropods (such as silkworms) is substantially homogenously mixed together in the apparatus. At least partially immersing the silkworm gland in the buffer solution means that osmotic pressure, enzymatic or mechanical dissection ensures that the material is released from the silkworm gland into the buffer solution.
[0020] The apparatus further incorporates a porous support, such as a porous net or a porous plate, which is placed between the holding device and the collection area of the material. The porous support provides an efficient technical solution for breaking up the highly viscous protein content flowing out of the glands, resulting in a uniformly mixed material collected in the collection area.
[0021] The porous support also serves as a filter medium to prevent unwanted contaminants entering the collection area of the material.
[0022] The porous support also serves as a technical means to control and change material properties of the collected material (i.e. the contents of the gland). For example, by changing the mesh or pore size and/or adjusting the position of the porous support relative to the position of the gland on the holding device and/or relative to the position of the collection area of the apparatus, it is possible to control exposure of the material to the buffer solution (and any additives in the buffer solution) in the apparatus. In a further embodiment, the exposure of the material to the buffer solution can also be controlled by using a non-porous support whereby the position of the non-porous support is such that the material is guided towards the collection area of the apparatus.
[0023] Additives can be incorporated into the buffer solution. It has been found that the solubilisation and sedimentation of the material in the buffer solution leads to a substantially even distribution of additives within the material.
[0024] These and other objects are also solved by a method comprising: Providing a gland containing at least partially the material; making an opening in the gland and positioning the gland by a holding device such that the gland is at least partially immersed in a buffer solution such that the material can exit the gland.
[0025] It is also possible to pass the material through a porous support (such as a porous plate or a porous net). As discussed above the provision of the porous support breaks up the highly viscous protein content flowing out of the glands which results in a uniformly mixed material collected in the collection area. Finally the material is collected at the bottom of the apparatus.
[0026] As is discussed below, the material consists of native or recombinant biomaterials which can be produced in arthropod glands such as for example proteins, peptides or carbohydrates or other suitable biological molecules and/or a combination of these. The materials can be used for a number of purposes including, but not limited to, the manufacture of fibres or films. Preferably the material is native or recombinant fibroin or fibroinfusion proteins known to one skilled in the art of recombinant silkworm technologies.
[0027] Extraction of arthropod protein in accordance with the invention avoids the need to use protein refolding techniques as is necessary if silk proteins are made from regenerated silk solution. Instead, the apparatus and method presented here enables a large scale extraction of native materials made and stored by the arthropod in the glands. By avoiding the protein refolding techniques and by using mild protein purification conditions, all or most of the functionality conferred by natural synthesis of the biomaterial in the arthropod's glands can be retained. For example, in the case of the silkworm the disclosed invention allows an efficient harvesting of native fibroin or recombinant fibroin without destroying high molecular weight multimeric fibroin protein complexes (tertiary and quaternary folding, described for example in Inoue et al in Eur. J. Biochem. 2004, 271, 356-366) by avoiding the use of denaturing agents which are widely used for making regenerated silks (for example see Altmann et al., Biomaterials 2003, 24, 401-416). From a commercial point of view, the disclosed apparatus enables a benign harvesting technique and preservation of the native features of fibroin in the extracted silkworm gland content. In addition, the apparatus forms the basis for the production of novel films, coatings, moulded objects or spun silk materials based on the enhanced properties of native compared with regenerated silk proteins.
[0028] Furthermore, the invention enables the mixing of the arthropod gland content with buffer and/or additives, thereby providing a means for the production of novel silks with properties conferred by the permanent or transient integration of additives. Since the solution is an aqueous solution and does not require any organic solvents as refolding agents for silk proteins (unlike the prior art discussed above), it is believed that, for example, any labile protein or peptide can be used as additives. Other examples of potential additives are listed below.
[0029] The invention also enables the homogenisation of the extracted gland content by passage through a porous net, thereby providing for homogenous mixing of the gland contents from more than one arthropod.
[0030] In summary, the disclosed apparatus enables the operator to manufacture gland content solutions with tuneable material properties such as for example protein concentration or biochemical composition by controlling parameters such as buffer composition, dimensions of openings in a porous support, flow distance of materials inside the apparatus and size of the collection area.
DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 shows the apparatus with a porous support.
[0032] FIG. 2 shows the use of the apparatus for harvesting arthropod gland contents.
[0033] FIG. 3 shows the method of use of the apparatus.
[0034] FIG. 4 shows the stress strain curve of Example 4.
[0035] FIG. 5 shows the apparatus with a solid support.
[0036] FIG. 6 shows a cross sectional SEM analysis of a silk membrane.
DETAILED DESCRIPTION OF THE INVENTION
[0037] For a complete understanding of the present invention and the advantages thereof, reference is now made to the following detailed description taken in conjunction with the Figures.
[0038] It should be appreciated that the various aspects of the invention discussed herein are merely illustrative of the specific ways to make and use the invention and do not therefore limit the scope of invention when taken into consideration with the claims and the following detailed description. In particular it should be noted that features of one embodiment of the invention may be combined with features of other embodiments of the invention.
[0039] The teachings of the cited documents should incorporated by reference into the description
[0040] FIGS. 1 , 2 and 5 show an apparatus 5 according to the present invention. The apparatus 5 comprises a container 10 , a material collection area 20 , and a buffer solution 30 with one or more additives 40 . The one or more additives 40 may be added at any stage during the use of the apparatus or alternatively no additives 40 need to be added. The apparatus 5 further contains a height adjustable (indicated by the arrow) gland holding device 50 which holds one or more arthropod glands removed from arthropods in position to facilitate release (elution) of the contents of the one or more glands. Optionally, the apparatus 5 contains a height and position adjustable (indicated by the arrows) support 60 with a pore size of 0.1-10 mm. The support 60 can be a porous net or a porous plate as indicated in FIG. 1 or a solid plate as indicated by FIG. 5 . The buffer solution 30 may contain for example 100 mM Tris or any other buffer type known to one skilled in the art of protein purification. The additives 40 may be by way of example only a therapeutically active substances or colouring agents.
[0041] The method of use of the apparatus 5 for extracting arthropod gland content is shown in overview in FIG. 2 and is described in FIG. 3 .
[0042] FIG. 2 shows the placement of the arthropod glands 70 on the holding device 50 (indicated by the arrow). To facilitate industrial harvesting of the silkworm glands. The holding device 50 is automatically loaded with the arthropod glands 70 by one or several robotic gland pick-up and transfer devices 80 . However, for small scale production, the apparatus 5 can also be loaded manually. The gland content material 90 is released out of the arthropod gland 70 and is collected in the material collection area 20 . Optionally, the porous support 60 may be used to improve homogeneous mixing with and increase exposure of the gland content 90 to the buffer 30 with or without the additives 40 . By changing the positions of holding device 50 and porous support 60 relative to each other and relative to the material collection area 20 , the apparatus 5 enables adjustment of the required concentration of the collected gland content 90 . Alternatively, no porous support 60 may be used at all thereby preserving the concentration of eluted gland content 90 as much as possible.
[0043] FIG. 3 summarises the method of use for apparatus 10 .
[0044] In a first step 200 the container 10 is filled with the buffer 30 .
[0045] In a further aspect of the present invention the container 10 may or may not be filled with one or more additives 40 .
[0046] In a next step 210 , the glands 70 are extracted from bodies of the arthropods, such as silkworms. This can be done, for example, using a method described in U.S. Pat. No. 7,041,797. At least one opening is made into an epithelial cell wall of the silkworm glands so that the content (silk proteins) can be released from the inside of the silkworm glands. The opening in the epithelial cell wall can be made by ultrasound, mechanical cutting or enzymatic dissection. The opening in the epithelial cell wall can also be carried out by cutting the silkworm gland roughly in half. The exact position of the opening in the epithelial cell wall and method of making the opening are not crucial for practicing the invention. The opened glands 70 are then placed either manually or with one of the robotic pick-up and transfer devices 80 onto the holding device 50 of the apparatus 10 . Such pick-and-place devices are known to one skilled in the art of laboratory automation and allow the physical manipulation of the silkworm gland 70 by means of a pick-and-place functional device, such as a gripper. The transferred silkworm glands 70 are arranged on the holding device 50 in a manner enabling the efficient release of the content 90 of the silkworm gland 70 and an efficient packing of the silkworm glands 70 inside the container 10 . In one embodiment of the invention, the silkworm glands 70 from about 7 silkworms are used, however this is not limiting of the invention and can be easily scaled up to several magnitudes by increasing the dimensions of the holding device 50 and of the apparatus 5 .
[0047] In the next step 220 , gland content 90 flows out of the silkworm gland 70 into the container 10 and is collected in the material collection area 20 . The silkworm gland 70 is at least partially immersed. Optionally, the gland content 90 passes through porous support 60 . As discussed above, the use of the porous support 60 has the advantage of improving homogeneity and adjusting material properties of the gland content 90 by varying the positions of the porous support 60 and/or the holding device 50 in the container 10 . In addition, the porous support 60 may also be used for reducing impurities from the released gland content 90 .
[0048] In step 230 , the gland content 90 collected in the material collection area 20 may be stored in the container 10 or transferred into a further suitable storage container (not shown). The collected gland content 90 has a protein content of around 1-30% and can be loaded with useful additives during or after the extraction process to confer novel functionality to the collected gland material. In addition, the collected gland content 90 is substantially homogeneous, especially if the collected gland content 90 was passed through the porous support 60 . This homogeneous distribution of the collected gland content 90 and the ability to confer the one or more additives to the gland contents 90 contrasts with prior art methods in which it has not been possible to mix the material native silk proteins from more than one silkworm gland 70 or to incorporate the one or more additives 40 into the material.
[0049] It should be noted that this method is equally applicable to native proteins and peptides (not only limited to silk proteins) and their recombinant analogous and fusion proteins extracted in native form from the glands of wild type or recombinant arthropods such as silkworms from the family Bombycidae, including but not limited to silkworms from the genera Antherea, Attacus, Samia, Bombyx and Telea . The extracted materials include, but are not limited to, ABAB-block polymer type peptides and proteins, such as fibroin.
[0050] The one or more additives 40 can be added to the extracted gland content 90 , either to the buffer solution 30 at any stage of the extraction or directly to gland content 90 harvested in the material collection area 20 .
[0051] The range of additives 40 that can be added is extensive and it is envisaged that the following additives 40 could be used:
[0052] Organic Additives
[0053] Small molecular entities
[0054] Peptides
[0055] Proteins
[0056] Carbohydrates
[0057] Lipids
[0058] Nucleic acids such as DNA, RNA, PNAs and other nucleic acid analogues with more than 100 bases length as well as fragments thereof with less than 100 bases length such as for example siRNAs
[0059] Inorganic Additives:
[0060] Additives or precursors that improve or render mechanical, optical, electrical or catalytic properties
[0061] Minerals such as phosphates, carbonates, sulphates, fluorides, silicates etc. and mineraloids such as clays, talc, and silicas,
[0062] Salts of alkali and alkaline earth metals, transition metals, post transition metals and alloys thereof,
[0063] Metal complexes such as metal ions coordinated with EDTA or other chelating agents,
[0064] Insulators such as metal oxides like Fe2O3, Al2O3, TiO2,
[0065] Any III-V or II-VI semiconductor and conductors, such as metals and alloys thereof,
[0066] Carbon-based additives, such as fullerenes, carbon nanotubes, fibres or rods, graphite
[0067] Hydrophobic, hydrophilic or amphiphilic additives to adjust the solubility of the gland content in the buffer solution and thus provide differing concentrations of extracted material.
[0068] Nanoparticles
[0069] Physiologically active compounds such as
[0070] Antibodies and their analogous
[0071] Antiseptics, antiviral agents and antibiotics
[0072] Anti-coagulants and anti-thrombotics
[0073] Vasodilatory agents
[0074] Chemotherapeutic agents
[0075] Anti-proliferative agents
[0076] Anti-rejection or immunosuppressive agents
[0077] Agents acting on the central and peripheral nervous system
[0078] Analgesics
[0079] Anti-inflammatory agents
[0080] Hormones such as steroids
[0081] Mineralization agents for tooth regeneration such as fluorapatite for tooth regeneration
[0082] Mineralization agents for bone regeneration such as hydroxylapatite, tricalcium phosphate, marine animal derived particles such as corals and chitosans and the like
[0083] Growth factors such as
[0084] bone morphogenic proteins BMPs
[0085] bone morphogenic-like proteins GFD's
[0086] epidermal growth factors EGFs
[0087] fibroblast growth factors FGFs
[0088] transforming growth factors TGFs
[0089] vascular endothelial growth factors VEGFs
[0090] insulin-like growth factors IGFs
[0091] nerve repair and regeneration factors NGFs
[0092] platelet-derived growth factors PDGFs
[0093] Proteins functioning as cell or protein binding agents such as collagen IV, polylysine, fibronectin, cadherins, ICAM, V-CAM, N-CAM, selectins, neurofascins, oxonin, neuroglinin, fascilin
[0094] Cell-binding motives such as for example the RGD or RADAR recognition sites for cell adhesion molecules
[0095] Wound healing agents
[0096] Agents for preventing scar-formation such as for example Cordaneurin
[0097] Other naturally derived or genetically engineered therapeutically active proteins, polysaccharides, glycoproteins or lipoproteins
[0098] Therapeutically active cells such as for example stem cells or autologous cells derived from a site of the patient
[0099] Agents for detecting changes of pH such as neutral red
[0100] Agents promoting 1-sheet formation of the extracted gland proteins
[0101] Agents such as biodegradable polymers which degrade at controllable rates thereby enabling controlled biodegradability
[0102] Agents such as protease inhibitors which inhibit protease activity for example in the site of implantation in the patient thereby enabling controlled biodegradability
[0103] Aprotic solvents improving hydrogen bond formation in silk proteins such as ether, ester, acidanhydride, ketones (e.g. acetone), tertiary amines, dimethylformamide, pyridine, furane, thiophen, trichlorethane, chloroform and other halogenated hydrocarbons, dimethylsulphoxide, dimethylsulphate, dimethylcarbonate, imsol, anisol, nitromethane.
[0104] Agents enhancing release of physiologically active compounds
[0105] Naturally derived or chemically synthesised dyes
[0106] Naturally derived or genetically engineered colouring agents such as green fluorescent protein
[0107] Naturally derived or genetically engineered structural load bearing proteins such as actin, silk, collagen or fibronectin and analogous or derivates thereof.
[0108] Electrically conducting and semi-conducting materials
[0109] Polyelectrolytes with bound positive or negative charges
[0110] Ionic liquids
[0111] Materials conferring transient or permanent magnetism
[0112] Water soluble polymers such as polylactic acid or polycaprolactone
[0113] Glass fibres
[0114] It should be understood that the list of additives is not intended to be limiting of the invention but is exemplary of the additives that can be added to the extracted gland material 90 .
[0115] The extracted gland material 90 can be used for forming objects, for example by coating, moulding or spinning as defined in the spinning apparatus disclosed in European Patent 1244828. If the one or more additives 40 are added to the extracted gland material 90 , the formed objects can have additional properties. For example, one of the additives 40 to encourage the growth of tissue could be added to the extracted gland material 90 so that the formed objects can be used as a medical implant.
EXAMPLES
Example 1
[0116] The silkworm glands 70 of four Bombyx mori silkworms at the end of their fifth instar were extracted by removing the silkworm gland 70 from the body of the Bombyx mori silkworms as described above with reference to the U.S. Pat. No. 7,041,797. Each of the silkworm glands was cut into half. The posterior halves of the silkworm glands 70 were placed with a pair of forceps on a net positioned inside a Petri dish which was filled with 100 mM ammonium acetate buffer having a pH 7.8. In total, eight posterior silkworm glands 70 were transferred. The eight silkworm glands 70 were incubated for 60 min for osmotic shock and release of the content of the silkworm gland 70 . The emptied silkworm glands 70 were then removed from the surface of the net using a pair of forceps. Where necessary, a sliding movement over the edge of the Petri dish was used in order to extract any remaining silkworm gland material left inside the silkworm gland. The extracted silkworm gland material was left overnight on the surface of the net which allowed the silkworm gland material to pass through the net and sediment at the bottom of the Petri dish. The net was then removed from the Petri dish and the silkworm protein from the silkworm gland harvested using a 5 ml disposable syringe.
Example 2
[0117] Eight posterior halves of the silkworm glands 70 were extracted as described in Example 1. Microscopic analysis of any remaining material stuck to the net and of the filtered gland content collected in the Petri dish demonstrated the efficient separation of epithelial cell debris and decomposed, denatured gland materials from the homogeneous gland content in the Petri dish.
Example 3
[0118] To demonstrate the possibility of incorporating additives 40 (“dopants”) in the gland content during the extraction, eight posterior halves of the silkworm glands were extracted in a buffer solution 30 of 100 mM ammonium acetate buffer and an additive 40 , of 1.75 mM neutral red. The buffer solution 30 had a pH 7.8. This was compared with four posterior halves extracted in 100 mM ammonium acetate buffer solution 30 at pH 7.8 without further additives 40 . The addition of the additive 40 to the buffer solution did not lead to aggregation or destabilisation of the extracted gland material 90 from the silkworm gland.
[0119] The gland material containing the neutral red additive 40 was transferred into a Petri dish and dried at 50° C. to form a film. The film was found to be stable and retained red colour when incubated in water at room temperature for three months, thus demonstrating the stable integration of the additive into the gland material.
[0120] The silkworm gland material was extracted as described above containing 0.18 mM neutral red additive 40 was further tested successfully for spinnability using the biomimetic spinning device of European Patent 1244828 yielding uniformly red coloured silk fibres with diameter of about 5 μm collected on two aluminium reels.
Example 4
Material Properties of Extracted Gland Materials
[0121] A film was cast using the gland material extracted in accordance with the method of Example 1. The cast film was water insoluble and did not change its properties upon repeated wetting and drying in water or organic solvents. Tensile testing was performed in d-H 2 O on a ZwickRoell TC-FR2.5TN tensile tester at 10 mm/min with sample geometries of 40 mm×2.5 mm×0.06 mm. The film exhibited breaking strength in d-H 2 O of about 20 MPa at approximately 100% breaking elongation (for data see FIG. 4 ). Cross-sections of the film were analysed by a Scanning Electron Microscope (SEM) at high resolution. FIG. 6 (scale bar 2 μm) demonstrates a homogenous SEM ultrastructure of the silk fibroin membrane without detectable pores and without a detectable granular or micellar-like morphology.
Example 5
Reproducibility of Gland Content Extraction
[0122] The silkworm glands of seven Bombyx mori silkworms at the end of their fifth instar were extracted by removing the silkworm gland from the body of the silkworms as described for example in the U.S. Pat. No. 7,041,797. Each of the silkworm glands was cut into half. The posterior halves of the silkworm glands (in total 14) were placed with a pair of forceps on a bar positioned at the top of a cylinder with approx. 30 mm diameter and approx. 100 mm length containing a 100 mM ammonium acetate, pH 7.8 buffer and a net with mesh size 1 mm, positioned at approx. 46 mm distance from the closed bottom of the cylinder. The whole content of the opened silk glands was released, passed through the net and collected at the bottom of the collection area 20 . The protein concentration of the collected whole gland content was then determined by drying in an oven at 60° C. The extraction procedure was performed five times, yielding gland protein concentrations of 7.0%, 7.2%, 7.2%, 6.7% and 7.1% and an overall protein concentration of 7±0.22%
Example 6
Adjusting Protein Concentration of Extracted Gland Content
[0123] Four silk gland extractions with 14 posterior halves each were performed with the apparatus. For each one of the silk gland extractions, 14 posterior halves were prepared as described in Example 5. The concentration of the extracted gland content was adjusted by varying the position of the porous net to the bottom of the cylinder between 10 mm, 20 mm and 46 mm. One of the extractions was performed with the porous net removed allowing direct passage of the gland content from the gland to the bottom of the cylinder. The protein concentration of the collected whole gland content was then determined by drying in an oven at 60° C. The resulting protein concentrations were: 20% for extraction without the porous net, 15% with the porous net positioned at 10 mm distance from the bottom of the cylinder, 11% with 20 mm distance, 7% with 46 mm distance and 5% with 100 mm distance.
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An apparatus and method for the extraction of material from glands of arthropods. The apparatus comprises a container in which at least part of the glands are placed and a buffer solution at least partially immersing the glands. Gland material is collected in the material collection area of container. In use the material is released from glands into the buffer solution and sedimented at the bottom of the container. The method comprises: a first step of removing from a body of the arthropod the gland containing at least partially the material; a second step of making an opening in an epithelium of the gland; and a third step of placing the gland in a container at least partially immersed in a buffer solution such that the materials exit the glands and sediments in the material collection area of the container.
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The invention described and claimed herein was made in part with funds from Grant No. AI 32301 from the National Institutes of Health and in part with funds from U.S Army Medical Research Grant DAMD 17-93C3122. The U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the isolation, purification and characterization of derivatives of 1,4-bis-(3,4-dihydroxyphenyl)-2,3-dimethylbutane (nordihydroquaiaretic acid, NDGA). The derivatives were isolated from leaf and flower extracts of the creosote bush ( Larrea tridentata , Zygophyllaceae) and together with NDGA can be used to suppress Tat transactivation in lentiviruses, including the HIV virus.
2. Description of the Related Art
Tat is a transactivator of human immunodeficiency virus (HIV) gene expression and is one of the two or more necessary viral regulatory factors (Tat and Rev) for HIV gene expression. Tat acts by binding to the TAR RNA element and activating transcription from the long terminal repeat (LTR) promoter.
The Tat protein stabilizes elongation of transcription and has also been shown to be involved in transcription initiation. Previous studies have shown that Tat mediates reduction of antibody-dependent T cell proliferation, contributing substantially to the failure of the immune response. Tat also directly stimulates Kaposi's cell growth.
Since Tat has no apparent cellular homologs, this strong positive regulator has become an attractive target for the development of anti-AIDS drugs (see FIG. 1 ). In contrast to currently available HIV reverse transcriptase inhibitors (AZT, DDI) or potential protease inhibitors that prevent new rounds of infection, an inhibitor which suppresses viral gene Tat regulated expression of integrated proviral DNA will arrest the virus at an early stage (Hsu et al., Science 254:1799-1802, 1991).
Efforts aimed at the elucidation of factors which control gene expression at transcriptional and post-transcriptional levels in host eukaryotes have recently made possible quantitative assessment of Tat function (Sim, Ann. N.Y. Acad. Sci . 616: 64-70, 1990, the entire contents of which are hereby incorporated by reference and relied upon). To screen for inhibitors for Tat regulated transactivation (Tat-TRS), the secreted placental alkaline phosphatase (SEAP) reporter gene is put under the control of HIV-1 LTR promoter in the plasmid pBC12/HIV/SEAP. The Tat-coded activity is supplied by a second plasmid construct pBC12/CMV/t2. Transient cotransfection of COS cells with these two plasmids leads to secretion of alkaline phosphatase into the culture medium which is analyzed by a simple calorimetric assay (Berger et al., Gene 66: 1-10, 1988, the entire contents of which are hereby incorporated by reference and relied upon). The SEAP assay, therefore, provides an indirect determination of Tat transactivation. An inhibitor should cause reduction of the SEAP activity which is due to inhibition of the expression of the SEAP mRNA via transactivation of the HIV-1 LTR promoter by Tat protein (Tat-TRS).
SUMMARY OF THE INVENTION
In the present application, we disclose Tat-TRS inhibitory activity of the desert plant Larrea tridentata . Among several plant extracts prepared from rain forest and desert medicinal plants used in traditional medicinal against viral affections, only the total extract from the leaves and flowers of the creosote bush ( Larrea tridentata ) showed Tat-TRS inhibitory activity. This extract also inhibits HIV cytopathic effects on human lymphoblastoid cells chronically infected with the virus as assessed by the newly developed soluble-formazan assay (Weislow et al., JNCI 81: 577-586, 1989, the entire contents of which are hereby incorporated by reference and relied upon).
The present invention discloses compounds of the structural formula:
wherein R 1 , R 2 , R 3 and R 4 are each selected from the group consisting of HO—, CH 3 O— and CH 3 (C═O)O—, provided that R 1 , R 2 , R 3 and R 4 are not each HO— simultaneously.
Each compound was isolated from leaf-flower extracts of the creosote bush Larrea tridentata and is a derivative of 1,4-bis-(3,4-dihydroxyphenyl)-2,3-dimethylbutane (nordihydroquaiaretic acid, NDGA).
In addition, NDGA and each derivative can be used to suppress Pat transactivation of a lentivirus, including the HIV virus, in a cell by administering NDGA or a derivative thereof to the cell.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 graphically illustrates the life cycle of HIV-1 and different sites of action of potential therapeutic agents including Tat-TRS inhibitors. The basal transcription step is indicated by 1 and the viral regulatory protein dependent transactivation step by 2.
FIG. 2 demonstrates the induction of the secreted alkaline phosphatase (SEAP) expression in the standard SEAP assay.
FIG. 3 shows the inhibition of Tat-TRS activity by creosote bush total extract in the secreted alkaline phosphatase (SEAP) assay.
FIG. 4 shows an analysis of plant-derived HIV Tat inhibitors in Component Lo by gas chromatography (GC) using an analytical non-destructive capillary cross-linked 5% phenylmethylsiloxane (HP-5) column. Component Lo is a mixture of four components. The time (minutes) of elution appears on each peak.
FIG. 5 shows an analysis of plant-derived HIV Tat inhibitors in Component Gr by gas chromatography (GC) using an analytical non-destructive capillary cross-linked 5% phenylmethylsiloxane (HP-5) column. Component Gr is a complex mixture. The time (minutes) of elution appears on each peak.
FIG. 6 illustrates the inhibition of Tat-induced SEAP expression by the plant-derived single compound Malachi 4:5-6 (Mal 4) and NDGA in the secreted alkaline phosphatase (SEAP) assay.
FIG. 7 depicts the quantitation of XTT formazan production as a measurement of viable cells in Mal 4 treated cultures of either HIV infected or uninfected CEM-SS cells in two separate experiments. The percent XTT formazan production for infected cells without Mal 4 treatment for experiment 1 was 8.9% and for experiment 2 was 7.5%. For experiment 1, uninfected cells are represented by •-• and infected cells by x-x. In experiment 2, uninfected cells are represented by •- - - • and infected cells by x - - - x. The EC 50 was found to be 4.25 μg/ml or 13.4 μM. The IC 50 was estimated to be 100 μg/ml or 325 μM.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention discloses the isolation, purification and characterization of derivatives of 1,4-bis-(3,4-dihydroxyphenyl)-2,3-dimethylbutane or nordihydroquaiaretic acid (NDGA). Each derivative of NDGA was isolated, purified and characterized according to the following procedures.
Materials and Methods
Cell line: COS-7 cells with SV40 origin of replication were maintained in Isocove's Modified Dulbecco's Medium (IMDM) supplemented with 10% fetal calf serum (FCS) and antibiotics. Cells were incubated in a humidified 95% O 2 /5% CO 2 incubator at 37° C.
Plasmids: The plasmid pBC12/HIV/SEAP containing the Tat-sensitive HIV LTR promoter with the SEAP reporter gene but no Tat-coded function was used to express SEAP basal activity; pBC12/CMV/t2 supplied the Tat-coded function, i.e., the induced SEAP level. pBC12/RSV/SEAP containing the constitutive Tat-insensitive LTR promoter of Rous Sarcoma Virus (RSV) served as a positive control. All plasmids were obtained from Dr. Bryan Cullen, Duke Medical Center. PlasmidE pSEAP and pBKCMV and HIV LTR and Tat DNA are commercially available from Clontech and Stratagene. Plasmid transformation was achieved in E. coli MC1061 strain, which was obtained from Dr. Barbara Bachmann, Department of Biology Yale University. E. coli MC1061 strain can also be purchased from Clontech. Plasmid DNAs were purified using Qiagen® purification kit (Qiagen).
Chemical Reagents: Diethanolamine (#31589) and p-nitrophenylphosphate (#71768) were purchased from Fluka BioChemika, and L-homoarginine (#H-1007) was purchased from Sigma Co. The lipospermine DOGS (Transfectam®, #E123 A, Promega) was used in DNA transfection studies.
Preparation of Plant Testing Materials: The leaves and flowers of the creosote bush were collected based on ethnopharmacological inquiries. Plant materials were dried and ground in a 3 mm screen Willy mill. In pilot studies, 1 g of the plant powder was initially extracted by successive macerations using a mixture of chloroform:methanol. The extract was concentrated to residue. The entire 176 mg of the crude extract generated were treated 7 times with 3 ml of hexane. This step afforded 137 mg of hexane-insoluble (HI) materials and 31 mg of hexane-soluble (HS) materials. All these extracts were monitored stepwise by SiO 2 TLC with cerium sulfate charring, 2% CeSO 4 (w/V) in 5.6% H 2 SO 4 (v/v), and by the SEAP assay for anti Tat-TRS activity.
For the SEAP assay, test materials were dissolved in 10% DMSO solution made in calcium/magnesium-free PBS. The suspension was centrifuged and the stock solution (10 mg/ml) was filter-sterilized using a Millex®-GS 22 μm filter (Millipore). Appropriate dilutions of the stock solution were prepared in a final DMSO concentration of 0.2% in PBS to obtain the various concentrations of test compounds.
Differential Fractionation and Purification of the Active Ingredient by Countercurrent Chromatography (CCC): Based on the preliminary results of the above fractions in the SEAP assay, further fractionation of the active HI fraction by CCC was undertaken. This led to the identification of two major active fractions denoted “Green” and “Yellow” components. Identification of the most active fractions from these prospective studies prompted a full scale differential fractionation of plant powder in the attempt to generate a large quantity of the Green and Yellow fractions. This fractionation was carried out on 101.4 g of plant powder, and started with a hexane treatment step, as outlined in Table 1.
Further fractionation of the major components from the organic phase (OG) obtained after chloroform:water partition was achieved by countercurrent liquid-liquid partition chromatography using the versatile cross-axis planet centrifuge (CPC) as described by Ito and Conway, CRC Critical Reviews of Analytical Chemistry 17: 65 et seq., 1986, the entire contents of which are hereby incorporated by referenced and relied upon. The optimal solvent system was a mixture of hexane:EtOAC:MeOH:0.5% NaCl in the ratio of 6:4:5:5, with the upper phase (organic layer) as the mobile phase. Five g of the organic fraction were dissolved in 23 ml of a mixture of the two phases and introduced into the coil via a loop valve. The mobile phase pumped through the coil while rotating it at 800 rpm. At a flow rate of approximately 4 ml per minute, approximately 32% of the stationary phase was initially lost (68% retention). After the appearance of mobile phase in the elute, fractions of mobile phase were collected, evaporated to dryness, monitored by TLC and pooled accordingly into 5 batches: Solvent front (SF), Green (Gr), Yellow (Ye), Red and Stationary phase (StP). All these fractions were then monitored by the SEAP assay for anti Tat-TRS activity.
Further purification of the Green and Yellow fractions was achieved by CCC using an epicyclic coil planet centrifuge known as the Ito multilayer coil separator-extractor (Ito and Conway, CRC Critical Reviews of Analytical Chemistry 17: 65 et seq., 1986, the entire contents of which are hereby incorporated by reference and relied upon). The solvent system was a mixture of hexane:EtOAC:MeOH:0.5% NaCl (7:3:5:5). Two hundreds mg of Green fraction afforded 6.8 mg of a component termed Gr, i.e., ≈0.051% total yield based on the original plant powder. Similar studies on the Yellow fraction (Ye) generated 9.3 mg of a component denoted Lo. These purified components (Lo and Gr) each consists of several compounds, and their respective “mother” fractions were stored at 4° C. until tested for biological activity and used for further characterization.
TABLE 1
DIFFERENTIAL FRACTIONATION AND COUNTERCURRENT CHROMATOGRAPHY
(CCC) OF NDGA DERIVATIVES FROM THE CREOSOTE BUSH, LARREA TRIDENTATA.
Cell Culture and DNA Transfection: COS cells were maintained as previously described (Cullen, Cell 46: 973-982, 1986, the entire contents of which are hereby incorporated by reference and relied upon). DNA transfection was performed using a modified procedure of the lipospermine (Transfectam®, Promega #E123A) method originally described elsewhere (Loeffler and Behr, Methods in Enzymology 217: 599-618, 1993, the entire contents of which are hereby incorporated by reference and relied upon). Briefly, a day before DNA transfection, Linbro® 24 flat bottom well of 17-mm diameter plates were pretreated with 0.5 ml sterile solution of 0.1% gelatin. The plates were kept in the hood for 1 hour (all transfection steps were performed in the hood, unless otherwise stated). The gelatin solution was aspirated and the plates were washed with 0.5 ml of IMDM supplemented with 10% fetal calf serum and antibiotics (complete medium). COS cells were seeded at a density of ≈1.5×10 5 cells per 17-mm plate and incubated in a humidified 95% O 2 /5% CO 2 incubator at 37° C. DNA transfection was performed at 30-50% cell confluency. The stock solution of the Transfectam reagent, DOGS, was prepared according to the manufacturer's advice at 1 mg/0.380 ml (2.38 mg/ml or 3.4 mM) in 10% (v/v) ethanol in distilled water.
The transfection cocktail consisted of two solutions prepared in sterile tubes:
a) Solution A contained a sterile 150 mM NaCl solution+plasmid DNAs (non selected/selected gene in 2:1 ratio): 0.35 μg of pBC12/HIV/SEAP per well+0.175 μg of pBC12/CMB/t2 (coding for Tat function) per well.
b) Solution B contained an equal volume of 150 mM NaCl and a volume of Transfectam® determined to be 6 times the total amount of DNAS. Solutions A and B were homogenized and immediately mixed.
Ten minutes were allowed for the reaction to proceed. Meanwhile, the growth medium was removed from the subconfluent COS cells and 300 μl (100 μl of complete IMDM+200 μl serum-free medium) were added to each well. The transfection cocktail was dispensed to the wells in equal volume. Control samples containing no DNA were similarly treated and received sterile 150 mM NaCl solution alone. All samples were incubated for 10 to 12 hours after which 700 μl of complete growth medium were added. Test compounds prepared in 5% DMSO/Ca-Mg-free PBS (for non-water-soluble materials) were immediately added at various concentrations to the wells. Drug-untreated control samples received 5% DMSO/PBS solution alone (final DMSO concentration of 0.2%). All samples were then incubated for an additional 48 hours after which 300 μl of each culture supernatant was removed for SEAP analysis.
The Secreted Alkaline Phosphatase (SEAP) Assay: The secreted alkaline phosphatase analysis was performed as originally described (Berger et al., Gene 66: 1-10, 1988, the entire contents of which are hereby incorporated by reference and relied upon). Briefly, a 250-μl aliquot was removed from COS cell culture supernatants, heated at 65° C. for 5 minutes to selectively inactivate endogenous phosphatase (SEAP is heat stable) and centrifuged in a microfuge for 2 minutes. One hundred μl of 2×SEAP assay buffer (1.0 M diethanolamine, pH 9.8; 0.5 mM MgCl 2 ; 10 mM L-homoarginine) were added to 100-μl aliquot of the samples. The solution was mixed and transferred into a 96-well flat-bottom culture dish (Corning). Twenty μl of pre-warmed substrate solution (120 mM p-nitrophenylphosphate dissolved in 1×SEAP assay buffer) were dispensed with a multipipeter into each well containing the reaction mixture. A 405 of the reaction was read at 5-minute intervals at 37° C. for 60 minutes using an EL340i microplate reader (Bio-tek Instruments, Inc.) with 5-second automatic shakings before each reading. The change in absorbance was plotted against time in the standard assay of SEAP induction. In the drug screening assay, the percent inhibition of SEAP expression was calculated at 30 minutes as follows:
% Inhibition=100−[(CT + −C + )×100]
where:
C −
Control sample (no DNA, no drug)
CT −
Control sample (+DNA, no drug)
C +
Drug-treated sample (no DNA, + drug)
CT +
Drug-treated sample (+DNA, + drug)
Optimization of the Transfection Technique: Various techniques are utilized in the DNA transfection of eukaryotic cells. These procedures include DNA coprecipitation with calcium phosphate or cationic polymers, cell membrane weakening either by chemical means (detergents, solvents, enzymes, amphophilic polymers) or by physical means (thermic, osmotic or electric shocks, or particle bombardment). These techniques suffer, to some extent, variable efficiency and varying degrees of cytotoxicity.
Prerequisites for cells to be amenable to DNA uptake, i.e., to cross the intact cytoplasmic membrane, are “compaction and masking of DNA charges” (Loeffler and Behr, Methods in Enzymology 217: 599-618, 1993). These requirements have been successfully met with the newly developed Transfectam® procedure. The Transfectam reagent (dioctadecylamidoglycyl spermine) is a synthetic cationic lipopolyamine which contains a positively charged spermine headgroup with a strong affinity for DNA (K d =10 −5 -10 −7 M). This spermine headgroup is covalently attached to a lipid moiety by a peptide bond. The lipospermine molecules bind to DNA, coating it with a lipid layer. In the presence of excess lipospermine, cationic lipid-coated plasmid DNA vesicles are formed and the lipid portion of the complex fuses with cell membrane. DNA internalization is believed to occur by endocytosis.
Transfectam-mediated transfection has been shown to offer greater efficiency than existing methods (Barthel et al., DNA and Cell Biology 12(6): 553-560, 1993). In addition, Transfectam® is a stable and virtually non-cytotoxic reagent. However, factors for optimization of transfection in the specific COS cell line had to be addressed. These factors include the duration of transfection, the ratio of the Transfectam reagent to DNA, DNA concentration and other dilution factors such as NaCl volume and strength. The results of optimization of transfection conditions are shown below.
a) Duration of transfection: COS cells were incubated with a fixed plasmid DNA concentration in time course studies. These studies aimed at the selection of the suboptimal incubation time point for inhibition studies of SEAP expression by various test compounds. The results of the time-course induction of SEAP expression (results not shown) indicate a gradual time-dependent increase in SEAP expression. The onset of this induction began at less than 4 hours and reached a maximum at 24 hours. No significant difference was observed between the 10, 12 and 15-hour values. Therefore, the 12-15 hours endpoint was selected as the appropriate suboptimal incubation period for inhibition of SEAP expression in all subsequent drug screen studies.
b) DNA concentration: The optimal DNA concentration for transfection was determined based on previous studies with Transfectam reagent (Loeffler and Behr, Methods in Enzymology 217: 599-618, 1993). For cotransfection, the ratio 2:1 (nonselected gene/selected gene) was found to be the most appropriate as reported elsewhere (Hsu et al., Science 254: 1799-1802, 1991, the entire contents of which are hereby incorporated by reference and relied upon). The nonselected pBC12/HIV/SEAP plasmid was utilized at a concentration of 0.35 μg/well and pBC12/CMV/t2 plasmic coding for Tat function at a concentration of 0.75 μg/well in Linbro® 24 flat bottom well of 17-mm diameter plates.
c) Ratio of Transfectam to DNA and Determination of Ionic Strength: The optimal ratio of Transfectam® (DOGS) to plasmid DNA and the ionic strength of NaCl used were a modification of the previously reported values (Loeffler and Behr, Methods in Enzymology 217: 1799-1802, 1993) and determined as follows: From the original 1 mg/0.400 ml (2.38 mg/ml) stock solution of Transfectam® prepared in 10% (v/v) ethanol in distilled water, 6 times the volume (μl) of stock solution was required for each μg DNA used. The optimal ionic strength of the solution was provided by an appropriate volume of 150 mM NaCl determined by the relation:
Volume (μl) of NaCl=Volume (μl) Transfectam/0.6
The results of Tat-induced SEAP levels in the standard assay after optimization of these conditions, are illustrated in FIG. 2 . Briefly, COS cells were maintained in Isocove's Modified Dulbecco's Medium (IMDM) supplemented with 10% fetal calf serum (FCS) and antibiotics. Triplicate cell samples were seeded at a density of ≈1.5×10 5 cells per well in Linbro® 24 flat bottom wells of 17-mm diameter and incubated in a humidified 95% O 2 /5% CO 2 incubator at 37° C. until they reached 50% confluency. Subconfluent cells were transfected using the lipospermine procedure (Loeffler and Behr, Methods in Enzymology 217: 599-618, 1993). The medium of the subconfluent cells was aspirated and replaced by 300 μl of fresh minimum medium (IMDM supplemented with 3% FCS). COS cells were transfected with either pBC12/HIV/SEAP alone (0.35 μg/well) or pBC12/CMV/t2 (coding for Tat function) at 0.175 μg/well+pBC12/HIV/SEAP (0.35 μg/well) or with buffer alone (no DNA control samples). The plates were incubated for 12 to 15 hours after which, 700 μl of complete medium (IMDM containing 10% FCS) were added. Cells were then incubated for 48 hours after which, a 250-μl aliquot was removed from COS cell culture supernatants and heated at 65° C. for 5 minutes to selectively inactivate endogenous phosphatases (SEAP is heat stable). The samples were then centrifuged in a microfuge for 2 minutes. One hundred μl of 2×SEAP assay buffer (1.0 M diethanolamine, pH 9.8; 0.5 mM MgCl 2 ; 10 mM L-homoarginine) were added to 100-μl aliquot of the samples. The solution was mixed and transferred into a 96-well flat-bottom culture dish (Corning). Twenty μl of pre-warmed substrate solution (120 mm p-nitrophenylphosphate dissolved in 1×SEAP assay buffer) were dispensed with a multipipetter into each well containing the reaction mixture. A 405 of the reaction was read at 5-minute intervals at 37° C. for 60 minutes using an EL340i microplate reader (Bio-tek Instruments, Inc.) with 5-seconds automatic shaking before each reading. The change in absorbance was converted in mU of SEAP expression as previously described (Berger et al., Gene 66: 1-10, 1988) and plotted against time.
These results indicate a nearly 65-fold increase in SEAP induction after 1 hour relative to the control (no DNA) levels or the induction of nonselected gene (HIV/SEAP) alone.
Assay-Guided Isolation of Creosote Bush Extract Active Component(s) by Countercurrent Chromatography: As stated above, the differential fractionation and purification by countercurrent chromatography (CCC) of the creosote bush extract constituents led to the isolation of two major components (Table 1). 6.8 mg of the component termed Gr was isolated from the Green fraction on Sio 2 TLC. The total percent yield was ≈0.051% based on the original plant powder. 9.3 mg of the component Lo was isolated from the Yellow fraction (Ye).
Inhibition of Tat-TRS Activity by Extracts from Creosote Bush Leaves and Flowers: In several plant extracts tested with the SEAP assay, only the extract from the creosote bush, Larrea tridentata , leaves and flowers showed significant inhibitory activity of HIV Tat protein. Creosote bush displayed a dose-response inhibition of SEAP expression as illustrated in FIG. 3 . Briefly, triplicate samples of COS cells were transfected with a mixture of pBC12/HIV/SEAP and pBC12/CMV/t2 (coding for Tat function) in 2:1 ratio, using the lipospermine procedure as described above. Cells were incubated for 12-15 hours after transfection. Creosote bush extract stock solution (10 mg/ml) was made in calcium/magnesium-free PBS and 10% DMSO, and filter-sterilized using a Millex®-GS 22 μm filter (Millipore). The appropriate concentrations of creosote bush extract were added to the transfected cells at a final DMSO concentration of 0.2% and samples were incubated for 48 hours. For SEAP analysis, a 250-μl aliquot was removed from COS cell culture supernatants, heated at 65° C. for 5 minutes to selectively inactivate endogenous phosphatases (SEAP is heat stable) and centrifuged in a microfuge for 2 minutes. One hundred μl of 2×SEAP assay buffer (1.0 M diethanolamine, pH 9.8; 0.5 mM MgCl 2 ; 10 mM L-homoarginine) were added to 100-μl aliquot of the samples. The solution was mixed and transferred into a 96-well flat-bottom culture dish (Corning). Twenty μl of pre-warmed substrate solution (120 mM p-nitrophenylphosphate dissolved in 1×SEAP assay buffer) were dispensed with a multipipetter into each well containing the reaction mixture. A 405 of the reaction was read at 5-minute intervals at 37° C. for 60 minutes using an EL340i microplate reader (Bio-tek Instruments, Inc.) with 5-second automatic shaking before each reading. The percent inhibition of SEAP expression was calculated at 30 minutes as follows:
% Inhibition=100−[(CT − −C − )/(CT − −C − )×100]
where:
C −
Control sample (no DNA, no drug)
CT −
Control sample (+ DNA, no drug)
C +
Drug-treated sample (no DNA, + drug)
CT +
Drug-treated sample (+ DNA, + drug)
As seen in FIG. 3, the onset of this inhibition started at a concentration of 20 μg/ml and reached a maximum inhibitory activity at 600 μg/ml. The estimated EC 50 (the concentration exhibiting 50% of inhibition) for this crude material was 110 μg/ml. As the purification of the active ingredients progressed, there was a stepwise increase in the activity of the active ingredient(s) which tripled (68%) with the organic phase (OG) fraction compared to 21% from the original total crude extract.
Inhibition of HIV Cytopathic Effects: A compound inhibiting Tat transactivation should in principle block HIV replication. Consequently, creosote bush extract was tested at the National Cancer Institute (NCI) for inhibition of HIV-1 cytopathic effects using the soluble-formazan assay (Weislow et al., JNCI 81: 577-586, 1989, the entire contents of which are hereby incorporated by reference and relied upon). In principle, CEM-SS cells (ATCC, Rockville, Md.) are cocultivated with HIV-producing H9 cells. Viruses infect the host CEM-SS cells, replicate and kill most of the CEM-SS cells in a week. If the drug inhibits HIV production, CEM-SS cells are protected from HIV-induced cell death. The tetrazolium (XTT) reagent is therefore metabolically reduced by the viable cellsc to yield a colored formazan product which is measurable by colorimetry at 450 nm.
In practice, triplicate samples of CEM-SS cells (5000) were plated in 96-well microtiter plate. Appropriate concentrations of test compounds were added in a final volume of 100 μl calcium/magnesium-free PBS in 5% DMSO. Control samples received the compound medium (PBS) alone. Five minutes later, 500 highly infectious HIV-1 producing H9 cells or normal H9 cells were added to the wells containing the appropriate drug concentrations. The microtiter plates were incubated at 37° C. in 95% O 2 /5% CO 2 for 6 days after which a 50-μl mixture of XTT and N-methylphenazonium methosulfate (PMS) was added. The plates were reincubated for additional 4 hours for the color development (XTT formazan production). The plates were sealed, their contents were mixed by automatic shaking and the OD 450 of samples was determined in a microplate reader. Each value represents the average of 3 determinations. No significant difference was found between the means of the duplicate values of the uninfected cells and HIV-challenged cells, in presence of test compounds. In contrast, there was a significant difference (p<0.05) between HIV-challenged samples in the presence or absence of test compounds.
The results of these studies are summarized in Table 2. At a concentration of 0.75 μg/ml for component Gr, there was an average 58% protection (cell viability) against HIV as opposed to 15% viability in drug-free samples challenged with HIV. At a concentration as low as 0.187 μg/ml, component Lo exhibited even stronger inhibitory activity of HIV cytopathic effects. The cell viability was 87%, very close to that of not treated control cells (89%), in contrast to 14% viability for the drug-free samples challenged with HIV. These compounds were devoid of cytotoxicity at the concentrations used.
TABLE 2
INHIBITION OF HIV-1 CYTOPATHIC EFFECTS BY CREOSOTE
BUSH EXTRACT COMPOUNDS IN THE SOLUBLE-FORMAZAN ASSAY.
Concentration of
the test sample
which yielded
max protection
Percent of live cells at day 6 as
against HIV
measured by XXT Formazan production
without
Uninfected
HIV infected
HIV infected
killing the cells
plus
plus
minus
Test Sample
μg/ml
test sample
test sample
test sample
Fraction Green
0.187
59
67
16
Component G r - duplicates
0.75
80
67
16
Component G r
0.75
70
48
14
Fraction Yellow (Ye)
0.187
60
57
14
Component L o - duplicates
0.187
91
86
14
Component L o
0.187
89
87
14
Structure elucidation of the active components of creosote bush extract: The chemical characterization of the purified plant active constituents was achieved mainly by mass spectroscopy and by H- and C-nuclear magnetic resonance (NMR). Component Lo was found to be a mixture of four related compounds (L1, L2, L3 and L4). Resolution and characterization of each peak of the mixture was accomplished by gas chromatography (GC) using an analytical non-destructive capillary cross-linked 5% phenylmethylsiloxane (HP-5) column attached to a mass spectroscope (MS). The GC studies revealed that the first compound (L1) represented 6% of the mixture; the second (L2) was 76% of the mixture (MW=316); the third (L3) was isomeric with L2 and represented 9% of the total mixture (MW=316); and the fourth compound (L4) represented 9% of the mixture (MW=358). The time (minutes) of elution of these compounds is indicated on the peaks (FIG. 4 ).
Component Gr consisted of fifteen compounds. Resolution and characterization of each peak of the mixture was accomplished by gas chromatography (GC) using analytical non-destructive capillary cross-linked 5% phenylmethylsiloxane (HP-5) column attached to a mass spectroscope (MS). The GC studies revealed that four (G1, G2, G3 and G4) of the fifteen compounds are lignans and structurally related to the L compounds. The time (minutes) of elution of these compounds is indicated on the peaks (FIG. 5 ).
The structures of these eight compounds (L1, L2, L3, L4, G1, G2, G3 and G4) are described as follows:
L1 has the composition C 18 H 22 O 4 and has been identified as a previously known chemical, 1,4-bis-(3,4-dihydroxyphenyl)-2,3-dimethylbutane (nordihydroquaiaretic acid, NDGA, Merck Index, 10th Edition, #6534). The structural formula for L1 is as follows:
L2 has the composition C 19 H 24 O 4 and has been identified as 3-O-methyl-NDGA or 1-(3,4-dihydroxyphenyl)-4-(3-methoxy-4-hydroxyphenyl)-2,3-dimethylbutane. The structural formula for 3-O-methyl-NDGA is as follows:
L3 also has the composition C 19 H 24 O 4 and has been identified as 4-O-methyl-NDGA or 1-(3,4-dihydroxyphenyl)-4-(3-hydroxy-4-methoxyphenyl)-2,3-dimethylbutane. 4-O-methyl-NDGA is also known as Malachi 4:5-6 or Mal 4. The structural formula for 4-O-methyl-NDGA is as follows:
L4 has the composition C 21 H 26 O 5 and has been identified as 3-O-methyl-4-O-acetyl-NDGA or 1-(3,4-dihydroxyphenyl)-4-(3-methoxy-4-acetoxyphenyl)-2,3-dimethylbutane. The structural formula for 3-O-methyl-4-O-acetyl-NDGA is as follows:
G1 has a molecular weight of 344, a composition of C 21 H 22 O 4 and has been identified as 3,3′,4-tri-O-methyl-NDGA or 1-(3-hydroxy-4-methoxyphenyl)-4-(3,4-dimethoxyphenyl)-2,3-dimethylbutane. 3,3′,4-tri-O-methyl-NDGA has the following structural formula:
G2 has a molecular weight of 344, a composition of C 21 H 22 O 4 and has been identified as 3,4,4′-tri-O-methyl-NDGA or 1-(3-methoxy-4-hydroxyphenyl)-4-(3,4-dimethoxyphenyl)-2,3-dimethylbutane. The structural formula for 3,4,4′-tri-O-methyl-NDGA is as follows:
G3 and G4 each has a molecular weight of 372 and a composition of C 22 H 28 O 5 . G3 is either 3′,4-di-O-methyl-3-O-acetyl-NDGA (as in G3a) or 3,3′-di-O-methyl-4-O-acetyl-NDGA (as in G3b).
3′,4-di-O-methyl-3-O-acetyl-NDGA is also known as 1-(3-methoxy-4-hydroxyphenyl)-4-(3-acetoxy-4-methoxyphenyl)-2,3-dimethylbutane and has the following structural formula:
G3a:
3,3′-di-O-methyl-4-O-acetyl-NDGA is also known as 1-(3-methoxy-4-hydroxyphenyl)-4-(3-methoxy-4-acetoxyphenyl)-2,3-dimethylbutane and has the following structural formula:
G3b:
Similarly, G4 is either 4,4′-di-O-methyl-3-O-acetyl-NDGA (as in G4a) or 3,4′-di-O-methyl-4-O-acetyl-NDGA (as in G4b). 4,4′-di-O-3-O-acetyl-NDGA is also known as 1-(3-hydroxy-4-methoxyphenyl)-4-(3-acetoxy-4-methoxyphenyl)-2,3-dimethylbutane and has the following structural formula:
G4a:
3,4′-di-O-methyl-4-O-acetyl-NDGA is also known as 1-(3-hydroxy-4-methoxyphenyl)-4-(3-methoxy-4-acetoxyphenyl)-2,3-dimethylbutane and has the following structural formula:
G4b:
In addition to the above described isolation and purification procedures, each disclosed derivative of NDGA may be prepared by chemical synthesis following either methylation and/or acetylation of NDGA according to the procedure of Ikeya et al., Chem. Pharm. Bull . 27(7): 1583-1588, 1979, the entire contents of which are hereby incorporated by reference and relied upon.
Large scale purification of component Lo and two pure compounds (L2 and L3) from component Lo: A large scale CCC fractionation of a batch of plant materials was initiated to generate a larger quantity of component Lo. A total of 110 g plant powder was first treated with 700 ml hexane 5 times. The hexane soluble materials (1.17 g) were discarded. The hexane insoluble material (HI fraction) was dried and extracted 3 times by successive macerations with 800 ml chloroform:methanol. This afforded 20 g of total extract (Tex) which was combined with 7.6 g of HI fraction obtained from a previous batch differential extraction. A 27.6 g total. of crude plant materials thus generated was divided into two batches of 10 g and 17.6 g. These batches were initially run separately on the large-capacity versatile Cross-Axis CPC (Shinomiya et al., J. Chromatogr . 644:215-229, 1993, the entire contents of which are hereby incorporated by reference) using the solvent system hexane:EtOAc:MeOH:0.5% NaCl in 6:4:5:5 ratio with the upper phase (organic layer) as the mobile phase. The fractions were pooled exclusively according to the TLC patterns and four major fractions were identified from the two CCC operations and denoted fraction Green (Gr)(1.12 g), fraction Lo (2.87 g), fraction End (1.78 g) and finally, the stationary phase SP (20.84). The entire 2.87 g of fraction Lo was further fractionated in the large model triplet CPC with the hexane:EtOAc:MeOH:H 2 O system in 7:3:5:5 ratio, using the aqueous layer as mobile phase. Four fractions denoted LYI (0.375); LYII (0.113 g); LYIII (0.280 g) and LYIV (2.80 g) were identified according to the elution order and the TLC patterns. These fractions were assayed for anti Tat-TRS activity at 10 μg/ml. Based on the test results, LYI was selected for further purification.
Isolation of L2 and L3 pure compounds from LYI fraction of component Lo: The less hydrophobic fraction LYI was selected for further purification using the previously improved conditions, i.e., the triplet CPC and Hex:CHCl 3 :MeOH:10 mM NaCl solvent system in 1:4:4:2 ratio. This afforded preparation of 148 mg of homogeneous L3 and 109.3 mg of pure L2 as examined by NMR and mass spectroscopy. The structures of L3 ( Malachi 4:5-6) and L2 have been described above.
Compounds L2 and L3 are derivatives of a previously identified chemical, 1,4-bis-(3,4-dihydroxyphenyl)-2,3-dimethyl butane (nordihydroquaiaretic acid, NDGA, Merck Index, 10th Edition, #6534). The structural formula for NDGA, which is identical to that of Li described above, is as follows:
The anti-HIV activity (the inhibition of Tat regulated HIV transactivation) of NDGA and its derivatives was previously unknown. Comparative anti-HIV transactivation activity for NDGA and derivative Malachi 4:5-6 (Mal 4) are illustrated in FIG. 6 . Briefly, duplicate samples of subconfluent COS cells were co-transfected with plasmid pBC12/HIV/SEAP and pBC12/CMB/t2 (coding for Tat function) using the lipospermine procedure as described above. Cells were then incubated for 12-15 hours. The test compounds were initially solubilized in 10% DMSO/calcium-magnesium-free PBS and added to the transfected cells in the appropriate concentrations at a final DMSO concentration of 0.2%. The samples were incubated for 48 hours after which, a 250-μl aliquot was removed from COS cell culture supernatants, and SEAP was analyzed as in the standard assay as in FIG. 3 . The percent inhibition of SEAP expression was calculated at 30 minutes as follows:
% Inhibition=100−[(CT + −C + )/(CT − −C − )×100]
where:
C −
Control sample (no DNA, no drug)
CT −
Control sample (+ DNA, no drug)
C +
Drug-treated sample (no DNA, + drug)
CT +
Drug-treated sample (+ DNA, + drug)
Each point represents the average of two determinations. No significant difference was apparent between the EC 50s of Mal 4 and NDGA which were 8 μg/ml (25 μM) and 6 μg/ml (20 μM), respectively. The EC 50s are defined as the inhibitory concentration of the compound at which the Tat regulated HIV transactivation is reduced to 50% of that in untreated control cells.
The inhibition of transactivation of HIV promoter activity by Mal 4 and NDGA were compared in Table 3.
TABLE 3
INHIBITION OF TRANSACTIVATION OF HIV PROMOTER
ACTIVITY BY NATURAL COMPOUNDS MAL 4 and NDGA.
Inhibition of Tat-induced Seap Expression
Test
(% inhibition/concentration of test compound)
Compound
%
μm
%
μm
%
μm
%
μm
Mal 4
13.6
9.5
60.4
31.3
92
62.7
100
95
NDGA
17.0
9.9
73.8
32.6
88.1
65.2
92.9
99
The compounds NDGA and Mal 4 were assayed as described for FIG. 6 . Control samples were run in quadruplicate. The percentage inhibition was determined after 30 minutes and the OD 405 values were:
C −
Control sample (no DNA, no drug): 0.091
CT −
Control sample (+DNA, no drug): 0.805.
The quantitation of XTT formazan production as a measurement of viable cells in Mal 4 treated cultures of CEM-SS cells in shown in FIG. 7 . Each figure shows infected or uninfected CEM-SS target cells (10 4 /M well) with serial dilutions of Mal 4. EC 50 . represents the concentration of Mal 4 (e.g. 13.4 μM) that increases (protects) XTT formazan production in infected culture to 50% of that in uninfected, untreated culture cells. IC 50 represents inhibitory or toxic concentration of Mal 4 (e.g., 325 μM, estimated) that reduces XTT formazan production in uninfected cultures to 50% of that in untreated, uninfected control cells. Levels of XTT formazan in untreated, infected control cells were 9% of those in untreated, uninfected control cells. The soluble-formazan assay for HIV-1 cytopathic effects was conducted according to the procedure described by Weislow et al., JNCI 81: 577-586, 1989, the entire contents of which are hereby incorporated by reference and relied upon.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Thus, it is to be understood that variations in the derivatives of NDGA and the method of suppression of Tat transactivation can be made without departing from the novel aspects of this invention as defined in the claims.
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The present invention reveals the isolation, purification and characterization from the creosote bush Larrea tridentata of compounds of the structural formula:
where R 1 , R 2 , R 3 and R 4 are each selected from the group consisting of HO—, CH 3 O— and CH 3 (C═O)O—, provided that R 1 , R 2 , R 3 and R 4 are not each HO—0 simultaneously. Each compound is a derivative of 1,4-bis-(3,4-dihydroxyphenyl)-2,3-dimethylbutane (nordihydroquaiaretic acid, NDGA). In addition, NDGA and each derivative can be used in a method to suppress Tat transactivation of a lentivirus, including the HIV virus, in a cell by administering NDGA or a derivative of NDGA to the cell.
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BACKGROUND OF THE INVENTION
The present invention relates to a heater and a method for generating an aerosol by application of heat to an indexing substrate.
Electrically powered systems for generating a flavorful aerosol from an underlying substrate are known.
For example, U.S. Pat. No. 5,060,671 incorporated herein by reference, describes an article in which a flavor-generating medium is electrically heated to evolve inhalable flavors or other components in vapor or aerosol form. A two-component device with a detachable heater/flavor generating medium portion is described. The heater/flavor generating portion, when used, may be discarded and replaced with a new heater/flavor generating portion. The power supply/control unit is reusable.
The article of U.S. Pat. No. 5,060,671 uses multiple heaters to heat discrete portions of the substrate. Sequential firing of the heaters is controlled by circuitry. Such circuitry and the multiple-heater arrangement are complex and can be costly to manufacture.
The concept of moving a circumferential heater down an extruded rod by automatic means mechanical or electromagnetic, is disclosed in U.S. Pat. No. 5,269,327 at column 7, lines 45-62.
U.S. Pat. No. 5,388,594 also describes an electrical smoking system for delivering flavors to a consumer. In that disclosure, a substantially cylindrical cigarette is inserted into a convenient hand-held lighter. The disclosure of that patent is incorporated herein by reference.
The cigarette is smoked normally and as a puff is taken, the pressure drop in the lighter causes one of a series of electrically resistive heaters to be fired. The electrically resistive heater heats the cigarette surface to a temperature which liberates certain tobacco flavors in a tobacco containing layer or the tobacco itself.
The pressure drop causes air to flow into the housing and into the cigarette. The vaporized products from the heated flavorful substrate flow through the cigarette body, through a filter, and then are ingested by the consumer.
Each heater is fired accordingly to an electronic control which selects the heater to be powered-up.
In each of these disclosures, a heat source is moved longitudinally down a cylindrical substrate either by mechanical or electronic manipulation.
Other methods of generating an aerosol from a substrate are known, e.g. from U.S. Pat. No. 5,479,948. That disclosure teaches moving a tobacco substrate in web form past an electrical heating structure in thermal proximity thereto. The web is provided in a container like an audio cassette tape, with the web replacing the magnetic recording medium on a dispense reel and a take-up reel.
Each of the above patents incorporated herein by reference, suffers from mechanical and electrical complexity, in requiring complex control circuitry, a plurality of heaters, or motors, gears, and reels. It is desirable to provide an electrical aerosol-generating article which generates an aerosol from a substrate, and which is simple, and inexpensive to manufacture.
SUMMARY OF THE INVENTION
To overcome the problems, cost, and complexity in providing an electrically powered article for generating an aerosol from an substrate in thermal proximity, the present invention contemplates supplying the end user with an indexing mechanism which rotates a cylindrical substrate of flavor-generating medium about an axis of rotation in thermal proximity with a single heater located along the circumference of the medium.
The rotation brings a portion of circumference of the flavorful aerosol generating medium into thermal proximity with the heater. For ease of reference, the flavor generating medium may be thought of as cigarette-shaped; but any geometric shape may be used which has an approximately cylindrical cross section for at least a portion of its length.
Also contemplated by the present invention is an airflow channel which assures a stream of air passes over the heater and flavor-containing substrate.
The basic apparatus for a flavorful aerosol/vapor generating device is disclosed in commonly assigned U.S. Pat. No. 5,388,594, which is expressly incorporated herein by reference in its entirety.
Such an apparatus includes a hand-held lighter unit formed with a plurality of heaters, e.g. eight, and control circuitry to fire the heaters in a predetermined pattern.
This leads to increased complexity, and consequently, increased costs. Further, the additional heaters provide additional frictional contact points between the flavor substrate and the hand-held unit. After the heaters have fired, the substrate is often considerably weakened, and may disintegrate at a frictional contact point thereby causing a jam or clog.
Applicants have developed a novel apparatus for indexing a cylindrical type substrate into thermal contact with a single heater element. This arrangement is simple and easy to manufacture, less complex, and less likely to malfunction and lead to consumer dissatisfaction.
A single heater element is provided which may have a dedicated air flow channeled to the single heater element in thermal proximity to the substrate. The air flows into the heating zone and through the heated substrate.
As the flavorful substrate is heated to a temperature sufficient to release a vapor aerosol, the channeled air is directed to this portion of the substrate directly, causing it to be thoroughly mixed. Thereafter, a wheel, lever, push-button or similar mechanism may be actuated to advance the cigarette in a rotational movement along a longitudinal axis.
BRIEF DESCRIPTION OF THE DRAWINGS
Novel features and advantages of the present invention in addition to those discussed above will become apparent to persons of ordinary skill in the art from a reading of the following detailed description in conjunction with the accompanying drawings wherein similar reference characters refer to similar parts and in which:
FIG. 1 is a perspective view of an apparatus including a lighter and cigarette, according to the present invention;
FIG. 2 is a longitudinal sectional view of the lighter taken along line 2--2 of FIG. 1 with a partially inserted cigarette therein, according to the present invention;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 2;
FIG. 5 is a longitudinal sectional view similar to FIG. 2 but illustrating another lighter, according to the present invention;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5;
FIG. 7 is a longitudinal sectional view of another mechanism for rotating the inserted cigarette;
FIG. 8 is a cross-sectional view of the cigarette;
FIG. 9 is a perspective view of a flow guiding sleeve, according to the present invention; and
FIG. 10 is another view of the sleeve.
DETAILED DESCRIPTION OF THE INVENTION
Referring in more particularity to the drawings, FIG. 1 illustrates an embodiment of the invention comprising a lighter 10 and a cigarette 12. The cigarette has a tobacco rod portion 14 and a filter option 16. Also, a plug or filter portion 18 may be employed to optimize airflow through surface 20 of the cigarette.
The cigarette is heated by proximate contact with a heating element, which causes heat to be transferred to a tobacco-containing substrate which rises in temperature. As more fully described in the disclosures referenced above, the increase in temperature of the tobacco or tobacco containing substrate causes the evolution an aerosol or "smoke" component.
Lighter 10 is configured with an aperture 22 which corresponds in diameter to cigarette 12. Aperture 22 may be surrounded by a sealing ring 24 which restricts air flow and provides a retaining force holding cigarette 12 in place. Ring 24 may also be rotatably mounted so that it maintains frictional contact with the cigarette, but allows rotation with respect to lighter 10. The sealing ring may be formed with air-flow passages as desired to adjust resistance-to-draw.
Lighter 10 is further provided, in one embodiment, with a lever 26 which moves in the direction indicated by arrow 28. As shown in FIG. 2, lever 26 communicates through a housing 30 of lighter 10 via a linkage rod 32.
Linkage rod 32 terminates in a vertical gear 34, which is in toothed engagement with a horizontal gear 36. This toothed engagement is preferably designed to permit a certain degree of one-directional slipping, i.e. such as that associated with a ratchet mechanism.
The horizontal gear 36 is connected to a vertical shaft 38 which provides driving force for rotation about a vertical axis.
Vertical shaft is connected to drive an indexing wheel 40 which contacts a pawl 42 and a sensor 44. Pawl 42 provides a limited fixed rotation in radians. That is, it will for a single partial rotation allow only a certain number of radians to pass before locking the indexing wheel by entering notch 45 (as seen in FIGS. 2-4) and preventing the shaft from rotating. Pawl 42 may be released by a number of mechanisms, including a push button, lever 45a, or automatic release. The sensor 44 counts the number of times the wheel 40 is indexed.
The presently preferred cigarette is illustrated in FIG. 8. Cigarette wrapping paper forms an outer layer 46. Outer layer 46 has a selected air permeability such that a transverse air flow is maintained in the cigarette through the walls, i.e. the air passes through the heated flavorful substrate and carries the volatilized flavor component in an air current toward a consumer.
In a preferred embodiment, a sublayer 48 of the cigarette is a tobacco mat or tobacco flavored mat in thermal proximity to the outer layer. Finally, an interior 50 is preferably filled with tobacco. Discerning smokers recognize that the aroma of tobacco forms an important aspect of the taste component of smoking, and filling the interior with premium tobacco adds to the flavor.
Returning to exemplary FIG. 2, it may be seen that cigarette 12 has a first ("coal") end 50 which is inserted into the housing 30 of the lighter. Sealing ring 24 is rotatably mounted in an upper end 52 of the housing. Upon complete insertion, coal end 50 seats in a receptacle 54 formed with teeth 56. Teeth 56 grip the end of the cigarette and prevent rotation relative to the indexing wheel 40.
Linkage rod 32 may be flexible, allowing a downward deflection of vertical shaft 38 when pressure is applied to receptacle 54. The terminal end of vertical shaft 38 then may contact button 58. This button may be a "reset" or "initialization" button which starts controller 60 and begins a smoking cycle involving the cigarette and lighter. A power source 62 powers the system, and a heater 64 is connected to power source 62 via a conductor 66 and the controller 60.
Initially, the system is set to "off". Insertion of a cigarette causes the initialization button 58 to be reset and turn the system "on".
When a consumer draws on the filter, a pressure drop is sensed by a sensor in or connected to controller 60. The heater element is energized through conductor 66 and rises to a high temperature. The cigarette is in thermal proximity to the heater and the surface layer is heated. Heat is transferred to the flavor generating substrate (tobacco mat, tobacco, both, or other flavors) which evolves flavored vapors which the consumer ingests.
After sufficient power has been used or a preset time has elapsed (determined by the controller) to volatilize the flavor substrate, the heater is de-energized and disabled. Subsequent puffs will be to no avail unless the cigarette is rotationally advanced.
The consumer, who may desire subsequent puffs, advances the cigarette rotationally by moving lever 26 after release of pawl 42 from engagement with the indexing wheel. This drives the gears and advances the cigarette such that a new, fresh section of the cigarette and underlying flavor containing substrate is brought into thermal proximity with the heater. The cigarette is advanced the same angular distance as the indexing wheel, which wheel is formed with indentations or notches 45 into which the pawl falls. The indentations stop angular displacement and trigger the sensor 44 informs the controller that fresh substrate is available.
The angular distance between the indentations is chosen to give a uniform distance between discrete "stops" over a complete rotation of the cigarette. This number of stops equals the number of "puffs" which may be taken from a single cigarette. After each puff is taken, a counter notes the number of puffs. After a preselected number of puffs are taken, usually equaling the number of indentations, the system is switched off and disabled.
As shown in FIG. 8, the cross sectional area of the cigarette or other flavorful substrate is conceptually divided into "quadrants" which are determined by the number of radians in each quadrant, or, the angle theta. The overall cigarette, being somewhat circular in cross-section, generally has 360 degrees in its cross-section. If the cross section is divided into eight wedges, each containing a certain amount of surface area, the angle theta is 45 degrees. The number of discrete wedges may be increased, or decreased, to a point, and the number of available fresh areas to heat on the substrate may be correspondingly increased or decreased. Preferably, the number of available fresh surfaces in a substrate should be about eight, and may be from six to ten, or even from four to twelve. Certainly, there should be at least two for efficient utilization of the substrate.
Alternative preferred and simpler versions of present invention are illustrated in the drawings and described below.
FIG. 5 illustrates a version of the indexing mechanism which is "direct drive"; and has a single drive wheel 68 which may advance the cigarette in its angular rotation. Conveniently located external wheel protrusion 68a is that portion of the wheel which extends past the housing 30 of the lighter portion. The wheel is offset slightly from center to allow for the protrusion. As shown in FIG. 6, the drive wheel may have an external perimeter formed with grooves 69 which enable it to be rapidly turned without slippage from outside the housing of the lighter.
Returning to FIG. 5, a spring 70 keeps the wheel biased upwardly. Receptacle 72 is shown attached to guide frame 74 which receives the cigarette and maintains its position in thermal proximity to the heater 76. Guide frame 74 has transverse supports 74a and 74b which resist torsional stresses when the cigarette is rotated by actuation of the drive wheel 68 or otherwise handled by the consumer.
Upon insertion of a cigarette, the wheel 68 is pushed against spring 70, and contacts initialization button 78 mounted on controller 80. When the consumer draws on the cigarette substrate, pressure drop sensor 82 detects the drop in pressure and fires heater 76. The wheel is then rotated, and pawl mechanism 84 stops the rotation at a preselected point. The cycle is then repeated. Pawl 84 has a protrusion 86 which allows for release and rotation of the wheel. Sensor 88 counts the rotation cycles of the wheel and reports this number to the controller.
FIG. 7 shows a push-button advance embodiment of the present invention. The push button 90 is kept elevated by a biasing spring 92. A detent rod 94 is formed with a horizontal engaging pin 96, which fits in sliding engagement in a groove 98 formed in an indexing sleeve 100. When push button 90 is depressed, the detent rod 94 causes horizontal engaging pin 96 to slide downwardly in groove 98.
Groove 98, being formed in sleeve 100, is connected in rigid engagement to guide frame 102 which houses the cigarette. Groove 98 is formed on an angle such that when pin 98 slides therein downwardly, indexing sleeve is rotated in the direction of the arrow shown. At the end of the downward stroke, pin 98 contacts stop 104, and the user releases pressure on the push button 90. Biasing spring 92 causes the push button, detent rod, and horizontal pin to retract, whereupon pin 96 becomes lodged in recess 106 and rotational motion ceases. The apparatus then functions as described for the embodiment of FIGS. 1 and 5, for example.
The single heater also provides an unexpected benefit in that air flow management around the substrate is substantially simplified and simultaneously enhanced. Air flow, it is believed, will affect the aerosol formation and mixing vapor with ambient air may enhance aerosol formation. Applicants do not wish to be bound by this theory, but it is thought that a thorough mixing of ambient causes a subjective improvement in the overall quality of the taste component delivered and increased uniformity of delivery over the repeated course of use.
More specifically, as the heater does not move, a dedicated air channel opening 116 is formed in a sleeve about the cigarette, as more clearly shown in FIG. 9, which is a perspective view of the internal components of this embodiment of the lighter with the housing removed.
Heater 108 is connected to power via conductors 110. The heater is in thermal proximity with a flow guiding (or "ventilation") sleeve 112, which is maintained in static relation to the heater. Heat from the heater passes through aperture 116 which is contoured to match the heating surface of the heater. The lower portion 114 of the flow guiding sleeve is closed and substantially all of the air drawn when a user inhales comes through aperture 116. Alternatively, the lower portion 114 of the sleeve may be open, allowing the drawing of ambient air through a second aperture (not shown).
The heater may be formed from any suitable heater element, including platinum, quartz, titanium aluminides, iron aluminides, semiconductors, ceramics, cermet materials, or the like. Preferably, the heaters will have thermal and oxidative stability, e.g. such as those disclosed in U.S. Pat. Nos. 5,573,692; 5,659,656; 5,595,706; 5,498,855; 5,498,850; 5,468,963; 5,408,574; 5,224,498 and 5,093,894; each of which is incorporated by reference.
Such an arrangement allows for an increased velocity of transverse air flow, and possibly better mingling with the ambient air. As theoretically illustrated in FIG. 10, the velocity of air passing through the aperture 116 is large, illustrated by the arrows. This allows a greater flow to pass over the heater and heated cigarette which is giving off vapor and aerosol, for more efficient utilization of the cigarette substrate. Furthermore, where the transverse air flow intersects the longitudinal air flow, substantially more turbulence may be generated and provide additional desired mixing of the vapor product with ambient air, resulting in surprisingly enhanced flavor. This explanation is offered only by way of possible explanation; and the applicants do not wish to be bound by this theory.
Although the preferred method of heating is by resistive heating of an electrical resistive heating element, other methods such as inductive or heat radiation may be used as a way of transferring heat to the cigarette. An inductor, which in a preferred embodiment is a piece of magnetically susceptible material is placed either inside or external to the cigarette. It receives electromagnetic energy from a susceptor coil, warms up, and thereby transfers heat to the tobacco or other substrate. In other embodiments, a quartz lamp or laser light heat the tobacco substrate.
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A system for heating a cigarette to evolve an aerosol upon consumer request comprises a cigarette and a lighter. The lighter includes a housing into which the cigarette is inserted, and a stationary heater inside the housing is positioned in thermal proximity to the cigarette. The cigarette is rotatably mounted inside the housing. When a puff is desired, heat is applied to the cigarette to produce the aerosol. Prior to the next puff, the cigarette is slightly rotated to position a fresh portion of the cigarette in proximity to the stationary heater, and this procedure is repeated until the cigarette is spent.
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BACKGROUND OF THE INVENTION
1. Field of Invention
This invention pertains to three dimensional fabrics, and more particularly three dimensional fabrics having a continuous length in at least one dimension, and an apparatus for producing the same.
2. Description of the Prior Art
With the advent of modern fibers, three-dimensional fabrics have become candidates for structural members. These fibers include various synthetic materials, as well as graphite, silicon, boron, ceramic, glass or other similar filaments which until recently have not been associated with fabrics. Typically, a three-dimensional lattice is made of the fibers. The lattice is then impregnated with a reinforcing material such as a resin or ceramic, matrix. In the case of metal matrix composites, (or by the use of pre-impregnated yarns) the matrix may be woven right in, and cured by heat, etc. (uv). After the assembly has cured and solidified it could be reduced to its final shape by machining or other similar well-known methods.
However most of the methods to produce such fabrics was tedious because they did not lend themselves to automation. Furthermore, many methods and devices were capable of producing only fabrics of finite shapes and dimensions.
U.S. Pat. Nos. 4,080,915 and 3,904,464 illustrate the present state of the art.
OBJECTIVES AND SUMMARY OF THE INVENTION
An objective of the present invention is to provide a method and device for making continuously a three-dimensional fabric.
Another objective is to provide a method and device for making three-dimensional fabrics of different cross-sections.
A further objective is to provide a device which can be automatically operated at high speeds.
Yet a further objective is to provide a three-dimensional fabric which is relatively strong and is resistant to distortive forces.
These and other objectives and advantages shall become apparent in the following description of the invention. A three-dimensional fabric, made in accordance with this invention comprises a plurality of warp yarns arranged in a predetermined array, and two sets of orthogonal weft yarns interwoven with the warp yarns. The sets are laid in alternate courses and each course is interconnected at the opposed ends with the previous course of the same set.
The device for making the above fabric comprises a forming bed constructed and arranged so that it moves with respect to warp yarns, or vice versa the warp yarns move with respect to the bed while the fabric is woven. Means are provided to move in a reciprocating manner the yarns of each weft set in and out of the warp yarn matrix in cyclical strokes. Further means are provided for interlocking each weft course with a previous weft course of the same set in the middle of each stroke.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of the apparatus constructed according to the invention;
FIG. 2 shows a plan view of the apparatus of FIG. 1 with the top plate removed;
FIG. 3 shows a plan view of the top plate;
FIG. 4 shows a bottom view of the top plate;
FIGS. 5-7 show the relative positions of different elements of the invention during operation;
FIGS. 8a-e show the different types of cross-sections of three-dimensional fabrics that could be made with the apparatus;
FIG. 9 shows a mechanism for driving the members of FIGS. 1-7;
FIGS. 10 and 11 show alternate embodiments of the apparatus; and
FIG. 12 shows a longitudinal sectional view of the fabric made in accordance with each invention.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus for making three-dimensional fabrics, its method of operation and the structure of the fabrics shall now be described. It should be understood that in the following description the terms up, down, left, right and so on shall be used only for the sake of clarity and that the subject apparatus may operate in various other positions.
The apparatus is adapted two weave to two orthogonal weft yarns are alternately in the X and Y direction (shown in FIG. 2) around warp yarns extending in the Z direction, said Z direction being generally perpendicular to the plane defined by X and Y.
A fabric former bed 10 is secured perpendicularly to a base 12. The bed is hollow and its internal cavity is continuous with an opening 14 through base 12 allowing the fabric formed on the top face 16 of the bed to be drawn through the bed and base in a continuous fashion. A top plate 18 is disposed above the bed and it is provided with three groups of holes. The first group 20 guides the warp yarns towards the former bed 10 as can be seen from this guide the warp yarns are arranged in a preselected array of rows and columns X and Y. The weft yarns are woven between these warp yarns, with one set of weft yarn X being pushed along the rows of the array while the other set Y of weft yarns is pushed along the array columns. The second group of holes 22 guides the X weft yarns while the third group 122 guides the Y yarns. (The elements for weaving the X-yarns are identified from here on by two digit numbers while the corresponding elements for the Y yarns are indicated by the numeral 1 followed by the same number). The warp and weft yarns have been omitted from FIGS. 1-4 for the sake of clarity. A plurality of horizontal yarn guides 24 are mounted on a yarn guide push assembly 26. All the yarn guides have the same length and are disposed in parallel with each other as shown. The assembly 26 in its turn is mounted on yarn guide holder comprises two vertical spaced plates 30, 32 with two elongated holes 34, 36. The assembly 26 is provided with mounting pins 38, 40 (on each side of the assembly) which fit in and ride the lower camming surfaces 42, 44 of holes 34, 36 respectively.
Each yarn guide 24 is terminated in a vertical L-shaped head defined by a first leg 46 extending downward from the main body of the respective yarn guide, and a second, relatively shorter, leg 48. The yarn guide is relatively thin so that it can slip with ease between the warp yarns. This movement is facilitated by the short leg 48. The yarn guide is also provide with a first hole 50 and a second hole 52 disposed at the upper and lower ends of leg 46 as shown.
It is clear from FIG. 1 that the motion of assembly 26 (and therefore the yarn guides) is limited by the shape and size of holes 34, 36. Preferably these holes are arranged and disposed so that in the farthest position of the assembly 26 from former bed 10, (FIG. 1) the guide members are adjacent to the bed. As the assembly moves toward the bed the yarn guides move across the top of the former bed until they move past the bed. As shown in FIG. 1, the holes 34, 36 are shaped so that in the farthest position of the assembly from the former bed, the lower end of leg 46 of each yarn guide is disposed slightly below the top surface 16 of the bed. As the assembly is moved toward the bed (in the X direction) camming surfaces 42, 44 force the assembly diagonally upward to insure that leg 46 clears the top of the former bed.
Mounted on, or adjacent to fabric former bed 10 are a plurality of needles 54. Preferably each needle 54 is mounted in parallel on needle assembly 56. The needles 54 extend vertically, as shown. Assembly 56 is secured between two vertical guides 58 which allow the assembly to move freely up and down (i.e. in the direction). The assembly 56 is provided with a hole 60 which is provided so that an activating rod (not shown) can engage the assembly to move the needles 54 as required.
Each needle 54 ends in an upper curved head 62 and beneath the head 62 there is a (has p) 64 pivotably connected to the needle shaft which may rotate in the vertical plane. These types of needles are well-known in the knitting industry. The needles and their assembly is arranged and disposed so that they can move between a lower position (shown in FIG. 1) in which needle head 62 is below the top surface 16 of the former bed 10 to an upper position (shown in FIG. 6).
There is also a yarn retainer mechanism 80 which is also secured to the base 12 as shown. Near its upper end the mechanism has a transversal, i.e. horizontal slot 82 which houses a retainer bar 84. The retainer bar is free to move horizontally in a transversal direction (i.e. Y) with respect to yarn guides 24. The bar ends in a pointed tip 86, and is provided with a pin 88 provided to engage a retainer bar activating rod (not shown).
The top plate 18 may be affixed to walls 30, 32, 130, 132 of the yarn guide holders. In addition to holes 20,22, 122 the top is also provided with two elongated openings 66, 166. On the bottom side of the top plate (see FIG. 4) a guide deflector assembly 68 is mounted on opening 66 in such a manner that the assembly is movably by longitudinally along opening 66. The guide deflector 68 has a plurality of slots 70 extending transversally across its width. Preferably one end of each slot is slightly enlarged as at 72. Except at 72, the width of each slot is slightly larger than the width of the yarn guides. The guide deflector 68 is positioned so that each of slots is facing a corresponding yarn guide across the former bed.
The operation of the apparatus is now described in conjunction with FIGS. 5-7. Initially yarns form separate spools (not shown) are threaded through the appropriate holes of top plate 18. The warp yarns 74 are secured to a member 76 disposed within or underneath former bed and used to tension said warp yarns and to draw the formed fabric downward; away from surface 16. The weft yarns are each threaded through the top 50 and bottom 52 holes of the respective yarn guides 4. FIG. 5 shows the initial position of yarn guide 24. In a previous cycle weft yarn 78 has been pulled through warp yarns 77 around needle 54, forming a loop 81 and back through warp yarns 74 so that it now extends toward guide 24 blow retainer bar 86. The second set of weft yarns 178 lie on top of the first set 78 as shown.
For the next course, the yarn guide 24 starts moving toward guide deflector 68. As previously explained, because of the shape of holes 34, 36 in yarn guide holder 30, the yarn guide first rises at an angle with respect to horizontal so that the extreme lower end of 48 clears the retainer bar 86, and the yarns of the second set 178. Once passed there obstacles the yarn guide moves essentially horizontally. Simultaneously needle 54 rises upward with loop 81 remaining on the shaft but shifting to the base of the needle knocking the hasp over. Preferably the movements of the yarn guide 24 and needle 54 are synchronized so that they reach their extreme position substantially at the same time. While the yarn guides weave the weft yarn through the warp yarns in the X direction its lower leg 46 tamps down the Y weft yarns underneath. As shown in FIG. 6, the guide deflector is positioned so that the short leg or nose 48 of the yarn guide 24 reaches the guide deflector just as lower hole is approximately even with needle 54. From this point on the yarn guide slips into the corresponding slit 70 within the guide deflector until the lower leg 46 moves past needle 54. Next, the guide deflector moves in the Y direction transversally to the yarn guide until leg 46 passes yarn 78 across the face of needle 54. The yarn guide 24 is then moved back toward its original position. However since its nose 48 is still engaged by guide deflector 68, the leg 46 moves past the opposite side of needle 54 so that yarn 78 is looped around needle head 62. As the yarn guide moves back, the retainer bar is retracted releasing some yarn 78. The extra slack is taken up by the yarn guide, thus tightening the new loop formed on the needle. This same action also pulls the yarn 78 snugly around the warp and weft yarns disposed adjacent to yarn 78 at the starting point of yarn guide 24. Once the yarn guide 24 completes its stroke, the needle 54 moves down. Since the loop 81 formed in the previous course, is maintained in its position by the tension of the yarn the new loop 83 (FIG. 7) is pulled through old loop 81 by needle 54. It can be seen that in this manner each warp yarn of a course is interlocked or secured to the previous course. This motion also performs the fabric edge on the side opposite needle 54. When the yarn guide completes its cycle the retainer bar is moved back, to lie transversally across the yarns as shown in FIGS. 5 and 7. The purpose of the yarn retainer is to keep the respective weft yarns from jamming up against the Z-warp yarns during the weaving process. Now a course is laid in the y direction. Thus consecutive courses in the X and Y directions are laid in an identical fashion, continuously and the formed fabric is drawn through the former bed.
The cross-sectional shape of the formed fabric is determined by the pre-selected array of the warp yarns. In FIGS. 1-7 a 5×5 square array has been selected. For this array six yarn guides are positioned in both X and Y directions. In general for an N×M array N+1 yarn guides are needed in one direction and M+1 yarn guides are needed in the other. In this manner the warp yarns are woven to both the X and Y yarns. Alternatively, the last guide yarn in either the X- and Y-direction may be omitted.
The warp yarns may be formed into any desired array. For example, they may be arranged to form a fabric having a square, rectangular, L-shaped, U-shaped or H-shaped cross-section. These various alternatives are shown in FIGS. 8a-h. Of course the former bed, yarn guides and needles must be laid out accordingly.
A drive mechanism 90 is provided preferably underneath 12 as a motive means for operating the different members of the device. As shown somewhat schematically in FIG. 9, the mechanism 90 comprises a motor 90 which turns shift 94 at a continuous speed. Mounted on the shaft are a plurality of cams 92 for activating each element. The cams are mounted on the shaft at a predetermined angle so that each element is operated at the proper time. Cams 92 are operatively connected by rods (such as rods 96 in FIG. 1) to the respective elements (such as the yarn guide assembly 26) to convert the rotational movement of the cams into corresponding translational (i.e. horizontal or vertical oscillational) movement of the respective elements for the X and Y warp yarns may be operated form a single axle, or a second axle 194 may be provided at right angle with axle 94, and each axle may be used to drive the elements of one of the systems.
In summary, the different elements for the X-weft system operate in the following order (the movement directions are defined in the coordinate system shown in FIGS. 1 and 2).
______________________________________STEP ELEMENT MOVEMENT______________________________________1 Yarn retainer +Y2a Yarn guide +X2b Needles +Z3 Guide deflector -Y4 Yarn retainer -Y5 Yarn guide assembly -X6 Needles -Z______________________________________
The elements for the Y weft system are operated in the same sequence, after which the whole cycle is repeated.
In addition to the yarn guide and needle weaving scheme described above, alternate schemes may also be utilized for the same purpose. For example in the embodiment of FIG. 10 the weft yarn is attached to a guide bar 202 and needles 204 move horizontally through the warp yarns 206 as shown.
According to another embodiment shown in FIG. 11, yarn guide 210 moves weaves leaving yarn 212 through warp yarns 214. Opposite the yarn guide there is a shuttle or looper mechanism 216 which is used to loop another thread through the lacing yarn.
A cross-sectional view of the final product is shown in FIG. 12. Each weft yarn 78 and 178 is woven through warp yarns 74. At one side of the fabric the yarns are formed into loops 81 as consecutive courses of weft yarns in the X direction are laid or woven, each X course is interconnected to the previous X course at both ends; at one end the connection is made by the continuous X yarns. At the other end, the loops of the course engage the corresponding loop of the previous course. The courses in the Y direction are similarly interconnected. The X and Y courses alternate. In this description, a course comprises a plurality of parallel yarns oriented respectively either in the X or the Y direction which have been woven between the Z warp yarns during a single cycle as described above.
In the above description the term "yarn" has been used in a generic sense to describe the materials being interwoven in three dimensions. Its obvious that for an m×n material, m×n warp yarns; and m+n+2 weft yarns are used. Obviously these yarns can have different compositions. While the weft yarns have to be relatively flexible because they are bent at a fairly small radius of curvature, the warp yarns are held relatively straight so that they can be fairly stiff. The following materials could be used, although it is evident that other materials may be just as suitable as yarns: a single monofilament; a plurality of monofilaments (twisted or untwisted) made out of natural or manmade fibers; wires or rods made of copper, aluminum, graphite, steel, and so forth.
Obviously numerous modifications may be made to the subject invention without departing from its scope as defined in the appended claims. For example for relatively stiff warp yarn such as metallic rods, it may be more practical to move the forming bed longitudinally with respect to the rods rather than drawing the rods through the bed.
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A method and device for forming a three-dimensional fabric continously is disclosed. The fabric has a plurality of warp yarns arranged in a two-dimensional array and two sets of weft yarns are interwoven with the weft yarns to form alternate courses. The courses of corresponding weft yarns are interlocked at opposite sides to form a fabric with high dimensional stability to resist deforming. The method and device can be operated at high speed to produce fabrics of any length.
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to methods and apparatus for gravel packing a single zone in a well.
When producing fluids from one or more zones in a well, it is sometimes desirable to gravel pack the zone or zones from which fluid is being produced. Such packing is helpful in cases where the well is in an unconsolidated formation. When fluid flows through such a formation into the well bore, loose formation sand and the like may be carried with the fluid into the bore and produced to the surface of the well. This situation is harmful both to the formation, causing its collapse and preventing further fluid flow, and to the producing equipment, causing severe wear.
In order to prevent such production in unconsolidated formations, a fine gravel pack is placed in the bore at the level of the zone from which fluid is to be produced. Typically, the well bore is cased and perforated at a production zone, although open holes (uncased well bores) are packed as well. A plug is used to seal the bore beneath the zone. Immediately above the plug, a slotted screen or liner is positioned adjacent the zone and a fine gravel is packed on all sides of the screen. Fluids are then produced from the zone through the gravel pack which acts as a filter to prevent production of particulate matter from the formation to the surface of the well.
Various downhole tools provide means for lowering a screen to a selected zone and packing gravel about the screen. Such tools are typically lowered on tubing and include conduits which connect the tubing to the lower part of the tool at which point the screen is suspended. A gravel slurry is pumped down the tubing to the exterior of the screen to deposit gravel about the screen. The fluid from the slurry passes through the screen and returns to the surface of the well in the bore annulus. Many past tools are designed for packing more than one zone in a single well and may require more than one trip to the level of the zone being packed. All of the tools, whether designed for single or multiple zone packing, include various means whereby ports or valves are open and closed, typically in response to tubing manipulation by the well operator, to either treat the zone with a fluid prior to packing or to change the fluid-flow configuration in the tool subsequent to packing in order to clean the tubing and annulus with a clean fluid. Such opening and closing is often effected by shearing pins. Tools with such ports or valves are disadvantageous due to their mechanical complexity.
In contrast, the present invention overcomes all of the limitations and disadvantages of the prior art by providing a new and advantageous method and apparatus for gravel packing a zone in a well in which packing and thereafter flushing the downhole equipment is achieved without manual operation of downhole ports or valves. A further advantage of the present invention includes provision of an apparatus which permits setting a screen on the bottom of a well without the necessity of establishing a reference and without damaging the screen.
The present invention includes coaxially aligned inner and outer conduits which depend downwardly from a crossover that is adapted to be suspended from the bottom of a tubing string. The crossover permits fluid communication between the tubing string and the annulus between the inner and outer conduits as well as between the inner conduit and the annulus between the tubing and the casing. Beneath the crossover, an elastomeric packer extends about the circumference of the outer conduit. Anchor slips are provided beneath the packer to permit compression of the packer into a bore-sealing condition when the slips are anchored in the bore. A slidable screen support is positioned over the outer conduit beneath the packer. A clutch interconnects the screen support with the conduit, such being engaged so as to transmit rotary and longitudinal movement to the screen support when the support is at its lowermost position on the conduit. A screen is threadably attached to the support.
When the apparatus is lowered into a well bore and when the screen hits the bottom, the clutch between the support and outer conduit disengages and permits tubing string manipulation to effect setting of the anchor slips and compression of the packer. Thereafter, a gravel slurry is pumped down the tubing to deposit gravel about the screen. The fluid passes through the screen and returns to the surface via the inner conduit and the bore annulus. After packing, the packer seal is disengaged and a clean fluid is circulated downwardly through the bore annulus and then upwardly in the tubing to flush out gravel which might be present. The tubing is raised to engage the clutch and then rotated to unscrew the screen and thereafter raised to the surface leaving the gravel packed screen downhole.
These and other attendant advantages of the instant invention will become apparent in view of the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a, 1b, 1c, 1d, 1e and 1f, together, constitute a longitudinal cross-sectional view of a preferred embodiment of the invention suspended in a well casing, FIGS. 1b-1d being successive downward continuations of FIG. 1a.
FIG. 2 is an enlarged planar elevation view illustrating the details of the drag block J-slot construction in the drag block sleeve.
FIG. 3 is a cross-sectional view of a portion of the instant embodiment of the invention with the anchor slips engaged with the well casing and with the packer in a casing-sealing condition.
FIGS. 4a and 4b are a view of the lower portion of the instant embodiment of the invention in an open hole at the bottom of a well casing, FIG. 4b being a successive downward continuation of FIG. 4a.
FIG. 5 is the view of FIG. 3 after packing and after disengagement of the anchor slips and unsealing the packer.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings, particularly 1a-1f, indicated generally at 10 is the preferred embodiment of the gravel packer of the invention. The preferred embodiment is shown suspended from a tubing string 12 in a casing 14 of a well drilled in formation 16. Casing 14 extends to an open hole 17 (FIGS. 4a and 4b) of the well bottom. Tubing string 12 extends from the gravel packer to the surface of the well.
Speaking now only generally of the structure and operation of the gravel packer, a screen 22 (FIG. 1f) is suspended from the bottom of the packer. The packer is lowered to the bottom of the well (or to a plug in the well) at which point a gravel pack is to be created for producing fluids from the formation through the pack and up the well. At that point, anchor slips 24, 26 are engaged with the well casing to prevent further downward movement and pressure is applied via the tubing string to deform an elastomeric packer indicated generally at 28 into sealing engagement with the well casing. Thereafter, a gravel slurry is pumped down the tubing string through an outer conduit 30, and out gravel packing ports 33, 34 (FIG. 1e). The fluid in the slurry passes through screen 22 to its interior while depositing gravel about the outside of the screen. The fluid travels up an inner conduit 33 to the surface of the well via the annulus between the casing and the tubing. Thereafter, the anchors are disengaged from the well casing to unseal the packer and a cleaning fluid is circulated to flush away stray gravel. The tubing string is then rotated, thus unscrewing the screen from the gravel packer, and the packer is raised on the tubing leaving the screen and gravel pack in position for fluid production from the formation.
Examining in more detail the structure and cooperation of the parts of gravel packer 10, tubing 12 is attached to the gravel packer via a cylindrical adapter 34. Adapter 34 includes helical threads 36 on the interior of its upper end (to which tubing 12 is threadably attached) and threads 38 on its lower outside surface to which a crossover 40 is threadably engaged. Crossover 40 includes a cylindrical outer piece 42 and an inner piece or block 44 in the shape of a rectangular block. Block 44 includes bores 46, 48, bore 46 passing through the block horizontally and being in communication with ports 50, 52 formed in outer piece 42. Bore 48 depends downwardly in block 44 from bore 46. The block is fixedly mounted into position as shown. The block is of a size so that fluid may pass from the upper portion of outer piece 42 to the lower portion. Conduit 30 is threadably engaged with the lower portion of piece 42; thus, the upper portion of piece 42 (and hence the interior of tubing 12) is in fluid communication with the annulus between inner conduit 32 and outer conduit 30.
Inner conduit 32 is threadably engaged via threads 54 with bore 48 of block 44. Accordingly, bore 46 as well as the annulus between tubing 12 and casing 14 (via ports 52) is in fluid communication with the interior of conduit 32. As can be seen in FIG. 1a, various O-rings are appropriately positioned adjacent threaded connections to prevent fluid communication through the connections.
An upper shoe 55 extends about the outer circumference of conduit 30, the lower surface of shoe 55 abutting against packers 56. Packers 56 are formed of an elastomeric material and extend about the outer circumference of conduit 30. The lower surface of packers 56 abuts an upper surface of a lower shoe 58. The lower shoe likewise extends about the circumference of the outer conduit and is threadably engaged to a slip body 60.
The slip body is cylindrical in shape and includes six incline surfaces, two of which are surfaces 62, 64. All of the surfaces are formed at the same angle as surfaces 62, 64 and are all spaced at 60° intervals about the circumference of slip body 60. Six anchor slips like slips 24, 26, are distributed about the circumference of the slip body immediately therebeneath. Each of the slips includes flat surfaces like surface 66 on slip 24 which are flush against each slip's associated incline surface on slip body 60.
The six slips are engaged at their lower ends to a split ring collar 68. Collar 68 is of conventional construction and permits both pivotal and radially outward movement of the slips as will later be more fully explained.
Indicated generally at 70 is a drag block assembly. Included in assembly 70 are four drag blocks, like drag blocks 72, 74. The drag blocks are spaced at 90° intervals about the circumference of a drag block sleeve 76. The sleeve is substantially cylindrically shaped and is carried on a mandrel 78. Mandrel 78 is threadably engaged at its upper end to the lower end of conduit 30. The lower mandrel includes four lugs, like lug 80, each lug extending into a corresponding slot, like slot 82 in sleeve 76. FIG. 2 is a view of the slot in the sleeve as viewed from the inside of the sleeve.
Each drag block includes a surface which is biased toward casing 14 by a spring, like spring 84 in drag block assembly 70. The surface of each drag block has a relatively high frictional coefficient. Each drag block is restrained from further radially-outward travel by upper and lower retainers, like retainers 84, 86, respectively, for drag block 74. When the gravel packer is contained in conventional casing, like casing 14, each of the four drag blocks is firmly biased by the springs against the inside casing wall.
Mandrel 78, in FIG. 1c, includes an interior thread at its lower end which is threadably engaged with the upper end of a lower mandrel 88. The lower mandrel is a downward extension of mandrel 78 and, like mandrel 78, is in coaxial alignment about conduit 32. The lower end of mandrel 88 includes a shoulder 90 about the circumference of the mandrel. Also included are four lugs like lugs 92, 94 which extend upwardly from shoulder 90. Each lug is formed along approximately 50° of arc about the circumference of mandrel 88. The lugs are distributed at 90° intervals about the circumference of the mandrel. Each lug is tapered from its top center to its edges.
A slidable sleeve 96 is mounted over mandrel 88. The sleeve is substantially cylindrically shaped and is in coaxial alignment with mandrel 88. Slots, like slots 98, 100 are formed on the inner circumference of sleeve 96. Four slots are so formed, each being of a size sufficient to just receive one of the lugs on mandrel 88, like slot 98 receives lug 92 and slot 100 receives lug 94. When the sleeve is so fitted over the slots, it is restrained from relative rotation with respect to mandrel 88. If the sleeve is raised to the point where the lugs are not contained within the slots, the sleeve is rotatable on mandrel 88.
The lower end of sleeve 96 includes a threaded connection 102 which is connected to a lower case 104. The lower case is cylindrically shaped and at its lower end includes a threaded connection 106 (FIG. 1e). Connection 106 couples the lower case to a lower port body 108. The port body includes a bore 110 which extends through the vertical axis of the body along its length. Contained within bore 110 and passing therethrough is conduit 32. Gravel ports 33, 34 place bore 110 in fluid communication with the annulus between the casing and the tool.
A tubing adapter 112 is threadably secured to the lower end of port body 108 and is fixed thereto with set screws 114, 116. Tubing adapter 112 includes a bore 118 which is centered therein and extends through the adapter along its length. Conduit 32 passes through bore 118. A back-off sub 120 includes threaded connections at its upper end which are in threaded engagement with threads on adapter 112 and at its lower end which are threadably engaged to threads on the upper end of screen 22. A cylindrical wash pipe 122 is threadably mounted on the lower end of the tubing adapter.
A conventional one-way check valve 126 is mounted in washpipe 122 as shown. Valve 126 permits fluid flow in the washpipe and conduit only in an upward direction. O-rings indicated generally at 128 are in sealing engagement between conduit 32 and port body 108.
Screen 22 includes a plurality of fine holes indicated generally at 124 on its side about the circumference thereof. As will later become more fully apparent, holes 124 are of a size small enough to prevent gravel used to pack the screen from passing therethrough but are of a size large enough to permit fluids produced from the formation to pass through the gravel and into the screen.
Operation
When it is desired to pack a single zone in a well, the gravel packer is suspended from tubing string 12 and is lowered to the zone to be packed. During the lowering process, the tool is in the condition shown in FIGS. 1a-1f. The slips, like slips 24, 26 are all in their radially innermost position. As the tool is lowered, drag blocks 72, 74 slide against casing 14 and lug 80 is generally in the position illustrated in FIG. 2. Lug 80 may reciprocate between the position shown in FIG. 2 and a position directly beneath the position of FIG. 2; however, lug 80 will not travel along the dashed line in FIG. 2 since, as will be later more fully explained, rotational movement of the tubing string is required for lug 80 to so travel.
The slots within sleeve 96 (FIG. 1d), like slots 98, 100, have received in them their associated lugs on mandrel 88. During the lowering process all of the structure attached to the sleeve is hanging from the sleeve which is prevented from further downward movement by shoulder 90 on mandrel 88.
When screen 22 reaches the bottom of the well, the lower end of the screen strikes the bottom of hole 17 as shown in FIG. 4b. The tubing is able to continue further downward movement since mandrel 88 in FIG. 1d begins downward movement relative to sleeve 96 after the screen hits the bottom. As soon as the screen hits the bottom, the operator notices a reduction in weight of the tubing string, thus indicating to the operator that the screen is on the bottom. Thereafter, the operator lowers the tubing until mandrel 88 has moved downwardly from sleeve 96 to approximately the position illustrated in FIG. 4a. This insures that the lugs on the lower end of the mandrel are disengaged from the slots in sleeve 96, thus permitting rotation and a small range of longitudinal movement of the drill string without moving the sleeve or any structure which depends from the sleeve, including screen 22.
After the position of FIGS. 4a and 4b is achieved, the anchor slips, like slips 24, 26 are engaged with the casing and packers 56 are compressed to form a seal. To engage the anchor slips, the tubing string is lifted slightly, thus assuring that each of the lugs on mandrel 78, like lug 80 is at the position in its associated slot, as shown in FIG. 2. Thereafter, the tubing string is rotated to the right causing movement of the lug along the dotted line into the vertical leg on the right in FIG. 2. As soon as each lug is aligned in its associated vertical leg, the tubing is moved downwardly. Since the drag blocks are in frictional engagement with the wall's interior casing surface, the drag blocks maintain collar 68 and each of the anchor slips in a fixed position relative to downward movement of slip body 60. As the slip body moves downwardly, each of the slips is forced radially outwardly due to the action of the incline surfaces of the slip body, like surface 62, against the flat surface, like surface 66, on each of the slips. Ultimately, the slips are forced into contact with the well casing and prevent further downward movement by virtue of the grabbing action of the slips against the casing. As weight is set on the tubing string, the elastomeric packer 56 deforms into sealing engagement with the casing as shown in FIG. 3. Accordingly, fluid communication between the casing annulus above and below the packer is prevented.
After sealing the casing, the seal may be tested by injecting fluid under pressure at the surface into the annulus between tubing 12 and casing 14. Check valve 126 prevents passage of the fluid in the annulus through bores 50, 52 (FIG. 1a) into bore 46 and through conduit 32. Thus, if packer 56 has formed an effective seal, there is no pressure drop in the annulus when pressure is applied thereto by way of fluid injection.
After testing the seal, gravel packing of the screen may proceed. A gravel slurry is injected into tubing 12 at the surface. The slurry is a fluid which contains gravel suspended therein. The slurry descends downwardly in tubing 12 through crossover 40 into the annulus between the outer surface of conduit 32 and the inner surface of conduit 30. Mandrel 78 extends downwardly from conduit 30 and lower mandrel 88 extends downwardly from mandrel 78, each mandrel forming a continuous annulus about conduit 32 through which the slurry passes. The slurry continues through a somewhat larger annulus formed between the outer surface of conduit 32 and the inner surface of casing 104; through the annulus between the outer surface of conduit 32 and the inner surface of bore 110; and out gravel packing ports 33, 34. Such flow is indicated by arrows in FIGS. 4a and 4b.
The flow continues downwardly into hole 17 and through holes 124 in screen 22. As will be recalled, the gravel is sized slightly larger than holes 124. As the flow continues, gravel in the slurry is deposited and packed about the exterior of screen 22. The fluid from the slurry passes through holes 124 into wash pipe 122 and upwardly through valve 126 in washpipe 122. Conduit 32 communicates with bore 46 in crossover 40 (FIG. 1a) thus permitting the fluid from the slurry to pass through ports 50, 52 into the annulus between tubing 12 and casing 14 and from thence upwardly to the surface.
The flow of slurry down tubing 12 with the return of fluid from the slurry up the annulus continues until the operator notes an increase in pressure in tubing 12 which indicates that holes 124 in screen 22 are covered and that the screen is packed. After the operator determines, by way of measurement of pressure in tubing 12, that the screen is sufficiently packed, the flow of slurry is disconnected and packers 56 are unsealed. Packers 56 are unsealed by a simple upward movement on the tubing string. No rotation is required. As can be seen in FIG. 2, each of the lugs like lug 80, when the slips are anchored and the packer is set, are in the vertical leg to the right on slot 82. When upward movement on the tubing string occurs, lug 80 travels from the vertical leg along the dashed line against the upper surface of the slot to the position shown in FIG. 2, thus returning the drag block assemblies and slips to the position of FIG. 1b. When the slips are released from their engagement with the casing, packers 56 decompress and likewise return to the configuration of FIG. 1b. It should be noted that only a slight upward movement is required to disengage the anchors and unseal the packers. Sleeve 96 remains in substantially the same position with respect to the lugs on the lower end of mandrel 88 as that illustrated in FIG. 4a.
After the packers are unsealed, it is desirable to pump a clean fluid from the surface into the annulus between tubing 12 and casing 14. Check valve 126 prevents flow from the annulus into the interior of conduit 32 via ports 50, 52 in the crossover. Since the packers are unsealed, the flow of clean fluid continues downwardly beyond the packers and into hole 17 and from thence into gravel packing ports 33, 34. The screen is packed with gravel so the flow of clean fluids enters gravel packing ports 33, 34 and passes upwardly through the annulus in which the slurry traveled downwardly. This flow is illustrated by arrows in FIG. 5. The upward flow of clean fluid continues into tubing 12 to the surface. The flow of fluid washes away any stray gravel which may remain.
After such washing, tubing 12 is raised until the slots in sleeve 96, like slots 98, 100 are engaged with their associated lugs at the bottom of mandrel 88. When the lugs and slots are engaged, rotational movement of the tubing string can be translated to sleeve 96 and to all of the structure depending from the sleeve. After such slot and lug engagement, the operator rotates the tubing string to the right thus unscrewing the threaded connection between tubing adapter 112 and back-off sub 120. The tubing string is then raised thus raising the tool and leaving back-off sub 120 and screen 22 downhole in a fully packed condition.
While the invention has been particularly shown and described with reference to the foregoing preferred embodiment, it will be understood by those skilled in the art that other changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined in the appended claims.
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Apparatus adapted to be lowered on a tubing string for setting a gravel pack at the bottom of a well. Conduits provide a gravel-slurry flow path from the bottom of the tubing to a screen which is suspended from a housing at the lower end of the conduits. A packer is provided between the tubing and the housing for sealing the well bore during gravel packing. When the screen hits the bottom of the well, a clutch connected between the housing and the conduit disengages to prevent transmission of tubing movement to the screen during the gravel packing process. Upon packing completion, tubing string rotation releases the screen to permit raising of the apparatus on the tubing string.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a 35 USC 371 application of PCT/EP2006/068499 filed on Nov. 15, 2006.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is based on a high-pressure pump, in particular for a fuel injection apparatus of an internal combustion engine.
2. Description of the Prior Art
A high-pressure pump of this kind is known from DE 102004027825 A1. This high-pressure pump has at least one pump element equipped with a pump piston that is driven into a stroke motion and delimits a pump working chamber. During the suction stroke of the pump piston, fuel is drawn from a fuel inlet via an inlet valve and during the delivery stroke of the pump piston, fuel is displaced from the pump working chamber via an outlet valve into a high-pressure region, for example a reservoir. The outlet valve has a valve member at least approximately in the form of a ball, a part of whose upper surface, functioning as a sealing surface, cooperates with a valve seat situated in a valve housing. In the open state when the sealing surface of the valve member is lifted away from the valve seat, the valve member opens a first flow cross section between the valve member and the valve housing. Downstream of the sealing surface, a second flow cross section is formed between the valve member and the valve housing. The outlet valve is embodied so that in the open state of the valve, the second flow cross section between the valve member and the valve housing is smaller than the first flow cross section situated in the vicinity of the sealing surface of the valve member. As a result of this, there is a lower flow speed and therefore a higher static pressure in the region of the sealing surface of the valve member than in the region of the second flow cross section. This improves the flow through the valve since the valve member opens in a stable fashion. Due to the hydraulic forces produced, however, the outlet valve can have a tendency to vibrate in some circumstances so that the outlet valve does not remain open in a stable fashion but instead opens and closes several times, interfering with the operating behavior of the high-pressure pump and causing a significant amount of strain on the high-pressure pump due to pressure peaks that occur in the pump working chamber when the outlet valve is closed. This also leads to a large amount of wear on the valve member and/or the valve seat. Moreover, the valve member can also execute movements perpendicular to its stroke direction, causing the valve member to strike the valve seat from different directions during the closing of the valve, which likewise leads to a large amount of wear.
SUMMARY AND ADVANTAGES OF THE INVENTION
The high-pressure pump according to the invention has the advantage over the prior art that the flow through the inlet valve and/or the outlet valve is further improved and an inexpensive ball is used as the valve member. The enlarged third flow cross section provided here achieves a particularly stable opening of the inlet valve and outlet valve since the compressive force acting on the valve member in the opening direction is further increased in the region of the third flow cross section. As a result, in addition to improving the flow through the valve, this also improves the service life of its components and therefore of the high-pressure pump as a whole. The enhanced flow through the valve improves the filling of the pump working chamber and the high-pressure region.
The invention simplifies the manufacture of the valve since it is unnecessary to manufacture any undercut in the valve housing in order to produce the third flow cross section that is larger than the second flow cross section. One embodiment achieves a reliable guidance of the valve member so that it is unable to execute any uncontrolled movements perpendicular to its stroke direction, thus making it possible to minimize the wear on the valve member and valve seat. An insert piece according to the invention can simultaneously function as a support for a closing spring acting on the valve member. It is also possible to prevent uncontrolled movements of the valve member perpendicular to its stroke direction.
BRIEF DESCRIPTION OF THE DRAWINGS
Two exemplary embodiments of the invention are shown in the drawings and will be explained in detail below.
FIG. 1 shows a longitudinal section through a high-pressure pump for a fuel injection apparatus of an internal combustion engine,
FIG. 2 shows an enlarged longitudinal section through a first exemplary embodiment of an outlet valve of the high-pressure pump in the open state,
FIG. 3 shows a cross section through the outlet valve in FIG. 2 , along line III-III,
FIG. 4 shows a longitudinal section through a second exemplary embodiment of an outlet valve in the open state, and
FIG. 5 shows a cross section through the outlet valve in FIG. 4 , along line V-V.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a high-pressure pup 10 for a fuel injection apparatus of internal combustion engine that is preferably embodied in the form of an autoignition internal combustion engine. The high-pressure pump 10 delivers highly pressurized fuel to a reservoir 12 from which fuel is drawn for injection into the internal combustion engine. A fuel delivery pump 14 supplies fuel to the high-pressure pump 10 . The high-pressure pump 10 has at least one pump element 16 that has a pump piston 20 driven at least indirectly into a stroke motion by a drive shaft 18 of the high-pressure pump 10 . The pump piston 20 is guided in a sealed fashion in a cylinder bore 22 extending at least approximately radially in relation to the drive shaft 18 and delimits a pump working chamber 24 in the outer end region of the cylinder bore 22 oriented away from the drive shaft 18 . The drive shaft 18 has a cam or a shaft section 26 eccentric to its rotation axis 19 that produces the stroke motion of the pump piston 20 with the rotary motion of the drive shaft 18 . The pump working chamber 24 can be connected to a fuel inlet coming from the fuel delivery pump 14 by means of an inlet valve 30 embodied in the form of a check valve, which opens toward the pump working chamber 24 . The pump working chamber 24 can also be connected to a fuel outlet, which leads to the reservoir 12 , by means of an outlet valve 32 embodied in the form of a check valve that opens away from the pump working chamber 24 . During the suction stroke, the pump pistol 20 in the cylinder bore 22 moves radially inward so that the volume of the pump working chamber 24 is increased. During the suction stroke of the pump piston 20 , the inlet valve 30 is opened due to the resulting pressure difference since the fuel delivery pump 14 generates a pressure that is higher than the pressure prevailing in the pump working chamber 24 so that fuel supplied by the fuel supply pump 14 is sucked into the pump working chamber 24 . During the suction stroke of the pump piston 20 , the outlet valve 32 is closed since a higher pressure prevails in the reservoir 12 than in the pump working chamber 24 .
By way of example, the outlet valve 32 will be described in greater detail below in conjunction with FIG. 2 . For example, the outlet valve 32 is inserted into a bore 34 of a housing part 36 of the high-pressure pump; the bore 34 opens into the cylinder bore 22 approximately radial to the longitudinal axis of the cylinder bore 22 , for example. In this case, the bore 34 has regions with different diameters; an end region 34 a of the bore 34 opening out into the cylinder bore 22 has the smallest diameter. At its other end oriented away from the cylinder bore 22 , the end region 34 a is adjoined by another region 34 b whose diameter increases in the direction oriented away from the cylinder bore 22 . The region 34 b can, for example, be embodied as at least approximately the shape of a truncated cone and constitutes a valve seat for a valve member of the outlet valve 32 , which valve member will be described in greater detail below. At its end oriented away from the cylinder bore 22 , the seat region 34 b is adjoined by another region 34 c that has a significantly larger diameter than the end region 34 a and the seat region 34 b . This yields an annular shoulder 38 oriented away from the cylinder bore 22 at the transition from the seat region 34 b to the region 34 c . The transition from the annular shoulder 38 to the region 34 c can, for example, be rounded as shown in FIG. 2 . At its end oriented away from the cylinder bore 22 , the region 34 c is adjoined by a region 34 d whose diameter is smaller than the diameter of the region 34 c . The transition from the region 34 c to the region 34 d can, for example, be rounded or can be embodied approximately in the form of a truncated cone. In relation to the region 34 d , the region 34 c consequently constitutes an undercut in the bore 34 . All of the regions 34 a , 34 b , 34 c , 34 d of the bore 34 are embodied coaxial to the longitudinal axis 35 of the bore 34 . The region 34 d of the bore 34 is connected to the high-pressure reservoir 12 .
The outlet valve 32 has a valve member 40 embodied at least approximately in the form of a ball that is situated in the bore 34 and cooperates with the seat region 34 b . The diameter of the valve member 40 is slightly smaller than the diameter of the region 34 d of the bore 34 so that the valve member 40 is able to move in the direction of the longitudinal axis 35 of the bore 34 . The valve member 40 can, for example, be acted on in the direction toward the seat region 34 b by a prestressed spring 42 . The spring 42 can, for example, be embodied in the form of a helical compression spring and be clamped between the valve member 40 and a support element 44 inserted into the bore 34 .
When the outlet valve 32 is closed, the valve member 40 rests with a part of its surface, which constitutes a sealing surface, against the seat region 34 b of the bore 34 . If the force acting on the valve member 40 in the opening direction that is generated by the pressure prevailing in the pump working chamber 24 is greater than the force acting on a valve member 40 in the closing direction that is generated by the closing spring 42 and by the pressure prevailing in the high-pressure reservoir 12 , then the outlet valve 32 opens and the valve member 40 lifts away from the seat region 34 b . The stroke direction of the valve member 40 is oriented in the direction of the longitudinal axis 35 of the bore 34 . This lifting movement opens a first flow cross section 50 for the fuel between the seat region 34 b and the valve member 40 ; this first flow cross section depends on the opening stroke of the valve member 40 and increases in magnitude with the increasing opening stroke. The first flow cross section 50 is embodied in the form of an annular gap between the valve member 40 and the seat region 34 b . Between the region 34 d of the bore 34 and the valve member 40 , a second flow cross section 52 is opened that is independent of or only slightly dependent on the opening stroke of the valve member 40 . Between the first flow cross section 50 and the second flow cross section 52 , a third flow cross section 54 is opened between the region 34 c of the bore 34 and the valve member 40 ; this third flow cross section 54 depends on the opening stroke of the valve member 40 , i.e. it increases in magnitude with the increasing opening stroke, but is always greater than the first flow cross section 50 and the second flow cross section 52 . The third flow cross section 54 is embodied in the form of an annular gap between the valve member 40 and the bore region 34 c . Preferably, the second flow cross section 52 is smaller than the first flow cross section 50 when the valve member 40 has traveled the length of its given maximum opening stroke. This embodiment of the flow cross sections 50 , 52 , 54 results in the fact that when the outlet valve 32 is open, essentially the entire half of the valve member 40 oriented toward the cylinder bore 22 is acted on by a high average pressure that holds the valve member 40 in its open position in a stable fashion. In particular, the surface of the valve member 40 situated in the region 34 c of the bore 34 is acted on by a high pressure since in this third and largest flow cross section 54 , the lowest flow speed occurs and therefore the highest static pressure prevails.
It is possible for the valve member 40 to be situated at least approximately coaxially in the region 34 d of the bore 34 and for the second flow cross section 52 to be embodied in the for of an annular gap between the valve member 40 and the bore region 34 d . It is also possible for the second flow cross section 52 to be embodied as asymmetrical over the circumference of the valve member 40 so that the valve member 40 is intentionally held with a particular circumference region resting against a guide in the region 34 d of the bore 34 . This avoids movements of the valve member 40 perpendicular to its stroke direction since the valve member 40 is kept in contact with the guide. The region 34 d of the bore 34 can be provided with slots 56 that extend approximately parallel to the longitudinal axis 35 and are arranged uniformly or non-uniformly around the circumference of the bore 34 , as shown in FIG. 3 . With uniformly distributed slots 56 , the valve member 40 can be positioned with a small amount of play transverse to its stroke direction in the bore region 34 d . The play of the valve member 40 transverse to its stroke direction in the bore region 34 d can be less than or equal to approximately 10% of the diameter of the valve member 40 . With non-uniformly distributed slots 56 , a larger compressive force is exerted in a circumference region that contains more slots 56 or wider slots, thus holding the valve member 40 in contact with the opposite circumference region of the bore region 34 d , which consequently functions as a guide for the valve member 40 .
FIGS. 4 and 5 show the outlet valve 32 according to a second exemplary embodiment in which the basic embodiment with the three defined flow cross sections 50 , 52 , 54 is the same as in the first exemplary embodiment. The pump housing pan 36 contains the bore 34 whose end region 34 a opens out into the cylinder bore 22 and the end region 34 a oriented away from the cylinder bore 22 is adjoined by the seat region 34 b . The end of the seat region 34 b oriented away from the cylinder bore 22 is adjoined by a bore region 34 c with a diameter significantly larger than that of the end region 34 a ; the annular shoulder 38 is formed at the transition from the seat region 34 b to the bore region 34 c . The bore region 34 c has a separate insert piece 60 inserted into it, which is embodied in the form of a sleeve and ends a certain distance a before the annular shoulder 38 in the direction of the longitudinal axis 35 of the bore 34 . In its end region oriented toward seat region 34 b , the insert piece 60 has a number of slots 62 distributed over its circumference, extending at least approximately parallel to the longitudinal axis 35 of the bore 34 . On the basis of the slots 62 , a corresponding number of ribs 64 are formed at the end region of the insert piece 60 . The slots 62 and ribs 64 can be distributed uniformly or, as shown in FIG. 5 , non-uniformly around the circumference of the insert piece 60 . With a non-uniformly distributed arrangement of the ribs 64 , the valve member 40 is selectively held in contact with at least one of the ribs 64 , which rib or ribs consequently function(s) as a guide for the valve member 40 . The second flow cross section 52 is formed between the valve member 40 and the insert piece 60 ; the size of the second flow cross section 52 is determined by the width of the slots 62 and the radial distance between the valve member 40 and the ribs 64 .
If the ribs 64 are uniformly distributed, then the valve member 40 is preferably guided in a movable fashion, with a small amount of play transverse to its stroke direction between the ribs 64 of the insert piece 60 , permitting the valve member 40 to execute little or no movement perpendicular to its stroke direction. The play of the valve member 40 transverse to its stroke direction between the ribs 64 can, for example, be less than 10% of the diameter of the valve member 40 . The third flow cross section 54 is formed between the valve member 40 and the part of the bore region 34 c that extends to the insert piece 60 and has the length d in the direction of the longitudinal axis 35 . Compared to the embodiment according to the first exemplary embodiment, the embodiment of the outlet valve 32 according to the second exemplary embodiment has the advantage that the bore region 34 c can be embodied with a constant diameter, thus requiring no undercut in the bore 34 in order to achieve the third flow cross section 54 that is larger than the second flow cross section 52 since the second flow cross section 52 is defined by the insert piece 60 .
In its end region oriented away from the valve member 40 , the insert piece 60 is provided with openings 66 to permit fuel to pass through. An arbor 68 is provided in the insert piece 60 , coaxial to the longitudinal axis 35 and preferably of one piece with the insert piece 60 . The closing spring 42 is supported on the insert piece 60 and is guided on the arbor 68 . The end of the arbor 68 oriented toward the valve member 40 preferably constitutes a stop for the valve member 40 , which the valve member comes into contact with when it reaches its maximum opening stroke. The insert piece 60 can itself be affixed in the bore region 36 c by being press-fitted or screwed, for example, into the bore region 34 c . Alternatively, the insert piece 60 can also be affixed by means of an additional fastener 70 that can be press-fitted or screwed, for example, into the bore region 34 c . The fastener 70 in this case has at least one opening to allow fuel to pass through. Alternatively, it is also possible for the closing spring 42 to be supported on a support element other than the insert piece 60 , which support element is provided in addition to the insert piece 60 .
The inlet valve 30 can be embodied in the same way as described above for the outlet valve 32 . The inlet valve 30 is situated in the housing part 36 of the high-pressure pump; this housing part can, for example, be constituted by a cylinder head that is connected to another housing part in which the drive shaft 18 is supported or can be constituted by the very housing part in which the drive shaft 18 is also supported. A fuel supply conduit 72 that is connected to the fuel supply pump 14 leads to the inlet valve 30 .
In a high-pressure pump, it is possible for only the outlet valve 32 to be embodied in the fashion described in FIGS. 2 through 5 , while the inlet valve 30 has a different embodiment. Alternatively, it is also possible for only the inlet valve 30 of a high-pressure pump to be embodied in the fashion described in FIGS. 2 through 5 , while the outlet valve 32 has a different embodiment. Furthermore, it is also possible for both the inlet valve 30 and the outlet valve 32 in a high-pressure pump to be embodied in the fashion described in FIGS. 2 through 5 .
The foregoing relates to the preferred exemplary embodiment of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
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The high-pressure pump has at least one pump element which has a pump plunger which is driven in a reciprocating motion and defines a pump working space into which fuel is drawn in from a fuel feed via an inlet valve during the suction stroke of the pump plunger and from which fuel is displaced into a high-pressure region via an outlet valve during the delivery stroke of the pump plunger. The inlet valve and/or the outlet valve has a valve member at least approximately in the shape of a ball which acts as a sealing surface with a valve seat arranged in a valve housing. The valve member, in its open state, is lifted with its sealing surface from the valve seat, a first cross section of flow is cleared between the valve member and the valve seat, and downstream of the first cross section of flow, a second cross section of flow is formed between the valve member and the valve housing. In the direction of flow between the first cross section of flow and the second cross section of flow, a third cross section of flow is formed between the valve member and the valve housing, said third cross section of flow being larger than the first cross section of flow and the second cross section of flow.
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BACKGROUND OF THE INVENTION
[0001] The natural intervertebral disc contains a jelly-like nucleus pulposus surrounded by a fibrous annulus fibrosus. Under an axial load, the nucleus pulposus compresses and radially transfers that load to the annulus fibrosus. The laminated nature of the annulus fibrosus provides it with a high tensile strength and so allows it to expand radially in response to this transferred load.
[0002] In a healthy intervertebral disc, cells within the nucleus pulposus produce an extracellular matrix (ECM) containing a high percentage of proteoglycans. These proteoglycans contain sulfated functional groups that retain water, thereby providing the nucleus pulposus within its cushioning qualities. These nucleus pulposus cells may also secrete small amounts of cytokines such as interleukin-1β and TNF-α as well as matrix metalloproteinases (“MMPs”). These cytokines and MMPs help regulate the metabolism of the nucleus pulposus cells.
[0003] In some instances of disc degeneration disease (DDD), gradual degeneration of the intervetebral disc is caused by mechanical instabilities in other portions of the spine. In these instances, increased loads and pressures on the nucleus pulposus cause the cells within the disc (or invading macrophases) to emit larger than normal amounts of the above-mentioned cytokines. In other instances of DDD, genetic factors or apoptosis can also cause the cells within the nucleus pulposus to emit toxic amounts of these cytokines and MMPs. In some instances, the pumping action of the disc may malfunction (due to, for example, a decrease in the proteoglycan concentration within the nucleus pulposus), thereby retarding the flow of nutrients into the disc as well as the flow of waste products out of the disc. This reduced capacity to eliminate waste may result in the accumulation of high levels of toxins that may cause nerve irritation and pain.
[0004] As DDD progresses, toxic levels of the cytokines and MMPs present in the nucleus pulposus begin to degrade the extracellular matrix, in particular, the MMPs (as mediated by the cytokines) begin cleaving the water-retaining portions of the proteoglycans, thereby reducing its water-retaining capabilities. This degradation leads to a less flexible nucleus pulposus, and so changes the loading pattern within the disc, thereby possibly causing delamination of the annulus fibrosus. These changes cause more mechanical instability, thereby causing the cells to emit even more cytokines, thereby upregulating MMPs. As this destructive cascade continues and DDD further progresses, the disc begins to bulge (“a herniated disc”), and then ultimately ruptures, causing the nucleus pulposus to contact the spinal cord and produce pain.
[0005] One proposed method of managing these problems is to remove the problematic disc and replace it with a porous device that restores disc height and allows for bone growth therethrough for the fusion of the adjacent vertebrae. These devices are commonly called “fusion devices”, or “interbody fusion devices”.
[0006] Current spinal fusion procedures include approaches such as transforaminal lumbar interbody fusion (TLIF), posterior lumbar interbody fusion (PLIF), and extreme lateral interbody fusion (XLIF). TLIF and PLIF spinal fusion surgeries require refraction of neural tissues including the spinal cord and/or exiting nerve roots. Retraction is typically performed with hand held dural retractors that are manually placed and secured by an operative assistant who is standing on the contralateral side of the patient.
[0007] This position across from the surgeon greatly reduces visibility of the neural retraction for the operative assistant, increasing the risk of neural damage. Frequent adjustment of the retractor is required to ensure proper positioning, distance and the amount of dural retraction force applied. Significant patient risk, including dural tears, can be incurred if excessive retraction is applied or if the spinal cord is inadvertently released during the procedure.
[0008] In addition, the presence of the neural retractor crowds or obscures the surgical site, thereby minimizing visibility and access to the disc space for the operating surgeon.
[0009] Cloward, “A Self-Retaining Spinal Dural Retractor” J. Neurosurg., 1952 March; 9(2):230-2, discloses a modified Hoen laminectomy retractor having a retraction spatula.
[0010] U.S. Pat. No. 7,569,054 (Michelson) discloses a tubular member having a passage and opposing bone penetrating extensions adapted to piece opposed vertebral bodies.
[0011] The objective of this device is to reduce operative site crowding to enhance disc access while providing for consistent and stable dural retraction.
SUMMARY OF THE INVENTION
[0012] The present inventors have developed a device and a method for neural tissue retraction for spinal surgery that overcomes the disadvantages associated with conventional spinal cord retraction.
[0013] In particular, the device is a self-retaining retractor clip. When used in spinal surgery, the self-retaining nature of the clip eliminates the need to continuously manually retract the neural structures.
[0014] Preferred devices of the present invention include a) a self-retaining neural retraction clip, b) a neural retraction clip with controlled refraction level, and c) a neural retraction clip with off-set retraction means.
[0015] Therefore, in accordance with the present invention, there is provided a neural tissue retractor comprising:
a) first and second legs, each leg having an inner portion and a outer portion, b) a curved intermediate section connecting the inner portions of the first and second legs to provide (typically, spring-like) compression and expansion, c) first and second feet respectively extending from the outer portions of the first and second legs, each foot having a tooth adapted to pierce a vertebral body.
DESCRIPTION OF THE FIGURES
[0019] FIG. 1A-1C discloses various views of a self-retaining neural refraction clip of the present invention.
[0020] FIG. 1D discloses a neural retraction clip of the present invention retaining by opposing vertebrae.
[0021] FIGS. 2A-C disclose the neural retraction clip of the present invention having a lock and key mechanism for controlling the degree of retraction.
[0022] FIG. 2D shows the clip of FIGS. 2A-2C in its use location.
[0023] FIGS. 3A-3C discloses various views of a self-retaining neural retraction clip of the present invention having a retractor shield.
[0024] FIGS. 3D-F show the clip of FIGS. 3 A- 3 Cc in its use location.
[0025] FIG. 4A discloses a self-retaining neural retraction clip of the present invention having loops for receiving inserter pins.
[0026] FIG. 4B shows the clip of FIG. 4A attached to an inserter.
[0027] FIG. 4C discloses the assembly of FIG. 4B inserted between opposing vertebrae.
[0028] FIGS. 5A-B show an implanted clip of the present invention having tether attached thereto.
[0029] FIG. 6 shows a clip of the present invention attached to a lamina.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Now referring to FIGS. 1A-C , the self retaining neural retraction clip includes a spring clip having two attached feet. In use, the spinal cord is retracted, the clip is compressed and is placed between two adjacent vertebral bodies. Once the clip is in place, the compression is released so that the spiked feet pierce into and become seated within the endplate of each vertebral body. The spikes on the feet prevent clip rotation and ensure that the device maintains its position. The clip can have various geometries to minimize neural impingement.
[0031] Therefore, in accordance with the present invention, there is provided a neural tissue retractor 10 comprising:
a) first and second legs 1 , each leg having an inner portion 3 and a outer portion 5 , b) a curved intermediate section 7 connecting the inner portions of the first and second legs to provide spring-like compression and expansion, c) first and second feet 9 respectively extending from the outer portions of the first and second legs, each foot having a tooth 11 adapted to pierce a vertebral body.
[0035] In some embodiments, the curved intermediate portion comprises a portion of substantially a circle. Preferably, the portion of the circle defines an arc of at least about 270 degrees, more preferably at least 300 degrees.
[0036] In some embodiments, each foot has at least two teeth extending therefrom. Preferably, each foot extends substantially perpendicularly from its respective leg.
[0037] In some embodiments, the two legs of the present invention are substantially parallel to define a plane. In some embodiments, thereof, the curved intermediate portion lies substantially in the plane formed by the two legs. In other embodiments, the curved intermediate portion extends out of the plane formed by the two legs. This curve can lie in a multitude of planes. In some embodiments, (as in FIG. 1B ), the extension of the curved intermediate portion out of the plane is due to an anterior-posterior curve in the curved intermediate portion. In other embodiments (as in FIGS. 3B and 4A ), the extension of the curved intermediate portion out of the plane is due to a medial-lateral curve in the curved intermediate portion.
[0038] In some embodiments, the interior of the curved intermediate portion of the clip is substantially open (as in FIG. 1A ). In others, the interior of the curved intermediate portion of the clip is at least 25% closed (as in FIG. 1C ).
[0039] Also in accordance with the present invention, there is provided a method of preserving retraction of a neural tissue (such as a spinal cord), comprising the steps of:
a) retracting the neural tissue, b) compressing a clip of the present invention, c) placing the clip between two endplates of adjacent vertebral bodies so that each foot is substantially perpendicular to a respective vertebral body, and d) releasing the compression upon the clip such that the spiked feet become seated into the endplate of each vertebral body.
FIG. 1D discloses the clip 10 attached in position in the spine.
[0044] Now referring to FIGS. 2A-2C , the neural clip with controlled retraction level includes a self-retaining neural retraction clip along with rotatable retraction level and locking means. The adjustable retraction is accomplished with the use of a rotating key-based lock on the feet of the clip. In this case, the compressed clip is placed between the vertebral bodies and released such that the spiked feet are seated into each vertebral body. The clip is rotated to retract the cord. The keyway lock allows incremental rotation until the desired amount of spinal cord retraction is achieved.
[0045] Therefore, in accordance with the present invention, there is provided a neural tissue retractor 20 comprising:
a) first and second legs 21 , each leg having an inner portion 23 and a outer portion 25 , b) a curved intermediate section 27 connecting the inner portions of the first and second legs to provide spring-like compression and expansion, c) first and second feet 29 respectively extending from the outer portions of the first and second legs,
wherein each leg and its respective foot are connected by rotating lock and key connection 31 .
[0049] In some embodiments (as in FIG. 2C ), key of the lock and key mechanism is presented as a rod 33 having a plurality of spaced longitudinally oriented projections 35 , while the corresponding lock 37 is presented as a tube having a plurality of mating longitudinal grooves 39 .
[0050] In some embodiments (as in FIG. 2C ), a rod 33 is formed by an extension of a leg 21 , while the tube is formed as an extension of a foot. In others, a rod is formed by an extension of a foot, while the tube is formed as an extension of a leg.
[0000] FIG. 2D discloses the clip 20 attached in position in the spine.
[0051] Now referring to FIGS. 3A-C , the neural clip with conformable off-set retraction means is very similar to the clip with controlled retraction, except the retractor blade is off-set from the attachment location allowing placement at varying distances from the spinal cord. The retraction shield geometry is designed with conforming radius in the medial-lateral and anterior-posterior planes to minimize impingement upon the spinal cord.
[0052] Therefore, in accordance with the present invention, there is provided a neural tissue retractor 40 comprising:
a) first and second legs 41 , each leg having an inner portion 43 and a outer portion 45 , b) a curved intermediate section 47 connecting the inner portions of the first and second legs to provide spring-like compression and expansion, c) first and second feet 49 respectively extending from the outer portions of the first and second legs, d) a retractor shield 51 connected to the curved intermediate section.
[0057] In some embodiments, the retractor shield is curved. In some embodiments, the retractor shield is connected to the curved intermediate portion substantially at the apex 48 of the curved intermediate portion (i.e., the portion opposite the legs). In some embodiments, the shield is connected to the curved intermediate section to form a substantially V-shaped clip (as shown in FIG. 3C ).
[0058] FIGS. 3D-F disclose the clip 40 attached in position in the spine.
[0059] In some embodiments, insertion of the clip of the present invention is accomplished by using clamping forceps to secure the legs of the clip and squeeze them into a compressed configuration. Now referring to FIG. 4B , in one preferred embodiment, each leg of the clip has a loop extending therefrom, and each arm 81 of the forceps 83 has a pin 85 adapted for reception in a loop. In use, each pin is inserted into a respective loop, and the forceps are squeezed to provide the desired level of leg compression.
[0060] Preferably, the inserter can be shielded to minimize inadvertent damage to soft tissue or neural tissue. Also preferably, the inserter device can be used to extract the clip from the patient after the operation is completed.
[0061] Therefore, now referring to FIGS. 4A-C , in accordance with the present invention, there is provided a neural tissue retractor 60 comprising:
a) first and second legs 61 , each leg having an inner portion 63 and a outer portion 65 , each leg having an inserter receptor 71 adapted for connection with an inserter, b) a curved intermediate section 67 connecting the inner portions of the first and second legs to provide spring-like compression and expansion, c) first and second feet 69 respectively extending from the outer portions of the first and second legs.
Preferably, the inserter receptor is a loop.
FIG. 4C discloses the clip 60 attached in position in the spine.
[0065] Now referring to FIGS. 5A-B , additional soft tissue retraction can be accomplished by pre-attaching the clip to a tether, securing the clip to bony structures, and then tensioning and securing the tether to either the patient, an external retraction system or the operating table.
[0066] Therefore, in some embodiments, the retractor clip 90 of the present invention has a tether 91 attached thereto. In some embodiments, the tether is attached to the shield 93 . In some embodiments, the tether is attached to the curved intermediate portion. In some embodiments, the tether is attached to at least one leg.
[0067] Now referring to FIG. 6 , the clip 100 of the present invention can also be attached to other locations to distract neural tissues in a similar fashion. The alternate attachment locations are generally bony landmarks adjacent to the neural tissues. These landmarks include the lamina (as shown in FIG. 6 ), the pars, the facets, pedicles, and the spinous processes.
[0068] The neural retraction clip of the present invention can be produced from a variety of biocompatible metals or plastics. Suitable metals include stainless steel, titanium, nitinol or cobalt-chrome. Selection of these materials will allow the clip to be first squeezed to produce elastic compression for insertion and then released to produce expansion for vertebral body securement. A semi-rigid to rigid polymer with shape memory properties such as PEEK, polypropylene, polyethylene can also be utilized. These materials would allow multiple compression cycles without structural fatigue as well as radio-lucency to enable intra-operative imaging of the surgical site. Hybrid components can also be selected, and include producing the spikes and clip from TiN for expansion and the shield from a conformable polymer (like polypropylene) to maximize conformance to the neural tissues. The material selection can provide either elastic or plastic deformation.
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A self-retaining neural retraction clip, preferably having controlled retraction level and an off-set retraction means. This device can reduce operative site clutter to enhance disc access while providing consistent and stable dural retraction.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to color printing cellulosic articles and, more particularly, to a new method of screen printing fabrics, in which the fabric article is first selectively printed with a dye blocking print paste, then printed with a color binder print paste over at least a portion of the area printed with the dye blocking print paste and finally printed with a dye enhancing print paste and subsequently dyed to bring out the print.
(2) Description of the Prior Art
Traditional screen printing of garments is done by printing ink, binder, thickener and softener combinations on dyed or white prepared for print (PFP) garments. A detailed description of the screen printing process is published in the Encylopedia of Textiles, Second Edition, 1972 Prentice-Hall, Inc., Englewood Cliffs N.J., the disclosure of which is hereby incorporated by reference in its entirety. The following discussion is taken from the above-referenced Encyclopedia of Textiles.
The screen printing method in textiles is basically a stencil process. A wooden or metal frame is covered with a bolting cloth, which may be made of silk, fine metal thread, or nylon. The fabric is covered with a film and the design areas are cut out of the film just as in stencil making. The frame is then laid on the fabric and color is brushed or squeezed through the open areas of the film by the use of a big rubber knife or squeegee.
Originally, the design was cut out of film and then adhered to the screen. Today the cutting is done mechanically by a photo-chemical process which reproduces the design exactly as it was painted in the art which is being reproduced.
In printing, one screen is used for each color and these are accurately registered one on the other by the use of fixed stops attached to an iron rail running the length of the table. The length of the table determines the number of yards which can be printed at one laying; this varies depending on the available space, though 30 yards is considered the smallest space which is practical for economic production.
While screen printing, either by hand or machine, is a slower and more expensive process than roller printing, it has several virtues. From the point of view of design, pattern repeats can be much larger than in roller printing. Also, since the process is slower, pigment colors can be laid on in heavy layers to produce a handicraft effect. From an economic point of view, it does not require as large an investment as roller printing because the runs can be shorter, especially in the hand operation. This has encouraged smaller converters to adopt the screen method and to experiment more with design than they would be able to do in the roller method, where they would be required to contract for a minimum of about 8000 yards per pattern.
One of the most important physical parameters for good screen printing is that the print paste is thick enough to stand in a gel state until it is dried and cured. This assures clean crisp definition of the print. However, the print paste still must flow readily and evenly. These two properties are defined as the rheology of the print paste and the most desirable property is called pseudo-plastic or the ability of the paste to become less viscous when moved by pump or mechanical device and to thicken or become more viscous when it stills.
Because of the nature of the print paste, screen prints are generally opaque and rubbery to the touch. In addition, these prints are not very durable especially when washed. There has been much work done in developing softer prints that do not crack and peel after washing and these softened prints are called "plastisols," but they are still based on pigments, binder, thickener and are still a surface coating which can be "felt".
One approach to solving this problem is disclosed in U.S. patent application Ser. No. 08/922,221, filed Sep. 2, 1997, now U.S. Pat. No. 5,984,977, which is hereby incorporated by reference in its entirety. However, some dye sites may still remain when using the teachings in this application. These sites may be sufficient to prevent multiple color dyeing since small traces of dyes may make true colors more difficult to achieve.
Another approach to solving this problem is disclosed in U.S. patent application Ser. No. 09/260,841. filed Mar. 2, 1999 which is hereby incorporated by reference in its entirety. However, this invention was still limited to producing dye-free, base and dark dyed regions of a single color.
Thus, there remains a need for a new method of screen printing in which the garment or fabric may be color printed using traditional screen printing techniques while, at the same time, provides printed areas which can not be rubbed off or felt to the touch.
SUMMARY OF THE INVENTION
The present invention is directed to a dyeing and printing system for use in color printing articles or fabrics formed from cellulose prior to dyeing. In the preferred embodiment, the dyeing system composition includes the selective use of a dye blocking print paste, a color binder print paste and a dye enhancing print paste to selectively decrease or increase the shade of the dyed portions of a cellulose article, such as a woven or knitted cotton or cotton/polyester article or fabric while, at the same time, permitting the resisted areas to be colored differently.
In the preferred embodiment, the dye blocking print paste includes a thickener and dye blocking agents. The dye blocking agents includes an ether-forming cross-linking resin, which may be pre-catalyzed, an ester-forming cross-linking resin, a reductive catalyst and a dye resist.
In the preferred embodiment, the color binder print paste includes an organic pigment; a cross-linking, polymeric binder; a thickener and the balance water. The cross-linking, polymeric binder is preferably a water-based, film forming binder such as a mixture of homopolymers and copolymers of polyacrylic acid. In order to keep the hand of the fabric smooth, the cross-linking, polymeric binder has a Tg (glass transition temperature) less than about 10° F. and, preferably, a Tg between about -20° F. and -45° F.
Also, in the preferred embodiment, the dye enhancing print paste includes a thickener and an epoxy functional quaternary ammonium-enhancing agent. The thickener for both print pastes, preferably, is an acid alkali stable hydroxypropyl guar derivative, polysaccharide, dispersed in an invert emulsion.
Accordingly, one aspect of the present invention is to provide a dyeing and printing system for use in color printing articles formed from cellulose prior to dyeing. The composition includes: a layer of a dye blocking print paste; and a layer of a color binder print paste printed on the surface of the first layer of dye blocking print paste.
Another aspect of the present invention is to provide a dyeing and printing system for use in color printing articles formed from cellulose prior to dyeing. The composition includes: a layer of a dye blocking print paste, the dye blocking print paste including: (i) a thickener; and (ii) dye blocking agents, the dye blocking agents including an ether-forming, cross-linking resin, an ester-forming, cross-linking resin, a catalyst and a dye resist; and a layer of a color binder print paste printed on the surface of the first layer of dye blocking print paste.
Still another aspect of the present invention is to provide a dyeing and printing system for use in color printing articles formed from cellulose prior to dyeing. The composition includes: a layer of a dye blocking print paste, the dye blocking print paste including: (i) a thickener; and (ii) dye blocking agents, the dye blocking agents including an ether-forming, cross-linking resin, an ester-forming, cross-linking resin, a catalyst and a dye resist; a layer of a color binder print paste printed on the surface of the first layer of dye blocking print paste; and a dye enhancing print paste, the dye enhancing print paste including: (i) a thickener and (ii) an enhancing agent.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings and examples.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-sectional view of a partially treated cellulosic fabric constructed according to the present invention; and
FIG. 2 shows a cross-sectional view of a fully treated fabric.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as "forward," "rearward," "left," "right," "upwardly," "downwardly," and the like are words of convenience and are not to be construed as limiting terms.
The present invention is performed in the reverse order of traditional garment or fabric screen printing. According to the present invention, the garment or fabric is print prepared (e.g. scoured and bleached white) or griege (unprepared) with a chemical system including a dye blocking print paste and a dye enhancing print paste. The dye blocking print paste includes a wetting agent, a thickener paste; and dye blocking agents, the dye blocking agents including a cross-linking resin and a dye resist to selectively decrease the shade of the dye. In the preferred embodiment, the dye enhancing print paste includes a wetting agent, thickener and a dye enhancing agent which is used to selectively increase the shade of the dye.
In the preferred embodiment, the thickener paste for both the dye blocking and the dye enhancing print paste is an acid alkali stable hydroxypropyl guar derivative, polysaccharide, dispersed in an invert emulsion. Specifically, the polysaccharide concentrate includes about 35 weight percent water, 10 weight percent emulsifier, 10 weight percent polysaccharide and 45 weight of a petrol solvent.
Also, the cross-linking resins used in the dye blocking print paste are preferably glyoxal resins and polycarboxylic acids. In the preferred embodiment, one of the dye resists used in the dye blocking print paste is a low molecular weight polyacrylic acid having a molecular weight of about 2000. One suitable dye resist is sold under the tradename BURCO® Dye Resist 118 by Burlington Chemical Company, Inc. of Burlington, N.C., the assignee of the present invention.
Finally, the enhancing agent used in the dye enhancing print paste is preferably an epoxy functional quaternary ammonium compound. One suitable dye enhancer is sold under the tradename BURCO® DCE by Burlington Chemical Company, Inc. of Burlington, N.C., the assignee of the present invention.
The cellulosic article, garment or fabric is then dyed to the desired shade with the dye blocking and dye enhancing print pastes selectively either reducing the amount of dye on the fabric or enhancing the dye on the fabric. If we measure the background and set it arbitrarily as 100%, the enhanced regions are 250% deeper in color and the blocked regions are 99% lighter than the background.
Further examples of the present invention can be seen in a camo print on 100% cotton knit fabric where various concentrations of the enhancer chemical are printed on and then dyed.
The present invention can be best understood by a review of the following examples:
EXAMPLES 1-2
A dye blocking print paste was prepared using both pre-catalyzed glyoxal resin and a conventional glyoxal resin according to the amounts in weight percent shown in Table 1. Cotton fabric was printed with the dye blocking print paste, the print paste was allowed to dry and cure and conventional reactive and direct dyeing were made. The results are shown in Table 1, below:
TABLE 1______________________________________ Pre- Catalyzed Poly- Glyoxal Glyoxal Acrylic Wetting ShadeEx. Paste Resin Resin Acid Agent Difference______________________________________1 15 15 wt. % -- 5 wt. % 0.1 wt. % -90%wt. %2 15 -- 15 wt. % 5 wt. % 0.1 wt/ % Nowt. % Effect!______________________________________
As can be seen, only the dye blocking print paste including a pre-catalyzed glyoxal resin was effective in blocking the dye.
EXAMPLES 3-6
A dye blocking print paste was prepared using pre-catalyzed glyoxal resin according to the amounts in weight percent shown in Table 2. Cotton fabric was printed with the dye blocking print paste, the print paste was allowed to dry and cure and conventional reactive and direct dyeing were made. The results are shown in Table 2, below:
TABLE 2______________________________________ Pre- Catalyzed Poly- Glyoxal Glyoxal Acrylic Wetting ShadeEx. Paste Resin Resin Acid Agent Difference______________________________________3 15 15 wt. % -- 5 wt. % 0.1 wt. % -90%wt. %4 15 10 wt. % -- 5 wt. % 0.1 wt. % -60%wt. %5 15 5 wt. % -- 5 wt. % 0.1 wt. % -30%wt. %6 15 2.5 wt. % -- 5 wt. % 0.1 wt. % -10%wt. %______________________________________
As can be seen, the dye blocking print paste having between about 5 to 15 wt. % pre-catalyzed glyoxal resin produced a linear relationship between the weight percent of resin and the shade difference in blocking the dye.
EXAMPLES 7-10
A dye blocking print paste was prepared using pre-catalyzed glyoxal resin according to the amounts in weight percent shown in Table 3 and both with and without polyacrylic acid. Cotton fabric was printed with the dye blocking print paste, the print paste was allowed to dry and cure and conventional reactive and direct dyeing were made. The results are shown in Table 3, below:
TABLE 3______________________________________ Pre- Catalyzed Poly- Glyoxal Glyoxal acrylic Wetting ShadeEx. Paste Resin Resin Acid Agent Difference______________________________________7 15 15 wt. % -- 5 wt. % 0.1 wt. % -90%wt. %8 15 15 wt. % -- -- 0.1 wt. % -60%wt. %9 15 2.5 wt. % -- -- 0.1 wt. % Nowt. % Effect!10 15 -- -- 15 wt. % 0.1 wt. % Nowt. % Effect!______________________________________
As can be see, the addition of polyacrylic acid improved the effectiveness of the dye blocking print paste 50% when comparing Example 7 to Example 8. In addition, only the dye blocking print paste including a pre-catalyzed glyoxal resin was effective in blocking the dye even when the amount of polyacrylic acid was increase to 15 wt. %.
Dyeings were than made using the thickener of the present invention along with a conventional epoxy functional quaternary ammonium compound to form a dye enhancing print paste. This compound has been used in the past to react with cellulose to yield a permanent cationic site on the cellulose to improve dye yield. If we measure the background and set it arbitrarily as 100%, the enhanced regions were 250% deeper in color than the background when dyed with fiber reactive and direct dyes.
Finally, fabric was screen printed using a combination of the blocking print paste and enhancing print paste according to the present invention. Dyeing to the desired shade with the blocking and enhancing print pastes selectively either reduced the amount of dye on the fabric or enhanced the dye on the fabric. If we measure the background and set it arbitrarily as 100%, the enhanced regions were 250% deeper in color and the blocked regions were 90% lighter than the background!
In a further improved embodiment as disclosed in U.S. patent application Ser. No. 09/260,841 filed Mar. 2, 1999 the dye blocking agents may include a pre-catalyzed ether-forming cross-linking resin, an ester-forming cross-linking resin, a catalyst and a dye resist. It has been discovered that the addition of an ester-forming cross-linking resin and catalyst improves the strength, the light scattering (KS value) and further reduces the excluded dye sites of the resist portion of the fabric as shown below.
EXAMPLES 11-13
Dye blocking print pastes were prepared using a thickener and different dye blocking agents and a dye resist. The dye blocking agents included only a pre-catalyzed, ether-forming, cross-linking resin; only an ester-forming, cross-linking resin and a catalyst; and the combination of a pre-catalyzed, ether-forming, cross-linking resin, an ester-forming, cross-linking resin, and a catalyst. Cotton fabric was printed with the dye blocking print paste, the print paste was allowed to dry and cure and conventional reactive and direct dyeing were made. The results are shown in Table 4, below:
TABLE 4______________________________________ Fabric Strength (compared Light Dye to Scatter Excluded Blocking untreated (KS DyeEx. Agent fabric) value) Sites______________________________________11 Pre- 60% 100% 98% Catalyzed (base) Ether- forming, cross linking Resin (only)12 Ester- 100% 70% 97% forming, cross linking Resin (only)13 Both 100% 140% 99% resins (present invention)______________________________________
As can be seen, the dye blocking print paste including the additional cross-linking resin and catalyst is a significant improvement.
In the preferred embodiment, the ester-forming cross-linking resin are carboxylic acids. Specifically, the resin is a 50/50 mixture of polymaleic acid and butanetetracarboxylic acid at between about 5 to 15 weight percent of the total weight percent of the dye blocking print paste with about 8 weight percent of the total weight of the dye blocking print paste being preferred.
Also, in the preferred embodiment, the catalyst is reductive with sodium hypophosiphite at a 1 to 4 ratio to the ester-forming cross-linking resin being preferred.
A cellulosic article, garment or fabric dyed to the desired shade with the improved blocking print paste further reduces the amount of dye on the fabric. If we measure the background and set it arbitrarily as 100%, the enhanced regions are still 250% deeper in color and the improved blocked regions are 99% lighter than the background.
As discussed above, traditional methods for printing apparel, more particularly cellulosic articles, garments or fabric, involve dyeing and otherwise treating the fabric in a continuous roll or by batch system processing, followed by cut and sew operations, and finally printing onto the dyed garment. According to the present invention as claimed herein, the traditional process is substantially reversed. First the undyed fabric is cut and sewn into garments; then the individual garments are printed; and lastly the printed garments are dyed. This allows very quick turnaround since the garments and fabrics are pre-printed and the color develops during dyeing.
In a preferred embodiment of the present invention, the dye blocking print paste, including the dye blocking agents, is applied directly to the undyed textile garment after the cut and sew operations or processes have been performed. Fabrics may also be printed before dyeing or cut and sew. Application of the dye blocking print paste is directed to regions where a printed design is desired.
The dye blocking agents essentially create a color-free "white" region; a portion or all of which can be used for accepting the color binder print paste. Thus, the true color of the pigment used in the color binder print paste is visible after the final garment dyeing process. Surprisingly, the resultant printed area, including dye blocking agents and application of the color binder print paste, has greater durability compared to a printed area created with a pigment and binder alone.
Referring now to the drawings in general and FIG. 1 in particular, it will be understood that the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. As best seen in FIG. 1, a multi-color dyeing and printing system, generally designated 10, is shown constructed according to the present invention. As shown in FIG. 1, the portion of the fabric printed with the dye blocking print paste 12 swells the fabric's fibers 14 so that the fibers absorb some of the dye blocking agents, while some of the dye blocking agents remain on the fabric surface 15.
Following the application of the dye blocking agents onto a predetermined design area, at least the treated design area is flash dried via exposure to an infrared dryer. Then, a color binder print paste is applied directly onto at least a portion of the design area already treated with dye blocking agent, as best seen in FIG. 2. In the preferred embodiment, printing of the color binder print paste layer is improved when at least some of the water is not removed from the treated printed design area during the dye blocking print paste flash drying step.
The color binder print paste forms a pigment containing film on the dye blocking print paste-treated design area of the garment. Then, the treated design area is again flash dried. Significantly and surprisingly, some interaction appears to occur between the dye blocking agents in the dye blocking print paste and the color binder print paste. Finally, the treated design area is cured. In a preferred embodiment, the cure process involves about two minutes exposure to 350° F.
In the preferred embodiment, the color binder print paste comprises a pigment, a cross-linking polymeric binder, and the balance water. In the preferred embodiment, the pigment may be an organic pigment or an inorganic pigment. More preferably, the pigment is an organic pigment selected from the group consisting of mono-azo, dis-azo, phthalolyanine, azo methine, anthaquinone, perinone, perylene, and quinacridone pigments as described in Chapter 15 of Dye and Their Intermediates by Abrahunt (Second Edition 1977) which is hereby incorporated by reference in its entirety.
Also in a preferred embodiment, the pigment shade is controlled by varying the weight percent of the pigment in the color binder print paste between about 0.001 and 10 wt. %, depending upon the color preference.
Preferably, the cross-linking polymeric binder is a water-based, film-forming binder. Consistent with industry convention, a "film" is defined in the Modern Plastics Encyclopedia (as referenced by Synthetic Binders for Pigment Printing, The Pigment Printing Handbook published by the American Association of Textile Chemists and Colorists (1995) which is hereby incorporated by reference in its entirety), as "a flat section of a thermoplastic resin or a regenerated cellulosic material that is very thin in relation to its length and breadth and has a nominal thickness not greater than 0.25 mm."
Various film-forming materials are commercially available, having a range of densities, melt indexes, copolymers and blends, including additives for plasticizing, coloring, impact modification, ultraviolet stabilization, fire retardence, biodegradability and durability, as also set forth in the above references.
More preferably, the water-based, film-forming, cross-linking polymeric binder is a low crock binder, for example a homo-copolymer polyacrylic acid available from Eastern Color and Chemical Company of Providence, R.I. Also preferably, the cross-linking polymeric, water-based, film-forming binder is a soft polymer; that is, it has a Tg of less than about 10° F. More preferably, the polymeric binder has a Tg between about -20° F. and -45° F. Additionally, the polymeric binder is preferably between about 0.01 wt. % and 35 wt. % by weight of the color binder print paste.
In a preferred embodiment, the color binder print paste further includes a thickener, preferably a polyacrylic acid, for example, ASE60 commercially available from the Rhoman Hass Co of Philadelphia, Pa. More preferably, the thickener is used to adjust the color binder print past to a viscosity of about 10,000 cps.
Also in a preferred embodiment, the color binder print paste further includes a pH adjacent to adjust the pH of the color binder print paste to between about 7 and 12 pH; more preferably, the pH adjuster is ammonia.
In a further improved embodiment as claimed in the present invention, the multi-color dyeing and printing system may include multiple color binder print pastes having pigments of different colors and/or shades.
Additionally, according to an improved embodiment as claimed in the present invention, the multi-color dyeing and printing system may include a color binder print paste having a pigment and a cross-linking polymeric binder, where the binder includes an ether-forming cross-linking resin applied in sequential laminate combination with the dye blocking agents, which may include a pre-catalyzed ether-forming cross-linking resin, an ester-forming cross-linking resin, a catalyst and a dye resist, the color binder print paste interacts with the dye blocking agents to form cross-links. It has been discovered that the addition of a water-based, film-forming binder having a cross-linking resin improves the durability and color retention by further reducing the excluded or printed dye sites of the treated design area of the fabric as shown below.
EXAMPLES 14-18
The multi-color dyeing and printing system was evaluated using different combinations of dye blocking print pastes and color system variations. The variations of the color system were prepared using pigments, cationic dyes, vat dyes, and bifunctional reactive dyes with the dye blocking print paste. Cotton fabric was printed with the dye blocking print paste and each of these color systems which was then flash dried; then cured and conventional reactive and direct dyeing were made of the entire garment sample. The results are shown in Table 5, below (note that durability was rated on a scale of 1-5, with 5 being most durable):
TABLE 5______________________________________ Color Binder ColorEx. System Retention Durability______________________________________14 Pigment About 10% 1 (only)15 Cationic Dye 25-30% 2 (only)16 Vat Dye Less than 10% 1 (only)17 Bifunctional About 10% 1 Fiber Reactive Dye (only)18 Pigment & 100% 5 Cross- linking Polymeric Binder (present invention)______________________________________
As can be seen, the multi-color dyeing and printing system including both a pigment and a cross-linking polymeric binder was a substantial and significant improvement over the alternative approaches.
Thus, a cellulosic article, garment or fabric dyed to the desired shade with the improved dye blocking agents and printed with the color binder print paste according to the present invention substantially eliminates the amount of false dyeing on the fabric in the treated print design area, thereby providing true print colors in the design area even after dyeing. If we measure the background and set it arbitrarily as 100%, the improved blocked regions are at least 99% lighter or "whiter" than the background, and, as a result, the multi-color printed area is true to the pigment color and shade.
EXAMPLES 19-22
The multicolor dyeing and printing system of the present invention was evaluated using different combinations of dye blocking agents and color binder print paste, including different process steps. The variations of the color binder system combinations were prepared using the following processes:
EXAMPLE 19
Cotton fabric was printed with the dye blocking print paste which was flash dried; then the treated fabric area was printed with color binder print paste and flash dried; then conventional reactive and direct dyeing were made (not curing step).
EXAMPLE 20
Cotton fabric was printed with a mixture of the dye blocking print paste and the color binder print paste and flash dried; then cured, and conventional reactive and direct dyeing were made.
EXAMPLE 21
Cotton fabric was printed with the dye blocking print paste which was flash dried; then the treated fabric area was printed with color binder print paste having no binder, but only pigment and flash dried; then cured and conventional reactive and direct dyeing were made.
EXAMPLE 22 (The Present Invention)
Cotton fabric was printed with the dye blocking print paste which was flash dried; then the treated fabric area was printed with color binder print paste and flash dried; then cured and conventional reactive and direct dyeing were made. The results are shown in Table 6, below:
TABLE 6______________________________________Color Binder System Color Retention______________________________________Ex. 19 About 10%Ex. 20 About 10%Ex. 21 Less than 10%Ex. 22 100%Dye Blocking Agents applied 1.sup.st,then flash dried; Color BinderPrint Paste allied 2.sup.nd then flashdried & cured (present invention)______________________________________
As can be seen, the multi-color dyeing and printing system, including a pigment and a cross-linking polymeric binder applied as a laminate after application of the dye blocking print paste, was again a significant improvement over the alternative approaches.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, while the preferred embodiment of this invention is directed to color printing cotton and cotton/polyester fabrics, it could be easily adapted to color printing other cellulosic articles. Also, non-polymer organic acids, such as citric acid, maleic acid and BTCA, other cationics and other thickeners may work. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims.
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A dyeing and printing system for use in color printing articles or fabrics formed from cellulose prior to dyeing. In the preferred embodiment, the dyeing system composition includes the selective use of a dye blocking print paste, a color binder print paste and a dye enhancing print paste to selectively decrease or increase the shade of the dyed portions of a cellulose article, such as a woven or knitted cotton or cotton/polyester article or fabric while, at the same time, permitting the resisted areas to be colored differently.
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BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention generally relates to a method and apparatus for automatically generating solid models and to a computer readable storage medium storing programs for automatically generating solid models, and more particularly, to a method and an apparatus for automatically generating a solid model from a plurality of plan views such as front, side, top and bottom views, and to a computer readable storage medium which stores a program for automatically generating a solid model by use of the method.
2. Related Art
Three plan views selected from views such as front, side, top and bottom views are often used to describe a three-dimensional object. By use of such plan views, the three dimensional object can be described using a three-dimensional computer aided design (CAD) system.
However, it requires complicated operations to input necessary information to the CAD system, and there are demands to automatically generate a three-dimensional object from three plan views.
Conventionally, there is a first technique which automatically generates a three dimensional object, that is, a solid model, from three plan views. This first technique obtains candidates of apexes from the three plan views, and then obtains candidates of edge lines from the candidates of the apexes. A wire frame model is generated based on the candidates of the apexes and the candidates of the edge lines. Next, a surface model having surfaces surrounded by the edge lines is generated. Finally, a solid model is generated by determining which side of each surface of the surface model the object exists.
On the other hand, there is a second technique which prepares within a system basic shapes such as a parallepiped, cylinder and cone shapes. This second technique retrieves loops or closed sequences of line segments in each of the three plan views. Then, a correspondence among the retrieved loops in each of the plan views is obtained, so as to successively create the basic shapes.
According to the first and second techniques described above, it is a precondition that the geometrical shape is strictly drawn on the three plan views. But in actual mechanical drawings, simplified drawings including the following simplifications are used as the base.
(1) Complicated interpenetrating lines are approximated by straight or arcuate lines; and
(2) Shapes and the like of tools and jigs used for the process are only drawn by imaginary lines, and edge lines which are generated as a result are omitted.
The three plan views including the simplifications (1) and (2) described above are mainly used to process and produce the object. In addition, machine tools such as lathes and milling machines are used to process surfaces of the object. On the other hand, information that is accurately drawn on the three plan views relates to the shape of the surfaces and not to the shape of the edge lines. For these reasons, there was a problem in that it is impossible to generate a correct solid model according to the first technique or the second technique described above.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide a novel and useful method and apparatus for automatically generating a solid model and to a computer readable storage medium storing a program for automatically generating a solid model, in which the problem described above is eliminated.
Another and more specific object of the present invention is to provide a method and apparatus for automatically generating a solid model and to a computer readable storage medium storing a program for automatically generating a solid model, wherein a correct solid model can be generated automatically by extracting surface information from three plan views even if the three plan views are simplified diagrams.
Still another object of the present invention is to provide an apparatus for automatically generating a solid model from a plurality of plan views, comprising extraction means for extracting information related to surfaces from the plan views, first generation means for generating candidate surfaces based on the information extracted by the extraction means, second generation means for generating candidate surfaces and candidate edge lines by obtaining intersecting lines among the candidate surfaces generated by the first generation means, third generation means for generating candidate solids by determining combinations of the candidate surfaces generated by the second generation means, and selection means for collating the candidate solids generated by the third generation means with the plan views and selecting a matching candidate solid as a solid model. According to the apparatus of the present invention, it is possible to automatically generate a correct solid model by extracting surface information from the plan views, even if the plan views are simplified views.
A further object of the present invention is to provide a computer-implemented method for automatically generating a solid model from a plurality of plan views, comprising the steps of (a) extracting information related to surfaces from the plan views, (b) generating candidate surfaces based on the information extracted by the step (a), (c) generating candidate surfaces and candidate edge lines by obtaining intersecting lines among the candidate surfaces generated by the step (b), (d) generating candidate solids by determining combinations of the candidate surfaces generated by the step (c), and (e) collating the candidate solids generated by the step (d) with the plan views and selecting a matching candidate solid as a solid model. According to the computer-implemented method of the present invention, it is possible to automatically generate a correct solid model by extracting surface information from the plan views, even if the plan views are simplified views.
Another object of the present invention is to provide a computer readable storage medium storing a program to be executed by a computer, comprising extraction means for causing the computer to extract information related to surfaces from the plan views, first generation means for causing the computer to generate candidate surfaces based on the information extracted by the extraction means, second generation means for causing the computer to generate candidate surfaces and candidate edge lines by obtaining intersecting lines among the candidate surfaces generated by the first generation means, third generation means for causing the computer to generate candidate solids by determining combinations of the candidate surfaces generated by the second generation means, and selection means for causing the computer to collate the candidate solids generated by the third generation means with the plan views and to select a matching candidate solid as a solid model. According to the computer readable storage medium of the present invention, it is possible to cause the computer to automatically generate a correct solid model by extracting surface information from the plan views, even if the plan views are simplified views.
Other objects and further features of the present invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system block diagram showing an embodiment of a solid model generating apparatus according to the present invention;
FIG. 2 is a system block diagram showing a computer system which realizes the functions of the solid model generating apparatus shown in FIG. 1 by software;
FIG. 3 is a flow chart for explaining the basic operation of the embodiment;
FIG. 4 is a flow chart for explaining the operation of steps S1 and S2 shown in FIG. 3 in more detail;
FIG. 5 is a perspective view showing an original solid;
FIGS. 6A through 6D are diagrams showing candidate surfaces extracted from the three plan views of the original solid shown in FIG. 5;
FIG. 7 is a flow chart for explaining the operation of a step S3 shown in FIG. 3 in more detail;
FIG. 8 is a perspective view showing a solid which is stored by the operation shown in FIG. 7;
FIG. 9 is a flow chart for explaining the operation of a step S4 shown in FIG. 3 in more detail;
FIG. 10 is a diagram for explaining detection of a candidate surface by the operation shown in FIG. 9;
FIG. 11 is a flow chart for explaining the operation of the steps S4 and S5 shown in FIG. 3 for a particular case;
FIG. 12 is a perspective view showing candidate surfaces for explaining the operation shown in FIG. 11;
FIG. 13 is a perspective view showing 4 combinations which are obtained by the operation shown in FIG. 11 with respect to the original solid shown in FIG. 5;
FIG. 14 is a flow chart for explaining the operation of a step S6 shown in FIG. 3 in more detail; and
FIGS. 15A and 15B respectively are diagrams for explaining a box.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a system block diagram showing an embodiment of a solid model generating apparatus according to the present invention. The solid model generating apparatus generally includes a surface information extraction unit 1, a candidate surface generation unit 2, a candidate surface and edge line generation unit 3, a deletion unit 4, a candidate solid generation unit 5, and a solid model selection unit 6.
The surface information extraction unit 1 provisionally extracts information related to surfaces of a three-dimensional object, that is, a solid model to be generated, based on three plan views selected from top, bottom, right side, left side, front and rear views of the object. The candidate surface generation unit 2 generates candidate surfaces based on the information related to the surfaces. The candidate surface and edge line generation unit 3 obtains intersecting lines among the candidate surfaces and generates candidate surfaces or candidate edge lines.
The deletion unit 4 deletes a candidate surface or a candidate edge line which cannot possibly exist in the solid. The candidate solid generation unit 5 determines combinations of the surfaces and generates candidate solids. The solid model selection unit 6 collates the candidate solids with the three plan views, and selects a correct solid as the solid model.
When collating the candidate solids with the three plan views, the solid model selection unit 6 judges a match when projections of the candidate solid on the three plan views fall within predetermined boxes. Accordingly, even if the three plan views are simplified drawings, it is possible to extract the surface information from the three plan views and automatically generate a correct solid model.
FIG. 2 is a system block diagram showing a computer system which realizes the functions of the solid model generating apparatus shown in FIG. 1 by software. In FIG. 2, a computer system includes a central processing unit (CPU) 11, a read only memory (ROM) 12, a random access memory (RAM) 13, an input device 14 such as a keyboard and a mouse, and a display unit 15 which are coupled via a bus 16.
The CPU 11 executes programs stored in the ROM 12 in response to an instruction input from the input device 14. Various data including intermediate data which are obtained during operations carried out by the CPU 11 are stored in the RAM 13. An output which is obtained as a result of executing a program by the CPU 11 is displayed on the display 15. Of course, a single storage unit may be used as the ROM 12 and the RAM 13. A computer system having a known construction may be used as this computer system 10.
The computer system 10 automatically generates a solid model using an embodiment of a solid model generating method according to the present invention. In addition, the ROM 12 forms an embodiment of a computer readable storage medium according to the present invention which stores a program for automatically generating a solid model by use of the solid model generating method.
Of course, the computer readable storage medium according to the present invention is not limited to the ROM 12, but may be any kind of computer readable semiconductor memory device such as ROM, RAM, PROM, EPROM and EEPROM, computer readable disks such as magnetic, optical and magneto-optic disks, and computer readable cards or the like suitable for storing a program for carrying out the solid model generating method according to the present invention. It goes without saying that if a magnetic disk is used as the ROM 12, a known magnetic disk drive is coupled to the bus 16 and the magnetic disk is loaded into the magnetic disk drive.
FIG. 3 is a flow chart for explaining the basic operation of this embodiment. The operation shown in FIG. 3 is carried out by the computer system 10 shown in FIG. 2, and corresponds to the embodiment of the solid model generating method.
In FIG. 3, a step S1 provisionally extracts the surface information from the three plan views, and a step S2 generates the candidate surfaces based on the surface information. A step S3 obtains intersecting lines among the candidate surfaces, and generates candidate surfaces or candidate edge lines. A step S4 deletes a candidate surface or a candidate edge line which cannot possibly exist in the solid. A step S5 determines combinations of the surfaces and generates candidate solids. A step S6 collates the candidate solids with the three plan views, and selects a correct solid as the solid model.
The step S1 corresponds to the operation of the surface information extraction unit 1, and the step S2 corresponds to the operation of the candidate surface generation unit 2. The step S3 corresponds to the candidate surface and edge line generation unit 3, and the step S4 corresponds to the operation of the deletion unit 4. The step S5 corresponds to the operation of the candidate solid generation unit 5, and the step S6 corresponds to the operation of the solid model selection unit 6.
FIG. 4 is a flow chart for explaining the operation of the steps S1 and S2 shown in FIG. 3 in more detail.
In FIG. 4, a step S11 obtains a closed loop from a specified one of the three plan views. For example, a closed loop L1 of a side view shown in FIG. 6A which will be described later is obtained by this step S11.
A step S12 decides whether or not vertical or horizontal lines corresponding to a maximum and a minimum of the closed loop exist in the other plan views. For example, a decision to determine whether or not surfaces L2 and L3 respectively corresponding to the front and top views which are the other plan views corresponding to the maximum and minimum of the closed loop L1 in the side view shown in FIG. 6A and obtained in the step S11 exist is made this step S12.
If the decision result in the step S12 is YES, a step S13 sets the closed loop obtained in the step S11 as a candidate surface, and the process advances to a step S14. On the other hand, the process advances to the step S14 without setting the closed loop obtained in the step S11 as the candidate surface if the decision result in the step S12 is NO.
The step S14 decides whether or not the end of the specified plan view is reached and all of the closed loops in the specified plan view are obtained. The process advances to a step S15 if the decision result in the step S14 is YES. However, the process returns to the step S11 if the decision result in the step S14 is NO, so as to repeat the steps S11 through S14.
By carrying out the above described steps S11 through S14, the closed loops are obtained from the specified plan view, and the candidate surface is obtained if the vertical or horizontal lines corresponding to the maximum and minimum of each closed loop exist in the other plan views, thereby generating the candidate surface of the plane from the three plan views.
The step S15 obtains a circle or arc from the specified plan view. For example, A circle L1a of a side view shown in FIG. 6C which will be described later is obtained by this step S15.
A step S16 decides whether or not a straight line corresponding to a contour line of the circle or arc exists in the other plan views. For example, a decision to determine whether or not straight lines L2a and L3a corresponding to the contour line of the circle L1a in the side view shown in FIG. 6C and obtained in the step S15 exists in the front and top views which are the other plan views is made in the step S16.
If the decision result in the step S16 is YES, a step S17 sets the circle or arc obtained in the step S15 as a candidate surface, and the process advances to a step S18. On the other hand, the process ends without setting the circle or arc obtained in the step S15 as the candidate surface if the decision result in the step S16 is NO.
The step S18 decides whether or not the end of the specified plan view is reached and all of the circles and arcs in the specified plan view are obtained. The process ends if the decision result in the step S18 is YES. On the other hand, the process returns to the step S15 if the decision result in the step S18 is NO, so as to repeat the steps S15 through S18.
By carrying out the above described steps S15 through S18, the circles and arcs are obtained from the specified plan view, and the candidate surface is obtained if the straight lines corresponding to the contour of the circle or arc exist in the other plan views, thereby generating the candidate surface of cylindrical surface from the three plan views.
Similarly, it is possible to generate the candidate surfaces with respect to a cone, sphere, and ring surface in addition to the plane and the cylindrical surface described above. The "plane" is parallel to one surface and perpendicular to other two surfaces or, perpendicular to one surface and non-perpendicular to and non-parallel to other two surfaces or, non-parallel to and non-perpendicular to all of three surfaces. The "cylindrical surface" has a center axis perpendicular to one of surfaces. The "cone" has a center axis perpendicular to one of surfaces. The "sphere" and "ring surface" respectively have a center axis perpendicular to one of surfaces.
FIG. 5 is a perspective view showing an original solid. FIGS. 6A through 6D are diagrams showing candidate surfaces extracted from the three plan views of the original solid shown in FIG. 5.
In FIG. 5, B1 through B10 denote boundary lines of contour edge lines, and I1 through I8 denote dimension lines of candidate edge lines. In addition, P1 and P2 denote planes, and C1, C2 and C3 denote cylinders. The original solid shown in FIG. 5 has a hollow cylindrical shape, and this original solid can be described by the three plan views, namely, the front, top and side views, as shown in FIG. 6A.
A description will be given of the surface extraction by referring to the three plan views, that is, the front, top and side views, of the original solid shown in FIG. 5, by referring to FIGS. 6A through 6D.
FIG. 6A is a diagram for explaining the extraction of the plane from the three plan views. FIG. 6A shows a state where the closed loop L1 of the side view is obtained, the vertical or horizontal line corresponding to the maximum and the minimum of the closed loop L1 exists in the other plan views (that is, the top and side views), and the candidate surface of the plane is generated, by carrying out the steps S11 through S14 shown in FIG. 4.
FIGS. 6B through 6D are diagrams for explaining the extraction of the cylindrical surface from the three plan views. FIGS. 6B through 6D show a state where the circle or arc L1a of the side view in FIG. 6C is obtained, the straight line corresponding to the contour line of the circle or arc L1a exists in the other plan views (that is, the top and side views), and the candidate surface of the cylindrical surface is generated, by carrying out the steps S15 through S18 shown in FIG. 4.
FIG. 6B shows a case where a contour line corresponding to the contour line of the circle in the top view exists in the front and side views, and the candidate surface of the cylindrical surface is obtained.
FIG. 6C shows a case where a contour line corresponding to the contour line of the circle L1a in the side view exists in the front and top views, and the candidate surface of the cylindrical surface is obtained.
FIG. 6D shows a case where a contour line corresponding to the contour line of the circle in the side view exists in the front and top views, and the candidate surface of the cylindrical surface is obtained.
FIG. 7 is a flow chart for explaining the operation of the step S3 shown in FIG. 3 in more detail.
In FIG. 7, a step S21 obtains all intersecting lines among the candidate surfaces. All intersecting lines among the candidate surfaces generated by the operation shown in FIG. 4 are obtained. A step S22 stores the intersecting lines obtained in the step S21 in the RAM 13, as candidate edge lines. A step S23 stores boundary lines of the candidate surfaces in the RAM 13, as candidate edge lines. In addition, a step S24 stores all surfaces surrounded by the candidate edge lines in the RAM 13, as candidate surface segments.
By carrying out the above described steps S21 through S24, the intersecting lines are obtained with respect to the candidate surfaces which are generated from the three plan views shown in FIGS. 6A through 6D by carrying out the operation shown in FIG. 4. These intersecting lines are stored as the candidate edge lines. In addition, the boundary lines of the candidate surfaces are stored as the candidate edge lines, and all of the surfaces surrounded by the candidate edge lines are stored as the candidate surface segments. As a result, a solid shown in FIG. 8 is obtained, and a total of 17 surface segments are stored.
FIG. 9 is a flow chart for explaining the operation of the step S4 shown in FIG. 3 in more detail, that is, an operation of deleting the candidate edge line or surface.
In FIG. 9, a step S31 decides whether or not a condition A is satisfied, that is, whether or not the number of candidate surfaces having the candidate edge lines as constituent elements thereof is one. If the decision result in the step S31 is YES, it is found that there exists only one candidate surface having the candidate edge line as its constituent element, and a step S32 deletes the candidate edge line which clearly does not exist. For example, if the condition A is satisfied with respect to a candidate edge line 100 shown in FIG. 10 which will be described later, the step S32 deletes this candidate edge line 100. On the other hand, the process advances to a step S33 if the decision result in the step S31 is NO.
The step S33 decides whether or not there exists a candidate surface having the deleted candidate edge line as its constituent element. If the decision result in the step S33 is YES, a step S34 deletes this candidate surface having the deleted candidate edge line as its constituent element. For example, when the step S32 deletes the candidate edge line 100 shown in FIG. 10, the step S33 deletes a surface "a" shown in FIG. 10 which is the candidate surface having the deleted candidate edge line 100 as its constituent element. On the other hand, the process advances to a step S35 if the decision result in the step S33 is NO.
The step S35 projects the candidate edge line and decides whether or not a corresponding line exists in each surface. If the decision result in the step S35 is YES, it is found that a line corresponding to each surface of the candidate edge line exists, and a step S36 determines that this candidate edge line is acceptable. On the other hand, the process advances to a step S37 if the decision result in the step S35 is NO.
The step S37 decides whether or not a candidate surface on the surface side of the candidate edge line is smoothly connected, that is, normal vectors of two surfaces traverse the candidate edge line and continuously connect. If the decision result in the step S37 is YES, a step S38 determines that this candidate surface is acceptable. On the other hand, if the decision result in the step S37 is NO, a step S39 deletes this candidate surface.
Therefore, based on the three plan views, it is possible to delete the combinations which do not exist with respect to the candidate edge lines and the candidate surfaces which are generated.
FIG. 10 is a diagram for explaining the deletion of the candidate surface. FIG. 10 shows candidate surfaces "a", "b" and "c". When the condition A is satisfied, that is, the number of candidate surfaces having the candidate edge lines as constituent elements thereof is one, the candidate edge line 100 shown in FIG. 10 is deleted. By deleting this candidate edge line 100, the decision result in the step S33 shown in FIG. 9 becomes YES, and the surface "a" is deleted in the step S34. The combinations which do not exist with respect to the candidate edge lines and the candidate surfaces which are generated are deleted in this manner based on the three plan views.
FIG. 11 is a flow chart for explaining the operation of the steps S4 and S5 shown in FIG. 3 for a particular case. In addition, FIG. 12 is a perspective view showing surfaces for explaining the operation shown in FIG. 11.
In FIG. 11, a step S41 extracts a candidate surface having a candidate edge line L shown in FIG. 12 as its candidate edge line. Hence, in the case shown in FIG. 12, the step S41 extracts candidate surfaces S1, S2 and S3 respectively having the candidate edge line L as their candidate line.
A step S42 decides whether or not the number of candidate surfaces extracted in the step S41 is 2.A step S43 determines that the extracted candidate surfaces are acceptable if the decision result in the step S42 is YES. On the other hand, if the decision result in the step S42 is NO, a step S44 creates a combination of 2 candidate surfaces.
After the step S43 or S44, a step S45 creates a solid based on the information obtained from the three plan views. In other words, the step S45 creates a combination of the surfaces which can exist as a solid.
A step S46 decides whether or not 3 surfaces exist on the created solid. If the decision result in the step S46 is NO, a step S47 deletes the created solid. On the other hand, if the decision result in the step S46 is YES, a step S48 sets the created solid as a candidate solid.
Therefore, based on the candidate edge lines and the candidate surfaces which are generated from the three plan views, all combinations of the surfaces which can exist as a solid are generated. For example, in the case of the original solid shown in FIG. 5, 4 combinations are generated as shown in FIG. 13.
FIG. 14 is a flow chart for explaining the operation of the step S6 shown in FIG. 3 in more detail.
In FIG. 14, a step S51 projects the generated candidate solid. More particularly, the candidate solid (or model) generated by the step S48 shown in FIG. 11 is projected on the three plan views. A step S52 compares the projection lines and the figures in the three plan views for all of the elements of the three plan views.
A step S53 decides whether or not all projection lines satisfy a predetermined condition. If the decision result in the step S53 is YES, the projection lines which are obtained by projecting the generated candidate model on the three plan views satisfy the predetermined condition, and it is judged that the projection lines match corresponding lines on the three plan views. Hence, if the decision result in the step S53 is YES, a step S54 determines that the generated candidate solid is a correct solid model. On the other hand, if the decision result in the step S53 is NO, a step S55 starts to judge the next candidate solid.
FIGS. 15A and 15B respectively are diagrams for explaining a box. FIG. 15A shows a box which is used to judge whether or not the candidate solid matches the drawing on the three plan views when the candidate solid is projected on the three plan views. This rectangular box shown in FIG. 15A is used to judge whether or not the elements on the three plan views fall within this box when judging the match between the candidate solid and the drawing on the three plan views. FIG. 15A shows the box which is used by the operation shown in FIG. 14 when determining whether or not the projection lines of the generated candidate solid projected on the three plan views satisfy the predetermined condition.
FIG. 15B shows a solid which matches the drawing on the three plan views. FIG. 15B shows the solid model which matches the drawing on the three plan views shown in FIGS. 6A through 6D when the 4 candidate solids shown in FIG. 13 are collated with the three plan views shown in FIGS. 6A through 6D.
When collating the candidate solid and the drawing on the three plan views in the operation shown in FIG. 14, the collating operation may be carried out based on a polygon which circumscribes a collating portion of the candidate solid which is the subject of the collating operation when projecting the collating portion of the candidate solid on the three plan views.
Further, the present invention is not limited to these embodiments, but various variations and modifications may be made without departing from the scope of the present invention.
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An apparatus automatically generates a solid model from a plurality of plan views. The apparatus includes an extraction unit for extracting information related to surfaces from the plan views, a first generation unit for generating candidate surfaces based on the information extracted by the extraction unit, a second generation unit for generating candidate surfaces and candidate edge lines by obtaining intersecting lines among the candidate surfaces generated by the first generation unit, a third generation unit for generating candidate solids by determining combinations of the candidate surfaces generated by the second generation unit, and a selection unit for collating the candidate solids generated by the third generation unit with the plan views and selecting a matching candidate solid as a solid model.
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U.S. GOVERNMENT
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of U.S. Defense Advanced Research Projects Agency (“DARPA”) CCIT Phase 2 contract No.: HR0011-04-C-0048.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to microelectronic element chips, and processes for their fabrication.
2. Related Art
Myriad microelectronic elements have been formed on conductive wafers such as silicon wafers. Multiple such devices may be formed on a single wafer, which then may be diced to separate the devices as chips. A single chip may contain a number of microelectronic elements integrated into a circuit.
As this vast chip technology continues to evolve, the potential magnitude of conductor interconnections between a chip and further circuitry with which the chip may be integrated accordingly continues to grow. Implementation of early chip technology included the practice of bonding wire conductor interconnections on top of microelectronic elements formed on the chip. With ever greater multiplicity of potential conductor interconnections with a chip, direct chip attachment (“DCA”) technology has been developed, including provision of conductor interconnections that may pass through the chip itself from one side of the wafer to the other. However, the need for sufficient conductor interconnections for the large numbers of microelectronic elements that may be formed on a single chip constitutes a continuing problem, and a limitation in chip design.
There is a continuing need for new types of chip structures for direct chip attachment that may facilitate further growth in the potential magnitude of microelectronic elements to be formed on a chip, and a need for processes that facilitate the fabrication of such chip structures.
SUMMARY
In an implementation example, an apparatus is provided, including a chip substrate having a first chip surface facing away from a second chip surface; an array of microelectronic elements on the first chip surface; and an array of conductors each in communication with one of the microelectronic elements, the conductors passing through the chip substrate and fully spanning a distance between the first and second chip surfaces.
In another example, a process is provided, including: providing an apparatus including a chip substrate having a first chip surface facing away from a second chip surface, an array of microelectronic elements being on the first chip surface, an array of conductors each being in communication with one of the microelectronic elements and partially spanning an average distance between the first and second chip surfaces; bonding a temporary support carrier onto the array of microelectronic elements; removing a portion of the chip substrate, thereby reducing the average distance between the first and second chip surfaces; and forming an under bump metallization pad at the second chip surface in electrical communication with a conductor.
Other systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE FIGURES
The invention can be better understood with reference to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
FIG. 1 is a cross-sectional view showing an implementation of an example of a microelectronic element array chip with direct chip attachment (“DCA”) pads (“Microelectronic Element Array with DCA Pads”).
FIG. 2 is a top view, taken on line 2 - 2 , of the Microelectronic Element Array with DCA Pads shown in FIG. 1 .
FIG. 3 is a cross-sectional view, taken on line 3 - 3 , of the Microelectronic Element Array with DCA Pads as shown in FIG. 1 .
FIG. 4 is a cross-sectional view showing an array of microelectronic elements formed on a top surface of a typical chip substrate.
FIG. 5 is a flow-chart showing an example of an implementation of a process for fabricating the Microelectronic Element Array with DCA Pads.
FIG. 6 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads during its fabrication.
FIG. 7 is a top view of the Microelectronic Element Array with DCA Pads during its fabrication, taken on line 7 - 7 .
FIG. 8 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads during its fabrication.
FIG. 9 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads during its fabrication.
FIG. 10 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads during its fabrication.
FIG. 11 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads during its fabrication.
FIG. 12 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads during its fabrication.
FIG. 13 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads during its fabrication.
DETAILED DESCRIPTION
FIG. 1 is a cross-sectional view showing an implementation of an example of a microelectronic element array chip with direct chip attachment (“DCA”) pads (“Microelectronic Element Array with DCA Pads”) 100 . FIG. 2 is a top view, taken on line 2 - 2 , of the Microelectronic Element Array with DCA Pads 100 shown in FIG. 1 . FIG. 3 is a cross-sectional view, taken on line 3 - 3 , of the Microelectronic Element Array with DCA Pads 100 as shown in FIG. 1 .
The Microelectronic Element Array with DCA Pads 100 includes a chip substrate 102 on which an array of microelectronic elements 104 is formed. Throughout this specification, the term “microelectronic element” means a device including electrical conductors that affect the device in operation. The term “microelectronic element” includes, as an example, semiconductor devices, passive filters, sensors, and optoelectronic devices including micro-electro-mechanical systems (“MEMS”). The term “semiconductor device” means, throughout this specification, a device that utilizes a doped semiconductor p-n hetero-junction between Group 3-5, 2-6, or 4-4 semiconductors that allows a controlled flow of electrons and/or holes across the hetero-junction. As examples, “semiconductor devices” include transistors and diodes. The term “MEMS” means, throughout this specification, a device on a chip substrate 102 that integrates mechanical elements, actuators for the mechanical elements, and electronics for controlling the actuators. In an implementation, a MEMS device may include sensors. As a further example, a MEMS device may include optical elements, such as mirrors controlled by the actuators.
Throughout this specification, the term “array” means an arrangement of a plurality of microelectronic elements 104 on a chip substrate 102 . As an example, the Microelectronic Element Array with DCA Pads 100 may include a five by five (5×5) array of twenty-five (25) microelectronic elements 104 on a chip substrate 102 , arranged in five rows and five columns as shown in FIG. 2 . It is understood that an “array” may include any number of microelectronic elements 104 arranged in any number of rows and columns, that the rows and columns may have equal or unequal spacing or lengths, that the rows and columns may or may not be mutually orthogonal, that such an array may incorporate one or more complex repeating patterns of relative locations for microelectronic elements 104 on a chip substrate 102 , that an array may include individual microelectronic elements 104 or groups of such elements positioned at selected relative locations on a chip substrate, and that an array may include microelectronic elements randomly positioned on a chip substrate.
As an example, each microelectronic element 104 may include four element conductors 106 in communication with the microelectronic element and extending into the chip substrate 102 away from the microelectronic element. As an example, the microelectronic elements 104 may be MEMS micro-mirror elements. In this example, the four element conductors 106 in communication with each MEMS micro-mirror element may operate as controllers serving to power one or more actuators causing a micro-mirror in the MEMS micro-mirror element to be moved in a specified direction. It is understood that each microelectronic element 104 may include any selected number of element conductors 106 , and that different microelectronic elements 104 in the Microelectronic Element Array with DCA Pads 100 may have different numbers of element conductors. It is further understood that by “element conductors 106 in communication with the microelectronic element” is meant that the element conductors 106 are placed in positions relative to the microelectronic element 104 that are suitable for its operation. As examples, the element conductors 106 may form an electrical connection with circuit elements within the microelectronic elements 104 or may generate an electromagnetic field affecting the microelectronic elements 104 depending on their structure and operating design.
The element conductors 106 extend from points 108 where they communicate with the microelectronic elements 104 to points 110 after passing through the chip substrate 102 . As an example, the chip substrate 102 may be formed of a conductor such as polysilicon or a composition including silicon (“Si”). In this example, the element conductors may be surrounded by insulator layers 112 .
FIG. 3 shows a ten by ten (10×10) array of element conductors 106 in an implementation of a five by five (5×5) array of microelectronic elements 104 that each may need four (4) element conductors for operation of the microelectronic elements. It is seen in FIG. 3 that as the magnitude of the array of microelectronic elements 104 to be formed on a chip substrate 102 is increased, and as the number of element conductors 106 needed for operation of each microelectronic element increases, the density and total number of element conductors needed for the Microelectronic Element Array with DCA Pads 100 may accordingly increase. As a further example, it is seen that as the dimensions of a Microelectronic Element Array with DCA Pads 100 increases, the number of element conductors 106 needed for the Microelectronic Element Array with DCA Pads 100 increases as a function of n×m, where n is the width and m is the height of the array represented by the arrows 114 and 116 respectively. The same increase as a function of n×m is seen with respect to the array of microelectronic elements 104 at the same density shown in FIG. 3 . Meanwhile, the size of the perimeter of the chip substrate 102 increases only as a function of 2×n plus 2×m. Hence, as the size and density of the array are increased, the impracticality of wire bonding of element conductors on top of the microelectronic elements 104 and over the perimeter of the Microelectronic Element Array with DCA Pads 100 , and the resulting need for DCA bonding, correspondingly increase.
FIG. 4 is a cross-sectional view showing an array 400 of microelectronic elements 104 formed on a top surface 402 of a typical chip substrate 404 . As an example, the thickness of a chip substrate 404 having a diameter of 200 millimeters, as represented by the arrow 406 , may be about 725 micrometers plus or minus about 25 micrometers. Efforts to provide DCA pads for a microelectronic element 104 at a bottom surface 408 of a chip substrate 404 having a thickness of such a magnitude may be problematic. As an example, forming extensions of the element conductors 106 to reach the bottom surface 408 may be difficult, as attempting to fill an array of through wafer vias extending to the bottom surface 408 with a conductor may result in the formation of voids. Patterning of through wafer vias having high aspect ratios may accordingly be difficult. In an implementation, internal stresses in the chip substrate 404 may by generated by filling such an array of through wafer vias with a conductor, potentially causing distortion of the structure of the array 400 of microelectronic elements 104 . Such distortion may complicate further fabrication steps or make completion of the array 400 unfeasible. As another example, forming extensions of the element conductors 106 having lengths adequate to traverse the thickness of the chip substrate 404 as represented by the arrow 406 may result in degraded performance of the array 400 of microelectronic elements 104 due to the high lengths of the element conductors.
Referring again to FIG. 1 , the Microelectronic Element Array with DCA Pads 100 accordingly includes a chip substrate 102 having a substantially reduced average thickness, as represented by the arrow 118 . As an example, the average thickness represented by the arrow 118 may be less than about 150 micrometers. In another implementation, the average thickness represented by the arrow 118 may be less than about 100 micrometers. The Microelectronic Element Array with DCA Pads 100 may be fabricated according to an implementation of a process discussed below that may be less susceptible to defective formation of extensions of the element conductors 106 , the extension being formed onto a bottom surface 120 of the Microelectronic Element Array with DCA Pads 100 . Furthermore, the Microelectronic Element Array with DCA Pads 100 may provide better performance in operation than the array 400 of microelectronic elements 104 formed on a typical chip substrate 404 . Since the average thickness represented by the arrow 118 is substantially less than the thickness represented by the arrow 406 , the element conductors 106 in the Microelectronic Element Array with DCA Pads 100 have a substantially shorter path length to the bottom surface 120 than do the element conductors 106 in the array 400 of microelectronic elements 104 to the bottom surface 408 . The thickness of the chip substrate 102 represented by the arrow 118 may be inadequate to mechanically support the Microelectronic Element Array with DCA Pads 100 . The example process for fabricating the Microelectronic Element Array with DCA Pads 100 discussed below may facilitate fabrication and DCA bonding of the Microelectronic Element Array with DCA Pads 100 without breakage or other damage to the Microelectronic Element Array with DCA Pads 100 otherwise potentially caused by the reduced thickness of the chip substrate 102 .
The Microelectronic Element Array with DCA Pads 100 may include a barrier layer 122 . The barrier layer 122 may in an implementation be formed of a dielectric composition that is not a conductor. Each element conductor 106 is in electrical communication with an under-bump metallization pad 124 passing through a hole in the barrier layer 122 . As an implementation, the under-bump metallization pads 124 may be mutually separated by an insulating protective layer 126 . As an example, each under-bump metallization pad 124 may be in electrical communication with a solder bump 128 . It is understood that the solder bump may be formed of a suitable conductor, which may be a solder composition or may be another conductive composition.
FIG. 1 shows the Microelectronic Element Array with DCA Pads 100 after DCA bonding to a substrate 130 forming part of another device with which the Microelectronic Element Array with DCA Pads 100 has been integrated. As examples, the substrate 130 may be a circuit board or another chip substrate. In an implementation, the substrate 130 may include bonding pads 132 formed of a conductor composition, in electrical communication with electrical circuitry within the substrate 130 , and in electrical communication with the solder bumps 128 and the under-bump metallization pads 124 .
FIG. 5 is a flow-chart showing an example of an implementation of a process 500 for fabricating the Microelectronic Element Array with DCA Pads 100 . FIG. 6 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads 100 at a stage 600 during its fabrication. FIG. 7 is a top view of the Microelectronic Element Array with DCA Pads 100 at stage 600 of its fabrication taken on line 7 - 7 . FIG. 8 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads 100 at a stage 800 during its fabrication. FIG. 9 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads 100 at a stage 900 during its fabrication. FIG. 10 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads 100 at a stage 1000 during its fabrication. FIG. 11 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads 100 at a stage 1100 during its fabrication. FIG. 12 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads 100 at a stage 1200 during its fabrication. FIG. 13 is a cross-sectional view showing an example of a Microelectronic Element Array with DCA Pads 100 at a stage 1300 during its fabrication.
The process 500 starts at step 502 . At step 504 , an array 400 of microelectronic elements 104 formed on a typical chip substrate 404 , as shown in FIG. 4 and discussed above, may be provided or fabricated. The array 400 of microelectronic elements 104 formed on a chip substrate 404 includes a element conductor 106 in electrical communication with microelectronic elements 104 in the manner as discussed above in connection with FIG. 1 . However, the element conductors 106 do not traverse the full thickness of the chip substrate 404 as represented by the arrow 406 , but instead terminate at points 110 . As an example, a barrier layer 122 may be interposed within the chip substrate 404 at the points 110 . In an implementation, the chip substrate 404 is formed of a conductive composition, and the element conductors 106 are surrounded by insulator layers 112 as discussed above in connection with FIG. 1 .
In an implementation, the thickness of a chip substrate 404 having a diameter of 200 millimeters, as represented by the arrow 406 , may be about 725 micrometers plus or minus about 25 micrometers. It is understood that such a thickness of the chip substrate 404 is merely an example, and arrays 400 of microelectronic elements 104 on chip substrates 404 having other thicknesses may be utilized. The array 400 of microelectronic elements 104 as shown in FIG. 4 may be fabricated utilizing conventional techniques for making such devices on a chip substrate 404 . As an example, the array 400 of microelectronic elements 104 formed on a chip substrate 404 may be commercially obtained. In an implementation, an array 400 of microelectronic elements 104 formed on a chip substrate 404 having such a thickness may be selected as a starting material for utilization in the process 500 , as the thick chip substrate 404 may provide good mechanical support for the array 400 of microelectronic elements 104 during the initial steps of the process 500 now discussed.
Referring to FIGS. 6 and 7 showing fabrication of a Microelectronic Element Array with DCA Pads 100 at stage 600 , at step 506 a temporary support carrier 602 having perforations 604 is provided or fabricated. The temporary support carrier 602 includes a bottom surface 606 having suitable dimensions selected for bonding onto the top surface 402 of the array 400 of microelectronic elements 104 . The temporary support carrier further includes a top surface 608 opposite the bottom surface 606 . The perforations 604 reach both the bottom and top surfaces 606 and 608 , respectively.
At step 508 , the bottom surface 606 of the temporary support carrier 602 is bonded onto the top surface 402 of the array 400 of microelectronic elements 104 . In an implementation, a layer 610 of an adhesive composition may be interposed between the top surface 402 of the array 400 and the bottom surface 606 of the temporary support carrier 602 to form a bond. As an example, an adhesive composition suitable for subsequent dissolution by a solvent composition compatible with the array 400 of microelectronic elements 104 may be selected. By “compatible” is meant throughout this specification that the solvent composition will not cause any significant damage to the array 400 . The perforations 604 facilitate introduction of such a solvent composition to portions of the layer 610 that are exposed by the perforations 604 and are covered by the adhesive composition, in order to dissolve the adhesive as discussed further below. As an example, a protective passivation layer 612 may be formed on the top surface 402 of the array 400 before application of the layer 610 of an adhesive composition. Such a protective passivation layer 612 may protect the array 400 of microelectronic elements 104 from contamination or other damage by the layer 610 of an adhesive composition. In an implementation, the protective passivation layer 612 is formed of a composition suitable for subsequent removal as discussed below. As examples, the passivation layer may include silicon dioxide or silicon nitride or a mixture.
Referring to FIG. 8 showing fabrication of a Microelectronic Element Array with DCA Pads 100 at stage 800 , at step 510 the bottom surface 408 of the chip substrate 404 as shown in FIG. 6 is removed to expose the barrier layer 122 . As an example, the portion of the chip substrate 404 between the barrier layer 122 and the bottom surface 408 may be removed by a series of steps including backgrinding, polishing, and etching to the barrier layer 122 . In an implementation, the barrier layer 122 is formed of a composition including silicon dioxide, the chip substrate 404 is formed of a composition including silicon, and a wet etching composition that erodes silicon dioxide more slowly than it erodes silicon is selected. In another implementation, the barrier layer 122 may be omitted, and an etching process may be carried out over a controlled time period to stop at the bottom surface 120 .
Referring to FIG. 9 showing fabrication of a Microelectronic Element Array with DCA Pads 100 at stage 900 , at step 512 the barrier layer 122 may be selectively etched to expose the element conductors 106 that are in contact with the barrier layer 122 . As an example, a photoresist may be applied onto the barrier layer 122 , and exposed to light through a mask configured to enable subsequent removal of those portions of the photoresist overlying the element conductors 106 . A suitable etching composition may then be applied onto the photoresist for selective removal of the exposed regions of the barrier layer 122 , leaving holes 902 in the barrier layer 122 .
Referring to FIG. 10 showing fabrication of a Microelectronic Element Array with DCA Pads 100 at stage 1000 , at step 514 an array of under bump metallization (“UBM”) pads 124 are formed in electrical communication with the element conductors 106 at the points 110 . As an example, the UBM pads 124 may be formed by multiple cycles of a liftoff photoresist process with successive application of metallization layers. In an implementation, the UBM pads 124 may include one or more types of layers successively applied onto the element conductors 106 , including adhesion, diffusion barrier, solder bump wetting, and oxidation-protective layers. An adhesion layer may be applied to the element conductors 106 to facilitate adhesion of subsequently applied layers. A diffusion barrier layer may then be applied to reduce migration of a solder composition, discussed below, into the element conductors 106 . A solder wetting layer may then be applied to facilitate wetting of the UBM pads 124 by solder bumps 128 discussed below. An oxidation-protective layer may then be applied to reduce oxidation of the UBM pads 124 . It is understood that each of the adhesion, diffusion barrier, solder bump wetting, and oxidation-protective layers may be formed by multiple cycles of a liftoff photoresist process, and that one or more of such layers may be omitted or applied in a different order. After completion of the liftoff photoresist process, portions of the photoresist composition may be left behind on the barrier layer 122 surrounding the UBM pads 124 . In an implementation, these portions of the photoresist composition may be retained on the barrier layer 122 , forming an insulating layer 126 between the UBM pads 124 .
In an implementation (not shown), step 514 may include the formation of lateral conductors on the barrier layer 122 in electrical communication with the element conductors 106 , in order to transform the array of element conductors 106 as shown in FIG. 3 into a different array layout selected for compatibility with an array of bonding pads 132 on a substrate 130 forming part of another device with which the Microelectronic Element Array with DCA Pads 100 is to be been integrated. As an example, a layer of a conductive composition may be applied onto the barrier layer 122 . The layer of conductive composition may then be patterned by application and lithographic exposure of a photoresist followed by etching of the regions unprotected by the photoresist, leaving behind lateral conductors on the surface of the barrier layer 122 each in electrical communication with an element conductor at a point 120 . The lateral conductors, as an example in the form of wires, may then be covered by an insulating layer. The insulating layer may then be selectively removed forming vias in communication with exposed ends of the lateral conductors distal to the element conductors 106 . The vias may then be filled with a conductive composition to form conductors arranged in a selected transformed array. The above-discussed aspects of step 514 earlier discussed and shown in FIG. 10 may then be carried out.
Referring to FIG. 11 showing fabrication of a Microelectronic Element Array with DCA Pads 100 at stage 1100 , at step 516 an array of solder bumps 128 may be formed on the UBM pads 124 . As an implementation, the solder bumps 128 may be formed by a liftoff photoresist process as earlier discussed. In examples, the solder bumps 128 may be formed of a conductor composition including tin, indium, or a mixture. Referring to FIG. 11 , the photoresist layer 1102 may form wells into which the composition utilized for forming the solder bumps 128 may drop down and penetrate. As an implementation, the photoresist layer 1102 may form wells having walls that taper to a smallest width where ends 1103 of the solder bumps 128 will be formed. Portions 1104 of a conductor composition utilized for forming the solder bumps 128 may be deposited on the photoresist layer 1102 . The portions 1104 of the conductor composition may be subsequently removed along with the photoresist layer 1102 , due to differences in height of the solder bumps 128 and portions 1104 of the conductor composition on the photoresist layer 1102 . As an example, the photoresist layer 1102 may be temporarily left on the insulating protective layer 126 to protect the solder bumps 128 and UBM pads 124 from damage. In another implementation, an additional protective layer 1106 may be applied onto the solder bumps 128 , the portions 1104 of the conductor composition and the photoresist layer 1102 to further protect the solder bumps and the UBM pads 124 from damage. As an example, the protective layer 1106 may be formed of a photoresist composition.
In an implementation, step 516 may include dicing multiple arrays 400 of microelectronic elements 104 , as formed on a single wafer. As an example, dicing may be carried out after formation of the solder bumps 128 . In an implementation, dicing may be carried out prior to removal of the photoresist layer 1102 . As another example, the protective layer 1106 may be applied prior to dicing. The photoresist layer 1102 and the protective layer 1106 may protect the arrays 400 of microelectronic elements 104 from contamination by wafer debris and other damage during dicing.
Referring to FIG. 12 showing fabrication of a Microelectronic Element Array with DCA Pads 100 at stage 1200 , at step 518 the photoresist layer 1102 and the portions 1104 of the conductor composition may be removed to expose the UBM pads 124 and the solder bumps 128 for DCA bonding onto a second substrate 130 . The photoresist layer 1106 , if present, may be removed at the same time. In an implementation, the temporary support carrier 602 may remain bonded at stage 1200 onto the top surface 402 of the array 400 of microelectronic elements 104 . In an example, removal of the temporary support carrier 602 from the array 400 of microelectronic elements 104 prior to bonding of the array 400 onto a second substrate 130 may result in deformation or breakage of the array 400 due to inadequate mechanical strength of the chip substrate 404 .
Referring to FIG. 13 showing fabrication of a Microelectronic Element Array with DCA Pads 100 at stage 1300 , at step 520 the array 400 of microelectronic elements 104 is positioned on a second substrate 130 for DCA bonding of the array of UBM pads 124 and solder bumps 128 onto and in alignment with an array of conductors on the surface 1302 of the second substrate 130 . As an example, the second substrate 130 may include an array of bonding pads 132 formed of a conductor composition. In an implementation, bonding may be carried out by applying heat at a controlled temperature tolerable by the array 400 and the second substrate 130 . Pressure between the solder bumps 128 and the bonding pads 132 may, as an example, be applied. In an implementation, the solder bumps 128 may then be subjected to a reflow process. As an example, spaces 1304 between the array 400 and the second substrate 130 may be underfilled with an insulating composition. In an implementation, care is taken in such underfilling so that the temporary support carrier 602 and the microelectronic elements 104 are not contaminated by the insulating composition. As an example, the insulating composition may include silicon nitride. In another implementation, dicing of a wafer including multiple arrays 400 of microelectronic elements 104 is delayed until after completion of step 520 .
Referring to FIG. 13 , at step 522 the temporary support carrier 602 may then be removed, yielding the Microelectronic Element Array with DCA Pads 100 DCA bonded onto the second substrate 130 . In an implementation, a solvent for the adhesive layer 610 may be applied to the perforations 604 and the temporary support carrier 602 may then be removed. In an implementation where a protective passivation layer 612 is present, it may then be suitably removed. The process 500 then ends at step 524 .
It will be understood that the foregoing description of numerous implementations has been presented for purposes of illustration and description. As an example, modifications may be made in the structures of the Microelectronic Element Arrays with DCA Pads 100 while providing the UBM pads and a chip substrate with a reduced path length of element conductors through the chip substrate for DCA bonding. This description is not exhaustive and does not limit the claimed invention to the precise forms disclosed. Modifications and variations are possible in light of the above description or may be acquired from practicing the invention. The claims and their equivalents define the scope of the invention.
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Apparatus including a chip substrate having a first chip surface facing away from a second chip surface; an array of microelectronic elements on the first chip surface; and an array of conductors each in communication with one of the microelectronic elements, the conductors passing through the chip substrate and fully spanning a distance between the first and second chip surfaces. Process including: providing an apparatus including a chip substrate having a first chip surface facing away from a second chip surface, an array of microelectronic elements being on the first chip surface, an array of conductors each being in communication with one of the microelectronic elements and partially spanning an average distance between the first and second chip surfaces; bonding a temporary support carrier onto the array of microelectronic elements; removing a portion of the chip substrate, thereby reducing the average distance between the first and second chip surfaces; and forming an under bump metallization pad at the second chip surface in electrical communication with a conductor.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] Embodiments of the present invention generally relate to an apparatus and methods for generating a downhole overpull force. More specifically, the present invention relates to jarring with a downhole overpull generator.
[0003] 2. Description of the Related Art
[0004] In a conventional downhole fishing operation, a bottom hole assembly is lowered into a wellbore on a drill string. The bottom hole assembly typically includes a slinger, a jar, and a fishing tool (such as an overshot) that are connected via drill collars and drill pipe. A jar is a device that is used downhole to deliver an impact load to another downhole component, especially when that object is stuck in the wellbore. The jar generally includes a device for storing energy (e.g. a spring or a pressure chamber) and a triggering device that is configured to activate the jar at a predetermined instant, thereby allowing the jar to deliver the impact load.
[0005] During the fishing operation, the bottom hole assembly is lowered into the wellbore and attached to the object stuck in the wellbore by utilizing the fishing tool. Thereafter, a rig at the surface of the wellbore is used to pull up on the drill string, imparting a force on the drill string and storing the created energy in the slinger and the drill string. At a predetermined pull force and/or time, the triggering device in the jar activates the jar, thereby causing the jar to deliver the impact load to the object stuck in the wellbore.
[0006] The use of a bottom hole assembly in a conventional fishing operation may be effective in dislodging an object stuck in a vertical wellbore since the rig is able to pull up on the drill string and generate the energy for use with the jar. However, a problem arises when the same bottom hole assembly is used in a deviated wellbore. In this situation, the rig is not fully pulling up on the drill string and generating the energy for use with the jar due to the curvature and the associated friction between the drill string and the wall of the wellbore.
[0007] Therefore, there is a need for a device and a method of generating a overpull force downhole. There is a further need for a device and a method of fishing with a downhole overpull generator.
SUMMARY OF THE INVENTION
[0008] The present invention generally relates to an apparatus and method of fishing with an overpull generator. In one aspect, a method of impacting an object in a wellbore is provided. The method includes the step of running an assembly into the wellbore on a conveyance member and attaching the assembly to the object, wherein the assembly comprises an overpull generator and a delay force release device. The method also includes the step of generating an overpull force in the wellbore by selectively activating the overpull generator. Additionally, the method includes the step of applying an impact force to the object by activating the delay force release device and releasing the generated overpull force, thereby dislodging the object stuck in the wellbore.
[0009] In another aspect, a method of freeing an object stuck in a wellbore is provided. The method includes the steps of generating an overpull force downhole and storing the overpull force downhole. The method also includes the step of selectively releasing the overpull force in the wellbore and applying a force to the object to free the stuck object.
[0010] In a further aspect, an assembly for dislodging an object stuck in a wellbore is provided. The assembly includes an overpull generator configured to generate an overpull force in the wellbore. The assembly also includes a delay force release device configured to selectively release the overpull force and apply an impact force. Additionally, the assembly includes a coupling member configured to attach to the object stuck in the wellbore.
[0011] In yet a further aspect, an overpull generator for use in generating an overpull force in a wellbore is provided. The overpull generator includes a housing having a section configured to transmit torque. The overpull generator further includes a series of fluid actuated pistons disposed in the housing. The overpull generator also includes a piston rod movable in the housing between a first position and a second position by utilizing the series of fluid actuated pistons, the piston rod having a section configured to transmit torque.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0013] FIG. 1 is a view illustrating a bottom hole assembly disposed in a wellbore with a piston rod in an overpull generator in an extended position.
[0014] FIG. 2 is a view illustrating the bottom hole assembly disposed in the wellbore with the piston rod in the overpull generator in a retracted position.
[0015] FIG. 3 is a view illustrating the bottom hole assembly disposed in the wellbore after an object in the wellbore has been dislodged.
[0016] FIG. 4 is a sectional view of the overpull generator.
[0017] FIG. 5 is a cross-sectional view taken along line 5 - 5 in FIG. 4 .
DETAILED DESCRIPTION
[0018] The present invention generally relates to an apparatus and method of jarring with an overpull generator. More specifically, the invention relates to a bottom hole assembly that includes an overpull generator that works in conjunction with a delay force release device to dislodge an object stuck in the wellbore. It is to be noted, however, that even though the overpull generator will be described in relation to the delay force release device, the present invention is not limited to a delay force release device, but is equally applicable to other types of downhole tools. Additionally, the present invention will be described as it relates to a deviated wellbore. However, it should be understood that the present invention may be employed in a vertical or a non-deviated wellbore without departing from the principles of the present invention. To better understand the novelty of the apparatus of the present invention and the methods of use thereof, reference is hereafter made to the accompanying drawings.
[0019] FIG. 1 is a view illustrating a bottom hole assembly 200 disposed in a wellbore 10 with an overpull generator 100 in an extended position. The bottom hole assembly 200 is generally used to dislodge an object 20 that is stuck in the wellbore 10 . As will be described herein, the bottom hole assembly 200 includes the overpull generator 100 configured to apply a force, a slinger 160 configured to store the energy, a delay force release device 150 configured to release the stored energy, and a coupling member 175 configured to grip the object 20 . The bottom hole assembly 200 may also include an optional anchor device 170 that is configured to secure the bottom hole assembly 200 in the wellbore 10 .
[0020] It should be noted that the overpull generator 100 is positioned in the bottom hole assembly 200 proximate the delay force release device 150 . This arrangement minimizes pulling force loss due to wellbore friction relative to the conventional fishing operation. In other words, in the conventional fishing operation, the drill string is pulled at the surface to create an overpull, however, this arrangement results in a relatively lower tension at the bottom hole assembly due to an interface 75 with the wellbore 10 . Furthermore, due to wellbore friction at the interface 75 , it may be hard to determine how much force is actually experienced at the bottom hole assembly in the conventional fishing operation which may reduce the effectiveness of the operation. Additionally, there is typically a limit to how much tension can be applied by some rigs/hoists, and a limit to the tensile rating of the drill string (or another type of conveyance member). However, by using the overpull generator 100 in the wellbore 10 , the overpull generator 100 enables these limitations to be circumvented by ensuring the necessary load is applied directly to the bottom assembly 200 . Additionally, not only is it possible to generate a higher load, but a known load can be applied based upon the known piston characteristics of the overpull generator 100 . Further, when the overpull generator 100 is used in combination with downhole instrumentation and optional data communication (e.g. wires, EM, mud pulse), the operational characteristics can be determined and then tailored to suit the situation in the wellbore 10 .
[0021] The overpull generator 100 is configured to create a force which is used by the other components in the bottom hole assembly 200 to dislodge the object 20 . The energy is generated by moving a piston rod 110 of the overpull generator 100 between an extended position and a retracted position, as shown in FIGS. 1-3 . Although the bottom hole assembly 200 in FIGS. 1-3 shows the overpull generator 100 in a downward position, the overpull generator 100 may be in an upward position, thereby reversing the direction of the actuation force and the release force without departing from principles of the present invention. Generally, the overpull generator 100 includes a plurality of pistons 125 that activate due to a pressure drop in the bottom hole assembly 200 . The overpull generator 100 will be described in greater detail in FIGS. 3 and 4 .
[0022] The slinger 160 is configured to store energy that is generated by the overpull generator 100 . Generally, the slinger 160 is a tool that is used in conjunction with the delay force release device 150 to store energy that comes from the overpull generator 100 . An example of a slinger is set forth in U.S. Pat. No. 6,328,101, which is herein incorporated by reference in its entirety. The energy, once released by the slinger 160 , provides an impact force that operates associated downhole tools to help the release of the object 20 stuck in the wellbore 10 . The energy may be stored in the slinger 160 by any means known in the art, such as by a mechanical spring or a compressible fluid.
[0023] The delay force release device 150 is generally a device that releases energy after a certain period of time. The delay force release device 150 may be any type of device known in the art that is configured to release energy, such as a jar. An example of a jar is set forth in U.S. Pat. No. 6,202,767, which is herein incorporated by reference in its entirety. As known in the art, a jar is a device that is used downhole to deliver an impact load to another downhole component, especially when that component is stuck. The delay force release device 150 may be hydraulically activated by using a timer comprising a viscous flow meter, whereby at a predetermined over pull force generated by the overpull generator 100 a detent releases thereby allowing the delay force release device 150 to release. Alternatively, the delay force release device 150 may be mechanically activated by using a mechanical timer, whereby at a predetermined overpull force generated by the overpull generator 100 the mechanical timer allows the delay force release device 150 to release. Even though the respective designs may be different, each device uses energy that is stored in the slinger 160 and is suddenly released by the delay force release device 150 when it fires.
[0024] The delay force release device 150 can be designed to strike up, down, or both. In the case of jarring up above the stuck object 20 , as shown in FIG. 1 , the slinger 160 and a plurality of drill collars 190 , 195 are pulled upward by the overpull generator 100 but the stuck object does not move. Since the slinger 160 and the drill collars 190 , 195 are moving up, this means that the slinger 160 and the drill collars 190 , 195 are stretching and storing energy. When the delay force release device 150 reaches a predetermined overpull force, the delay force release device 150 suddenly allows one section of the delay force release device 150 to move axially relative to a second section, being pulled up rapidly in much the same way that one end of a stretched spring moves when released. After a few inches of movement, this moving section slams into a steel shoulder in the delay force release device 150 , imparting an impact load on the stuck object 20 .
[0025] The coupling means 175 is a tool that is capable of connecting to the object 20 in the wellbore 10 , such as an overshot. The coupling means 175 may be configured to engage on the outside surface of the object 20 stuck in the wellbore 10 . Typically, the coupling device 175 includes a grapple or similar slip mechanism that grips the object 20 such that a force and jarring action may be applied to the object 20 . If the object 20 cannot be removed, a release system within the coupling device 175 allows the coupling means 175 to be disengaged and retrieved.
[0026] The bottom hole assembly 200 optionally may include the anchor device 170 . The anchor device 170 may be positioned in the bottom hole assembly 200 above the overpull generator 100 . The anchor device 170 may include a slip mechanism that is configured to grip the walls of the wellbore 10 in order to secure the bottom hole assembly 200 in the wellbore 10 . In another embodiment, the anchor device may be part of the overpull generator 100 .
[0027] The bottom hole assembly 200 optionally may also include a vibration member (not shown). An example of a vibration member is set forth in U.S. Pat. No. 6,164,393, which is herein incorporated by reference in its entirety. The vibration member is used to generate vibration that works in conjunction with the impact force of the delay force release device 150 to dislodge the object 20 stuck in the wellbore 10 . The vibration member may generate the vibration by any suitable means known in the art, such as oscillating a moving mass, creating a cyclic restriction to fluid flowing through the bottom hole assembly 200 , an electromagnetic oscillator, creating pressure pulses in a fluid, or injecting gas, a liquid, or a combination thereof into fluid operatively associated with the device in the bottom hole assembly 200 .
[0028] The bottom hole assembly 200 may include a hydraulic or mechanical disconnect device (not shown) to allow the operator to disconnect from the object 20 and retry the downhole operation. An example of a disconnect device is described in U.S. patent application Ser. No. 11/842,837, which is herein incorporated by reference in its entirety. The use of the disconnect device allows the operator to disconnect and reconnect to the object 20 multiple times.
[0029] The bottom hole assembly 200 may include a sensing member (not shown) that is configured to measure a downhole parameter. In one embodiment, the sensing member may be configured to measure the impact force applied by the delay force release device 150 to the object 20 . In a further embodiment, the sensing member may be configured to measure the amount of force (i.e. energy) generated by the overpull generator 100 . In another embodiment, the sensing member may be configured to measure a torque, a direction of rotation and a rate of rotation of a component in the bottom hole assembly 200 . The sensing member may send the measured data to the surface via a communication line in the conveyance member 50 . Alternatively, the sensing member may send the measured data to a memory device in the bottom hole assembly 200 which is capable of storing the measured data until the data is retrieved when the bottom hole assembly 200 is removed from the wellbore 10 . Further, the sensing member may send the measured data to the surface via EM or mud pulse devices. The measured data may be used by an operator to effectively perform the downhole operation. For instance, the operator may use the data to tailor the downhole operation (or subsequent attempts) to dislodge the object 20 stuck in the wellbore 10 .
[0030] The bottom hole assembly 200 is disposed in the wellbore 10 on a conveyance member 50 . The conveyance member 50 may be any type of member that is capable of positioning the bottom hole assembly 200 in the wellbore 10 , such as a drill string, coiled tubing, Corod®, etc.
[0031] In operation, the bottom hole assembly 200 is positioned in the wellbore 10 to allow the coupling member 175 to attach to the stuck object 20 . Thereafter, the conveyance member 50 is pulled upward to remove any slack that may be in the in the conveyance member 50 . Next, the piston rod 110 is moved to the extended position by further pulling up on the conveyance member 50 . Alternatively, the bottom hole assembly 200 may be lowered into the wellbore 10 with the piston rod 110 in the extended position. In either case, the overpull generator 100 is in the extended position in order to generate the energy to be used by the delay force release device 150 . Subsequently, fluid is pumped down the conveyance member 50 into the overpull generator 100 to create a pressure differential which causes the pistons 125 in the overpull generator 100 to retract the piston rod 110 . The movement of the piston rod 110 from the extended position to the retracted position generates an overpull force (i.e. energy) that is stored in the slinger 160 and will be used to dislodge the object 20 stuck in the wellbore 10 . At a predetermined overpull force, the delay force release device 150 fires thereby releasing the energy stored in the slinger 160 and imparting an impact load on the stuck object 20 . The impact load may be 3 to 5 times the initial overpull force. Further, if the anchor member 170 is part of the bottom hole assembly 200 , then the anchor device 170 is set prior to the movement of the piston rod 110 from the extended position to the retracted position in order to support the overpull force generated by the overpull generator 100 . Additionally, if there is a vibrator in the bottom hole assembly 200 , then the vibrator may be activated when the fluid is pumped down the conveyance member 50 to create the pressure differential that activates the overpull generator 100 .
[0032] The movement of the piston rod 110 of the overpull generator 100 from the extended position to the retracted position generates an overpull force (i.e. energy) that will be used to dislodge the object 20 stuck in the wellbore 10 . The overpull generator 100 is activated by a pressure differential between the inside the overpull generator 100 and the outside the overpull generator 100 . The pressure differential causes the plurality of pistons 125 in the overpull generator 100 to retract the piston rod 110 . The pressure differential may be generated by regulating the flow rate through the overpull generator 100 or by using a restriction in the overpull generator 100 . If the pressure drop across the overpull generator 100 is not sufficient with the existing bottom hole assembly 200 , then an orifice sub (not shown) may be included in the bottom hole assembly 200 , and positioned below the overpull generator 100 in order to create the pressure differential required to activate the overpull generator 100 and move the piston rod 110 from the extended position to the retracted position. In one embodiment, the overpull generator 100 is activated at a predetermined threshold pressure differential. In this embodiment, the overpull generator 100 may include a frangible member (not shown), such as a shear screw, between components of the overpull generator 100 , wherein the frangible member is configured to shear (or break apart) at a predetermined pressure differential thereby allowing the pistons 125 to retract the piston rod 110 . Alternatively, the overpull generator 100 may include a biasing member (not shown), such as a spring, that is configured to bias the rod 110 , wherein at a predetermined pressure differential the biasing force of the biasing member is overcome thereby allowing the pistons 125 to retract the piston rod 110 . Further, the overpull generator 100 may include a combination of frangible members and biasing members.
[0033] Although the bottom hole assembly 200 in FIGS. 1 and 2 illustrate a single overpull generator 100 attached to the delay force release device 150 , it should be understood, however, that any number of overpull generators 100 may be employed in the bottom hole assembly 200 , without departing from principles of the present invention. The use of more than one overpull generator 100 with the delay force release device 150 may be beneficial if there is a need for additional energy to activate the delay force release device 150 or if there is a need for additional stroke in the assembly 200 . In another embodiment, a first overpull generator 100 may be positioned in the bottom hole assembly 200 to activate the delay force release device 150 and a second overpull generator 150 may be positioned in the bottom hole assembly 200 between the delay force release device 150 and the coupling device 175 to push against the object 20 to create a push/pull effect. In a further embodiment, the bottom hole assembly 200 may include multiple delay force release devices 150 working in conjunction with multiple overpull generators 100 . In the embodiments with multiple overpull generators 100 , each overpull generator 100 may have a separate orifice sub to active the overpull generator 100 or a single orifice sub may be moved through the bottom hole assembly 200 to selectively activate each overpull generator 100 at a specified time. In a further embodiment, the overpull generator 100 may be configured to be electrically activated. In this embodiment, the piston rod 110 is movable between the extended position and the retracted position due to an electrical signal. The electrical signal may be communicated from the surface via the conveyance member 50 , such as wireline, wired drill pipe, wired coiled tubing, wired Corod®, or wireline run with the drill string.
[0034] FIG. 3 is a view illustrating the bottom hole assembly disposed in the wellbore after the object 20 in the wellbore 10 has been dislodged. As illustrated, the piston rod 110 of the overpull generator 100 is in the retracted position and the slinger 160 is deactivated. After the object 20 has been dislodged, the bottom hole assembly 200 may be used to remove the object 20 from the wellbore 10 .
[0035] FIG. 4 is a cross-sectional view of the overpull generator 100 . Generally, the overpull generator 100 converts wellbore fluid energy into mechanical energy. As illustrated, the overpull generator 100 includes a top sub 105 , the plurality of pistons 125 connected in series, and the piston rod 110 . For clarity purposes, the overpull generator 100 is shown in FIG. 4 with the piston rod 110 in a retracted position. As discussed herein, the piston rod 110 of the overpull generator 100 is movable between the extended position and the retracted position to generate the overpull force (i.e. energy) that is used by the other components in the bottom hole assembly 200 . As also discussed herein, the pistons 125 cause the piston rod 110 of the overpull generator 100 to move from the extended position to the retracted position. The pistons 125 are operated by a pressure differential that is created between the outside and the inside of the overpull generator 100 . If the pressure drop across the overpull generator 100 proximate the bottom sub 110 is not sufficient, then the orifice sub (not shown) may be lowered into the bottom hole assembly. The orifice sub may be positioned below the overpull generator 100 in order to create the pressure differential required to activate the overpull generator 100 and move the piston rod 110 from the extended position to the retracted position. It should be noted that the orifice sub may function as an actuation switch, whereby the overpull generator 100 is selectively activated at a predetermined time.
[0036] As illustrated in FIG. 4 , the overpull generator 100 includes a bore 120 formed therein. The bore 120 has an enlarged inner diameter. The bore 120 is used to pump fluid through the overpull generator 100 . Additionally, the bore 120 may be used to run downhole tools, such as wireline tools, a plasma cutting torch, logging tools such as a freepoint indicator, backoff explosives, a camera, or a string shot, through the overpull generator 100 to perform other downhole wellbore operations. Additionally, darts or balls could be pumped through the bore 120 of the overpull generator 100 to activate a tool below the overpull generator 100 .
[0037] FIG. 5 is a cross-sectional view taken along line 5 - 5 in FIG. 4 . The overpull generator 100 may also be configured to transmit torque through the overpull generator 100 . As shown in FIG. 5 , a spline arrangement 115 is formed between the piston rod 110 and a housing 130 . A rotational force (i.e. torque) that is generated above the overpull generator 100 may be transferred through the overpull generator 100 via the spline arrangement 115 to a point below the overpull generator 100 . The transfer of the rotational force may be useful in dislodging the object stuck in the wellbore or for performing another downhole operation. It should be noted that the overpull generator 100 may transmit the rotational force when the piston rod 110 is in the extended position and the retracted position. In another embodiment, a hexed arrangement, a keyed arrangement or any other torque transmitting arrangement may be formed between the piston rod 110 and the housing 130 that is configured to transmit torque through the overpull generator 100 .
[0038] As described herein, the overpull generator 100 and the delay force release device 150 has been used in a bottom hole assembly 200 that is configured to dislodge a previously stuck object in the wellbore 10 . In another embodiment, the overpull generator 100 and the delay force release device 150 may be part of a drill string assembly (not shown) having a drill bit at a lower end thereof. In this embodiment, if the drill bit becomes stuck during the drilling operation, then the overpull generator 100 may be activated by creating a pressure differential in the drill string assembly. In similar manner as described herein, the overpull generator 100 generates an overpull force that is used by the delay force release device 150 to dislodge the stuck drill bit. In a further embodiment, the overpull generator 100 may be used with the drill bit without the delay force release device 150 .
[0039] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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The present invention generally relates to an apparatus and method of jarring with an overpull generator. In one aspect, a method of dislodging an object stuck in a wellbore is provided. The method includes the step of running an assembly into the wellbore on a conveyance member and attaching the assembly to the object, wherein the assembly comprises an overpull generator and a delay force release device. The method also includes the step of generating an overpull force in the wellbore by selectively activating the overpull generator. Additionally, the method includes the step of applying an impact force to the object by activating the delay force release device and releasing the generated overpull force, thereby dislodging the object stuck in the wellbore. In a further aspect, an assembly for dislodging an object stuck in a wellbore is provided. In yet a further aspect, an overpull generator for use in generating an overpull force in a wellbore is provided.
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GOVERNMENT INTEREST
This invention was made with government support under Contract No. DE-FC07-05ID14636 awarded by the Department of Energy. The government has certain rights in this invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to nuclear reactor internals and more specifically to apparatus for maintaining the alignment of the nuclear reactor internals.
2. Description of the Prior Art
The primary side of nuclear reactor power generating systems which are cooled with water under pressure comprises a closed circuit which is isolated from and in heat-exchange relationship with a secondary side for the production of useful energy. The primary side comprises the reactor vessel enclosing a core internals structure that supports a plurality of fuel assemblies containing fissile material, the primary circuit within heat exchange steam generators, the inner volume of a pressurizer, pumps and pipes for circulating pressurized water; the pipes connecting each of the steam generators and pumps to the reactor vessel independently. Each of the parts of the primary side comprising a steam generator, a pump and a system of pipes which are connected to the vessel form a loop of the primary side. The primary side is also connected to auxiliary circuits, including a circuit for volumetric and chemical monitoring of the pressurized water. The auxiliary circuit, which is arranged branching from the primary circuit, makes it possible to maintain the quantity of water in the primary circuit by replenishing, when required, with measured quantities of water, and to monitor the chemical properties of the coolant water, particularly its content of boric acid, which is important to the operation of the reactor.
The average temperature of the core components during full power reactor operation is approximately 580 F (304° C.). Periodically, it is necessary to shut down the reactor system for maintenance and to gain access to the interior side of the pressure vessel. During such an outage, the internal components of the pressure vessel can cool to a temperature of approximately 50° F. (10° C.). The internal components of the pressure vessel typically consist of upper and lower internals. The upper internals include a control rod guide tube assembly, support columns, conduits for instrumentation which enter the reactor vessel through the closure head, and a fuel assembly alignment structure, referred to as the upper core plate. The lower internals include a core support structure referred to as the core barrel, a core shroud that sits inside the core barrel and converts the circular interior of the barrel to a stepped pattern that substantially corresponds to the perimeter profile of the fuel assemblies that constitute the core supported between a lower core support plate and the upper core plate. As an alternate to the shroud, a bolted baffle former structure consisting of machined horizontal former and vertical baffle plates, has been employed. It is particularly important to maintain a tight alignment of the reactor internals upper core plate and a top plate of the shroud with the control rod drive mechanisms to assure that the control rods can properly scram; i.e., drop into the core, when necessary. This is particularly challenging when one considers the thermal expansion and contraction that has to be accommodated through power ramp-up and cool down sequences, where temperatures can vary between 50° F. (10° C.) and 580° F. (304° C.)
In conventional designs, lateral alignment of the upper internals components was accomplished with a series of single pins located around the circumference of the core barrel. The upper core plate alignment pins fit in notches in the upper core plate and locate the upper core plate laterally with respect to the lower internals assembly. The pins must laterally support the upper core plate so that the plate is free to expand radially and move axially during differential thermal expansions between the upper internals and the core barrel. FIG. 1 is a simplified cross-section of such a conventional reactor design. A pressure vessel ( 10 ) is shown enclosing a core barrel ( 32 ) with a thermal shield ( 15 ) interposed in between. Some plants have neutron pads in lieu of the thermal shield. The core barrel ( 32 ) surrounds the core ( 14 ) which is held in position by an upper core plate ( 40 ). The upper core plate ( 40 ) is aligned by the alignment pins ( 19 ) which extend through the core barrel ( 32 ) into notches ( 21 ) in the upper core plate ( 40 ). The notches ( 21 ) permit the core barrel to grow with thermal expansion at a greater rate than the upper core plate ( 40 ) during start up without compromising the lateral position of the upper core plate ( 40 ). The installation sequence of the core shroud ( 17 ) in new advanced passive plant designs requires a modified design that will prevent lateral movement of the upper core plate and the core shroud while enabling thermal growth and differential expansion between both the shroud and the upper core plate and the core barrel, while maintaining rotational stability.
New passive nuclear plant designs employ a core shroud assembly that is primarily a welded structure. The typical manufacturing process is to assemble the core shroud fully outside the lower internals core barrel. After assembly, the core shroud assembly is lowered into the lower internals. In this arrangement, it is not possible to have protruding alignment pins ( 19 ) to engage the upper internal's core plate. The protruding alignment pins would interfere with the core shroud bottom plate, core shroud panel reinforcements, etc., during insertion within the core barrel. Therefore, an alternate alignment feature was identified to accommodate the advanced passive plant internals design.
To align the core shroud and upper internals this alternate alignment feature comprises four alignment plates, secured to the lower internals core barrel with a set of bolts and dowel pins. The alignment plates are installed after installation of the core shroud assembly within the lower internals. Custom fit inserts are used to align both the lower and upper internals with each other via the alignment plates. However, the installation of the alignment plates involves machining four slots, or grooves, in the inside diameter of the core barrel; one groove is required for each alignment plate. The grooves are required to verify set up of the alignment plates prior to installation of the core shroud assembly. The alignment plates are installed in the lower internals after installation of the core shroud assembly. To provide clearance to slide the alignment plate into the machined groove in the core barrel inside diameter, the core shroud top plate slot depth is increased 0.750″ (1.905 centimeters), as compared to nominal value. This 0.750″ (1.905 centimeter) increase occurs at a location adjacent to one of the more limiting core shroud top plate ligaments. After securing each alignment plate with dowel pins and six bolts, the 0.750″ (1.905 centimeter) gap between the alignment plate and the core shroud top plate is filled by installation of a customized insert. In view of the installation sequence for installing the alignment plates, it's likely that it may be difficult to remove the core shroud assembly, should there be a need during the 60 year design life of the advance passive plant designs. Accordingly, an alternate design is desired that would further facilitate manufacture, installation and removal of the core internals while maintaining rotational alignment between the core shroud and the upper core plate.
It is an object of this invention to provide such a further improvement that will additionally facilitate manufacture, satisfy the alignment requirements and permit later removal of the core shroud assembly in tact.
SUMMARY OF THE INVENTION
In addition to providing features to assure that the upper internals of the reactor vessel are aligned with lower internals during installation, desirably the design of the reactor internals should also include features that facilitate the removal of both lower and upper internals without extensive field operations. This invention presents a design that both aligns the upper core plate with the core shroud and does not require hardware removal when preparing the core shroud for removal from the lower internals. The basic alignment features of this invention comprise a plurality of jacking blocks peripherally spaced around the top plate of the core shroud; jacking studs radially outwardly extending from the jacking blocks; and alignment posts vertically extending and peripherally spaced around the top plate of the core shroud spaced from the jacking blocks.
When assembled together each combination of a jacking block and a jacking stud form a jacking block assembly. The jacking block assemblies and alignment posts are installed on the top plate of the core shroud and secured with full penetration welds. Anywhere from eight to sixteen jacking block assemblies would be evenly distributed azimuthally around the core shroud centerline. Preferably, the number of jacking block assemblies would be between 12 and 16. Four alignment posts, 90 degrees apart, would be placed azimuthally around the core shroud centerline to engage openings in the upper core plate from the underside.
The main purpose of the jacking block assemblies is to center, or align, the core shroud top plate within the core barrel during final assembly at manufacturing. Alignment is made by adjusting the radial extension of the threaded jacking studs that extend radially outward from mating threaded openings in the jacking blocks. After final positioning, the threads of the jacking studs are preferably “staked” or “spot” welded to the jacking blocks to lock the studs into position. During reactor operation, the loads at the top of the core shroud would be carried radially via the jacking studs to the core barrel. A hard surface liner formed from a material such as stellite is preferably welded to the core barrel inner surface opposite the jacking studs to accommodate the relative movement of the studs and the core barrel due to the different rates of thermal expansion and contraction over the range of reactor operating temperatures.
During installation of the upper internals over the lower internals, chamfered lead-in surfaces on the alignment posts will assure proper alignment of the upper core plate inserts prior to engagement of upper core plate fuel guide pins with the fuel assembly top nozzles. Preferably radial guides or bumpers extend from the peripheral surface on the outside diameter of the upper core plate, that are spaced circumferentially to provide additional guidance for the upper core plate within the lower internals core barrel during installation. The thickness of these bumpers may also be customized so that the in-plane loading of the upper core plate during reactor operation can be transferred as a radial load to the core barrel.
Preferably, each alignment post has a radially outwardly extending bumper to provide a shared load path for in-plane upper core plate loads which are transferred to the core barrel. The bumper can be formed from an insert on the backside of the alignment post and the thickness would be determined from “as built” measurements of the mating hardware. Alternately, the bumper on the alignment post can be replaced or supplemented with a jacking stud similar to that provided on the jacking block assemblies. Desirably, the front end of the stud is rounded to engage the core barrel while the back end of the stud has a machined contour that can be engaged by an installation tool. The outside circumference of the alignment post stud is threaded to engage mating threads in the alignment post. After installation of the core shroud assembly, the jacking studs in the alignment posts can be adjusted to achieve the desired gap with the core barrel. A hole is provided in the backside of the alignment post for the installation tool to engage the jacking stud for adjustment. Preferably, a locking feature such as a locking cup or tack weld is used to secure the jacking stud in place.
BRIEF DESCRIPTION OF THE DRAWINGS
A further understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
FIG. 1 is a cross-sectional view of a nuclear reactor vessel showing the pressure vessel, thermal shield, core barrel, core shroud and the core fuel assemblies;
FIG. 2 is a simplified schematic of a nuclear reactor system to which this invention may be applied;
FIG. 3 is an elevational view, partially in section, of a nuclear reactor vessel and internal components to which this invention may be applied;
FIG. 4 a is a perspective view of a core shroud jacking block of this invention;
FIG. 4 b is a perspective view of a core shroud jacking stud of this invention;
FIG. 4 c is a perspective view of a core shroud jacking block assembly with a jacking stud shown threaded inside the jacking block;
FIG. 5 is a perspective view of an alignment post of this invention;
FIG. 6 is a perspective view of a jacking block assembly and alignment post installed on a core shroud top plate with the core shroud vertical plates that extend down from the core shroud top plate removed for simplicity;
FIG. 7 is a perspective view of a portion of the core shroud top plate shown inside a portion of the core barrel and illustrates a jacking block assembly aligning the core shroud top plate within the core barrel;
FIG. 8 a is a perspective view illustrating the engagement of the upper internals upper core plate notch with an alignment post;
FIG. 8 b is a perspective view of the upper core plate fully engaged with the lower internals core shroud top plate;
FIG. 9 is a perspective view of a peripheral section of the upper core plate showing a radial bumper on a portion of the upper core plate's circumference;
FIG. 10 is a perspective view of the upper core plate engaging an alignment post with inserts added on the sides and back of the upper core plate slot;
FIG. 11 is a perspective view of two threaded jacking studs for an alignment post showing a rounded front section and articulated rear section;
FIG. 12 is a perspective view of an alignment post modified for a threaded jacking stud;
FIG. 13 is a cross-sectional view of an upper core plate, alignment post and shroud top plate assembly showing a cross-section of the jacking stud mounted in the alignment post in juxtaposition to the core barrel; and
FIG. 14 is a cross-sectional view of an upper core plate, alignment post and top shroud plate assembly of FIG. 13 , showing an alternated arrangement in which the alignment post is affixed to the upper core plate and extends downward through a slot in the shroud top plate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, FIG. 2 shows a simplified nuclear reactor primary system, including a generally cylindrical reactor pressure vessel ( 10 ) having a closure head ( 12 ) enclosing a nuclear core ( 14 ). A liquid reactor coolant, such as water, is pumped into the vessel ( 10 ) by pumps ( 16 ) through the core ( 14 ) where heat energy is absorbed and is discharged to a heat exchanger ( 18 ), typically referred to as a steam generator, in which heat is transferred to a utilization circuit (not shown), such as a steam-driven turbine generator. The reactor coolant is then returned to the pump ( 16 ), completing the primary loop. Typically, a plurality of the above-described loops are connected to a single reactor vessel ( 10 ) by reactor coolant piping ( 20 ).
An exemplary reactor design is shown in more detail in FIG. 3 . In addition to a core ( 14 ) comprised of a plurality of parallel, vertical co-extending fuel assemblies ( 22 ), for purposes of this description, the other vessel internal structures can be divided into the lower internals ( 24 ) and the upper internals ( 26 ). In conventional designs, the lower internals function is to support, align and guide core components and instrumentation, as well as direct flow within the vessel. The upper internals restrain or provide a secondary restraint for the fuel assemblies ( 22 ) (only two of which are shown for simplicity), and support and guide instrumentation and components, such as control rods ( 28 ).
In the exemplary reactor shown in FIG. 3 , coolant enters the vessel ( 10 ) through one or more inlet nozzles ( 30 ), flows downward through an annulus between the vessel and the core barrel ( 32 ), is turned 180° in a lower plenum ( 34 ), passes upwardly through a lower support plate ( 37 ) and a lower core plate ( 36 ) upon which the fuel assemblies ( 22 ) are seated and through and about the assemblies. In some designs the lower support plate ( 37 ) and lower core plate ( 36 ) are replaced by a single structure, the lower core support plate, at the same location as ( 37 ). The coolant flow through the core and surrounding area ( 38 ) is typically large, on the order of 400,000 gallons per minute at a velocity of approximately 20 feet per second. The resulting pressure drop and frictional forces tends to cause the fuel assemblies to rise, which movement is restrained by the upper internals, including a circular upper core plate ( 40 ). Coolant exiting the core ( 14 ) flows along the underside of the upper core plate and upwardly through a plurality of perforations ( 42 ). The coolant then flows upwardly and radially to one or more outlet nozzles ( 44 ).
The upper internals ( 26 ) can be supported from the vessel or the vessel head and include an upper support assembly ( 46 ). Loads are transmitted between the upper support assembly ( 46 ) and the upper core plate ( 40 ), primarily by a plurality of support columns ( 48 ). A support column is aligned above a selected fuel assembly ( 22 ) and perforations ( 42 ) in the upper core plate ( 40 ).
Rectilinearly moveable control rods ( 28 ) typically include a drive shaft ( 50 ) and a spider assembly ( 52 ) of neutron poison rods that are guided through the upper internals ( 26 ) and into aligned fuel assemblies ( 22 ) by control rod guide tubes ( 54 ). The guide tubes are fixedly joined to the upper support assembly ( 46 ) and connected by a split pin ( 56 ) force fit into the top of the upper core plate ( 40 ). The pin configuration provides for ease of guide tube assembly and replacement if ever necessary and assures that core loads, particularly under seismic or other high loading accident conditions are taken primarily by the support columns ( 48 ) and not the guide tubes ( 54 ). This assists in retarding guide tube deformation under accident conditions which could detrimentally affect control rod insertion capability.
Though not shown in FIG. 3 , the design of this invention includes a core shroud positioned inside the circular core barrel ( 32 ) that converts the inner profile of the core barrel to a stepped circumferential profile that matches the peripheral outline of the fuel assemblies ( 22 ) within the core. A portion of the shroud's stepped inner circumferential profile can be observed in FIG. 6 , which provides a perspective view of a portion of the top plate ( 90 ) of the core shroud assembly ( 88 ), with the alignment features of this invention. The vertical shroud panels that extend down from each of the stepped profiles on the inner periphery of the core shroud top plate ( 90 ), to surround the core, are not shown for simplicity. The core shroud top plate ( 90 ) is shown in FIG. 6 with two jacking block assemblies ( 98 ) circumferentially spaced on either side of an alignment post ( 100 ). The jacking block assemblies ( 98 ) are circumferentially positioned at the periphery of the core shroud top plate ( 90 ). There are anywhere from approximately eight to sixteen jacking block assemblies equally spaced around the circumference of the periphery of the core shroud top plate ( 90 ). The jacking block assemblies ( 98 ) are used to center the core shroud assembly ( 88 ) within the core barrel ( 32 ). The alignment post ( 100 ) of which there are preferably four equally spaced around the circumference of the periphery of the core shroud top plate ( 90 ) are used to align the upper core plate ( 40 ) with the core shroud assembly ( 88 ).
Accordingly, the alignment system of this invention basically consists of three main components: (i) jacking blocks ( 94 ); (ii) jacking studs ( 96 ); and (iii) alignment posts ( 100 ). When assembled together, the jacking block ( 94 ) and the jacking stud ( 96 ) form a jacking block assembly ( 98 ) which can be better observed from the perspective view shown in FIG. 4 c . The jacking block alone is shown in FIG. 4 a and is constructed from a metal block ( 110 ), such as stainless steel with a threaded hole ( 102 ) centered through it. A stem ( 104 ) extends below the block ( 110 ) and is closely received within a hole in the core shroud top plate ( 90 ) and secured therein by a full penetration weld. The jacking stud ( 96 ) is shown in FIG. 4 b and has a circumferential thread ( 106 ) that mates with the thread in the threaded hole ( 102 ) in the jacking block ( 94 ). The jacking stud ( 96 ) has an articulated rear end ( 108 ) which mates with a complimentary recess in an installation tool that can be used to turn the jacking stud ( 96 ) within the threaded hole ( 102 ) in the jacking block assembly ( 98 ).
As previously stated the main purpose of the jacking block assemblies ( 98 ) is to center, or align the core shroud assembly ( 88 ) within the core barrel ( 32 ) during final assembly at manufacturing. Alignment is made by adjusting the threaded jacking studs ( 96 ). After final positioning, the threads ( 106 ) of the jacking stud ( 96 ) are “staked” or “spot” welded to the jacking block ( 94 ). During reactor operation, the loads at the top of the core shroud assembly ( 88 ) would be carried radially via the jacking studs ( 96 ) to the core barrel ( 32 ). As can be seen in FIG. 7 , preferably a hard surface ( 92 ) such as stellite is affixed to the inside surface of the core barrel ( 32 ), such as by welding, in the area that abuts the radially outward end of the jacking stud ( 96 ). The size of the hard surface ( 92 ) that interfaces with the jacking stud ( 96 ) should be large enough to accommodate the differential thermal expansion of the core shroud assembly ( 88 ) and the core barrel ( 32 ) as shown in FIG. 7 , so that the abutting end of the jacking stud ( 96 ) remains in contact with the hard surface ( 92 ) through all phases of reactor operation.
The alignment post ( 100 ) is best shown in FIG. 5 . The alignment post ( 100 ) has a chamfered upper end ( 112 ) that tapers outwardly to a vertical side wall ( 114 ) that extends approximately halfway down the alignment post. The vertical wall ( 114 ) at an end opposite the chamfer ( 112 ) has a lower section ( 116 ) that extends outward to form an acute angle with the base ( 120 ). Similar to the jacking block assemblies ( 98 ) the alignment post ( 100 ) has a welding stem ( 122 ) that extends from the base ( 120 ) and is received in a corresponding opening in the top plate ( 90 ) of the core shroud assembly ( 88 ) where it is secured by a full penetration weld. A bumper ( 124 ) extends from the radial outward face ( 126 ) of the alignment post ( 100 ) as will be explained in greater detail hereafter. During installation of the upper internals within the lower internals, the chamfered (lead-in) surfaces ( 112 ) on the alignment post ( 100 ) will assure proper alignment of the upper core plate ( 40 ) inserts ( 118 ) prior to engagement of the upper core plate ( 40 ) fuel guide pins with the fuel assembly top nozzles as can be seen from FIG. 8 a . Though the alignment post ( 100 ) is shown as being received within a slot ( 128 ) in the upper core plate ( 40 ), it should be appreciated that the alignment post ( 100 ) can also be situated radially inward from the edge of the core shroud top plate ( 90 ) and be received within a hole in the upper core plate ( 40 ) instead of the slot ( 128 ) without departing from the intent of this invention. The final installed configuration of the upper core plate ( 40 ) with the lower internals is illustrated in FIG. 8 b.
FIG. 9 shows a guide or bumper ( 130 ) that radially extends from the edge of the upper core plate ( 40 ) to provide additional guidance for the upper core plate ( 40 ) as it is lowered within the lower internals core barrel ( 32 ) during installation. The radial thickness of this bumper ( 130 ) may be also customized so that the in-plane loading of the upper core plate during reactor operation can be transferred as a radial load to the core barrel ( 32 ). As noted with regard to FIG. 5 , the alignment post ( 100 ) is designed with a bumper ( 124 ). The purpose of the bumper ( 124 ) is to provide a shared load path for in-plane upper core plate loads. The thickness (i.e., the radial extent) of the bumper ( 124 ) would also be determined from “as built” measurements of the mating hardware. If necessary, the upper core plate ( 40 ) could also be designed to include an additional insert ( 119 ) on the backside of the slots ( 128 ) as illustrated in FIG. 11 .
An alternate design for the bumper ( 124 ) on the alignment post ( 100 ) is shown in FIGS. 11 and 12 . FIG. 11 shows two perspectives of the alignment post jacking stud ( 132 ) to provide views of the front ( 134 ) and rear ( 136 ) of the jacking stud ( 132 ). The front end ( 134 ) of the stud ( 132 ) is rounded to engage the core barrel ( 32 ) on its inner circumference while the back end ( 136 ) of the stud ( 132 ) has a machined recess ( 138 ) that engages a complimentary shaped tool to facilitate turning the stud during installation. The outside circumference of the stud ( 132 ) is threaded to engage into mating threads in a recess ( 140 ) in the radial outward face ( 126 ) of the alignment post ( 100 ) as shown in FIG. 12 . After installation of the core shroud assembly ( 88 ), the jacking studs ( 132 ) on the alignment post ( 100 ) can be adjusted to achieve the desired gap with the core barrel. A hole ( 142 ) is provided in the backside of the alignment post ( 100 ) for a tool to engage the jacking stud ( 132 ) for adjustment. FIG. 13 shows a cross-sectional view of the core shroud top plate ( 90 ) and upper core plate ( 40 ) taken along a vertical plane that dissects an alignment post ( 100 ) and shows a jacking stud ( 132 ) in Juxtaposition to the core barrel ( 32 ). The front face ( 134 ) of the jacking studs ( 132 ) on the alignment post ( 100 ) and the radial outward face of the jacking studs ( 96 ) on the jacking block assemblies ( 98 ) both abut a hardened surface ( 92 ) such as stellite, on the core barrel ( 32 ). As previously mentioned, the hard surface ( 92 ) should be large enough to accommodate the differential thermal expansion between the core shroud assembly ( 88 ) and the core barrel ( 32 ). FIG. 14 shows an alternate configuration in which the alignment post ( 100 ) is affixed to the underside of the upper core plate ( 40 ) by, for example a full penetration weld, and the lower portion of the alignment post ( 100 ) extends downward through a slot in the core shroud top plate ( 90 ). In all other respects the configuration shown in FIG. 14 is the same as that shown in FIG. 13 .
Accordingly, the alignment system of this invention requires few parts, requires relatively easy assembly and does not require machining of the core barrel to accommodate final installation of the core shroud assembly. Furthermore, the alignment system of this invention facilitates easy removal of the core shroud should there ever be a future need.
The welding of the jacking blocks ( 94 ) and the alignment posts ( 100 ) to the core shroud top plate ( 90 ) is completed during core shroud assembly, not after the core shroud assembly is installed in the lower internals core barrel ( 32 ). Therefore, a significant savings in manufacturing process time will be realized since final positioning of the core shroud top plate ( 90 ) would be made by adjusting the jacking studs ( 96 ) as compared to the process of installing alignment plates described in the Background of the Invention Section hereof. Furthermore, should there be a need to remove the core shroud subsequent to reactor operation, the time required to loosen the studs in the core shroud jacking block assemblies ( 98 ) would be negligible when compared to that which would be required for the removal of the alignment plates described in the a foresighted application.
While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular embodiments disclosed are meant to be illustrative only and not limiting as to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalence thereof.
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An alignment system that employs jacking block assemblies and alignment posts around the periphery of the top plate of a nuclear reactor lower internals core shroud to align an upper core plate with the lower internals and the core shroud with the core barrel. The distal ends of the alignment posts are chamfered and are closely received within notches machined in the upper core plate at spaced locations around the outer circumference of the upper core plate. The jacking block assemblies are used to center the core shroud in the core barrel and the alignment posts assure the proper orientation of the upper core plate. The alignment posts may alternately be formed in the upper core plate and the notches may be formed in top plate.
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GOVERNMENT CONTRACT RIGHTS
The U.S. Government has a non-exclusive license in this invention adn the right in limited circumstances to require this patent owner to license others on reasonable terms as provided by Federal Acquisition Regulation (FAR-1984 Edition) 52.227-12 entitled "Patent Rights Retention by Contractor".
BACKGROUND OF THE INVENTION
b 1. Field of the Invention
The present invention relates to phase-locked loop apparatus for producing adjustable microwave frequencies in the range of 7 to 10 gigahertz in steps of 5 to 10 megahertz. More specifically, the present invention relates to a computerized control multiple-loop phase-locked loop circuit employing a novel frequency synthesizer.
2. Description of the Prior Art
Frequency synthesizer systems are known and have been classified in U.S. Class 328, Subclass 14; and in Class 331, Subclasses 16, 22 and 19; and are further classified in International Class H03L 7/18 and 7/22.
Prior art basic linearized phase-locked loops are well known and include a VCO having an output coupled to a divide by N device, a mixer, a phase detector and a low pass filter in the loop and have an external reference frequency applied to the phase detector so that deviations of the VCO from the reference frequency cause the phase detector to generate an error voltage which when applied to the VCO adjust the VCO frequency to match the referencve frequency.
Multiple-loop phase-lock loops are known and have been employed in frequency synthesizing systems, however, such systems have heretofore been relatively complex, employed a plurality of N identical digit modules and complex circuitry similar to that set forth in U.S. Pat No. 4,626,787 and references discussed therein.
There is an unmet requirement for simple, low power, broad range frequency synthesizer which is capable of operating in the microwave frequency range. The frequency synthesizer apparatus needs to be compact, of light weight and easily controlled by a remote processor controller over small steps without the requirement of hardware modifications.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a novel synthesized microwave frequency generator for generating frequencies up to 20 gigahertz.
It is another principal object of the present invention to provide a synthesized microwave frequency generator having computor control steps of about 5 megahertz.
It is another principal object of the present invention to provide a multiple-loop microwave frequency synthesizer controllable by a processor controller for programmably setting frequency dividers.
It is another general object of the present invention to provide a high stability microwave frequency synthesizer having a relatively low frequency stable reference voltage generator for its base frequency.
It is yet another general object of the present invention to provide a novel sampling mixer circuit for utilization in a multi-loop microwave frequency synthesizer system.
It is general object of the present invention to provide an economical, lightweight microwave frequency synthesizer system.
According to these and other objects of the present invention there is provided a frequency synthesizer comprising a phase-locked loop system having an upper and a lower phase-locked loop and a novel sampler mixer mutually connected in the feedback path of the upper phase-locked loop and in the output path of the lower phase-locked loop. A plurality of programmable frequency dividers are connected in the upper and the lower phase-locked loop which are computer controlled to provide a wide range of adjustable frequencies up to about 20 giagahertz at the output of the synthesizer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a prior art multiple-loop phase-locked loop circuit of the type employed to generate frequencies up to about 500 megahertz;
FIG. 2 is a schematic block diagram with the present invention multiple-loop phase-locked loop circuit for generating adjustable microwave frequencies up to about 20 gigahertz;
FIG. 3 is a schematic block diagram of the present invention microwave sampling mixer employed in the circuit of FIG. 2; and
FIG. 4 is a more detailed schematic block diagram of the balun transformer and the impulse driving circuit of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Refer now to FIG. 1 showing a prior art multiple-loop phase-locked loop circuit of the type employed to generate frequencies up to about 500 magahertz. Generator 10 comprises a reference frequency generator 11 for generating frequencies on line 12 which are applied to the phase detector 13 to produce an output signal on line 14. The output signal on line 14 is an error signal produced by the comparison of the reference frequency signal on line 12 and the VCO signal on line 15. The error signal is applied to loop filter 16 to process and amplify the signal and produce an output on line 17 which drives the voltage controlled oscillator (VCO) 18. The locked oscillator 18 output signal on line 19 is coupled to line 21 and is applied as an input via line 21 to the low pass filter 22 which eliminates harmonics and noise from the RF signal on line 23. The RF signal on line 23 is applied to mixer 24 along with the local oscillator input on line 25 to produce an IF output on line 26. The IF output on line 26 is filtered in IF filter 27 to eliminate spurious output signals of the mixer 24 and to provide a clean IF signal on line 28 which is applied to the divide by N circuit 29.
The reference frequency generator signal on line 31 is applied to the phase detector 32 in the lower loop. The output of the phase detector on line 33 is applied to the loop filter 34 to produce the aforementioned error signal on line 35 which is applied to the voltage controlled oscillator 36 to produce the phase-locked loop output signal on line 37 which is applied to a diide by Q circuit 38 to produce the voltage control oscillator signal on line 39 from the lower frequency VCO 36 in the lower loop. For purposes of this discussion the elements 32 through 39 comprise the lower loop. The output of the lower loop voltage control oscillator on line 37 is applied to the comb generator 41 that produces harmonics of the voltage controlled oscillator 36 on line 42 which are applied to the voltage tuned filter 43 to produce the local oscillator (LO) output signal on line 25.
Employing the state of the art commercially available devices and using the highest frequency voltage controlled oscillator 18 the output of this prior art circuit is limited to about 5 gigahertz when employing gallium arsenside voltage controlled oscillator technology.
Refer now to FIG. 2 showing a schematic block diagram of a multiple-loop phase-locked loop circuit 40 for generating frequencies up to 20 gigahertz. The synthesizer circuit or system 40 comprises a reference frequency generator 44 selected for the highest stable frequency which is presently limited to approximatly 200 megahertz employing ECL technology. The output of the reference frequency generator is applied via line 45 to a divide by L circuit 46 and to a divide by M circuit 47 for producing the pre-determined and desired output step frequency on line 48. The stable step frequency is preferably approximately 5 megahertz but may be any desired step obtainable by dividing the reference frequency by an integer. Phase detector 49 produces an error signal on line 51 which is applied to upper loop filter 52 to produce a processed error signal on line 53. The error signal on line 53 adjusts and controls voltage controlled oscillator 54 to produce the locked VCO frequency output on line 55. The VCO signal on line 55 is coupled to line 56 to provide a coupled VCO output signal to low pass filter 57 which produces the RF frequency signal on line 58. The RF signal on line 58 is applied to the present invention sampling mixer 59 to produce an IF output on line 61 which is applied to the IF filter 62 to produce a clean IF signal on line 63. The clean IF signal on line 63 is applied to the programmable divide by N circuit 64 to produce the upper VCO signal on line 65 that is applied to the phase detector 49 to produce an error signal on line 51. The upper loop in the present invention comprises the elements 49 through 65 and the programmable divide by M circuit 46.
The lower loop of the present invention comprises the programmable divide by L circuit 47 which produces the step down reference frequency generator signal on line 66 which is applied to the phase detector 67 to provide an error signal on line 68 which is applied to loop filter 69 to produce the voltage error signal on line 71. The voltage error signal on line 71 adjustably controls the lower voltage control oscillator 72 to produce the locked VCO signal on line 73 which is hardwired connected to a node 74. Output 75 line connects node 74 to a programmable divide by Q circuit 76 whose output on line 77 is connected to the phase detector 67 completing the lower loop comprising elements 67 through 77.
The locked lower loop VCO signal on line 78 is applied as a LO signal to the sampling mixer circuit 59 and to a frequency multiplier 79 via line 81. Preferably the multiplier 79 is selectable over a range of integers depending on the output frequency range desired. The output of the multiplier 79 on line 82 is applied to mixer 83 along with the upper loop voltage controlled oscillator output signal on line 55 to produce the sum of the two input frequencies on line 84. The higher sum frequency from mixer 83 is applied to a band pass filter 85 to eliminate the difference frequency and provide a clean signal line 86 which is processed and amplified by amplifier 87 to provide the desired output microwave frequency on line 88. The elements 83 to 87 are commonly referred to as an up-converter because they produce the sum frequency of the two lower input frequencies rather than the difference frequencies.
Microprocessor controller 89 preferably comprises an inexpensive microprocessor chip combined with a programmable read only memory which produces output signals on bus 91 capable of setting the programmable divider circuits 46, 47, 54 and 76. In the preferred embodiment synthesizer circuit 40, the divide by L and M circuits 46 and 47 extend the range of tunable frequencies beyond those heretofore obtained in the prior art. The synthesizer circuit 40 is operable without the extended range divider circuits 46 and 57 but since all other components of the circuit are present they do not penalize the cost of the preferred embodiment circuit. Even if circuits 46 and 47 are set an an integer of one, so as to eliminate them functionally from the circuit, the system 40 is still operable.
Refer now to FIG. 3 showing a more detailed schematic block diagram of the novel sampling mixer circuit 59 of FIG. 2. The sampling mixer circuit 59 is shown having the local oscillator input line 78, the RF input line 58 and the IF output 61 connected thereto as shown in FIG. 2. The local oscillator signal on line 78 is applied to amplifier 92 to produce the amplified signal on line 93 applied to balun transformer 94. The dual outputs 95 from balun 94 are applied to the impulse driving circuit 96 to produce dual outputs on line 97 which are applied to the load 99 in the form of a diode bridge comprising microwave diodes 98. The output of the load 99 on line 101 is the IF signal which is amplified and processed in amplifier 102 to produce the desired IF signal on line 61 as described hereinbefore. The line 61 is provided with a matched impedance resistor 103 to prevent reflections on IF line 61.
Refer now to FIG. 4 which is a more detailed detailed schematic block diagram of the balun transformer and the impulse circuit of FIG. 3. The local oscillator signal on lines 93 is applied to the primary winding 104 of balun transformer 94 via resistor 105. The center tapped secondary winding 106 of the balun 94 provides balance signals on lines 95. Inductance 107 and capacitor 108 provide means for impedance matching the signal on lines 95 to the step recovery diode 109. The step recovery diode 109 generates a sharp on/off transition in response to the local oscillator input at lines 93 and the impulse signal is applied to the load 99 through the coupling capacitors 111 and 112. Resistor 113 provides a DC return path for the step recovery diode 109.
Having explained a preferred embodiment sampling mixer mixer circuit for use in a multiple-loop phase-locked loop circuit it will be understood that a high stability output frequency can be generated which can also be upconverted to provide high stability microwave frequencies. Further, it will be understood that employing the present invention synthesizer circuit 40 that the frequencies of the voltage controlled oscillators in the lower loop and the upper loop may be extended to provide the desirable microwave frequencies as well as being employed to cover the range of frequencies covered by prior art devices.
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A multiple-loop microwave frequency synthesizer is provided with an upper and a lower phased-lock loop. The phased-lock loops are mutually connected to a novel sampling mixer and their outputs are connected to an up-converter for providing microwave frequency generated signals. The phased-lock loops are provided with a plurality of programmable frequency dividers connected to a processor controller to provide a wide range of adjustable frequencies up to 20 gigahertz at the output of the frequency synthesizer.
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TECHNICAL FIELD
This invention relates to locking mechanisms and reconfigurable clamps incorporating locking mechanisms.
BACKGROUND OF THE INVENTION
Clamps are used extensively to temporarily locate sheet metal parts during the fabrication of sheet metal parts, usually by spot welding, into vehicle bodies or body subassemblies. Clamps are typically specific to one vehicle body style and to one location on that body style. Thus due to variations in external sheet metal, the same clamp cannot be used on a broad range of vehicle bodies even when general similarities exist between them. Thus the number of vehicle body variants which can be fabricated on a particular body assembly line is restricted.
SUMMARY OF THE INVENTION
A selectively lockable assembly includes a body, a pin that is selectively movable with respect to the body, an actuator member that is selectively movable in first and second directions with respect to the body, and a locking member that is operatively connected to the body such that the body restricts rotation of the locking member in at least one direction. The actuator member is configured to urge the locking member against the pin when the actuator member is urged in one of the first and second directions. The locking member being urged against the pin locks the pin with respect to the body. The selectively lockable assembly improves upon prior art lockable assemblies by preventing rolling of the locking member with respect to the body and the pin, thereby enhancing the fastening of the pin with respect to the body.
A reconfigurable clamp is also provided. The clamp includes a body, a plurality of pins that are operatively connected to the body and that are selectively movable with respect to the body, an actuator member that is operatively connected to the body and that is selectively movable with respect to the body in first and second directions, and a locking member. The locking member is operatively connected to the body such that the body restricts rotation of the locking member in at least one direction. The actuator member is configured to urge the locking member against at least one of the pins when the actuator member is urged in one of the first and second directions.
The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, perspective view of a clamp assembly having a plurality of pins;
FIG. 2 is a schematic, cross-sectional bottom view of the clamp assembly of FIG. 1 ;
FIG. 3 is a schematic, cross-sectional side view of the clamp assembly of FIG. 1 ;
FIG. 4 is a schematic, perspective view of a locking element in the clamp assembly of FIG. 1 ;
FIG. 5 is a schematic, sectional side view of the clamp assembly of FIG. 1 ;
FIG. 6 is a schematic, fragmentary sectional view of the clamp assembly of FIG. 1 with one of the pins in a first position; and
FIG. 7 is a schematic, fragmentary sectional view of the clamp assembly of FIG. 1 with the pin of FIG. 6 in a second position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 , a reconfigurable clamp 10 is schematically depicted. The clamp 10 includes a body 12 , which, in the embodiment depicted, is generally cylindrical, but which may be characterized by other shapes within the scope of the claimed invention. The clamp 10 also includes a plurality of pins 14 A-F that are selectively movable with respect to the body 12 . The clamp 10 also includes a pin 14 G that is fixed with respect to the body 12 . The body 12 defines a plurality of elongated holes 16 A-F, each of which at least partially contains a respective one of the pins 14 A-F.
FIG. 3 is a schematic, cross-sectional view of the clamp 10 , which depicts pins 14 C, 14 F and holes 16 C, 16 F. It should be noted that pins 14 C, 14 F are representative of all of the movable pins 14 A-F, and that holes 16 C, 16 F are representative of all of holes 16 A-F. The holes 16 C, 16 F extend through the body 12 from the tip 18 of the body 12 to the base 20 of the body 12 . In the embodiment depicted, the pins 14 C, 14 F are generally cylindrical. The holes 16 C, 16 F are generally cylindrical. Each hole 16 C, 16 F is characterized by a respective segment 22 that has a uniform diameter. Each pin 14 C, 14 F is characterized by a respective segment 26 that has a uniform diameter and that is positioned within a respective one of segments 22 . The diameter of segments 22 is slightly larger than the diameter of segments 26 so that the surfaces defining segments 22 restrict the movement of the pins 14 C, 14 F to substantially linear translation in either a first direction D 1 or a second direction D 2 , which is opposite the first direction D 1 . As used herein, directions D 1 and D 2 are relative to the clamp 10 . Each pin 14 A-F is capable of individual motion in the first or second direction without inducing motion in any of the other pins 14 A-F.
Referring again to FIG. 1 , each pin 14 A-F includes a respective end, or tip 30 A-F. Each of the pins 14 A-F in FIG. 1 is depicted in a respective extended position in which the tip of each pin is a predetermined distance outside the holes 16 A-F and from the tip 18 of the body 12 . Referring again to FIG. 3 , a spring 32 is positioned within hole 16 C between a base plate 34 and pin 14 C and urges the pin 14 C in the first direction D 1 to its extended position. Similarly, a spring 32 is positioned within hole 16 F between base plate 34 and pin 14 F and urges the pin 14 F in the first direction D 1 to its extended position. Springs (not shown) identical to the springs shown at 32 are also in holes 16 A, 16 B, 16 D, 16 E between the base plate 34 and a respective one of pins 14 A, 14 B, 14 D, 14 E to bias the pins 14 A, 14 B, 14 D, 14 E in their respective extended positions.
Hole 16 C includes a section 36 having a diameter greater than the diameter of section 22 . A lip 38 is formed in the body 12 where segment 22 and segment 36 meet. Pin 14 C includes a wide section 40 that has a diameter greater than the diameter of section 22 , but less than the diameter of section 36 . Section 40 of pin 14 C is within section 36 of hole 16 C. Thus, section 36 of hole 16 C is wide enough to accommodate translation of section 40 therein. However, the lip 38 and the section 40 are sufficiently positioned to contact each other when the pin 14 C is in its extended position. Thus, the physical part interference between section 40 and the lip 38 prevents movement of the pin 14 C in the first direction D 1 beyond the extended position. Each pin 14 A-F also includes a respective tapered portion 43 , which, in the embodiment depicted, decreases in diameter in the second direction D 2 .
The body 12 also defines a central hole 42 , which, in the embodiment depicted, is cylindrical and has a common centerline with the body 12 . In the embodiment depicted, the pins 14 A-F and holes 16 A-F are equidistant from the hole 42 and thus are arranged about a circle having the hole 42 at its center. An actuator member 44 is located within the central hole 42 . The actuator member 44 is a plunger that is selectively movable in the first and second directions D 1 , D 2 . A spring 48 urges the actuator member 44 in the second direction D 2 . More specifically, the spring 48 is within the hole 42 between a closed end of the hole 42 and a collar 52 , and urges the collar 52 in the second direction D 2 . The collar 52 acts on a lip 56 formed on the actuator member 44 and thereby transfers the force of the spring 48 to the actuator member 44 .
The actuator member 44 is characterized by a tapered portion 58 that decreases in diameter in the second direction D 2 . The tapered portion 58 in the embodiment depicted is frustoconical, i.e., has the shape of a frustum of a cone. The tapered portion is characterized by outer surface 62 .
The clamp 10 further includes a member 66 that is configured to selectively contact the actuator member 44 and to cause the actuator member 44 to move in the first direction D 1 , against the force of spring 48 . In the embodiment depicted, member 66 is operatively connected to a pneumatic actuator, as shown at 70 in FIG. 5 . Other devices or techniques of moving actuator member 44 may be employed within the scope of the claimed invention. For example, the clamp 10 may include a servomotor or solenoid to move the actuator member 44 , the actuator member 44 may be manually moved (such as via a mechanical linkage), etc.
Referring again to FIG. 2 , the body 12 defines three lateral apertures, or holes 74 A, 74 B, 74 C, each of which extends laterally from the outer surface of the clamp body 12 to the central hole 42 . Each of the lateral holes 74 A, 74 B, 74 C is also open to a respective two of the holes 16 A-F such that two of the pins 14 A-F are accessible from one of the lateral holes 74 A, 74 B, 74 C. Thus, each hole 74 A, 74 B, 74 C interconnects the central hole 42 and a two of the holes 16 A-F.
More particularly, in the embodiment depicted, at least a portion of each of the of the lateral holes 74 A, 74 B, 74 C is coextensive with a portion of two of the holes 16 A-F. Portions of hole 74 A are coextensive with portions of holes 16 A and 16 F. Portions of hole 74 B are coextensive with portions of holes 16 B and 16 C. Portions of hole 74 C are coextensive with holes 16 D and 16 E.
The clamp 10 also includes three locking members 78 A, 78 B, 78 C. Each of the locking members 78 A, 78 B, 78 C is at least partially located within a respective one of the holes 74 A, 74 B, 74 C. Referring to FIG. 4 , locking member 78 is representative of locking members 78 A, 78 B, 78 C. Locking member 78 includes a substantially spherical portion 82 and a generally polygonal portion 86 . In the embodiment depicted, the generally polygonal portion 86 has a form approximating that of a rectangular parallelepiped. The spherical portion 82 and the polygonal portion 86 are interconnected by a cylindrical or rod-like portion 88 , one end of which terminates on the surface of the spherical portion 82 while the other end terminates on one face of the polygonal portion 86 . As shown in FIG. 4 , the portions 86 , 88 may exhibit features such as chamfers and rounded corners to enable a smoother transition and blending of their individual geometries.
Referring again to FIG. 2 , portion 82 of member 78 A is between actuator member 44 and pins 14 A, 14 F such that portion 82 of member 78 A contacts surface 62 of the actuator member 44 and the tapered portions 43 of pins 14 A, 14 F. Portion 88 of member 78 A is between pins 14 A, 14 F. Portion 86 of member 78 A is in hole 78 A such that the movement of member 78 A is restricted, as will be explained in more detail. Portion 82 of member 78 B is between actuator member 44 and pins 14 B, 14 C such that portion 82 of member 78 B contacts surface 62 of the actuator member 44 and the tapered portions 43 of pins 14 B, 14 C. Portion 88 of member 78 B is between pins 14 B, 14 C. Portion 86 of member 78 B is in hole 74 B such that the movement of member 78 B is restricted. Portion 82 of member 78 C is between actuator member 44 and pins 14 D, 14 E such that portion 82 of member 78 C contacts surface 62 of the actuator member 44 and the tapered portions 43 of pins 14 D, 14 E. Portion 88 of member 78 C is between pins 14 D, 14 E. Portion 86 of member 78 C is in hole 74 C such that the movement of member 78 C is restricted.
In the embodiment depicted, the body 12 of the clamp 10 also defines holes 90 . Each hole 90 is opposite a respective one of holes 74 A-C, and may facilitate maintenance of the clamp 10 by providing access to the locking members 78 A-C.
Referring to FIG. 5 , hole 74 B and locking element 78 B are schematically depicted. Hole 74 B is representative of holes 74 A, 74 C. Locking element 78 B is representative of locking elements 78 A, 78 C. The locking member 78 B and the hole 74 B are configured such that interaction between the body 12 and the locking member 78 B prevents rotation of the locking member 78 B with respect to the body 12 in at least two directions.
Referring to FIGS. 4 and 5 , the polygonal portion 86 functions as a polygonal key, interacting with the body 12 inside hole 74 B to prevent rotation of the member 78 B about axis A 1 . That is, the perimeter 92 of the polygonal portion 86 interacts with the surface of the body 12 that defines the hole 74 B such that the body 12 prevents the rotation of the locking member 78 B about axis A 1 . A portion of the spherical portion 82 protrudes outward from the lateral hole 74 B into the central hole 42 to contact surface 62 of the actuator member 44 . Another portion of the spherical portion 82 remains in the lateral hole 74 B. The height of the lateral hole 74 is only marginally larger than the diameter of the spherical portion 82 and the height of the polygonal portion 86 ; thus the surface of the body 12 that defines the hole 74 B also prevents rotation of the locking member 78 B about axis A 2 . Axes A 1 and A 2 are perpendicular to each other and are perpendicular to the first and second directions D 1 , D 2 . The surfaces of the body 12 that define hole 74 B also prevent movement of the locking member 78 B in either the first direction D 1 or the second direction D 2 .
Referring again to FIGS. 2 , 3 , and 5 , the spring 48 exerts a force on the actuator member 44 in the second direction via the collar 52 . The surface 62 of the actuator member 44 is angled relative to the second direction D 2 such that the actuator member 44 transfers the force from the spring 48 to the spherical portions 82 of the locking members 78 A-C. The force exerted on the spherical portions 82 by the surface 62 includes a lateral component, i.e., a component that is orthogonal to the first and second directions D 1 , D 2 , and that urges the spherical portions 82 away from the central hole 42 and into the tapered portions 43 of the pins 14 A-F, thereby locking the pins 14 A-F with respect to the body 12 . Thus, the actuator member 44 and the locking members 78 A-C are part of a locking mechanism 93 that selectively prevents movement of the pins 14 A-F relative to the body. Each locking member 78 A, 78 B is prevented from rotating about an axis that is parallel to the first and second directions D 1 , D 2 by the surface 62 and two of the pins 14 A-F acting thereon. Thus, in the embodiment depicted, the locking members 78 A-C are prevented from rotating, and their movement is limited to lateral translation.
The clamp 10 is reconfigurable; that is, the locking mechanism 93 is selectively releasable so that the positions of the pins 14 A-F with respect to the body 12 are selectively variable. FIGS. 6 and 7 schematically depict operation of the locking mechanism 93 during reconfiguration of the clamp 10 , i.e., during repositioning of the pins with respect to the clamp body 12 . Although only pin 14 C is shown in FIGS. 6 and 7 , it should be noted that the interaction between pin 14 C and the locking mechanism 93 is identical to the interaction between the other selectively movable pins 14 A-B, 14 D-F and the locking mechanism 93 .
Referring to FIG. 6 , pin 14 C is shown in its extended position. Spring 48 urges actuator member 44 in the second direction D 2 ; in turn, surface 62 of the actuator member 44 drives spherical portion 82 of locking member 78 B outward and against the tapered portion 43 of pin 14 C, thereby locking pin 14 C with respect to the body 12 . Friction between the spherical portion 82 of the locking member 78 B and the pin 14 C prevents movement of the pin 14 C in the first direction D 1 . It should be noted that, in the embodiment depicted, the force exerted by the spring (shown at 32 in FIG. 3 ) is sufficient to overcome friction between the pin 14 C and the body 12 , but is not sufficient to overcome the friction between the locking element 78 B and the pin 14 C.
The pin 14 C is prevented from moving in the second direction D 2 due to friction between the locking member 78 B and the pin 14 C, and also because the tapered portion 43 is angled relative to the second direction D 2 such that movement of the pin 14 C in the second direction causes the locking member 78 B to exert a reaction force on the pin 14 C in the first direction.
It should be noted that, if spherical balls are used in place of locking elements 78 A-C, then the balls could rotate, or “roll,” relative to the body and to the pins, and thus the pins may “drift” from their intended positions. The locking members 78 A-C, by being keyed to the body 12 , are prevented from rolling in a direction that would compromise the ability to lock the pins 14 A-F with respect to the body 12 .
To unlock the pin 14 C, and thereby to permit translation of the pin 14 C in either the first or the second direction D 1 , D 2 , the actuator member 44 is moved in the first direction D 1 . More specifically, in the embodiment depicted, the actuator (shown at 70 in FIG. 5 ) exerts a force on member 66 (shown in FIGS. 3 and 5 ), which transmits the force to the actuator member 44 . The force exerted by the actuator 70 is sufficient to overcome the bias of the spring 48 , and the actuator member 44 moves in the first direction to the position shown in phantom at 44 A. Correspondingly, surface 62 moves in the first direction D 1 to the position shown in phantom at 62 A.
The taper of surface 62 is such that movement of the actuator member 44 in the first direction D 1 increases the distance between surface 62 and the tapered portion 43 , and thus the spherical portion 82 of the locking member 78 B. Thus, locking member 78 B is not tightly wedged between the surface 62 and the tapered portion 43 of the pin, thereby permitting relative movement of the pin 14 C relative to the body 12 . Thus, when the surface is at the position shown at 62 A, the locking member 78 B can move laterally, away from the pin 14 C (and pin 14 B) to the position shown in phantom at 78 BB in FIG. 5 ; correspondingly, the spherical portion 82 of the locking member 78 B moves laterally, further into the central hole 42 , to the position shown in phantom at 82 A in FIG. 6 , where it does not contact the pin 14 C, or, if contact occurs between the spherical portion 82 and the pin 14 C, the friction therebetween is low.
Thus, movement of the member 44 to the position shown at 44 A unlocks the pin 14 C with respect to the body 12 , and the pin 14 C is selectively movable. In an exemplary use, the clamp 10 is employed by a robotic arm or other fixture to manipulate or hold sheet metal components for vehicle bodies. In prior art systems, a robotic arm or other fixture would require a new clamp, or significant machining of a clamp, to handle sheet metal components having different shapes or contours. The clamp 10 is reconfigurable such that the clamp 10 can be used for sheet metal components of differing contours and shapes.
Referring to FIG. 7 , to reconfigure the clamp 10 for a particular sheet metal contour, a representative piece of sheet metal 94 is pressed against the tips 30 A-F of the pins 14 A-F when the pins 14 A-F are unlocked, i.e., when the actuator member 44 is in the position shown at 44 A in FIG. 6 . The axis of advance of the sheet metal part 94 should be such as to locate the point of contact between the fixed pin 14 G and the sheet metal part 94 at a predetermined location on the sheet metal part 94 , which is preferably a location of minimal local curvature. The sheet metal part 94 will continue to contact and displace the pins 14 A-F until the sheet metal part 94 contacts the fixed pin 14 G and the relative motion between the sheet metal part 94 and the clamp body 12 ceases. Preferably at the point when contact occurs between the sheet metal part 94 and the fixed pin 14 G, the sheet metal part 94 will contact all of the plurality of movable pins 14 A-F.
The sheet metal 94 will move each pin 14 A-F in the second direction D 2 , against the bias of the springs shown at 32 in FIG. 3 , to a respective position in which the tips 30 A-F approximate the contour of the sheet metal 94 . Thus, in FIG. 7 , pin 14 C has been moved in the second direction D 2 by the sheet metal 94 from its extended position to the position shown in FIG. 7 . It should be noted that the stationary pin 14 G is used as a reference location capable of identifying the location of the clamped sheet metal 94 in the reference frame of the tooling and thus for specifying the operating location of the clamp 10 .
After the pin 14 C has been moved to the position shown in FIG. 7 , then the actuator (shown at 70 in FIG. 5 ) is deactivated, and the spring 48 urges the actuator member 44 in the second direction D 2 until the actuator member 44 is in the position shown in FIG. 7 and driving the spherical portion 82 of locking member 78 B against pin 14 C (and pin 14 B), thereby to lock the pins 14 C and 14 B with respect to the body 12 . It should be noted that the locking element 78 B in FIG. 7 contacts tapered portion 43 at a wider portion of the tapered portion 43 in FIG. 7 than in FIG. 6 ; accordingly, the locking element 78 B is closer to the centerline of hole 42 in FIG. 7 than in FIG. 6 . Thus, once the pneumatic actuator is deactivated and the spring 48 moves the actuator member 44 in the second direction D 2 , the locking element 78 B prevents the actuator member 44 from returning to its original position shown at 44 in FIG. 6 . Since all three locking members 78 A-C may move laterally as a result of pin movement, the actuator member 44 is movable laterally, such as to the position shown at 44 B, in order to find a location such that it acts on all three locking members 78 A-C. Thus, the actuating member 44 is not rigidly connected to the collar (shown at 52 in FIG. 3 ) or to the member (shown at 66 in FIG. 3 ).
It should be noted that the locked condition is achieved through the urging of actuator spring 48 , without the need for any action of the actuator (shown at 70 in FIG. 5 ). Thus the locking action may be achieved without the application of external power to the reconfigurable clamp 10 . Hence the reconfigurable clamp 10 maintains its geometry even in the case of a power failure which incapacitates the external source of power. The locking members 78 A-C may be hardened to limit deformation during stress. In an exemplary embodiment, springs (not shown) may be used to bias the locking members 78 A-C into contact with surface 62 of the actuator member 44 . The springs shown at 32 and 48 are depicted as compression coil springs; however, those skilled in the art will recognize other spring configurations that may be employed within the scope of the claimed invention. In an exemplary embodiment, the springs 32 , 48 are plunger springs. Pin 14 G is depicted as a member attached to the body 12 ; however, within the scope of the claimed invention, the pin 14 G may be part of the body 12 .
In the above description it has been assumed that the transfer of the shape of the sheet metal part 94 to be supported and the clamp 10 is achieved through contact between the sheet metal part 94 and the reconfigurable clamp 10 . Alternatively, a solid block into which a representation of the relevant section of the sheet metal part 94 has been rendered may also be used. Such a procedure may be desirable if it is desired to set the form of the reconfigurable clamp 10 off-line and bring it to the operating location with the shape already preset.
In alternative embodiments, and within the scope of the claimed invention, the tapered portions 43 on the movable pins 14 A-F may be oriented such that the diameter of the tapered portions 43 increase in the second direction D 2 , instead of in the first direction D 1 as shown. Similarly, and within the scope of the claimed invention, the tapered portion 58 on the actuator member 44 may be oriented such that the diameter of the tapered portion 58 increases in the second direction D 2 , instead of in the first direction D 1 as shown.
While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
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A selectively lockable assembly includes a body, a pin, a locking member, and a plunger that is configured to selectively urge the locking member against the pin to lock the pin with respect to the body. The locking member is keyed to the body in a manner to prevent or limit rotation of the locking member and thereby limit movement of the pin under load. A corresponding clamp is also provided.
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FIELD OF THE INVENTION
The present invention relates generally to hardcopy devices which advance media through a printzone for printing, such as electrophotographic printers or as illustrated herein, inkjet printing mechanisms. More particularly, the present invention relates to an operating system for controlling a greeting card feeder module used in conjunction with a duplexing printing mechanism to easily print greeting cards which are comparable with store-bought greeting cards.
BACKGROUND OF THE INVENTION
The term “hardcopy device” includes a variety of printers and plotters, including those using inkjet and electrophotographic technologies to apply an image to a hardcopy medium, such as paper, transparencies, fabrics, foils and the like. Inkjet printing mechanisms print images using a colorant, referred to generally herein as “ink.” These inkjet printing mechanisms use inkjet cartridges, often called “pens,” to shoot drops of ink onto a page or sheet of print media. Some inkjet print mechanisms carry an ink cartridge with a full supply of ink back and forth across the sheet. Other inkjet print mechanisms, known as “off-axis” systems, propel only a small ink supply with the printhead carriage across the printzone, and store the main ink supply in a stationary reservoir, which is located “off-axis” from the path of printhead travel. Typically, a flexible conduit or tubing is used to convey the ink from the off-axis main reservoir to the printhead cartridge. In multi-color cartridges, several printheads and reservoirs are combined into a single unit, with each reservoir/printhead combination for a given color also being referred to herein as a “pen.” As the inkjet industry investigates new printhead designs, one trend is toward using a “snapper” reservoir system where permanent or semi-permanent printheads are used and a reservoir carrying a fresh ink supply is snapped into place on the printhead.
Each pen has a printhead formed with very small nozzles through which the ink drops are fired. The particular ink ejection mechanism within the printhead may take on a variety of different forms known to those skilled in the art, such as those using piezo-electric or thermal printhead technology. For instance, two earlier thermal ink ejection mechanisms are shown in U.S. Pat. Nos. 5,278,584 and 4,683,481, both assigned to the present assignee, the Hewlett-Packard Company. In a thermal system, a barrier layer containing ink channels and vaporization chambers is located between a nozzle orifice plate and a substrate layer. This substrate layer typically contains linear arrays of heater elements, such as resistors, which are energized to heat ink within the vaporization chambers. Upon heating, an ink droplet is ejected from a nozzle associated with the energized resistor.
To print an image, the printhead is propelled through a printzone back and forth across the page, ejecting drops of ink in a desired pattern as it moves. By selectively energizing the resistors as the printhead moves across the page, the ink is expelled in a pattern on the print media to form a desired image (e.g., picture, chart or text). The nozzles are typically arranged in linear arrays usually located side-by-side on the printhead, parallel to one another, and perpendicular to the scanning direction of the printhead, with the length of the nozzle arrays defining a print swath or band. That is, if all the nozzles of one array were continually fired as the printhead made one complete traverse through the printzone, a band or swath of ink would appear on the sheet. The width of this band is known as the “swath height” of the pen, the maximum pattern of ink which can be laid down in a single pass. The print media, such as a sheet of paper, is moved through the printzone typically one swath width at a time, although some print schemes move the media incrementally by, for instance, halves or quarters of a swath width for each printhead pass to obtain a shingled drop placement which enhances the appearance of the final image.
Whether the printing mechanism uses either a snapper cartridge system, an off-axis system, a replaceable cartridge system or some other inkjet system, drop placement on the media must be coordinated with the incremental advance of the media through the printzone for sharp, vivid images and text, which are free of print defects, such as color banding, improper spacing, and printed line overlapping. Many types of inkjet printing mechanisms use a series of conventional paper drive rollers or tires to frictionally engage the print media and incrementally advance the media through the printzone, moving either a full or fractional swath width.
One such media advancing system is described in U.S. Pat. No. 5,838,338, currently assigned to the Hewlett-Packard Company. One inkjet printer, specifically the DeskJet® 970 model color inkjet printer sold by the Hewlett-Packard Company, has a duplexer unit. Other printers, such as the DeskJet® 930 and 950 models of color inkjet printers, also sold by the Hewlett-Packard Company, may be used in conjunction with an optional duplexing module sold by the Hewlett-Packard Company as the Automatic Two-Sided Printing Module, stock no. C6463A. As the home computer market grows, as well as business applications, consumers have a desire to print greeting cards on their own printers, and as print quality advances increase, current inkjet printers have the ability to produce greeting cards which are of a quality comparable to a store bought greeting card. Additionally, with the increasing popularity of the Internet and electronic commerce, there are many websites which offer a variety of greeting card designs that consumers can download and print. For example, one such website may be located at www.printablecards.com. Indeed, in the future stores may even offer greeting card media in pre-cut sizes, such as 7×10 inch sheets which could be pre-scored to easily fold into a 5×7 inch greeting card.
Unfortunately, even with the ready availability of both pre-cut media and greeting card designs on the Internet and other software programs, most people still do not print their own greeting cards because of the complexity of the process, particularly when using currently available inkjet printers. Most consumers typically print on letter size media and only occasionally wish to print a greeting card, such as for holidays, birthdays and the like. For example, using a Microsoft Windows® based operating system on a home computer, printing a greeting card is a complicated lengthy process both in terms of physical hardware changes that need to be made to the printer, as well as software manipulation.
For example, FIGS. 5A and 5B together form a flow chart illustrating a prior art greeting card printing method. Since the drawings are labeled 5 A and 5 B, we will begin our discussion of this method with the letter C for the first step. Assuming an inkjet printer has been being used in a normal fashion for printing on letter-sized (8 ½×11 inch), in a removing step C, the user must first remove this normal sized paper (or other media) from the input tray and find a place to put the stack, which for some users with a slightly a cluttered work area may be a difficult task in itself. Then in a loading step D, the greeting card media is loaded into the input tray of the printer. Then in a width adjusting step E, the media width adjuster must be moved to snuggly press the stack against the side of the input tray. Then in a length adjusting step F, the media length adjuster must then be moved to snuggly press the greeting card stack back toward the media picking and feed mechanism.
Now the greeting card media has been loaded into the printer, the method continues with a software running step G, where the user then begins to run a particular greeting card software application. As mentioned above, this software application might be something which the user purchased, or it may be a design downloaded from the Internet or something custom created by the user using word processing or graphics programs. Then in a selecting step H, the user selects which greeting card to print. Then to begin the printing process, in an illustrated Microsoft Windows® brand based software application, in a selecting step I, the user must first select the “File” menu and then select the “page set-up” option. In another selecting step J, in the “page set-up” pop-up window, the user must then select the greeting card media size option, here illustrated as 7×10 inches. In another selecting step K in the “page set-up” pop-up window, the user must then select two-sided printing so a picture image or other text appears on the front of the finished card, and a greeting appears on the inside of a card. Then in another selecting step L, having selected the media size in step J and duplex printing in step K, the user must then select the “ok” feature on the “page set-up” pop-up window to close this window and continue the operation.
In a further selecting step M, the user must then again enter the file menu and then select the option “print”. Now transitioning from FIG. 5A to FIG. 5B, at the top we see another selecting step N, where under the print pop-up screen, the user must now select the properties option which generates another pop-up screen having several different layers of selection based upon the particular type of printer being used. Then in another selecting step, the user must select the “features” tab to bring the variety of features available into view. In a further selecting step P on the features screen, a user must select two-sided printing. Following this selection of two-sided printing, in a selecting step Q, the user must indicate that two-sided printing is desired by activating the “ok” feature to close the properties window. In a further selecting step R, the user must then select “ok” to close the print screen and initiate printing of the greeting card. Of course between steps Q and R, a user might also wish to select the number of copies of the card they would like to print if more than one card was desired.
Finally, in a printing step S, the printer finally prints the greeting card, performing the required duplexing operation to print on both the inside and outside of the card after which, the card is deposited by the printer in the output tray. Having completed this tortuous process to this point, the user must then return the printer to the normal operating state for, in this example, printing on letter-sized paper. In a moving step T, the user moves the media width adjuster on the printer to the far left position to begin to release the greeting card media. In another moving step U, the media length adjusters moved to the fully extended or “out” position so the remaining blank greeting card media can be removed from the input tray of the printer. It is apparent some users may wish to reverse steps T and U. Having removed the greeting card media from the input tray, in a loading step V, the normal sized paper or other media is returned to the input tray. After the media has been loaded, in an adjusting step W, the media width adjuster must be moved against the normal size media to push it tightly against the side of the input tray. Finally, in a length adjusting step X, the media length adjuster is pushed toward the rear of the printer, to move the media stack into engagement with the media picking and feed mechanisms to leave the printer ready for a normal print job.
In reviewing this earlier printing routine required to change from a normal printing mode to printing a greeting card and then return the printer to the normal state, nearly every letter of the alphabet has been used. Indeed, steps I and M really include two steps, one of selecting the file menu and the other then selecting which option is required under the file menu. Furthermore, between steps U and V an additional step could have been added for the process of unloading the greeting card media. Moreover, if the printer was not capable of duplex printing, while steps K and P could be eliminated after a user printed one side of the greeting card in step S, the card would still need to be placed back in the top of the input tray media stack to allow printing on the other side of the card by repeating the remainder of the steps D through S, before moving on with steps T through the end to return the printer to normal sized media. Effectively, without the ability to print with an automatic duplexer, the method nearly doubles in length. This system is just far to complicated for the majority of simple users who wish to quickly print a greeting card and continue on with other tasks in their day. Moreover, since most users only occasionally print greeting cards and this is not a daily occurrence they must remember all of these steps in order to successfully print a greeting card without unnecessarily wasting media where several months may go by between uses for instance, between Christmas and Valentine's Day, between Valentine's Day and Easter, and then perhaps between Easter and the following Christmas. Unfortunately, the only clear memory a user may have of the last time they tried printing a greeting card is that it was just too complicated and troublesome, leaving them to conclude it would be far easier just to go to the store and buy a card.
Thus, a need exists for a simple uncomplicated way for users to print greeting cards which is quick and easy to repeat, with minimal interruption of normal printing.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a method is provided for printing images on a first-sized media and on opposing first and second surfaces a second-sized media. The method includes the step of providing a hardcopy printing mechanism having a frame, a first input device for storing a supply of the first-sized media, a duplexer unit for inverting media, a controller responsive to input signals to print images, and a second input device for receiving a sheet of the second-sized media. In a loading step, a sheet of the second-sized media is loaded into the second input device. In an initiating step, a software program is initiated. The software program includes a selection of images each having a first portion and a second portion. The method also includes the steps of selecting one of the images from the selection of images, and generating input signals for the controller in response to the selecting step. In a first printing step, the first portion of the selected image is printed on the first surface of the loaded sheet of second-sized media, and thereafter, the second portion of the selected image is printed on the second surface of the second-sized media, while retaining a supply of the first-sized media in the first input device.
An overall goal of the present invention is to provide a hardcopy device with a greeting card feeder module and operating system which is easy to use.
Another goal of the present invention is to provide a hardcopy device with a greeting card feeder module and operating system which reliably produces clear crisp images.
A further goal of the present invention is to provide a retrofit kit, including hardware, software, and optionally a sample supply of greeting card stock, which allows consumers, who have previously purchased a printer without a greeting card feeder module, the option of retrofitting their printer with a new greeting card feeder module and associated software.
An additional goal of the present invention is to provide a hardcopy device with a greeting card feeder module and operating system which allows a user to quickly switch between their normal print media, such as letter-sized paper, and specialty sized print stock, such as greeting card stock.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a, partially schematic, fragmented, perspective view of one form of a hardcopy printing device, here an inkjet printer having a duplexer device, and including one form of a greeting card feeder module and operating system of the present invention for printing on specialty-sized print media, and in particular, on greeting card stock.
FIG. 2 is an enlarged perspective view of the greeting card feeder module of FIG. 1, shown removed from the printer.
FIG. 3 is a fragmented, enlarged top plan view of the greeting card feeder module of FIG. 1, showing one form of a biasing device for pushing greeting card media toward the side of the module.
FIG. 4 is a flow chart illustrating one form of a greeting card feeder operating system of the present invention which may be used in the printer of FIG. 1 .
FIGS. 5A and 5B are two portions of a flow chart illustrating a commonly used, cumbersome, prior art manner of printing greeting cards.
FIG. 6 is a front elevational view replicating a computer screen display of one form of a first display produced by the greeting card operating system of FIG. 1 .
FIG. 7 is a front elevational view replicating a computer screen display of one form of a second display produced by the greeting card operating system of FIG. 1 .
FIG. 8 is a front elevational view replicating a computer screen display of one form of a third display produced by the greeting card operating system of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an embodiment of a hardcopy device, here shown as an inkjet printing mechanism, and in particular, an inkjet printer 20 , constructed in accordance with the present invention, which may be used for printing for business reports, correspondence, desktop publishing, and in particular, for printing greeting cards, in an industrial, office, home or other environment. A variety of inkjet printing mechanisms are commercially available, although some of the more important advantages of the printer 20 may be appreciated best by people printing in a typical home environment. While it is apparent that the printer components may vary from model to model, the typical inkjet printer 20 includes a chassis 22 surrounded by a housing, casing or enclosure 24 , typically of a plastic material. Sheets of print media are fed through a printzone 25 by a print media handling system 26 using a series of internal conventional media drive rollers (not shown). The print media may be any type of suitable sheet material, such as paper, transparencies, mylar, and the like, but for convenience, the normal print mode is illustrated using plain paper, such as letter-sized paper, as the normal print medium. After printing, a sheet exiting the printzone 25 is propelled onto a pair of retractable output drying wing members, such as wing 28 . The pair of wings 28 momentarily hold a newly printed sheet above any previously printed sheets still drying in an output tray 30 before retracting to the sides to drop the newly printed sheet into the output tray.
The printer 20 also has a printer controller, illustrated schematically as a microprocessor 32 , that receives instructions from a host device, typically a computer, such as a personal computer (not shown). Indeed, many of the printer controller functions may be performed by the host computer, by the electronics on board the printer, or by interactions therebetween. As used herein, the term “printer controller 32 ” encompasses these functions, whether performed by the host computer, the printer, an intermediary device therebetween, or by a combined interaction of such elements. The printer controller 32 may also operate in response to user inputs provided through a key pad 34 located on the exterior of the casing 24 . A monitor coupled to the computer host may be used to display visual information to an operator, such as the printer status or a particular program being run on the host computer. Personal computers, their input devices, such as a keyboard and/or a mouse device, and monitors are all well known to those skilled in the art.
One or more inkjet cartridges, here illustrated as a black ink cartridge 35 and a color ink cartridge 36 , may be slideably supported in a conventional manner by a carriage mechanism (not shown) for reciprocating travel back and forth across the printzone 25 for printing, and into a servicing region 38 for printhead maintenance and storage. The cartridges 35 and 36 are often called “pens” by those in the art. The printer 20 has a cartridge drive mechanism, such as a DC motor and drive gear assembly (not shown) coupled to drive the pens 35 , 36 in this reciprocating fashion in response to control signals received from the controller 32 . A conventional optical encoder device (not shown) may be used to provide the controller 32 with feedback information as to the position of the pens over the printzone 25 . The illustrated color pen 36 is a tri-color pen, although in some embodiments, several discrete monochrome pens may be used. While the color pen 36 may contain a pigment based ink, for the purposes of illustration, pen 36 is described as containing three dye based ink colors, such as cyan, yellow and magenta. The black ink pen 35 is illustrated herein as containing a pigment based ink. It is apparent that other types of inks may also be used in pens 35 , 36 , such as paraffin based inks, as well as hybrid or composite inks having both dye and pigment characteristics.
The illustrated pens 35 , 36 each have bodies that define reservoirs for storing a supply of ink therein. The bodies of pens 35 , 36 each support conventional printheads (not shown), with each printhead having an orifice plate with a plurality of nozzles formed therethrough in a manner well known to those skilled in the art. The illustrated embodiment uses thermal inkjet printheads, although other types of printheads may be used, such as piezoelectric printheads. The printheads 35 , 36 typically include a plurality of resistors which are associated with the nozzles. Upon energizing a selected resistor, a bubble of gas is formed with the bubble ejecting a droplet of ink from the nozzle and onto a sheet of media in the printzone 25 under the nozzle. The printhead resistors are selectively energized in response to firing command control signals received from the controller 32 . The pens 35 , 36 are illustrated as replaceable inkjet cartridges, which when emptied are removed and replaced with fresh cartridges each having new printheads. Thus, the illustrated printer 20 may be considered as a “replaceable cartridge” inkjet printer.
The illustrated printer 20 is fitted with a removable duplexer module 40 , which provides for automatic auto-duplexing, that is, two-sided printing so an image may be applied to both sides of a sheet of media. Such a duplexer module, mentioned in the Background section above, is commercially available from the Hewlett-Packard Company as the Automatic Two- Sided Printing Module, stock no. C6463A, which may be used in conjunction with the DeskJet® 930 and 950 models of color inkjet printers. The Hewlett-Packard Company also offers the DeskJet® 970 model color inkjet printer which comes with this duplexer unit model installed. Thus, in the illustrated embodiment, the duplexer unit 40 serves as a portion of the media handling system 26 .
Another portion of the media handling system 26 is the media input tray 42 , which is shown in FIG. 1 as holding a stack of letter-sized paper 44 . In the illustrated embodiment, the media tray 42 is designed as a drawer-type tray slidably supported between two fixed side panels 45 extending outwardly from a main body portion of the casing 24 . Preferably, the input tray drawer 42 slides outwardly in the positive Y-axis direction to allow for ease of loading the media 44 in the tray. In referring to the background section above, the stack of paper 44 and the input tray 42 comprises the “normal” type of media which most users typically employ. Either before the input tray 42 is pushed back into the printing position shown in FIG. 1, a media length adjuster 46 and a media width adjuster 48 are pushed into contact with the stack 44 to hold the sheets firmly in a proper position for picking by the media drive rollers (not shown). In the illustrated embodiment, the length adjuster 46 pushes the media stack 44 in a negative Y-axis direction, and into engagement with the media picking mechanism, where as the width adjuster 48 pushes the stack into the negative X direction which serves to present the sheets to the pick rollers in an aligned, non-skewed fashion.
FIG. 1 shows the printer 20 equipped with one form of a greeting card feeder module 50 , constructed in accordance with the present invention. The greeting card feeder module 50 includes a fixed portion 52 and a pivoting portion 54 which is pivotally attached to the fixed portion 52 by a pair of hinges, such as hinge 55 . The hinge 55 allows the pivoting portion 54 to rotate upwardly to provide easier access to the media input tray 42 . To temporarily hold the pivoting portion 54 above the media stack 44 , one or both of the side panels 45 may have a door stop feature 56 which holds the pivoting portion 54 at an angled orientation to free a user's hands to adjust the media stack 44 and adjusters 46 , 48 . Preferably the door stop 56 is sized and positioned, in combination with the features of the greeting card feeder module 30 to allow gentle hand pressure to move the pivoting portion 54 over the stop when moving between the elevated and loading position and the lowered printing position. Together, the fixed portion 52 and the pivoting portion 54 of the greeting card feeder module 30 define the output tray portion 30 of printer 20 . While the input tray 42 is preferably designed to hold a variety of different sizes of media, from 3×5 inches up to legal sized 8 ½×14 inch paper, or continuously fed Z-fold or banner type paper, including a stack of envelopes. However, some users may prefer the convenience of being able to feed a single envelope through the printzone 20 without having to remove the normal media 44 . Thus, the fixed portion 52 of the greeting card feeder module may be formed to define a manual envelope feed slot 58 .
The pivoting portion 54 of the greeting card feeder module 50 defines a greeting card stock feed slot 60 , shown in FIG. 1 with a standard sized piece of greeting card stock 62 inserted therein ready for printing. FIGS. 2 and 3 illustrate other features of the greeting card feeder module 50 . For ease of compatibility with current printer designs, the fixed portion 52 of the module 50 may be of the same construction as current output tray designs, for instance, including a pair of extending side rails, such as side rail 64 which has a pair of snap fit members 66 extending downwardly therefrom for receipt by a pair of mating features such as features 68 formed within the inner portions of the fixed side panels 45 (see FIG. 1) other conventional assembly features of the fixed tray portion 52 may include a rear wall 70 , and alignment features 72 and 74 which are used to positively receive the module 50 within the printer chassis 22 and align the module with other portions of the media handling system including the input or pick rollers and the media output rollers (not shown). As shown in FIG. 2, preferably the fixed portion 52 of the module has an extending platform portion 75 which extends beyond the hinges 55 to lie under a portion of the pivoting tray portion 54 . One useful feature for this extending ledge 75 is that it makes it more difficult for a user to get their fingers, clothing, jewelry or other items caught or tangled in the internal moving portions of the printer, namely, the media pick and feed rollers (not shown). To aid a user in understanding intuitively that the pivoting portion 54 of the module 50 does indeed pivot in an upward direction, preferably a rounded front portion 76 of plate 54 is embossed or molded with a textured gripping region 77 . Other embossed or molded tactile indicators are shown on the duplexer 40 in FIG. 1, including a pair of depressible installation/uninstallation buttons located to each side of the duplexer, such as button 78 , and a jam-clearing door button 79 . When button 79 is depressed, the top and rear portions of the duplexer casing are hinged to open and allow access to the internal rollers of the duplexer to allow easy removal of any jammed media.
FIG. 3 illustrates another important feature of the greeting card feeder 50 , which is a width biasing member or push arm 80 . Preferably the push arm 80 is pivotally attached to an undersurface 83 of the ledge portion 75 (see FIG. 2 ). Preferably the push arm 80 is biased away from a mounting feature 84 extending downwardly from the ledge undersurface 83 by a biasing member, such as a compression spring 85 . The spring 85 serves to push arm 80 into engagement with the free side edge of the sheet of greeting card stock 62 , as shown in FIG. 3 . Since all commercial greeting cards are not cut exactly to a nominal width, here illustrated as 7 inches in width with a 10 inch length, this push arm width adjuster 80 advantageously serves to align the opposite edge of the card stock tightly against and alignment edge 86 of the input slot 60 . Thus, use of the biasing arm 80 advantageously allows the greeting card feeder 50 to easily compensate for slight variations and differences in the widths of particular greeting card media which typically fall within commercial cut tolerances. Before leaving our discussion of the push arm 80 , it is noted that a variety of other biasing mechanisms other than a coil compression spring 85 may be used to push the arm 80 into engagement with a sheet of greeting card stock 62 . For instance, rather than a coil spring, a leaf spring may be used, or a torsional spring member wrapped around the mounting post 82 , as well as tensioning springs which would pull the arm 80 into contact with the edge of the card stock.
Another useful feature of the pivoting plate 54 of the feeder 50 is a beveled ramp portion 88 which assists a user in guiding a sheet of card stock 62 into the feed slot 60 . As far as how far back, that is in the negative Y direction, a user must insert a sheet of cardstock 62 , most users soon develop an intuitive feel or understanding that a sheet of media must be pushed rearwardly into engagement with the pick rollers, since this is the standard practice when loading a normal stack of media 44 in the regular input tray 42 , as well as when feeding an envelope through the manual feed slot 58 . Thus, given that the feeder module 50 is designed for single sheet manual feeding, it is believed that a user's hand serves this rearward biasing function just as well if not better than any mechanical biasing member.
FIG. 4 is a flowchart 90 illustrating one form of a greeting card feeder operating system, operated in accordance with the present invention using the greeting card feeder module 50 , as assembled in printer 20 with the auto-duplexer unit 40 installed. In a loading step 92 , a sheet of card stock 62 is loaded by hand into the feed slot 60 of the feeder module 50 . During this loading process, the push arm 80 under the urging force of spring 85 automatically guides the card stock 62 into engagement with the right edge 86 of feed slot 60 , as shown in FIG. 3 . Most users intuitively know to push the card stock 62 all the way toward the rear of the printer, until the rearward most edge of sheet 62 encounters the media pick mechanism (not shown). Now the media is ready in the feeder 50 , in a running step 94 the user runs the desired greeting card software application which, is discussed in the background section above, may be an application already loaded on a user's computer, or one accessible from the internet or other networking mechanisms. Once the software is up and running, in a selecting step 96 , a user then selects which greeting card to print on the loaded sheet of media 62 . Then in another selecting step 98 , a user selects a print button feature on a software operating system which may accompany the greeting card feeder module, or another print feature, such as that which accompanies most word processing systems. Following the selecting step 98 , the printer 20 then picks the sheet of media 62 from the feeder module 50 and in a printing step 100 prints first one side of a card, followed by the duplexer module 40 inverting the card stock to allow the printer to print on the other side of the card. Preferably to improve throughput, which is a term used to define the speed of printing typically measured in pages per minute, the side of the card having the shortest drying time is printed first. Most often the inside of the card has the shortest drying time because it typically has a text message, while the outside of the card usually has a more graphic design, so for most cards the inside message may be printed first. Following this printing, the freshly made greeting card is then delivered into the printer output tray 30 , lying on top of the fixed base plate 52 and the pivoting plate 54 , in a location generally extending over the feed slot 60 .
FIGS. 6-8 illustrate one form of a series of screen displays produced for user interaction when running the illustrated greeting card software of steps 94 - 98 shown in FIG. 4 . FIG. 6 illustrates an opening screen display 102 of the software routine of step 94 . The opening screen display 102 includes a title 104 , here “greeting card maker,” along with a conventional set of display sizing and program exiting options 105 , a help request indicia 106 , and an exit request 108 . Also shown in the opening screen 102 is a select occasion option 110 . FIG. 7 illustrates a second screen display 112 which is provided to a user after selecting the select occasion option 110 from screen display 102 in FIG. 6 . The screen display 112 includes a greeting card menu 114 , showing various holidays including anniversaries, birthdays, Christmas, Father's Day, Grandparent's Day, Mother's Day, and Valentine's Day as few examples. It is apparent that menu 114 may be expanded to include other holidays, such as Thanksgiving and Easter, Thank You cards, and Friendship cards.
In the illustrated example, a birthday card option 115 has been selected and the program has generated a secondary option menu 116 . The secondary option 116 has several examples of different types of customized birthday cards including a generic card, one for a brother and one for a father. In the illustrated example, a brother option 118 has been selected to generate a birthday card for a brother. FIG. 8 shows a third screen display 120 which resulted from the selection of a birthday card for a brother on the display 112 of FIG. 7 . Display 120 shows a card generation screen 122 which shows a first selection for a birthday card suitable to send to one's brother. The card generation screen 122 has an outside display portion 124 and a card interior display portion 125 , which each have indicia thereunder such as the “front” indicia 126 and the “inside” indicia 128 . If this is the desired card, the print card step 98 of FIG. 4 may then be implemented by selecting a print card option 130 on the card generation screen 122 . If this is not the desired card to be sent, a user may browse through a library of cards stored within the program, by choosing a next card option 132 on the generation screen 122 .
Thus, the next card option 132 forms a portion of the selecting a greeting card step 96 of FIG. 4, with the print card option 130 option being selected to complete the step and send printing instructions from a host computer device to the printer controller 30 . By starting with step 94 to run the software application illustrated, in a minimum of three screen displays 102 , 112 and 120 , for instance, a greeting card may be selected and printed using the illustrated greeting card generation software application of steps 94 - 98 , it is apparent that additional options and selections may be added to provide users with greater choices in the types of greeting cards by adding to the menu 114 and secondary menu 116 of FIG. 7, as well as adding additional greeting card selections which may be viewed on the card generation display 122 . Furthermore, it is also apparent that the greeting card feeder module 50 may be used in conjunction with other greeting card software applications, beyond that illustrated in FIGS. 6-8, although the illustrated greeting card maker application preferred for its simplicity and ease of use.
Conclusion
Thus, the new method capable of using the greeting card feeder 50 in conjunction with the duplexer unit 40 advantageously reduces the number of steps a user is required to employ to print a greeting card. For example, from the nearly 20 steps described in the background section with regard to the flowchart of FIGS. 5A and 5B, a user now performs five steps to print a greeting card. Granted, the running step 94 and the selecting step 96 are similar to steps G and H in the prior system, and step 100 is similar to step S, but the remaining two steps 92 and 98 are vast simplification over the methods which users had to employ previously to print greeting cards. Indeed, none of the earlier greeting card software applications had any manner for receiving an input from a user to indicate that a printer had auto-duplexing capability, such as that provided by the duplexer module 40 . Thus, greeting cards printed from these earlier software applications were first printed usually on the exterior of the card, after which a user had to manually invert the sheet and reload it into the printer to print the inside of the card, further complicating the illustrated prior art operating system of FIGS. 5A and 5B. Indeed, some of these earlier software applications were not even designed to handle the special sized greeting card media, requiring a couple of extra steps to be inserted between the selecting steps P and Q. For instance, an additional selection might be required to reduce the greeting card content to fit a smaller area, such as the area of ¼ of a letter-sized sheet which, through careful folding and single sided printing could be fashioned into a homemade greeting card. Unfortunately these earlier greeting card software applications designed for letter-sized paper were limited to producing a greeting card which was only the size of a typical party invitation or thank-you note, but not the larger size of a typical birthday card or holiday greeting card. Furthermore, the letter-sized plain paper media was typically too flimsy and easily wrinkled, not leading to any type of a durable greeting card comparable to those available in the stores.
Using the illustrated greeting card feeder operating system 90 , the number of steps required to successfully print a homemade greeting card having store bought type quality are drastically reduced. While some users may lament the loss of the capability to print many different sizes of greeting cards using the feeder module 50 , the simplicity offered by this system is believed to be far more advantageous for the majority of users. Moreover, by eliminating the need to reconfigure the normal media input tray 42 to accommodate specially sized greeting card stock 62 , the speed with which a greeting card can be printed is drastically increased. The quickness with which a commercial quality greeting card can be printed using the method of flowchart 90 and the card feeder module 50 in conjunction with duplexer 40 is a significant advantage for many users who perhaps at the last minute realize they have forgotten an important birthday or other event and don't have time to go to a store and shop for a card. Furthermore, the ease of use of the feeder module 50 and operating method 90 are particularly advantageous for users which only infrequently need to print a card and may have difficulty remembering all of the steps illustrated in FIGS. 5A and 5B when many months intervene between uses.
Another trade-off in flexibility and features versus ease of use of method 90 and the feeder module 50 was the elimination of the ability to personalize a greeting card using method 90 . However, one of the main goals of the feeder module 50 and method 90 was to produce store bought quality greeting cards, and even store bought cards required a user to sign their name at a minimum or add other personal messages to the card by hand. In the future, the software could allow customization while adding only 1-2 steps above the simplest solution. Another trade-off made was the elimination of multiple media sizes for the card feeder. However, once again greeting card companies and stationery companies are tending to print more standard size cards to lower their media handling and purchasing costs. And finally, most people who receive a greeting card printed using the feeder module 50 and the method 90 are recipients of a gift, and they don't know what media sizes were available at the store or one's own home or office.
Thus, consumers now have a printing system which allows them to print store bought quality greeting cards at home or work using the new commercially available greeting card media using a reliable robust system which is not only fast but easy to use and which will no doubt save consumers money over purchasing store bought greeting cards.
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A hardcopy printing mechanism and a greeting card feeder retrofit kit therefor, along with an operating method are provided for printing images on a first-sized media, and on both surfaces a second-sized greeting card media without removing the first-sized media from its normal supply tray. The hardcopy device may be an electrophotographic or inkjet printer preferably equipped with a duplexer module which inverts media from a printed first surface to an opposing second surface for printing an image thereon. For a printer having an alignment surface, and a width adjuster to push the first-sized media against the alignment surface, the greeting card feeder includes a biasing member which pushes the card stock against the alignment surface. The retrofit kit includes a supply of pre-scored greeting card stock and a software program with a group of greeting card images for a consumer to select from to print store-bought quality greeting cards.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/568,942, filed May 7, 2004.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a device for conveniently carrying animal waste while walking one's dog. Dog owners in urban areas and in many rural areas are required to keep their dogs on a leash while taking the dog for a walk. Those owners also are required to clean up after their pets. Thus, a common problem facing pet owners is how to pick up and dispose of the dog's waste while walking the dog on a leash. The most common solution is to pick up the waste with a small plastic bag of the type obtained in grocery stores, twist or tie the bag so as to seal the waste therein and then carry the bag to a disposition site, all while continuing to walk the dog. This can present logistical nightmares when walking two dogs at the same time while carrying the waste and encountering another dog or cat. Even walking a single dog while carrying its excrement is unpleasant for many people and often results in disposing of the bag and its contents at the earliest possible opportunity which is not always appreciated by nearby property owners. The present invention provides a means for conveniently carrying the bag while continuing to walk the dog with a minimum of inconvenience thereby obviating the precarious situation described above and the urgency to dispose of the bag and its contents.
SUMMARY OF THE INVENTION
[0003] Briefly, the present invention comprises a carrying device which is adapted to be readily attached to a conventional dog leash for carrying one or more empty plastic bags and/or a bag containing the dog's excrement in a sealed disposition. The carrying device of the present invention has an aperture extending therethrough for use in tethering the device to a dog leash and defines a generally planar body portion formed of a resilient plastic material that has a plurality of slits extending therethrough. The slits all intersect at a small common central aperture such that said slits define a plurality of adjacent, tapered, resilient fingers therebetween. Upon placing an object relatively light in weight such as a plastic bag through said central aperture, the formed fingers will bear against and hold the object in place.
[0004] In the preferred application, the carrying device of the present invention is used to carry a flexible plastic bag containing a dog's excrement by the bag's twisted end. After picking up the dog's excrement with the bag and twisting the open end of the bag to seal the waste therein, the twisting portion of a plastic bag is simply pushed through the small central aperture in the body portion of the device adjacent the intersection of the slits therein, the formed resilient fingers will separate to allow the passage of the twisted end of the bag therethrough and thereafter bear against and grip the twisted portion of the bag, holding that portion of the bag in its twisted disposition so as to prevent air flow therefrom while supporting and carrying the bag and its sealed contents. As a result, a dog's excrement then can be readily carried by the leash extending between the dog and its owner in an airtight disposition without requiring the owner to hold the bag while walking the dog. Thus, a person can walk their dog while having both hands continuously available to control the dog or one person can readily walk two dogs on two separate leashes while conveniently carrying the waste evacuated by one or both dogs while on their walk.
[0005] In addition to the above-described application, the bag carrying device of the present invention could also be attached to one's person, bicycle handle bars, inside cars and trucks, in the household, etc. and used to carry empty bags as well as a variety of other items.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of the carrying device of the present invention.
[0007] FIG. 2 is a perspective view of the carrying device of the present invention attached to a dog leash.
[0008] FIG. 3 is a perspective view of the carrying device of the present invention attached to a dog leash and carrying a filled waste disposal bag.
[0009] FIG. 4 is a perspective view of the carrying device of the present invention illustrating the flexible gripping fingers formed thereby.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0010] Referring now in detail to the drawings, the bag carrying device 10 of the present invention has body portion 12 , is formed of resilient, plastic material, is of generally planar construction and defines an attachment aperture 14 therein adapted to receive a short resilient attachment cord 16 for securing the device to a conventional dog leash 18 intermediary of its ends as illustrated in FIG. 2 . The body portion 12 also defines a plurality of intersecting radial slits 20 therein that extend through the body portion and intersect at a common location defined by a small central aperture 22 so as to define a plurality of adjacent, resilient and converging fingers 24 in a generally central area of the body portion of the bag carrying device 10 . To prevent tearing of the body portion 12 , each of the slits 20 preferably terminate at their outer ends in small rounded apertures 20 ′.
[0011] In use, a person walking their dog can insert one or more small plastic bags 25 through the carrying device 10 at aperture 22 whereupon the resilient fingers 24 will separate to allow the passage of the bag or bags therethrough and thereafter bear against and support the bags such that they do not need to be independently carried by the pet owner. By providing the small aperture 22 at the intersection of the slits 20 , the inner ends of the resilient fingers are rounded to prevent tearing the bags.
[0012] After the dog attends to its business, the owner can pull one of the bags from the device, insert his or her hand into the bag, pick up the excrement with the bagged hand, invert the bag about the excrement and seal the bag by twisting (or tying) its open end. The twisted end of the bag is then inserted back through aperture 22 adjacent the inwardly directed pointed ends of fingers 24 . The resiliency in the fingers will cause the fingers to press against the twisted end of the bag, so as to maintain the end of the bag in a tight twisted disposition thereby maintaining the airtight closure of the bag as shown in FIG. 3 . In addition, the resiliency in the fingers will support the weight of the bag and the animal waste contained therein so that they can be carried by the leash between the owner and the dog enabling the person walking the dog to continue walking the dog in a convenient manner while the bag excrement is carried by the leash. In this manner, the bag carrying device 10 enables the person walking his or her dog to use their hands solely to hold onto the leash or leashes to control their dog or dogs without having to concurrently carry the dog's waste in the same or other hand. The result is better control over their dog(s) and a much more pleasant walk for the owner.
[0013] By way of example, the bag carrying device 10 is formed of a resilient plastic material such as polyvinylchloride, approximately 0.125 inches thick so as to provide the flexibility and resiliency desired in the formed fingers 24 necessary to function as a carrying device in the manner above described. The small central aperture 22 provided at the point of intersection of slits 20 to round the ends of fingers 24 defines a diameter of about 0.125 in. Four equally-spaced slits 20 are utilized with each slit passing through the center of central aperture 22 so as to define eight tapered fingers 24 with each finger being about 1.125 in. in length. The small apertures 20 ′ at the outer ends of slits 20 are preferably about 2 mm. in diameter. The leash attachment aperture 14 is about 0.250 in. in diameter so as to receive a knotted 2 millimeter diameter elastic cord 16 defining a closed loop length of about 4.5 centimeters (see FIGS. 2 and 3 ). While various different tethers, including clips and other forms of attachment members, could be employed to secure the device 10 to a leash or a variety of other objects (support fixtures), elastic cord 16 provides a versatile looped securement for the device and one that will maintain the waste and/or disposal bag(s) in place on leashes of varying sizes and configurations without sliding up or down the leash.
[0014] It is to be understood that the aforesaid dimensions are by way of example only and could be varied without departing from the spirit and scope of the invention. For example, the size and configuration of the central aperture 22 , the number of slits 20 and thus the number of fingers 24 could be varied as well as the length and width of the slits. Other resilient materials could also be used to form the device or the body of the device. As device 10 could be used to carry a wide variety of objects (e.g. towels, gloves, paint brushes, tools, paper items, clothing, etc.) other than the waste disposal bags discussed above, the configurations and dimensions of the various parameters defining the gripping fingers 24 would depend, at least in part, on the intended use of the carrying device. In addition, the device 10 could be permanently attached to an item such as a dog leash or formed as an integral part of the leash or other item. The device could also be sewn into clothing and used to carry objects. Further, by using a transparent material to form the carrying device 10 , the device can be conveniently attached to other products at the point of purchase, without obliterating or otherwise obscuring the label of the other product at the point of sale. One could also place an additional item, e.g., promotional product or written material (not shown) in aperture 22 so that the additional item would be carried by the device 10 which in turn is carried by the base product. Thus, the carrying device 10 could be used as a point of sale co-pack device.
[0015] In a modification of the present invention (not shown), the carrying device could be enlarged, multiple pluralities of intersecting slits added and the resulting device used as a point of purchase rack display. In such an application, the body portion of the device could be several inches tall and wide and contain a plurality of sets of intersecting slits preferably arranged in rows and columns. Each individual set of slits would be similar to the single set employed in carrying device 10 and illustrated in the accompanying drawings. With a plurality of sets of slits, such a device would be adapted to receive and carry a corresponding plurality of products therein (e.g. writing pens, flashlight batteries, etc.) being offered for sale. Thus, on a single flat board formed of the same resilient plastic material described above, rows of products could be carried by the board with each individual product being held by a set of fingers. A purchaser would simply pull the object from the board thus obviating the need to individually package each item. For such applications, the number, width and length of the slits ( 20 ) as well as the size of the central apertures ( 22 ) could be designed for the particular products adapted to be carried by the board. It should be noted, however, that the intersecting slits and the resilient fingers formed by the slits allow a relatively large variance in the size and shape of the product to be held thereby without requiring any such modifications.
[0016] Various other changes and modifications may be made in carrying out the present invention without departing from the spirit and scope thereof. Insofar as these changes and modifications are within the purview of the appended claim, it is to be considered as part of the present invention.
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A device particularly adapted for carrying one or more plastic bags of the type used to gather a dog's excrement while walking the dog on a leash. The device comprises a flexible planar body portion, an attachment surface proximate one end of the body portion for securing the body portion to a dog leash and a plurality of slits extending through the body portion and intersecting at a common aperture so as to define a plurality of adjacent resilient fingers between the slits for engaging and pressing against a portion of one or more plastic bags inserted therethrough. A tether is preferably provided between the attachment surface and the leash for the securement of the device on the leash.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical lens system for taking image, and more particularly to a two-lens type optical lens system for taking image used in a mobile phone camera.
2. Description of the Prior Art
In recent years, with the popularity of mobile phone cameras, the length of such lens systems have been reduced continuously, and the sensor of a general digital camera is none other than CCD (Charge Coupled Device) or CMOS (Complementary Metal Oxide Semiconductor). Due to advances in semiconductor manufacturing, the pixel size of sensors has been reduced from the early 7.4 um to the current 1.75 um. Therefore, there's increasing demand for miniaturization of the lens system.
In consideration of aberration correction, a conventional mobile phone's lens assembly usually consists of three lens elements, one of the typical structures is the Triplet type. However, when the length of the lens assembly is reduced from 5 mm to less than 3 mm, less space is available for the optical system, making it difficult to incorporate three lens elements into the space of the optical system. Therefore, the lens elements must become thinner, causing poor uniformity if the lens is made from plastic injection molding.
The present invention mitigates and/or obviates the afore-mentioned disadvantages.
SUMMARY OF THE INVENTION
To solve the problem of the optical system for taking image, the present invention provides an optical system for taking image, which consists of two lens elements with refractive power and an aperture stop.
A two-lens type optical system for taking image in accordance with the present invention consists of two lens elements with refractive power, from the object side to the image side:
an aperture stop;
a first lens element with positive refractive power having a convex object-side surface and a concave image-side surface, both the object-side surface and the image-side surface of the first lens element being aspheric;
a second lens element with positive refractive power having a concave object-side surface and a convex image-side surface, both the object-side surface and the image-side surface of the second lens element being asphenic.
In the present two-lens type optical lens system for taking image, the refractive power of the system is mainly provided by the first lens element with positive refractive power, and the second lens element with positive refractive power serves to balance and correct the various aberrations caused by the system. Such arrangements can effectively improve the image quality.
The first lens element provides strong positive refractive power, and the aperture stop is located close to the object side, so that the exit pupil of the optical lens system will be far away from the image plane. Therefore, the light will be projected onto the sensor with a relatively small incident angle, this is the telecentric feature of the image side, and this feature is very important to the photosensitive power of the current solid-state sensor, and can improve the photosensitivity of the sensor while reducing the probability of the occurrence of shading.
In the present two-lens type optical lens system for taking image, plastic or glass material is introduced to make lens elements. The surface of lens element is aspheric, allowing more design parameters (than spherical surfaces), so as to better reduce the aberration and the number of the lens elements, so that the total track length of the system can be reduced effectively.
In the present two-lens type optical lens system for taking image, the focal length of the first lens element is f1, the focal length of the optical lens system is f, and they satisfy the relation: f/f1>0.9.
If the value of f/f1 is smaller than the above lower limit, the refractive power of the system will be weak, the total track length of the system will be too long, and it will be difficult to suppress the incident angle of the light with respect to the sensor. Further, it will be better if f/f1 satisfies the relation:
f/f 1<1.25.
In the present two-lens type optical lens system for taking image, the focal length of the second lens element is f2, the focal length of the optical lens system is f, and they satisfy the relation:
0< f/f 2<0.45.
The second lens element serves to balance and correct the various aberrations caused by the system. If the value of f/f2 is smaller than the above lower limit, the back focal length of the system will be too long. Further, it will be better if f/f2 satisfies the relation:
0.05 <f/f 2<0.25.
And it will be much better if f/f1 and f/f2 satisfy the relation:
( f/f 1)−( f/f 2)>0.35.
In the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the first lens element is R1, the radius of curvature of the image-side surface of the first lens element is R2, and they satisfy the relation:
0.45 <R 1 /R 2<0.7.
If the value of R1/R2 is lower than the lower limit as stated above, it will be difficult to correct the astigmatism caused by the system. On the other hand, if the value of R1/R2 is higher than the above upper limit, it will be difficult to correct the spherical aberration caused by the system. And it will be better, if the value of R1/R2 satisfies the relation:
0.5 <R 1 /R 2<0.65.
In the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, and they satisfy the relation:
0.85 <R 3 /R 4<1.4.
the above relation is helpful for correcting high order aberrations of the system.
And it will be better if the value of R3/R4 satisfies the relation:
0.95 <R 3 /R 4<1.35.
In the present two-lens type optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
N1<1.59.
The above relation enables the system to obtain better image quality.
In the present two-lens type optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relation:
| V 1 −V 2|<10.
The above relation can effectively correct the Coma caused by the system.
In the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the second lens element is R3, when it satisfies the relation: 1/R3<−0.01 mm −1 , this contributes to correct the Coma of the system.
In the present two-lens type optical lens system for taking image, the radius of curvature of the image-side surface of the second lens element is R4, when it satisfies the relation: 1/R4<−0.01 mm −1 , the absolute value of the R4 is relatively small, which contributes to reducing the back focal length of the system.
In the present two-lens type optical lens system for taking image, the tangential angle of an image-side surface of the second lens element at the position of its effective optical diameter is ANG22, and it satisfies the relation:
ANG 22<−50 deg.
The above relation can effectively reduce the incident angle of the light with respect to the sensor while improving the correction of the off axis aberration.
The tangential angle at a point on the surface of a lens is defined as the angle between the tangential plane, Plane Tan, passing through that point and a plane, Plane Norm, normal to the optical axis and passing through that point. Let T and N be the points of intersection between the optical axis and these two planes Plane Tan and Plane Norm, respectively. This tangential angle is less than 90 degree in absolute value. The sign of the tangential angle is taken to be negative if N is closer than T to the object side of the optical lens system, and positive otherwise. In the present two-lens type optical lens system for taking image, the edge thickness of the first lens element is ET1, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relation:
ET1<0.35 mm
ET 1 /f <0.2.
The above relations facilitate correction of astigmatism of the system.
The edge thickness is; the distance between two planes normal to the lens axis, the first of which is defined as the plane passing through points on the lens object-side surface at the position of its effective optical diameter, and the second defined as the plane passing through points on the lens image-side surface at the position of its effective optical diameter.
In the present two-lens type optical lens system for taking image, an object to be photographed is imaged on an electronic sensor, a total track length of the system is TL, a maximum image height of the system is ImgH, and they satisfy the relation:
TL/ImgH< 2.2.
The above relation contributes to the miniaturization of the system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an optical lens system for taking image in accordance with a first embodiment of the present invention;
FIG. 2 shows the aberration curve of the first embodiment of the present invention;
FIG. 3 shows an optical lens system for taking image in accordance with a second embodiment of the present invention;
FIG. 4 shows the aberration curve of the second embodiment of the present invention;
FIG. 5 shows an optical lens system for taking image in accordance with a third embodiment of the present invention; and
FIG. 6 shows the aberration curve of the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be clearer from the following description when viewed together with the accompanying drawings, which show, for purpose of illustrations only, the preferred embodiment in accordance with the present invention.
Referring to FIG. 1 , which shows a two-lens type optical lens system for taking image in accordance with a first embodiment of the present invention, and FIG. 2 shows the aberration curve of the first embodiment of the present invention. The first embodiment of the present invention is a two-lens type optical lens system for taking image consisting of two lens elements with refractive power, and the two-lens type optical lens system for taking image comprises: from the object side to the image side:
A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a concave image-side surface 12 , and both the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
A plastic second lens element 20 with positive refractive power has a concave object-side surface 21 and a convex image-side surface 22 , and both the object-side surface 21 and the image-side surface 22 of the first lens element 20 are aspheric.
An aperture stop 30 is located in front of the first lens element 10 .
A sensor cover glass 50 is located behind the second lens element 20 and has no influence on the focal length of the system.
An image plane 60 is located behind the sensor cover glass 50 .
The equation of the curve of the aspheric surfaces is expressed as follows:
X
(
Y
)
=
(
Y
2
/
R
)
/
(
1
+
sqrt
(
1
-
(
1
+
k
)
*
(
Y
/
R
)
2
)
)
+
∑
i
(
A
i
)
*
(
Y
i
)
wherein:
X: the height of a point on the aspheric lens surface at a distance Y from the optical axis relative to the tangential plane of the aspheric surface vertex;
Y: the distance from the point on the curve of the aspheric surface to the optical axis;
k: the conic coefficient;
Ai: the aspheric surface coefficient of order i.
In the first embodiment of the present two-lens type optical lens system for taking image, the focal length of the first lens element is f1, the focal length of the second lens element is f2, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
f 1 /f 1=1.04
f/f 2=0.19
f//f 1 −f/f 2=0.85.
In the first embodiment of the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the first lens element is R1, the radius of curvature of the image-side surface of the first lens element is R2, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, and they satisfy the relations:
1 /R 3=−0.61 mm −1
1 /R 4=−0.78 mm −1
R 1 /R 2=0.59
R 3 /R 4=1.29.
In the first embodiment of the present two-lens type optical lens system for talking image, the refractive index of the first lens element is N1, and it satisfies the relation:
N1=1.543
In the first embodiment of the present two-lens type optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relation:
| V 1 −V 2|=0
In the first embodiment of the present two-lens type optical lens system for taking image, the tangential angle of an image-side surface of the second lens element at the position of its effective optical diameter is ANG22, and ANG22=−66.8 deg.
The definition of the tangential angle is the same as before.
In the first embodiment of the present two-lens type optical lens system for taking image, the total track length of the system is TL, the maximum image height of the system is ImgH, and they satisfy the relation:
TL/ImgH= 1.94.
In the first embodiment of the present two-lens type optical lens system for taking image, the edge thickness of the first lens element is ET1, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
ET1=0.26 mm
ET 1 /f= 0.20.
The definition of the edge thickness is the same as before.
The detailed optical data of the first embodiment is shown in table 1, and the aspheric surface data is shown in table 2, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
TABLE 1
(Embodiment 1)
f (focal length) = 1.32 mm, Fno = 2.85,
HFOV (half of field of view) = 32.9 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Aperture
Plano
−0.077
Stop
2
Lens 1
0.39150(ASP)
0.288
Plastic
1.543
56.5
1.27
3
0.66698(ASP)
0.185
4
Lens 2
−1.64379(ASP)
0.548
Plastic
1.543
56.5
6.85
5
−1.27619(ASP)
0.030
6
Cover
Plano
0.400
Glass
1.517
64.2
Glass
7
Plano
0.250
8
Image
Plano
TABLE 2
Aspheric Coefficients
Surface #
2
3
4
5
K =
−4.37912E−01
−6.34894E−02
−2.90270E+02
−1.14455E+01
A4 =
3.16388E−01
1.67214E+00
−1.13309E+01
−3.54089E−01
A6 =
4.41682E+01
2.44412E+02
2.44816E+02
−1.20303E+01
A8 =
−3.69800E+02
−1.01733E+04
−5.03020E+03
8.03101E+01
A10 =
−8.32340E+02
2.08590E+05
5.08493E+04
−1.94648E+02
A12 =
4.90487E+04
−1.40944E+06
−2.63213E+05
−5.11108E+02
A14 =
−2.03976E+05
7.58510E+05
6.12515E+05
3.27313E+03
A16 =
−1.51834E+05
−4.93423E+04
4.24121E+04
−4.48455E+03
Referring to FIG. 3 , which shows a two-lens type optical lens system for taking image in accordance with a second embodiment of the present invention, and FIG. 4 shows the aberration curve of the second embodiment of the present invention. The second embodiment of the present invention is a two-lens type optical lens system for taking image consisting of two lens elements with refractive power, and the two-lens type optical lens system for taking image comprises: from the object side to the image side:
A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a concave image-side surface 12 , and both the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
A plastic second lens element 20 with positive refractive power has a concave object-side surface 21 and a convex image-side surface 22 , and both the object-side surface 21 and the image-side surface 22 of the first lens element 20 are aspheric.
An aperture stop 30 is located in front of the first lens element 10 .
An IR cut filter 40 is located behind the second lens element 20 and has no influence on the focal length of the system.
A sensor cover glass 50 is located behind the IR cut filter 40 and has no influence on the focal length of the system.
An image plane 60 is located behind the sensor cover glass 50 .
The equation of the curves of the aspheric surfaces of the second embodiment has the same form as that of the first embodiment.
In the second embodiment of the present two-lens type optical lens system for taking image, the focal length of the first lens element is f1, the focal length of the second lens element is f2, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
f 1 /f 1=1.12
f/f 2=0.10
f//f 1 −f/f 2=1.02.
In the second embodiment of the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the first lens element is R1, the radius of curvature of the image-side surface of the first lens element is R2, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, and they satisfy the relations:
1/ R 3=−0.53 mm −1
1/ R 4=−0.52 mm −1
R 1 /R 2=0.62
R 3 /R 4=0.98.
In the second embodiment of the present two-lens type optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
N1=1.543
In the second embodiment of the present two-lens type optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relation:
| V 1 −V 2|=0
In the second embodiment of the present two-lens type optical lens system for taking image, the edge thickness of the first lens element is ET1, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
ET1=0.40 mm
ET 1/ f =0.16.
The definition of the edge thickness is the same as before.
In the second embodiment of the present two-lens type optical lens system for taking image, the tangential angle of an image-side surface of the second lens element at the position of its effective optical diameter is ANG22, and ANG22=−56.2 deg.
The definition of the tangential angle is the same as before.
In the second embodiment of the present two-lens type optical lens system for taking image, the total track length of the two-lens type optical lens system is TL, the maximum image height of the two-lens type optical lens system is ImgH, and they satisfy the relation:
TL/ImgH= 2.14.
The detailed optical data of the second embodiment is shown in table 3, and the aspheric surface data is shown in table 4, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
TABLE 3
(Embodiment 2)
f (focal length) = 2.46 mm, Fno = 2.9,
HFOV (half of field of view) = 30.0 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Aperture
0.64735(ASP)
0.477
Plastic
1.543
56.5
2.19
Stop/
Lens 1
2
1.05138(ASP)
0.308
3
Lens2
−1.88250(ASP)
0.893
Plastic
1.543
56.5
24.3
4
−1.92279(ASP)
0.100
5
IR filter
Plano
0.300
Glass
1.517
64.2
6
Plano
0.100
7
Cover
Plano
0.450
Glass
1.517
64.2
Glass
8
Plano
0.450
9
Image
Plano
TABLE 4
Aspheric Coefficients
Surface #
2
3
4
5
K =
0.00000E+00
−6.67249E+00
0.00000E+00
1.00000E+00
A4 =
−1.33595E−01
1.30406E+00
−9.53159E−01
−8.42790E−02
A6 =
2.67131E+00
7.03352E+00
3.60696E+00
7.10030E−03
A8 =
−8.69897E+00
−1.34183E+02
−4.57290E+01
−5.81401E−01
A10 =
5.62516E+00
1.18694E+03
1.43667E+02
9.89732E−01
A12 =
3.89553E+01
−2.75284E+03
−1.99135E+02
−6.95112E−01
Referring to FIG. 5 , which shows a two-lens type optical lens system for taking image in accordance with a third embodiment of the present invention, and FIG. 6 shows the aberration curve of the third embodiment of the present invention. The third embodiment of the present invention is a two-lens type optical lens system for taking image consisting of two lens elements with refractive power, and the two-lens type optical lens system for taking image comprises: from the object side to the image side:
A plastic first lens element 10 with positive refractive power has a convex object-side surface 11 and a concave image-side surface 12 , and both the object-side surface 11 and the image-side surface 12 of the first lens element 10 are aspheric.
A plastic second lens element 20 with positive refractive power has a concave object-side surface 21 and a convex image-side surface 22 , and both the object-side surface 21 and the image-side surface 22 of the first lens element 20 are aspheric.
An aperture stop 30 is located in front of the first lens element 10 .
An IR cut filter 40 is located behind the second lens element 20 and has no influence on the focal length of the system.
A sensor cover glass 50 is located behind the IR cut filter 40 and has no influence on the focal length of the system.
An image plane 60 is located behind the sensor cover glass 50 .
The equation of the curves of the aspheric surfaces of the third embodiment has the same form as that of the first embodiment.
In the third embodiment of the present two-lens type optical lens system for taking image, the focal length of the first lens element is f1, the focal length of the second lens element is f2, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
f/f 1=1.12
f/f 2=0.16
f//f 1 −f/f 2=0.96.
In the third embodiment of the present two-lens type optical lens system for taking image, the radius of curvature of the object-side surface of the first lens element is R1, the radius of curvature of the image-side surface of the first lens element is R2, the radius of curvature of the object-side surface of the second lens element is R3, the radius of curvature of the image-side surface of the second lens element is R4, and they satisfy the relations:
1 /R 3=−0.54 mm −1
1 /R 4=−0.57 mm −1
R 1 /R 2=0.57
R 3 /R 4=1.05.
In the third embodiment of the present two-lens type optical lens system for taking image, the refractive index of the first lens element is N1, and it satisfies the relation:
N1=1.543
In the third embodiment of the present two-lens type optical lens system for taking image, the Abbe number of the first lens element is V1, the Abbe number of the second lens element is V2, and they satisfy the relation:
| V 1 −V 2|=0
In the third embodiment of the present two-lens type optical lens system for taking image, the edge thickness of the first lens element is ET1, the focal length of the two-lens type optical lens system for taking image is f, and they satisfy the relations:
ET1=0.34 mm
ET 1/ f= 0.15.
The definition of the edge thickness is the same as before.
In the third embodiment of the present two-lens type optical lens system for taking image, the tangential angle of an image-side surface of the second lens element at the position of its effective optical diameter is ANG22, and ANG22=−62.5 deg.
The definition of the tangential angle is the same as before.
In the third embodiment of the present two-lens type optical lens system for taking image, the total track length of the system is TL, the maximum image height of the system is ImgH, and they satisfy the relation:
TL/ImgH= 1.99.
The detailed optical data of the third embodiment is shown in table 5, and the aspheric surface data is shown in table 6, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm, and HFOV is half of the maximal field of view.
TABLE 5
(Embodiment 3)
f (focal length) = 2.21 mm, Fno = 2.85,
HFOV (half of field of view) = 32.9 deg.
Curvature
Focal
Surface #
Radius
Thickness
Material
Index
Abbe #
length
0
Object
Plano
Infinity
1
Aperture
0.61158(ASP)
0.414
Plastic
1.543
56.5
1.98
Stop/
Lens 1
2
1.08069(ASP)
0.279
3
Lens 2
−1.85541(ASP)
0.960
Plastic
1.543
56.5
13.87
4
−1.76019(ASP)
0.100
5
IR filter
Plano
0.300
Glass
1.517
64.2
6
Plano
0.100
7
Cover
Plano
0.400
Glass
1.517
64.2
Glass
8
Plano
0.310
9
Image
Plano
TABLE 6
Aspheric Coefficients
Surface #
2
3
4
5
K =
−5.22757E−02
−3.18655E+00
8.58498E−01
−2.72761E−02
A4 =
−3.81844E−02
8.72919E−01
−1.98682E+00
−3.52299E−02
A6 =
7.25009E+00
9.05408E+00
2.37415E+01
−3.37020E−01
A8 =
−9.48652E+01
−1.10828E+02
−3.05086E+02
3.64891E−01
A10 =
6.36165E+02
7.01340E+02
1.64481E+03
−4.50268E−01
A12 =
−1.41475E+03
3.80505E+01
−4.03874E+03
3.91933E−01
A14 =
−1.76200E+02
1.66665E−02
2.13262E+01
−3.50198E−01
TABLE 7
Embodiment 1
Embodiment 2
Embodiment 3
f
1.32
2.46
2.21
Fno
2.85
2.90
2.85
HFOV
32.9
30.0
32.9
f/f1
1.04
1.12
1.12
f/f2
0.19
0.10
0.16
f/f1 − f/f2
0.85
1.02
0.96
1/R3
−0.61
−0.53
−0.54
1/R4
−0.78
−0.52
−0.57
R1/R2
0.59
0.62
0.57
R3/R4
1.29
0.98
1.05
N1
1.543
1.543
1.543
|V1 − V2|
0.0
0.0
0.0
ET1
0.26
0.40
0.34
ET1/f
0.20
0.16
0.15
ANG22
−66.8
−56.2
−62.5
TL/ImgH
1.94
2.14
1.99
It is to be noted that the tables 1-6 show data from the different embodiments, however, the data of the different embodiments is obtained from experiments. Therefore, any product of the same structure is deemed to be within the scope of the present invention even if it uses different data. Table 7 is the data relevant to the respective embodiments of the present invention.
While we have shown and described various embodiments in accordance with the present invention, it is clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention.
|
A two-lens type optical lens system for taking image consists two lens elements with refractive power, from the object side: a positive first lens element with a convex object-side surface and a concave image-side surface, both the object-side surface and the image-side surface of the first lens element being aspheric; a positive second lens element with a concave object-side surface and a convex image-side surface, both the object-side surface and the image-side surface of the second lens element being aspheric, and an aperture stop located in front of the first lens element. A focal length of the first lens element is f1, a focal length of the second lens element is f2, a focal length of the optical lens system is f, a radius of curvature of the object-side surface of the second lens element is R3, and they satisfy the relations: f/f1>0.9; (f/f1)>(f/f2)>0.35; and 1/R3<−0.01 mm −1 .
| 6
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 10/380,188, filed on Mar. 3, 2003, which claims benefit to International PCT Application PCT/USAU01/00830 filed Jul. 10, 2001, which claims the priority of three Provisional Australian applications PQ8679 filed Jul. 10, 2000, PQ8908 filed Jul. 24, 2000 and PQ8909 filed Jul. 24, 2000, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to syringes for medical injector systems that inject medical fluids into a patient's vascular system.
BACKGROUND OF THE INVENTION
[0003] Medical injectors and syringes for injecting contrast media into a patient for imaging biological structures are known in the art. For example, U.S. Pat. No. 4,677,980, issued to D. M. Reilly et al. on Jul. 7, 1987, and entitled “Angiographic Injector and Angiographic Syringe for Use Therewith,” which is assigned to the same Assignee as the subject application, discloses an angiographic injector apparatus. The apparatus is designed for injecting contrast media into the vascular system of an animal, in which syringes are rear-loaded into a pressure jacket of the injector. More specifically, the apparatus comprises a rotatable turret which carries a pair of the pressure jackets and which is rotatable so that when one of the pressure jackets, into which a syringe has been rear-loaded, is in an injection position, the other pressure jacket is in a position in which an associated syringe can be rear-loaded. Subsequently, when injection of contrast media from the first syringe is completed, the turret is rotated to move the first syringe to an unloading-loading position, with the second pressure jacket and the syringe concurrently being moved into the injection position.
[0004] In the apparatus disclosed in the '980 patent, a drive member of the angiographic injector can be drivingly connected to, or disconnected from, a plunger of a syringe at any point along the path of travel of the syringe plunger by a releasable mechanism. However, for the releasable mechanism to correctly operate, the syringe plunger must be properly oriented to mate with the injector piston. Further, during loading of the syringe on the injector, the syringe must be correctly aligned within a respective pressure jacket to allow the syringe plunger and the injector piston to connect to and disconnect from each other.
[0005] An improved apparatus over the '980 patent apparatus is disclosed in U.S. Pat. No. 5,383,858, issued to D. M. Reilly et al. on Jan. 24, 1995, and entitled “Front-Loading Medical Injector and Syringe for Use Therewith,” which is also assigned to the same Assignee as the present application. In the apparatus described in the '858 patent, the syringe is front-loaded onto, in at least one embodiment, a pressure jacket-less injector, overcoming one of the drawbacks of the '980 patent injector apparatus.
[0006] The injector described in the '858 patent has a first release mechanism for attaching and releasing the syringe from the injector. In addition, the apparatus includes a second release mechanism that engages and disengages the injector piston from the syringe plunger. Upon rotation of the syringe, the syringe is attached to or released from the injector and, simultaneously, the plunger is attached to or released from the piston. The structure disclosed requires that the syringe be installed on the injector in a specific orientation so that the syringe can releasably engage the injector and, simultaneously, the plunger can releasably engage the piston. In addition, as with the syringe disclosed in the '980 patent, during assembly the syringe plunger must be correctly oriented within the syringe.
[0007] Another injector apparatus is disclosed in U.S. Pat. No. 5,300,031, issued to C. Neer et al. on Apr. 5, 1994, and entitled “Apparatus for Injecting Fluid into Animals and Disposable Front Loadable Syringe Therefor.” The '031 patent discloses various embodiments of a pressure-jacketed injector wherein a syringe is loaded into and removed from an injector pressure jacket through an opening provided in the front end of the pressure jacket. To retain the syringe within the pressure jacket, for example, during an injection operation, the front end of the syringe is locked to the front end of the pressure jacket. To correctly connect the syringe to the pressure jacket, the syringe may only be inserted into the pressure jacket in one orientation.
[0008] In each example discussed above, the syringe must be connected to the injector in a specific orientation to assure proper syringe mounting. Proper alignment is required to assure that the syringe may be operated properly during a medical imaging procedure. The required orientation, however, hinders rapid attachment and replacement of the syringe. The required orientation may also increase the manufacturing assembly cost and complexity of the syringe.
[0009] Accordingly, while the above injector and syringe apparatuses have proven effective, a need has arisen for a simpler front-loading medical injector. More specifically, to facilitate further the loading operation, a need has arisen for a syringe that can be easily connected to the injector without regard for the specific orientation of the syringe and/or syringe plunger. In addition, to simplify assembly of the syringe components, a need has arisen for a syringe with a plunger that does not need to be oriented in a specific relation to the barrel or base of the syringe. Furthermore, to minimize the time required to prepare an injector for an injection procedure, a need has arisen for injectors providing automated features. There is a further need to add automated features which contribute to the safety of the patient, for example, by decreasing the chances of cross-contamination.
[0010] Medical fluids are normally packaged in containers or bottles, which have an elastomer bung (or cork) in the top. The bung can be pierced with a conventional needle or a plastic spike to draw fluid from the bottle into the syringe. However it is common practice to simply remove the bung, and draw up fluid into the syringe using a plastic cannula. This practice exposes the fluid to ambient microbes, and allows contamination, and thus increases the risk of undesirable infection of the patient. Certain vented spikes with special microbe filters have been developed to address this problem. However in use, the filling procedure is very tedious, and some fluid is often lost through the filter. Where large volumes are drawn into the syringe according to known methods, it can be very difficult to simultaneously hold the bottle inverted, and draw back the syringe.
[0011] Another important requirement when using syringe pumps to inject patients is to ensure that all air is purged from the system, including the tube, before it is connected to the patient. If this is not done, then it is possible that a bubble of air may be injected into the patient which can cause serious illness.
[0012] It has also been found that existing injector apparatus and injectors do not have features which discourage inadvertent re-use of syringes and associated tubes and spikes, which can result in the serious hazard of cross infections from one patient to the next.
[0013] Luer connectors are found on the outlet of most syringes used in medicine, and are well defined in International Standard ISO594. A locking thread is sometimes found associated with luer connectors, termed “luer locking”, and are particularly used for higher pressure applications, where the thread assists closure and retention of the connections.
[0014] Flexible plastic tubing is used in many medical applications for conveying drugs, fluid, contrast etc between syringes and patients. The tubes are normally manufactured from flexible plastic, with luer connectors bonded to each end to facilitate secure and releasable male and female connections. Connectors are normally moulded from rigid plastic, having a luer outlet, with an cylindrical inlet sized to accept a close interference fit with the relatively soft tube. The tubing is forced over (or inside) the cylindrical inlet end, and is traditionally bonded using solvent or cement adhesive. For higher pressure applications the bond must be very certain and secure to avoid bursting.
[0015] On occasions, the tubing may be attached permanently to the syringe, for example to reduce manufacturing costs, reduce the chances of spilling contaminated fluids, or to protect the tip of the syringe from contamination. However bonding directly to syringes is rarely successful or certain because syringes are usually moulded from polypropylene. Some tubing materials are also difficult to bond. Moreover, bonding normally requires the use of powerful solvent cements such as cyclohexanone, or cyanoacrylates, both of which release harmful vapours, and can leave unwanted residues.
[0016] In this specification, unless the contrary is expressly stated, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date:
(a) publicly available; (b) known to the public; (c) part of common general knowledge; or (d) known to be relevant to an attempt to solve any problem with which this specification is concerned.
SUMMARY OF THE INVENTION
[0021] According to a first aspect of the invention, there is provided a syringe holder for a medical injector system comprising a cradle member adapted to receive a barrel of the syringe; and a pivotable catch to releasably lock the syringe in the cradle member wherein the catch is biased towards a first position and engages the syringe at the first position and disengages the syringe at a second position.
[0022] By providing a pivotable catch to releasably lock the syringe, it is possible to enable front-loading of syringes into the syringe holder by removing the requirement of a front wall on the cradle. A person skilled in the art will appreciate that the catch surface can be varied in length to engage a larger (or smaller) amount of the syringe surface.
[0023] According to a particularly preferred embodiment, the syringe holder further comprises a positioning device located on the cradle member to locate one end of the syringe in a predetermined location in the cradle member.
[0024] According to one preferred embodiment, the cradle member is a sleeve and surrounds the barrel of the syringe. Preferably such a sleeve is adapted to support the syringe against expansion under pressure to provide support against internal pressure during expulsion of fluid. This allows the wall thickness of the barrel to be reduced, thereby saving manufacturing costs.
[0025] According to another preferred embodiment, the catch mechanism engages a front shoulder of the syringe. Preferably the catch engages the syringe through a hole defined in the cradle or sleeve.
[0026] According to another preferred embodiment, upon insertion of the syringe barrel into the cradle or sleeve, a front portion of the catch engages a corresponding front portion of the syringe, to thereby retain the syringe within the cradle or sleeve. To remove the syringe from the cradle or sleeve, a rear portion of the catch is depressed, causing the front portion to disengage from the syringe barrel.
[0027] The syringe may be loaded through the front end of the pressure sleeve by simply sliding until the catch locks automatically. This manner of loading from the front is simple, requiring no twisting or conscious locking action by the operator. The syringe may also be simply released by pressing the syringe release button, and withdrawing the syringe forward. The catch may be part of the cradle member to enable assembly and replacement to/from the sleeve, for cleaning or renewal.
[0028] The syringe holder is preferably fabricated from transparent hard plastic, and comprises a plain cylinder having an open end, cut off at an angle of approximately 50 degrees to enable easy insertion of the syringe. Construction from transparent material provides unobstructed vision of the syringe and its contents, particularly of the forward end where all air must be purged following filling. Typically the sleeve is of one piece construction (optionally including a spring), and low cost to manufacture by fabricating from plain stock tubing, or moulding process.
[0029] The rear end of the sleeve is preferably fixed (preferably releasably for cleaning) to the injector, aligned co-axially with the injector plunger—this enables the syringe to be removed from the injector at any time without fear of the plunger touching the inside of the syringe (and thereby possibly contaminating it). Volume graduations may be printed onto the sleeve of the holder, and are thereby not required on the syringe.
[0030] The syringe is loaded rear first into the front of the holder, which forms a close fitting sleeve supporting the syringe against expansion under the high pressures endured with injectors. The holder preferably has a square notch towards the front which allows access for, and supports the syringe catch whilst under load. Two round holes in the sleeve are preferable to act as hinge sockets for the catch.
[0031] Preferably the catch is moulded as a partial cylinder shape from a hard flexible plastic, and has 2 opposing hinge posts which snap into corresponding holes in the sleeve. For replacement or cleaning purposes the catch assembly can be removed by simply spreading the sides apart until the hinge posts clear their respective holes.
[0032] According to another preferred embodiment, the cradle member has a biasing member to partially eject the syringe from the cradle member upon release of the catch. Preferably the biasing member upon insertion of the syringe barrel is actuated, thereby biasing the barrel towards a partially ejected position so that the barrel is partially ejected from the sleeve upon release of the catch. Preferably the self-ejecting mechanism (created by the biasing member) comprises a spring and is preferably located at the rear of the sleeve, which upon insertion of the syringe barrel is compressed.
[0033] According to another preferred embodiment, the biasing member is adapted to engage and minimize rotation of the syringe.
[0034] According to another preferred embodiment, the biasing member is adapted to operate or engage an optical sensor or switch, which advises the injector control unit of the presence of a syringe.
[0035] According to one embodiment, the cradle member may be permanently attached to the injector, rather than removed each time the syringe is replaced, thereby improving convenience, and reducing the chance of dropping and soiling the sleeve.
[0036] An extension tube can be permanently attached to the syringe. Being front loaded, the associated connecting tube need not be disconnected from the syringe following injection, reducing the risk of spilling contaminated blood.
[0037] The catch may be of any suitable shape. According to a particularly preferred embodiment, the front shoulder of the syringe is of a complimentary shape to an engaging portion of the catch. The catch surface may be longer (such as about half of the syringe circumference or substantially co-extensive with the cradle) to more easily retain the syringe on the injector.
[0038] The engaging portion of the catch may be of any suitable shape. According to certain preferred embodiments, it is wedge shaped, concave or convex. Optimally the catch mechanism is wedged against the forward edge of an associated notch in the syringe sleeve, transferring most of the load onto the notch (and thus the sleeve and injector), and not on the catch hinges.
[0039] As the syringe is loaded into the sleeve the syringe catch is pushed aside. Once the syringe is fully home the front of the syringe clears the catch, and the catch latches due to tension from the spring under the button, forming a fixed stop in front of the front rim of the syringe. If the catch is a dovetail shape, then it is unlikely to partially close, and even if it were to, any tension from the syringe would draw the dovetail catch closed.
[0040] During injection the forward force of the syringe is borne by the catch. Such a catch forms a dovetail between the syringe and the notch in the sleeve, so that the catch cannot be released, nor slip whilst under load.
[0041] According to another preferred embodiment the holder or the injector system comprises an illumination member to illuminate the syringe holder. The illumination member may be mounted, engaged or attached to any suitable component of the holder or injector system Preferably it is mounted to the holder. According to another preferred embodiment, it is mounted to the injector and preferably in the nose of the injector. The illumination member may be of any suitable type or light source. It may be a lamp, or globe, it may be a Light Emitting Diode (LED). Preferably the illumination member is placed at the exposed rear end of the holder cradle member or sleeve so that some of the light is received and transmitted along the walls of the cradle member or sleeve. As with any thin, dense, transparent material, most of the received light is internally reflected longitudinally, as well as laterally, producing a diffused glow at the front end of the cradle member or sleeve. Preferably the cradle member or sleeve has a bevelled front end of the sleeve which is preferably frosted (for example, it may be sanded) to achieve maximum diffusion, and is therefore visible form a wide angle. Any suitable light source may be used, but they are preferably focused or reflected so that most of their output is projected towards the sleeve. The provision of an illumination member has a variety of useful benefits. In particular it will assist visualisation of the holder and other components in radiography rooms which are dimly lit for certain procedures.
[0042] According to another preferred embodiment, the syringe holder comprises an engagement portion to enable simple releaseable engagement with a medical injector. Preferably the engagement portion comprises a locking member and preferably the locking member comprises a slot or a pin.
[0043] Such a removable syringe holder provides benefits including:
(a) Allows the syringe holder to be easily removed by the operator for cleaning; (b) Allows easy replacement if worn or damaged; (c) Enables the injector to accept a different size or type of syringe; and (d) Removal for shipment reduces the overall packaging size.
[0048] To engage a syringe holder according to the present embodiment with the injector (or injector nose), the sleeve is first inserted into the nose and with gentle inwards pressure, rotated until the bayonet grooves engage the bayonet posts. At this point the holder fully enters the nose, and the holder is rotated clockwise to lock. The bayonet groove and post sets may be spaced evenly around the circumference, or they could also be oriented at matching odd angles so that the holder can only engage in a particular orientation. Preferably there is also provided a Fluid Seal & Friction Device. It may be a simple O-ring or wiper ring, and has two important roles:
(a) prevent fluids from entering the injector; (b) provide a friction means to decrease the possibility of inadvertent removal of the syringe holder.
[0051] According to a particularly preferred embodiment, the syringe holder comprises a blocking member to regulate disengagement of the holder with the medical injector. Preferably the blocking member stops disengagement of the holder with the medical injector if a syringe is present in the holder. According to a particularly preferred embodiment, the blocking member stops disengagement of the holder with the medical injector if the plunger is not in a particular position. According to another particularly preferred embodiment, the blocking member stops disengagement of the holder with the medical injector if the plunger is not in a sufficiently retracted state.
[0052] A blocking member according to the present invention if in the form of a lock post is preferably positioned adjacent to the syringe sensor and therefore the syringe holder cannot be removed whilst a syringe is installed, nor during an injection. Additionally, a syringe cannot be installed unless the holder is locked fully (for example by clockwise rotation). This embodiment is particularly useful in the absence of a sensor to verify syringe presence. It will be appreciated that the holder according to this embodiment could not be attached if a syringe were already installed.
[0053] Preferably a lock post according to this embodiment is of similar width to, and mounted on the same axis as the syringe flag form of the sensing system according to this invention (discussed below). As the holder is attached, the flag almost touches it when the bayonet slots are fully engaged with the bayonet posts (without rotating). According to this embodiment, in the mounted position, with a syringe installed and the flag pushed back, the holder cannot be rotated the wrong way (in the present case anti-clockwise).
[0054] According to a further aspect of the invention, there is provided a hub for a syringe for use with a medical injector system, comprising an outer surface adapted to slidingly engage with a barrel of the syringe, and an inner surface having a substantially annular engaging portion adapted to be releasably engaged by a plunger to permit the hub to be selectively withdrawn along the barrel by the plunger.
[0055] By providing a hub with these features, a number of benefits can be obtained which relate to the efficiency of use and safety of the patient to be injected as set out below. Since the plunger remains on the injector, then a syringe having a hub according to the present invention can be fitted over it and thus enable front loading which is much quicker. In addition, front loading avoids the requirement of detaching any extension tubing from the front (nearest the patient) of the syringe and thus decreases the chance of spilling blood which may be contaminated.
[0056] The engaging portion may be of any convenient conformation for example, it may be a cavity, a groove or a ridge. Where the engaging portion is a groove, the groove may define a semi-circular cross-section or the groove may extend at least partially along the circumference of the inner surface of the hub. Preferably there are no protrusions from the rear of the hub to impede its movement along the barrel of a syringe.
[0057] A hub of this type has many advantages. The thin and uniform wall thickness is ideally suited to injection moulding and provides economies of manufacture in light of the reduced material volume required, the reduced moulding cycle time and the requirement for only simple tooling.
[0058] According to one preferred embodiment, the inner surface of the hub is complementary in shape to an outer surface of the plunger. Preferably the inner surface of the hub comprises an interior hollow that contacts the plunger. Such an arrangement allows for a form fit which has the advantage of providing a reinforcing effect to the hub. This allows the wall thickness of the hub to be reduced as compared with hubs of the prior art, thus contributing to the abovementioned economies of manufacture. Preferably the plunger has a tapered front end, which is inherently “self centering” as it engages the hub. This also provides uniform, coaxial support of any seal associated with the hub and improved sealing as compared with hubs of the prior art—particularly at the high pressures used in certain medical injectors. At high pressures the hub can be forcibly expanded to improve its seal against the syringe barrel.
[0059] The preferred resilient nature of the hub advantageously provides for positive-fit or force-locking of the retention members at the engagement portion and enables considerable force to be applied when the contents of the syringe are expelled at high pressures.
[0060] The hub may also be adapted to engage a seal associated with at least a portion of an outer surface of the hub, or alternatively, the hub may perform the function of a seal. The hub or seal may be used in combination with an o-ring. Preferably the seal, whether it is separate from the hub or not, has an extended leading edge to increase the efficiency of the seal under pressure.
[0061] According to a further aspect of the invention there is provided a plunger for a syringe for use with a medical injector system, the syringe having a barrel and a hub slidingly engaging the barrel, the plunger comprising a retention member adapted to releasably engage a substantially annular engaging portion on an inner surface of the hub to permit the hub to be selectively withdrawn along the barrel by the plunger.
[0062] As discussed above, by providing a plunger disposed within the housing and comprising a retention member to releasably engage the engaging portion of the hub, it is possible to utilize a single plunger associated with the injector system with multiple syringes, each with a hub according to the present invention. The retention member enables the plunger to engage and lock onto the hub and thereby drive it either backwards or forwards along the syringe barrel to draw fluid into or out of the syringe. Preferably there is more than one retention member.
[0063] A retention member according to the present invention may be of any suitable type. Preferably the retention member is mechanically and/or electrically releasably engaged with the hub. According to this embodiment, it is possible to cause the plunger to engage the hub by actuation (as opposed to automatic engagement by pushing or forcing the plunger into the hub). This creates greater control over locking and release of the hub by the plunger, which is important for applications where the plunger movement is controlled electronically. For example, it is particularly advantageous to be able to release the hub at the most front (outlet) portion of the syringe after expulsion of fluid since this will minimize the possibility of re-use of the syringe. According to another preferred embodiment, the releasable engagement is at least partly actuated by a weight mechanism.
[0064] According to one preferred embodiment, the releasable engagement is actuated by retraction of the plunger. According to another embodiment, the plunger may be adapted with a weight mechanism such that the retention members are activated (for example, they may protrude from the plunger) when the plunger is in a particular orientation.
[0065] According to another preferred embodiment, the releasable engagement occurs automatically on retraction of the plunger and automatically releases the hub during and following forward movement of the plunger, leaving the syringe unlocked following an injection, free to be removed safely. Such an embodiment operates as follows:
[0066] The nose portion of the actuation member (the Cone) is attached to the actuation member, which in turn is fixed to the plunger drive. The plunger is driven backward to draw up (fill) a syringe, then forward to expel the syringe. It should be noted that the plunger is slidingly engaged with the actuation member, but with a limited free play. Note also that free sliding of the plunger may also be somewhat reduced by a Friction Seal. According to this embodiment, whenever the plunger drive and actuation member reverse direction, the plunger does not move until the actuation member has traveled some millimeters, and the hub lock mechanism changes state.
[0067] The actuation member slides inside the momentarily stationary plunger. The drive and actuation members move forward relative to the plunger and lock pins, allowing them to retract and unlock the syringe. The plunger does not move (due to friction of the Seal) until the shoulder of the plunger drive strikes the rear of the plunger, at which point the hub begins advancing, expelling the syringe. The purpose of unlocking the hub is to allow removal of the used syringe following an injection.
[0068] When the plunger begins to retract again the plunger (and hub) is momentarily stationary—the Cone retracts relative to the Lock Pins, extending them to lock the hub onto the Plunger. A shoulder on the actuation member then strikes the Inner Shoulder of the Plunger, retracting it and the hub back for filling etc.
[0069] Hence this system automatically ensures that the hub is either locked or unlocked at the appropriate time, avoiding inconvenience and enhancing safety of the injector—for the operator and the patient. Of course, a controller associated with the injector may be programmed to allow for the inherent “free play” whenever the plunger reverses direction.
[0070] Benefits of this embodiment include:
(a) Whenever the plunger is advanced the lock pins automatically immediately retract, allowing the plunger to freely enter the hub, regardless of whether the hub had already engaged the plunger. With a gravity operated lock system the piston has to engage the plunger before the head is tilted up (and locked). (b) With a gravity operated system the head has to be tilted downward to unlock, and the syringe can then be removed. (c) The syringe hub can be retracted at any time, including to test the patency of a needle. Previously pre-filled syringes can easily be “topped up” at any time. Previously pre-filled syringes can now be purged with the head oriented upwards (This was not possible with the gravity lock system because the lock pins automatically extend when oriented vertically, but the plunger will not yet have engaged the hub). (d) The hub is always left unlocked following an injection, allowing safe removal of the syringe at this logical point in the injector sequence. (e) The hub is automatically and immediately locked whenever the plunger is retracted, ensuring the hub will be pulled back. (f) New syringes may have the plunger assembled and left in any position along the barrel (for the previously described Gravity Lock system the hub must be located at the very rear of the barrel). (g) This concept is robust and reliable.
[0078] According to another preferred embodiment, the retention mechanism is biased to lock only when the syringe is oriented vertically (as necessary when filling & purging), and is automatically unlocked in the injection position. This is desirable to prevent drawing up blood into the syringe, or its re-use. Given certain controls over plunger movement this mechanism can form part of an injection system which can minimise or prevent re-use of a syringe, thereby helping prevent cross infection from one patient to the next. For example, given the following scenario:
[0079] New syringes are usually supplied with the retention members and hub in the fully retracted position. Syringes are loaded through the front end of a fixed retaining sleeve (which is part of the holder) of the injector, which aligns the syringe and hub with the plunger of the injector. The injector can only inject following filling, and with the syringe oriented such that its front (outlet) portion is at the same level or below its back (furthest from the patient) portion, that is, the syringe is in a horizontal or down orientation to avoid injecting any residual small amounts of air. With this system the plunger is automatically retracted immediately after completion of an injection, thereby leaving the used hub in the expelled position. The plunger can only be retracted on demand if the syringe is oriented vertically. For the injector plunger to lock into the hub, the plunger must be fully engaged with the hub before the retaining members are extended (this system extends the retaining members as the plunger is tilted from the horizontal to the vertical). As a new syringe is loaded, the hub will, by default, engages the plunger of the injector and as the injector is subsequently tilted up a weight mechanism, such as a weighted rod slides backward due to gravity, and thereby actuates the retention member to secure the hub onto the plunger. The injector can now retract the plunger, and fill the syringe by drawing fluid down into it.
[0080] If a used (even partially expelled) syringe were loaded into the injector, its hub would, by default, be positioned forward of the retracted plunger and cannot engage with it. When the injector is tilted up (thus tilting the front of the syringe up), the retention members extend, but do not secure the hub. Hence the hub cannot be drawn back and the syringe can not be re-filled.
[0081] As syringes for use with and according to the present invention do not have their own plunger, there is no protrusion from the rear of the syringes. Therefore there is little danger of dislodging the hub in transit and during handling. (As described above, the syringe is best assembled with the hub as far back as possible).
[0082] According to another preferred embodiment, the retention member is biased away from engagement with the hub.
[0083] In another preferred embodiment, the retention member comprises an actuation member disposed at least partially within a bore defined in the plunger and a locking member is located at or adjacent one end of the retention member and/or plunger, the locking member being movable by the retention member into or out of engagement with the engaging portion of the hub.
[0084] The retention member may comprise any suitable member, but preferably it is a cam or a cone. Preferably the cam or cone is moved into and out of the bias position by a weight mechanism which causes the protrusion of the retention member in accordance with a given orientation of the plunger.
[0085] According to another preferred embodiment, the actuation member has a rod portion and a nose portion and the locking member is, in the unlocked position, located between the plunger and the nose portion. Preferably the actuation member is movable longitudinally along the bore in the plunger and preferably the retention member comprises a pin. In a particularly preferred embodiment, there is more than one pin.
[0086] According to a still further preferred embodiment, the plunger is adapted for manual filling of the syringe. By adapting the plunger for manual filling of the syringe, it is possible to hand fill syringes without the need to load them in the injector. This has the benefit of allowing a number of syringes to be pre-filled and thereby speed up the process of changing from one syringe to the next, and allows filling of a new syringe when the injector is injecting a previous patient. In addition a plunger according to this aspect of the invention can be used to hand fill a series of syringes and then be placed into the injector for injection of patients, thereby minimizing the need for separate hand filling devices.
[0087] Preferably the plunger according to this aspect of the invention is sufficiently shorter than the barrel of the syringe such that it can not reach the hub when the hub is located at the front most portion of the syringe barrel. In other words, the plunger is slightly shorter than the full syringe stroke, thereby is incapable of engaging the hub after the syringe has been used (assuming the syringe was fully expelled). A plunger/plunger device according to this aspect of the invention will decrease the chances of re-use of syringes (and thus cross-contamination) by being incapable of grasping and retracting the hub within the syringe. Preferably the plunger is sufficiently shorter than the barrel of the syringe such that it can not reach the hub when the hub is located at the front most portion of the syringe barrel.
[0088] According to a further aspect of the invention, there is provided a plunger for a syringe for use with a medical injector system, the syringe having a barrel and a hub slidingly engaging the barrel, the plunger comprising a retention member adapted to releasably engage an engaging portion of the hub to permit the hub to be selectively withdrawn along the barrel by the plunger; and a sensor to detect a level of engagement between the plunger and the hub.
[0089] A sensor according to this aspect of the invention may be any suitable sensor, such as a mechanical, electromagnetic or light sensor. Preferably the sensor detects full engagement between the plunger and hub. Where the sensor is a light sensor, then preferably it comprises a fibre optic cable.
[0090] According to one preferred embodiment, an optic fibre is embedded inside the plunger having one end exposed and flush with the surface of the plunger, and carefully positioned so that the end is masked by the hub just as the plunger fully engages the hub. The flexible fibre is routed out the rear end of the plunger, and via a suitable slack loop the other end of the fibre is connected to a photo detector which can respond to light transmitted through the fibre. Note that the plunger moves back and forth often, and so the fibre is a convenient and reliable means for communicating with the plunger. For the present invention the hub is made from opaque material, whilst the syringe barrel is transparent.
[0091] The injector is always used in a normally illuminated environment, and hence the fibre normally “sees” light (in the absence of a syringe hub). Of course, if the room lights are inadequate, the plunger can be illuminated by the injector with visible or infrared light. As the plunger engages the hub, the ambient light is cut off from the tip of the fibre, signalling the photo detector and Control Unit.
[0092] This device detects when the plunger has entered the piston, and when connected to the Injector Control Unit, provides the following benefits and enhancements:
(a) where the syringe has been pre-filled, the plunger must be engaged with the hub prior to initiating the injection, so that when the injector is started the hub begins expelling immediately. This device enables the injector to safely and accurately engage the hub and plunger, without pushing the hub (which could cause unwanted waste and mess). (b) If used in association with the syringe sensing system described below, where the syringe has been pre-filled or the hub is not fully retracted, the plunger can automatically advance to engage the hub, then stop accurately. (c) Where an automatically (for example, electronically) controlled hub and plunger engagement mechanism is employed, this sensor can be used to indicate that the piston retention mechanism is ready for locking. (d) If used in association with a gravity locked plunger and a syringe presence sensor, this device can signal whether the hub is fully retracted when the syringe is first loaded, thereby confirming whether the syringe is new, or alerting the operator that the syringe has been used and may be contaminated. (e) The device can also generate a signal if the piston becomes detached during retraction or filling.
[0098] According to a still further aspect of the invention there is provided a device for manually filling a syringe for use with a medical injector system, the syringe having a barrel and a hub slidingly engaging the barrel, the device comprising a plunger and a retention member adapted to releasably engage an engaging portion of the hub to permit the hub to be selectively withdrawn along the barrel by the plunger.
[0099] Such a device enables the operator to hand fill syringes without the need to load them in the injector. This has the benefits of allowing a number of syringes to be pre-filled and thereby speed up the process of changing from one syringe to the next, and allows filling of a new syringe when the injector is injecting a previous patient. In addition a device according to this aspect of the invention can be used to hand fill a series of syringes and then be placed into the injector for injection of patients, thereby minimizing the need for separate hand filling devices.
[0100] Preferably a device according to this aspect of the invention is sufficiently shorter than the barrel of the syringe such that it can not reach the hub when the hub is located at the front most portion of the syringe barrel. In other words, the device is slightly shorter than the full syringe stroke, thereby is incapable of engaging the hub after the syringe has been used (assuming the syringe was fully expelled). A device according to this aspect of the invention will decrease the chances of re-use of syringes (and thus cross-contamination) by being incapable of grasping and retracting the hub within the syringe. Preferably the device is sufficiently shorter than the barrel of the syringe such that it can not reach the hub when the hub is located at the front most portion of the syringe barrel.
[0101] Preferably the retention member is mechanically and/or electrically releasably engaged with the hub.
[0102] According to another preferred embodiment, the releasable engagement is at least partly actuated by a weight mechanism. According to another preferred embodiment, the releasable engagement is actuated by retraction of the plunger. Preferably the retention member is biased away from engagement with the hub.
[0103] According to a further preferred embodiment the retention member comprises an actuation member disposed at least partially within a bore defined in the plunger and a locking member is located at or adjacent one end of the retention member and/or plunger, the locking member being movable by the retention member into or out of engagement with the engaging portion of the hub. The retention member may be of any suitable form, it may be a cam, it may be a cone.
[0104] According to another preferred embodiment the actuation member has a rod portion and a nose portion and the locking member is, in the unlocked position, located between the plunger and the nose portion. Preferably the retention member comprises a pin.
[0105] According to another aspect of the invention, there is provided a method for hand filling a syringe comprising a hub according to the present invention and a device for hand filling according to the present invention comprising the steps of; (i) introducing the device into the syringe barrel and engaging the device with the inner surface of the hub (ii) activating the device such that the retention member engages the engaging portion of the hub; and (iii) withdrawing the engaged hub along the syringe barrel whilst drawing liquid into the syringe.
[0106] According to a further aspect of the invention, there is provided a syringe for use with a medical injector system including a hub as described above.
[0107] According to a further aspect of the invention, there is provided a syringe for use with a medical injector system including a plunger as described above.
[0108] In a particularly preferred embodiment of a syringe according to this aspect of the invention, it comprises a plunger as described above and a hub as described above.
[0109] According to another aspect of the invention, there is provided a sensing system for use with a medical injector system comprising a sensing member to detect the presence of a syringe holder associated with the medical injector system. The sensor may be of any suitable type such as a light sensor, mechanical sensor or electromagnetic sensor. Preferably it is a light sensor. Where the sensor is a light sensor, then preferably the sensing system further comprises a reflecting member to reflect light to the sensing member. The reflecting member may be associated with any suitable component, such as the syringe, or the injector system. The sensor system may alternatively comprise a light interruptor, contacts, or mechanical switch component.
[0110] According to one preferred embodiment, during assembly of the holder a syringe stop (or bush) and spring stop are normally fixed in place inside the holder by any suitable means such as cement, screws, or pins. Both stops have a small longitudinal groove in their outer surface to support a slidable syringe flag, which, together with the flag spring are held in place by the two stops. The compression spring is lodged between the rear fixed spring stop and the flag tabs, thereby biasing the flag forward. With no syringe loaded the flag protrudes forward of the syringe stop, and its tabs lodge against the rear of the syringe stop. A secondary function of the syringe stop is to bear and centre the plunger, and prevent stray fluid around and/or from the syringe from entering the injector.
[0111] In brief, a sensing system according to this aspect of the invention can perform at least three functions:
1 Syringe ejector: According to one embodiment, the sensing system comprises a flag which is slidingly mounted in a groove, and is biased forward by a flag spring. As the syringe is loaded into the holder the rear rim of the syringe strikes the flag, pushing it rearward and compressing the flag spring until the tip of the flag is flush with the syringe stop. When the syringe catch is opened the syringe is partially ejected forward by the flag, making the syringe easier to grasp and remove. 2 Anti Rotation Device: Unlike most other syringe/holder arrangements, with the present invention the syringe can be rotated about its axis. When a tube is attached to the syringe (after it has been loaded), the operator needs to twist the connection clockwise to engage and lock the connection to the syringe thread. To restrain the syringe from rotating it would ordinarily need to be held with the other hand, however the flag may perform this role. The forward tip of the flag is bevelled & sharpened, and thus can dig into the syringe and thereby decrease rotation of the syringe. 3 Syringe Sensor: In association with the sensing system the flag detects the presence of a syringe in the holder. Reflective infrared sensors such as Sharp GP2L24 are readily available examples of sensors that may be used as part of the system. As the flag is pushed back by the syringe the reflective rear end of the flag is detected by the sensor, which in turn may signal a controller associated with the injector system.
[0115] Electronic sensing of the syringe, coupled to a controller associated with the injector system enhances the functionality and safety of the injector. For example:
(a) To avoid cross infection from patient to patient it is important that the syringe is replaced before the injector can allow a subsequent filling or injection. (b) Where a gravity operated plunger/hub locking mechanism is employed, the syringe should only be removed when the injector head is oriented horizontally (ie when the piston is unlocked)—if removal is attempted in the vertical orientation, the injector controller can alert the operator. (c) In the case of an electrically operated piston lock, the injector controller can automatically lock following loading of a syringe. (d) As with any injector, the syringe should not be removed unless the hub is unlocked from the plunger (otherwise the hub could be separated from the syringe barrel, potentially spilling contaminated fluid or drug). In the case of certain of the described embodiments the syringe is only able to be removed at the end of a forward (inject) stroke. Hence the controller must not allow retraction of the plunger until the sensor advises that the syringe has been removed following an injection. (e) With all syringe holders, to avoid accidental opening or failure during an injection it is important that the device is fully locked in position before it can be used. If a syringe holder is not fully engaged with the injector system, it should be noted that the flag will not intersect the proximity sensor (preventing operation of the injector) until the holder is fully rotated to the locked position, and a syringe is present.
[0121] Similarly, a person skilled in the art will appreciate that configurations which do not utilize a flag but instead utilize some other form of sensing mechanism will have the same and other benefits. Other benefits of a sensor system according to the present aspect of the invention include:
(a) The sensitive electronic proximity sensor is fully protected from stray injection fluids which could damage or interfere with the sensor. (b) Because the holder according to certain embodiments is able to be removed for washing, the sensor is not exposed to washing fluids. (c) The system is solid state (apart from the flag) and therefore robust & reliable.
[0125] According to a further aspect of the invention, there is provided a medical injector system for injecting fluid from a syringe into a patient, the syringe having a barrel and a hub slidingly engaging the barrel, the hub comprising an inner surface having an engaging portion adapted to be releasably engaged by a plunger, the injector system comprising: (i) a plunger for driving the hub, the plunger comprising a retention member adapted to releasably engage the engaging portion of the hub; and (ii) a syringe holder comprising: a cradle member adapted to receive a barrel of the syringe; and a pivotable catch to releasable lock the syringe in the cradle member. Preferably there is also provided a positioning device located on the cradle member to locate one end of the syringe in a predetermined location in the cradle member
[0126] According to a preferred embodiment, the syringe holder comprises an engagement portion to enable simple releaseable engagement with a medical injector. Preferably the engagement portion of the syringe holder comprises a locking member. The locking member of the syringe holder may comprise any suitable means of locking. Preferably it comprises a slot or a pin.
[0127] According to a further preferred embodiment, the medical injector system further comprises (i) a tube adapted to be connected to syringe to conduct fluid into or out of the syringe; and (ii) a connector to connect the tube to a vessel containing medical fluid and thereby enable withdrawal of the fluid from the vessel into the syringe wherein the connector comprises a hollow spike to create an aperture through a bung in the vessel upon piercing of the bung by the spike.
[0128] Preferably the connector further comprises (i) a male luer portion having a locking collar; and (ii) a disengagement portion to enable permanent disengagement of the spike from the male luer portion. Preferably the disengagement portion comprises a frangible neck. Preferably the spike comprises a barbed portion to resist removal of the spike from the vessel.
[0129] It will be readily appreciated that the connections may comprise any convenient connection means known in the art such as bayonet, snaplock or screw connections. The spike may be broken off to leave a male luer tip on the end of an associated tube.
[0130] The combination spike, optionally a frangible (vented or sealed) spike, and male luer connector device may be permanently connected to a tube and syringe. Using this combination, optimally the device can only be filled once, and thereby cannot possibly infect a multi-dose bottle of medical fluid or cross infect another patient.
[0131] If the spike connector is made as a frangible part of the connector, and is permanently attached to the tube and syringe, it is very difficult for the syringe to be refilled, and thereby cross infect the bottle or another patient. In addition, such an arrangement further reduces material costs. The syringe, spike connector means and frangible spike may be supplied as one set. Preferably, the spike connector can be snapped off prior to attachment of the tube to an intravenous catheter and hence to a patient.
[0132] According to another preferred embodiment, the medical injector system further comprises a clamp between the tube and a male luer connector of the syringe, the clamp being moveable into a locking thread of the male luer connector thereby clamping the tube to the male luer connector. Preferably the clamp comprises a gripping portion to increase the grip between it and the tube. The gripping portion may be of any suitable type, such as barbed rings, barbed teeth, a screw thread, serrated grip, a ridge (for example an annular ridge), a rear flange or an internal taper. In a particularly preferred embodiment the clamp is tamper evident.
[0133] According to a particularly preferred embodiment, the medical injector system further comprises a base member and a sensor to detect orientation of the syringe holder with respect to the base member. Preferably the sensor detects the angle between the syringe holder and base member.
[0134] According to another preferred embodiment, there is provided a switch to automatically initiate or inhibit movement of the plunger in the barrel depending on its orientation. The switch may be activated by any suitable mechanism. According to one preferred embodiment, it is activated by a weight mechanism.
[0135] According to a particularly preferred embodiment, there is further provided a controller to control the plunger. Preferably at least some of the injector operation may be automated by electronics or software. For example, the injector may have one or more gravity or syringe angle operated tilt switches to automatically initiate or inhibit movement of at least the syringe during operation of the injector.
[0136] According to another preferred embodiment, the system has a controller and a sensor to detect orientation of the syringe holder with respect to the base member. The sensor may sense any suitable feature, but preferably it detects the angle between the syringe holder and base member.
[0137] Preferably the controller is operable to move the plunger to test patency of an intravascular catheter connected via a tube to the syringe. At present this has to be checked manually, with great care being exercised so as to avoid damaging, and possibly rupturing the vein.
[0138] Preferably a medical injector system according to this embodiment will utilize a hub, plunger, syringe holder, 1 or more sensor(s) and/or syringe as herein described.
[0139] Where there is a sensor, then preferably it communicates with a controller associated with the injector system to further control the movement of the plunger. Preferably the communication enables engagement of the plunger and the hub without thereby moving the hub. According to one preferred embodiment, the communication enables releasable locking of the hub to the plunger. According to another preferred embodiment, the communication causes releasable locking of the hub to the plunger. According to a still further preferred embodiment, the communication enables detection of used syringes.
[0140] According to yet another preferred embodiment, a signal is created if the sensor detects the hub at a position forward of its most retracted state. According to another preferred embodiment, the communication enables detection of errors. Preferably a signal is created if the hub and plunger disengage prematurely.
[0141] According to another preferred embodiment, the communication enables movement of the plunger to either fill or expel fluid from the syringe. For example, the communication may either enable or disable movement of the plunger. This may occur for a variety of reasons, or based on a variety of stimuli. For example, movement of the plunger may be disabled after use, if the syringe has not been removed, or before use if the syringe has not been engaged to a specified level.
[0142] According to another preferred embodiment, a signal is created if removal of the syringe is attempted at certain orientations of the syringe. Preferably the signal is created if removal is attempted while the syringe is in a substantially vertical orientation.
[0143] According to another preferred embodiment, a signal is created indicating the syringe has not been removed. Preferably the signal is created if the syringe is not removed immediately following use.
[0144] According to a particularly preferred embodiment of the invention, there is provided method of filling a syringe with medical fluid from a sealed vessel the syringe for use with a medical injector system comprising the steps of: (i) elevating the front portion of the syringe relative to the back portion; (ii) advancing a plunger to a position within the syringe corresponding to a predetermined patient dose; (iii) controlling movement of the plunger in a sequence of forward and backward movements to expel air from the syringe and any attached tube into the vessel bottle, and draw the desired dose of fluid into the syringe.
[0145] According to a still further aspect of the invention, there is provided a method of filling a syringe with medical fluid from a sealed vessel, the syringe for use with a medical injector system as herein described, comprising the steps of: (i) elevating the front portion of the syringe relative to the back portion; (ii) advancing the plunger to a position within the syringe corresponding to a predetermined patient dose; and (iii) controlling movement of the plunger in a sequence of forward and backward movements to expel air from the syringe and any attached tube into the vessel bottle, and draw the desired dose of fluid into the syringe.
[0146] According to these methods, all outside air is excluded in order to substantially reduce the chances of introducing microbes to the fluid and patient. Furthermore, the method provides a convenient and expedient way of filling and purging both the syringe and the tube in one operation, and as well as reducing costs of materials used and speed of syringe filling as compared with traditional methods. Filling and purging of the syringe and associated extension tube may be carried out in one combined operation. According to another preferred embodiment, all elements of the fluid path are connected as one sealed system.
[0147] According to this embodiment, the combined forces of air pressure in the bottle with partial vacuum in the syringe generate a greater pressure difference between the two vessels than conventional vented systems, thereby resulting in a faster syringe filling time.
[0148] In a preferred embodiment of the method of filling, after driving of the spike connector into the bung and selection of an automatic “FILL” function on the injector, the injector then performs a sequence of controlled forward and back movements of the piston, such that all air in the syringe and tube is transferred to the bottle, and the desired dose of fluid is drawn into the syringe.
[0149] According to another preferred embodiment of the method, it further comprises the step of automatically restricting the direction of movement of the plunger depending on the orientation of the syringe. Preferably the plunger may move either forward or backward when oriented with its front portion elevated with respect to its back portion and only in the forward direction when oriented with the back portion elevated with respect to its front portion. This reduced the chance of an air bubble being injected into a patient by ensuring that air bubbles will be at the back of the syringe. Preferably this step may be enabled by a tilt switch or sensor so that the syringe is inclined with the front portion elevated when expelling air and filling so to minimise trapping of air in the syringe.
[0150] According to another aspect of the invention there is provided a method of injecting a patient using a medical injector system as herein described comprising the steps of (i) engaging the plunger with the hub, (ii) driving the hub along the syringe barrel; and (ii) expelling fluid from the syringe into a patient.
[0151] According to a further aspect of the invention, there is provided a method for engaging a syringe holder as herein described with a medical injector according to claim [ind], comprising the steps of: (i) aligning the engaging portion of the syringe holder with a complimentary portion on the medical injector; and (ii) engaging the syringe holder with the medical injector.
[0152] According to one preferred embodiment, there is the further step of detecting a level of engagement between the syringe holder and the medical injector system.
[0153] According to a still further aspect of the invention, there is provided a method for disengaging a syringe holder as herein described from a medical injector as herein described comprising the steps of: (i) disengaging the engaging portion of the syringe holder from the medical injector; and (ii) removing the syringe holder from the medical injector.
[0154] Preferably there is the further step of detecting a level of disengagement between the syringe holder and the medical injector system.
[0155] According to a further aspect of the invention, there is provided a method for loading a syringe into a syringe holder associated with a medical injector system as herein described, comprising the steps of: (i) inserting the syringe barrel in the cradle member such that the catch is displaced; and (ii) allowing the catch mechanism to return into its biased position to engage the syringe and thereby retain the syringe in the cradle member.
[0156] According to a still further aspect of the invention there is provided a method for removing a syringe from a syringe holder associated with a medical injector system as herein described comprising the steps of: (i) releasing the catch to unlock the syringe; and (ii) withdrawing the syringe from the cradle member.
[0157] According to a further aspect of the invention, there is provided a method for loading a syringe into a syringe holder of a medical injector system as herein described comprising the steps of: (i) inserting the syringe barrel in a cradle of the syringe holder; and (ii) sensing the presence of the syringe in the holder with a sensing member associated with the sensing system.
[0158] According to a further aspect of the invention, there is provided a method for removing a syringe from a syringe holder of a medical injector system as herein described comprising the steps of: (i) withdrawing the syringe from the cradle member; and (ii) sensing the absence of a syringe in the holder with a sensing member associated with the sensing system. Preferably there is the further step of automatically retracting the plunger after withdrawal of the syringe. Preferably there is a still further step of restricting retraction of the plunger until the syringe has been withdrawn. According to one preferred embodiment, there is a further step of prompting retraction of the plunger after the syringe has been withdrawn.
[0159] According to another aspect of the invention, there is provided a method of connecting a syringe hub to a plunger using a medical injector system as herein described comprising the steps of: (i) introducing the plunger into a syringe barrel within which the hub is slidingly engaged and engaging the plunger with the inner surface of the hub; and (ii) activating the plunger such that a retention member engages the engaging portion of the hub. Preferably there is the further step of detecting a level of engagement between the plunger and the hub.
[0160] According to a further aspect of the invention, there is provided a method for modifying a medical injector system comprising a syringe holder, comprising the steps of: (i) replacing the syringe holder with a syringe holder as herein described; and (ii) attaching a plunger as herein described.
[0161] According to another aspect of the invention, there is provided a method for modifying a medical injector system comprising a syringe holder, comprising the steps of: (i) replacing the syringe holder with a syringe holder as herein described; and (ii) attaching a plunger as herein described.
[0162] According to a further aspect of the invention, there is provided a method for modifying a medical injector system comprising the steps of: (i) replacing the syringe holder with a syringe holder as herein described; and (ii) attaching a plunger as herein described.
[0163] According to another aspect of the invention, there is provided a method for modifying a medical injector system comprising the step of adding a sensing system as herein described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0164] FIG. 1 shows a prior-art injector with a syringe loaded;
[0165] FIG. 2 a shows various components of the syringe as used in the present invention;
[0166] FIG. 2 b shows an assembled syringe;
[0167] FIG. 2 c shows the assembled syringe of FIG. 2 b in conjunction with a plunger;
[0168] FIG. 3 a shows oblique side views of the hub;
[0169] FIG. 3 b shows a side view of the hub;
[0170] FIG. 3 c shows a cross sectional view of the assembled hub and seal;
[0171] FIG. 3 d shows a front view of the hub;
[0172] FIG. 3 e shows a rear view of the hub;
[0173] FIG. 4 a shows alternative conformations of the engaging portion of the hub, in the form of grooves;
[0174] FIG. 4 b shows a cross section of the hub and engaging portion;
[0175] FIG. 4 c shows a cross section of the hub and engaging portion, having a conventional seal, with an extended leading edge;
[0176] FIG. 4 d shows a cross section of the hub and engaging portion, having a seal integral to the hub;
[0177] FIG. 4 e shows a cross section of the hub and engaging portion, having an o-ring seal;
[0178] FIG. 4 f shows further alternative conformations of the engaging portion of the hub;
[0179] FIG. 5 shows example dimensions of the hub;
[0180] FIG. 6 shows a cross-section of the plunger engaging the hub;
[0181] FIG. 7 shows a cross sectional side view of one possible embodiment of the plunger/hub interlocking arrangement;
[0182] FIG. 8 shows a front cross-section along the line A-A of FIG. 7 ;
[0183] FIG. 9 shows an alternative arrangement of FIG. 8 ;
[0184] FIG. 10 shows an alternative example of the plunger/hub interlocking arrangement;
[0185] FIG. 11 shows a front cross-section along the line A-A of FIG. 10 ;
[0186] FIG. 12 shows an alternative arrangement of FIG. 11 ;
[0187] FIG. 13 shows an alternative arrangement for the plunger/hub interlocking arrangement;
[0188] FIG. 14 shows a front cross-section along the line A-A of FIG. 13 ;
[0189] FIG. 15 shows yet another alternative of the plunger/hub interlocking arrangement;
[0190] FIG. 16 shows a front cross-section along the line A-A of FIG. 15 showing the cam in detail;
[0191] FIG. 17 shows yet another alternative example of the plunger/hub interlocking arrangement, having a ring actuated hub locking mechanism;
[0192] FIG. 18 a shows a side view of the syringe holder with catch;
[0193] FIG. 18 b shows the syringe holder and catch of FIG. 18 a with the syringe and hub located in the syringe holder;
[0194] FIG. 18 c shows a side oblique view of the syringe holder and catch of FIG. 18 a;
[0195] FIG. 18 d shows a side oblique view of the syringe holder, catch and syringe of FIG. 18 b;
[0196] FIG. 18 e shows a side oblique view of a syringe holder, catch and syringe according to the present invention;
[0197] FIG. 19 shows a cross section side view of the syringe holder/syringe combination within the sleeve of the injector, with the syringe retained by a catch;
[0198] FIG. 20 shows a cross-section along the line A-A of FIG. 19 ;
[0199] FIG. 21 shows a cross-section along the line B-B of FIG. 19 ;
[0200] FIG. 22 a shows a cross section side view of the syringe holder/syringe combination within the sleeve of the injector, with the syringe retained by a catch depicting the illumination member;
[0201] FIG. 22 b shows the arrangement of FIG. 19 with a self-ejecting mechanism;
[0202] FIG. 23 a shows a plunger adapted to be a syringe hand filler and associated holder;
[0203] FIG. 23 b shows a syringe and syringe holder comprising a concave syringe front flange and corresponding dovetail catch;
[0204] FIG. 23 c shows a perspective view of a syringe with a concave front flange;
[0205] FIG. 23 d shows a cross-sectional view of a syringe with a concave front flange;
[0206] FIG. 23 e shows a cross-sectional view of a dovetail catch according to the present invention;
[0207] FIG. 23 f demonstrates in cross-section, various alternative arrangements of catches according to the present invention;
[0208] FIG. 24 shows the connection and orientation of certain key elements in the system, as oriented during the filling sequence;
[0209] FIG. 25 shows an example of a Barbed Spike for tapping the bung of a medical fluid bottle;
[0210] FIG. 26 shows various views of an example of a combination male luer connector and frangible spike;
[0211] FIG. 26 a is an oblique view of combination Luer connector with frangible spike, locking collar, and tube, before assembly;
[0212] FIG. 26 b is a longitudinal axial cross-section view of combination Luer connector with frangible spike, and locking collar, after assembly;
[0213] FIG. 26 c shows a combination Luer connector with frangible spike, locking collar, and tube, after assembly and bonding;
[0214] FIG. 26 d is a combination Luer connector with frangible spike and locking collar, shown after the spike has been “snapped off” at the frangible neck;
[0215] FIG. 27 shows an example of a male Luer Connector with barbed frangible spike, and locking collar, as follows:
[0216] FIG. 27 a shows a longitudinal axial cross-section view of a Luer Connector with barbed frangible spike, locking collar, and bonded tube;
[0217] FIG. 27 b shows an example of a Luer Connector with barbed frangible spike and locking collar, after assembly and bonding; and
[0218] FIG. 27 c shows a shorter example of a Luer Connector with barbed frangible spike, locking collar, and bonded tube;
[0219] FIG. 28 shows a combination Luer Connector with frangible spike, permanently bonded to the associated Extension Tube and Syringe to form a non re-usable set for injecting patients;
[0220] FIG. 29 illustrates a typical syringe male Luer lock connector;
[0221] FIG. 29 a shows an outer overall view of the luer lock of FIG. 30 ;
[0222] FIG. 29 b Figure shows a longitudinal axial cross-sectional view of a typical syringe luer lock connector;
[0223] FIG. 30 illustrates a longitudinal axial cross-sectional view of an ordinary soft plastic tube pushed over the tip of a typical luer;
[0224] FIG. 31 demonstrates various views of the basic or Plain form of a clamp according to the present invention;
[0225] FIG. 31 a demonstrates a side view of the Plain clamp;
[0226] FIG. 31 b demonstrates an oblique view of the Plain clamp;
[0227] FIG. 31 c depicts the Plain Clamp in longitudinal axial cross-section;
[0228] FIG. 31 d depicts a longitudinal axial cross-sectional view of a soft plastic tube pushed over the tip of a luer, and the plain clamp pressed into the female locking thread of a luer locking syringe;
[0229] FIG. 32 depicts a clamp with barbed rings;
[0230] FIG. 32 a depicts an oblique outer view of a clamp having annular barbed rings added to the outer surface;
[0231] FIG. 32 b depicts a longitudinal axial cross-sectional view of a clamp having annular barbed rings added to the outer surface;
[0232] FIG. 32 c depicts a longitudinal axial cross-sectional view of a barbed clamp pressed into the female locking thread of a luer locking syringe, and clamping a tube onto the associated male luer tip;
[0233] FIG. 33 depicts a clamp with male threads;
[0234] FIG. 33 a depicts a plain clamp with male threads;
[0235] FIG. 33 b depicts a plain clamp having male outer threads, with the addition of serrated grip to the rear end of the clamp;
[0236] FIG. 33 c depicts a longitudinal axial cross-sectional view of a plain clamp having male outer threads added to the outer surface;
[0237] FIG. 33 d depicts a longitudinal axial cross-sectional view of a clamp having male outer threads, screwed into the female locking thread of a luer locking syringe, and clamping a tube onto the associated male luer tip;
[0238] FIG. 33 e depicts a longitudinal axial cross-sectional view of a clamp having male outer threads, with the addition of an annular ridge added to the inside surface of the clamp;
[0239] FIG. 33 f depicts a longitudinal axial cross-sectional view of a clamp having male outer threads plus an annular internal ridge, screwed into the female locking thread of a luer locking syringe, and clamping a tube onto the associated male luer tip;
[0240] FIGS. 34 & 35 illustrate flanges added to the rear end of clamps;
[0241] FIG. 34 a illustrates a side view of a Threaded Clamp with a plain flange added to the rear end of the clamp;
[0242] FIG. 34 b illustrates a rear view of a Threaded Clamp with a plain flange added to the rear end of the clamp;
[0243] FIG. 35 a illustrates a side view of a Tamperproof Threaded Clamp having barbed teeth added to the outer perimeter of the flange;
[0244] FIG. 35 b illustrates a rear view of a Tamperproof Threaded Clamp having barbed teeth added to the outer perimeter of the flange;
[0245] FIG. 36 illustrates a side perspective view of a syringe holder with an engagement portion to enable releasable engagement with a medical injector and sensing system to detect the presence of the syringe;
[0246] FIG. 37 a illustrates an exploded perspective view of a syringe holder with a bayonet attachment, loaded syringe and sensing system to detect the presence of a syringe;
[0247] FIG. 37 b illustrates a cross-sectional view of the holder and syringe of FIG. 37 a;
[0248] FIG. 37 c illustrates a syringe flag for use with the syringe sensing system;
[0249] FIG. 37 d illustrates a cross sectional view of the injector nose with holder lock post;
[0250] FIG. 38 a illustrates a longitudinal cross-sectional view of a syringe holder with a bayonet attachment, loaded syringe and sensing system to detect the presence of a syringe;
[0251] FIG. 38 b illustrates a lateral cross sectional view of the syringe holder and syringe of FIG. 38 a through the line MM;
[0252] FIG. 38 c illustrates a lateral cross sectional view of the syringe holder and syringe of FIG. 38 a through the line LL;
[0253] FIG. 38 d illustrates a lateral cross sectional view of the syringe holder and syringe of FIG. 38 a through the line KK;
[0254] FIG. 38 e illustrates a syringe flag for use with the syringe sensing system;
[0255] FIG. 39 a illustrates a cross sectional view of a syringe in a syringe holder demonstrating a particularly preferred embodiment of the engagement mechanism between the hub and plunger during movement of the plunger to expel fluid from the syringe;
[0256] FIG. 39 b illustrates the syringe and syringe holder of FIG. 39 a during movement of the plunger to draw fluid into the syringe;
[0257] FIG. 40 illustrates a longitudinal cross sectional view of a plunger and hub demonstrating a preferred embodiment of the sensor to detect engagement between the hub and plunger;
[0258] FIG. 41 illustrates an injector with tilt switches in the injecting (down) position;
[0259] FIG. 42 illustrates an injector with tilt switches in the filing (up) position;
DESCRIPTION OF PREFERRED EMBODIMENTS
[0260] A typical injector system used for similar applications as the present invention includes an automatic injector device 100 . The injector will normally have a data entry pad 110 together with a display 120 for entering data and viewing data respectively. The type of data that may be entered into the system includes injecting rates and volumes. The system according to the prior art includes a pressure jacket or sleeve 140 which is connected to injector 100 for retaining an appropriate syringe 300 . Tube 400 connects syringe 300 to the patient (not shown). The prior-art arrangement of the injector as shown in FIG. 1 suffers from a number of disadvantages. Firstly, to install syringe 300 into injector 100 , sleeve 140 must first be removed or opened to allow syringe 300 to be rear- or breech-loaded into the sleeve 140 and fixed therein by reattaching or closing sleeve 140 . In some cases, sleeve 140 is completely closed, like that shown in FIG. 1 , requiring that tube 400 be attached after loading and removed before unloading the syringe 300 . This increases the amount of time required to load the syringe, and increases the risks of spillage of contaminated blood. These disadvantages are addressed by the system of the present invention, which allows the syringe 300 to be loaded into the injector 100 directly from the front and does not require sleeve 200 to be removed, loaded and re-inserted into injector 100 .
[0261] To allow syringe 300 to be inserted easily from the front, the syringe itself may be flangeless. That is, the outer cylindrical surface of the syringe may be free of any interfering projections which normally exist on syringes.
[0262] A syringe in accordance with the present invention is shown in FIG. 2 a wherein there is shown the barrel of the syringe 300 , into which are inserted a hub 310 and corresponding seal 320 . Upon assembly of hub 310 and barrel 300 , the syringe appears as shown in FIG. 2 b . The hub and seal can be manufactured as one component [illustrated in FIG. 4 d ]. For the preferred embodiment the hub is made from semi-rigid plastic, whilst the seal is made from elastomer. In practice, manufacturers of the syringe could sell the syringe barrel either empty, or pre-filled with the required amount of medical fluid to be injected into the patient, which is retained inside the barrel by the hub and seal combination.
[0263] To inject the drug contained within the syringe, a plunger 130 , which is operatively connected to the injector 100 , engages the inner surface of the hub 310 and it is actuated by the injector 100 in accordance with the required controlled motion. As plunger 130 is driven into syringe barrel 300 , this causes hub 310 and seal 320 to be driven relatively towards the other end of barrel 300 , thereby injecting the drug through tube 400 into the patient (not shown). The hub according to the present invention may be made of any suitable semi-rigid plastic such as polypropylene or styrene, whilst the seal could be made from an elastomeric substance such as Santoprene, Kraton, Improflex, Kraiburg. etc.
[0264] The hub 310 is shown from various angles in FIG. 3 . In particular, annular groove 311 is shown on the inside surface of hub 310 . The cross-section of the groove may take on any appropriate shape as shown in FIG. 4 a including, semi-circular, squared and triangular cross-sections. In addition, FIG. 4 c shows a hub assembled with a seal 320 having an extended leading edge on the seal lip to improve sealing under pressure. FIG. 4 d shows a hub and seal combined in one piece which provides the benefits of reduced manufacturing costs. Other advantages of this arrangement are also apparent such as (1) increased lubricity if a low friction material such as polypropylene is used, (2) elimination of silicone or other lubricants, (3) reduction of particles in syringe; and (4) reduced/eliminated assembly costs. The purpose of this groove will be described in more detail below. FIG. 4 e further depicts a hub having an annular seal 312 seen in cross section.
[0265] The dimensions of the hub will obviously be made in accordance with the particular syringe being used. By way of example, it is envisaged that they will typically be of the order of the dimensions shown in FIG. 5 .
[0266] The tip of injector plunger 130 is formed so as to effectively engage with the inner surface of hub 310 as clearly shown in FIG. 6 . Annular groove 311 is also clearly seen as defining a space between the wall of the hub 310 and the surface of the tip of injector plunger 130 . This engagement between plunger 130 and hub 310 is such as to provide a form fit so that the force actuated by injector plunger 130 is efficiently imparted to hub 310 , causing the hub and associated seal 320 (not shown in FIG. 6 ) to travel forward along the inner surface of syringe 300 , and thereby expel the contents of the syringe.
[0267] It is envisaged that injector plunger 130 will be useful for emptying a pre-filled syringe. However, empty new syringes are often filled just prior to use within such injectors, which requires the hub and seal to be retracted by plunger 130 . It will be seen that by itself, plunger 130 does not grip or retain hub 310 . Therefore another mechanism is required to allow plunger 130 to effectively grip hub 310 and enable it to withdraw the hub and seal from the syringe barrel. Groove 311 provides such a mechanism.
[0268] As can be seen in FIG. 7 , upon retraction of the plunger, pins 142 protrude from plunger 130 at the location of groove or recess 311 . Pins 142 , filling groove or recess 311 , act as retention members allowing hub 310 to be withdrawn from the syringe barrel 300 as injector plunger 130 is withdrawn. The mechanism by which pins 142 are caused to enter groove or recess 311 may take on many forms as now discussed in further detail in FIGS. 7 to 16 .
[0269] In one embodiment as shown in FIG. 7 , plunger 130 may include actuating rod 140 with a cam element 141 projecting from a nose end of actuating rod 140 . Cam element 141 is an oval-shaped rod, which upon insertion of plunger 130 into syringe barrel 300 , lies in a horizontal plane. Pins 142 rest against the outer surface of cam element 141 and are biased towards cam element 141 via springs 143 . In this position, the outer ends of pins 142 lie within or below the surface of plunger 130 . Once the plunger/hub/seal arrangement has reached the end of syringe barrel 300 , and is required to be retracted from the barrel, actuating rod 140 may be rotated about its axis, such that cam element 141 now lies in a vertical plane as shown in FIG. 8 . As cam element 141 rotates, pins 142 , which are biased against the surface of cam element 141 , are caused to be pushed out towards the surface of plunger 130 such that their outer ends protrude from plunger 130 and are received in groove or recess 311 as shown in FIG. 7 . In this position, hub 310 is retained by plunger 130 and is able to be withdrawn from syringe barrel 300 . As discussed above, this mechanism may take on many forms, a further one of which is shown in FIG. 9 . In this case, cam element 141 may have a square cross-section which allows the four pins 142 to be extended from plunger 130 to be received in groove or recess 311 . The heads of pins 142 are biased against the four sides of cam element 141 and upon rotation of cam element of 141 , are caused to be biased against the four corners of cam element 141 , resulting in pins 142 protruding from the surface of plunger 130 .
[0270] In another embodiment of a mechanism for actuating pins 142 shown in FIGS. 10 to 12 , cam element 141 is replaced by a cone element 144 . In this embodiment, pins 142 are biased against the outer surface of cone element 144 by springs 143 as in the previous embodiment. In use, plunger 130 is inserted into syringe barrel 300 and hub 310 , whilst actuating rod 140 is pressed as far as possible against the forward surface 131 of plunger element 130 . In this position, pins 142 rest against the narrowest portion of cone element 144 and are biased away from the outer surface of plunger 130 by springs 143 . Before or upon retraction of plunger 130 , actuating rod 140 is pulled away from surface 131 causing pins 142 to slide along cone element 144 up the cone surface. This causes pins 142 to be pushed out and to protrude from the outer surface of plunger 130 to be received in groove or recess 311 . Hub 310 is thereby retained by plunger 130 and able to be moved along the syringe barrel 300 . This arrangement also allows for four pins to be used to be received in groove or recess 311 as shown in FIG. 12 . The cone arrangement of FIGS. 10-12 may also be used in a “gravity operated” locking mechanism whereby plunger 130 only retains hub 310 when the syringe assumes a particular orientation. Such an arrangement (as shown in FIGS. 13 and 14 ) is particularly useful when it is desired to prevent re-use of a syringe between patients. This is desirable to reduce the risks of cross-patient infection or contamination.
[0271] It will be appreciated that it is advisable to tilt the injector upward during syringe filling in order to ensure that air is kept at the syringe outlet for subsequent removal prior to injection. Additionally, it is advisable to tilt the injector downward during injection (to keep any remaining air in the syringe by the hub so that any air will remain in the tubing between the syringe and the patient after the injection, and therefore not enter the patient.
[0272] Generally, new syringes are supplied with the hub and seal arrangement placed in a fully retracted position, ie near the back of syringe barrel 300 . It is also customary to retract the plunger following each use. In one embodiment, with the injection unit 100 oriented down, the syringe is loaded through the front end of the cylindrical sleeve in the injector unit, which aligns the syringe with the plunger. As a consequence, hub 310 engages plunger 130 . It should be noted that if a used syringe had been loaded, the hub would not engage the fully retracted plunger (i.e., because the hub would not be in the fully retracted position within the syringe barrel). To fill the syringe, the injector with the syringe loaded therein is then tilted vertically. As the injector unit is tilted vertically weight rod element 145 drops down within a cylindrical cavity 132 in plunger 130 as shown in FIG. 13 . As weight rod element 145 drops, cone element 144 causes pins 142 to be pushed out to protrude from the outer surface of plunger 130 to be received in groove or recess 311 of hub 310 . Thus, hub 310 is retained by plunger 130 . Upon tilting up, plunger 130 is able (through an automatic tilt switch and controls) to push hub 310 and associated seal 320 (not shown) towards the top end of syringe barrel 300 until the plunger cannot advance any further and seal 320 rests up against the front end of syringe barrel 300 , expelling the unwanted air.
[0273] Upon actuating the plunger in the reverse direction, hub 310 and seal 320 are retracted and the syringe is able to be filled. To inject the contents of the syringe into the patient, the injector unit is returned to a downward position and plunger 130 is once again advanced along syringe barrel 300 , expelling the contents of the syringe. As the injector assembly assumes a downward orientation, weight rod element 145 returns to a forward-most position within cavity 132 . This causes pins 142 to be retracted below the outer surface of plunger 130 due to springs 143 and due to the fact that the heads of pins 142 are now allowed to rest against the narrow portion of cone element 144 . Upon completion of the injection procedure, plunger 130 is automatically retracted from syringe barrel 300 and, because pin elements 142 have been retracted into plunger 130 , hub 310 is no longer retained by the plunger and therefore remains at the front-most portion of syringe barrel 300 . Accordingly, the used syringe (whether just used, or later reloaded) cannot be reused because given that hub 310 has been advanced (at least partially) along the syringe barrel 300 , the hub will not be engaged with the fully retracted plunger 130 , and cannot be retained when the injector is tilted up.
[0274] If the injector unit was raised to assume a vertical position again, weight rod element 145 drops down due to gravity, causing pins 142 to extend beyond the top surface of plunger 130 . If plunger 130 were advanced into the barrel 300 , it will not be able to proceed past the back end of hub 310 due to the protrusion of the pins. This will alert the unit operator that the syringe has been used and prompt them to obtain an unused syringe.
[0275] Yet a further possible implementation of the locking mechanism involves the use of cam element 154 connected to an actuating rod 133 which is contained within the body of plunger 130 . This arrangement is shown in FIGS. 15 and 16 . During the advancement of plunger 130 /hub 310 /seal 320 combination into the barrel 300 of the syringe, actuating rod 133 is orientated such that cam element 134 is positioned with its nose pointed downwards from the point of view of FIGS. 15 & 16 , such that no part of cam element 134 protrudes from plunger 130 . Once hub 310 with seal 320 (not shown in FIG. 15 or 16 ) is then required to be retracted, actuating rod 133 is rotated in the direction of the curved arrows such that the nose of cam element 134 protrudes from the surface of plunger 130 and is received in groove or recess 311 . In this manner, hub 310 and connected seal 320 are retained by plunger 130 and may be retracted within the syringe barrel upon retraction of plunger 130 .
[0276] It will also be appreciated that pin elements 142 ( FIGS. 7 to 14 ) need not be individual pins but may take the form of a unitary ring within plunger 130 which may lie flush with or below the surface of plunger 130 during the advancing stage and which may be caused to expand to protrude from the surface of plunger 130 to be received in groove or recess 311 .
[0277] Such an arrangement is shown in FIG. 17 , in which plunger 130 is divided into two sections—a main body portion 139 and a nose portion 136 . Connecting these two portions is an actuating rod 135 , a front end of which is embedded in nose portion 136 . By pushing actuating rod 135 forward, nose portion 136 is caused to be longitudinally displaced by a small amount, forming gap 137 between main body portion 139 and nose portion 136 . The radial ends of gap 137 are chamfered, creating void 138 , the size of which is dependent on the size of gap 137 . Within void 138 , lies an expandable ring 800 . This may be a rubber o-ring, a metal circlip, or any other suitable ring element. Ring 800 is biased towards its centre, such that it will tend to lie as deep as possible within void 138 , and below the surface of plunger 130 . This will be the position assumed when plunger 130 is moving forward along the syringe.
[0278] To retract hub 310 , actuating rod 135 is moved backwards to cause gap 137 to close, in turn causing void 138 to become smaller. This in turn pushes ring 800 radially outwards, to protrude from plunger 130 , and to be received in groove or recess 311 , thereby retaining hub 310 to plunger 130 .
[0279] It will be understood that groove or recess 311 need not in fact encompass the full circumference of the inner surface of hub 310 , but may take the form of individual recesses or depressions within the surface of hub 310 to receive individual pins from plunger 130 . It will be understood that if rod 135 were the driving member of the injector, and plunger body 139 were restrained by a friction ring system such as that described in FIGS. 39 a and 39 b , the hub retention function described above will operate automatically.
[0280] The loading and retention of syringe barrel 300 inside injector unit 100 will now be described with reference to FIGS. 18 a - e to 21 . FIGS. 18 a to 18 d show various views of a syringe cradle member in the embodiment wherein the cradle member is a sleeve 200 and associated catch 500 . FIG. 18 e depicts the embodiment wherein the cradle member is a cradle 205 containing syringe barrel 300 .
[0281] The left-most (rear) end of sleeve 200 (from the view of the depictions) is inserted into a receiving opening in the injection unit, while syringe barrel 300 is slipped rear first into sleeve 200 via the oblique opening appearing on the right hand side of sleeve 200 as seen from the figures. FIGS. 18 b and d show various views of the embodiment wherein the cradle member is a sleeve 200 containing syringe barrel 300 . Also visible are hub 310 and connected seal 320 which are positioned at the base end of syringe 300 as described previously. Catch 500 is pivotally connected to sleeve 200 as can be seen in FIGS. 19 , 20 and 21 . Syringe holder 200 is engaged in nose 10 of the injector (not shown). The connection between catch 500 and holder 200 is via catch hinges 510 . Spring 540 biases one end of catch 500 away from the body of sleeve 200 such that syringe catch 520 is biased upwards and through sleeve aperture 530 as seen in FIG. 19 . Upon insertion of syringe barrel 300 into sleeve 200 , syringe catch 520 is displaced downwards by a downward force caused by the syringe sliding across the sloped top surface of syringe catch 520 (actuated by a human operator). Once syringe barrel 300 has been fully inserted into sleeve 200 (determined by syringe stop ring 210 ), spring catch 520 snaps back to assume its steady state position to engage a front portion 330 of syringe barrel 300 , thereby retaining it within sleeve 200 . This retention is strong enough to withstand the pressure experienced by the syringe upon actuation of the injector forcing plunger 130 into the barrel 300 to expel the contents of the syringe. In fact, the upright front edge 521 of catch 520 is angled so that it lies parallel to the front edge of sleeve aperture 530 , which is itself similarly angled. This angle is chosen carefully to be greater than 90 degrees to the moment of force exerted by flange 330 on forward edge of aperture 530 . In this way, the engagement forms a wedge or “dove-tail'”, which prevents catch 520 from being released when the syringe is forced forward by the plunger, thereby providing a highly secure retention means.
[0282] Furthermore, syringe sleeve 200 is close-fitting to the inserted syringe barrel 300 . This helps to support the syringe against expansion under the high pressures caused in injectors, thereby enabling a thinner walled, lower cost syringe. Sleeve 200 is also preferably transparent, to allow an unobstructed view of the contents of the syringe (e.g., to determine is air is present in the syringe), which itself is transparent.
[0283] As discussed previously, this arrangement allows the syringe to be loaded into the injector unit in a single action by simply sliding it into a receiving sleeve from the front and without having to remove any part of the injecting unit. Further, the syringe and the hub need not be oriented in a particular manner. This saves a great deal of time and effort in syringe assembly and everyday use of the injector, and results in a simpler construction of the injector.
[0284] FIG. 22 a demonstrates another preferred embodiment whereby there is an illumination member in the form of Light emitting diodes (LEDs) 4200 which are placed at the exposed rear (left-most) end of syringe sleeve 200 so that some of the light is received and transmitted along the walls of the sleeve. As with any thin, dense, transparent material, most of the received light is internally reflected longitudinally, as well as laterally, producing a diffused glow at the front end of the sleeve as depicted by arrows 4250 . The beveled front end of the sleeve 4255 is preferably frosted (eg sanded) to achieve maximum diffusion, and is visible form a wide angle. Any suitable light source may be used, but they are preferably focused or reflected so that most of their output is projected towards the sleeve. Thus, in the embodiment depicted, they are LEDs.
[0285] The illumination sources may be various colours, and/or pulsed to provide many attractive effects, and may be used to remind the operator, for example, to remove the syringe.
[0286] It should be noted that the patient's blood may sometimes find its way into tube 400 and syringe 300 by virtue of the fact that, on occasion, while connected to the patient, the hub is retracted to draw blood back through tube 400 and into the syringe, for example to verify that the needle has properly entered the patient's vein. Since the syringe can be loaded from the front, tube 400 (as depicted in the FIG. 1 in relation to the prior art), may be permanently fixed to the syringe, and need not be connected and disconnected after use. This reduces the risk of spilling contaminated blood.
[0287] To further increase the efficiency of the system, syringe stop ring 210 may consist of 2 parts, separated by a spring element 220 , as shown in FIG. 22 b . The first part is a fixed part 210 a which is essentially a portion of stop ring 210 in FIG. 18 and is fixed to syringe sleeve 200 . The second part is a sliding ring 210 b , which is able to slide over the inner surface of sleeve 200 . Coil Spring element 220 biases sliding ring 210 b away from fixed ring 210 a and towards the front end of sleeve 200 . When the syringe 300 is loaded into sleeve 200 , its rear rim will engage slide ring 210 b and force it towards fixed ring 210 a , compressing spring element 220 there between, until spring catch 520 snaps back to retain syringe 300 as described above. In this state, syringe 300 is biased against catch 520 by the force of spring element 220 acting on sliding ring 210 b . Accordingly, when syringe catch 520 is disengaged from syringe 300 (by pushing on syringe catch release button 550 ), syringe 300 is automatically partially ejected from sleeve 200 to facilitate removal thereof from the injector.
[0288] Some injector users prefer to manually fill syringes without the use of an injector. This ability is also of great benefit when users wish to pre-fill syringes, particularly when the injector is in constant use.
[0289] On the occasions where a syringe is desired to be manually filled, the present invention also provides for easy filling of the syringe. This is accomplished by way of a hand filler 700 as shown in FIG. 23 a . This device is effectively a hand-held version of the plunger 130 described in detail above, and works in a similar manner. In use, the hub 310 and seal 320 could be located anywhere along the syringe. To fill the syringe, the hub/seal must be drawn back towards the rear of the syringe. To do this, hand plunger 700 is introduced into the syringe barrel 300 , and pushed into the hollow of hub 310 . In this position, pins 750 within the head of the hand filler do not protrude beyond the surface of the hand plunger 700 . This is because cone element 730 , inside the hand filler, is biased forward by spring elements 740 , causing pins 750 to rest against the narrowest portion of cone element 730 . Upon retraction by hand (with the fingers 610 of the operator engaging the handle 710 of the plunger), cone element 730 is pulled back with the head of hand plunger 700 , forcing pins 750 outwards to be received in groove or recess 311 , thereby engaging hub 310 and seal 320 . Thus engaged, the hub and seal are drawn back through syringe 300 with the hand plunger 700 , at the same time drawing in liquid through hole 340 and filling the syringe. When the hub 310 and seal 320 have reached the back of the syringe, hand plunger 700 is disengaged from hub 310 by reducing backward force on the plunger, allowing cone element 730 to move forward under the force of spring element 740 , and allowing pins 750 to withdraw from recess or groove 311 as previously described. The filled syringe is then ready to be loaded into the injector 100 as described above. It should be noted that no part of the device can, at any stage touch the inner bore of the syringe, which could contaminate the sterility of the syringe. It should also be noted that the mechanism retaining the hub to the plunger can take many forms, including those described in FIGS. 7 to 17 .
[0290] In another embodiment, the filled syringe may be left connected with the hand filler, and the combination may be connected at the neck 735 to the front end of a suitably modified injector. In this application, the hand filler becomes a syringe holder and pressure sleeve. The complete hand filler device is used to firstly fill the syringe, then the filler device (with syringe) is placed into the injector. The injector pushes on the rear end 710 to expel fluid from the syringe.
[0291] Where the hand filler device illustrated is provided only for filling (in association with an injector made for injecting the syringe), then as long as all syringes are fully expelled (as is the convention), then if the length of the plunger 700 were shortened by only a few millimetres, it could not fill a used (fully expelled) syringe because it can not reach the hub.
[0292] In a further embodiment, the contents of syringe 300 can be expelled by hand force on plunger knob 710 (i.e., an injector syringe such as 300 could be used as a more conventional hand-held syringe).
[0293] As with most injector syringes, syringes as used in the present invention are preferably supplied with the hub/seal in the fully retracted position.
[0294] The various mechanisms for retaining the hub to the plunger of the present invention are preferably arranged such that they can be actuated whilst the plunger is in the fully retracted position, and thereby preferably engage, retain, and fill a new syringe. However, the invention contemplates that the plunger can be arranged to engage the hub at any suitable location within the syringe.
[0295] Following use, the hub and seal of a used (or partially used) syringe will typically be left somewhere forward of the fully retracted position, and hence the devices of the present invention usually do not engage, retain, fill or operate a used syringe, thereby eliminating, or drastically reducing, instances of cross-patient contamination. However, the invention broadly contemplates arrangements wherein the hub can be left at any position within the syringe.
[0296] It will readily be appreciated that there are a number of possible designs for the catch for retaining the syringe within the cradle member/sleeve. FIGS. 23 b to 23 e illustrate a syringe 300 and syringe holder 200 , catch 500 and catch member 520 . The inner edge 526 of the catch 520 is of complementary shape to a concave front flange on the syringe 300 . FIG. 23 f shows three embodiments of the interface between the inner edge of the catch 520 and the front of the syringe 300 .
[0297] The preferred embodiment of an additional embodiment of the invention comprises the essential elements illustrated and oriented as shown in FIG. 24 . An extension tube 1010 is firstly fitted to the tip 1012 of an injector syringe 1014 . The syringe 1014 is then fitted to an injector (or syringe pump) 1016 . The system operator (not shown) then programs the desired patient injection volume on the injector control panel (not shown), and then the operator tilts the combined injector 16 and syringe 1014 unit upwards as illustrated in FIG. 24 , at which point a position or angle sensing tilt switch in the injector preferably causes the piston 1032 of the syringe 1014 to advance automatically by the injector to the desired volume. It will be appreciated by those familiar with the art that such programming and automatic control of the injector is quite known, although not in response to the tilting operation, or means of triggering. Of course, the operator could also initiate some or all of these actions. As the combined injector 1016 and syringe 1014 unit is tilted upwards, any subsequent fluid 1028 from bottle 1026 will fall to the bottom of syringe 1014 , and air 1030 in the syringe 1014 will rise to the syringe tip 1012 , and be expelled through tube 1010 when the piston is advanced. The free end of tube 1010 is then connected to the socket end 1018 of a special non-vented spike 1020 which is shown in FIG. 24 , and in more detail in FIG. 25 . The sharp end 1022 of spike 1020 is then driven into the soft rubber bung 1024 of the fluid bottle 1026 . The sharp tip 1022 of spike 1020 pierces the bung 1024 of the bottle 1026 , creating a path from the bottle contents 1028 through the spike 1020 and tube 1010 to the syringe. It should be noted that at this point the system is sealed from outside air, and pressure in the system will be neutral. It should also be noted that spike 1020 has a barbed neck 1021 as shown in FIG. 25 to ensure it will not be forced out of the bung 1024 when the system is later pressurised. The bottle 1026 is then mounted or hung inverted (as illustrated in FIG. 24 ) so that fluid 1028 can be drawn out through the spike 1020 and tube 1010 etc.
[0298] The “FILL” button (not shown) is now selected on the injector 1016 by the operator, and preferably performs the following sequence automatically:
[0299] The syringe piston 1032 is driven fully forward to the tip 1012 of the syringe 1014 , compressing the air 1030 in the syringe, tube, and bottle. Much of the sterile air 1030 in the syringe and tube 1010 will be driven into the bottle 1026 , and rise to the air space 1034 in bottle 1026 . It will be appreciated by those familiar with the art that such air 1030 will be sterile as long as the syringe 1012 was manufactured and sterilised with the hub 1032 fully retracted (i.e. filled with air) as illustrated in FIG. 2 b . Without delay, the piston 1032 is then automatically retracted to slightly over (eg 130%) the programmed volume, and fluid 1028 is transferred quickly from the bottle 1026 via spike 1020 and tube 1010 into the syringe 1014 , aided by both air pressure 1034 in the bottle 1026 , plus a partial vacuum in the syringe due to retraction of piston 1032 . Following a short delay to allow the pressure to equalise and fluid to fully transfer, the syringe 1014 is filled to more than the programmed fluid volume, plus some residual air. The piston 1014 is then immediately and automatically advanced back to the desired programmed volume, purging any residual air and surplus fluid back to the bottle 1026 , leaving the syringe 1014 entirely filled with the programmed volume of fluid, with no air in either the syringe 1014 , or tube 1010 .
[0300] At this stage the “FILL” sequence is complete, and it is important to note that the system has neutral pressure (because the piston has been returned back to the position at which the system was sealed) so that when the tube is disconnected from the bottle (or the spike is removed), the system neither sucks air, nor drips fluid.
[0301] The bottle 1026 is now righted, and the tube 1010 is disconnected or detached from the spike connector 1018 , and may now be connected to the patient, ready for injection.
[0302] It will be appreciated by those familiar with the art that the following facts and arrangements are normal procedure in this field, and may not be well illustrated or described in this document, however are important to the implementation and operation of the invention:
Components used in the fluid path, and air contained within each is sterilised during manufacture. There is usually a small void of air or gas in bottles of medical fluid. Before tapping, the protective cap over the bung centre is removed (to allow access to for the spike), however the bung retainer 1025 (shown in FIG. 24 ) is left on the bottle (otherwise the bung may be dislodged by air pressure during filling). Injector syringes are typically supplied fitted with the plunger retracted (i.e. it is filled with sterile air) The syringe, tube, and spike would have standard luer locking connectors to ensure they are secure and sealed under pressure.
[0308] The following variations to the system could enhance the invention under some circumstances:
The Fill sequence program could be extended with an additional forward-retract cycle—particularly for volumes approaching the maximum capacity of the syringe. This is to ensure that all air has been expelled. When a syringe is to be filled to near capacity (>75%) there is insufficient travel on the piston to retract 130%. Hence additional strokes are required to expel all the air. This “130%” figure is a function of the volume of (air) the tube, and air space in the bottle—a greater tube volume (or less air space in the bottle) requires more over travel. During the fill sequence, the first compression stroke of the piston would preferably expel all the air from the syringe—particularly for x-ray contrast, where the bottles normally have a significant air space. Alternatively, to optimise performance even with bottles having relatively small air space, during the compression the injector could sense the pressure in the system (for example by sensing the load on the drive means) and retract prematurely if the pressure approached unsafe levels. The controlling electronics and associated displays and audible enunciators could prompt the operator as to what step or otherwise to take next in the filling routine. The injector tilt switches (or sensors) could be used to trigger or inhibit other functions of the injector, for example inhibit injection until the injector and syringe are oriented downward, or enable higher flow rates during fill (rates that would be unsafe for injecting into patients). The syringe 1014 could be supplied with the extension tube 1010 and spike 1014 already assembled (as shown in FIG. 24 ) during manufacture, further reducing operator time. The Syringe 1014 and Tube 1010 could be manufactured with the tube 1010 permanently attached and bonded directly to the syringe tip 1012 , protecting the sterility of the syringe tip 1012 , and reducing manufacturing & material costs by dispensing with connector 1013 , which is normally used to adapt the tubing 1010 to the syringe tip 1012 (as illustrated in FIGS. 31 to 33 , and described below). As well, safety is improved by ensuring the tube cannot be disconnected, possibly releasing contaminated fluids. An air detector (optical, ultrasonic, etc) could be fitted to the tubing, ensuring there is no air present after filling, and disallowing operation of the injector until the air is removed. The syringe 1014 and associated extension tube 1010 could be permanently bonded 1039 to a special combination patient connector with frangible spike (as shown in FIG. 27 c .), and all supplied as one set 1060 . This set could provide a reduced cost, as well as a non-reusable system which could prevent patient to patient cross-infection. This concept is described in detail as follows:
[0318] The complete set 1060 (as shown in FIG. 28 ) is used to fill the syringe much as described previously, however after filling is complete, instead of disconnecting the spike from the tube, spike 60 is then snapped off, and as before, leaves a male luer connector on the end of the tube for connection to the patient. Importantly however, with the spike removed the syringe is less likely to be inadvertently re-filled, and hence cannot be used with more than one patient, thus preventing cross-infection from one patient to the next.
[0319] It is understood that a conventional spike can still be attached after the frangible spike is removed and therefore used to re-fill, and possibly cause contamination. This could be overcome by adopting a non-standard connector (eg larger diameter Luer). This would require a non-standard mating connector on the needle. Also, if the contents of a bottle are used to fill more than one syringe (as is often the case) the bottle cannot be inadvertently contaminated by re-filling a used syringe.
[0320] FIGS. 26 and 27 show various examples 1040 and 1050 of combination male luer connector with frangible spikes and tube 1010 . FIG. 28 shows the complete set 1060 having an extension tube 1010 bonded at each end to the syringe 1014 and frangible connector/spike 1050 .
[0321] The alternative combination connector/spikes are illustrated and described as follows:
[0322] FIGS. 26 a to 26 d show various views of an example of a combination 1040 of male Luer connector 1046 with frangible spike 1042 , and locking collar 1047 . FIG. 26 a is an oblique view of combination Luer connector 1046 with frangible spike 1042 and locking collar 1047 before assembly. Disc 1043 simply provides a grip for holding the spike. The frangible neck 1044 is seen clearly in FIG. 26 b , which is a longitudinal axial cross-section view of a combination Luer connector 46 with frangible spike 1042 and locking collar 1047 , after assembly. The locking collar has a conventional female luer locking thread for retaining the patient needle, which is connected after the spike is detached. Small raised nodules or barbs 1048 serve as detents to discourage the collar from sliding off the connector once assembled. The locking collar 1047 is not essential to the invention, however is advisable when used with pressure injectors.
[0323] FIG. 26 c shows a side view of the combination connector/spike/collar 1040 , after assembly and bonding to the tube 1010 .
[0324] FIG. 26 d shows a combination connector/spike/collar 1040 after the spike has been detached at the frangible neck 1044 , leaving a standard male luer lock connector 1046 on the end of the tube 1010 .
[0325] FIGS. 27 a to 27 c show various views of an alternate example of a combination 1050 of male Luer connector 1046 with barbed frangible spike 1051 , and locking collar 1047 . The barbs 1053 are useful in discouraging the spike from being dislodged from the bung 1025 of the bottle 1026 during the pressurization phase of filling.
[0326] FIG. 27 a shows a longitudinal axial cross-section view of combination 1050 connector/barbed frangible spike/collar.
[0327] FIG. 27 b shows combination 1050 connector/barbed frangible spike/collar, after assembly and bonding to the tube 1010 .
[0328] FIG. 27 c shows a shorter example of combination 1050 connector/barbed frangible spike/collar. It will be appreciated by those familiar with the art that the spike may well be significantly shorter (in proportion) depending on the size of the bottle and bung.
[0329] FIG. 28 shows an example of combination 1060 connector/barbed frangible spike/collar permanently bonded to the associated Extension Tube 1010 and Syringe 1014 , to form a non re-usable set 1060 for injecting patients.
[0330] The complete set 1060 is used as follows: Firstly the spike 1051 is inserted into the bung (not shown in FIG. 28 ), and the syringe 1014 is filled as previously described. After the spike 1051 is withdrawn from the bung, the spike end 1051 is “snapped off” at the frangible neck 1044 and discarded, leaving the conventional male luer lock tip 1046 for connection to the patient (not shown). It should be noted that the patient (not shown) cannot possibly be connected to the set 1041 until the spike 1051 is detached. Once separated however, the spike 1051 cannot ordinarily be reconnected, and hence associated tube 1010 and syringe 1014 cannot be re-filled, thus ensuring only one patient can be injected per set—ie this prevents any chance of inadvertent cross infection from one patient to the next.
[0331] It would be appreciated by those familiar with the art that a vented spike could also be combined frangibly with a male luer connector, however the syringe would be filled in a more conventional manner.
[0332] It should be noted that all cross-section views in FIGS. 29 to 33 are longitudinal, through the axis of the parts.
[0333] As required above and elsewhere in medicine, it is often desirable to connect or bond a flexible plastic tube directly to a rigid plastic spout or luer outlet. A typical male Luer Lock connection is illustrated in FIG. 29 , before connection. FIG. 29 a shows an overall view, and FIG. 29 b shows a longitudinal axial cross-section view. The syringe body 2010 has an outlet connector tip 2011 which has a tapered male luer outer surface 2014 , surrounded by a female locking thread 2012 of larger diameter, on the same axis but slightly forward of the thread. It should be noted that almost all luer tapers 2014 are made to a standard diameter, with a taper of approximately 6% as defined in International Standard ISO594. The outer luer taper 2014 is clearly evident in cross-section FIG. 29 b . Syringes 2010 (including tip 2011 and thread 2012 ) are normally injection moulded from tough semi-rigid transparent polypropylene.
[0334] FIG. 30 illustrates a soft plastic tube 2016 pushed fully over the syringe tip 2011 . The tip 2011 has a tapered outer 2014 , and the tubing 2016 stretches and conforms to the taper 2014 , and the resultant outer surface 2018 of the tubing forms an enlarged taper.
[0335] In FIG. 31 the basic form of clamp invention is shown before and after fitting.
[0336] The clamp 2020 is formed in a cylindrical shape with a hollow inner tapered diameter 2021 from semi rigid plastic, with a small chamfer 2022 on the leading edge to assist assembly. The clamp 2020 is installed by simply pushing over the tapered outer surface 2018 of the tube, and inside the female thread 2012 of the syringe connection. It will be understood by those familiar with the art that the clamp 2020 has suitably precise dimensions for a firm interference fit on both its inner and outer diameters, as illustrated, to suit the wall thickness and compliance of both the tubing and the syringe.
[0337] When force fitted, the inner taper 2021 of clamp 2020 firmly squeezes the tubing 2016 onto the tip 2011 of the syringe 2010 , as shown in FIG. 31 . The syringe tip 2011 is also made from semi-rigid plastic, and all components deform slightly to exert even pressure on the luer tip/tube connection, ensuring it is sealed very effectively.
[0338] Alternate variations to the basic clamp design are illustrated in FIGS. 32 to 35 .
[0339] In FIG. 32 small barbed annular rings 2032 have been added to the outer surface of the barbed clamp 2030 to improve retention inside the female locking thread of the connector. The clamp 2030 is pressed over the tube 2016 and into the syringe 2010 as above, and the barbs 2032 interfere with and grip the female thread 2012 ensuring it cannot be dislodged. As above, inner taper 2021 of clamp 2030 firmly squeezes the tubing 2016 onto the tip 2011 of the syringe 2010 . This type of clamp would suit permanent and tamperproof applications because the clamp would be almost impossible to remove without the use of tools.
[0340] In FIG. 33 , male threads 2042 have been added to the outer surface of two similar styles of clamp 2040 and 2050 , which mate with the female thread 2012 of the syringe 2010 , and have a tapered inner surface 2021 . The purpose of thread 2042 is to assist assembly, as well as firmly clamp the tube 2016 onto luer taper 2014 . During assembly the clamps 2040 or 2050 are simultaneously pushed and screwed inside the syringe thread 2012 and over the tube 2016 , squeezing the tube 2016 onto the luer taper 2014 , resulting in a more secure, tighter fitting connection than those described above. As above, inner taper 2021 of clamps 2040 and 2050 firmly squeezes the tubing 2016 onto the tip 2011 of the syringe 2010 .
[0341] FIG. 33 b has additional barbed serrations 2054 to the rear end of the clamp, which assist in gripping and twisting the clamp during assembly.
[0342] It will be understood by those familiar with the art that the rear end or flange may take many forms to suit hand, machine, or tooled assembly, and/or to discourage disassembly.
[0343] FIG. 33 c shows a longitudinal cross-section of either clamp 2040 or 2050 , showing male threads 2042 , and internal taper 2021 to mate with outer taper 2018 of tube 2016 .
[0344] FIG. 33 d shows a longitudinal cross-section of either clamp 2040 or 2050 ,
[0345] FIG. 33 e shows a longitudinal cross-section of clamp 2060 , showing male threads 2042 , plus an internal annular ridge 2062 added to the inside surface of the ridged clamp 2060 .
[0346] FIG. 33 f shows clamp 2060 after being simultaneously pushed and screwed inside the syringe thread 2012 and over the tube 2016 , squeezing the tube 2016 onto the luer taper 2014 . The internal ridge 2062 of clamp 2060 concentrates the squeezing action to a short area 2064 [not seen in FIG. 33 f ] of the union with the tube 2016 , providing a more concentrated pressure and improved sealing compared with those described above. Alternately, it could be argued by those familiar with the art that clamp 2060 provides an equivalent seal to those above, with less assembly (and disassembly) force.
[0347] It will be understood by those familiar with the art that one or more annular rings may be included on the inner surface of any of the above clamp styles, and that the profile of the ridge may be varied to suit the hardness of the particular tubing employed (not illustrated).
[0348] FIGS. 34 and 35 illustrate various flanges 2072 and 2082 (respectively) added to the rear end of the threaded clamp style 2040 previously shown in FIG. 33 a . Both clamps 2070 and 2080 have male threads 2042 on their outer surface to mate with syringe female thread 2012 , for the purpose of assisting assembly and firmly clamping the tube 2016 . FIG. 35 has additional barbed teeth 2082 on the outer perimeter of the flange 2083 which assist clockwise tightening 2084 of the clamp 2080 , but hinder anti-clockwise unscrewing, thereby making the connection virtually tamperproof. Both clamps 2070 and 2080 are inserted into the syringe (and clamp the tube) in the same manner as those described above, and may or may not have annular rings on their inner surface.
[0349] If a removable clamp is required, clamp 2070 in FIG. 34 would be preferred. Alternatively the flange of clamp 2070 could have non-directional serrations added to assist grip in either direction (not illustrated).
[0350] Alternatively, a clamp of style 2080 in FIG. 35 b , but having barbs oriented opposite to those on clamp 2080 would ensure the clamp is not over-tightened, as well as improve the likelihood that the clamp could always be removed (not illustrated).
[0351] FIG. 36 illustrates a side perspective view of a syringe holder with an engagement portion to enable releasable engagement with a medical injector and sensing system to detect the presence of the syringe. Syringe holder 200 is engaged in injector nose 10 of the medical injector (not shown). Bayonet posts 3010 and a blocking member (holder lock post 3015 ) on injector nose 10 form part of the engagement mechanism between syringe holder 200 and the injector. Syringe 300 is loaded into holder 200 and retained by catch 500 . The injector nose 10 has a sensor or switch 3110 for sensing the presence of a syringe in holder 200 . According to the embodiment illustrated, it is an optical sensor.
[0352] Holder lock post 3015 is adjacent to syringe sensor 3110 and therefore syringe holder 200 cannot be removed whilst a syringe is installed, nor during an injection. Additionally, a syringe cannot be installed unless holder 200 is locked fully (in this case clockwise). This embodiment is particularly useful in the absence of a sensor to verify syringe presence. It will be appreciated that holder 200 could not be attached if a syringe were already installed.
[0353] To engage syringe holder 200 with injector nose 10 , the holder is first inserted into the nose and with gentle inwards pressure, rotated until grooves 3020 (as shown in FIG. 37 a ) engage bayonet posts 3010 . At this point holder 200 fully enters the nose 10 , and the holder is rotated to lock it in place. Whilst 3 bayonet groove/post sets are illustrated spaced evenly around the circumference, they could also be oriented at matching odd angles so that the holder can only engage in a particular orientation. Seal 3145 could be a simple O-ring or wiper ring, and has 2 important roles:
(a) prevent fluids from entering the injector (b) provide a friction means to decrease the possibility of inadvertent removal of the holder.
[0356] FIGS. 37 a - d and 38 a-e illustrate several views of a syringe holder with a bayonet attachment 3010 , a blocking member (holder lock post 3015 ), loaded syringe and sensing system to detect the presence of a syringe. Injector nose 10 is fitted with a fluid seal 3145 , a spring stop ring 3140 against which syringe flag spring 3130 abuts. A syringe stop and plunger bush 3135 sits within injector nose 10 and syringe 300 briefly engages bush 3135 to limit movement of the syringe 300 towards the medical injector. Bush 3135 has at least one groove 3150 in which tabs 3122 (as depicted in FIG. 37 c ), are slidingly engaged. Spring 3130 is compressed during assembly between stop ring 3140 and Tabs 3122 on Flag 3120 , thereby biasing Flag 3120 forward (to the right). With no syringe installed Tabs 3122 rest against Bush 3135 , and the pointed tip of Flag 3120 protrudes to the right of bush 3135 .
[0357] Syringe holder 200 with grooves 3020 are introduced into injector nose 10 and the groove is engaged with pins 3010 and rotated to thereby lock it in place. When syringe barrel 300 is inserted into holder 200 , it depresses syringe flag 3120 and thus pushes tabs 3122 of the flag against spring 3130 . Biased catch 500 snaps shut and locks syringe 300 in place within the holder.
[0358] Holder lock post 3015 is of similar width to, and mounted on the same axis, as flag 3120 . As holder 200 is attached, flag 200 almost touches it (the lock post?) when bayonet slots 3020 are fully engaged with posts 3010 (without rotating). In the mounted position, with a syringe installed and flag 3020 pushed back, holder 200 cannot be rotated the wrong way (in the present case anti-clockwise) because the flag 200 will engage the lock post 3015 and thereby prevent rotation of the holder 200 within the injector nose 10 .
[0359] Flag 3120 has a beveled tip 3124 to engage syringe 300 and thereby grip it to minimize rotational movement. The movement of flag 3120 towards the injector triggers sensor 3110 which thereby creates a signal to the effect that a syringe is present in the holder.
[0360] In the present case, sensor 3110 is a combination light emitter and detector sensing light reflected off the metallic surface of Flag 3120 . The signal created may go to a controller which thereby integrates the information and controls the movement of the syringe plunger 130 . For example, the controller may restrict movement of the plunger until after the sensor creates a signal that a syringe is present. When syringe 300 is removed from holder 200 , spring 3130 pushes flag 3120 away from sensor 3110 and thereby eliminates the reflections.
[0361] During assembly of holder 200 onto injector nose 10 , bush 3135 and spring stop 3140 are normally fixed in place inside the holder by means of cement, screws, or pins. Both stops have a small longitudinal groove 3150 in their outer surfaces to support slidable syringe flag 3120 which, together with flag spring 3130 , are held in place by bush 3135 and stop 3140 . Spring 3130 is lodged between spring stop 3140 and tabs 3122 , thereby biasing the flag forward. With no syringe loaded, flag 3120 protrudes forward of the syringe stop 3135 , and its tabs lodge against the rear of the syringe stop. A secondary function of the syringe stop is to bear and centre the plunger, and prevent stray fluid around the syringe from entering the injector.
[0362] In brief, the Syringe Flag device has 3 main functions:
1. Syringe ejector: Flag 3120 is slidably mounted in groove 3150 , and is biased forward by flag spring 3130 . As syringe 300 is loaded into holder 200 the rear rim strikes the flag, pushing it rearward and compressing the spring until the tip of the flag is flush with bush 3135 . When catch 500 is opened, syringe 300 is partially ejected forward by the flag, making the syringe easier to grasp and remove. 2. When a tube is attached to the syringe (after it has been loaded), the operator needs to twist the connection to engage and lock the connection to the syringe thread. To restrain the syringe from rotating it would ordinarily need to be held with the other hand. However flag 3120 can perform this role. The forward tip 3124 of flag 3120 is beveled & sharp like a chisel, digging into the syringe a little, thereby restraining rotation of the syringe. 3. The flag assists detection of the presence of a syringe in holder 200 . Reflective infrared sensors such as Sharp GP2L24 are readily available types of sensors 3110 . As the flag is pushed back by the syringe the reflective rear end of the flag is detected by the sensor, which in turn signals the controller. Those familiar with the art will appreciate that various other forms of detection or mechanical switching could be used to sense movement of the Flag 3120 .
[0366] FIGS. 39 a & b illustrate cross sectional views of a syringe in a syringe holder demonstrating a particularly preferred embodiment of the engagement mechanism between the hub and plunger.
[0367] Plunger 3600 is slidingly engaged with actuation member 3610 but with a limited free play between them due to space 3625 . Note also that free sliding of plunger 3600 is somewhat subdued by the seal 3146 . Whenever drive member 3500 and actuation member 3610 reverse direction, plunger 3600 does not move until space 3625 is traversed. Actuation member 3610 and its associated cone 3650 operate pins 3640 to automatically engage or disengage hub 310 at the appropriate time.
[0368] Holder 200 is engaged in injector nose 10 . Syringe 300 has been fitted into holder 200 . FIG. 39 a demonstrates this embodiment in the situation where the plunger is expelling fluid from the syringe. Shoulder 3520 of plunger drive 3500 engages and pushes plunger 3600 and actuation member 3610 which is disposed within a bore in plunger 3600 . Actuation member 3610 has a rod portion 3165 [not seen; labeled in FIG. 39 ] and a nose portion 3650 which is cone shaped. The forward movement of nose portion 3650 allows locking members in the form of pins 3640 which are biased by spring 3660 to retract from engagement with the engagement portion of hub 310 . Thus hub 310 is automatically unlocked during and following forward movement of plunger 130 . The purpose of unlocking the hub is to allow removal of the used syringe following an injection.
[0369] On retraction of plunger drive 3500 , shoulder 3520 of plunger drive 3500 withdraws from the rear edge of plunger 3600 and thereby actuation member 3610 is drawn away from hub 310 . Plunger 3600 is momentarily stationary, causing nose portion 3650 to slide along pins 3640 and thereby force them to extend from plunger 3600 and engage the engaging portion of the hub 310 . Shoulder 3630 on actuation member 3610 traverses space 3625 and engages shoulder 3620 in the bore and enables nose portion 3650 to be positioned alongside pins 3640 by stopping actuation member 3610 from moving relatively further away from them. Thus hub 310 is automatically retained during and following retraction movement of plunger drive 3500 , enabling retraction of the hub, and filling of the syringe.
[0370] Hence this system automatically ensures that the hub is either locked or unlocked at the appropriate time, avoiding inconvenience and enhancing safety of the injector—for the operator and the patient. Of course, the Controller must be programmed to allow for the inherent free play whenever the plunger reverses direction.
[0371] FIG. 40 illustrates a longitudinal cross sectional view of a plunger and hub demonstrating a preferred embodiment of the sensor to detect engagement between the hub and plunger. Syringe 300 has a hub 310 slidingly disposed within it. Sensor 3300 is a light sensor with an optical fibre cable 3350 which is partially embedded in plunger 130 . Optical fibre 3350 has an exposed end 3355 which is flush with the surface of plunger 130 and detects incident light 3360 which passes through transparent syringe 300 . Incident light is then transmitted 3365 along optical cable 3350 . When plunger 130 has fully engaged hub 310 , which is opaque, incident light will not be able to hit the end of optical cable 3350 . Therefore, the light sensor 3360 will detect the absence of light and create an appropriate signal. Of course, if the room lights are inadequate for the sensor to operate, the Plunger can be illuminated by the injector with visible or infrared light.
[0372] This signal may be sent to a controller via cable 3370 to enable further control over the movement of plunger 130 . For example, it may allow plunger 130 to automatically stop upon full engagement with hub 310 without thereby causing hub 310 to be moved forward. According to this embodiment, since the aperture at the end of the optic fibre is small, then the ambient light is cut off abruptly as the plunger enters the hub, and so the accuracy and predictability of the system is enhanced. Similarly, because of the high contrast between the engaged and non-engaged states, the level of ambient or illuminated light is not critical.
[0373] FIGS. 41 & 42 illustrate one embodiment of the medical injector with tilt switches in the injecting and filing positions. Injector Head 4000 contains the control and drive elements of the Injector and is mounted at Head Pivot 4050 to Injector Pedestal 4100 , which preferably stands on a wheeled base (not shown). Head 4000 is able to tilt about the pivot by at least 90 degrees.
[0374] A small Switch Tab 4030 extends from Injector Pedestal 4030 . Switches 4010 and 4020 are fixed to the head in such positions as to strike the Switch Tab at the opposing positions of DOWN ( 4020 ) and UP ( 4010 ), at which points the appropriate switch changes state, and communicates to the Control circuitry (not shown) the orientation of head 4000 . These communications can be used to initiate or inhibit a plurality of functions, operations, displays, responses, and/or safeguards in the injector.
[0375] Those familiar with the art will appreciate that various alternate sensors could be used in place of Switches 4010 and 4020 , such as magnetic, optical, or mechanical. It will also be noted that a plurality of Tabs and Switches may be used to sense multiple orientations of the head.
[0376] It should also be noted that the above concepts operate without regard to earth's gravitation.
[0377] It will be understood by those familiar with the art that the inventions described above could be applied to any standard male luer locking connector, as found on many medical and other devices. It will also be understood that various combinations of outer and inner surfaces, combined with any of the above mentioned rear ends or flanges are possible, depending on the application.
[0378] The word ‘comprising’ and forms of the word ‘comprising’ as used in this description do not limit the invention claimed to exclude any variants or additions.
[0379] Modifications and improvements to the invention will be readily apparent to those skilled in the art. Such modifications and improvements are intended to be within the scope of this invention.
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Aspects of a syringe for use with a medical injector system. The hub having an outer surface adapted to slidingly engage with a barrel of the syringe, and an inner surface having a substantially annular engaging portion adapted to be releasably engaged by a plunger to permit the hub to be selectively withdrawn along the barrel by the plunger.
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RELATED APPLICATION
[0001] This application is a continuation of, and claims the benefit of, U.S. patent application Ser. No. 11/089,170 to Arthur Geringer, et al., which claims the benefit of provisional application Ser. No. 60/557,862 to Geringer et al. filed on Mar. 30, 2004.
[0002] U.S. patent application Ser. No. 11/089,170 is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to door locks, and in particular to electric door locks that can be operated in both the fail-safe and fail-secure mode.
[0005] 2. Description of the Related Art
[0006] Security doors to prevent theft or vandalism have evolved over the years from simple doors with heavy duty locks to more sophisticated egress and access control devices. Hardware and systems for limiting and controlling egress and access through doors are generally utilized for theft-prevention or to establish a secured area into which (or from which) entry is limited. For example, retail stores use such secured doors in certain departments (such as, for example, the automotive department) which may not always be manned to prevent thieves from escaping through the door with valuable merchandise. In addition, industrial companies also use such secured exit doors to prevent pilferage of valuable equipment and merchandise.
[0007] One type of door lock which has been used in the past to control egress and access through a door is an electromagnetic system which utilizes an electromagnet mounted on a door jamb, with an armature mounted on the door held by the electromagnet to retain the door in the closed position when the electromagnet is actuated. Such locking mechanisms are illustrated in U.S. Pat. No. 4,439,808, to Gillham, U.S. Pat. No. 4,609,910, to Geringer et al., U.S. Pat. No. 4,652,028, to Logan et al., U.S. Pat. No. 4,720,128 to Logan, Jr., et al., and U.S. Pat. No. 5,000,497, to Geringer et al. All of these references utilize an electromagnet mounted in or on a door jamb and an armature on the door held by the electromagnet to retain the door in the closed position. Such electromagnetic locking systems are quite effective at controlling egress and access through the door they are installed on. Unfortunately, however, such systems are quite expensive, and require a fairly complex installation, often with the electromagnet being mounted in the door jamb.
[0008] Another type of system which is known in the art is the electric door strike release mechanism, in which a latch bolt located in and extending from a locking mechanism located in a door is receivable in an electrically operable door strike mounted in the frame of the door. The door may be opened either by retracting the latch bolt into the locking mechanism to thereby disengage it from the door strike, or by electrically actuating the door strike mechanism to cause it to open and to thereby release the extended latch bolt from the door strike mechanism. Typically, such electrically operable door strikes pivot to allow the door to close without the door strike mechanism being electrically actuated. Such door strike mechanisms are illustrated in U.S. Pat. No. 4,017,107, to Hanchett, U.S. Pat. No. 4,626,010, to Hanchett et al., and in U.S. Pat. No. 5,484,180, to Helmar. Like the electromagnet/armature systems discussed above, electrically operated door strike systems are also expensive, and require a significant installation into the door jamb, which must usually be reinforced.
[0009] Electrically operable door locks have also been developed that can be installed on a door through which access is to be controlled by an electrically operable security system. Such a lock is disclosed in U.S. Pat. No. 5,876,073 to Geringer et al. The door opening mechanism of the door lock is selectively locked and unlocked by controlling the supply of electricity to the door lock to thereby control access or egress through the door. The electrically operable door lock uses an electromagnetic actuator to drive a locking member between a locked position in which it engages a latch actuating member to prevent it from being rotated to retract a latch bolt to open a door, and an unlocked position in which it is disengaged from the latch actuating member to allow it to be rotated to retract the latch bolt to open the door. By reversing the position of the electromagnetic actuator in the door lock apparatus, the system may operate in either a fail secure mode in which the electromagnetic actuator must be powered to unlock the door, or a fail safe mode in which the electromagnetic actuator must be powered to lock the door.
SUMMARY OF THE INVENTION
[0010] One embodiment of an electric door lock according to the present invention is interchangeable between fail safe and fail secure modes and comprises a housing for receiving a plurality of internal components of the door lock. A window is included in the housing, the window allowing access to the internal components to change the operation of the lock between fail safe and fail secure modes.
[0011] Another embodiment of an electric door lock according to the present invention that is interchangeable between fail safe and fail secure modes also comprises a housing for receiving a plurality of internal components of the door lock. The housing has a removable cover plate. A switching mechanism is included for altering the internal components to change the operation of the lock between fail safe and fail secure modes without removing the cover plate.
[0012] These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of one embodiment of a lock according to the present invention with its cover removed so that its internal components are visible;
[0014] FIG. 2 is a plan view of one embodiment of a lock according to the present invention with its cover removed so that its internal components are visible;
[0015] FIG. 3 is a plan view of a portion of the locking arm and cam mechanism shown in FIGS. 1 and 2 ;
[0016] FIG. 4 is a plan view of one embodiment of a cover plate according to the present invention;
[0017] FIG. 5 is a perspective view of one embodiment of a locking arm according to the present invention.
[0018] FIG. 6 is a perspective view of one embodiment of a locking arm and solenoid arrangement according to the present invention;
[0019] FIG. 7 is a perspective view of one embodiment of a lock according to the present invention with its cover in place; and
[0020] FIG. 8 is a perspective view of a door utilizing a lock according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The inventions herein are described with reference to a particular lock but it should be understood that the inventions can be similarly used in other types of locks and other devices unrelated to locks. The components described herein can have many different shapes and sizes beyond those shown and can be arranged in many different ways beyond those described herein.
[0022] One embodiment of a fail safe/fail secure lock according to the present invention comprises an electrically operable lock that can be changed to operate in either the fail safe mode or fail secure mode. It is generally understood in the industry that the fail safe mode of a lock describes a mode wherein the door can be opened by the lock doorknob when power to the lock is turned off or interrupted (i.e. power failure). Conversely, the fail secure mode describes a mode wherein the door cannot be opened by the doorknob when power to the lock is off or lost.
[0023] The lock generally comprises a lock housing holding the lock's internal components, which include a mechanism for allowing the lock to be changed between the fail safe and fail secure modes. In conventional locks, changing between the fail safe and fail secure modes requires opening the housing, such as by removing the cover, to access the internal components and manipulating the internal components. This can be an overly complex and inconvenient procedure and can result in damage to the internal components or lost internal components. Locks according to the present invention comprise a mechanism for allowing the lock to be changed without opening the lock housing. Different mechanisms can be used according to the present invention, with one mechanism being an access window that allows access to a limited section of the lock's internal components. The internal components can be accessed through the window to change the lock between fail safe and fail secure modes. The window and the lock's internal components are also arranged such that they remain secure and will not fall out of the lock housing through the access window. The lock also includes internal components that allow for improved reliability and extended life.
[0024] It will be understood that when an element is referred to as being “on”, “connected to”, “coupled to” or “in contact with” another element or layer, it can be directly on, connected or coupled to, or in contact with the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on”, “directly connected to”, “directly coupled to” or “directly in contact with” another element or layer, there are no intervening elements or layers present.
[0025] FIGS. 1 and 2 show one embodiment of a lock 10 according to the present invention that can be quickly and easily changed to operate in either the fail safe or fail secure mode, without opening the housing. The lock 10 generally comprises a housing 12 that can be many different shapes and sizes, but has a height, width and depth so that it can be mounted within a door and is large enough to securely hold the lock's internal components described below. The housing can be made of many different rigid and durable materials, with a preferred material being a metal. The housing 12 is shown in FIGS. 1 and 2 with its cover plate removed so that the internal lock components are shown to facilitate explanation of the operation of the lock's internal components. The lock 10 in FIG. 1 is also shown with a portion of the back of housing cutaway so that the internal components can be viewed for ease of explanation. It is understood, however, that when the lock 10 is finally assembled (as shown in FIG. 7 ), the housing is complete with its cover plate installed such that the housing 12 and its cover plate surround and hold the internal lock components.
[0026] The housing 12 comprises a back plate 13 to which many of the lock's internal components are mounted. The lock further comprises a front plate 14 that is arranged so that when the lock 10 is installed in the door, the front plate 14 is flush with the leading edge of the door. A latch bolt 16 is mounted within the housing 12 and a pivotally mounted retraction lever 18 is also mounted within the housing 12 in proximity to the latch bolt 16 . A doorknob or opening lever (“doorknob”) can be mounted to the lock 10 at the retraction lever 18 such that rotation of the doorknob causes rotation of the retraction lever 18 . In most embodiments an inside and outside doorknob can be mounted to the retraction lever 18 with the doorknobs being on opposite sides of the lock 10 . The latch bolt 16 is urged to the extended position by the bias of latch bolt spring 24 , and the retraction lever 18 has a retraction finger 20 that is mechanically coupled to the latch bolt rod 22 so that rotational movement of the retraction lever 18 overcome the bias of spring 24 . This in turn causes the latch bolt 16 to retract into the housing 12 .
[0027] As shown, the front portion of the latch bolt 16 extends through a bolt opening 26 in the front plate 14 in its extended position and is arranged to engage a strike plate (not shown) in a door frame. The latch bolt 16 can also be retracted as described above so that all or most of the latch bolt's front portion is retracted into the housing 12 . In normal use, door lock 10 is mounted in a door to allow a user to operate a doorknob and the latch bolt 16 to release the door. When the door is locked by the door lock 10 the latch bolt 16 extends from front plate 14 to engage a strike plate (shown in FIG. 8 ). When the door can be opened, the latch bolt 16 is retracted and disengages from the strike plate.
[0028] An auxiliary latch 28 is mounted within the housing 12 parallel to the latch bolt 16 , and comprises a front portion that extends from auxiliary latch opening 30 in the front plate 14 . The auxiliary latch 28 is urged by the auxiliary latch spring 32 to the extended position, and the auxiliary latch 28 can be moved to a retracted position within the housing 10 , against the force of spring 32 , by a force applied to the end of auxiliary latch 28 . In operation, the auxiliary latch 28 and spring 32 cooperate to hold the latch bolt 16 at a predetermined position. In one embodiment according to the present invention, the auxiliary latch 28 is arranged such that when in its retracted position, the latch bolt 16 can only be retracted by the inside doorknob and the key cylinder. When the auxiliary latch 28 is in its extended position the latch bolt 16 can be retracted. In operation, when the door is closed, the auxiliary latch 28 can be compressed by the frame of the door or the strike plate, and holds the latch bolt 16 at its extended position such that the latch bolt 16 is blocked against operation driven by the outside doorknob.
[0029] A key cylinder (not shown) can be mounted within cylinder opening 34 and a bolt lever 36 extends between the latch bolt rod 22 and the key cylinder. Operation of the key cylinder causes the bolt lever 36 to move about a bolt lever pin 38 such that when the proper key is inserted in the key cylinder and rotated, the bolt lever 36 is rotated about the bolt lever pin 38 . When the end of the bolt lever 36 at the latch bolt 16 moves away from the front plate 14 , the bolt lever 36 operates on the latch bolt 16 such that the latch bolt 16 retracts into the lock housing 12 .
[0030] The lock 10 also comprises a solenoid 40 , a locking arm 42 , and a locking cam 44 , all of which cooperate to allow or block the retraction lever 18 from operating under force of doorknob to retract the latch 16 . This allows the lock 10 to operate in the fail safe and fail secure modes. The retraction lever 18 has a locking tab 46 that mates with a locking slot 48 in the locking cam 44 . When the locking tab 46 is mated with the locking slot 48 , the retraction lever 18 is blocked from retracting the latch bolt 16 . Conversely, when the locking tab 46 is not mated with the locking slot 48 the retracting lever can retract the latch bolt 16 .
[0031] The solenoid 40 is mounted near the top of the housing 10 at a solenoid holder 50 . The solenoid 40 comprises a solenoid body 52 and a plunger 54 , with the solenoid body 52 having an internal coil (not shown) that can be energized to create a magnetic field that operates to pull the plunger 54 within the solenoid body 52 . The plunger 54 also comprises a plunger tip 56 with a plunger spring 58 arranged on the plunger 54 , between the plunger tip 56 and solenoid body 52 . When the solenoid 40 is energized, the plunger is drawn into the solenoid body 52 against the force of the spring 58 , compressing the spring 58 between the solenoid body 52 and the plunger tip 56 . When the solenoid 40 is not energized (such as in a power failure) the coil is not energized and the plunger 54 at least partially extends from the solenoid body 52 under force of the spring 58 .
[0032] The plunger 54 is connected to one end of the locking arm 42 and as the plunger 54 goes though the movement of being drawn into and extending from the solenoid body 52 , the locking arm 42 is pulled toward or pushed away from the solenoid body 52 . First and second bushings 57 a and 57 b (shown in FIG. 2 ) are arranged within the housing 12 and adjacent to the locking arm 42 so that the locking arm 42 is substantially prevented from sliding toward the front plate 14 . Instead, its primary motion is sliding back and forth under the force of, and in relation to, the solenoid 40 .
[0033] The locking arm 42 is connected between the plunger 54 and the locking cam 44 and the locking arm 42 cooperates with the locking cam 44 to allow the lock 10 to operate in either the fail safe or fail secure mode. The locking arm 44 and locking cam 42 have cooperating switching mechanisms that can be manipulated to change the operation of the lock between fail safe and fail secure modes depending upon how the locking arm 42 is connected to the locking cam 44 . Many different mechanisms can be utilized according to the present invention, and in one embodiment, the locking cam 44 has a slot that can be engaged by locking arm 42 using different engagement mechanisms, such as a screw, pin, rod, clamp, etc. The locking arm 42 has two engagement locations for mounting the engagement mechanism, with one of the two locations allowing engagement with the slot for operation of the lock in fail safe mode and the other for operation in the fail secure mode.
[0034] In one embodiment according to the present invention, and as shown in FIGS. 1 and 2 , the two engagement locations on the locking arm 42 comprise a threaded fail safe hole 60 and a threaded fail secure hole 62 . The engagement mechanism comprises a slot screw 64 that is also threaded to mate with the holes 60 , 62 . The holes 60 , 62 are arranged over a V-shaped slot 66 in the locking cam 44 such that when the slot screw 64 is threaded into one of the holes 60 , 62 , the screw 64 passes into the slot 66 .
[0035] Operation of the solenoid 50 causes the locking arm 42 to move forward and back with the action of the solenoid plunger 54 , which in turn causes the screw 64 to slide within slot 66 . As described above, the locking arm 42 does not substantially move toward the front plate 14 so that the sliding action of the screw 64 in the slot 66 causes the locking cam 44 to move forward and back in relation to the front plate 14 . When the screw 64 is in the fail safe hole 60 as shown in FIG. 1 , and power is off to the solenoid (or there is a power failure), the plunger 54 extends from the solenoid body 52 under the force of the spring 58 and the locking arm 42 is pushed toward the bottom plate of the housing 12 . At the same time, the screw 64 slides within the slot 66 , moving the locking cam 44 away from the front plate 14 . This action moves the retraction lever's locking tab 46 out of the cam's locking slot 48 , which in turn allows the retraction lever 18 to operate to retract the latch bolt 16 . Accordingly, in this arrangement the lock 10 operates in fail safe mode by allowing the lock to operate when power is off or lost.
[0036] Referring now to FIG. 3 , the screw 64 is threaded into the fail secure hole 62 . When power is off or there is a power failure, the locking arm is pushed down by the plunger 54 . This causes the screw 64 to slide in the slot 66 , but instead of moving the cam 44 away from the front plate 14 , the cam is pushed toward the front plate. This causes the locking tab 46 to mate with the locking slot 48 , which prevents the retraction lever 18 from retracting the latch bolt 16 . In this arrangement the lock 10 operates in fail secure mode by not allowing the lock to operate when power is off or lost.
[0037] FIG. 4 shows one embodiment of a lock cover plate 70 according to the present invention that is arranged to fit over the lock 10 such that the housing 12 and cover plate 70 provide an enclosure for the lock's internal components. The plate comprises a key cylinder opening 72 so that a key can operate on the key cylinder, and a doorknob opening 74 so that a doorknob can be mounted to the retraction lever. The plate 70 also comprises several smaller holes 76 that can be used for mounting or to hold pins within the lock 10 .
[0038] The plate 70 also comprises an access window 78 that is arranged over the screw 64 , and the fail safe and fail secure holes 60 , 62 (shown in FIGS. 1-3 ). The holes 60 , 62 can be accessed through the window so that the screw 64 can be threaded into one of the holes without removing the plate 70 . Similarly, the screw 62 can be removed from one of the holes 60 , 62 through the window 78 and turned into the other of the holes 60 , 62 . This allows the lock 10 to be quickly and easily changed between the fail safe and fail secure modes without removing the front plate. This also allows the mode of the lock to be changed without the danger of damaging or misplacing the lock's internal components.
[0039] In one embodiment according to the present invention, the window is sized so that the screw 64 can be removed by a screwdriver or other similar tool. Other embodiments according to the present invention can have different sized windows, such as a window large enough to remove the screw using a larger tool, or by hand. In still other embodiments, the cover plate can have more than one window, such as two windows allowing the screw 64 to be removed from one of the holes through one window and inserted into the other hole through the second window.
[0040] FIGS. 5 and 6 show one embodiment of a locking arm 80 according to the present invention, with the locking arm 80 coupled to the plunger 82 of a solenoid 84 as shown in FIG. 6 . Like the solenoid described above, solenoid 84 has a spring to bias the plunger 82 in the extended position when the solenoid is not energized (power off or failure). The plunger end 86 of the locking arm 80 attaches to the solenoid plunger 82 (shown in FIG. 1 ). At the other end, the locking arm comprises a tab 87 having fail safe and fail secure holes 88 , 90 as described in FIG. 1 . A linking section 92 extends between the plunger end 86 and tab 87 , and a stop 94 prevents the arm from extending too far down under action of the solenoid.
[0041] The locking arm 80 comprises an improvement over the prior art in that the prior locking arm comprises a surface that can be in contact with the lock's back (reference number 13 in FIGS. 1 and 2 ). This contact can cause a significant point of friction that can result in an added load to the operation of the solenoid. Any added load can reduce the life of a solenoid thereby reducing the overall life of the lock. The locking arm 80 contacts the back plate 13 along one edge 96 that results in much less friction between the arm 80 and back plate 13 . The locking arm 80 also has less mass compared to prior mechanisms, such that the solenoid 84 can more easily move the locking arm 80 compared to prior mechanisms. This results in a reduced load on the solenoid 84 , which further enhances reliability and lifespan of the solenoid 84 .
[0042] FIG. 7 shows one embodiment of a lock 100 according to the present invention after the cover plate 102 has been mounted in place to the lock housing 104 . The cover plate 102 has an access window 106 which allows for the lock 100 to be changed between the fail safe and fail secure modes as described above by changing the location of the slot screw between the fail safe and fail secure holes. In this embodiment, this is accomplished by accessing the slot screw with a screwdriver through the access window 106 . This is typically done before the lock 100 is installed in a door. The lock is then installed in a door and connected to electrical conductors that carry a power and control signals to control whether the lock can be opened. When power from the conductors is off or lost, a fail condition exists and depending on the location of the slot screw, the lock will either be “safe” to be operated to open its door, or “secure” such that it cannot be operated to open its door.
[0043] FIG. 8 shows one embodiment of a door system 110 that can utilize a lock according to the present invention. The door system 110 comprises a door 112 mounted in a door frame, usually by hinges, such that the door 112 can swing open and closed on the hinges. A lock 116 according to the present invention, is mounted in the door 112 such that the lock's front plate 118 is flush with the door's leading edge 120 . The latch bolt extends from the lock 116 and door 112 though the front plate 118 and is arranged to engage a strike plate 124 in the door frame 114 to hold the door closed. Electrical power and control signals are transmitted over conductors 126 that typically run from the door system controller (not shown), through the door frame 114 near the hinges, through the door 112 and into the lock 116 . The lock 116 is configured to work in the fail safe or fail secure mode such that when power to the lock is interrupted, the lock will either be operable or not. If the lock is in the fail safe mode and door 112 is closed with the latch bolt 122 engaging the strike plate at the time power is interrupted, the lock will be operable at the handle 126 to open the door. If it is in the fail secure mode when power is interrupted, the handle 126 will not be operable to open the door 112 .
[0044] Although the present invention has been described in considerable detail with references to certain preferred configurations thereof, other versions are possible. The invention can be used in different locks and different components can be used in the locks described above. Many different solenoids can be used in the lock including single or multiple stage coils that are operable with different voltages, such as 12 or 24 volts. The steps taken above to interchange the lock between fail safe and fail secure modes can be taken in different order and different steps can be used. Therefore the spirit and scope of the claims should not be limited to the preferred version contained herein.
|
An electric door lock interchangeable between fail safe and fail secure modes comprising a housing for receiving a plurality of internal components of the door lock. A window is included in the housing, the window allowing access to the internal components to change the operation of the lock between fail safe an fail secure modes.
| 4
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PRIORITY
[0001] This application claims the benefit of priority of U.S. Provisional Patent Application No. 61/176,503, filed May 8, 2009, the contents of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to lipid compounds of the general formula (I):
[0000]
[0000] wherein
R 1 is a C 10 -C 22 alkyl group, a C 10 -C 22 alkenyl group having 1-6 double bonds, or a C 10 -C 22 alkynyl group having 1-6 triple bonds; R 2 and R 3 are the same or different and may be chosen from a hydrogen atom, a hydroxy group, an alkyl group, a halogen atom, an alkoxy group, an acyloxy group, an acyl group, an alkenyl group, an alkynyl group, an aryl group, an alkylthio group, an alkoxycarbonyl group, a carboxy group, an alkylsulfinyl group, an alkylsulfonyl group, an amino group, and an alkylamino group, with the proviso that R 2 and R 3 cannot both be a hydrogen atom; or R 2 and R 3 together form a cycloalkyl group, such as cyclopropane, cyclobutane, cyclopentane, or cyclohexane; X is a carboxylic acid or a derivative thereof, such as, a carboxylic ester, a carboxylic anhydride, carboxamide, phospholipid, monoglyceride, diglyceride, or triglyceride;
or a pharmaceutically acceptable salt, solvate, solvate of such salt or a prodrug thereof.
[0007] In embodiments where R 2 and R 3 are different, the compounds of formula (I) are capable of existing in stereoisomeric forms. It will be understood that the invention encompasses all optical isomers of the compounds of formula (I) and mixtures thereof.
[0008] The present disclosure also relates to pharmaceutical compositions and lipid compositions comprising at least one compound of formula (I). In addition, the present disclosure includes compounds of formula (I) for use as medicaments or for use in therapy, such as for the treatment of diseases related to the cardiovascular, metabolic, and inflammatory disease areas.
BACKGROUND
[0009] Dietary polyunsaturated fatty acids (PUFAs) have effects on diverse physiological processes impacting normal health and chronic diseases, such as the regulation of plasma lipid levels, cardiovascular and immune functions, insulin action, neuronal development and visual function.
[0010] Due to their limited stability in vivo and their lack of biological specificity, PUFAs have not achieved widespread use as therapeutic agents. Chemical modifications of the n-3 polyunsaturated fatty acids have been performed by several research groups in order to change or increase their effects.
[0011] For example, the hypolipidemic effects of (4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaenoic acid (DHA) was potentiated by introducing a substituent in the α-position of (4Z,7Z,10Z,13Z,16Z,19Z)-ethyl docosa-4,7,10,13,16,19-hexaenoate (DHA EE). (WO 2006/117664) It is reported that obese, high fat-fed mice treated with alpha-substituted DHA derivatives prevented and reversed obesity and glucose intolerance. (Rossmeisl, M., et al., Obesity (Silver Spring) 2009 Jan. 15.)
[0012] Several research groups have prepared unsaturated fatty acids with oxygen incorporated in the β-position (Flock, S. et al., Acta Chemica Scandinavica, (1999) 53: 436 and Pitt, M J, et al., Synthesis, (1997) 1240-42).
[0013] A novel group of fatty acid derivatives combining an oxygen atom in β-position with a α-substituents represented by the general formula (I) has been developed. These novel fatty acids reduce lipid levels in a dyslipidemic mice model to a greater extent than naturally occurring polyunsaturated fatty acids.
DESCRIPTION OF THE FIGURES
[0014] FIG. 1 : Cholesterol and triglyceride levels in APOE*3Leiden mice after administration of one embodiment of the present disclosure and Omacor™.
[0015] FIG. 2 : Cholesterol and triglyceride levels in APOE*3Leiden.CETP mice after administration of one embodiment of the present disclosure and fenofibrate.
[0016] FIG. 3 : HDL levels in APOE*3Leiden.CETP mice after administration of one embodiment of the present disclosure and fenofibrate.
SUMMARY
[0017] One object of the present disclosure is to provide lipid compounds having improved biological activity compared to naturally occurring polyunsaturated fatty acids. This object may be achieved by a lipid compound of formula (I)
[0000]
[0018] For example, the present disclosure relates to compounds of formula (I), wherein:
R 1 is a C 10 -C 22 alkyl group, a C 10 -C 22 alkenyl group having 1-6 double bonds, or a C 10 -C 22 alkynyl group having 1-6 triple bonds; R 2 and R 3 are the same or different and may be chosen from a hydrogen atom, a hydroxy group, an alkyl group, a halogen atom, an alkoxy group, an acyloxy group, an acyl group, an alkenyl group, an alkynyl group, an aryl group, an alkylthio group, an alkoxycarbonyl group, a carboxy group, an alkylsulfinyl group, an alkylsulfonyl group, an amino group, and an alkylamino group, with the provisio that R 2 and R 3 cannot both be a hydrogen atom; or R 2 and R 3 together can form a cycloalkyl group, such as cyclopropane, cyclobutane, cyclopentane, or cyclohexane; X is a carboxylic acid or a derivative thereof, such as, a carboxylic ester, a carboxylic anhydride, a carboxamide, a phospholipid, or a triglyceride;
or a pharmaceutically acceptable salt, solvate, solvate of such salt or a prodrug thereof.
[0023] In at least one embodiment, the alkyl group may be chosen from methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, and n-hexyl. The alkenyl group may be chosen from allyl, 2-butenyl, and 3-hexenyl. The alkynyl group may be chosen from propargyl, 2-butynyl, and 3-hexynyl. The halogen atom may be chosen from fluorine, chlorine, bromine, and iodine. The alkoxy group may be chosen from methoxy, ethoxy, propoxy, isopropoxy, sec-butoxy, phenoxy, benzyloxy, OCH 2 CF 3 , and OCH 2 CH 2 OCH 3 . The acyloxy group may be chosen from acetoxy, propionoxy, and butyroxy. The aryl group is a phenyl group. The alkylthio group may be chosen from methylthio, ethylthio, isopropylthio, and phenylthio. The alkoxycarbonyl group may be chosen from methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, and butoxycarbonyl. The alkylsulfinyl group may be chosen from methanesulfinyl, ethanesulfinyl, and isopropanesulfinyl. The alkylsulfonyl group may be chosen from methanesulfonyl, ethanesulfonyl, and isopropanesulfonyl. The alkylamino group may be chosen from methylamino, dimethylamino, ethylamino, and diethylamino. The carboxylate group may be chosen from ethyl carboxylate, methyl carboxylate, n-propyl carboxylate, isopropyl carboxylate, n-butyl carboxylate, sec-butyl carboxylate, and n-hexyl carboxylate. The carboxamide group may be chosen from carboxamides, such as N-methyl carboxamide, N,N-dimethyl carboxamide, N-ethyl carboxamide and N,N-diethyl carboxamide.
[0024] In at least one embodiment of the invention, one of the substituents R 2 and R 3 of the compound of formula (I) is hydrogen and the other one is chosen from a hydroxy group, an alkyl group, a halogen atom, an alkoxy group, an acyloxy group, an acyl group, an alkenyl group, an alkynyl group, an aryl group, an alkylthio group, an alkoxycarbonyl group, a carboxy group, an alkylsulfinyl group, an alkylsulfonyl group, an amino group, and an alkylamino group.
[0025] In another embodiment of the invention, the substituents R 2 and R 3 of the compound of formula (I) are the same or different and may be chosen from a hydroxy group, an alkyl group, a halogen atom, an alkoxy group, an acyloxy group, an acyl group, an alkenyl group, an alkynyl group, an aryl group, an alkylthio group, an alkoxycarbonyl group, a carboxy group, an alkylsulfinyl group, an alkylsulfonyl group, an amino group. For example, R 2 and R 3 may be chosen from methyl, ethyl, n-propyl, or isopropyl.
[0026] When derived or prepared from a polyunsaturated fatty acid, R 1 is typically a C 10 -C 22 alkenyl group with 3-6 double bonds, e.g. 3-6 methylene interrupted double bonds in Z configuration. For example, R 1 may be chosen from:
a C 1-5 alkenyl with 4 methylene interrupted double bonds in Z-configuration, a C 1-8 alkenyl with 3-5 double bonds, e.g. a C 1-8 alkenyl with 5 methylene interrupted double bonds in Z configuration, a C 20 alkenyl with 5 methylene interrupted double bonds in Z-configuration, or a C 22 alkenyl with 6 methylene interrupted double bonds in Z-configuration.
[0031] Furthermore, R 1 may be a C 10 -C 22 alkynyl group, e.g. a C 16 -C 22 alkynyl with 1-6 triple bonds.
[0032] The present disclosure also relates to salts of the compound of formula (I). Such salts may be represented by
[0000]
[0000] wherein X is COO − , and Z + may be NH 4 + , a metal ion such as Li + , Na + , or K + , a protonated primary amine such as tert-butyl ammonium, (3s,5s,7s)-adamantan-1-ammonium, 1,3-dihydroxy-2-(hydroxymethyl)propan-2-ammonium or a protonated aminopyridine (e.g., pyridine-2-ammonium), a protonated secondary amine such as diethylammonium, 2,3,4,5,6-pentahydroxy-N-methylhexan-1-ammonium, N-ethylnaphthalen-1-ammonium, a protonated tertiary amine such as 4-methylmorpholin-4-ium, a protonated guanidine such as amino((4-amino-4-carboxybutyl)amino)methaniminium or a protonated heterocycle such as 1H-imidazol-3-ium,
or by
[0000]
[0000] wherein X=COO − , and Z 2+ may be Mg 2+ or Ca 2+ , or a diprotonated diamine such as ethane-1,2-diammonium or piperazine-1,4-diium.
[0033] Another representative salt is
[0000]
[0000] wherein X is COO − , and Z n+ is protonated Chitosan:
[0000]
[0034] Furthermore, the present disclosure relates to compounds of formula (I), wherein X is a carboxylic acid in the form of a phospholipid. Such compounds may be represented by the following formulas (II-IV),
[0000]
[0000] wherein W is:
[0000]
[0000] wherein W is:
[0000]
[0000] wherein W is:
[0000]
[0035] Compounds of formula (I), wherein X is a carboxylic acid in the form of a triglyceride, a 1,2-diglyceride, a 1,3 diglyceride, a 1-monoglyceride and a 2-monoglyceride, are also included within the present disclosure. These are hereinafter represented by the formulas (V), (VI), (VII), (VIII) and (IX), respectively.
[0000]
[0036] The compounds of formula (I) are capable of existing in stereoisomeric forms. It will be understood that the invention encompasses all optical isomers of the compounds of formula (I) and mixtures thereof. Hence, compounds of formula (I) that exist as diastereomers, racemates, and enantiomers are included within the scope of the present disclosure.
[0037] The present disclosure also relates to at least one lipid compound according of formula (I) for use as a medicament.
[0038] In a further embodiment, the present disclosure provides a food supplement, a food additive, or a nutraceutical preparation comprising a lipid compound of formula (I).
[0039] Such a food supplement may be produced for administration through any route of administration. For example, the food supplement may be administered as a liquid nutritional or as a beverage.
[0040] The food supplement may be in the form of a capsule, e.g. a gelatin capsule, and the capsule may be flavoured.
[0041] In still a further embodiment, the present disclosure provides a pharmaceutical composition comprising at least one compound of formula (I), optionally together with one or more pharmaceutically acceptable carriers or excipients.
[0042] The novel lipid compounds and compositions of the disclosure may be formulated in conventional oral administration forms, e.g. tablets, coated tablets, capsules, powders, granulates, solutions, dispersions, suspensions, syrups, emulsions, and sprays, using conventional excipients, e.g. solvents, diluents, binders, sweeteners, aromas, pH modifiers, viscosity modifiers, antioxidants, corn starch, lactose, glucose, microcrystalline cellulose, magnesium stearate, polyvinylpyrrolidone, citric acid, tartaric acid, water, ethanol, glycerol, sorbitol, polyethylene glycol, propylene glycol, cetylstearyl alcohol, carboxymethylcellulose, or fatty substances, such as hard fat or suitable mixtures thereof. Conventional formulation techniques, well known in the art, may be used to formulate the lipid compounds according to the present disclosure.
[0043] The compositions may be administered by conventional administration routes, for example, orally. The use of orally administrable compositions, e.g. tablets, coated tablets, capsules, or syrups are included within the scope of this disclosure. For example, in some embodiments, the composition may be in the form of a gelatin capsule, a tablet, or a sachet.
[0044] A suitable daily dosage of the at least one compound according to formula (I) may range from about 1 mg to about 3 g. For example, in some embodiments, the daily dose ranges from about 1 mg to about 10 g, from about 50 mg to about 1 g, from about 10 mg to about 2 g, from about 50 mg to about 500 mg, from about 50 mg to about 200 mg, from about 100 mg to about 1 g, from about 100 mg to about 500 mg, or from about 100 mg to about 250 mg.
[0045] The pharmaceutical composition according to the present disclosure may be used as a medicament.
[0046] The present disclosure also relates to lipid compositions comprising at least one lipid compound according to formula (I). Suitably, the lipid composition may comprise at least 60% by weight, or at least 80% by weight of the at least one compound of formula (I).
[0047] The lipid composition may further comprise a pharmaceutically acceptable antioxidant, e.g. tocopherol or 3-BHA.
[0048] Further, the present disclosure relates to a lipid composition for use as a medicament.
[0049] Additionally, the present disclosure relates to the use of a lipid compound according to formula (I) for use in:
activation or modulation of at least one of the human peroxisome proliferator-activated receptor (PPAR) isoforms α, γ or δ, wherein said compound e.g. is a pan-agonist or modulator, the prevention or treatment of an inflammatory condition, the prevention or treatment of rheumatoid arthritis, the prevention or treatment of inflammatory bowel disease, the prevention or treatment of metabolic syndrome, the prevention and/or treatment of a dyslipidemic condition, e.g. hypertriglyceridemia (HTG), the prevention and/or treatment of elevated triglyceride levels, LDL cholesterol levels, and/or VLDL cholesterol levels, the treatment and/or the prevention of obesity or an overweight condition, the reduction of body weight and/or for preventing body weight gain, the treatment and/or the prevention of a fatty liver disease, e.g. non-alcoholic fatty liver disease (NAFLD), the treatment and/or the prevention of an inflammatory disease or condition, the treatment and/or the prevention of atherosclerosis, the treatment and/or the prevention of peripheral insulin resistance and/or a diabetic condition, the treatment and/or prevention of type 2 diabetes, or the reduction of plasma insulin, blood glucose and/or serum triglycerides.
[0065] The present disclosure also relates to lipid compounds according to formula (I) for the treatment of the above mentioned conditions, and to methods for the treatment and/or prevention of the conditions listed above, comprising administering to a mammal in need thereof a pharmaceutically effective amount of a compound according to formula (I).
[0066] In addition, the present disclosure encompasses methods for manufacturing lipid compounds of formula (I). The raw material may e.g. originate from a vegetable, a microbial and/or an animal source, such as a marine fish oil. In at least one embodiment marine oil or a krill oil is used.
DETAILED DESCRIPTION
[0067] The present inventors have found that compounds of formula (I) have remarkably good pharmaceutical activity.
[0068] As used herein, the term “lipid compound” relates to fatty acid analogues derived from e.g. saturated fatty acids, monounsaturated fatty acids, polyunsaturated fatty acids and lipids comprising 1-6 triple bonds. It is to be understood that derived from includes preparation of the compounds of formula (I) from fatty acids, such as saturated fatty acids, monounsaturated fatty acids, polyunsaturated fatty acids and lipids comprising 1-6 triple bonds. Such fatty acids may occur naturally or be synthetic.
[0069] A “pharmaceutically effective amount” relates to an amount that will lead to the desired pharmacological and/or therapeutic effects, i.e. an amount of the disclosed product which is effective to achieve its intended purpose. While individual patient needs may vary, determination of optimal ranges for effective amounts of the disclosed product is within the skill of the art. Generally, the dosage regimen for treating a condition with the disclosed product of this invention is selected in accordance with a variety of factors, including the type, age, weight, sex, diet and medical condition of the patient.
[0070] By “a pharmaceutical composition” is meant a lipid compound according to the present disclosure in any form suitable to be used for a medical purpose.
[0071] “Treatment” includes any therapeutic application that can benefit a human or non-human mammal. Both human and veterinary treatments are within the scope of the present disclosure. Treatment may be in respect of an existing condition or it may be prophylactic, for example, preventative.
[0072] Fatty acids are straight chain hydrocarbons possessing a carboxyl (COOH) group at one end (α) and (usually) a methyl group at the other (ω) end. In chemistry, the numbering of the carbon atoms starts from the α end.
[0000]
[0073] The α carbon refers to the first carbon after the carbon that attaches to the functional group, and the second carbon is the β carbon.
[0074] As used herein, the expression “methylene interrupted double bonds” relates to the case when a methylene group (—CH 2 —) is located between two double bonds in a carbon chain of a lipid compound.
[0075] More particularly, the inventors have surprisingly found that the following lipid compound categories A-D are particularly preferable.
Category A
[0000]
derived from saturated fatty acids
R 1 is a C 10 -C 22 alkyl
Example i:
R=C 14
[0078]
Category B
[0000]
derived from monounsaturated fatty acids
R 1 is a C 10 -C 22 alkenyl having 1 double bond
Example ii:
R 1 =C 18
[0081]
Example iii:
R 1 =C 14
[0082]
Category C:
[0000]
derived from polyunsaturated fatty acids
R 1 is a C 20 alkenyl having 5 double bonds
Example iv:
[0085] R 1 =C 20 with 5 methylene interrupted double bonds in Z-configuration
[0000]
Category D:
[0000]
derived from polyunsaturated fatty acids
R 1 is a C 22 alkenyl having 6 double bonds
Example v:
[0088] R 1 =C 22 with 6 methylene interrupted double bonds in Z-configuration
[0000]
Category E:
[0000]
derived from polyunsaturated fatty acids
R 1 is a C 18 alkenyl having 3 double bonds
Example vi:
[0091] R 1 =C 18 with 3 methylene interrupted double bonds in Z-configuration
[0000]
Category F:
[0000]
derived from polyunsaturated fatty acids
R 1 is a C 15 alkenyl having 4 double bonds
Example vii:
[0094] R 1 =C 15 with 4 methylene interrupted double bonds in Z-configuration
[0000]
Category G:
[0000]
derived from polyunsaturated fatty acids
R 1 is a C 18 alkenyl having 5 double bonds
Example viii:
R 1 =C 18 with 5 methylene interrupted double bonds in Z-configuration
[0000]
Category H:
[0000]
X is a carboxylic acid in the form of a triglyceride, diglyceride, monoglyceride or phospholipid
Example ix:
[0098] X=a carboxylic acid in the form of a triglyceride
[0000]
Example x:
[0099] X=a carboxylic acid in the form of a 2-monoglyceride
[0000]
Category I
[0000]
X is a carboxylate salt
Example xi:
[0101]
n=1 or 2
Category J
[0000]
derived from lipids comprising 1-6 triple bonds
R 1 is a C 10 -C 22 alkynyl
Example xii:
[0105] R 1 =C 14 with 1 triple bond
[0000]
[0106] The compounds of categories A-J above, where R 2 and R 3 are different, are capable of existing in stereoisomeric forms, i.e. all optical isomers of the compounds and mixtures thereof are encompassed. Hence, the said compounds may be present as diastereomers, racemates, and enantiomers.
[0107] Specific examples of preferred lipid compounds according to the present disclosure include:
Category A:
[0108]
2-(Tetradecyloxy)butanoic acid (1)
R 1 =C 14 H 29 , R 2 =ethyl, R 3 =H and X=COOH
[0000]
2-ethyl-2-(tetradecyloxy)butanoic acid (2)
R 1 =C 14 H 29 , R 2 =R 3 =ethyl and X=COOH
[0000]
2-(tetradecyloxy)propanoic acid (3)
R 1 =C 14 H 29 , R 2 =methyl, R 3 =H and X=COOH
[0000]
2-methyl-2-(tetradecyloxy)propanoic acid (4)
R 1 =C 14 H 29 , R 2 =R 3 =methyl and X=COOH
[0000]
2-methoxy-2-(tetradecyloxy)acetic acid (5)
R 1 =C 14 H 29 , R 2 =methoxy, R 3 =H and X=COOH
[0000]
2-ethoxy-2-(tetradecyloxy)acetic acid (6)
R 1 =C 14 H 29 , R 2 =ethoxy, R 3 =H and X=COOH
Category B:
[0115]
(Z)-2-(tetradec-6-en-1-yloxy)butanoic acid (7)
R 1 =C 14 H 27 , R 2 =ethyl, R 3 =H and X=COOH
[0000]
(Z)-2-ethyl-2-(tetradec-6-en-1-yloxy)butanoic acid (8)
R 1 =C 14 H 27 , R 2 =R 3 =ethyl and X=COOH
[0000]
(Z)-2-(tetradec-6-en-1-yloxy)propanoic acid (9)
R 1 =C 14 H 27 , R 2 =methyl, R 3 =H and X=COOH
[0000]
(Z)-2-methyl-2-(tetradec-6-en-1-yloxy)propanoic acid (10)
R 1 =C 74 H 27 , R 2 =R 3 =methyl and X=COOH
[0000]
(Z)-2-methoxy-2-(tetradec-6-en-1-yloxy)acetic acid (11)
R 1 =C 14 H 27 , R 2 =methoxy, R 3 =H and X=COOH
[0000]
(Z)-2-ethoxy-2-(tetradec-6-en-1-yloxy)acetic acid (12)
R 1 =C 14 H 27 , R 2 =ethoxy, R 3 =H and X=COOH
Category C:
[0122]
2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoic acid (13)
R 1 =C 20 H 31 , R 2 =ethyl, R 3 =H and X=COOH
[0000]
2-ethyl-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoic acid (14)
R 1 =C 20 H 31 , R 2 =R 3 =ethyl and X=COOH
[0000]
2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)propanoic acid (15)
R 1 =C 20 H 31 , R 2 =methyl, R 3 =H and X=COOH
[0000]
2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)-2-methylpropanoic acid (16)
R 1 =C 20 H 31 , R 2 =R 3 =methyl and X=COOH
[0000]
2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)-2-methoxyacetic acid (17)
R 1 =C 20 H 31 , R 2 =methoxy, R 3 =H and X=COOH
[0000]
2-ethoxy-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)acetic acid (18)
R 1 =C 20 H 31 , R 2 =ethoxy, R 3 =H and X=COOH
Category D:
[0129]
2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaen-1-yloxy)butanoic acid (19)
R 1 =C 22 H 33 , R 2 =ethyl, R 3 =H and X=COOH
[0000]
2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaen-1-yloxy)-2-ethylbutanoic acid (20)
R 1 =C 22 H 33 , R 2 =R 3 =ethyl and X=COOH
[0000]
2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaen-1-yloxy)propanoic acid (21)
R 1 =C 22 H 33 , R 2 =methyl, R 3 =H and X=COOH
[0000]
2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaen-1-yloxy)-2-methylpropanoic acid (22)
R 1 =C 22 H 33 , R 2 =R 3 =methyl and X=COOH
[0000]
2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaen-1-yloxy)-2-methoxyacetic acid (23)
R 1 =C 22 H 33 , R 2 =methoxy, R 3 =H and X=COOH
[0000]
2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaen-1-yloxy)-2-ethoxyacetic acid (24)
R 1 =C 22 H 33 , R 2 =ethoxy, R 3 =H and X=COOH
Category E:
[0136]
2-((9Z,12Z,15Z)-octadeca-9,12,15-trien-1-yloxy)butanoic acid (25)
R 1 =C 18 H 31 , R 2 =ethyl, R 3 =H and X=COOH
[0000]
2-ethyl-2-((9Z,12Z,15Z)-octadeca-9,12,15-trien-1-yloxy)butanoic acid (26)=C 18 H 31 , R 2 =R 3 =ethyl and X=COOH
[0000]
2-((9Z,12Z,15Z)-octadeca-9,12,15-trien-1-yloxy)propanoic acid (27)
R 1 =C 18 H 31 , R 2 =methyl, R 3 =H and X=COOH
[0000]
2-methyl-2-((9Z,12Z,15Z)-octadeca-9,12,15-trien-1-yloxy)propanoic acid (28)
R 1 =C 18 H 31 , R 2 =R 3 =methyl and X=COOH
[0000]
2-methoxy-2-((9Z,12Z,15Z)-octadeca-9,12,15-trien-1-yloxy)acetic acid (29)
R 1 =C 18 H 31 , R 2 =methoxy, R 3 =H and X=COOH
[0000]
2-ethoxy-2-((9Z,12Z,15Z)-octadeca-9,12,15-trien-1-yloxy)acetic acid (30)
R1=C 18 H 31 , R2=ethoxy, R3=H and X=COOH
Category F:
[0143]
2-((3Z,6Z,9Z,12Z)-pentadeca-3,6,9,12-tetraen-1-yloxy)butanoic acid (31)
R 1 =C 15 H 23 , R 2 =ethyl, R 3 =H and X=COOH
[0000]
2-ethyl-2-((3Z,6Z,9Z,12Z)-pentadeca-3,6,9,12-tetraen-1-yloxy)butanoic acid (32)
R 1 =C 13 H 23 , R 2 =R 3 =ethyl and X=COOH
[0000]
2-((3Z,6Z,9Z,12Z)-pentadeca-3,6,9,12-tetraen-1-yloxy)propanoic acid (33)
R 1 =C 15 H 23 , R 2 =methyl, R 3 =H and X=COOH
[0000]
2-methyl-2-((3Z,6Z,9Z,12Z)-pentadeca-3,6,9,12-tetraen-1-yloxy)propanoic acid (34)
R 1 =C 15 H 23 , R 2 =R 3 =methyl and X=COOH
[0000]
2-methoxy-2-((3Z,6Z,9Z,12Z)-pentadeca-3,6,9,12-tetraen-1-yloxy)acetic acid (35)
R 1 =C 15 H 23 , R 2 =methoxy, R 3 =H and X=COOH
[0000]
2-ethoxy-2-((3Z,6Z,9Z,12Z)-pentadeca-3,6,9,12-tetraen-1-yloxy)acetic acid (36)
R 1 =C 15 H 23 , R 2 =ethoxy, R 3 =H and X=COOH
Category G:
[0150]
2-((3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-yloxy)butanoic acid (37)
R 1 =C 18 H 27 , R 2 =ethyl, R 3 =H and X=COOH
[0000]
2-ethyl-2-((3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-yloxy)butanoic acid (38)
R1=C18H 27 , R2=R3=ethyl and X=COOH
[0000]
2-((3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-yloxy)propanoic acid (39)
R 1 =C 18 H 27 , R 2 =methyl, R 3 =H and X=COOH
[0000]
2-methyl-2-((3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-yloxy)propanoic acid (40)
R 1 =C 18 H 27 , R 2 =R 3 =methyl and X=COOH
[0000]
2-methoxy-2-((3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-yloxy)acetic acid (41)
R 1 =C 18 H 27 , R 2 =methoxy, R 3 =H and X=COOH
[0000]
2-ethoxy-2-((3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-yloxy)acetic acid (42)
R 1 =C 18 H 27 , R 2 =ethoxy, R 3 =H and X=COOH
Category H:
[0157]
propane-1,2,3-triyl tris(2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate) (43)
R 1 =C 20 H 31 , R 2 =ethyl, R 3 =H and X=a carboxylic acid in the form of a triglyceride
[0000]
1,3-dihydroxypropan-2-yl 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (44)
R 1 =C 20 H 31 , R 2 =ethyl, R 3 =H and X=a carboxylic acid in the form of a 2-monoglyceride
Category I:
[0160]
sodium 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (45)
R 1 =C 18 H 31 , R 2 =ethyl, R 3 =H, X=COO − and Z + is Na + .
[0000]
potassium 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (46).
R 1 =C 18 H 31 , R 2 =ethyl, R 3 =H, X=COO − and Z + is K.
[0000]
ammonium 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (47)
R 1 =C 18 H 31 , R 2 =ethyl, R 3 =H, X=COO − and Z + is NH 4 + .
[0000]
tert-butyl-ammonium 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (48).
R 1 =C 18 H 31 , R 2 =ethyl, R 3 =H, X=COO − and Z + is tert-butyl ammonium.
[0000]
1,3-dihydroxy-2-(hydroxymethyl)propan-2-aminium 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (49).
R 1 =C 18 H 31 , R 2 =ethyl, R 3 =H, X=COO − and Z + is 1,3-dihydroxy-2-(hydroxymethyl)propan-2-ammonium.
[0000]
magnesium 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (50).
R 1 =C 18 H 31 , R 2 =ethyl, R 3 =H, X=COO − and Z 2+ is Mg 2+ .
[0000]
calcium 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (51).
R 1 =C 18 H 31 , R 2 =ethyl, R 3 =H, X=COO − and Z 2+ is Ca 2+ .
Category J:
[0168]
2-(tetradec-12-ynyloxy)butanoic acid (52)
R 1 =C 14 H 25 , R 2 =ethyl, R 3 =H and X=COOH
[0000]
2-ethyl-2-(tetradec-12-yn-1-yloxy)butanoic acid (53)
R 1 =C 14 H 25 , R 2 =R 3 =ethyl and X=COOH
[0000]
2-(tetradec-12-yn-1-yloxy)propanoic acid (54)
R 1 =C 14 H 25 , R 2 =methyl, R 3 =H and X=COOH
[0000]
2-methyl-2-(tetradec-12-yn-1-yloxy)propanoic acid (55)
R 1 =C 14 H 25 , R 2 =R 3 =methyl and X=COOH
[0000]
2-methoxy-2-(tetradec-12-ynyloxy)acetic acid (56)
R 1 =C 14 H 25 , R 2 =methoxy, R 3 =H and X=COOH
[0000]
2-ethoxy-2-(tetradec-12-yn-1-yloxy)acetic acid (57)
R1=C 14 H 25 , R 2 =ethoxy, R 3 =H and X=COOH
[0175] Specific embodiments of compounds according to the present disclosure include the following.
General Synthetic Methods for the Compounds Described Herein.
[0176] The compounds of general formula (I) can be prepared by the following general procedures:
Method I:
[0177]
Method II:
[0178]
Method III:
[0179]
[0180] The alcohols of formula (X) described in method I, II and III may be prepared directly from the carboxylic esters of, for example, naturally occurring fatty acids; e.g. alpha-linolenic acid, conjugated linoleic acid, or eicosapentaenoic acid (EPA) by reduction with a reducing agent like lithium aluminum hydride (LAH) or diisobultyl aluminum hydride (DIBAL-H) at −10° C. to 0° C. The alcohols can also be prepared by degradation of the polyunsaturated fatty acids, such as EPA and DHA, as described by Holmeide et al. ( J. Chem. Soc., Perkin Trans. 1 (2000) 2271.) In this case, one can start with purified EPA or DHA, but it is also possible to start with fish oil containing EPA and DHA.
[0181] Compounds of formula (XI) and (XII) are commercially available, or they are known in the literature, or they are prepared by standard processes known in the art. The leaving group (LG) present in compounds of formula (XI) may, for example, be mesylate, tosylate or a suitable halogen, such as bromine. Other leaving groups will be apparent to the skilled artisan.
[0182] Using method I, the alcohols of formula (X) can react in a substitution reaction with a compound of formula (XI) in the presence of base such as an alkali metal hydroxide, for example NaOH in an appropriate solvent system. Suitable solvent systems include a two-phase mixture of toluene and water. In those cases where R2 and/or R3 present in the compound of formula (XI) are hydrogen, an alkylation step may be added to the sequence (Step II) in order to replace one or both of these hydrogen's with an alkyl group. Such alkylation may be performed by treating the product from Step I with an alkyl group bearing a suitable leaving group, for example a halogen, such as bromine or iodine, or other leaving groups that will be apparent to a person of ordinary skill in the art, in the presence of base, such as LDA in an appropriate solvent system.
[0183] Using method II, the alcohols of formula (X) can be converted using functional group interconversion, by methods familiar to persons skilled in the art, to compounds where the terminal hydroxy group have been transformed into a suitable leaving group (LG). Suitable leaving groups include bromine, mesylate, and tosylate, or others that will be apparent to one of ordinary skill in the art. These compounds can be reacted further (step IV) in a substitution reaction with the appropriately substituted hydroxy acetic acid derivatives (compounds of formula XII), in the presence of base in an appropriate solvent system.
[0184] Using method III, the alcohol of formula (X) can react with the appropriately substituted hydroxy acetic acid derivatives (compounds of formula XII), under classic or non-classic Mitsunobu conditions, using methods familiar to persons skilled in the art.
[0185] If the acid derivatives used are carboxylic esters, hydrolysis can be performed to obtain the free fatty acids. An esterifying group such as a methyl or an ethyl group may be removed, for example, by alkaline hydrolysis using a base such as an alkali metal hydroxide, for example LiOH, NaOH or KOH or by using an organic base, for example Et 3 N together with an inorganic salt, for example LiCl in an appropriate solvent system. A tert-butyl group may be removed, for example, by treatment with an acid, for example an organic acid such as trifluoroacetic acid or formic acid in an appropriate solvent system. Suitable solvent systems include dichloromethane. An arylmethylene group such as a benzyl group may be removed, for example, by hydrogenation over a catalyst such as palladium-on-carbon in an appropriate solvent system.
[0186] Salification of a carboxylic acid of formula (I) can be performed by treating it with a suitable base in an appropriate solvent system. Removal of the solvent will give the resulting salt.
[0187] The preparation of compounds of formula (I), according to method I, II or III, may result in mixtures of stereoisomers. If required, these isomers may be separated by means of chiral resolving agents and/or by chiral column chromatography through methods known to the person skilled in the art.
Method IV.
[0188] The compounds of formula (I) wherein X is a carboxylic acid derivative in the form of a phospholipid can be prepared through the following processes.
[0000]
[0189] Acylation of sn-glycero-3-phosphocholine (GPC) with an activated fatty acid, such as fatty acid imidazolides, is a standard procedure in phosphatidylcholine synthesis. It is usually carried out in the presence of DMSO anion with DMSO as solvent. (Hermetter; Chemistry and Physics of lipids , (1981) 28, 111.) Sn-Glycero-3-phosphocholine, as a cadmium (II) adduct can also be reacted with the imidazolide activated fatty acid in the presence of DBU (1,8-diazabicyclo[5.4.0]undec-7-ene) to prepare the phosphatidylcholine of the respective fatty acid. (International application number PCT/GB20031002582.) Enzymatic transphosphatidylation can effect the transformation of phosphatidylcholine to phosphatidyletanolamine. (Wang et al, J. Am. Chem. Soc ., (1993) 115, 10487.)
[0190] Phospholipids may also be prepared by enzymatic esterification and transesterification of phospholipids or enzymatic transphosphatidylation of phospholipids. (Hosokawa, J. Am. Oil Chem. Soc. 1995, 1287, Lilja-Hallberg, Biocatalysis , (1994) 195.)
Method V
[0191] The compounds of formula (I) wherein X is a carboxylic acid derivative in the form of a triglyceride can be prepared through the following process. Excess of the fatty acid can be coupled to glycerol using dimethylaminopyridine (DMAP) and 2-(1H-benzotriazol-1-yl)-N,N,N′,N′-tetramethyluroniumhexafluorophosphate (HBTU).
Method VI
[0192] The compounds of formula (I) wherein X is a carboxylic acid derivative in the form of a diglyceride can be prepared by reaction of the fatty acid (2 equivalents) with glycerol (1 equivalent) in the presence of 1,3-dicyclohexylcarbondiimide (DCC) and 4-dimethylaminopyridine (DMAP).
Method VII
[0193] The compounds of formula (I) wherein X is a carboxylic acid derivative in the form of a monoglyceride can be prepared through the following processes.
[0000]
[0194] Acylation of 1,2-O-isopropylidene-sn-glycerol with a fatty acid using DCC and DMAP in chloroform gives a monodienoylglycerol. Deprotection of the isopropylidene group can be done by treating the protected glycerol with an acidic (HCl, acetic acid etc.). (O'Brian, J. Org. Chem ., (1996) 5914.)
[0195] There are several synthetic methods for the preparation of monoglycerides with the fatty acid in 2-position. One method utilizes esterification of the fatty acid with glycidol in the presence of 1-(3-dimethylaminopropyl)-3-ethylcarbodiimidehydrochloride (EDC) and 4-dimethylaminopyridine (DMAP) to produce a glycidyl derivative. Treatment of the glycidyl derivative with trifluoroacetic anhydride (TFAA) prior to trans-esterification the monoglyceride is obtained (Parkkari et al, Bioorg. Med. Chem. Lett . (2006) 2437.)
[0000]
[0196] Further methods for the preparation of mono-, di- and tri-glycerides of fatty acid derivatives are described in international Application No. PCT/FR02/02831.
[0197] It is also possible to use enzymatic processes (lipase reactions) for the transformation of a fatty acid to a mono-, di-, tri-glyceride. A 1,3-regiospecific lipase from the fungus Mucor miehei can be used to produce triglycerides or diglycerides from polyunsaturated fatty acids and glycerol. A different lipase, the non-regiospecific yeast lipase from Candida antartica is highly efficient in generating triglycerides from polyunsaturated fatty acids. (Haraldsson, Pharmazie , (2000) 3.)
Preparation, Characterization and Biological Testing of Specific Fatty Acid Derivatives of Formula (I)
EXAMPLES
[0198] The disclosure will now be further described by the following non-limiting examples, in which standard techniques known to the skilled chemist and techniques analogous to those described in these examples may be used where appropriate. Unless otherwise stated:
evaporations were carried out by rotary evaporation in vacuo; all reactions were carried out at room temperature, typically in the range between 18-25° C. with solvents of HPLC grade under anhydrous conditions; column chromatography was performed by the flash procedure on silica gel 40-63 μm (Merck) or by an Armen Spotflash using the pre-packed silica gel columns “MiniVarioFlash”, “SuperVarioFlash”, “SuperVarioPrep” or “EasyVarioPrep” (Merck); yields are given for illustration only and are not necessarily the maximum attainable; the nuclear magnetic resonance (NMR) shift values were recorded on a Bruker Avance DPX 200 or 300 instrument, and the peak multiplicities are shown as follows: s, singlet; d, doublet; dd, double doublet; t, triplet; q, quartet; p, pentet; m, multiplett; br, broad; the mass spectra were recorded with a LC/MS spectrometer. Separation was performed using a Agilent 1100 series module on a Eclipse XDB-C18 2.1×150 mm column with gradient elution. As eluent were used a gradient of 5-95% acetonitrile in buffers containing 0.01% trifluoroacetic acid or 0.005% sodium formate. The mass spectra were recorded with a G 1956 A mass spectrometer (electrospray, 3000 V) switching positive and negative ionization mode.
Example 1
Preparation of tert-butyl 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate
[0205]
[0206] Tetrabutylammonium chloride (0.55 g, 1.98 mmol) was added to a solution of (5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-ol, (3.50 g, 12.1 mmol) in toluene (35 mL) at ambient temperature under nitrogen. An aqueous solution of sodium hydroxide (50% (w/w), 11.7 mL) was added under vigorous stirring at room temperature, followed by t-butyl 2-bromobutyrate (5.41 g, 24.3 mmol). The resulting mixture was heated to 50° C. and additional t-butyl 2-bromobutyrate was added after 1.5 hours (2.70 g, 12.1 mmol), 3.5 hours (2.70 g, 12.1 mmol) and 4.5 hours (2.70 g, 12.1 mmol) and stirred for 12 hours in total. After cooling to room temperature, ice water (25 mL) was added and the resulting two phases were separated. The organic phase was washed with a mixture of NaOH (5%) and brine, dried (MgSO 4 ), filtered and concentrated. The residue was purified by flash chromatography on silica gel using increasingly polar mixtures of heptane and ethyl acetate (100:0→95:5) as eluent. Concentration of the appropriate fractions afforded 1.87 g (36% yield) of the title compound as an oil. 1 H NMR (300 MHz, CDCl3): δ 0.85-1.10 (m, 6H), 1.35-1.54 (m, 11H), 1.53-1.87 (m, 4H), 1.96-2.26 (m, 4H), 2.70-3.02 (m, 8H), 3.31 (dt, 1H), 3.51-3.67 (m, 2H), 5.10-5.58 (m, 10H).
Example 2
Preparation of 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoic acid
[0207]
[0208] tert-Butyl 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (19.6 g, 45.5 mmol) was dissolved in dichloromethane (200 mL) and placed under nitrogen. Trifluoroacetic acid (50 mL) was added and the reaction mixture was stirred at room temperature for one hour. Water was added and the aqueous phase was extracted twice with dichloromethane. The combined organic extract was washed with brine, dried (Na 2 SO 4 ), filtered and concentrated. The residue was subjected to flash chromatography on silica gel using increasingly polar mixtures of heptane, ethyl acetate and formic acid (90:10:1→80:20:1) as eluent. Concentration of the appropriate fractions afforded 12.1 g (71% yield) of the title compound as an oil. 1 H-NMR (300 MHz, CDCl 3 ): δ 0.90-1.00 (m, 6H), 1.50 (m, 2H), 1.70 (m, 2H), 1.80 (m, 2H), 2.10 (m, 4H), 2.80-2.90 (m, 8H), 3.50 (m, 1H), 3.60 (m, 1H), 3.75 (t, 1H), 5.30-5.50 (m, 10H); MS (electro spray): 373.2 [M-H] − .
Example 3
Preparation of (4S,5R)-3-((S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoyl)-4-methyl-5-phenyloxazolidin-2-one and (4S,5R)-3-((R)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoyl)-4-methyl-5-phenyloxazolidin-2-one
[0209]
[0210] DMAP (1.10 g, 8.90 mmol) and DCC (1.90 g, 9.30 mmol) were added to a mixture of 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoic acid (3.20 g, 8.50 mmol) in dry dichloromethane (100 mL) held at 0° C. under nitrogen. The resulting mixture was stirred at 0° C. for 20 minutes. (4S,5R)-4-methyl-5-phenyloxazolidin-2-one (1.50 g, 8.50 mmol) was added and the resulting turbid mixture was stirred at ambient temperature for five days. The mixture was filtrated and concentrated under reduced pressure to give a crude product containing the desired product as a mixture of two diastereomers. The residue was purified by flash chromatography on silica gel using 15% ethyl acetate in heptane as eluent. The two diastereomers were separated and the appropriate fractions were concentrated. (4S,5R)-3-((S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoyl)-4-methyl-5-phenyloxazolidin-2-one eluted first and was obtained in 1.1 g (40% yield) as an oil. (4S,5R)-3-((R)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoyl)-4-methyl-5-phenyloxazolidin-2-one was obtained in 0.95 g (34% yield) as an oil.
(4S,5R)-3-((S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoyl)-4-methyl-5-phenyloxazolidin-2-one (E1)
[0211] 1 H-NMR (300 MHz, CDCl 3 ): δ 0.90 (d, 3H), 1.00 (t, 3H), 1.07 (t, 3H), 1.45-1.57 (m, 2H), 1.62-1.76 (m, 3H), 1.85-1.95 (m, 1H), 2.05-2.15 (m, 4H), 2.87 (m, 8H), 3.39 (m, 1H), 3.57 (m, 1H), 4.85-4.92 (m, 2H), 5.30-5.45 (m, 10H), 5.75 (d, 1H), 7.32 (m, 2H), 7.43 (m, 3H).
(4S,5R)-3-((R)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoyl)-4-methyl-5-phenyloxazolidin-2-one (E2)
[0212] 1 H-NMR (300 MHz, CDCl 3 ): δ 0.98 (d, 3H), 0.99 (t, 3H), 1.08 (t, 3H), 1.40-1.52 (m, 2H), 1.55-1.75 (m, 3H), 1.80-1.90 (m, 1H), 2.05-2.15 (m, 4H), 2.84 (m, 8H), 3.39 (m, 1H), 3.56 (m, 1H), 4.79 (pent, 1H), 4.97 (dd, 1H), 5.30-5.45 (m, 10H), 5.71 (d, 1H), 7.33 (m, 2H), 7.43 (m, 3H).
Example 4
Preparation of (S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoic acid
[0213]
[0214] Hydrogen peroxide (35% in water, 0.75 mL, 8.54 mmol) and lithium hydroxide monohydrate (0.18 g, 4.27 mmol) was added to a solution of (4S,5R)-3-((S)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoyl)-4-methyl-5-phenyloxazolidin-2-one (1.10 g, 2.13 mmol) in tetrahydrofuran (12 mL) and water (4 mL) held at 0° C. under nitrogen. The reaction mixture was stirred at 0° C. for 30 minutes. 10% Na 2 SO 3 (aq) (30 mL) was added, the pH was adjusted to −2 with 2M HCl and the mixture was extracted twice with heptane (30 mL). The combined organic extract was dried (Na 2 SO 4 ), filtered and concentrated. The residue was subjected to flash chromatography on silica gel using increasingly polar mixtures of heptane and ethyl acetate (98:8→1:1) as eluent. Concentration of the appropriate fractions afforded 0.48 g (60% yield) of the title compound as an oil. 1 H-NMR (300 MHz, CDCl 3 ): δ0.90-1.00 (m, 6H), 1.48 (m, 2H), 1.65 (m, 2H), 1.85 (m, 2H), 2.10 (m, 4H), 2.80-2.90 (m, 8H), 3.55 (m, 1H), 3.60 (m, 1H), 3.88 (t, 1H), 5.35-5.45 (m, 10H); MS (electro spray): 373.3 [M-H] − ; [α] D +37° (c=0.104, ethanol)
Example 5
Preparation of (R)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoic acid
[0215]
[0216] Hydrogen peroxide (35% in water, 0.65 mL, 7.37 mmol) and lithium hydroxide monohydrate (0.15 g, 3.69 mmol) was added to a solution of (4S,5R)-3-((R)-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)butanoyl)-4-methyl-5-phenyloxazolidin-2-one (0.95 g, 1.84 mmol) in tetrahydrofuran (12 mL) and water (4 mL) held at 0° C. under nitrogen. The reaction mixture was stirred at 0° C. for 30 minutes. 10% Na 2 SO 3 (aq) (30 mL) was added, the pH was adjusted to ˜2 with 2M HCl and the mixture was extracted twice with heptane (30 mL). The combined organic extract was dried (Na 2 SO 4 ), filtered and concentrated. The residue was subjected to flash chromatography on silica gel using increasingly polar mixtures of heptane and ethyl acetate (98:8→50:50) as eluent. Concentration of the appropriate fractions afforded 0.19 g (29% yield) of the title compound as an oil. 1 H-NMR (300 MHz, CDCl 3 ): δ 0.90-1.00 (m, 6H), 1.48 (m, 2H), 1.65 (m, 2H), 1.85 (m, 2H), 2.10 (m, 4H), 2.80-2.90 (m, 8H), 3.55 (m, 1H), 3.60 (m, 1H), 3.88 (t, 1H), 5.35-5.45 (m, 10H); MS (electro spray): 373.3 [M-H] − ; [α] D −31° (c=0.088, ethanol)
Example 6
Preparation of tert-butyl 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)propanoate
[0217]
[0218] A mixture of (5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-ol, (1.00 g, 3.47 mmol), tetrabutylammonium chloride (0.24 g, 0.87 mmol) and t-butyl α-bromo propionate (3.62 g, 17.3 mmol) was dissolved in toluene (36 mL) and placed under nitrogen. An aqueous solution of sodium hydroxide (50%, 8 mL) was added slowly under vigorous stirring and the resulting mixture was stirred at ambient temperature for twenty hours. Water was added and the mixture was extracted three times with ether. The combined organic extract was washed with brine, dried (Na 2 SO 4 ), filtered and concentrated. The residue was purified by flash chromatography on silica gel using 2% ethyl acetate in heptane as eluent. Concentration of the appropriate fractions afforded 1.40 g (90% yield) of the title compound as an oil. 1 H-NMR (300 MHz, CDCl 3 ): δ 0.95 (t, 3H), 1.41 (d, 3H), 1.48 (s, 9H), 1.48-1.66 (m, 4H), 2.05 (m, 4H), 2.83 (m, 8H), 3.35 (m, 1H), 3.55 (m, 1H), 3.79 (q, 1H), 5.32-5.44 (m, 10H).
Example 7
Preparation of 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)propanoic acid
[0219]
[0220] Trifluoroacetic acid (2 mL) was added to a solution of 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)propanoate (1.40 g, 3.36 mmol) in dichloromethane (10 mL) held under nitrogen and the reaction mixture was stirred at room temperature for three hours. Diethyl ether (50 mL) was added and the organic phase was washed with water (30 mL), dried (Na 2 SO 4 ) and concentrated. The residue was subjected to flash chromatography on silica gel using increasingly polar mixtures of heptane, ethyl acetate and formic acid (95:5:0.25→80:20:1) as eluent. Concentration of the appropriate fractions afforded 0.67 g of slightly impure product. This material was dissolved in heptane (15 mL), washed three times with water (5 mL), dried (Na 2 SO 4 ), filtered and concentrated to afford 0.50 g (41% yield) of the title compound as an oil. 1 H-NMR (300 MHz, CDCl 3 ): δ 0.99 (t, 3H), 1.40-1.48 (m, 5H), 1.67 (m, 2H), 2.09 (m, 4H), 2.80-2.60 (m, 8H), 3.53 (m, 2H), 4.01 (q, 1H), 5.31-5.47 (m, 10H); MS (electro spray): 359.2 [M-H] − .
Example 8
Preparation of tert-butyl 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)-2-methylpropanoate
[0221]
[0222] A mixture of (5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-ol, (0.83 g, 3.14 mmol), tetrabutylammonium chloride (0.24 g, 0.85 mmol) and t-butyl α-bromo isobutyrate (3.50 g, 15.7 mmol) was dissolved in toluene (15 mL) and placed under nitrogen. An aqueous solution of sodium hydroxide (50%, 5 mL) was added slowly under vigorous stirring at room temperature. The resulting mixture was heated to 60° C. and stirred for six hours. The mixture was cooled, added water and extracted three times with ether. The combined organic extract was washed with brine, dried (Na 2 SO 4 ), filtered and concentrated. The residue was purified by flash chromatography on silica gel using a gradient of 5-10% ethyl acetate in heptane as eluent. Concentration of the appropriate fractions afforded 0.60 g (44% yield) of the title compound as an oil. MS (electro spray): 453.3 [M+Na] + .
Example 9
Preparation of 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)-2-methylpropanoic acid
[0223]
[0224] Trifluoroacetic acid (5 mL) was added to a solution of tert-butyl 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaenyloxy)-2-methylpropanoate (600 mg, 1.39 mmol) in dichloromethane (20 mL) under nitrogen and the reaction mixture was stirred at room temperature for two hours. Water was added and the aqueous phase was extracted twice with dichloromethane. The combined organic extract was washed with brine, dried (Na 2 SO 4 ), filtered and concentrated. The residue was purified by flash chromatography on silica gel using a mixture of heptane, ethyl acetate and formic acid (80:20:1) as eluent. The appropriate fractions were concentrated and the residue (135 mg) was purified further by flash chromatography on silica gel using a gradient of 5-10% of a Mixture of ethyl acetate and formic acid (95:5) in heptane as eluent. Concentration of the appropriate fractions afforded 80 mg slightly impure product. This material was dissolved in heptane (5 mL), washed twice with water (5 mL), dried (Na 2 SO 4 ), filtered and concentrated to afford 40 mg (8% yield) of the title compound as an oil. 1 H-NMR (300 MHz, CDCl 3 ): δ 0.99 (t, 3H), 1.47 (s, 6H), 1.64 (m, 2H), 2.07 (m, 4H), 2.81-2.88 (m, 8H), 3.46 (t, 2H), 5.29-5.44 (m, 10H); MS (electro spray): 373.3 [M-H] −
Example 10
Preparation of 2-((3Z,6Z,9Z,12Z)-pentadeca-3,6,9,12-tetraenyloxy)butanoic acid
[0225]
[0226] A mixture of (3Z,6Z,9Z,12Z)-pentadeca-3,6,9,12-tetraen-1-ol (S. Flock, Acta Chemica Scandinavica , (1999) 53, 436-445) (0.22 g, 1.00 mmol), tetrabutyl ammonium chloride (0.10 g, 0.33 mmol) and t-butyl 2-bromobutyrate (1.11 g, 5.00 mmol) was dissolved in toluene (10 ml) and placed under nitrogen. An aqueous solution of sodium hydroxide (50%, 4 ml) was added slowly under vigorous stirring at room temperature. The resulting mixture was heated to 50° C. and stirred for two hours and then at ambient temperature over night. After cooling to room temperature, water was added and the aqueous phase was extracted three times with ether. The combined organic extract was washed with water and brine, dried (Na 2 SO 4 ), filtered and concentrated. The residue was purified by flash chromatography on silica gel using 5% ethyl acetate in heptane as eluent. Concentration of the appropriate fractions afforded 0.30 g of the t-butyl ester as an oil. The residue was dissolved in dichloromethane (10 mL) and placed under nitrogen. Trifluoroacetic acid (2 mL) was added and the reaction mixture was stirred at room temperature for one hour. Water was added and the aqueous phase was extracted twice with dichloromethane. The combined organic extract was washed with brine, dried (Na 2 SO 4 ), filtered and concentrated. The residue was purified by flash chromatography on silica gel using a mixture of heptane, ethyl acetate and formic acid (80:20:1) as eluent. Concentration of the appropriate fractions afforded 0.18 g (59% yield) of the desired product as an oil. 1 H-NMR (300 MHz, CDCl 3 ): δ 0.90-1.05 (m, 6H), 1.75-1.90 (m, 2H), 2.05-2.15 (m, 2H), 2.30-2.50 (m, 2H), 2.85 (m, 6H), 3.60 (m, 2H), 3.85 (t, 1H), 5.25-5.60 (m, 8H).
Example 11
Preparation of 2-((9Z,12Z,15Z)-octadeca-9,12,15-trienyloxy)butanoic acid
[0227]
[0228] A mixture of (9Z,12Z,15Z)-octadeca-9,12,15-trien-1-ol (1.26 g, 4.76 mmol), tetra-butyl ammonium chloride (0.36 g, 1.28 mmol) and t-butyl 2-bromobutyrate (2.86 g, 12.82 mol) was dissolved in toluene (15 mL) and placed under nitrogen. An aqueous solution of sodium hydroxide (50%, 6 mL) was added slowly under vigorous stirring at room temperature. The resulting mixture was heated to 60° C. and stirred for five hours. After cooling to room temperature, water was added and the aqueous phase was extracted three times with ether. The combined organic extract was washed with water and brine, dried (Na 2 SO 4 ), filtered and concentrated. The residue was purified by flash chromatography on silica gel using a gradient of 2.5-5% ethyl acetate in heptane as eluent. Concentration of the appropriate fractions afforded 1.36 g of the t-butyl ester as an oil. The residue was dissolved in dichloromethane (20 mL) and placed under nitrogen. Trifluoroacetic acid (5 mL) was added and the reaction mixture was stirred at room temperature for one hour. Water was added and the aqueous phase was extracted twice with dichloromethane. The combined organic extract was washed with brine, dried (Na 2 SO 4 ), filtered and concentrated. The residue was purified by flash chromatography on silica gel using a mixture of heptane, ethyl acetate and formic acid (80:20:1) as eluent. Concentration of the appropriate fractions afforded 0.38 g (23% yield) of the desired product as an oil. 1 H-NMR (300 MHz, CDCl3): δ 0.95-1.00 (m, 6H), 1.30-1.45 (m, 10H), 1.65 (m, 2H), 1.80 (m, 2H), 2.10 (m, 4H), 2.80 (m, 4H), 3.50 (m, 1H), 3.60 (m, 1H), 3.85 (t, 1H), 5.30-5.50 (m, 6H); MS (electro spray): 349.2 [M-H] − .
Example 12
Preparation of tert-butyl 2-ethyl-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate
[0229]
[0230] tert-Butyl 2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (480 mg, 1.11 mmol) was added dropwise over 30 minutes to a solution of lithium diisopropylamine (LDA) (2.0 M, 750 μL, 1.50 mmol) in dry tetrahydrofuran (10 mL) held at −70° C. under nitrogen. The reaction mixture was stirred for 30 minutes. Ethyl iodide (312 mg, 2.00 mmol) was added in one portion and the resulting mixture was warmed to ambient temperature during 1 hour. The reaction mixture was stirred at ambient temperature for 17 hours. The mixture was poured into saturated NH 4 Cl (aq.) (50 mL) and extracted with heptane (2×50 mL). The combined organic phases was washed successively with brine (50 mL), 0.25 M HCl (50 mL) and brine (50 mL), dried (MgSO 4 ), filtered and concentrated. The residue was purified by flash chromatography on silica gel using increasingly polar mixtures of heptane and ethyl acetate (100:0→95:5) as eluent. Concentration of the appropriate fractions afforded 343 mg (67% yield) of the title compound as an oil. 1 H NMR (300 MHz, CDCl3): δ 0.84 (t, 6H), 0.99 (td, 3H), 1.35-1.55 (m, 11H), 1.54-1.69 (m, 2H), 1.68-1.87 (m, 4H), 1.99-2.24 (m, 4H), 2.74-2.99 (m, 8H), 3.31 (t, 2H), 5.23-5.52 (m, 10H); MS (electro spray): 401.3 [M-1] −
Example 13
Preparation of 2-ethyl-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoic acid
[0231]
[0232] A mixture of formic acid (5 ml) and tert-butyl 2-ethyl-2-((5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-yloxy)butanoate (250 mg, 0.55 mmol) was stirred vigorously under nitrogen at room temperature for 4.5 hours. The formic acid was removed in vacuo. The residue was purified by flash chromatography on silica gel using increasingly polar mixtures of heptane and ethyl acetate (100:0→80:20) as eluent. Concentration of the appropriate fractions afforded 163 mg (74% yield) of the title compound as an oil. 1 H NMR (300 MHz, CDCl3): δ 0.86 (t, 6H), 0.99 (t, 3H), 1.36-1.57 (m, 2H), 1.68 (dd, 2H), 1.73-1.98 (m, 4H), 2.11 (tt, 4H), 2.70-3.01 (m, 8H), 3.39 (t, 2H), 5.20-5.56 (m, 10H). MS (electrospray): 481.4 [M+Na] + .
Example 14
Preparation of tert-butyl 2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaen-1-yloxy)propanoate
[0233]
[0234] An aqueous solution of sodium hydroxide (50% (w/w), 6 ml) was added portionwise to a mixture of (5Z,8Z,11Z,14Z,17Z)-icosa-5,8,11,14,17-pentaen-1-ol (2.01 g, 6.39 mmol), tert-butyl-2-bromobutyrat (2.85 g, 12.8 mmol) and tetrabutylammonium bisulfate (0.65 g, 1.91 mmol) in toluene (12 ml). The reaction mixture was vigorously stirred under N 2 -atmosphere and warmed to 50° C. The reaction mixture was stirred at 50° C. for a total of 22 hrs. Additional tert-butyl-2-bromobutyrat (1.43 g, 6.39 mmol) and (1.44 g, 6.44 mmol) was added after 1½ hrs and 3 hrs respectively. The mixture was cooled and added ice-water (˜50 ml) and heptane (50 ml), the phases were separated and the organic phase was concentrated under reduced pressure. Flash chromatography on silica gel (30 g) eluting with heptane-heptane/EtOAc (99:1) yielded 2.12 g of the title compound as a liquid. 1 H NMR (300 MHz, CDCl 3 ) δ 0.94-1.04 (m, 6H), 1.47 (s, 9H), 1.68-1.85 (m, 4H), 1.93-2.20 (m, 4H), 2.80-2.86 (m, 10H), 3.28-3.36 (m, 1H), 3.55-3.63 (m, 2H), 5.27-5.43 (m, 12H)
Example 15
Preparation of 2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaen-1-yloxy)butanoic acid
[0235]
[0236] A mixture of tert-butyl 2-((4Z,7Z,10Z,13Z,16Z,19Z)-docosa-4,7,10,13,16,19-hexaen-1-yloxy)propanoate (2.09 g, 4.58 mmol) in HCOOH (9 ml) was stirred at 40° C. under N 2 -atmosphere for 6 hrs. The reaction mixture was diluted with diethyl ether (100 mL), washed with water (30 mL), dried (MgSO 4 ), filtered and evaporated under reduced pressure. Dry-flash on silica gel (50 g) eluting with toluene-toluene (85:15) yielded 1.44 g of the crude title compound. Flash chromatography on silica gel (30 g) eluting with heptane-heptane/(EtOAc w/5% HCCOH) 98:2-95:5-80:20 yielded 1.07 g (58% yield) of the title compound as a liquid. 1 H NMR (200 MHz, CDCl 3 ) δ 0.97 (t, 3H), 0.99 (t, 3H), 1.64-1.91 (m, 4H), 2.00-2.23 (m, 4H), 2.78-2.87 (m, 10H), 3.42-3.66 (m, 2H), 3.85 (dd, 1H), 5.26-5.46 (m, 12H). MS (electrospray) (neg): 399 (M-H) − .
Example 16
Preparation of tert-butyl 2-((3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-yloxy)butanoate
[0237]
[0238] An aqueous solution of sodium hydroxide (50% (w/w), 6 mL) was added portionwise to a mixture of (3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-ol (1.66 g, 6.37 mmol), tert-butyl-2-bromobutyrat (2.86 g, 12.8 mmol) and tetrabutylammonium bisulfate (0.65 g, 1.91 mmol) in toluene (12 ml). The reaction mixture was vigorously stirred under N 2 -atmosphere and warmed to 50° C. The reaction mixture was stirred at 50° C. for a total of 25 hrs. Additional tert-butyl-2-bromobutyrat (1.43 g, 6.41 mmol) and (1.42 g, 6.38 mmol) was added after 1½ hrs and 3 hrs respectively. The mixture was cooled to room temperature and added water (30 mL) and heptane (50 mL), the resulting two phases were separated and the organic phase was dried (Na 2 SO 4 ), filtered and evaporated under reduced pressure. Flash chromatography on silica gel (30 g) eluting with heptane-heptane/EtOAc (99:1) yielded 1.55 g of the title compound as a liquid. 1 H NMR (300 MHz, CDCl 3 ) δ 0.96 (t, 3H), 0.97 (t, 3H), 1.48 (s, 9H), 1.64-1.86 (m, 2H), 2.03-2.12 (m, 2H), 2.39 (dd, J=12.1, 6.7 Hz, 2H), 2.79-2.86 (m, 8H), 3.29-3.37 (m, 1H), 3.57-3.66 (m, 2H), 5.27-5.49 (m, 10H).
Example 17
Preparation of 2-((3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-yloxy)butanoic acid
[0239]
[0240] A mixture of tert-butyl 2-((3Z,6Z,9Z,12Z,15Z)-octadeca-3,6,9,12,15-pentaen-1-yloxy)butanoate (2.09 g, 4.58 mmol) in HCOOH (9 mL) was stirred at 40° C. under N 2 -atmosphere for 6 hrs. The reaction mixture was diluted with diethyl ether (100 mL), washed with water (30 mL), dried (MgSO 4 ), filtered and evaporated under reduced pressure. Dry-flash on silica gel (50 g) eluting with toluene-toluene/EtOAc (85:15) yielded 1.44 g of the crude title compound. Flash chromatography on silica gel (30 g) eluting with heptane-heptane/(EtOAc w/5% HCCOH) 98:2-95:5-80:20 yielded 1.07 g (58% yield) of the title compound as a liquid. 1 H NMR (200 MHz, CDCl 3 ) δ 0.97 (t, 3H), 0.99 (t, 3H), 1.75-1.91 (m, 2H), 2.00-2.15 (m, 2H), 2.35-2.48 (m, 2H), 2.78-2.87 (m, 8H), 3.47-3.62 (m, 2H), 3.86 (dd, 1H), 5.25-5.55 (m, 10H). MS (electrospray) (neg): 345 (M-H) − .
Biological Testing
Example 18
Evaluation of PPAR Activation In Vitro
[0241] The assays were carried out in vitro using mammalian-one-hybrid assays (M1H) comprising GAL4-DNA binding domain-PPAR-LBD fusion constructs in conjunction with 5×GAL4-sites driven Photinus pyralis luciferase reporter constructs in transiently transfected HEK293 cells.
[0242] The cells were transfected 4-6 h and grown overnight before compounds were added. Compound incubation was 16-20 h.
[0243] Renilla reniformis luciferase, driven by a constitutive promoter, was included as internal control to improve experimental accuracy.
[0244] The compounds (A-C) and a positive control were tested at six different concentrations in duplicate. The positive controls were GW7647 (PPARα), GW501516 (PPARδ) and rosiglitazone (PPARγ), The efficacy of the controls were set to 100%.
[0000]
[0245] The results are presented in Table 1.
[0000]
TABLE 1
PPAR activation in vitro.
PPARα
PPARδ
PPARγ
Compound
EC 50
Efficacy
EC 50
Efficacy
EC 50
Efficacy
Pos. ctr.
0.45 nM
100%
0.33 nM
100%
22 nM
100%
A
307 nM
82%
inactive
inactive
806 nM
22%
B
405 nM
86%
inactive
inactive
644 nM
27%
C
167 nM
54%
inactive
inactive
515 nM
25%
Example 19
Evaluation of the Effects on In Vivo Lipid Metabolism in a Dyslipidemic Mouse Model (APOE*3Leiden Transgenic Mice)
[0246] This animal model has proven to be representative of the human situation with respect to plasma lipoprotein levels and its responsiveness to hypolipidemic drugs, such as statins and fibrates, and nutritional intervention. In addition, depending on the level of plasma cholesterol, APOE*3Leiden mice develop atherosclerotic lesions in the aorta resembling those found in humans with respect to cellular composition and morphological and immunohistochemical characteristics.
[0247] Female APOE*3Leiden mice were put on a semi-synthetic Western-type diet (WTD, 15% cocoa butter, 40% sucrose and 0.25% cholesterol; all w/w). With this diet the plasma cholesterol level reached mildly elevated levels of approximately 12-15 mmol/l. After a 4 week run-in period the mice were sub-divided into groups of 10 mice each, matched for plasma cholesterol, triglycerides and body weight (t=0).
[0248] The test substances were administered orally as admix to the Western-type diet. To facilitate the mixing of the compounds sunflower oil was added to a total oil volume of 10 mL/kg diet.
[0249] At t=0 and 4 weeks blood samples were taken after a 4 hour-fast to measure plasma cholesterol and triglycerides.
[0250] The test substance (A) was tested at 0.3 mmol/kg bw/day. The reference (Omega-3 acid ethyl esters, Omacor™, Lovaza™) was tested at 3.3 mmol/kg bw/day.
[0251] The results are shown in FIG. 1 .
Example 20
Evaluation of the Effects on In Vivo Lipid Metabolism in a Dyslipidemic Mouse Model (APOE*3Leiden.CETP Transgenic Mice)
[0252] The APOE*3Leiden.CETP transgenic mouse is a model where the human cholesterol ester transfer protein has been introduced to the APOE*3Leiden transgenic mouse. This results in a more human-like lipoprotein profile. This model is very well suited for testing the effects of drugs on plasma HDL and triglyceride levels.
[0253] Female APOE*3Leiden.CETP mice were put on a semi-synthetic modified Western-type diet (0.15% cholesterol and 15% saturated fat, all w/w). With this diet the plasma cholesterol level reaches moderately elevated levels of about 13-15 mmol/l and triglyceride levels of approximately 3 mmol/l. After a 4 week run-in period the mice were sub-divided into groups of 6 mice each, matched primarily for plasma cholesterol, triglycerides and body weight and secondarily for HDL-cholesterol (t=0).
[0254] The test substances were administered orally as admix to the Western-type diet.
[0255] At t=0 and 4 weeks blood samples were taken after a 4 hour-fast to measure plasma cholesterol, HDL-cholesterol and triglycerides.
[0256] The test substance (A) was tested at 0.18 mmol/kg bw/day. The reference (Fenofibrate) was tested at 10 mg/kg bw/day.
[0257] The results are shown in FIGS. 2 and 3 .
Example 21
Evaluation of the Effects on In Vivo Atherosclerosis Development in a Mouse Model (APOE*3Leiden.CETP Transgenic Mice)
[0258] This animal model has proven to be representative of the human situation with respect to plasma lipoprotein levels and its responsiveness to hypolipidemic drugs (like statins, fibrates etc.) and nutritional intervention. APOE*3Leiden.CETP mice develop atherosclerotic lesions in the aorta resembling those found in humans with respect to cellular composition and morphological and immunohistochemical characteristics.
[0259] Female APOE*3Leiden.CETP mice were put on a Western-type diet (WTD) with 0.15% cholesterol and 15% saturated fat; resulting in plasma cholesterol levels of about 13-15 mM. After a 3 week run-in period on the WTD, the mice were sub-divided into 4 groups of 15 mice, control (no treatment), compound A, fenofibrate and a low-cholesterol diet. The groups were matched for body weight, plasma total cholesterol (TC), HDL cholesterol (HDL-C) and triglycerides (TG) after 4 h fasting (t=0).
[0260] The test substances were administered orally as admix to the Western-type diet. To facilitate the mixing of the compounds sunflower oil was added to a total oil volume of 10 mL/kg diet. The test compound (A) was tested at initially at 0.1 mmol/kg bw/day and reduced to 0.04 mmol/kg bw/day at 4 weeks. The initial dose was based on a prior dose-finding study to establish the required dosage that would reduce VLDL/LDL cholesterol by 25-30%0.
[0261] The dosage of fenofibrate was initially 10 mg/kg bw/day and was reduced to 4.2 mg/kg bw/day (to parallel reductions in VLDL/LDL induced by compound A).
[0262] At t=0, 4, 8, 12 and 14 weeks blood samples were taken after a 4 hour-fast to measure food intake, total plasma cholesterol, HDL cholesterol and triglycerides and lipoprotein profiles. Atherosclerosis development in the aortic root (lesion number, total lesion area and lesion severity) was assessed at study-end.
[0263] The invention shall not be limited to the shown embodiments and examples.
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The present disclosure relates to lipid compounds of the general formula (I):
R 1 —O—C(R 2 )(R 3 )—X (I)
wherein R 1 is a C 10 -C 22 alkyl group, a C 10 -C 22 alkenyl group having 1-6 double bonds, or a C 10 -C 22 alkynyl group having 1-6 triple bonds; R 2 and R 3 are the same or different and may be chosen from different substituents; and X is a carboxylic acid or a derivative thereof, such as a carboxylic ester, a carboxylic anhydride, a phospholipid, triglyceride, or a carboxamide; or a pharmaceutically acceptable salt, solvate, solvate of such salt, or a prodrug thereof. The present disclosure also relates to pharmaceutical compositions and lipid compositions comprising at least one compound according to the present disclosure, and to such compounds for use as medicaments or for use in therapy, in particular for the treatment of diseases related to the cardiovascular, metabolic, and inflammatory disease area.
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This application is a continuation-in-part of U.S. patent application Ser. No. 08/639,196, filed Apr. 26, 1996, entitled “CATALYZED LUBRICANT ADDITIVES AND CATALYZED LUBRICANT SYSTEMS DESIGNED TO ACCELERATE THE LUBRICANT BONDING REACTION,” now U.S. Pat. No. 5,877,128, issued Mar. 2, 1999.
TECHNICAL FIELD
This invention relates generally to compositions and methods for coating a surface, and more particularly to a compositions and methods for catalytically chemically bonding a material to a surface.
BACKGROUND
As described in U.S. Pat. No. 5,877,128, filed Apr. 26, 1996, entitled, “CATALYZED LUBRICANT ADDITIVES AND CATALYZED LUBRICANT SYSTEMS DESIGNED TO ACCELERATE THE LUBRICANT BONDING REACTION,” which application is incorporated herein by reference, the present state of the arts are defined and illustrated by many disclosures with respect to the composition, formulation, and performance of lubricant additives, lubricant systems containing solid lubricant additives, the composition and formulation of metal coatings, the composition and formulation of catalysts, and the chemistry and performance of lubricants containing solid lubricant additives, all of which bear some relevance to the invention presented herein. Those disclosures employed as references in this patent application are listed hereinafter.
The references, other than United States Patents, are presented as follows:
L. L. Cao, Y. M. Sun, and L. Q. Zheng, “Chemical Structure Characterization of Boundary Lubrication Film Using X-ray Photoelectron Spectroscopy and Scanning Auger Microprobe Techniques,” Wear, 140 (1990), pp. 345-357;
Harold Shaub, John Pandosh, Anne Searle, and Stan Sprague, “Mechanism Studies with Special Boundary Lubricant Chemistry,” Society of Automotive Engineers, Paper 952475, 1995;
Hal Shaub, John Pandosh, Anne Searle, Stan Sprague, and Martin Treuhaft, “Engine Durability, Emissions and Fuel Economy Studies with Special Boundary Lubricant Chemistry,” Society of Automotive Engineers, Paper 941983, 1994;
Keith Perrin, John Pandosh, Anne Searle, Hal Shaub, and Stan Sprague, “Radioactive Tracer Study of Start-Up Wear Versus Steady-State Wear in a 2.3 Liter Engine,” Society of Automotive Engineers, Paper 952474, 1995.
Other useful references are as follows:
Kirk-Othmer, “Concise Encyclopedia of Chemical Technology,” John Wiley & Sons, Inc., 1985, pp. 37 and 292-297;
Jacqueline I. Kroschwitz, “Concise Encyclopedia of Polymer-Science and Engineering,” John Wiley & Sons, Inc., 1990, pp. 31-35 and 156-171;
R. E. Banks, B. E. Smart, and J. C. Tatlow, “Organofluorine Chemistry, Principles and Commercial Applications,” Plenum Press, 1994, pp. 397-401.
The United States Patent Application and the United States Patents which bear particular relevance or are of significant interest with respect to the present patent application are singled out and are cited. See U.S. Pat. Nos. 2,230,654; 2,510,112; 2,993,567; 3,194,762; 3,247,116; 3,314,889; 3,432,431; 3,493,513; 3,505,229; 3,536,624; 3,567,521; 3,592,700; 3,607,747; 3,636,172; 3,640,859; 3,723,317; 3,806,455; 3,909,431; 3,933,656; 3,969,233; 4,029,870; 4,036,718; 4,052,323; 4,127,491; 4,224,173; 4,252,678; 4,349,444; 4,363,737; 4,405,469; 4,465,607; 4,484,954; 4,500,678; 4,584,116; 4,615,917; 4,657,687; 4,770,797; 4,803,005; 4,834,894; 4,857,492; 4,859,357; 4,888,122; 4,892,669; 5,009,963; 5,160,646; 5,227,081; 5,350,727; 5,373,986; 5,447,896; 5,460,661. All of the above references are incorporated herein by reference.
As described in detail in U.S. Pat. No. 5,877,128, it generally has been established, through preexisting research work performed by others, that certain materials, such as Teflon® and polytetrafluoroethylene (“PTFE”), which are different designations for the same chemical composition, can be caused to chemically bond to a surface, such as a metallic surface, when exposed at elevated temperatures.
U.S. Pat. No. 5,877,128 teaches that these materials, such as PTFE, can be caused to chemically bond to a surface, such as a metallic surface, at relatively low (e.g., ambient) temperatures and atmospheric pressures, when the reactants are appropriately catalyzed. In a preferred embodiment, the catalysts disclosed comprise a transition metal such as platinum or palladium. U.S. Pat. No. 5,877,128 further discloses such applications as lubricating load-bearing wear surfaces, and non load-bearing applications and applications where “non-stick” properties are being sought, for example cookware surfaces, cling, and stain resistant surfaces, etc.
SUMMARY OF THE INVENTION
The concepts of the invention disclosed in the U.S. Pat. No. 5,877,128 were initially generally thought to be most advantageous when used primarily for applications utilizing the lubrication characteristics of the surface coating. However, some of the catalysts claimed, such as platinum and palladium, may be too expensive for some applications. In addition, further investigation has led to the conclusion that the same basic concepts are capable of causing surface coating films of PTFE, fluorine containing species, or other unreacted surface coating materials to be chemically bonded to the surface to be coated for applications utilizing other characteristics of the surface coating. For example, the present invention may provide a multilayered, persistent, solid, and corrosion and wear resistant surface coating on the skin (e.g., body panels) of a vehicle, such as an aircraft, not only to provide lubricated surfaces that would be expected to substantially reduce the drag coefficients of the aircraft, but also that could be designed to provide enduring, environmentally benign aircraft anti-icing capabilities, along with a large number of other beneficial properties. As used herein, “unreacted surface coating materials” are defined as including an individual material or combination of materials which may be employed to undergo a catalytically aided reaction wherein the materials are caused to chemically bond to a surface, and in particular refers to such materials prior to the catalytically aided chemical bonding reaction.
Prior art conventional surface coatings are available primarily as liquids or fusible compositions. Generally, the currently available surface coatings are categorized into two different classes.
The first class includes surface coating systems containing oil-modified alkyds, volatile organic compounds (VOCs), or other polymers containing drying oils, which coatings may be divided into the following subclasses:
(1) architectural surface coatings which require air drying applications to cause curing and adhesion, such as oxidizing alkyd resins;
(2) metal surface coatings which require air-drying or low temperature bake-on applications to cause curing and adhesion, such as alkyd and phenoplast, or nitrocellulose, chlorinated rubber, polystyrene, diisocyanate, or vinyl and epoxy;
(3) premium surface coatings with good color retention, and superior chemical and heat resistance which require air-drying or low temperature bake-on applications to cause curing and adhesion, such as alkyd and aminoplast, or aminoplast and epoxy, or alkyd and silicone; and
(4) surface coatings for use as undercoating or overcoating enamels which require bake-on applications to cause curing and adhesion, such as oil-modified epoxy resins and aminoplast.
The second class includes surface coating systems containing no alkyds or drying oils, which coatings may be divided into the following subclasses:
(1) surface coatings with good chemical resistance which require bake-on applications to cause curing and adhesion, such as vinyl acetals and/or phenolic, allylaminoplast, epoxy, along with 2,4,6-trimethylophenyl ether;
(2) surface coatings primarily for corrosion protection which require only ambient temperature applications to cause curing and adhesion, such as phenoplasts with or without epoxy, vinylacetal or aminoplast;
(3) surface coatings that exhibit chemical and discoloration resistance and exhibit high gloss or clear finishes which require elevated temperatures to cause curing and adhesion, such as polyester and triazine resin, allyl polyester, silicone, thermosetting acrylics, complex amino resins, and other polyesters;
(4) surface coatings for architectural products which require heat or air drying applications to cause curing and adhesion, such as vinyl acetate-chloride, copolymers vinylidiene or vinyl chloride-acrylonitrile copolymers, butadiene copolymers, acrylic copolymers, and polyvinyl acetate; and
(5) surface coatings for electric potting and insulation, as well as corrosion protection which require elevated temperature applications to cause curing and adhesion, such as nylons, cellulose ester and ethers, polyurethane, polytetrafluoroethylene, polyvinyl acetate, saturated polyesters, unsaturated polyesters and styrene, epoxy and polyamide, and copolymers of ethylene or propylene.
Prior art surface coating systems such as those listed above, are generally mixtures of the stated ingredients in aqueous or organic carrier fluids. In most instances, the coatings are applied to the surfaces to be coated wherein they are allowed to flow over such surfaces forming relatively thin, smooth surface coating films, aided principally by the surface tension forces of the viscous surface coating mixtures. Most surface coating mixtures are comprised of organic and/or inorganic unreacted coating materials, pigments, binders, and carrier fluids, along with other ingredients.
Binders are grouped into certain overlapping classes such as acrylics, vinyls, alkyds, polyesters, and others. The molecular structure of the binders and the forces operating between the molecules largely determine the mechanical properties of the surface coatings. The binders exist in the final surface coating, usually as a polymer of high molecular weight that may or may not be cross-linked. Binders are primarily responsible for the plastic quality of the surface coating.
Prior art surface coating systems are generally designed to be applied as liquids, preferably liquids exhibiting low viscosities, both to wet the surface to be coated, and to facilitate flow into the crevices and asperities which are universally found in solid surfaces. Generally, the necessary adhesive properties are activated in the conventional surface coating system by heating the system to the point where simple flow occurs, by dissolving or dispersing the material in a solvent, or by starting with a composition of liquid monomers or oligomers that polymerize or react after application. Eventually the adhesion producing elements of the conventional surface coating systems must undergo a phase change which is commonly referred to as “drying” and/or “curing,” which phase change is promoted by cooling, heating, solvent evaporation, or interaction with the surfaces to be coated. Ultimately, adhesion takes place as the surface coating systems congeal, cure, and pass from the liquid phase to the solid phase.
Prior art surface coatings generally rely upon the adhesive properties of the surface coating systems and the cleanliness and texture of the surface to be coated to provide adherence of the surface coatings to the coated surfaces. Adhesion is an interfacial phenomenon which involves surface wetting, but the remainder of the phenomenon definition appears to be uncertain. This uncertainty has given rise to several theories concerning the issue.
First, the electrical theory presumes that the adhesiveness of the surface coating systems and the surfaces to be coated are like two plates of a capacitor that becomes charged due to the proximity of the two substances. However, this theory fails to predict the bond that results when a layer of water is frozen and serves to join two blocks of ice, or when an epoxy adhesive is used to join two previously cured blocks of cast epoxy.
Second, the diffusion theory presumes the penetration of the surface to be coated by the surface coating system prior to its solidification. This theory is easily applied to many porous plastics; however, it does not appear applicable to metal, glass, glazed ceramics, etc.
Third, the adsorption theory specifies the concept of forces, such as van der Waals forces, acting across the space between molecules within surface coating system and the surface to be coated.
Fourth, the rheological theory suggests that the removal of weak boundary layers of surface materials such as plastics leaves the mechanical properties of the bond between the surface coating systems and the coated surfaces to be determined by the material composition within the bond region and the local stresses.
The invention set forth herein discloses novel catalyzed surface coating compositions and methods. Compositions include both catalyzed surface coating additives and catalyzed surface coating systems which contain one or more catalysts along with optional other ingredients. Unlike conventional surface coating systems and theories, the catalyzed surface coating compositions of this invention are capable of bonding to the surfaces to be coated by virtue of novel processes involving catalyzed chemical bonding reactions between such compositions and the surface to be coated, without the need for air drying, baking, evaporation of solvents and volatile organic compounds (VOCs), polymerization, phase change or other conventional means of curing, surface roughening, or surface alteration in order to effect adhesion. The chemical bonding of the surface coating is generally accomplished by chemical reactions which are initiated, promoted, accelerated, and/or made to produce greater yields as a consequence of the inclusion of one or more effective catalysts. By this process, for example, the hazards of VOCs and other unwanted surface coating byproducts are eliminated.
The catalyzed compositions of this invention generally consist of colloidal suspensions of very finely divided particles of unreacted surface coating materials (e.g., PTFE) in dispersant fortified carrier fluids (e.g., an aqueous or oil based carrier fluid), along with one or more effective catalysts, and optionally with other ingredients. These compositions may be formulated of ingredients which render them environmentally benign. These compositions may be designed to be applied to a surface to be coated at ambient temperature and atmospheric pressure. Alternatively, the catalyzed chemical bonding reaction may be promoted by increasing temperature and/or pressure. The results are expected to be multi-molecular layers of reaction products derived from PTFE, fluorine containing species, or the reaction products derived from other unreacted surface coating materials after being chemically bonded to the coated surface, although a single-molecular layer of reaction products may also be formed on the coated surface. As used herein, a “carrier fluid” is defined as including an individual fluid or combinations of fluids which may be employed to transport, suspend, distribute, disperse, propel, and/or generally surround and contain the other ingredients of this invention until such ingredients are delivered to the surface to be coated. The carrier fluid may be a lubricant, such as oil or water. In addition, the carrier fluid may be nonvolatile, requiring removal from the coated surface after application, or volatile, carrying the other ingredients to the surface but not remaining on the surface itself.
It is presently known that PTFE, as well as many fluorine containing species by themselves, are both benign and constitute non-stick surfaces that resist the adherence of most other substances. In addition, PTFE, along with various fluorine containing species, present surfaces that are somewhat impact resistant, resist erosion, and exhibit some of the lowest coefficients of friction of any known solid materials. Once the above described catalyzed chemical reactions take place on surfaces, the favorable characteristics of the reaction products, such as those reaction products derived from PTFE and/or various fluorine containing species, are expected to be imparted to the coated surfaces.
The beneficial properties generally expected to be imparted to the coated surface by the catalyzed chemical reactions of this invention include one or more of the following:
(1) increased wear resistance, for example the chemically bonded surface coating (e.g., PTFE) may prevent contact between the underlying surface and another surface or material, hence obviating or diminishing wear;
(2) increased non-stick properties, for example the chemically bonded surface coating (e.g., PTFE) may alter the characteristics of the exposed surface such that ice does not bond, hence providing anti-icing protection;
(3) increased dirt and stain resistance, for example the chemically bonded surface coating (e.g., PTFE), which may be applied to any surface including fabrics such as nylon, polyester, fiberglass, and other man-made and natural fibers, may provide a non-stick outer layer to which dirt and stain will not adhere or penetrate (e.g., for articles of clothing or other articles of manufacture);
(4) reduced coefficients of friction, for example the chemically bonded surface coating (e.g., PTFE) may alter the characteristics of the exposed surface such that the surface assumes the coefficient of friction of the coating material, hence reducing the drag coefficient under direct moving contact, such as those conditions which exist during turbulent flow conditions (e.g., for an aircraft or rocket passing through air, or a ship, submarine or torpedo passing through water);
(5) increased corrosion protection, for example the chemically bonded surface coating (e.g., PTFE) may provide an inert, impermeable outer layer which most corrosive agents cannot penetrate or alter (e.g., for oxidation resistance for structures such as buildings, bridges or near/offshore oil rigs, which are exposed to corrosive external elements such as acid rain or salt water, or for vessels containing corrosive agents);
(6) reduced surface erosion, for example the chemically bonded surface coating (e.g., PTFE) may provide both lubricity and impact resistance which properties serve to obviate or minimize erosion;
(7) improved impact resistance, for example the chemically bonded surface coating (e.g., PTFE) may provide a degree of resilience that may cushion impact better than would the surface prior to being coated;
(8) altered electrical conductivity, for example the chemically bonded surface coating (e.g., PTFE) may impart its electrical characteristics to the surface and in so doing may increase or decrease the electrical conductivity of the coated surface;
(9) altered dielectric constants, for example the chemically bonded surface coating (e.g., PTFE) may impart its electrical characteristics to the surface and in so doing may increase or decrease the effective dielectric constants of the coated surface;
(10) increased radar stealth characteristics, for example the chemically bonded surface coating (e.g., PTFE) may provide reduced reflectance of microwave energy when compared to the uncoated surface (e.g., for military vehicles such as aircraft, rockets or ships);
(11) reduced permeability, for example the chemically bonded surface coating (e.g., PTFE) may provide an impermeable outer layer that excludes the passage of virtually all materials including gases under very high pressures;
(12) increased water proofing, for example the chemically bonded surface coating (e.g., PTFE) may provide an impermeable outer layer which will exclude the passage of water (e.g., for articles of clothing, recreational equipment, or other articles of manufacture);
(13) improved pressure seal, for example the chemically bonded surface coating (e.g., PTFE) may provide an impermeable outer layer which when compressed will deform to some degree and will block fluid passage (e.g., for threads on fluid carrying tubular goods such as pipes or tubes, or for closely fitted metal-to-metal sealing elements like pistons, pneumatic and hydraulic rams);
(14) altered optical properties, for example the chemically bonded surface coating (e.g., PTFE) may provide an outer layer that will, in most cases, change the characteristics of the light reflected off of such surface;
(15) reduced osmosis of gases, for example the chemically bonded inner surface coating (e.g., PTFE) provides a layer that will, in most cases, reduce the ability of gases to osmose through the walls of the pressure vessel or container in which such gases may be stored;
(16) altered surface pigmentation, for example the chemically bonded surface coating material (e.g., PTFE) may include any number of pigments which may serve to add colors, designs, patterns, graphics, etc., to the coated surfaces;
(17) altered surface aesthetic, for example, the chemically bonded surface coating material (e.g., PTFE) may include any number of aesthetic enhancing features such as metal flakes, crystals, oyster shells, pearlescent materials, reflective materials, etc.;
(18) reduced surface energy, for example the chemically bonded surface coating (e.g., PTFE) may provide an outer layer that will tend to exhibit less surface energy than most surfaces to which such coatings may be applied; and
(19) reduced refractive index, for example the chemically bonded surface coating (e.g., PTFE) may provide an outer layer that will tend to reduce the refractive index of most surfaces to which such coating may be applied.
As a further example, the second property listed above, increased non-stick, may be very beneficial to the airline industry. The prior art use of glycols as aircraft deicers has been found to be objectionable because the surplus glycol materials sprayed on the aircraft during deicing operations tend to find their way into the atmosphere, into the soils, and/or into the storm drain systems, all of which events violate the U.S. Federal Clean Air Act and/or the U.S. Federal Clean Water Act. Ethylene glycol is deemed to be toxic by the U.S. Environmental Protection Agency (“EPA”) and is no longer procured by the U.S. Air Force for deicing. Propylene glycol based deicing compounds are less toxic and therefore have been regarded as being more favorable than ethylene glycol; however, such compounds have a significant adverse environmental impact as toxic colloidal dispersions in the atmosphere and as runoff in soils, and in surface and ground waters due to the high biological oxygen demand occasioned by propylene glycol degradation.
In addition, spraying and coating aircraft with various glycol products create a very temporary deicing/anti-icing protective condition that is time dependent, and may be totally ineffective if the aircraft is not launched before the protective coating dissipates. In any event, the degree of protection from this method of deicing is very transitory, with no adequate means of monitoring the duration of its short-lived effective period.
Accordingly, there is a significant need in the prior art for improved anti-icing technology that will exhibit improved longer lasting protection, and which may be designed to not have a negative environmental impact. If such improved anti-icing technology proves to be sufficiently successful, it may obviate the need for deicing in the manner in which it is presently practiced. Moreover, in the event the anti-icing technology imparts certain lubrication qualities, along with a host of other benefits, the merits of such technology may be all the more important.
The anti-icing properties associated with the chemically bonded PTFE and/or other fluorine containing species reaction products are not generally expected to significantly alter the propensity of ice to form on the coated aircraft surfaces, and therefore are not expected to directly contribute as a significant deicing mechanism. However, the aircraft surfaces, coated in accordance with the present invention, are expected to resist the adherence of ice on such coated surfaces. Therefore, if ice forms on the coated aircraft surfaces, it is expected that such ice may be quite simply removed by the stream of turbine engine gases when directed over the wing, fuselage, and other aircraft surfaces through the use of specially designed thrust reversers, by some mechanical displacement means, by a concentrated high pressure focused stream of others fluids (e.g., water), and/or various other means, at least when the aircraft is on the ground. In addition, it is expected that any ice formed on the aircraft non-stick coated surfaces while in flight automatically may be displaced by the inherent ever-present air turbulence continuously impacting the aircraft surfaces. Additionally, an anti-icing coating may be useful on other vehicles besides aircraft, such as ships (including boats), military vehicles, trains, automobiles (including trucks), etc.
Surface coatings are generally applied for the purpose of imparting to the coated surfaces one or more of the many beneficial properties cited above. In this regard, the coating capabilities inherent in this invention may ultimately prove to have advantages, not otherwise available from the state of the art conventional coating formulations and/or methods, with respect to any and all of those surfaces which are presently coated by conventional formulations and methods.
For example, organic halogen polymers, such as PTFE, would be expected to offer several advantages as surface coatings because it is expected that such polymers would impart their special properties to the surface to be coated. However, because of the poor solubility of organic halogen polymers in organic solvents and the need for elevated temperatures to cause the curing and adhesion of such polymers to the coated surface, such coatings and coating methods find very limited applications in the prior art. Furthermore, the relatively high temperatures required for curing and adhesion of the organic halogen polymers, which temperatures may be as high as 380° C., frequently cause the formation of pinholes in the final surface coatings. As a consequence, such organic halogen polymer surface coatings may not be favorably recommended as anti-corrosive coatings in the prior art, despite their inherent excellent chemical resistance.
By way of contrast, the surface coating formulations and methods of the present invention are expected to provide the means by which coatings of organic halogen polymers and other unreacted surface coating materials may be bonded to the coated surface by virtue of a catalytically aided chemical bonding reaction between the unreacted surface coating materials and the surface to be coated generally at or near ambient temperatures and pressures.
In addition to the aircraft surface coating applications set forth above, the surface coatings of this invention are expected to prove advantageous in the coating of any and all objects composed of solid or semisolid materials, including any and all surfaces which are presently coated by conventional coating formulations and methods. For example, the anti-corrosive properties of a chemically bonded surface coating would be very useful for protecting man-made structures, such as buildings, bridges, water or other towers, etc., that are exposed to the elements.
Catalyzed Surface Coating Additives
The present invention consists of novel concepts, including the concept of causing unreacted surface coating materials to become chemically bonded to surfaces as a consequence of catalytically aided chemical bonding reactions. In addition, this present invention provides the basis for a group of formulations for catalyzed surface coating additives, and for catalyzed surface coating systems. The catalyzed surface coating additives may comprise ingredients shown below as Items 1, 2, 3, and 4, and optionally any number of the remaining ingredients shown below as Items numbered 5 through 11.
Catalyzed Surface Coating Additive Ingredients
The ingredients of the catalyzed surface coating additives are as follows:
1. one or more carrier fluids,
2. one or more dispersants,
3. one or more catalysts,
4. one or more unreacted surface coating materials as ingredients wherein such ingredients may include pigmentation and other aesthetic features, and wherein one or more of the ingredients are selected from the unreacted surface coating materials group consisting of Teflon®, PTFE, polytetrafluoroethylene, perfluoropolyether, polyvinylidene fluoride, perfluoropolyether oxide, ethylene polymers, propylene polymers, fluorophenylene polymers, other polymers, other fluorinated inorganic and organic compounds, other fluorine containing species, plastics, ethers, amides of fatty acids, other monoesters of fatty acids, fatty acid compounds, metallic soaps, polyol molybdenum compounds, graphite, carbon halogens, barium fluoride, calcium fluoride, lithium fluoride, sulfurized fats, and esters,
5. any number of catalysts, wherein such catalysts are transition elements, and/or one or more compounds, in which one or more transition elements are included, and/or any combination of transition elements and compounds in which transition elements are included, wherein the transition elements are identified as those elements bearing atomic numbers 21 through 31, 39 through 49, and 71 through 81, all inclusive,
6. any number of catalysts, wherein such catalysts are non-transition elements, and/or one or more compounds in which one or more non-transition elements are included, and/or any combination of non-transition elements, and compounds of non-transition elements,
7. any number of catalysts wherein such catalysts are any combination of transition elements, non-transition elements, compounds in which transition elements are included, and/or compounds in which non-transition elements are included,
8. any number of catalysts, where such catalysts are homogeneous, heterogeneous, or any combination of homogeneous and heterogeneous catalysts,
9. any number of halogen elements, and/or any number of compounds in which halogen elements are included, and/or any combination of halogen elements and/or compounds in which halogen elements are included,
10. any number of detergents, and
11. any number of freezing point and/or boiling point altering agents.
Catalyzed Surface Coating Systems
The catalyzed surface coating systems of this invention comprise one or more of the catalyzed surface coating additives of this invention admixed with one or more carrier fluids, along with any number of other ingredients.
It is anticipated that the catalyzed surface coating systems of this invention shall be delivered to the surface to be coated by a number of different conventional methods well known to those skilled in the art, such as spray coating, immersion, brushing, wiping, mechanical transference, etc., and all such delivery methods are intended to be within the scope of the present invention.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives and catalyzed surface coating system formulations designed to impart one or more of the previously cited beneficial properties to the surfaces coated with such surface coatings.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives, specifically including one or more carrier fluids, dispersants, catalysts, unreacted surface coating materials, and any number of other ingredients.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives which shall include one or more carrier fluids, dispersants, catalysts, unreacted surface coating materials, and any number of halogen sources, detergents, freezing point and/or boiling point altering agents, and any number of other ingredients.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives wherein the ingredients, in addition to one or more of the dispersants, catalysts, and unreacted surface coating materials, include water as a carrier fluid.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives wherein the ingredients, in addition to one or more carrier fluids, dispersants, and unreacted surface coating materials, include one or more catalysts from the group, including but not limited to, one or more transition elements, and/or one or more compounds in which transition elements are included, and/or any combination of transition elements and transition element compounds, where the transition elements are identified as those elements bearing atomic numbers 21 through 31, 39 through 49, and 71 through 81, all inclusive.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives wherein the ingredients, in addition to one or more carrier fluids, dispersants, and unreacted surface coating materials, include one or more catalysts from the group, including but not limited to, one or more non-transition elements, and/or one or more compounds in which non-transition elements are included, and/or any combination of non-transition elements and non-transition element compounds.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives wherein the ingredients, in addition to one or more carrier fluids, dispersants, and unreacted surface coating materials, include one or more catalysts in concentrations required to initiate, to promote, to accelerate, and/or to increase the yield of reaction products and function effectively in the surface coating in situ catalyzed bonding reaction.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives wherein the ingredients, in addition to one or more of the carrier fluids, dispersants, catalysts, and unreacted surface coating materials, include a halogen source comprised of one or more halogen elements and/or compounds in which halogen elements are included, to function as starters and to contribute to the mass effect of the catalyzed surface coating reactions.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives wherein the ingredients, in addition to one or more of the carrier fluids, dispersants, catalysts, and unreacted surface coating materials, include detergents to facilitate better chemical interaction with the surface to be coated.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives wherein the ingredients, in addition to one or more of the carrier fluids, dispersants, catalysts, and unreacted surface coating materials, include freezing point and/or boiling point altering agents to broaden the ambient temperature conditions under which the catalyzed surface coating additives can be applied effectively.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating additives wherein the ingredients, in addition to one or more of the carrier fluids, dispersants, catalysts, and unreacted surface coating materials, include any number of other ingredients.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel catalyzed surface coating systems comprised of one or more catalyzed surface coating additives and one or more carrier fluids.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel methods to provide catalytically aided bonded surface coatings wherein catalyzed surface coating systems are applied to the surfaces to be coated, and the contact between said catalyzed surface coating systems and said surfaces results in catalytically aided chemical bonding reactions, which reactions, when completed, provide said surfaces with chemically bonded surface coatings.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel methods to provide catalytically aided bonded surface coatings wherein catalyzed surface coating systems are applied to the surfaces to be coated, and the contact between said catalyzed surface coating systems and said surfaces results in catalytically aided chemical bonding reactions, which reactions, when completed, provide said surfaces with chemically bonded surface coatings, all of which reactions go to completion under naturally occurring ambient temperature and pressure conditions.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel methods for applying surface coatings with the catalyzed surface coating systems of this invention.
It is a technical advantage of at least one preferred embodiment of the present invention to establish one or more novel methods to provide catalytically aided bonded surface coatings wherein such surface coating methods are applied to the surfaces to be coated, after the surfaces have been cleaned and are free of other coatings and/or any materials extraneous to the catalyzed surface coating reaction.
It is a technical advantage of at least one preferred embodiment of the present invention to impart one or more beneficial properties to the surfaces coated by the novel methods of this invention.
It is a technical advantage of at least one preferred embodiment of the present invention to establish a novel method of deicing aircraft by focusing the turbine intra-stage gases and/or the turbine exhaust gases of the aircraft engine and/or engines and/or of an auxiliary power unit (APU) on the ice-bearing aircraft surfaces to remove said ice through physical displacement and/or melting of said ice by said gases, prior to flight.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
DETAILED DESCRIPTION
After the filing of U.S. patent application Ser. No. 08/639,196, a number of tests have been conducted on a representative selection of catalyst candidates. More specifically, the catalyst candidates were admixed with a colloidal suspension of PTFE wherein the PTFE was in the form of particles, ranging in diameter from 2 microns down to submicron size, all suspended in a hydrocarbon mineral oil base (motor oil) treated with dispersants. This mixture was then admixed with graphite fluoride and halocarbon oil. The final composition of the mixture was as shown in Table 1 below:
TABLE 1
Catalytic Lubricant System
Ingredients
Weight %
Lubricant Base (motor oil)
92.0
Dispersant
1.2
PTFE
0.8
Graphite Fluoride
2.0
Halocarbon Oil
2.0
Catalyst
2.0
Total
100.0
Iron coupons with a radius of approximately one centimeter were cleaned and immersed in the above defined colloidal suspension for a period of eight hours at temperatures ranging from 50° C. to 200° C. and at atmospheric pressure. Following this immersion, the coupons were thoroughly rinsed to remove any unbonded solid PTFE material. The surfaces were then analyzed using X-ray Photoemission Spectroscopy (XPS) methods to detect carbon, fluorine, oxygen, and iron. The primary indicator used to determine the concentration of bonded PTFE and/or “fluorine containing species” on the iron surfaces was the intensity of the fluorine photoemission peaks, as displayed by the XPS equipment. It is believed that in the present catalytically aided chemical bonding process, a number of C—F bonds are broken to produce free fluorine along with a number of undefined remnants of the original PTFE molecules from which the fluorine and/or remnants were derived. These remnants, other similarly constituted compounds, and other substances which contain or contribute fluorine to the process are referred to by the all-inclusive term, “fluorine containing species,” herein.
By this method a number of the tested catalyst candidates appeared to be effective in causing the PTFE and/or other fluorine containing species to bond to the surface of the iron coupon at 0 psia and 100° C., the conditions existent within the sample compartment of the XPS equipment.
Subsequently, tests were conducted wherein the graphite fluoride, halocarbon oil and the catalyst were eliminated from the composition of the mixture into which the coupons were immersed, leaving only one remaining source of fluorine in the mixture, PTFE. Using the same test procedures cited above, very little PTFE and/or fluorine containing species were to be found bonded to the surface of the iron coupon. However, even in the absence of a catalyst candidate minor fluorine peaks were observed, indicating that minor amounts of PTFE and/or fluorine containing species had bonded to the iron coupon surface. It is believed in these instances that the iron of which the coupon was composed, which iron material is one of the transition elements known to exhibit catalytic properties in certain reactions, perhaps performed catalytic functions in these cases. As discussed hereinafter, ferric (iron) fluoride was generally shown to be an effective catalyst in this series of tests, which fact serves to lend additional credence to the above stated belief.
After conducting a number of duplicate tests, and several collateral confirming tests, it was further shown that the family of accumulated test results generally constituted support of the concept that PTFE and/or fluorine containing species could be caused to bond to the surface of the iron coupons at temperatures ranging from 50° C. to 200° C. at atmospheric pressure, and remain bonded to the coupon surface while being tested in the XPS equipment chamber at 100° C. and 0 psia.
In subsequent conventional tribological wear tests, in particular the Ball on Cylinder Test, the Predictive FZG Gear Test, the Predictive Ryder Gear Test, and the Shell Four-Ball Test, the introduction, one at a time, of six of the seven catalysts generally shown to be effective by the XPS test methods cited above, without the inclusion of any other ingredients, generally showed each of these catalysts to be individually very effective in improving the wear resistance of two specific commercial engine treatment lubricant products, Quaker State Slick 50® and Valvoline TM8®, both of which products contained PTFE. Most of these tests were conducted at 87° C. and at atmospheric pressure.
The same conventional tribological wear tests were run on a catalytic lubricant system containing the same ingredients as those displayed in Table 1, but in different concentrations, and ferric fluoride (FeF 3 ) was employed as the catalyst. The results showed this system to exhibit wear resistance, based on the Ball on Cylinder Test results, that were approximately three (3) times as great as the SAE 10W-30, API Service Category SJ, SH motor oil which was the lubricant base of this system.
The laboratory tests designed to establish specifications for the concepts contained in this invention are ongoing and it is expected that eventually an entire catalog of catalysts shall be developed, wherein the efficacy of the many different catalysts of this invention shall be defined with respect to their capability to initiate, to promote, to accelerate, and/or to increase the yield of the reaction products of this invention. The tested catalysts thus far generally shown to effectively promote the bonding reaction between an iron surface and PTFE and/or fluorine containing species, at the test conditions of 100° C. and 0 psia, are shown in Table 2 below:
TABLE 2
Tested Effective Catalysts
Symbol
Designation
1.
Pt
Platinum
2.
FeF 3
Ferric fluoride
3.
AlF 3
Aluminum trifluoride
4.
Na 3 AlF 6
Synthetic cryolite
5.
ZrF 4
Zirconium tetrafluoride
6.
TiF 3
Titanium trifluoride
7.
TiF 4
Titanium tetrafluoride
The catalysts may be grouped into various categories, such as transition metal-containing catalysts, fluorine-containing catalysts, aluminum-containing catalysts (including alumina), or other groupings. Each of the catalysts listed in Table 2 were tested at a concentration of two weight percent (2%). The optimal and/or minimal catalyst concentrations have not as yet been established. It is preferred that the catalyst is present in an amount sufficient only to act as a catalyst so as to initiate, to promote, to accelerate and/or to increase the yield of the surface coating chemical bonding reaction, with the catalyst remaining unchanged at the completion of the reaction. The specific weight percent concentration for the catalyst depends on the specific catalyst, but it is generally preferred that the weight percent be made as low as possible. For example, the weight percent is preferred to be under about 2%, more preferably under about 1%, even more preferably under 0.5%, and most preferably under about 0.1%.
One of the preferred and perhaps simplest embodiments of this invention is a composition comprising an aqueous carrier fluid, one or more dispersants for the purpose of creating a stable colloidal suspension of the mixture of ingredients, colloidal particles of PTFE as the unreacted surface coating materials, and one or more catalysts.
As used herein, the term “colloidal particles” generally means particles that have diameters ranging from approximately one micrometer to one nanometer. Because of the various forces acting between the particles and the dispersant fortified aqueous carrier fluid in which the particles are suspended, it is expected that the particles shall generally never precipitate or settle out of suspension for all practical purposes, unless subjected to extraordinary circumstances. There are many dispersants known to those skilled in the art, including organic polymers (e.g., polyacrylates, polymaleates, and acrylamide polymers) and condensed phosphates (e.g., polyphosphate salts). The PTFE commonly is reduced to colloidal size by having been subjected to bombardment in air by a strong electron beam or by a gamma ray. The bombardment process reduces the PTFE polymer to shorter chain PTFE molecules, and/or other fluorine containing species, which comprise other chemically active functional groups formed at the points of bond rupture. These active functional groups generally facilitate the establishment of a stable colloidal suspension and aid in the establishment of chemical bonding to the surfaces to be coated.
Preferred Embodiment of Catalyzed Surface Coating Additive
A preferred embodiment of a catalyzed surface coating additive of this invention is as shown in Table 3 below.
TABLE 3
Preferred Embodiment of Catalyzed Surface Coating Additive
Ingredients
Weight %
1.
Carrier Fluid
74.0
Water
2.
Dispersant
6.0
Polymer-Amine
3.
Catalyst
4.0
Synthetic Cryolite (Na 3 AlF 6 )
4.
Unreacted Surface Coating Materials
4.0
PTFE Colloidal Particles in a Stable Colloidal System
5.
Halogen Source
4.0
Stannous Fluoride
6.
Primary Detergent
4.0
Alkylphenolsalicylate Detergent
7.
Freezing Point and/or Boiling Point Altering Agents
4.0
Ethyl Alcohol
Total
100.0
Preferred Embodiment of Catalyzed Coating
A preferred embodiment of a catalyzed coating system of this invention is as shown in Table 4 below.
TABLE 4
Preferred Embodiment of Catalyzed Coating System
Ingredients
Weight %
1.
Catalyzed Surface Coating Additive
20.0
See formulation above.
2.
Carrier Fluid
80.0
Water
Total
100.0
The catalyzed surface coating additive may generally be used as an efficient method of transporting and storing a concentrated mixture which is intended to be added to a carrier fluid before application. Once mixed together with a carrier fluid to make the catalyzed surface coating system, the weight percentages of the preferred embodiments illustrated in Tables 3 and 4 would be as shown in Table 5 below.
TABLE 5
Detailed Weight Percentages of Preferred Embodiment
Catalyzed Surface Coating System
Ingredients
Weight %
1.
System Carrier Fluid
80.0
Water
2.
Additive Carrier Fluid
14.8
Water
3.
Dispersant
1.2
Polymer-Amine
4.
Catalyst
0.8
Synthetic Cryolite (Na 3 AlF 6 )
5.
Unreacted Surface Coating Materials
0.8
PTFE Colloidal Particles in a Stable Colloidal System
6.
Halogen Source
0.8
Stannous Fluoride
7.
Primary Detergent
0.8
Alkylphenolsalicylate Detergent
8.
Freezing Point and/or Boiling Point Altering Agents
0.8
Ethyl Alcohol
Total
100.0
With respect to the composition of the preferred embodiment catalyzed coating system above, it is believed that the formation of a surface coating on the coated surface involves bonding reactions between the PTFE and/or fluorine containing species and the underlying surface to be coated. The surface coating may comprise one or more of the following characteristics: multilayered, persistent, solid, corrosion resistant, impact resistant, wear resistant, and non-stick (e.g., anti-icing). In such reactions, it is believed that fluoride radicals are progressively delivered to the surface from the PTFE and/or the fluorine containing species, and in turn hydrogen is bonded in part to the former PTFE molecules and/or fluorine containing species, in place of the lost fluorine. Ultimately, where these types of reactions go to completion, the PTFE molecules and/or fluorine containing species may be converted to simple aliphatic hydrocarbon molecules, much like the composition of paraffin base mineral oils. The reactions are promoted by the presence of the catalyst or catalysts; however, any such catalysts are not consumed in the process. By definition, a catalyst is an agent present during a reaction, and an agent that may have a measurable effect on the initiation, the promotion, the rate, and/or the yield of the reaction, but remains unchanged chemically at the conclusion of the reaction.
The halogen source is generally a different material from the catalyst and the unreacted surface coating material, although for some applications it may be the same as either. Halogens are defined as the electronegative elements of Group VIIA of the periodic table and include, in descending order of activity, fluorine, chlorine, bromine, iodine, and astatine. Fluorine is the most active of all chemical elements, and hence is the most active halogen. The halogen source includes halogen elements and halogen element compounds, such as aluminum trifluoride (AlF 3 ), cryolite (Na 3 AlF 6 ), metal fluoroborates (e.g., Fe(BF 4 )), fluorospar (CaF 2 ), fluorapatite (Ca 5 (PO 4 ) 3 F), metal fluorides (e.g., FeF 3 , SnF 2 , ZnF 2 ), organic halogen polymers (e.g., polytetrafluoroethylene, polychlorotrifluoroethylene), halogenated hydrocarbons, other halogenated inorganic compounds, and other halogenated organic compounds.
The catalytically aided chemical bonding reactions discussed above cause an alteration in the chemical composition of the exterior of the coated surfaces, wherein the newly created and exposed surfaces then serve to redefine the performance of such surfaces.
The effectiveness of this invention is expected to be comparatively better than other alternatives in that the catalytic action serves to initiate, to promote, to accelerate the PTFE and/or fluorine containing species bonding reactions, and/or to increase the yield of the bonded PTFE and/or fluorine containing species derived surface coating films. In addition, the rapidly catalyzed, bonded surface coating film formation, and increased production of bonded surface coating film yields, will generally serve to fully coat the surface to which it is applied, and maximize the protection of such surface. In some applications, such as an anti-icing application, the film may diminish the opportunity for adjacent surfaces, which are absent bonded surface coatings (if any exist), to allow adherence of ice. However, it is preferred that when surfaces are maintained and replenished with enduring, continuous, protective, and bonded PTFE and/or fluorine containing species derived surface coating films, there will preferably be few or no uncoated unprotected surfaces. Additionally, it is not generally expected that this invention will reach the state of 100% surface protection for all purposes, but it is generally expected that with the application of this invention the goal of 100% surface protection has the prospect of being more nearly reached than by any other presently known method.
Based on research work conducted by L. L. Cao et al. at the Tribology Research Institute, Tsinghua University, Beijing, China, it was shown that metallic wear surfaces exposed to compressed contact with PTFE under elevated temperature conditions (i.e. 1800° F.), but without the presence of a catalyst or catalysts, resulted in surface film depositions that could be qualitatively divided into four layers, including the outermost layer of PTFE. A lubricating base oil carrier fluid containing PTFE was subjected to friction induced high temperature wear conditions and when the test was completed, the contacting surfaces of the iron (Fe) test specimens were analyzed using X-ray Photoelectron Spectroscopy and a Scanning Auger Microprobe. The chemical state of the fluorine containing species in the reaction films were shown to display four different chemical structures. The chemical structures and the related binding energies were as shown in Table 6 below.
TABLE 6
Composition of Reaction Products After L. L. Cao et al.
Binding
Chemical
Energy,
Description
Structure
Designation
eV
1.
Outermost Layer
(—CF 2 —CF 2 —)
Polytetra-
689.72
fluoroethylene
2.
Second Layer In
(—CFH—CFH—)
Polydi-
688.50
fluoroethylene
3.
Third Layer In
(—CFH—CH 2 —)
Polymono-
687.45
fluoroethylene
4.
Metal Surface
FeF x (x = 2 & 3)
Ferrous &
684.42
Ferric Fluoride
It was generally established that multilayered surface reaction films, with the structural layers set forth in Table 6, were formed on the metallic surface. The outermost or first layer was composed of an absorbed film of PTFE. The second layer was composed of a mixed reaction film, including various fluorine containing species, shown as Item 2 in Table 6. The third layer, shown as Item 3 in Table 6, exhibited a chemical structure in which there was a paucity of fluorine with respect to the second layer. The deepest layer, the fourth layer, shown as Item 4 in Table 6, consisted primarily of ferrous and ferric fluoride, along with some microparticles of PTFE.
The progression of chemical reactions postulated to develop the final four layers diagnosed by L. L. Cao et al., would be as follows:
1. Outermost Layer
1.1 Absorption of Polytetrafluoroethylene:
(—CF 2 —CF 2 —)
PTFE
2. Second Layer In
2.1 Dehydrogenation of Base Oil:
2.2 Severance of Fluorine-Carbon Bonds and First Stage Hydrogenation of PTFE:
3. Third Layer In
3.1 Dehydrogenation of Base Oil:
3.2 Added Severance of Fluorine-Carbon Bonds and Second Stage Hydrogenation of PTFE:
4. Metal Surface
4.1 Polymonofluoroethylene Bonding Reaction with Iron and Fluorine:
4.2 Fluorine Reaction with Ferrous Iron:
4.3 Fluorine Reaction with Ferrous Fluoride:
*In the “Metal Surface” reaction, 4.1 above, the reaction products could be as shown, or could be one or a combination of reaction products (fluorine containing species) selected from a group consisting of the following:
4.1.1
Fe(—CF 2 —CF 2 —) 2 ,
4.1.2
Fe(—CF 2 —CFH—) 2 ,
4.1.3
Fe(—CFH—CFH—) 2 ,
4.1.4
Fe(═CF—CFH—),
4.1.5
Fe(═CF—CF═),
4.1.6
FeF(—CF 2 —CF 2 —),
4.1.7
FeF(—CFH—CH 2 —),
4.1.8
Fe(—CF 2 —CF 2 —) 3 ,
4.1.9
Fe(—CF 2 —CFH—) 3 ,
4.1.10
Fe(—CFH—CFH—) 3 ,
4.1.11
2Fe(═CF—CFH—) 3 ,
4.1.12
2Fe(═CF—CF═) 3 , and
4.1.13
FeF 2 (—CF 2 —CF 2 —).
Whereas L. L. Cao et al. disclosed results wherein they dealt with a carrier fluid composed of hydrocarbon oil and a surface to be coated or substrate of iron (Fe), it is believed that essentially the same series of postulated chemical reactions would theoretically apply for other carrier fluids, such as an aqueous composition. The carrier fluid of the present invention is preferably liquid, but may also be a gas. For example, a refrigerant, such as a CFC or a more environmentally safe alternative, is liquid under pressure, but a liquid that changes to a gas at ambient conditions. Such a carrier fluid could be used to transport the other ingredients to a surface as a gaseous carrier fluid, leaving the other ingredients on the surface. Also, it is believed that the reaction products would be analogous, if, rather than iron (Fe), the substrate were alloys of iron, aluminum, magnesium, plastics, carbon fiber, glass fiber, resin/fiber composites, natural fibers, or other materials commonly employed in the fabrication of articles of manufacture, which may benefit from the protection of a surface coating such as those catalyzed surface coatings of this invention.
Also, in view of the fact that fluorine is the most electronegative element and the most reactive nonmetal known, it is postulated that it will react with virtually any material of which the surface to be coated may be constructed. Furthermore, it is anticipated that the progression of the in situ chemical reactions, postulated for the case wherein the coated surface was constructed of iron, would be essentially the same except that the chemical symbol for the material of the alternate surfaces to be coated may be different. In the event such surface material was other than iron, the chemical symbol for iron (Fe) would be replaced by the chemical symbol for the alternate surface material, and the combining ratios would be appropriately adjusted.
The presence of the catalyst, such as the synthetic cryolite in a preferred embodiment of this invention, serves to initiate the reactions, to promote the reactions, to accelerate the reactions, and/or to cause the reactions to exhibit a greater yield, and to allow the reactions to go to completion more rapidly under ambient conditions. As used herein with respect to the catalytic chemical bonding reaction, the generic term “promote” means one or more of the actions described above, i.e., initiate, promote, accelerate, cause to exhibit a greater yield, and allow to go to completion more rapidly. Any non-liquid or non-gaseous ingredients in the composition are preferably of colloidal size.
As used herein with respect to a group of two or more terms (e.g., a list of materials or processes), the phrases “and”, “or”, and “and/or” are generally intended to indicate any one of the terms or combinations of any of the terms. As used herein with respect to a group of materials, the phrase “any number” is intended to include the number 0 or greater.
Although this invention has been described in conjunction with a specific embodiment, it is evident that many alternatives, modifications, variations, and permutations will be apparent to those skilled in the relevant arts, in light of the foregone descriptions and discussions. Other embodiments will become apparent to those skilled in the relevant arts from a consideration of the concept, scope, spirit, specifications, and practices of this invention. It is contended that the alternatives, modifications, variations, and permutations in the embodiment and methods of this invention may be practiced, without departing from the concept, scope or spirit of this invention disclosed herein. Accordingly, it is contended that this invention is not confined to the particular embodiments, formulations, reactions, and methods presented herein, but rather such alternatives, modifications, variations, and permutations can be made herein without departing from the spirit and scope of the invention as defined by the Claims presented hereinafter.
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This invention discloses novel catalyzed surface composition altering formulations and methods and catalyzed surface coating formulations and methods, which contain one or more catalysts, along with optional other ingredients, wherein the catalysts serve to effect in situ chemical bonding reactions in that the catalysts function to initiate, to promote, to accelerate, and/or to increase the formation and yield of persistent, solid, corrosion-resistant, impact-resistant, wear-resistant, and/or non-stick surface compositions and surface coating films, which may exhibit pigmentation and other aesthetic features, and may be designed to be environmentally benign. This invention discloses novel means to alter the surface composition and to coat the surface of metals, plastics, fabrics, woods, and the like through catalytically supported chemical reactions that produce functionally improved surface performance for industrial, commercial, domestic and other purposes.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a water aerator and more specifically it relates to a Residential In-well Internal Water Aerator for the reduction/elimination of iron, hydrogen sulfide (rotten egg smell) and radon gas in residential wells.
2. Description of the Related Art
It can be appreciated that water aerators have been in use for years. Typically, water aerators are comprised of individual units which stand alone and are separate from the pump and delivery system of existing water systems. The main problem with conventional water aerators is the cost factor required in their set up. Another problem with conventional water aerators is that they are water aerators is the amount of property that is required to install the reservoir or tower. Requirements to achieve the desired aeration process with other water aerators such as mechanical water aerator systems, is the secondary power cost, as well as the ongoing maintenance costs.
While these devices may be suitable for the particular purpose to which they address, they are not as suitable for the average residential well in the reduction/elimination of iron, hydrogen sulfide (rotten egg smell) and radon gas. The main problem with conventional water aerators is that they are impractical for the average residence due to the cost factor involved in continuing maintenance, building specialty units and or the construction of a aeration spillway/aeration tower etc. Another problem with mechanical water aerator systems is the amount of property required to install the above aforementioned devices. Another problem with mechanical water aerator systems is the ongoing power and maintenance cost along with the number of pieces of equipment necessary for the aerator to function properly and be fault free. In these respects, the Residential In-well Internal Water Aerator according to the present invention substantially primarily located in reservoirs and water towers. Another problem with conventional departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of the reduction/elimination of iron, hydrogen sulfide (rotten egg smell) and radon gas.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of water aerators now present in the prior art, the present invention provides a new Residential In-well Internal Water Aerator construction wherein the same can be utilized for the reduction/elimination of iron, hydrogen sulfide and radon gas at the well site.
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new Residential In-well Internal Water Aerator that has many of the advantages of the water aerator mentioned heretofore and many novel features that result in a new Residential In-well Internal Water Aerator which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art water aerator, either alone or in any combination thereof.
To attain this, the present invention generally comprises an aerator nozzle and controls, UV light (optional) drip chambers, GAC (granular activated charcoal) filter chambers in sequence. Each section screws together to create an apparatus that hangs from the well cap. The water is pumped to the aerator by the well pump where the water is misted/aerated and drips through the series of drip screens, UV light (optional in drip chamber # 5 ), two GAC (granular activated carbon) filters to improve the taste and odor. The aeration in turn creates the degassing process of hydrogen sulfide, radon gas, and the precipitation process of iron.
This process is a continual recirculation of the water in the well, and allows the Residential In-well Internal Water Aerator to become an iron trap and a degassing chamber away from the premises and within the well casing, therefore continuously reducing the iron content and the degassing of the hydrogen sulfide and radon gas in the water provided to the residence. The Residential In-well Internal Water Aerator will need to be maintained on an as need basis. On a semi regular basis the control valve to the Residential In-well Internal Water Aerator needs to be exercised (closed and opened). This in turn flushes the nozzle and helps prevent the nozzle from clogging. The higher the iron content of the raw water source the more frequently the cleaning process of the Residential In-well Internal Water Aerator will be required. This involves pulling the unit from within the well casing, hosing it down (washing off the iron solids), and reinserting it into the well. This process can be done in about 30 to 40 minutes. This is not a stand alone system. Water is supplied to the Residential In-well Internal Water Aerator by a tap into the main water pipe of the residence directly from the pump at the well casing. Tap may also be done in the garage or basement for easy access to controls. The Residential In-well Internal Water Aerator is a leach system using existing pumps and pipes in turn supplies and rotates the raw source water in the well.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter.
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 the description and should not be regarded as limiting.
A primary object of the present invention is to provide a Residential In-well Internal Water Aerator that will overcome the shortcomings of the prior art devices. An object of the present invention is to provide a Residential In-well Internal Water Aerator that reduces/eliminates iron, hydrogen sulfide (rotten egg smell), and radon gas in residential wells.
Another object is to provide a Residential In-well Internal Water Aerator that is a chemical free answer for the reduction/elimination of iron, hydrogen sulfide (rotten egg smell), and radon gas from residential wells.
Another object is to provide a Residential In-well Internal Water Aerator that is economical and can be afforded by all in need.
Another object is to provide a Residential In-well Internal Water Aerator that does not have a continuous chemical replacement factor.
Another object is to provide a Residential In-well Internal Water Aerator that has no moving parts to wear out and DOES NOT require the continual replacement of certain segments of the equipment.
Another object is to provide a Residential In-well Internal Water Aerator that has a simplified maintenance program that the average homeowner can handle.
Another object is to provide a Residential In-well Internal Water Aerator that keeps the unpleasant smell of hydrogen sulfide away from the residence.
Another object is to provide a Residential In-well Internal Water Aerator that traps significant amounts of the iron on the apparatus and not on the fixtures and appliances in the residence.
Another object is to provide a Residential In-well Internal Water Aerator that greatly reduces/eliminates radon gas in the well water.
Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope of the present invention.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
FIG. 1 is a perspective view of the present invention showing the inside of the well casing.
FIG. 2 is a an Exploded/cross section view of the present invention showing all of the components of the first chamber GAC (granular activated carbon)/degassing/drip through chamber.
FIG. 3 is an exploded view of the present invention showing all of the components of the second Chamber GAC/drip through chamber.
FIG. 4 is an exploded/cross section view of the present invention showing all of the components of the third chamber aeration/degassing/drip chamber.
FIG. 5 is an exploded/cross section view of the present invention showing all of the components of the fourth Chamber aeration/degassing/drip chamber.
FIG. 6 is an exploded/cross section view of the present invention showing all of the components/specification of the fifth chamber aeration/degassing/drip chamber with optional UV lamp.
FIG. 7 is an exploded overview of the present invention showing all of the components/specifications of chamber the supply controls/nozzle apparatus installed in the fifth chamber.
FIG. 8 is an exploded/cross section view of the present invention showing all of the components/specification of the present aerator screens.
FIG. 9 is an exploded view of the present invention showing the optional UV light in place in the fifth chamber
FIG. 10 is an exploded view of the present invention showing the installation rod in place in the fifth chamber (applicable in all 5 chambers) during installation and removal in/from the well casing.
DETAILED DESCRIPTION OF THE INVENTION
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the attached figures illustrate a Residential In-well Internal Water Aerator which comprises a series of chambers attached together by conventional means. This is NOT a stand alone system. The Water/H2O is supplied to the Residential In-well Internal Water Aerator by a tap into the main water supply pipe line of the house directly from the pump at the well casing.
FIG. 1 . illustrates a perspective view of the invention within the well casing 101 . The high pressure tubing 111 as shown in FIG. 7 connects to a 90 degree street ell 113 that is connected to a nipple 108 B, a clean out plug 114 , a flat washer 113 , a galvanized coupler 116 and nozzle 117 from which the misting begins the aeration/drip process within the said Residential In-well Internal Water Aerator. (The water supply process will be explained in more detail in FIG. 7 ). The street ell/nozzle apparatus is the basis which allows the Residential In-well Internal Water Aerator to hang from the well cap 102 . The aeration/drip process takes place inside five 5-foot chambers, 118 , 127 , 128 , 130 , and 131 which are screwed together to hang from the well cap 102 .
FIG. 2 illustrates an exploded/cross section view of the first chamber 131 to be inserted into the well casing 101 and is comprised of a pvc pipe with GAC (Granular Activated Carbon) filtering media for the purpose of taste/odor control of hydrogen sulfide removal and degassing ports 122 and ( 122 A for a top view of same). There is a male adapter 126 at the bottom of the first chamber 131 and a female adapter 135 at the top of the first Chamber 131 for the purpose of attaching to the second chamber 130 . Two grommets 122 have been placed near the top for the purpose of securing a ¼″ nylon safety line. Two installation port holes 119 are drilled through the chamber 131 2″ from the top for the purpose of inserting the installation rod 120 ( FIG. 10 ) during installation and removal of the Residential In-well Internal Water Aerator in/from the well casing 101 , allowing for hands free installation/removal.
FIG. 3 is an exploded/cross section view of the second chamber 130 to be inserted into the well casing 101 and is comprised of a pvc pipe with GAC filtering media for the purpose of odor/taste control of hydrogen sulfide removal. There is a male adapter 126 at the bottom of the second chamber 130 for the purpose of attaching to the first chamber 131 . A male adapter 126 is located at the top of the second chamber 130 for the purpose of attaching to the third chamber 128 . At the bottom of the second chamber 130 immediately above the male adapter 126 is a fiber ventilation plug 129 to prevent the loss of GAC filtering media but allowing the water to flow through. Two installation port holes 119 are drilled through the chamber 130 2″ from the top for the purpose of inserting the installation rod 120 ( FIG. 10 ) during installation and removal of the Residential In-well Internal Water Aerator in/from the well casing 101 , allowing for hands free installation/removal.
FIG. 4 is an exploded/cross section view of the third chamber 128 to be installed into the well casing 101 and is comprised of a pvc pipe with degassing ports 122 and ( 122 A for the top view of same and internal drip aerator screens 124 and ( 124 A for the top view of the same) inserted vertically into the third chamber 128 . Two installation port holes 119 are drilled through the third chamber 128 2″ from the top for the purpose of inserting the installation rod 120 ( FIG. 10 ) during installation and removal of the Residential In-well Internal Water Aerator in/from the well casing, allowing for hands free installation/removal.
FIG. 5 is an exploded/cross section view of the fourth chamber 127 to be inserted into the well casing 101 and is comprised of a pvc pipe with degassing ports 122 and ( 122 A for the top view of the same), and internal drip aerator screens 124 and ( 124 A for the top view of same) ( FIG. 8 ) inserted vertically into the fourth chamber 127 . There is a female adapter 135 B at the bottom of the fourth chamber 127 and a male adapter 126 A at the top of the fourth chamber 127 . Two installation port holes 119 are drilled through the fourth chamber 127 2″ from the top for the purpose of inserting the installation rod 120 ( FIG. 10 ) during installation and removal of Residential In-well Internal Water Aerator in/from the well casing, allowing for hands free installation/removal.
FIG. 6 is an exploded/cross section view of the fifth and final chamber 118 to be inserted into the well casing 101 and is comprised of a pvc pipe with degassing ports 122 and ( 122 A for a top view of the same) and internal drip aerator screens 124 and ( 124 A for a top view of same) are inserted vertically into the fifth chamber 118 . This component has a female adapter 135 C at the bottom of the fifth chamber 118 , and a female adapter 135 D at the top of the fifth chamber 118 with a cleanout plug 114 .
The cleanout plug 114 has a hole an access port 115 , drilled in the top for the purpose of inserting the nozzle apparatus FIG. 7 108 B, 113 , 116 and 117 to be further explained in FIG. 7 which in turn mists the water starting the aeration process. An optional UV light 125 ( 126 A 125 A for a top view of same) can be centrally inserted into the fifth drip chamber 118 held in place by the internal drip aeration screens 124 ( 124 A for a top view of same). Two installation port holes 119 are drilled through the fifth chamber 2″ down from the top for the purpose of inserting the installation rod 120 ( FIG. 10 ) during installation and removal of Residential In-Well Internal Water Aerator in/from the well casing 101 , allowing for hands free installation/removal.
FIG. 7 is an exploded/overview showing the water supply/controls for the Residential In-Well Internal Water Aerator. It will be necessary to expose an area about not less than 2′ wide by 4′ long to provide access to of the primary water supply line 104 from the pump to the house on the outside of the well casing 101 to allow for the necessary tap. A hole will also need to be drilled offset of center in the top of the well casing cap 102 . (Be sure to note the location of the existing pitless adapter or well seal before drilling the hole in order to allow room for the Residential In-Well Internal Water Aerator in the well casing.). The tap will be made by cutting the primary water supply line 104 and inserting a tee 106 held in place by two hose clamps 105 , on each side of the supply tee 107 that is inserted into the primary water supply line 104 . A bushing 107 , is inserted into the tee 106 , followed by a nipple 108 , a ball valve 109 , nipple 108 A, tubing adapter 110 , high pressure tubing 111 , an adapter 110 , 90 degree street ell 112 , a flat washer 113 , a nipple 108 B, inserts through a flat washer 113 , a galvanized coupler 116 and a spray nozzle 117 . The street ell 112 becomes the support bracket on the topside of the well casing cap 102 for the Residential In-well Internal Water Aerator Residential In-well Internal Water Aerator. Three nozzles 117 are included interchangeable for light iron, medium iron, or heavy iron concentration in the well water. This allows the customer to customize the Residential In-Well Internal Water Aerator to their individual need.
FIG. 8 is an exploded/cross section view showing an internal drip aeration screen 124 in detail ( 124 A top view of same) for the third chamber 128 fourth chamber 127 and fifth chamber 118 . A total of four internal drip aeration screens (each 13¼″ lone and range from 1¼″ to 2″ in diameter) are inserted vertically into each of the third chamber 128 fourth chamber 127 and fifth chamber 118 . Once the water is misted into the fifth chamber 118 it goes through a drip process by which hydrogen sulfide is degassed. Additionally suspended iron solutions are precipitated into a solid that attaches to the drip screens thereby reducing iron solids from the raw water source.
FIG. 9 is an exploded view of an optional UV light 125 to be centrally inserted into the fifth drip chamber 118 held in place by the internal drip aeration screens 124 . The electrical wire includes the waterproof hook-up wire leads 123 , waterproof electrical box 133 , twist on wire connectors for UV light internal source 134 , and waterproof wire connectors for external source 134 A which in turn requires an electrical hook-up at the pump site.
FIG. 10 is an exploded view showing the installation rod 120 in place in the fifth chambers 118 (also applicable in the fourth chamber 127 , third chamber 128 , second chamber 130 and first chamber 131 ) during installation and removal of Residential In-well Internal Water Aerator in/from the well casing 101 allowing for hands free installation/removal. Alternatively, the third chamber 128 , fourth chamber 127 , and fifth chamber 118 ( FIGS. 4 , 5 , and 6 ) may need to be modified per size of the well casing 101 and placement of the pitless adapter/well seal in each individual well. Another alternative to the tap in the primary water supply line may vary depending upon the use of pvc, galvanized, brass or other piping material 104 . Another alternative is if the user chooses to run a high pressure tubing line 111 from the well casing to the basement or garage so the ball valve 109 can may be located inside the basement or garage. Another alternative is using drip screens in place of GAG with or without GAG. Another alternative is the use of green sand or zeolite in place of GAC. Another alternative is that the pattern of the aerator drip screens 124 and ( 124 A for a top view of the same) may be round instead of square. Another alternative would be a single aeration screen approximately 53″ long. Another alternative is with or without UV light 125 . In the cases with UV light 125 the UV exposure will meet or exceed N.S.F. (National Sanitation Foundation) minimum requirements. The UV light 125 will require water proof wire leads 123 , a waterproof electrical box 133 , wire nuts connectors 134 and 134 A and waterproof tape 137 . The UV power source will may come from the pump power source at the well site. For this option a utility box will need to be added at the well site.
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A Residential In-well Internal Water Aerator for reducing/eliminating iron, Hydrogen sulfide, and radon gas is a device that hangs within the well casing. Its support is achieved by the well cap. It is capable of degassing hydrogen sulfide and radon gas and precipitation of the iron to become a solid and attaching its self to the interior walls and drip screens of the Residential In-well Internal Water Aerator within the well, thus reducing/eliminating the stained fixtures, bad smell and the risk of radon gas from within the residence.
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[0001] The present application claims the benefit of U.S. Provisional Application Ser. No. 61/700,962 entitled “Purifying Portfolios Using Orthogonal Non-Target Factor Constraints”, filed on Sep. 14, 2012 which is hereby incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to methods for constructing investment portfolios designed to capture the behavior of one or more target factors. More particularly, it relates to improved computer based systems, methods and software for construction of factor portfolios using optimization by reducing the portfolio's exposure to non-target factors, commonly referred to as unintended bets.
BACKGROUND OF THE INVENTION
[0003] In 2011, there was an explosion of ETFs offering a wide selection of affordable “factor” exposures, including the Russell-Axioma Factor ETFs and PowerShares ETFs. The factors selected—volatility, beta and momentum, among others—are a subset of the “style risk factors” used by commercial equity fundamental factor risk models for the past three decades, so these factors clearly explain risk. Several of these factors have been also closely associated with highly successful hedge funds, so the implication is that these factors are also potential alpha signals.
[0004] Factor ETFs come in two principal flavors: simple factor ETFs and purified factor ETFs. All factor ETFs have a strong exposure to the targeted factor. Simple factor ETFs do that and nothing more. In contrast, purified factor ETFs deliver not only the target factor exposure but also take steps to explicitly reduce the exposure of the ETF to non-target factors. This purifies the target signal and reduces unintended exposures that may inadvertently harm performance.
[0005] Non-target factor exposures are neutral when they have the same or similar exposures as an underlying benchmark. Large exposure over-weights or under-weights relative to a benchmark, normally referred to as active exposures, can either be intended or unintended. In a factor ETF or factor portfolio, a large exposure to the target factor is an intentional exposure. Any other exposures, however, are likely to be unintended.
[0006] Unintended bets in a portfolio are flaws. From the perspective of a factor risk model, unintended bets produce additional risk for the portfolio, and good portfolio managers should not unintentionally take on additional risk. Furthermore, in practice, unintended bets often reduce the return of the portfolio. As a general rule, it is desirable to reduce the absolute magnitude of any active exposures to non-target factors.
[0007] For portfolio managers, purified ETFs or portfolios can be easier to work with since they are less likely to inadvertently alter the exposure of a composite set of holdings. A portfolio manager who buys a low volatility ETF expects that holding to make his overall exposure to volatility lower. Normally, however, the portfolio manager would not want that purchase to significantly change his overall exposure to size, value or growth. If, however, there were unintended bets in size, value, or growth, then the portfolio manager would need to do additional work to manage those exposures.
[0008] Optimization techniques are frequently used to construct a portfolio of holdings for a universe or set of potential investment opportunities or assets. For example, the stocks comprising the Russell 1000 index represent a universe of US large cap stocks. The stocks comprising the Russell 2000 index represent a universe of US small cap stocks.
[0009] Optimization has a long history in portfolio construction, including the construction of purified factor portfolios. Mean-variance portfolio optimization was first described by H. Markowitz, “Portfolio Selection”, Journal of Finance 7(1), pp. 77-91, 1952 which is incorporated by reference herein in its entirety. In mean-variance optimization, a portfolio is constructed that minimizes the risk of the portfolio while achieving a minimum acceptable level of return. Alternatively, the level of return is maximized subject to a maximum allowable portfolio risk. The family of portfolio solutions solving these optimization problems for different values of either minimum acceptable return or maximum allowable risk is said to form an “efficient frontier”, which is often depicted graphically on a plot of risk versus return. There are numerous, well known, variations of mean-variance portfolio optimization that are used for portfolio construction. These variations include methods based on utility functions, Sharpe ratio, and value-at-risk.
[0010] In these optimizations, the expected return or alpha signal, if present, serves as the target factor in the optimization.
[0011] Portfolio construction using optimization techniques makes use of an estimate of portfolio risk, and some approaches make use of an estimate of portfolio return. A crucial issue for these optimization techniques is how sensitive the constructed portfolios are to changes in the estimates of risk and return. Small changes in the estimates of risk and return occur when these quantities are re-estimated at different time periods. They also occur when the raw data underlying the estimates is corrected or when the estimation method itself is modified. Mean-variance optimal portfolios are known to be sensitive to small changes in the estimated asset return, variances, and covariances. See, for example, J. D. Jobson, and B. Korkei, “Putting Markowitz Theory to Work”, Journal of Portfolio Management, Vol. 7, pp. 70-74, 1981 and R. O. Michaud, “The Markowitz Optimization Enigma: Is Optimized Optimal?”, Financial Analyst Journal, 1989, Vol. 45, pp. 31-42, 1989 and Efficient Asset Management: A Practical Guide to Stock Portfolio Optimization and Asset Allocation, Harvard Business School Press, 1998, (the two Michaud publications are hence referred to collectively as “Michaud”) all of which are incorporated by reference herein in their entirety.
[0012] A number of procedures have been proposed to alleviate the sensitivity of optimized portfolios to changes or errors in the input data. The most common approach is to add constraints to the optimization problem that restrict the range of possible portfolio holdings. For example, the minimum and maximum asset allocation may be limited to, say, zero and two percent of the total portfolio value respectively. Alternatively, the minimum and maximum exposure of the portfolio to an industry, industrial sector, or country may also be incorporated in the portfolio construction strategy.
[0013] Commercial equity factor risk models predict risk using a set of data factors that capture important characteristics of the possible investment opportunities. These factors can include industries and countries. They can also include other “style” factors such as value, growth, size, and volatility. In practice, it is common to constrain the net exposure of the portfolio to each of these style factors so that it is close to the exposure of a benchmark portfolio. Typically, the factor scores for style factors are reported as standardized scores or “Z scores” by taking the raw factor score and subtracting the aggregate score for the benchmark and then dividing this benchmark relative value by the standard deviation of the raw factor scores. Z scores report all style factors in a common dimensionless format that makes it easier to determine if a given exposure is large or small. See for example, R. Litterman, Modern Investment Management: An Equilibrium Approach, John Wiley and Sons, Inc., Hoboken, N.J., 2003 (Litter man), which is incorporated by reference herein in its entirety.
[0014] A factor mimicking portfolio is defined as a portfolio in which the net exposure of the portfolio to a single target factor is one and the net exposure of the portfolio to a set of non-target exposures is identically zero. See Litterman for details. By construction, factor mimicking portfolios have perfect purity. The returns of a factor mimicking portfolio can be taken to represent the return of that factor. Often, the set of non-target factors are the factors from a commercial factor risk model. Commercial risk model vendors spend considerable effort selecting the set of factors used by the model so that they represent a broad range of expected asset returns as accurately as possible.
[0015] As with the asset holdings, industry, sector, and country constraints, style constraints are linear bounds on the portfolio holdings which can be readily solved using modern computer optimization software. The ease of use and intuitive simplicity of these constraints account for their popularity. Indeed, virtually all commercial portfolio optimization software allows a portfolio manager to impose these kinds of constraints. For example, Axioma sells a portfolio optimization software under the name Axioma Portfolio™ software with this functionality. (Axioma Portfolio is a trademark of Axioma, Inc.).
[0016] A central concept used by the present invention is the decomposition of a non-target factor into one part that aligns with the target factor and a second part that is orthogonal or perpendicular to the target factor. As the overlap between the target and non-target factors increases, the magnitude of the aligned part increases.
[0017] FIG. 1 illustrates a simple example where a target factor overlaps with two non-target factors. A target factor 150 is illustrated as a horizontal vector pointing to the right. A first non-target factor 152 is illustrated by a vector pointing to the upper right side of FIG. 1 . A second non-target factor 154 is shown by a vector pointing to the upper left of FIG. 1 . The acute angle between the first non-target factor 152 and the target factor 150 is shown by the angle 156 . The acute angle between the second non-target factor 154 and the target factor 150 is shown by the angle 158 . Note that since acute angles must be between zero and ninety degrees, this angle is measured between the second target vector and the extension of the target vector extending to the left.
[0018] FIG. 2 illustrates how a first non-target factor 162 is decomposed into the sum of two different vectors, a vector 164 representing the projection of the first non-target factor onto the target factor 160 and a vector 166 representing the orthogonal projection of the first non-target factor with respect to the target factor. By construction, the aligned projection points in the same direction as the target factor while the orthogonal projection is perpendicular to the target factor.
[0019] FIG. 3 illustrates how a second non-target factor 172 is decomposed into the sum of two different vectors, a vector 174 representing the projection of the first non-target factor onto the target factor 170 and a vector 176 representing the orthogonal projection of the first non-target factor with respect to the target factor. In this example, the aligned projection points in the opposite direction as the target factor which, of course, is still aligned with the target factor while the orthogonal projection is perpendicular to the target factor.
[0020] As the number of factors considered increases, it becomes more likely for there to be overlap between factors. To be sure, factors can be mathematically constructed so that they have no overlap. However, many intuitive and commonly used factors naturally have significant overlap. For example, Axioma's US Fundamental Factor Risk Model currently uses ten style factors and sixty eight industry factors. Historically, several of the factors have overlapped significantly.
[0021] FIG. 4 shows the historical overlap between two pairs of factors in Axioma's US Fundamental Factor Risk Model for a large cap benchmark of about 1000 stocks. The overlap is measured by plotting the acute angle between two factors. The smaller the acute angle, the more overlap there is between the two factors. If the two factors are orthogonal, then the acute angle is ninety degrees. FIG. 4 plots the acute angle between the market sensitivity factor and the volatility factor 200 and the acute angle between the size factor and the volatility factor 202 from 1987 to 2012. For virtually the entire time period, the angle for market sensitivity vs. volatility is smaller than the angle for size vs. volatility. Whereas the angle for size is 50 degrees at its smallest in early 2009, the angle for market sensitivity is often less than 40 degrees.
[0022] Since smaller angles mean more overlap, this means that there is significant overlap between Axioma's market sensitivity factor and its volatility factor.
[0023] The problem addressed by the current invention occurs when there is significant overlap between a target factor and a non-target factor used to purify the target portfolio. By construction, the exposure to the target factor is large. Hence, the exposure to an overlapping non-target factor is at least as large as the overlapping, aligned part of the non-target factor. Even if the optimization attempts to minimize or constrain the overlapping non-target factor to be as neutral (e.g., close to zero) as possible, its magnitude cannot be less than that derived from the overlapping part of it. In this case, the mutual goals of having a large target factor exposure and purifying (e.g., neutral or small absolute) non-target exposures are antagonistic.
[0024] For example, it is well known that volatility factors, which use some measure of historic asset volatility, and beta or market sensitivity factors, which use a measure of the historical correlation between an asset's return and a benchmark's return, have significant overlap. The beta of an asset is the covariance of the asset's return with those of a benchmark divided by the variance of the benchmark's return. By construction, the beta of a benchmark is one. One expects the beta of a low volatility portfolio to be significantly less than one; typical values would be 0.6 or 0.7. In other words, a low volatility portfolio generally cannot be neutral to beta since that would require its beta to be close to 1.0.
SUMMARY OF THE INVENTION
[0025] The present invention recognizes that current portfolio optimization software does not automatically adjust exposure constraints according to whether or not there is significant overlap between the factor being constrained and the desired target factor tilts that are to be either maximized or minimized.
[0026] One goal of the present invention, then, is to describe a methodology that will automatically adjust any exposure constraint based on the degree of overlap between it and one or more target factors.
[0027] Another goal is to describe an improved method for constructing purified portfolios; that is, portfolios with a large target factor exposure but limited or constrained non-target exposures.
[0028] Another goal of the present invention is to provide an easy way for investors to historically simulate the performance of the automatically adjusted exposure constraints through a backtest.
[0029] A more complete understanding of the present invention, as well as further features and advantages of the invention, will be apparent from the following Detailed Description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 illustrates a simple example of a target factor and two non-target factors;
[0031] FIG. 2 illustrates a first non-target factor being decomposed into an aligned component and orthogonal component;
[0032] FIG. 3 illustrates a second non-target factor being decomposed into an aligned component and orthogonal component;
[0033] FIG. 4 illustrates the historical overlap of two pairs of factors in Axioma's US Fundamental Factor Equity risk model from 1987 to 2012;
[0034] FIG. 5 shows a computer based system which may be suitably utilized to implement the present invention;
[0035] FIG. 6 shows performance statistics for four portfolios from a backtest using US equities from Jun. 30, 2009 and Aug. 31, 2012;
[0036] FIG. 7 shows the cumulative returns for four portfolios from a backtest using US equities from Jun. 30, 2009 and Aug. 31, 2012;
[0037] FIG. 8 shows the exposure to the volatility factor for three low volatility portfolios from a backtest using US equities from Jun. 30, 2009 and Aug. 31, 2012;
[0038] FIG. 9 shows the exposure to the size factor for three low volatility portfolios from a backtest using US equities from Jun. 30, 2009 and Aug. 31, 2012;
[0039] FIG. 10 shows the exposure to the market sensitivity factor for three low volatility portfolios from a backtest using US equities from Jun. 30, 2009 and Aug. 31, 2012;
[0040] FIG. 11 shows performance statistics for four portfolios from a backtest using European equities from Apr. 30, 2004 and Aug. 31, 2012;
[0041] FIG. 12 shows the cumulative returns for four portfolios from a backtest using European equities from Apr. 30, 2004 and Aug. 31, 2012;
[0042] FIG. 13 shows the exposure to the volatility factor for three low volatility portfolios from a backtest using European equities from Apr. 30, 2004 and Aug. 31, 2012;
[0043] FIG. 14 shows the exposure to the size factor for three low volatility portfolios from a backtest using European equities from Apr. 30, 2004 and Aug. 31, 2012;
[0044] FIG. 15 illustrates a simple schematic of a target factor and one non-target factor;
[0045] FIG. 16 illustrates the orthogonal non-target factor and the orthogonal alpha for the schematic of FIG. 15 ;
[0046] FIG. 17 illustrates the orthogonal non-target factor, the orthogonal alpha, and orthogonal holdings for the schematic of FIG. 15 ;
[0047] FIG. 18 illustrates benchmark weights, realized returns, and expected returns (“alpha”) for a simple numerical example of the invention using a universe of eight assets;
[0048] FIG. 19 illustrates factor risk model matrices including the matrix of factor exposures, the factor-factor covariance matrix, and the vector or specific risks for the simple numerical example of the invention using a universe of eight assets;
[0049] FIG. 20 illustrates exposures to non-target factors “Factor1” and “Factor2” and the exposures of these two factors that are orthogonal to the target factor “alpha” for the simple numerical example of the invention using a universe of eight assets;
[0050] FIG. 21 illustrates vectors of relative wealth allocations for four portfolios including the benchmark, an optimal portfolio with no constraints on the exposures to Factor1 and Factor2, an optimal portfolio with the active exposures relative to the benchmark to Factor1 and Factor2 limited to plus and minus ten percent, and an optimal portfolio with the active exposures relative to the benchmark to orthogonal Factor1 and orthogonal Factor2 limited to plus and minus ten percent for the simple numerical example of the invention using a universe of eight assets; and
[0051] FIG. 22 illustrates performance statistics for the four portfolios shown in FIG. 22 .
DETAILED DESCRIPTION
[0052] The present invention may be suitably implemented as a computer based system, in computer software which is stored in a non-transitory manner and which may suitably reside on computer readable media, such as solid state storage devices, such as RAM, ROM, or the like, magnetic storage devices such as a hard disk or solid state drive, optical storage devices, such as CD-ROM, CD-RW, DVD, Blue Ray Disc or the like, or as methods implemented by such systems and software. The present invention may be implemented on personal computers, workstations, computer servers or mobile devices such as cell phones, tablets, IPads™, IPods™ and the like.
[0053] FIG. 5 shows a block diagram of a computer system 100 which may be suitably used to implement the present invention. System 100 is implemented as a computer or mobile device 12 including one or more programmed processors, such as a personal computer, workstation, or server. One likely scenario is that the system of the invention will be implemented as a personal computer or workstation which connects to a server 28 or other computer through an Internet, local area network (LAN) or wireless connection 26 . In this embodiment, both the computer or mobile device 12 and server 28 run software that when executed enables the user to input instructions and calculations on the computer or mobile device 12 , send the input for conversion to output at the server 28 , and then display the output on a display, such as display 22 , or print the output, using a printer, such as printer 24 , connected to the computer or mobile device 12 . The output could also be sent electronically through the Internet, LAN, or wireless connection 26 . In another embodiment of the invention, the entire software is installed and runs on the computer or mobile device 12 , and the Internet connection 26 and server 28 are not needed. As shown in FIG. 5 and described in further detail below, the system 100 includes software that is run by the central processing unit of the computer or mobile device 12 . The computer or mobile device 12 may suitably include a number of standard input and output devices, including a keyboard 14 , a mouse 16 , CD-ROM/CD-RW/DVD drive 18 , disk drive or solid state drive 20 , monitor 22 , and printer 24 . The computer or mobile device 12 also has a USB connection 21 which allows external hard drives, flash drives and other devices to be connected to the computer or mobile device 12 and used when utilizing the invention. It will be appreciated, in light of the present description of the invention, that the present invention may be practiced in any of a number of different computing environments without departing from the spirit of the invention. For example, the system 100 may be implemented in a network configuration with individual workstations connected to a server. Also, other input and output devices may be used, as desired. For example, a remote user could access the server with a desktop computer, a laptop utilizing the Internet or with a wireless handheld device such as cell phones, tablets and e-readers such as an IPad™, IPhone™, IPod™, Blackberry™, Treo™, or the like.
[0054] One embodiment of the invention has been designed for use on a stand-alone personal computer running in Windows 7. Another embodiment of the invention has been designed to run on a Linux-based server system.
[0055] According to one aspect of the invention, it is contemplated that the computer or mobile device 12 will be operated by a user in an office, business, trading floor, classroom, or home setting.
[0056] As illustrated in FIG. 5 , and as described in greater detail below, the inputs 30 may suitably include a universe or set of potential investments, a target factor, a set of non-target factors, as well as other data needed to construct the portfolio such as portfolio optimization software, factor risk models, alpha signals, transaction cost models, asset bounds, etc.
[0057] As further illustrated in FIG. 5 , and as described in greater detail below, the system outputs 32 may suitably include the holdings for an optimized investment portfolio.
[0058] The output information may appear on a display screen of the monitor 22 or may also be printed out at the printer 24 . The output information may also be electronically sent to an intermediary for interpretation. For example, risk predictions for many portfolios can be aggregated for multiple portfolio or cross-portfolio risk management. Or, alternatively, trades based, in part, on the factor risk model predictions, may be sent to an electronic trading platform. Other devices and techniques may be used to provide outputs, as desired.
[0059] With this background in mind, we turn to a detailed discussion of the invention and its context. Suppose that there are N assets in an investment portfolio, and the weight or fraction of the available wealth invested in each asset is given by the N-dimensional column vector w. These weights may be the actual fraction of wealth invested or they may represent the difference in weights between a managed portfolio and a benchmark portfolio as described by Litterman. In this case, w=w p −w b where w p is an N-dimensional column vector representing the fraction of wealth invested by the investor and w b is an N-dimensional column vector representing the fraction of wealth invested in the benchmark or reference portfolio.
[0060] Suppose further that there is a target factor which is an N-dimensional column factor f and a matrix of M non-target factors given by the columns of the N×M dimensional matrix B. The target factor may be a vector of expected asset returns, which is sometimes called “alpha” and denoted with the Greek letter a. Alternatively, the target factor f may an N-dimensional column vector of factor scores. In a typical optimization problem, an optimal allocation of wealth is determined that either maximizes or minimizes the portfolio's exposure to f. That is, the product vector inner product w T f is either as large or as small as possible.
[0061] The overlap problem occurs when the matrix-vector product of the transpose of B and f is non-zero.
[0000] Non-Orthogonality B T f≠ 0 (1)
[0000] If f is orthogonal to each column of B, then this matrix product returns an M dimensional vector of zeros.
[0062] In existing portfolio optimization software, one is allowed to impose minimum and maximum constraints on the exposures of the final, optimized portfolio to each of the M factors. That is, in existing portfolio optimization software, the functionality exists to impose
[0000] L≦B T w≦U (2)
[0000] Here, L is an M-dimensional vector of lower bounds for the exposures of the portfolio and U is an M-dimensional vector of upper bounds for the exposures. If some of the constraints are unbounded, then the corresponding elements of L and U can be represented by minus infinity and plus infinity respectively. Since constraints with infinite bounds are automatically satisfied, high quality portfolio optimization software will omit such bounds and constraints when constructing the optimal portfolio.
[0063] In the present invention, we propose an alternative to this common type of constraint. Rather than constrain the exposure of the portfolio to the original factors, we constrain the exposure of the portfolio to that part of the original factors that is orthogonal to the target factor. That is, we first form a set of orthogonal non-target factors. For each of the M columns of B, we replace that column with its orthogonal projection. That is,
[0000]
B
(
j
)
′
=
B
(
j
)
-
(
f
T
B
(
j
)
f
T
f
)
f
,
j
=
1
,
…
,
M
(
3
)
[0000] where B (j) is the j-th column of the original matrix B. We assemble the orthogonal matrix of non-target factors, B′, by putting the columns together, and then replace equation (2) with
[0000] L≦B′ T w≦U (4)
[0000] The optimal portfolio returned by the optimization depends on the manner in which the original target factor and non-target factors are normalized. In the results reported below, each of the factors is a Z score.
[0064] In one embodiment of the invention, we set L and U to be a vector of zeros and impose the constraints as soft constraints with a linear penalty functions. The vanishing L and U drive the solution to be as neutral as possible, while the soft constraint simply penalizes any deviation from perfect neutrality. The only parameters needed are therefore the magnitude of the linear penalty. In the approach described here, it was found that a non-zero penalty magnitude usually improves portfolio performance. The constraints ( 4 ) could also be implemented with a quadratic penalty, or imposed as hard constraints. Alternatively, the constraints could also be inserted into Axioma's Constraint Hierarchy tool, a tool that automatically softens hard constraints whenever infeasibilities are found.
[0065] Mathematicians will recognize a similarity between equation (3) and Gram-Schmidt orthogonalization. If there were more than one target factor for a portfolio, we can extend the orthogonalization process to include these different target factors. If there are K target factors, the K target factors can be processed as the first K vectors using the Gram-Schmidt method. Then, each of the M non-target factors would be modified using the formula for the (K+1)-th vector in the Gram-Schmidt method. Alternatively, one can construct a matrix P that will project any vector into the null space of a set of one or more target factors. Each constraint would then be modified by pre-multiplying by the matrix P.
[0066] In some situations, it may be practical to nearly orthogonalize the constraints, so that each constraint is nearly but not exactly orthogonal. In this case, the acute angle between the approximately orthogonalized constraints and the target factor would be close to ninety degrees but not exactly ninety degrees. One way to do that would be to replace equation (3) with
[0000]
B
(
j
)
′
=
B
(
j
)
-
(
1
-
ɛ
j
)
(
f
T
B
(
j
)
f
T
f
)
f
,
j
=
1
,
…
,
M
(
5
)
[0000] where ε j is a small positive constant; that is, 0<ε j <<1. For the present invention, we use the terms orthogonalized and nearly orthogonalized interchangeably.
[0067] We now illustrate the use of the orthogonal non-target factor constraints using two backtests, a backtest using US equities and a backtest using European equities. In both backtests, the target factor is the volatility factor of Axioma's Fundamental Factor, Medium Horizon, Equity Risk Model. Axioma's US Fundamental Factor, Medium Horizon Equity Risk Model was used for the backtest with US equities, and Axioma's European Fundamental Factor, Medium Horizon Equity Risk Model was used for the backtest with European equities.
[0068] In each backtest, we minimize the exposure of the optimal portfolio to the volatility factor. The final active exposure is large and negative, indicating a low volatility exposure. Since we are targeting low volatility, the portfolios we are constructing will be less volatile than the underlying benchmarks.
[0069] In each backtest, we construct four portfolios each month. First, we construct a benchmark portfolio consisting of a market capitalization weighting of all assets in the investment universe. For the US backtest, we construct a large cap benchmark of approximately 1000 stocks. For the European backtest, we construct a large cap benchmark of approximately 1500 stocks.
[0070] Second, we construct a reference portfolio constructed by equi-weighting the 10% of the names in the universe with the lowest volatility score.
[0071] Third, we construct a traditional optimized portfolio which holds the same names as the reference portfolio but whose weights have been adjusted by optimization. The optimization objective minimizes the tracking error (e.g., active risk) between this optimized portfolio and the reference portfolio as predicted by the factor risk model. For this optimization, we purify the portfolio to non-target factors without any orthogonalization. The non-target factors are the style risk factors in the corresponding Axioma factor risk model, including the volatility factor. For each style factor, we impose benchmark neutral exposure (maximum exposure equals minimum exposure equals zero) as a soft constraint with a linear penalty for any positive or negative deviation from neutrality. Volatility is, of course, one of the factors in the style factors. In order to keep the target factor exposure strong, we constrain the target tilt of the optimized portfolio to be at least as low (e.g., large and negative) as the reference portfolio. Low volatility Z scores are negative, so the lower or more negative the exposure, the stronger the target tilt. The minimum and maximum holdings in any individual asset are zero and two percent of the total portfolio value.
[0072] Fourth, we construct an optimized portfolio identical to the traditional optimized portfolio but we impose non-target exposure constraints using the risk model style factors after they have been orthogonalized with respect to the volatility factor. Otherwise, the optimization is the same.
[0073] FIG. 6 shows the performance results 110 for the US backtest, which was rebalanced monthly between Jun. 30, 2009 and Aug. 31, 2012 using a universe of approximately 1000 large cap US equities.
[0074] For this set of backtests, we see that the best total return was obtained using the orthogonal style constraints. This case also had the highest Sharpe ratio and Information ratios. The optimized portfolios have somewhat lower turnover than the reference portfolio. By construction, the optimized portfolios can only hold at most the same names as the reference portfolio. In this case, the optimized portfolios hold about half the number of names as the reference portfolio. The predicted beta for the reference and optimized portfolios are virtually identical and well below one, as one would expect from a low volatility portfolio.
[0075] FIG. 7 compares the cumulative return of all four portfolios: the return of the benchmark 204 shown as a dashed-dotted line; the return of the reference portfolio 206 shown as a thin solid line; the return of the optimized portfolio with traditional constraints 208 shown as a dashed line; and the return of the portfolio optimized with orthogonal constraints 210 shown as a thick solid line.
[0076] The three low volatility portfolios have noticeably less volatility than the benchmark. Since mid-2011, the return of the portfolio optimized with orthogonal constraints has steadily outperformed the other three portfolios.
[0077] FIG. 8 shows the exposure of the three low volatility portfolios to the target factor, the volatility factor of the factor risk model: the exposure of the reference portfolio 212 shown by the thin solid line; the exposure of the traditional optimization 214 shown by the dashed line; and the exposure for the orthogonal optimization 216 shown by the thick solid line. The exposures of the optimized portfolios are at least as strongly negative as the reference portfolio, as imposed by the optimization.
[0078] FIG. 9 shows the exposure of the three low volatility portfolios to the size factor. The size factor in a factor risk model is a Z score value representing the natural logarithm of the market capitalization of all assets in the benchmark. The non-target exposure constraints in both optimizations have dramatically altered the size factor exposure. Whereas the exposure of the reference portfolio 218 is about −100% (a substantial small cap bias representing a non-pure exposure relative to volatility), the exposure of the two optimized portfolios— 220 for the traditional optimization and 222 for the constrained optimization—is about −40%. In other words, both the traditional constraints and the orthogonal constraints have neutralized or purified the size exposure by roughly 60%. The substantial small cap bias embedded in the reference portfolio has been dramatically corrected by both constraints.
[0079] In FIG. 9 , the size exposure of the two optimized portfolio is approximately the same. Usually, there is less than a five percent difference in their size exposures. This indicates that the overlap between size and volatility is relatively small, e.g., the acute angle between the target factor (volatility) and the non-target factor (size) is large.
[0080] FIG. 10 shows the exposure of the three low volatility portfolios to the market sensitivity factor from the factor risk model. As shown in FIG. 4 , there is more overlap between the market sensitivity factor and the volatility factor than there is for the size factor and the volatility factor. In other words, the acute angle between the volatility factor and the market sensitivity factor is smaller than the acute angle between the volatility factor and the size factor. As a consequence, we do not expect there to be a large difference between the reference and optimized portfolios. The market sensitivity factor exposure of the reference portfolio 224 is shown by the thin solid line, the portfolio with traditional optimization 226 is shown by the dashed line, and the portfolio with orthogonal optimization 228 is shown by the thick solid line. Usually, the three exposures arc within 10% to 20% of each other. However, as expected, the portfolio with orthogonal constraints often has less exposure to market sensitivity than the other two portfolios. In this case, constraining only the orthogonal component of the factor permits a much deeper exposure to the aligned part of the factor. This is the difference that purifies the holdings from unintended bets and enables the orthogonal constraints backtest to outperform the reference portfolio and the traditional optimization backtest.
[0081] FIG. 11 shows the performance results 120 for the European backtest, which was rebalanced monthly between Apr. 30, 2004 and Aug. 31, 2012 using a universe of approximately 1500 large cap European equities.
[0082] For this set of longer backtests, the best total return was once again obtained using the orthogonal non-target factor constraints. This case also had the highest Sharpe ratio and Information ratios. The optimized portfolios have somewhat lower turnover than the reference portfolio. The optimized portfolios hold about two fifths as many names as the reference portfolio. The predicted beta for the reference and optimized portfolios are virtually identical and well below one.
[0083] FIG. 12 compares the cumulative return of all four portfolios: the return of the benchmark 300 shown as a dashed-dotted line; the return of the reference portfolio 302 shown as a thin solid line; the return of the optimized portfolio with traditional constraints 304 shown as a dashed line; and the return of the portfolio optimized with orthogonal constraints 306 shown as a thick solid line.
[0084] FIG. 11 and FIG. 12 illustrate that the return of the portfolio optimized with orthogonal constraints steadily outperformed the other three portfolios. This illustrates that portfolios purified by imposing orthogonal non-target factor constraints can improve portfolio performance.
[0085] FIG. 13 shows the exposure of the three low volatility portfolios to the target factor, the volatility factor of the factor risk model: the exposure of the reference portfolio 308 shown by the thin solid line; the exposure of the traditional optimization 310 shown by the dashed line; and the exposure for the orthogonal optimization 312 shown by the thick solid line. The volatility exposures of all three portfolios are virtually identical.
[0086] FIG. 14 shows the exposure of the three low volatility portfolios to the size factor. The size factor in a factor risk model is a Z score value representing the natural logarithm of the market capitalization of each asset. The non-target exposure constraints in both optimizations have a dramatic effect for the size factor exposure. The size exposure of the reference portfolio 314 is generally about 75% lower (a substantial small cap biased, representing a non-pure exposure relative to volatility) than the exposure of the two optimized portfolios, the traditional optimization portfolio 316 and the constrained optimization portfolio 318 .
[0087] These two backtests illustrate cases in which target factor portfolios that have been purified using orthogonalized non-target factors outperform those purified using raw non-target factors as well as the simple reference portfolio. It is anticipated that portfolio managers will prefer to be able to automatically impose orthogonalized, non-target factor constraints as a standard feature in a portfolio optimization tool.
[0088] Although the present invention is different than the prior art, it possesses similarities to existing techniques used for portfolio construction using optimization. U.S. Pat. No. 7,698,202 describes a technique in which a factor risk model is augmented by additional risk associated with the vector that is the projection of the asset holdings into the null space of the set of factor risk model factors. That is, the additional risk is related to the orthogonal projection of the holdings. This patent is incorporated by reference herein in its entirety. In this procedure, there is no need for a target factor. The document “Refining Portfolio Construction When Alphas and Risk Factors are Misaligned” by J. Bender, J.-H. Lee, and D. Stefek, MSCI Barra Research Insight, March 2009, available at http://www.mscibarra.com/research/articles/2009/RI_Refining_Port_Construction.pdf describes a technique in which the objective function of a portfolio optimization problem is modified by a penalty associated with the vector that is the projection of the “alpha” vector, which is the vector of expected returns or, equivalently, the target factor into the null space of the set of factor risk model factors. That is, the objective function penalty is the orthogonal projection of the target factor. This document is incorporated by reference herein in its entirety.
[0089] Like the present invention, both of these techniques describe an orthogonal projection. However, the orthogonal projection in these two techniques is different than that described in the present invention. For these two techniques, the orthogonal projection is the projection into the null space of a set of factors used by a factor risk model. Specifically, let X be the matrix of factor exposures in a factor risk model (see U.S. Pat. No. 7,698,202 and Litterman for details). Then, the projection operator used by the prior art techniques is
[0000] P RM =I−X ( X T X ) −1 X T (6)
[0000] where I is the identity matrix and the inverse may be a pseudo-inverse if necessary. In the technique described in U.S. Pat. No. 7,698,202, the additional variance added to the predicted risk model variance is proportional to
[0000] σ RM 2 =c 2 w T P RM w (7)
[0000] for some constant c. For the technique described by Bender et al., the penalty in the objective function is proportional the
[0000] U=θ 2 α T P RM α (8)
[0000] for some constant θ, where α is the alpha vector, which is equivalent to the target vector in the present invention.
[0090] In the present invention, the orthogonal projection is with respect to the target vector, not a set of risk model factors. Formally, we can compute this projection as
[0000] P j =I−f ( f T f ) −1 f T (9)
[0000] which, because the target factor f is one dimensional, reduces to the formula given in equation (3).
[0091] FIGS. 15 , 16 , and 17 provide a further illustration of the difference of the present invention from the prior art. In FIG. 15 , there is a single non-target factor 402 and a target factor 404 , both of which are two dimensional for illustration purposes of the example. The non-target factor 402 may be a factor from a factor risk model in which case it could be termed a risk factor. The symbol b is used to indicate this factor. The target factor 404 may be the alpha signal or expected return. In mean-variance optimization, the expected return of the optimal portfolio is maximized. Alternatively, the exposure of the optimal portfolio to the target factor can be minimized, as it was in for the two backtests described herein for which the target factor was volatility. The symbol α is used to indicate this target factor.
[0092] In FIG. 16 , we have the same non-target factor 406 and the same target factor 408 . In addition, we show two different projections. The orthogonalized non-target factor 410 , computed as b arthog =P f b, is perpendicular to the target factor. In this example, it points to the upper left of FIG. 16 . The orthogonal alpha, computed as α orthog =P RM α and used in the work of Bender et al., is perpendicular to the non-target factor and points to the bottom right. As can be readily seen in FIG. 16 , these two vectors are not parallel. As a result, the changes they make to the optimization are not identical, and the present invention is therefore different than the prior art.
[0093] In FIG. 17 , we take the same example and add a set of holdings 422 , denoted by w. The target factor 416 is the same; the non-target factor 414 is the same; the orthogonalized non-target factor 418 is the same; and the orthogonal alpha 420 is the same. In order to illustrate the method of U.S. Pat. No. 7,698,202, we have added the set of holdings 422 . risk imposed in U.S. Pat. No. 7,698,202. The important thing to notice is that the orthogonal alpha 420 and the orthogonal holdings 424 are parallel in this simple example. As a result, their impact on the optimal holdings is parameterized by the same vector direction. This is a different direction than the direction considered in the present invention, the orthogonalized non-target factor 418 .
[0094] For the present invention, the impact of the orthogonalized constraint is to limit exposures that are orthogonal to the target vector. In this method, these orthogonal exposures are considered unintended bets and reduced and limited by the optimization. Unlike the prior art, the present invention does not limit the holdings in the direction defined by the target factor. The directions associated with the prior art can posses a non-zero component that aligns with the target factor and can therefore reduce the exposure of the optimal holdings in that direction. In fact, the paper “Do Risk Factors Eat Alphas?” by J.-H. Lee and D. Stefek, MSCI Barra Research Insight, April 2008, available at http://www.mscibarra.com/products/analytics/aegis/RI_Do_Risk_Models_Eat_Alphas_April — 08.pdf, incorporated by reference herein in its entirety, indicates that having constraints that overlap with alpha do degrade performance. The present invention explicitly ensures that the orthogonal constraints do not degrade alpha or performance.
[0095] In many optimizations, the direction of implied alpha can be different than the target factor. If we denote the asset-asset covariance matrix as Q, then the implied alpha is given by
[0000] α i =cQw (10)
[0000] where w represent the optimal holdings and c is a non-zero constant to be determined depending on how α 1 is to be normalized. The asset-asset covariance matrix can be derived from a factor risk model. The implied alpha is the expected return that would give the optimal holdings as the most simple mean-variance optimization problem. When the implied alpha and the target factor are not well aligned, this indicates that constraints imposed in the optimization problem have substantially affected the optimal solution.
[0096] A natural extension of the present invention is to apply it to the orthogonal projection of the implied non-target factor. One way to extend the present invention to consider implied alpha is to alter equation (3) to include risk-adjusted constraints
[0000]
B
(
j
)
′
=
QB
(
j
)
-
(
f
T
(
QB
(
j
)
)
f
T
f
)
f
,
j
=
1
,
…
,
M
(
11
)
[0097] Such risk-adjusted constraint can also improve portfolio performance. Alternatively, one can formally create the null projection matrix of Qw instead off and then use that as the target factor to alter the constraints. An optimization problem that simultaneously solves for the optimal holdings with orthogonalized constraints based on Qw instead off can also improve portfolio performance.
[0098] A simple, detailed, numerically worked out example is presented to illustrate the aspects of the invention. Consider a universe of eight assets identified as Asset1, Asset2, Asset2, Asset3, Asset4, Asset5, Assct6, Asset7, and Asset8. FIG. 18 shows a table 122 with benchmark weights, realized (e.g., actual) returns, and expected returns (“alpha” or α) for this universe of eight assets. The assets are ordered in terms of decreasing benchmark weight. The sum of the benchmark weights is 100%.
[0099] For this universe, a factor risk model comprising a matrix of factor exposures, denoted X, a matrix of factor-factor covariances, denoted S, and a vector of specific risks, denoted as D, is employed. FIG. 19 shows tables with the matrix of factor exposures 123 , the matrix of factor-factor covariances 124 , and the vector of specific risks 125 for the universe of eight assets.
[0100] The asset-asset covariance matrix for this universe is computed using matrix algebra by the formula
[0000] Q=XSX T +diag( D 2 ) (12)
[0101] The factor risk model has three factors, Factor1, Factor2, and Industry. For this example, Factor1 and Factor2 are considered to be non-target factors. The target factor is the expected return (e.g., “alpha” 122 ) shown in FIG. 18 . FIG. 20 shows the non-target factor exposures Factor1 126 and Factor2 127 as well as the orthogonalized, non-target factors for Factor1 and Factor2. From these results, it is seen that orthogonalizing Factor1 with respect to alpha alters its components substantially, whereas the changes in Factor2 after orthogonalization are more modest.
[0102] For this simple example, three optimal portfolios are computed.
[0103] First, an optimized portfolio is computed with no constraints on either Factor1 or Factor2. Mathematically, we define this optimization problem as:
[0104] Maximize
[0000] α T w (13)
[0000] subject to:
[0000] w 1 +w 2 +w 3 +w 4 +w 5 +w 6 +w 7 +w 8 =100% (14)
[0000] 0%≦w i ≦100%, i= 1, . . . , 8 (15)
[0000] ( w−w b ) T Q ( w−w b )≦2% (16)
[0000] Utilizing equation 13, the optimizer maximizes the portfolio's exposure to “alpha”, the expected return or target factor for this problem. Equation 14 indicates that the investment allocation uses all the funds available and is fully invested. Equation 15 indicates that the holdings in each of the eight assets must be positive (e.g., no shorting) and can be at most 100%. Equation 16 indicates that the tracking error or active risk in the final, optimized portfolio can be at most 2%. In this formula, w is used to indicate the optimized portfolio and w b to indicate the benchmark portfolio defined in FIG. 18 . This optimization problem is a standard mean-variance optimization problem used for portfolio construction.
[0105] The second optimized portfolio is computed using the same conditions shown in equations 13, 14, 15, and 16 plus two additional constraints on the active exposures of the optimized portfolio to Factor1 and Factor2. These are denoted mathematically as
[0000] −10%≦ f 1 T ( w−w b )≦10% (17)
[0000] −10%≦ f 2 T ( w−w b )≦10% (18)
[0000] where f 1 and f 2 are the exposure to Factor1 and Factor2 respectively. These two column vectors are shown in FIG. 20 under the headers Factor1 and Factor2, e.g., the center column in the tables. These two additional constraints ensure that the exposure of the optimized portfolio to Factor1 and Factor2 differs from the benchmark by no more than ten percent.
[0106] For the third optimization problem, the constraints shown in equations 17 and 18 are replaced by constraints on the orthogonalized exposures to Factor1 and Factor2. That is
[0000] −10%≦ g 1 T ( w−w b )≦10% (19)
[0000] −10%≦ g 2 T ( w−w b )≦10% (20)
[0000] where g 1 and g 2 are the orthogonal exposures to Factor1 and Factor2 respectively. These two column vectors are shown in FIG. 20 under the headers “Factor1 Orthogonal to Alpha” and “Factor2 Orthogonal to Alpha”, e.g., the right hand column in the tables.
[0107] All three optimization problems were solved using Axioma's portfolio construction software Axioma Portfolio™. The benchmark and optimal portfolio weights are shown in the table 128 in FIG. 21 . Notice that the portfolio allocations in all three optimal portfolios are similar. The addition of the exposure and orthogonal exposure constraints leads to relatively modest changes in the optimal portfolio allocations in this particular example. For all four portfolios shown in table 128 , the sum of the portfolio allocations across all eight assets adds up to 100%.
[0108] The table 129 in FIG. 22 shows several descriptive statistics for the four portfolios shown in 128 . The expected return for the three optimized portfolios based on alpha is larger than the expected return of the benchmark. This result is to be expected as the optimization has maximized this statistic. In terms of realized returns, all three optimized portfolios outperform the return of the benchmark. The benchmark has a realized return of 1.30%; the optimized portfolio with no exposure constraints has a realized return of 1.48%; the optimized portfolio with exposure constraints on Factor1 and Factor2 has a realized return of 1.34%, just barely out-performing the benchmark; and the optimized portfolio with orthogonal exposure constraints on Factor1 and Factor2 has a realized return of 1.52%, the best of all four portfolios.
[0109] Table 129 shows that when no exposure constraints are enforced (the first optimized portfolio), the optimized portfolio has an active exposure of +18.93% to Factor1 and −0.94% to Factor2. This active exposure represents a substantial exposure to Factor1, indicating that this portfolio is non-neutral or non-pure with respect to this factor.
[0110] When the constraints on the active exposures to Factor1 and Factor2 are applied (second optimized portfolio), the exposure to Factor1 is reduced to 10%, improving the purity of the portfolio at the expense of a reduction both in the expected return and the realized return.
[0111] When the constraints on the active, orthogonal exposures to Factor1 and Factor 2 are applied (third optimized portfolio), the constraint to orthogonal Factor1 is active and set at −10%. But the realized return increases in this case.
[0112] For all three optimization problems, the active exposure to Factor2 and the orthogonal Factor2 is within plus and minus 10%. The constraints shown in equations 18 and 20 are satisfied but inactive, so they do not affect the optimal solution in this particular case.
[0113] While the present invention has been disclosed in the context of various aspects of presently preferred embodiments, it will be recognized that the invention may be suitably applied to other environments consistent with the claims which follow.
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The quantitative construction of investment portfolios of securities such as stocks, bonds, or the like using optimization is addressed. More specifically, during optimization constraints on non-target factor exposures are automatically converted to constraints on the exposure of the projections of the non-target factors that are orthogonal to a specified target factor. Such constraints may be utilized to produce portfolios with superior performance to those produced with traditional factor exposure constraints.
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This application is a division of U.S. patent application Ser. No. 301,641 filed Sept. 14, 1981, which is a continuation-in-part of U.S. patent application Ser. No. 256,032 filed Apr. 21, 1981, now abandoned which is a division of U.S. patent application Ser. No. 38,724 filed May 14, 1979, now U.S. Pat. No. 4,279,518.
FIELD OF THE INVENTION
This invention relates to the field of dot matrix printing and more particularly to the field of dot matrix print heads for printing alpha-numeric characters and symbols.
BACKGROUND OF THE INVENTION AND PRIOR ART
Much of the current activity in the dot matrix print head industry is being directed to improving the printing speed (characters per second, lines per minute) of the head to meet the needs of large company users. Such increased printing speed is usually accomplished with little thought being given to and at the expense of ease of manufacture, cost, reliability, ease of repair, degree of training needed to perform repairs, ruggedness, long life, and cost-performance ratios. Often, these current print head designs require the use of expensive and sophisticated materials and technology such as tungsten print wires, synthetic ruby bearings, and powdered metal technology with its expensive and scarce blends.
In direct contrast to the high speed printing needs of large company users are the needs of the rapidly developing personal computer market and small business computer market. In the personal and small business computer markets, the printing speed of the head is of relatively minor and secondary importance in comparison to cost, reliability, ruggedness, long life, ease of repair, and the degree of training necessary to perform repairs. It was with these needs of the personal and small business computer markets in mind that the present invention was developed. In contrast to the expensive and somewhat exotic manufacturing technique used in making most of the current print heads (e.g., powdered metal technology, tungsten print wires), the present invention uses simpler stamping and screw machine technique, cheaper materials such as steel print wires, and greatly simplified manufacture and assembly procedures including the use of assembly aids for inserting the print wires into spaced-apart guide members, a grinding aid and method whereby all of the print wires can be more easily and quickly ground to the proper length, and unique coil assembly and mounting plate designs whereby the clappers or armatures are automatically aligned with the impact ends of the print wires during the assembly of the print head.
Illustrative of the state of the art in dot or wire matrix print heads are the following U.S. Patents:
______________________________________3,333,667 Nordin3,467,232 Paige3,828,908 Schneider3,842,955 Iwasaki3,854,564 Flaceliere et al3,889,793 Cattaneo3,896,918 Schneider3,897,865 Darwin et al3,929,214 Hebert3,991,869 Berrey3,994,381 Hebert4,004,671 Kondur, Jr.4,004,673 Burzlaff et al4,009,772 Glaser et al4,049,107 Murat4,049,108 Giessner4,051,941 Hebert4,060,161 Nelson et al4,079,824 Ku4,081,067 Schrag et al4,091,909 Lee4,117,435 Hishida et al4,135,830 Hishida et al4,140,406 Wolf et al4,141,661 Geis et al______________________________________
None of these patents, however, discloses the unique features of the present invention nor do any of these prior patents meet the needs and requirements of the developing personal and small business computer markets as well as the present invention.
SUMMARY OF THE INVENTION
This invention involves new and novel methods and apparatus relating to the assembly and structure of a dot matrix print head. The invention includes a unique coil assembly design comprising a bobbin, coil, and clapper built as a single unit that can be removeably placed among fixed pole pieces and yoke members mounted about a wire guide assembly. In the coil assembly, the bobbin has a first portion with an open-ended, hollow shape dimensioned to slideably receive a pole piece. It also has second and third bobbin portions mounted to and extending outwardly in opposite directions from this first bobbin portion. The coil is mounted about the first bobbin portion and the clapper of the coil assembly is mounted between the second and third bobbin portion for movement relative to the bobbin. The clapper mounting means on the second and third bobbin portion positions the central axis of the clappers substantially perpendicular to the axis of symmetry of the first bobbin portion and also includes means for restraining the clapper from movement along the central axis relative to the bobbin. In a second embodiment, a unique return spring arrangement is provided between the second bobbin portion and one end of the clapper.
The invention also includes a novel arrangement for supporting the coil assemblies in the print head whereby the clapper of each coil assembly is automatically aligned with the impact end of one of the print wires during the assembly of the print head. This supporting arrangement includes a mounting plate with free standing yoke portions and a plurality of pole pieces affixed to the mounting plate. The mounting plate, integral yoke portions, and pole pieces are all affixedly positioned relative to the wire guide assembly holding the print wires. Each second bobbin portion of each coil assembly also has an alignment slot dimensioned to slideably receive a respective yoke portion so that each coil assembly can be slid into place by receiving a pole piece in the first bobbin portion and a yoke portion in the alignment slot of the second bobbin portion. In this manner, the clapper of the respective coil assembly is automatically aligned with the impact end of one of the print wires during the assembly of the print head. This arrangement greatly simplifies the assembly process of the print head and significantly reduces the time required to assemble the print head for operation.
Other novel structural features of the present invention include unique designs for a heat sink member, wire guide members, snap-in retaining means between the bobbin and pole pieces, and mounting structure by which the print head is attached to the main guide and rail guide bearings of the printing mechanism. The present invention also includes novel methods of assembling the components of the print head including the use of assembly aids for inserting the print wires into the wire guide members and a grinding technique whereby all of the print wires can be easily and quickly ground to the proper length.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the print head of the present invention shown in use in one contemplated environment. For the sake of clarity, upstanding guide members 43 on the second portions of the bobbin members near the retaining screw 26 are not shown in this view.
FIG. 2 is a top view of the print head of the present invention with some parts broken away and others not shown for the sake of clarity.
FIG. 3 is a cross-sectional view of the print head taken along line 3--3 of FIG. 2.
FIG. 4 is a partially exploded view of the top half of FIG. 3 showing the relationship between many of the major parts of the print head including the coil assembly, heat sink member, mounting plate with its integral yoke portions, pole pieces, and the wire guide assembly.
FIG. 5 is a cross-sectional view of the bobbin member of the coil assembly of the present invention.
FIG. 6 is a top view of the bobbin member taken along line 6--6 of FIG. 5.
FIG. 7 is a top view of the coil assembly of the present invention taken along line 7--7 of FIG. 4 shown with the clapper member in its operating position on the bobbin member.
FIG. 8 is a view along line 8--8 of FIG. 4 showing a top view of the heat sink member of the present invention.
FIG. 9 is a view along line 9--9 of FIG. 4 showing a top view of the mounting plate of the present invention.
FIG. 10 is a partial cross-sectional view of the rear wire guide member of the present invention.
FIG. 11 is a top view of the rear wire guide member taken along line 11--11 of FIG. 10.
FIG. 12 is a bottom view of the rear wire guide taken along line 12--12 of FIG. 10.
FIG. 13 is a cross-sectional view of the middle wire guide member of the present invention.
FIG. 14 is a top view of the middle wire guide member taken along line 14--14 of FIG. 13.
FIG. 15 is a cross-sectional view of the front wire guide member of the present invention.
FIG. 16 is a top view of the front wire guide member taken along line 16--16 of FIG. 15.
FIG. 17 is a cross-sectional view of the top rear, and middle wire guide members 115, 91, and 93 of the wire guide assembly illustrating the manner in which the grooved assembly aid attached to the rear wire guide member assists in the proper assembly of the print wires between the rear and middle wire guide members 91 and 93.
FIG. 18 is a partial, cross-sectional view of an assembly aid 111 and procedure whereby all of the print wires can be easily and quickly ground to the proper length.
FIG. 19 is a cross-sectional view of a modified coil assembly design in which a return spring arrangement is mounted between the second bobbin member portion and the rear end of the clapper member.
FIG. 20 is a view along line 20--20 of FIG. 19 showing a side view of the return spring arrangement for the clapper member.
FIG. 21 is a top view of a print head with modified coil assemblies.
FIG. 22 is a cross-sectional view of the modified coil assembly taken along line 22--22 of FIG. 21.
FIG. 23 is a view taken along line 23--23 FIG. 22.
FIG. 24 is a view taken along line 24--24 FIG. 22 illustrating the abutting, interlocking relationship of the modified coil assemblies.
FIG. 25 is an exploded view of the print head of FIG. 21.
FIG. 26 is a cross-sectional view of a modified arrangement for resiliently attaching the print head to the main guide bearing which is mounted on the head shaft.
FIG. 27 is a cross-sectional view similar to FIG. 26 showing the manner in which the eccentric, main guide bearing can be rotated relative to the print head and head shaft to selectively move the print head toward and away from the platen to accommodate different paper thicknesses or multiple sheets of paper.
FIG. 28 is a view along line 28--28 of FIG. 27.
FIG. 29 is a cross-sectional view of a modified coil-wire guide assembly in which the wire guide for the impact end of the print wire is integral with the coil assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective view of the print head 1 of the present invention shown in use in one contemplated environment. In this view, the print head 1 is mounted for movement along head shaft 3 and rear guide rail 5 relative to the ribbon 7, paper 9, and platen 11. As best seen in FIGS. 1-4, the print head 1 of the present invention includes wire guide assembly 13, mounting plate 15 with upstanding yoke portion 17, pole pieces 19 fixedly secured to the mounting plate 15, heat sink member 21 with upstanding fingers 23, coil assemblies 25, and retaining screw 26 with resilient backstop 28.
Coil assemblies 25 each include a bobbin member 27, coil member 29, and clapper member 31. As best seen in FIGS. 4-7, the bobbin member of the coil assembly has first, second, and third portions. The first portion 33 has an open-ended, hollow shape dimensioned to slideably receive one of the pole pieces 19 therein. The second and third bobbin portions 35 and 37 are attached to and extend outwardly of a common end of the first portion 33 in substantially opposite directions as best seen in FIGS. 5 and 6. The second and third bobbin portions 35 and 37 include means for mounting the clapper member 31 therebetween for movement relative to the bobbin member. The clapper member mounting means includes the rear slot 39 in the upstanding member 41 of the second bobbin portion 35 and the slot between upstanding guide members 43 on the third bobbin portion 37. For clarity, guide members 43 are not shown in the perspective view of FIG. 1. The clapper member 31 is dimensioned to extend outwardly of the central axis A--A at the rear and middle of the clapper member 31 to engage respectively the members 41 and 43 whereby these members serve to restrain the clapper member 31 from movement along the central axis A--A relative to the bobbin member 27 as seen in FIG. 7. Slot 45 in the second bobbin portion 35 serves as an alignment slot to slideably receive the upstanding portion 17 of the yoke member as shown in FIGS. 3 and 4. The members 41 and 43 of the second and third bobbin portion 35 and 37 also serve to restrict the movement of the clapper member 31 whereby the central axis A--A thereof remains in a predetermined plane relative to the bobbin member 27 with this predetermined plane intersecting the alignment slot 45. In operation, the central axis A--A of the clapper member 31 and the central axis of the first bobbin portion 33 remain substantially perpendicular. Also illustrated in FIGS. 3-5 is the recess-detent retaining means 47 and 49 between the inner surface 48 of the first bobbin portion 33 and the outer surface 50 of the pole piece 19 (see FIGS. 4 and 5). In assembling the bobbin member 27 on the pole piece, the pole piece 19 is first slideably received in the first bobbin portion 33 until the recess-detent retaining means 47 and 49 mate as will be explained in more detail herebelow. Also in the assembly procedure, the coil member 29 is mounted about the first bobbin portion 33 and retained in place by the second and third bobbin portions 35 and 37 on one end and the lip member 51 on the other end.
The heat sink member 21 and mounting plate 15 are best seen in FIGS. 1-4, 8, and 9. Heat sink member 21 in FIG. 8 has a planar portion 53 with alignment slots 55 therethrough dimensioned to slideably receive the pole pieces 19 as shown in FIGS. 3 and 4. Holes 57 and semi-circular holes 59 in FIG. 8 are slightly larger than and designed to align with holes 61 and 63 in the mounting plate 15 of FIG. 9 to receive the heads of screws holding the mounting plate 15 to the wire guide assembly 13 and holding the rear guide rail, bearing support 65 to the mounting plate 15. Fingers 23 are integral with and extend upwardly from planar portion 53 of the heat sink member 21. Mounting plate 15 has holes 67 in FIG. 9 for receiving the ends of pole pieces and retaining them with the axes of the pole pieces substantially parallel to the axis of the wire guide assembly 13 in FIG. 3. Holes 69 in the mounting plate 15 are present to reduce cross-talk between the coil assemblies 25.
In assembling the print head 1 as best seen in FIGS. 3 and 4, the mounting plate 15 is first slid over the top portion 69 of the plastic, wire guide assembly 13 until it abuts the ledge 71 as shown in FIG. 3. The mounting plate 15 is then fixedly secured to the wire guide assembly 13 by screws placed in holes 61 and extending between the mounting plate 15 and outwardly extending ears (not shown) of the wire guide assembly 13. Screws are then placed through holes 61 to secure the bearing support 65 to the mounting plate 15. The heat sink member 21 is then moved downwardly in FIG. 4 to receive the pole pieces 19 in the alignment slots 55 until the heat sink member 21 abuts the mounting plate 15. Coil assemblies 25 are then moved downwardly in FIG. 4 to slideably receive the pole pieces 19 in the first bobbin portions 33 and the yoke portions 17 in alignment slots 45 of the second bobbin portions 35 until the recessed-detent retaining means 47 and 49 on the inner and outer surfaces 48 and 50 of the pole pieces 19 and first bobbin portions 33 mate. The first bobbin portion 33 is dimensioned so that the mating recess and detent 47 and 49 firmly holds the planar portion 53 of the heat sink member 21 between the lip member 51 and mounting plate 15 as shown in FIG. 3. When assembled, heat sink member 21 helps to transfer heat generated in the area of the pole pieces 19 and coil members 29 outwardly to the finger members 23. Also when assembled, the finger members 23 of the heat sink member 21 and the upstanding yoke portion 17 of the mounting plate 15 are interspersed to provide more surface area for heat loss and to substantially prevent access as by fingers, paper clips, and the like to the interior of the print head 1.
Of particular note in this assembly process is the interaction between the upstanding yoke portions or alignment members 17 and the alignment slots 45 in the second bobbin portions 35. Specifically, the alignment slots 45 are dimensioned to slideably receive the upstanding ends of the yoke portions 17 in a close fitting relationship. By receiving respective pole pieces 19 in the first bobbin portions 33 and the yoke portions 17 in the alignment slots 45 of the second bobbin portions 35, each coil assembly 25 is automatically aligned during assembly with the impact end 85 of the clapper member 31 in FIGS. 2 and 3 against the impact end 87 of one of the print wires 89. Further, as illustrated in FIG. 3, the free standing ends of the yoke portions 17 abut the clapper member 31 when the recess and detent 47 and 49 mate and serve respectively as fulcrums for the clapper members 31.
FIGS. 10-17 illustrate the rear, middle, and front wire guide members 91, 93, and 95 for the print wires 89. Rear and middle wire guide members 91 and 93 in FIGS. 10 and 13 each have a main body 97 and 97' with a planar surface 99 and 99' and a rim portion 101 and 101' attached to and extending upwardly from the planar surface 97 and 97'. The rim portion 101 and 101' has a cam surface 103 and 103' extending upwardly from the planar surface 99 and 99' and outwardly of an axis perpendicular to the planar surface 99 and 99'. The cam surface 103 and 103' intersects the planar surface 99 and 99' at a plurality of points forming a closed path in P as best seen in FIGS. 11 and 14. The rear and middle wire guide members 91 and 93 also have a plurality of holes 105 and 105' through the main body portion 97 and 97'. Each of these holes 105 and 105' extends along an axis substantially parallel to the above-mentioned axis of the cam surface 103 and 103' and intersects the closed path P. In this manner, the print wires 89 can be advanced toward the respective wire guide members 91 and 93 to first contact the cam surface 103 and 103' of the rim portion 101 and 101' and then slideably moved therealong into one of the holes 105 and 105'. In the rear wire guide member 91 as shown in FIG. 10, the hole 105 is defined by first and second surfaces 107 and 109. The first surface 107 extends downwardly from the planar surface 103 and inwardly of the axis of the hole 105 to form a truncated cone shape. The second surface 109 is substantially cylindrical and extends downwardly from the first surface 107 about the axis of the hole 105. The front wire guide member 95 in FIGS. 15 and 16 also has a rim portion 101" with a cam surface 103" and a planar surface 99" which is much smaller than corresponding planar surfaces 99 and 99' because the holes 105" are aligned and interconnected as can be seen in FIG. 16.
The grooved member 111 depending from the rear wire guide member 91 in FIG. 10 is an assembly aid for assisting the sequential insertion of the print wires 89 into the holes 105' of the middle wire guide member 93 as illustrated in FIG. 17. Referring to FIG. 17, the print wire 89 is first inserted through one of the holes 113 in the top wire guide member 115 shown in FIGS. 3, 4, and 17-19. The print wire 89 is then advanced along a substantially straight path (shown in solid lines in FIG. 17) toward and through the hole 105 in the rear wire guide 91 until the leading end of the print wire 89 contacts the grooved assembly aid 111 in the bottom of a predetermined groove thereof. By continuing to advance the print wire 89, the assembly aid 111 serves to apply a force to the print wire 89 in a direction substantially perpendicular to the substantially straight path 116 mentioned above whereby the print wire 89 assumes a first bowed shape defining a path 117. Further advancing of the lead end of the print wire 89 along the first bowed shaped path 117 causes the lead end to contact the cam surface 103' of the middle wire guide member 93 where it is guided into the hole 105'. The cam surface 103' serves as a second assembly aid and when the print wire 89 is passed through the hole 105' in the middle wire guide member 93, the print wire 89 assumes a second bowed shape 119 which has less bow than the first bowed shape 117. In this manner, contact with the assembly aid 111 is eliminated and the print wire 89 only bears against the top, rear, and middle wire guide members 115, 91, and 93. This assembly technique using the assembly aids 111 and 103' reduces the assembly time necessary to insert the print wires 89 and eliminates the need for an assembler to physically grip and guide the print wires 89 through the holes 105' in the middle wire guide member 93.
FIG. 18 also illustrates an assembly technique for grinding all of the print ends of the print wires 89 so they lie in a common plane A in the impact area. In this assembly method, the cap 123 is screwed downwardly until the surface 125 of the rim portion 127 abuts the tops of the pole pieces 19. At this point, the inner, planar surface 129 of the cap 123 contacts all of the impact ends 131 of the print wires 89 and advances the print ends of the print wires 89 out of the front wire guide member 95 as illustrated in FIG. 18. The print ends are then ground off in a common plane which is perpendicular to the axis of the wire guide assembly 13 and parallel to the planar surface 129 of the cap 123. The distance between the rim surface 125 and the inner surface 129 of the cap 123 is exactly the thickness of the impact end 85 of the clapper member 31. Consequently, the cap 123 can be removed and replaced with restraining screw 26 and backstop 28 in FIGS. 3 and 19 whereby the restraining screw 26 is advanced until the surface 133 of the backstop 29 is exactly in the same place that inner surface 129 was in at the time of the grinding. In practice, this is accomplished by advancing the restraining screw 26 until it abuts surface 135 of the wire guide assembly 3 in FIG. 19 and then backing the restraining screw 26 off a predetermined number of turns.
FIGS. 19 and 20 illustrate views of a modified coil assembly 25' of the present invention. In the modified coil assembly 25', a return spring 137 is provided for biasing the rear end portion 139 of the clapper member 31 toward the bottom side 141 of the slot 39'. As seen in FIGS. 19 and 20, a post member 143 is attached to and extends downwardly from the top side 145 of the slot 39'. The free end of the post member 143 extends toward the bottom side 141 of the slot 39' for about half the distance between the top and bottom sides 145 and 141. The coil spring 137 is positioned about the post member 143 between the top side 145 and the rear portion 139 of the clapper member 31 as illustrated in FIGS. 19 and 20. The cord spring 137 serves to bias the rear end portion 139 of the clapper member 31 toward the bottom side 141 of the slot 39 and away from the top side 145 and post member 143.
Further designs of the present invention for simplifying and reducing the time needed for assembly and disassembly include the clamp means 147 for removably mounting the print head 1 to the main guide bearing 149 in FIGS. 1 and 3 and the snap arrangement 151 for mounting the print head 1 to the bearing 153 which rides on the rear guide rail 5. In assembly, the print head 1 is clamped to the main guide bearing 149 by placing the main guide bearing 149 between clamp portion 155 on the print head 1 and clamp portion 157 on the lower end of the support member 65. Screw 159 and the screws holding the support member 65 to the mounting plate 15 as discussed above are then tightened so that the print head 1 is firmly clamped to the main guide bearing 149. The head shaft 3 could already be positioned in the main guide bearing 149 prior to this clamping or it can be slid into the main guide bearing 149 after the clamping procedure. The snap arrangement 151 by which the print head 1 is mounted to the bearing 153 includes the substantially U-shaped portion or member 161 on the top end of the support member 65 which has an inner surface substantially corresponding to the shape of the outer surface of the guide bearing 153. The guide bearing 153 has a resilient detent member 165 forming part of the outer surface. The inner surface of the U-shaped portion 161 has a mating recess portion 167 whereby the bearing 153 can be snapped into place and held against the U-shaped portion 161 of the support member 65 with the inner and outer surfaces thereof abutting each other. In one assembly procedure, the bearing 153 is snapped into place against the U-shaped portion 161 of the support member 65 and then the rear guide rail 5 inserted in the bearing 153 and in another procedure, the bearing 153 can be mounted on the rear guide rail 5 and then the U-shaped portion 161 snapped thereon.
In the print head 2 of FIGS. 21-28, a modified coil assembly 4 is illustrated. As best seen in FIG. 22 and like the other coil assemblies, the modified coil assembly 4 includes a bobbin member 6, coil member 8, and clapper member 10 with the coil member 8 being positioned about the first portion 12 of the bobbin member 6 and the clapper member 10 mounted between the second and third portions 14 and 16 of bobbin member 6. Unlike the other coil assemblies, the mounting means for the clapper member 10 of the modified coil assembly 4 includes inner and outer pairs of generally L-shaped members 18 and 20. As best seen in FIGS. 21-23, the inner and outer pairs of L-shaped members 18 and 20 of each bobbin member 6 are dimensioned to receive the clapper member 10 among them with the end portions of the clapper member 10 substantially abutting members 18 and 20. The clapper member 10 can be lifted out of or placed in the print head 2 by moving it relative to the L-shaped members 18 and 20 with the central axis A--A of the clapper member 10 remaining in a predetermined plane perpendicular to the view of FIG. 21. To keep the clapper member 10 in place, inner and outer elastic O-rings 22 and 24 are positioned in the included angles of the legs of the respective inner and outer pairs of L-shaped members 18 and 20 (see FIGS. 21 and 22). In this manner, any and all of the clappwer members 10 can be easily and quickly installed in or removed from the print head 2 by selectively removing and replacing O-rings 22 and 24 within the included angles of the L-shaped members 18 and 20. In an alternate procedure, the clapper members 10 can be placed in or removed from the print head 2 by removing just the outer O-ring 24, picking the tail 10' of the clapper member 10 up out of the mating detent 16' in the second bobbin member portion 16 (see FIGS. 21, 24, and 25), and then sliding the head 10" of the clapper member 10 out from under the O-ring 22.
In the preferred embodiment, the return spring 30 of the wire guide assembly 32 (see FIGS. 22 and 25) biases the impact end 34 of the print wire 36 against the clapper member 10 and pivots the clapper member 10 about O-ring 22 into its home position (FIG. 22) when the coil member 8 is deactivated. In this home position, the clapper member 10 abuts the O-ring 22 and the upstanding yoke portion 17 but is spaced from the O-ring 24. As shown in FIG. 22, the O-ring 22 is preferably positioned well away from the impact end 34 of the print wire 36 a distance of about two and preferably three or four diameters of the O-ring 22 so that a significant moment arm is developed by the return spring 30 on the clapper member 10 between the impact end 34 and the pivot point at the O-ring 22. In this manner, the back of the clapper member 10 is held firmly against the yoke portion 17. As shown in FIG. 23, the O-ring 22 is tensioned along its neutral axis N and is in shear at S at the L-shaped members 18 when the clapper member 10 is in its home position.
In assemblying the bobbin member 6 on the pole piece 44 in FIG. 22, the pole piece 44 is first received in the first portion 12 of the bobbin member 6 and then the bobbin member 6 is moved until the free end of the pole piece 44 is flush with the immediately adjacent planar surfaces of the second and third bobbin member portions 14 and 16 (see FIG. 22). Once in place, the bobbin member 6 is preferably held in place by a press fit or glue. The air gap g between the pole piece 44 and clapper member 10 is determined by the home position of the clapper member 10 (see FIG. 22). In its home position, the clapper member 10 abuts O-ring 22 and the upstanding yoke portion 17 under the biasing force of return spring 30. The portion 17 is fixed relative to pole piece 44 and the position of O-ring 22 in the included angle of L-shaped members 18 is fixed relative to the bobbin member 6. Consequently, the size of the of the gap g can be automatically and predictably adjusted by moving the bobbin member 6 relative to the pole piece 44. Adjustments in the gap g can obviously also be made by using different diameter O-rings 22 without having to move the bobbin member 6 relative to the pole piece 44. However, in the preferred embodiment, the desired gap g is calculated and the bobbin member 6 and O-ring 22 are then dimensioned so the correct gap g is automatically achieved when the free end of the pole piece 44 is flush with the second and third bobbin member portions 14 and 16 as illustrated in FIG. 22. When the coil member 8 is activated, the clapper member 10 moves from its home position to one abutting the pole piece 44 and second and third bobbin member portions 14 and 16 (actually there is a thin insulator 60 therebetween which is shown in FIG. 25 but not FIG. 22 for clarity). As the clapper member 10 moves between these two positions, the L-shaped members 18 and 20 maintain the central axis A--A of the clapper member 10 in a predetermined plane relative to the bobbin member 6.
Referring to FIGS. 22 and 25, the modified coil assembly 4 has a wire guide assembly 32 with a first portion 38 serving as a wire guide for print wires 36 (see FIG. 22) and an annular portion 40 which extends outwardly of the first portion 38. The annular portion 40 has a tab member 42 (see FIG. 25) extending outwardly of it. The pole pieces 44 are fixedly and symmetrically positioned about a first axis 46 fixed in relation to the print head. In the assembly procedure, the annular portion 40 abuts the pole pieces 44 to center the wire guide assembly 32 relative to the axis 46 and the tab member 42 extends radially between and abuts two pole pieces 44 to prevent rotation of the wire guide assembly 32 about the axis 46. The bobbin members 6 are retained on the pole pieces 44 by a press fit or glue and in the embodiment of FIGS. 21-27, the bobbin member 6 abuts the annular portion 40 of the wire guide assembly 32 (see FIG. 22) to prevent longitudinal movement of the wire guide assembly 32 along the axis 46. In the preferred assembly, the coil assemblies 4 are symmetrically positioned about the axis 46 with the L-shaped members 18 and 20 each having one leg extending parallel to the axis 46 and the other leg extending radially outwardly of the axis 46 (see FIGS. 21 and 22) so that the retaining O-rings 22 and 24 extend across the clapper members 10 generally transversely of the central axes A--A of the clapper members 10.
FIG. 24 illustrates the manner in which adjacent bobbin members 6 abut one another along the respective sides in an interlocking fashion. FIG. 24 also illustrates the manner in which the C-shaped retaining members 52 for the lead wires 54 of the coil members 8 also abut to form respective closed O-shapes about pairs of the lead wires 54. Referring to FIG. 24, the abutting sides of each bobbin member 6 have a respective male member 56 and corresponding female member or recess 58 with adjacent male and female interlocking in a mating relationship when the bobbin members 6 are mounted on the pole pieces 44. The interlocking also aids assembly and further serves to hold the bobbin members 6 in the correct positions in the print head 2 in addition to adding strength and dynamic integrity to the print head 2. Further, the assembly procedure of interlocking will also serve to correct small alignment errors. For example, if a pole piece 44 is slightly misaligned, the placing of the bobbin member 6 over it and then interlocking the bobbin member 6 with adjacent ones will physically move the pole piece to correct the misalignment and then keep it correctly aligned. The C-shaped retaining members 52 for the lead wires 54 of the coil members 8 also are an assembly aid and when positioned with adjacent ones abutting as in FIG. 24, they serve to effectively maintain pairs of the lead wires 54 from adjacent coil members 8 in the elongated, O-shape formed thereby.
Referring to FIG. 25, other parts of the print head 2 include the insulator 60, connector 62, snap-in near bearing 153, and nose assembly 64. The nose assembly 64 has multiple functions including acting as a retainer for wire guides 66, 66', and 66" and as a heat sink for the print head 2 as explained in more detail below.
Referring again to FIG. 25, a modified main guide bearing 68 is shown wherein it has a recess 70 with planar surface 72 parallel to the axis 74 of the main guide bearing 68 and spaced-apart sides 76 perpendicular to axis 74. The nose assembly 64 (see also FIGS. 26-27) has a mating planar surface 72' and spaced-apart side surfaces 76' corresponding to 72 and 76 wherein the mating side surfaces 76 and 76' serve to prevent movement of the main guide bearing 68 along the axis 74 relative to the print head 2 and the mating planar surfaces 72 and 72' prevent movement of the main guide bearing 68 about the axis 74 relative to the print head 2.
FIGS. 26-27 illustrates a modified arrangement for securing the print head 2 to the head shaft 3. In this modified arrangement, the main guide bearing 68' has an inner cylindrical surface 80 symmetrically positioned about the axis of the head shaft 3 which is the same as axis 74. The outer cylindrical surface 82 of the main guide bearing 68' is symmetrical about axis 84 which is parallel to and spaced from axis 74 wherein the surface 82 is eccentric relative to axis 74. The main guide bearing 68' is resiliently mounted to the print head 2 by the resilient C-shaped clamp 86. As shown in FIGS. 26-27, the outer cylindrical surface 82 has a recess 88 thereabout centered on the axis 74. The recess 88 has three flat bottoms or detents at 90, 92, and 94 made up of planar surfaces parallel to axis 74. As in the case of main guide bearing 68 of FIG. 25, the nose assembly 64 of the print head 2 is matingly received on the recess 88 with the corresponding side surfaces 76 and 76' abutting to prevent movement of the main guide bearing 68' along the axis 74 relative to the print head 2. Unlike the embodiment of FIG. 25, the modified arrangement of FIGS. 26-27 permits the print head 2 to be selectively moved along its longitudinal axis 96 toward and away from the platen 11 so that the print head can accommodate different thicknesses of paper or multiple sheets of paper. To so adjust the print head 2, the main guide bearing 68' can be rotated against the force of the resilient C-shaped clamp 86 between, for example, the positions of FIGS. 26 and 27. In FIG. 26, the planar surface or detent 92 abuts the print head 2 and in FIG. 27, planar surface 90 abuts the print head 2. The retaining force of the C-shaped clamp 86 is different in FIGS. 26 and 27; however, the distance between axes 74 and 96 is the same since planar detent 90, 92, and 94 are equidistant from axis 74. Further, axes 74 and 96 remain perpendicular to one another in FIGS. 26 and 27. The actual moving of the print head 2 relative to the platen 11 is accomplished as a result of the camming action between the eccentric outer surface 82 of the main guide bearing 68' and the C-shaped clamp 86 which is fixedly attached to the print head 2.
Referring to FIGS. 25-28, the nose assembly 64 is open sided in that the print wires 36 are retained between the two metallic planar members 98 and 100 of the nose assembly 64. In this manner, the print wires 36 can be easily reached with tweezers or other instruments from either of the open sides in case one or more of the print wires 36 need to be adjusted or replaced. As best seen in FIGS. 27 and 28 (the print wires 36 are not shown in FIG. 26 for the sake of clarity), the print wires 36 are aligned between retainers 66' and 66" substantially in a plane (see FIG. 28) which is perpendicular to the planar members 98 and 100 to further enhance the accessability of the print wires 36 from either of the open sides of the nose assembly 64. The open sided nature of the nose assembly 64 also permits the free flow of air therethrough for better cooling of the print head. Further, the inner and outer surfaces of members 98 and 100 also serve as a heat sink for the print head 2 to transfer heat not only to the air flowing through the nose assembly 64 but also to the area surrounding the nose assembly 64.
FIG. 29 is a further modification in which the wire guide 102 adjacent the impact end 34 of print wire 36 is integral with the bobbin member 6 and supported in a fixed position relative thereto. In this manner, the coil-wire guide assembly of FIG. 29 which includes a bobbin member 6, coil member 8, clapper member 10, and wire guide 102 can be easily and quickly placed as a unit among the fixed pole pieces 44 and upstanding yoke portions 17 of the print head and can likewise be easily and quickly removed as a unit therefrom by selectively manipulating the retaining O-rings 22 and 24.
While several embodiments of the present invention have been described in detail herein, various changes and modifications can be made without departing from the scope of the invention.
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This invention involves methods and apparatus relating to the assembly and structure of a dot matrix print head. The invention includes a single unit, coil assembly of a bobbin, coil, and clapper which can be removeably placed as a unit among fixed pole pieces and yoke members in the print head. The print head also includes a supporting arragement for the coil assemblies which automatically aligns the clapper of each coil assembly with the impact end of one of the print wires during the assembly of the print head. Other disclosed features of the invention are novel designs for the wire guide members, a heat sink member, and mounting structure by which the print head is attached to the main guide and rail guide bearings of the printing mechanism. The invention also includes novel assembly aids and procedures which simplify and hasten the assembly of the print head including the use of assembly aids for inserting the print wires into the wire guide members and a grinding technique whereby all of the print wires can be easily and quickly ground to the proper length. With the novel print head design of this invention, the mounting plate, heat sink member, and coil assemblies can all be slideably assembled together and retained in place by snap-in, mating recess-detent arrangements between each bobbin and pole piece. In this manner, the print head can be easily and quickly assembled for operation and easily and quickly disassembled for repairs.
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BACKGROUND OF THE INVENTION
The present invention relates to a missile, in particular for combatting moving targets such as airplanes, helicopters or the like, in which several propulsion units are arranged one after the other along its longitudinal axis, as well as a method for controlling the thrust of such a missile.
A prior art missile is describe in German reference DE 27 36 547 C1.
For combatting aircraft, helicopters or the like in the direct shot method (LOS method), prior art missiles can accelerate to a maximum speed of up to Mach 2.5 with a short thrust impulse of approximately 2.5 seconds in duration.
In the LOS method, at the time of launch there is already visual contact with the target. If at the start it has already been switched to the target, a corresponding missile follows a flight path which in the simplest case can be described by the steering law of proportional navigation. For combatting flying targets with the NLOS method, that is, flying targets to which there exists no visual connection, for example, concealed helicopters, missiles having a seeker head are known that scan a seek area with the seeker head and turn onto a course to the target after target detection. The typical path of such a missile consists of a start phase, in which the missile climbs to seek altitude in a relatively steep path, a seek phase, in which the missile flies along a relatively flat path and the seeker head scans the seek area for possible targets, and a final approach run phase, in which a target is detected and the missile flies to the detected target, which as a rule lies well below the seek altitude. The image processing speed of the seeker head sets a limit for the speed of the missile during the seek phase, which for example can be in the range from Mach 1.0 to Mach 1.2. In combatting a target at close range (at a distance of about 1000 m to 1500 m from the launch point), the missile must in addition follow a relatively narrow path radius in order to move from the seek phase into the final approach phase. If the speed of the missile is too great, this radius can no longer be followed. An additional limit for the speed during the seek phase results from this.
Missiles provided for use in the LOS method have a disadvantageous profile for use in the NLOS method, since at close range their speed is too great for the required narrow path radius during the transition to the approach run, and at long range (at distances of about 6000 m or more from the launch point) the cross-acceleration capacity is too low due to the drop in speed. Conversely, the known missiles for the NLOS method cannot immediately after the start achieve the high speeds required for the LOS method, since they are designed for an acceleration to a comparatively low speed in the seek phase.
German reference DE 27 36 547 C1, discloses a rocket with several propulsion unit stages arranged one after the other that are successively burned. However, the speed after the start phase is thereby determined by the thrust force of the first propulsion unit, so that the disadvantage remains that this speed is either too small for use in the LOS method or is too great for combatting targets at close range according to the NLOS method.
The aim of the present invention is to create a missile of the type named above that is suited both for combatting targets according to the LOS method and also for combatting targets at close range according to the NLOS method, as well as providing corresponding thrust regulation methods.
For the solution of this aim, it is inventively provided that in a missile of the type named above at least two propulsion units can be operated at the same time, and the missile comprises an ignition control means that can optionally ignite these two propulsion units simultaneously or successively.
According to the present invention, the thrust profile can be varied both with respect to the strength of the thrust and also with respect to the temporal course of the thrust. This makes it possible to use the same missile both in the LOS method and in the NLOS method. Before the launch, an item of information is inputted to the ignition control means concerning whether the missile is used in the LOS or the NLOS method. If the LOS method is selected, the ignition control means ignites the propulsion units simultaneously or shortly after one another. If the NLOS method is selected, the ignition control means ignites the second propulsion unit corresponding to a stored ignition program, for example, when the target is detected or after a predetermined time. Several ignition programs of this type, matched to different types of use and target types, can be stored in the ignition control means. The ignition program relevant for the respective use is selected before launching or is determined automatically by the missile on the basis of seeker head information. For the use in the NLOS method for combatting targets at close range, it is for example, not absolutely necessary to ignite an additional propulsion unit, as long as a sufficient speed is given when the target is detected. However, an additional acceleration in the final approach phase by means of an additional propulsion unit is advantageous for the improvement effect in the target. If no target detection ensues, the seek area can be enlarged by the ignition of an additional propulsion unit during the seek phase.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide that the temporal distance between the ignition of two propulsion units is variable.
In addition, the missile has a seeker head for the detection of possible targets in a target area. The ignition control means is set up to ignite a first propulsion unit in a start phase in order to bring the missile to a predetermined seek height, and to ignite at least one additional propulsion unit after the seeker head has detected a target.
In the present invention the ignition control means is set up to ignite a propulsion means after the missile has swung into the sight line to the target in the approach run, in particular in order to quickly reach even targets at the edge of the seek area with the use of NLOS and to improve the effect at the target.
The missile has a seeker head for the detection of possible targets in a target area. The ignition control means is set up to ignite a propulsion unit after a predetermined time period after launch, if the seeker head has not detected a target during this time.
In addition, the missile has a rudder positioning system with folding or tilting bearer surfaces, whereby a first propulsion unit is arranged in the longitudinal direction in front of the central module and a second propulsion unit is arranged in the longitudinal direction behind the central module.
The ignition control system is housed in the central module.
In the present invention the ignition control means ignites the propulsion unit lying in front of the central module before the propulsion unit lying behind the rudder control system, if these propulsion units are not ignited simultaneously.
The ignition control means has a programming means with an interface for the inputting of information concerning the ignition of the propulsion units.
In the present invention at least one propulsion unit is a solid fuel rocket propulsion unit.
Furthermore, at least one propulsion unit can be multiply ignited.
The present invention furthermore provides a method for controlling thrust in a missile for combatting moving targets with a seeker head for target location, comprising the following steps: emission of a thrust impulse for achieving a predetermined seek altitude and a predetermined seek speed, and emission of an additional thrust impulse after the missile has achieved the seek altitude.
The additional thrust impulse is emitted after the detection of a target by the seeker head.
In addition, a thrust impulse is emitted after the missile has swung into the sight line to the target.
Moreover, a thrust impulse is emitted after a predetermined time interval after the start, if no target has been detected.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel, are set forth with particularity in the appended claims. The present invention, together with further objects and advantages, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several Figures of which like reference numerals identify like elements, and in which:
FIG. 1 shows a cross-section through an inventive missile; and
FIG. 2 shows the flight paths during a close-range shot in the NLOS method for an inventive missile and an LOS missile according to the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an example of an inventive missile. In this missile, a seeker head 1, a warhead 2, a first propulsion unit 3, a central module 4 with a rudder positioning system, a second propulsion unit 5 and a launch propulsion unit 6 are arranged one after the other in the axial direction.
The seeker head 1 is provided with an image acquisition and image processing means that is set to the target to be combatted. For the combatting of airplanes or helicopters, the seeker head can be equipped with a scanning IR optics and an IR matrix sensor, as well as an associated image processing means, as specified in German reference DE 37 33 681 C1 (corresponding to U.S. Pat. No. 5,400,134 hereby incorporated by reference), to which reference is made with respect to the details of such a seeker head.
The first propulsion unit 3 is a solid fuel rocket propulsion unit, and has several (for example, four) jet nozzles 32, oriented at an acute angle to the longitudinal axis of the missile. On the basis of the orientation of these nozzles, the propulsion 3 can be operated without damaging the parts behind it, so that the propulsion unit 3 and the propulsion unit 6 can be ignited at the same time.
On the external side of the central module 4, several (for example, four) folding or tilting bearer surfaces 42, which are extended after the launch, are attached to produce lift. The electronic components for energy supply and for the steering of the missile via the rudder positioning system, as well as the ignition control system for igniting the propulsion units, are housed in the central module 4. In addition, the central module 4 has an interface (not shown) via which the items of information concerning the type of targets to be combatted and type of use (LOS or NLOS) can be inputted. In the simplest case, this interface can be formed by means of a corresponding switch or a keyboard. However, it can also be a data interface connected with a data processing unit in the central module 4.
The propulsion unit 5 is, like the propulsion unit 3, a solid fuel rocket propulsion unit, and comprises a central jet nozzle 5.2. The launch propulsion unit 6 is a conventional rocket propulsion unit for the discharge of the missile from a start means, and after the launch can be blown off or can remain on the missile. In the present example, both propulsion units are constructively integrated.
For use in the LOS mode, a corresponding item of information concerning the interface of the central module 4 is inputted into the ignition control system for the propulsion units. This ignition control system then, after the launch, ignites the two propulsion units 3 and 5 at the same time or one shortly after the other, so that the thrust of two propulsion units is available, and the missile can be accelerated quickly to the required speed. For particular situations, it can be advantageous to ignite the propulsion unit 5 with a short delay. However, the propulsion units 3 and 5 are advantageously in simultaneous operation, at least for a certain time.
For use in the NLOS method, corresponding to an input via the interface of the central module after the start and blowing off of the launch propulsion unit 6, the front propulsion unit 3 is first ignited, lending the missile enough thrust to reach the required seek height.
After the seek height has been reached, the missile swings into a flat seek path, and scans the target area for possible targets. If the seeker head has detected a target, the missile swings into the sight line to the target and the propulsion unit 5 is ignited for acceleration in the approach run. The curve for case 1 in FIG. 2 shows as an example the flight path of an inventive missile during the combatting of a target at a distance of 1500 m from the launch point in the NLOS method, whereby the second propulsion unit 5 is ignited after target detection. As can be seen, the target is hit correctly. For comparison, the curve for case 2 in FIG. 2 shows the case in which the second propulsion unit 5 is ignited immediately after the burning out of the first propulsion unit 3, which corresponds to the flight behavior of a conventional LOS missile. In this case the target is missed, since the narrow path radius required for the introduction of the final approach run cannot be flown after the target recognition. This also cannot be compensated by a steeper launch angle, as the curve for case 3 shows, in which the second propulsion unit is likewise ignited immediately after the burning out of the first propulsion unit, since here the permissible squint angle of the seeker head is exceeded.
If in the seek flight phase no target is detected within a predetermined time, the second propulsion unit 5 is likewise ignited and the seek flight is continued. In this way a larger range can be achieved in relation to a missile with only a single propulsion unit. The time of ignition of the second propulsion unit 5 is usefully chosen so that a maximum flight time is not exceeded for the overall range. In order then to still achieve an acceleration in the approach run if the second propulsion unit 5 is ignited in the seek flight, in a modification of the represented embodiment an additional propulsion unit can be provided for the acceleration of the warhead 2 in the approach run. This propulsion unit can be provided either behind the warhead 2, whereby the propulsion unit 3, the central module 4 with the rudder positioning system, and the propulsion unit 5 are then blown off after the sight line has been swung into. Alternatively, the additional propulsion unit can also be arranged behind the propulsion unit 5. In this case, it comprises a central jet nozzle, while the propulsion unit 5, like the propulsion unit 3, is provided with jet nozzles that are inclined at an acute angle in relation to the longitudinal axis.
The embodiment specified above can be varied in various respects. Thus, in place of a solid-fuel rocket propulsion unit, a liquid fuel rocket propulsion unit or ram jet engine can for example be used. If the second propulsion unit 5 is operated with liquid fuel, it is also possible temporarily to shut off this propulsion unit, and to reignite it if necessary, for example, for the prolongation of the seek flight phase or for acceleration in the approach run. For use in the NLOS method, the rear propulsion unit 5 can also first be ignited. It can thereby be provided to blow off the central module with the rudder positioning system and the rear propulsion unit 5 after target detection, while in the LOS method such a blowing off is omitted. The ignition criteria named above can be implemented in various stored ignition programs that are selected before launching. However, they can also be implemented in an ignition program as alternatives, whereby the ignition control means selects the matching alternative on the basis of the data acquired during the flight.
The features of the present invention disclosed in the above specification, the drawings and the claims can be essential for the realization of the present invention in its various embodiments, both individually and also in arbitrary combination.
The present invention is not limited to the particular details of the method and apparatus depicted and other modifications and applications are contemplated. Certain other changes may be made in the above described method and apparatus without departing from the true spirit and scope of the present invention herein involved. It is intended, therefore, that the subject matter in the above depiction shall be interpreted as illustrative and not in a limiting sense.
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A missile, in particular for combatting moving targets, has several propulsion units arranged one after the other along the longitudinal axis of the missile. At least two propulsion units arranged one after the other can be operated simultaneously, and the missile contains an ignition control that is set up for optional ignition of these propulsion units at the same time or successively.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/709,215 filed May 11, 2015, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/990,848 filed May 9, 2014, which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
[0002] The invention generally relates to archery and bow accessories. More specifically, the invention relates to stabilizers, quivers, and combinations thereof.
BACKGROUND OF THE INVENTION
[0003] The field of archery is ancient, and the bow has long been a staple of hunting and warfare. In modern times, the tradition of archery continues recreationally and in hunting as most U.S. states designate a bow hunting season for certain animals. As archery has developed through the centuries, new features and accessories have been added to the bow.
[0004] One new feature of the modern bow is a stabilizer, which is typically a shaft-like mass that extends forward from the bow. When an arrow is launched from a bow, the arrow is subjected to a sudden propulsive force, and consequently the bow is subjected to a sudden and equal reactive force transmitted through the bow string. Often, this propulsive force is accompanied by a vertical or lateral torque that may cause the arrow to deviate from its desired flight path.
[0005] Stabilizers have three purposes for the archer: balance, vibration damping, and making the archer hold the bow steadier while aiming. The balancing goal is to steady a bow in an archer's hand so that it does not noticeably tip to either side or tip overly frontward or backward while aiming. Next, many stabilizers have some form of a vibration damping system to dissipate vibration caused by the released energy during the shot. Lastly, as an archer aims the bow, it is noticeably easier to grip the bow if there is some mass positioned forward of the bow. All else being equal, a stabilizer that extends farther out in front of the bow will make steadier aiming possible as compared to a shorter stabilizer. Further descriptions of a stabilizer may be found in U.S. Pat. Nos. 6,742,723 and 5,992,403, which are hereby incorporated by reference in their entirety.
[0006] Another feature of the modern bow is the quiver, which allows an archer to conveniently carry arrows, bolts, or darts. Quivers may be disposed on a belt, slung over the back of the archer, carried in the archer's hand, or carried in the archer's backpack. However, the modern trend is to attach the quiver to the bow itself. An example of such a quiver is described in U.S. Pat. No. 6,105,566, which is hereby incorporated by reference in its entirety.
[0007] A bow-mounted quiver has many drawbacks. First, the quiver obstructs the view of the archer. A bow-mounted quiver is vertically oriented and disposed on either side of the bow. This necessarily restricts the view of the archer which can endanger the archer. A bow hunter must stalk his or her target and be in close proximity with the target, and an obstructed view may cause the hunter to miss a visual cue from the animal: a mother protecting her young, a rutting bull, etc. Another drawback is the weight of the quiver. An archer must elevate the bow with his or her arms during use, and added weight can fatigue the archer.
[0008] The weight of the quiver is also offset from the bow's center of gravity. Most bow-mounted quivers on the market today hold arrows on the right side of a right hand bow (left side of a left hand bow) as viewed by the archer shooting the bow. This placement causes the bow to balance off-center toward the dominant hand of the shooter (i.e., to the right for a right handed shooter). Therefore, the weight and position of the quiver affects the accuracy and precision of the bow. To remedy the issues associated with a bow-mounted quiver the archer may carry the quiver by hand, on a backpack, or on a belt as mentioned above. However, this would necessitate the use of a belt or backpack or result in fatigue of the archer if the archer carried the quiver by hand.
SUMMARY OF THE INVENTION
[0009] It is thus an aspect of embodiments of the invention to provide a stabilizer/quiver that functions as both a quiver and a stabilizer. It is another aspect of embodiments of the invention to provide a stabilizer/quiver that reduces the overall weight of the bow and improves the reliability of the bow. A separate stabilizer and quiver configuration weighs more than a combined stabilizer/quiver because two components have been reduced to one. Further, because there are fewer components, the stabilizer/quiver is less susceptible to failure. Thus, a combined stabilizer/quiver improves the reliability of the bow.
[0010] It is another aspect of embodiments of the invention to improve the effectiveness of the bow by improving its accuracy and precision. In some embodiments of the invention, the quiver is substantially aligned with the center of mass of the bow such that the quiver does not pull the bow to one side. The resulting balance of the bow relieves the archer from one source of inaccuracy and imprecision, which results in a more effective bow.
[0011] It is a further aspect of embodiments of the invention to provide a more compact bow. While target archers prefer longer stabilizers, hunters necessarily require more discrete stabilizers so they can move about varied terrain and stalk their target. The invention provides a more compact stabilizer, and thus a more compact bow, because the quiver and arrows of the invention contribute to the mass extending forward from the bow. Thus, the quiver and arrows contribute to the stabilizing function of the stabilizer/quiver, and embodiments of the invention need not be as long as they otherwise would be. The resulting bow provides additional mobility for a hunter who needs to traverse varied terrain.
[0012] It is another aspect of embodiments of the invention to improve the safety of the archer, specifically the hunter. As mentioned above, a vertically oriented quiver obstructs the view of the hunter, and the hunter may miss visual cues from the target, animals such as the target's mother, or the environment. A combined stabilizer/quiver is generally horizontally oriented, and thus, the hunter maintains a clear view of his target and the surrounding environment. This allows the hunter to properly anticipate and/or mitigate any potential threats, which improves the overall safety of the hunter.
[0013] It is a further aspect of embodiments of the invention to provide a stabilizer/quiver that may detach and quickly disassemble. The stabilizer/quiver of the invention may attach to the bow and may be secured by components that are tightened by hand and not necessarily by other means such as an Allen wrench or a screwdriver. A hand-operated means for securing the stabilizer/quiver allows the archer to detach and quickly disassemble the quiver for easier carrying or storage without the necessity of carrying, or remembering to carry, the proper tool.
[0014] It is another aspect of embodiment of the invention to provide a stabilizer/quiver that is rotatable relative to a bow. In some embodiments of the invention, the default position for the stabilizer/quiver is extending forward from the bow and generally parallel with the ground when the bow is in a firing position. Thus, the stabilizer/quiver contributes to the overall stability of the bow. However, in other instances it may be advantageous to adjust the position of the stabilizer/quiver for easy storage, to adjust the stabilizing function, etc. In some embodiments, a bow attachment is used to interconnect the stabilizer/quiver to a portion of the bow such as the riser. The bow attachment may comprise two or more components disposed about an axis such that the stabilizer/quiver rotates relative to the bow. Further, the bow attachment may comprise a bolt, screw, or other similar device that is configured to lock the position of the stabilizer/quiver relative to the bow once the position of the stabilizer/quiver has been adjusted. The stabilizer/quiver may rotate about the rotatable bow attachment such that the stabilizer/quiver may rotate parallel with the riser of the bow similar to traditional bow-mounted quiver, or the stabilizer/quiver may be incrementally rotated to adjust the stabilizing effect of the stabilizer/quiver, access to the arrows, etc.
[0015] It is another aspect of embodiments of the invention to provide a stabilizer/quiver that comprises fully adjustable components. In some embodiments, the stabilizer/quiver comprises a shaft, a broadhead hood and an arrow gripper that secure arrows, and a bow attachment that interconnects the stabilizer/quiver to the bow. The broadhead hood, the arrow gripper, and the bow attachment may be disposed about the shaft in any order and in any position along the shaft. For example, these components may be arranged such that the shaft extends forward like a stabilizer, but the arrows are disposed rearward of the riser of the bow. In other embodiments, both the shaft and the arrows may be disposed forward of the riser of the bow or both disposed rearward of the riser.
[0016] It is another aspect of embodiments of the invention to provide a quiver/stabilizer that comprises an adjustable shaft. The shaft may comprise one or more hinged sections such that the position of the hinged sections and the relative angle between hinged sections is adjustable. In another example, the shaft is telescoping in nature. Therefore, an archer may fully extend the shaft to provide the greatest stabilizing effect, and the archer may collapse the shaft to any shorter length to provide more maneuverability or easier storage.
[0017] It is another aspect of the invention to provide a stabilizer/quiver that has an adjustable length in response to the number of arrows the stabilizer/quiver carries. In some embodiments of the invention, the stabilizer/quiver carries arrows and the stabilizer/quiver functions as a stabilizer. As a user selects arrows from the stabilizer/quiver and fires the arrows, the weight of the stabilizer/quiver changes, and the stabilizing properties of the stabilizer/quiver may also change. Thus, in some embodiments, the shaft of the stabilizer/quiver extends further out as each arrow is selected to compensate for the reduced weight of the stabilizer/quiver. This movement may be induced manually, for example, by a mechanical system such as a ratchet and pawl or automatically, for example, by an electrical system such as an electrical linear motor. Now the stabilizer/quiver may have consistent stabilizing properties, even as arrows are selected and fired.
[0018] It is another aspect of various embodiments of the invention to provide a stabilizer/quiver that is fully compatible with bow attachments and configurations. For example, modern bows often comprise platforms and components to attach aftermarket parts such as optics and sights. Embodiments of the invention may comprise a bow attachment that is adapted to interconnect to any other feature commonly incorporated in bows.
[0019] It is another aspect of embodiments of the invention to provide a broadhead hood that covers the broadheads of an arrow for safety purposes. In some embodiments, the broadhead hood comprises a housing with a broadhead hood insert, and a user may insert the broadhead of an arrow into the broadhead hood insert. Next, the user may engage an adjustable feature that compresses a portion of the broadhead hood insert such that the broadhead hood insert grips or locks the broadheads snuggly in the broadhead hood. The ability to grip or lock the broadheads reduces vibrations in the overall bow configuration and it also aids the archer by preventing arrows from falling out of the broadhead hood as the archer negotiates varied terrain. When the archer has established a position and needs access to the arrows, the archer may simply engage the adjustable feature to relieve the compression within the broadhead hood insert.
[0020] It is another aspect of embodiment of the invention to provide a stabilizer/quiver that selectively interconnects to an existing stabilizer. Many bows in circulation already comprise a stabilizer. Therefore, some embodiments of the invention may comprise features such as a broadhead hood and an arrow gripper that attach to the preexisting stabilizer to form a stabilizer/quiver. The arrow gripper and the broadhead hood may comprise adjustable means such that the arrow gripper and the broadhead hood may compress about the outer surface of the stabilizer. In other embodiments, the arrow gripper and broadhead hood snap onto the existing stabilizer. It will be appreciated that a variety of means to attach components to an existing stabilizer are discussed elsewhere herein and known in the art.
[0021] One particular embodiment of the invention is a combined stabilizer/quiver for a bow, comprising a shaft having a proximate end, a distal end, and an outer surface; a bow attachment feature located near the proximate end of the shaft, the bow attachment feature is adapted to secure the shaft to a bow; a broadhead hood disposed about the outer surface of the shaft, the broadhead hood comprising at least one recess configured to receive a first portion of an arrow; and an arrow gripper disposed about the outer surface of the shaft, the arrow gripper comprising at least one slot configured to receive a second portion of the arrow.
[0022] Another embodiment of the invention is a system for stabilizing a bow and storing arrows, comprising a bow having a riser, and an arrow having an arrowhead and a body; a shaft extending from the riser of the bow, the shaft having a proximate end, a distal end, and an outer surface; a broadhead hood disposed about the outer surface of the shaft, the broadhead hood comprising at least one recess, wherein the arrowhead of the arrow is positioned in the at least one slot; and an arrow gripper disposed about the outer surface of the shaft, the arrow gripper comprising at least one slot, wherein the body of the arrow is positioned in the at least one slot.
[0023] Yet another embodiment of the invention is a combined stabilizer/quiver for stabilizing a bow and storing arrows, comprising a shaft having a proximate end, a distal end, and an outer surface; a bow attachment feature located near the proximate end of the shaft, the bow attachment feature is adapted to secure the shaft to a bow; a broadhead hood disposed near the distal end of the shaft and about the outer surface of the shaft, the broadhead hood comprising a housing at least partially defining a volume; and a broadhead hood insert disposed in the volume and comprising at least one recess, the broadhead hood insert is compressible between a first volume and a second volume; a tension lever operably interconnected to the broadhead hood insert, the tension lever is moveable between a first position and a second position to compress the broadhead hood insert between the first volume and the second volume; and an arrow gripper disposed between the bow attachment feature and the broadhead, the arrow gripper disposed about the outer surface of the shaft, the arrow gripper comprising at least one slot configured to receive a body of the arrow.
[0024] These and other advantages will be apparent from the disclosure of the invention(s) contained herein. The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the invention. Moreover, references made herein to “the invention” or aspects thereof should be understood to mean certain embodiments of the invention and should not necessarily be construed as limiting all embodiments to a particular description. The invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and Detailed Description and no limitation as to the scope of the invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the invention will become more readily apparent from the Detailed Description particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosures.
[0026] FIG. 1 is a side elevation view of a typical compound bow according to one embodiment of the invention;
[0027] FIG. 2 is an exploded perspective view of a combined stabilizer/quiver according to one embodiment of the invention;
[0028] FIG. 3 is a perspective view of an assembled stabilizer/quiver according to one embodiment of the invention wherein arrows are disposed within the stabilizer/quiver;
[0029] FIG. 4 is a side elevation view of a stabilizer/quiver according to one embodiment of the invention wherein the stabilizer/quiver is attached to a riser of a bow;
[0030] FIG. 5 is a side elevation view of a stabilizer/quiver according to one embodiment of the invention showing a vertical angle between the stabilizer/quiver and a riser;
[0031] FIG. 6 is a perspective view of a stabilizer/quiver according to one embodiment of the invention showing a horizontal angle between the stabilizer/quiver and a riser;
[0032] FIG. 7 is a perspective view of a broadhead hood according to one embodiment of the invention wherein a tension lever is open; and
[0033] FIG. 8 is a perspective view of a broadhead hood according to one embodiment of the invention wherein a tension level is closed.
[0034] To assist in the understanding of the embodiments of the invention the following list of components and associated numbering found in the drawings is provided herein:
[0000]
Component No.
Component
2
Bow
4
Riser
6
Upper Limb
8
Upper Bolt
10
Lower Limb
12
Lower Bolt
14
Upper Cam
16
Lower Cam
18
Bow String
20
Nocking Point
22
Cable Guard
24
Bow Sight
26
Arrow Rest
28
Grip
30
Stabilizer
32
Stabilizer/Quiver
34
Shaft
36
Arrow Gripper Bracket
38
First Portion
40
Second Portion
42
Arrow Gripper
44
Lockdown Bolt
46
Bow Attachment
48
Quick Detach Knob
50
Broadhead Hood
52
Broadhead Hood Insert
54
Arrow
56
Vertical Angle
58
Horizontal Angle
60
Tension Plate
62
Tension Lever
[0035] It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0036] The invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the invention, an embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, may be modified in numerous ways within the scope and spirit of the invention.
[0037] Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning.
[0038] Various embodiments of the invention are described herein and as depicted in the drawings. It is expressly understood that although the figures depict bows with quiver and stabilizer combinations, the invention is not limited to these embodiments. It should be further understood that the terms “arrow gripper bracket” and “bracket”, and “arrow gripper” and “gripper” may be used interchangeably, respectively.
[0039] Now referring to FIG. 1 , a typical compound bow 2 is provided. The central portion is a riser 4 , which is a central, rigid portion of the bow 2 . The riser 4 is where a user grips the bow 2 , and the riser 4 provides a central location to dispose other portions of the bow 2 and various accessories. Extending upward from the riser 4 is an upper limb 6 which is affixed to the riser 4 . In this embodiment, an upper bolt 8 is used to affix the upper limb 6 to the riser 4 . In other embodiments, the upper bolt 8 or another fastening means may be used to adjust the interconnection between the upper limb 6 and the riser 4 to provide different performance characteristics to the bow 2 . Similarly, a lower limb 10 extends downward from the riser 4 , and a lower bolt 12 affixes the lower limb 10 to the riser 4 .
[0040] Each of the upper limb 6 and the lower limb 10 have a proximate end, which is affixed to the riser 4 , and a distal end. An upper cam 14 is disposed on the distal end of the upper limb 6 , and a lower cam 16 is disposed on the distal end of the lower limb 10 . A bow string 18 is operatively interconnected to each the upper cam 14 and the lower cam 16 . Cams may come in a variety of forms including, but not limited to, single cams, hybrid cams, dual cams, binary cams, quad cams, and hinged cams. As a user engages the bow 2 and pulls on the bow string 18 , the upper cam 14 and the lower cam 16 rotate as the limbs 6 , 10 begin to flex. When the cams 14 , 16 completely rotate, the draw weight of the bow string 18 lets off, or in other words, the draw weight decreases from the peak draw weight. This allows an archer to maintain a drawn bow string 18 with less effort. The “let off” may be expressed in term of a percentage of the peak draw weight of the bow string 18 . Let off is typically between 60-85% of the peak draw weight of the bow string 18 . This means that a bow 2 may let off 60% of the peak draw weight of the bow string 18 , and the user needs to maintain only 40% of the peak draw weight to keep the bow string 18 drawn. Other bows may have let off between 50-99% of the peak draw weight.
[0041] FIG. 1 also illustrates other features typically found on a bow 2 . A nocking point 20 is disposed on the bow string 18 approximately halfway between the cams 14 , 16 . The nocking point 20 is near where the user locates an arrow on the bow string 18 . A cable guard 22 extends rearward from the riser 4 and past the bow string 18 . The cable guard 22 segregates additional portions of the bow string 18 from the portion of the bow string 18 that comprises the nocking point 20 such that the additional portions do not interfere with the arrow. A bow sight 24 is disposed on the riser 4 and aids the user in visualizing where a fired arrow will travel. The riser 4 also comprises an arrow rest 26 , which is where the shaft of a projectile rests as a user engages the bow 2 . Finally, the riser 4 comprises a grip 28 , which is the portion of the riser 4 that the user grips with his or her off hand.
[0042] Also depicted in FIG. 1 is a stabilizer 30 . The stabilizer 30 in this embodiment of the invention is affixed to the riser 4 of the bow 2 , and the stabilizer 30 extends forward from the bow 2 . The bow 2 may comprise a threaded female recess disposed on the forward end of the bow 2 , and the stabilizer 30 may comprise a threaded male insert such that an archer may screw the stabilizer 30 into the bow 2 . Embodiments of the invention may comprise similar attachment means and other attachments means discussed herein. As mentioned elsewhere herein, the general purpose of the stabilizer 30 is to provide balance to the bow 2 , to dampen vibrations as an arrow is fired, and to aid a user in holding a drawn bow 2 steady.
[0043] Now referring to FIG. 2 , an embodiment of a combined stabilizer/quiver 32 for a bow is provided. A shaft 34 provides length to the stabilizer/quiver 32 , and in this embodiment, the shaft 34 is cylindrically shaped having a proximal end and a distal end. An arrow gripper bracket 36 may be disposed about the shaft 34 towards the proximate end of the shaft 34 . A first portion 38 of the arrow gripper bracket 36 may be disposed around the shaft 34 , and the first portion 34 is cylindrically shaped but comprises a longitudinally disposed gap. A lockdown bolt 44 may be used to secure the arrow gripper bracket 36 to the shaft 34 . As a user engages the lockdown bolt 44 , the longitudinally disposed gap of the first portion 34 closes, and the first portion 34 of the arrow gripper bracket 36 compresses onto the outer surface of the shaft 34 of the stabilizer/quiver 32 .
[0044] The arrow gripper bracket 36 shown in FIG. 2 also comprises a second portion 36 that extends outward, radially from the shaft 34 of the stabilizer/quiver 32 . The second portion 36 comprises a recess and two ridges. An arrow gripper 42 comprises two grooves which correspond to the two ridges of the second portion 40 . This allows the arrow gripper 42 to longitudinally slide into the second portion 40 of the arrow gripper bracket 36 . The lockdown bolt 44 may secure the first portion 38 to the shaft 34 , and the lockdown bolt 44 may also continue through the first portion 38 , through the second portion 40 , and into the arrow gripper 42 in order to secure the arrow gripper 42 to the second portion 40 . It will be appreciated that there may be other embodiments of the invention where the arrow gripper 42 snaps into the second portion 40 or is secured on the second portion 40 with other attachment means. In yet further embodiments, the arrow gripper 42 is screwed onto the second portion 40 , is welded to the second portion 40 , or is a single continuous structure with the second portion 40 . The arrow gripper 42 may interface with the second portion 40 via any means commonly known in the art.
[0045] The arrow gripper 42 comprises at least one slot or aperture devoted to securing the body or shaft of an arrow. This slot comprises a portion that is approximately the same diameter as the arrow's body or shaft, but the slot also comprises an entry portion that is smaller than the diameter of the arrow's body or shaft. This configuration allows an arrow to snap into place in the arrow gripper 42 , which secures the arrow by virtue of the entry portion that has a diameter smaller than the arrow's body or shaft.
[0046] Next, a bow attachment 46 is disposed around the shaft 34 of the stabilizer/quiver 32 towards the proximate end of the stabilizer/quiver 32 . The bow attachment 46 is similar to the first portion 38 of the arrow gripper bracket 36 . The bow attachment 46 is cylindrically shaped with a longitudinal gap. A quick detach knob 48 is used to secure the bow attachment 46 to the shaft 34 of the stabilizer/quiver 32 and to a portion of the riser 4 of the bow 2 . As a user engages the quick detach knob 48 , the longitudinal gap closes and the bow attachment 46 compresses onto the outer surface of the shaft 34 of the stabilizer/quiver 32 . The bow attachment 46 may also be screwed, welded, formed continuously with, snapped, and and/or secured to the shaft 34 via any other means of interconnection discussed herein or commonly known in the art.
[0047] FIG. 2 shows a broadhead hood 50 disposed on the distal end of the shaft 34 of the stabilizer/quiver 32 . The broadhead hood 50 may be secured by means of a compression or interference fit. In other embodiments, the broadhead hood 50 may be secured by the lockdown bolt or the quick detach knob used by the arrow gripper bracket 36 and the bow attachment 42 , respectively.
[0048] The broadhead hood 50 comprises a housing with a recess configured to receive a broadhead hood insert 52 . The tips of arrows are typically fitted with a broadhead for hunting purposes, and broadheads generally comprise at least one sharpened edge, which can present a danger to the user if the sharpened edge is exposed. Thus, the broadheads may be disposed and secured in the broadhead hood insert 52 . The broadhead hood insert 52 may comprise a material that is punctured by the broadhead of an arrow, then the material compresses around the broadhead. In other embodiments, the material is cut out into a shape that receives and secures a broadhead. The material may be foam rubber, rubber, polyethylene, or other material commonly used in the art, and the broadhead hood insert 52 may comprise an adjustable feature such as a screw that allows an archer to compress the rubber around the broadhead. In yet further embodiments, the broadhead hood insert 52 may comprise locking features that snap into a notch or other geometrical feature of the broadhead. In this embodiment, the number of locking features may be greater than, less than, or equal to the number of slots in the arrow gripper 42 .
[0049] Another feature of the stabilizer/quiver 32 is the ability to dampen vibrations caused by operation of the bow 2 . The shaft 34 itself may be adjustable in length and/or shape. A shaft 34 configured in different shapes and disposed in different locations will provide different moment forces about the center of the bow's 2 mass, and thus different dampening and stabilizing properties. In addition, the shaft 34 will provide different mode shapes and frequencies. The shape of the shaft 34 may be manipulated with multiple segments, and the shaft 34 may be a shape other than a cylinder. For example, a square shaft, a shaft with a plurality of ribs, and/or a shaft with a plurality of apertures may provide optimum dampening qualities. Further, the shaft 34 may be encased in or cored with rubber, vibration foam, or any other material that enhances the vibration dampening properties of the combined stabilizer/quiver 32 .
[0050] An archer may adjust the shaft 34 until the desired dampening shape is achieved. In some embodiments of the invention, the shaft 34 comprises a hollow, enclosed volume which may be filled with a liquid. A shaft 34 with a liquid core may also provide enhanced dampening properties. Further, different segments of a segmented shaft 34 may be filled with various liquids, and other segments of the segmented shaft 34 may remain solid or hollow. In a single shaft 34 design, the interior of the shaft 34 may comprise a plurality of compartments which may be filled with a liquid. Further, the sides of the shaft 34 may be clear such that an archer may discern the amount of liquid in each compartment. Liquids may be water, and liquids may be less or more dense than water such as oil and mercury.
[0051] Other embodiments of the invention may employ other means to effectuate the dampening properties of the stabilizer/quiver 32 . The shaft may comprise a piston with an electronic timing system such that the piston is displaced as an archer fires an arrow. In this embodiment a sensor may be disposed on the limbs 6 , 10 such that the sensor discerns when the bow is drawn, then when the bow string 18 is release. The sensor may be in electronic communication with the stabilizer/quiver 32 and the piston system. When the sensor detects the bow string 18 release, the piston may adjust its position within the shaft 34 of the stabilizer/quiver 32 to counteract the flexing of the limbs 6 , 10 , and the propulsion of the projectile. In other embodiments, a spring system or hydraulic system may be employed within the shaft 34 . It will be appreciated that commonly known dampening devices may be passively or actively used in the shaft 34 of the stabilizer/quiver 32 to improve the dampening and stabilizing properties of the stabilizer/quiver 32 .
[0052] Now referring to FIG. 3 , a stabilizer/quiver 32 is provided where arrows 54 are disposed in the stabilizer/quiver 32 . The bodies or shafts of the arrows 54 are disposed in the slots of the arrow gripper bracket 36 , and the broadhead of the arrow is disposed in the broadhead hood insert 52 . Also shown in FIG. 3 is the proximate end of the bow attachment 46 , which may be screwed into a portion of the riser 4 of the bow 2 . In other embodiments, the bow attachment 46 may compress about a portion of the riser 4 similar to how the bow attachment 46 may compress around the outer surface of the shaft 34 of the stabilizer/quiver 32 .
[0053] The broadhead hood 50 , the arrow gripper bracket 36 , and the bow attachment 46 are all adjustable along the length of the shaft 34 of the stabilizer/quiver 32 . In one embodiment, the broadhead hood 50 remains disposed on the distal end of the shaft 34 , and the arrow gripper bracket 36 and the bow attachment 46 are moveable towards the distal end of the shaft 34 and are adjustable as far as the broadhead hood 50 . In this configuration, the shaft 34 and the arrows 54 are moved rearward relative to the riser 4 of the bow 2 . In another embodiment, the broadhead hood 50 is movable towards the proximate end of the shaft 34 and is adjustable as far as the arrow gripper bracket 36 and/or the bow attachment 54 . In this configuration, the shaft 34 remains extended forward as a traditional stabilizer, but the arrows 54 are disposed substantially rearward of the riser 4 of the bow 2 . In yet another embodiment, the arrow gripper bracket 36 is disposed on the proximate end of the shaft 34 , the broadhead hood 50 is disposed on the distal end of the shaft 34 , and the bow attachment 46 is disposed on the shaft 34 therebetween. The bow attachment 46 may then be adjusted or moved along the length of the shaft 34 . In this configuration, the shaft 34 and the arrows 54 move forward or rearward of the riser 4 of the bow 2 .
[0054] Now referring to FIG. 4 , a stabilizer/quiver 32 attached to a bow 2 is provided. The bow attachment 46 is secured to the riser 4 of the bow 2 , and the arrows 54 are disposed to one side of the riser 4 . In some embodiments, the bow attachment 46 may be secured to the front side of the riser 4 , and in other embodiments, the bow attachment 46 may be secured to the sides or the back of the riser 4 . Further, the arrows 54 may be arrayed on one side of the riser 4 , on both sides of the riser 4 , or through the riser 4 .
[0055] The arrow gripper 42 and the arrow gripper bracket 36 may attach to the shaft 34 of the stabilizer/quiver 32 in some embodiments of the invention, but in other embodiments the shafts of the arrows may be secured onto features of the riser 4 or the limbs 6 , 10 or any other component discussed herein.
[0056] In some embodiments, the stabilizer/quiver 32 is between 1 inch and 55 inches in length. In various embodiments, the stabilizer/quiver 32 is 12 inches to 50 inches in length. In some embodiments, the stabilizer/quiver 32 is 4 inches to 12 inches in length.
[0057] Now referring to FIGS. 5 and 6 , the stabilizer 30 is adjustable at various angles relative to the bow 2 , specifically the riser 4 of the bow 2 . It should be understood that while the stabilizer 30 is used for exemplary purposes, the same adjustability concepts apply to the stabilizer/quiver 32 in accordance with embodiments described elsewhere herein.
[0058] FIG. 5 shows that the stabilizer 30 may be adjustable in a plane through the vertical axis of the riser 4 and the longitudinal axis of the stabilizer 30 . A vertical angle 56 may be measured from a substantially horizontal plane. In the embodiment shown in FIG. 5 , the stabilizer is adjustable between 90 and −90 degrees from the horizontal plane. In other embodiments, the stabilizer 30 is fully adjustable about an axis, which means that the stabilizer 30 may rotate a full 360 degrees. The stabilizer 30 may be secured in various positions using a thumbscrew to, for example, impinge on a ball portion of a ball-and-socket joint to secure the stabilizer 30 in place. In other embodiments, the stabilizer 30 may be secured in various positions using an interference fit. For example, a protrusion on one component such as the stabilizer 30 may correspond to a depression in another component such as the riser 4 . When the protrusion and depression are aligned, there is no interference, but when the protrusion and depression fall out of alignment, the protrusion interferes with the non-depression portion of the riser 4 . Thus, this interference maintains the orientation of the stabilizer 30 relative to the riser 4 . A user may press the protrusion through the interference such that the protrusion is aligned with a second depression, and the stabilizer 30 is maintained in a second position relative to the riser 4 . A level such as a bubble level may be integrated into the stabilizer 30 to help a user such as a hunter orient the stabilizer 30 relative to the ground.
[0059] FIG. 6 shows a perspective view of a bow 2 comprising a stabilizer 30 wherein the stabilizer is adjustable in a horizontal plane through the longitudinal axis of the stabilizer 30 and substantially parallel to the ground when the bow 2 is in a firing position. A horizontal angle 58 is measured between the stabilizer 30 and a vertical plane through the vertical axis of the riser 4 and the longitudinal axis of the stabilizer 30 or a vertical plane through the vertical axis of the riser 4 and the string. In the embodiment depicted in FIG. 6 , the horizontal angle 58 may extend between 45 and −45 degrees. In other embodiments, the stabilizer 30 may be rotatable such that the stabilizer 30 extends rearward of the riser 4 . In other words, the horizontal angle 58 may extends between 180 and −180 degrees. In some embodiments, the adjustable orientation of the stabilizer 30 may be achieved with one or more rotatable axes disposed in the bow attachment 46 , a ball and socket joint, or any other joint commonly used to manipulate the position of an object.
[0060] Now referring to FIG. 7 , a detailed view of a broadhead hood 50 is provided. In this embodiment, the broadhead hood 50 comprises a housing where a broadhead hood insert 52 may be disposed. In this particular embodiment, the broadhead hood insert 52 is a foam rubber insert with recesses that receive broadheads or other arrowheads, but other embodiments may be comprised of other materials that deform in response to a force such as a physical or electromagnetic force. Some materials may have a volume fraction that characterizes the volume percentage of a particular material or void. For example, a low density foamed rubber may have a void fraction between approximately 35% and 80%. In some embodiments, the broadhead hood insert 52 is a material that has a void fraction between approximately 10% and 90%. In various embodiments, the broadhead hood insert 52 is a material that has a void fraction between approximately 35% and 80%. In some embodiments, the broadhead hood insert 52 is a material that has a void fraction of approximately 40%.
[0061] Adjacent to the broadhead hood insert 52 is a tension plate 60 , which is disposed along the majority of one surface of the broadhead hood insert 52 .
[0062] Disposed on the outer surface of the broadhead hood 50 is a tension lever 62 , which pivots about a pin or axis. The tension lever 62 comprises two ends: a handle end that extends outwardly from the broadhead hood 50 and a lever end that is operably interconnected to the tension plate 60 . In some embodiments, the handle end extends further from the pin or axis than the lever end. The tension lever 62 depicted in FIG. 7 is in an open position, meaning that the tension lever 62 , specifically the lever end, is not imparting any force on the tension plate 60 .
[0063] Now referring to FIG. 8 , the tension lever 62 of the embodiment shown in FIG. 7 is in a closed position. Now the tension lever 62 has pivoted about the pin or axis, the handle end of the tension lever 62 extends alongside the broadhead hood 50 , and the lever end of the tension lever 62 has pivoted into the tension plate 60 . The physical force from the tension lever 62 causes the tension plate 60 to press into the broadhead hood insert 52 , which causes the broadhead hood insert 52 to deform and press into the broadheads or other arrowheads that are disposed within the broadhead hood insert 52 . In the embodiment depicted in FIG'S. 7 and 8 , the four cutouts for the broadheads are arranged in a staggered fashion. Other embodiments may have a different number of cutouts, different arrangement of cutouts, etc. Further, in the embodiments depicted in FIG'S. 7 and 8 , the tension plate 60 is disposed along one side of the broadhead hood insert 52 such that the tension plate 60 presses against the flat side of the broadheads. In other embodiments, the tension plate 60 may be disposed along another surface or surfaces such that engagement of the tension lever 62 causes the tension plate 60 to press against the broadheads at a different angle.
[0064] The invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed.
[0065] The phrases “at least one”, “one or more”, and “and/or”, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B, and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.
[0066] Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification, drawings, and claims are to be understood as being modified in all instances by the term “about.”
[0067] The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.
[0068] The use of “including,” “comprising,” or “having,” and variations thereof, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.
[0069] It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts, and the equivalents thereof, shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.
[0070] The foregoing description of the invention has been presented for illustration and description purposes. However, the description is not intended to limit the invention to only the forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of the invention.
[0071] Consequently, variations and modifications commensurate with the above teachings and skill and knowledge of the relevant art are within the scope of the invention. The embodiments described herein above are further intended to explain best modes of practicing the invention and to enable others skilled in the art to utilize the invention in such a manner, or include other embodiments with various modifications as required by the particular application(s) or use(s) of the invention. Thus, it is intended that the claims be construed to include alternative embodiments to the extent permitted by the prior art.
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A combined stabilizer/quiver for a bow is provided that may store arrows and may also function as a stabilizer. The combined stabilizer/quiver may comprise a shaft that extends forward from the front side of a bow and functions as a stabilizer, and arrows may be disposed substantially parallel to the shaft and contribute to the stabilizing function. With two components combined into one, the bow has less weight, improved accuracy and precision, and greater versatility. Alternatively, a quiver is provided which is adapted to attach to a conventional stabilizer which is attached to a riser of a bow.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an Internet facsimile (FAX) apparatus for transmitting/receiving an image by G3 FAX via a telephone network, and also transmitting/receiving an image by Internet FAX via Internet.
[0003] 2. Description of the Related Art
[0004] Conventionally, an image can be transmitted/received by G3 FAX via a telephone network, and also can be transmitted/received by Internet FAX (a simple mode of Internet FAX) which does not require a communication fee by being subjected to LAN (local area network) connection to Internet.
[0005] In the simple mode, an A4-size and 200-dpi (dots per inch) image can be transmitted.
[0006] In the above-described conventional system, however, it is impossible to know the detailed functions of the communication partner's FAX apparatus in communication in the simple mode of Internet FAX.
[0007] Accordingly, the transmission side cannot know, for example, whether or not the apparatus at the reception side can use a B4-size recording sheet having a recording resolution of 400 dpi as the FAX function, and has a color reception function.
[0008] As a result, even if an original has been read with 400 dpi, the B4 size and in color at the transmission side, read image data can be transmitted only after being converting into 200 dpi and the A4 size.
[0009] Furthermore, in the above-described conventional system, it is impossible to know what type of Internet FAX mode is possessed by the apparatus at the reception side in communication in the G3 FAX mode.
[0010] In communication in the G3 FAX mode, it is also impossible to know whether or not the apparatus at the reception side as an Internet address.
[0011] Accordingly, it is impossible to switch from the G3 FAX mode to an appropriate mode from among Internet FAX modes which does not require a communication fee.
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to solve the above-described problems in the conventional system.
[0013] It is another object of the present invention to allow an apparatus having both the G3 FAX mode and the Internet FAX mode to notify the communication partner's apparatus of the FAX function of the transmitter's apparatus.
[0014] It is still another object of the present invention to allow an apparatus having both the G3 FAX mode and the Internet FAX mode to store the notified FAX function of the communication partner's apparatus so as to correspond to the address of the communication partner.
[0015] It is yet another object of the present invention to allow an apparatus having both the G3 FAX mode and the Internet FAX mode to form an image which is optimum for the FAX function of the communication partner's apparatus during Internet FAX transmission.
[0016] It is yet a further object of the present invention to provide an Internet FAX apparatus that can use a recording sheet of 400 dpi and the B4 size which represent a function superior to the function capable of being used in the simple mode of the Internet FAX and that can communicate image data using a color reception function, in the Internet FAX mode with free communication fee.
[0017] It is still another object of the present invention to provide an apparatus capable of notifying a communication partner's apparatus that the transmitter's apparatus has the Internet FAX mode, in the G3 FAX mode.
[0018] It is still another object of the present invention to provide an Internet FAX apparatus having the G3 FAX function and the Internet FAX function which can switch from the G3 FAX mode to an optimum mode from among Internet FAX modes which does not require a communication fee by notifying a communication partner's apparatus of the Internet address of the transmitter's apparatus in the G3 FAX mode.
[0019] According to one aspect of the present invention, a communication apparatus includes detection means for detecting a facsimile function of a communication partner's apparatus during communication by G3 facsimile communication means, and control means for performing control of causing the G3 facsimile communication means to disconnect communication in a G3 facsimile mode and shifting to communication by Internet facsimile communication means, based on the detection of the facsimile function of the communication partner's apparatus by the detection means.
[0020] According to another aspect of the present invention, a communication apparatus includes detection means for detecting a facsimile function of a communication partner's apparatus during communication by G3 facsimile communication means, and control means for causing Internet facsimile communication means to transmit an image in accordance with the facsimile function of the communication partner's apparatus detected by the detection means.
[0021] According to still another aspect of the present invention, a communication method includes the steps of detecting a facsimile function of a communication partner's apparatus during communication in a G3 facsimile mode, disconnecting communication in the G3 facsimile mode based on the detection of the facsimile function of the communication partner's apparatus, and shifting to communication in an Internet facsimile mode.
[0022] According to yet another aspect of the present invention, an image communication method having an Internet facsimile mode and a G3 facsimile mode includes the steps of detecting a facsimile function of a communication partner's apparatus during communication in the G3 facsimile mode, and transmitting an image in the Internet facsimile mode in accordance with the detected facsimile function of the communication partner's apparatus.
[0023] According to yet a further aspect of the present invention, an image communication apparatus having an Internet facsimile mode and a G3 facsimile mode includes function notification means for notifying a communication partner's apparatus that the image communication apparatus has an Internet facsimile function during communication in the G3 facsimile mode, and address notification means for notifying the communication partner's apparatus of an Internet facsimile address during the communication in the G3 facsimile mode.
[0024] According to still another aspect of the present invention, an image communication method having an Internet facsimile mode and a G3 facsimile mode includes the steps of notifying a communication partner's apparatus that a transmitter's apparatus has an Internet facsimile function during communication in the G3 facsimile mode, and notifying the communication partner's apparatus of an Internet facsimile address during the communication in the G3 facsimile mode.
[0025] According to still another aspect of the present invention, a communication apparatus includes detection means for detecting an Internet facsimile mode of a communication partner's apparatus during communication by G3 facsimile communication means, and control means for performing control of causing the G3 facsimile communication means to disconnect communication in a G3 facsimile mode and shifting to communication by Internet facsimile communication means, based on the detection of the Internet facsimile mode of the communication partner's apparatus by the detection means.
[0026] According to still another aspect of the present invention, a communication apparatus includes detection means for detecting an Internet facsimile mode of a communication partner's apparatus during communication by G3 facsimile communication means, and control means for causing Internet facsimile communication means to transmit an image in accordance with the Internet facsimile mode of the communication partner's apparatus detected by the detection means.
[0027] According to still another aspect of the present invention, a communication method includes the steps of detecting an Internet facsimile mode of a communication partner's apparatus during communication in a G3 facsimile mode, disconnecting the communication in the G3 facsimile mode and performing setting according to the detected Internet facsimile mode based on the detection of the Internet facsimile mode of the communication partner's apparatus, and shifting to Internet communication.
[0028] According to still another aspect of the present invention, a communication method having an Internet facsimile mode and a G3 facsimile mode includes the steps of detecting an Internet facsimile mode of a communication partner's apparatus during communication in the G3 facsimile mode, and transmitting an image in the Internet facsimile mode in accordance with the detected Internet facsimile mode of the communication partner's apparatus.
[0029] According to still another aspect of the present invention, an image communication apparatus having a plurality of Internet facsimile modes and a G3 facsimile mode includes mode notification means for notifying a communication partner's apparatus of an Internet facsimile mode possessed by the image communication apparatus during communication in the G3 facsimile mode, and address notification means for notifying the communication partner's apparatus of an Internet facsimile address during the communication in the G3 facsimile mode.
[0030] According to still another aspect of the present invention, an image communication method having a plurality of Internet facsimile modes and a G3 facsimile mode includes the steps of notifying a communication partner's apparatus of an Internet facsimile mode possessed by the transmitter's apparatus during communication in the G3 facsimile mode, and notifying the communication partner's apparatus of an Internet facsimile address during the communication in the G3 facsimile mode.
[0031] The foregoing and other objects, advantages and features of the present invention will become more apparent from the following detailed description of the preferred embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a block diagram illustrating the configuration of an Internet FAX apparatus according to a first embodiment of the present invention;
[0033] FIG. 2 is a diagram illustrating optional signals, each for notifying an Internet address according to ITU-T (International Telecommunication Union-Telecommunication Standardization Sector) T30 recommendation in the first embodiment;
[0034] FIG. 3 is a diagram illustrating a format of address data in the first embodiment;
[0035] FIG. 4 is a flowchart illustrating one-touch transmission in the first embodiment;
[0036] FIG. 5 is a flowchart illustrating Internet FAX transmission in the first embodiment;
[0037] FIG. 6 is a flowchart illustrating TIFF (Tag Image Data Format) conversion in the first embodiment;
[0038] FIG. 7 is a flowchart illustrating Internet FAX reception in the first embodiment;
[0039] FIGS. 8 and 9 are diagrams, each illustrating a protocol in the first embodiment;
[0040] FIG. 10 is a diagram illustrating the format of a DIS signal according to the T30 recommendation in a second embodiment of the present invention;
[0041] FIG. 11 is a diagram illustrating the format of a DCS signal according to the T30 recommendation in the second embodiment;
[0042] FIG. 12 is a diagram illustrating optional signals, each for notifying an Internet address according to the T30 recommendation in the second embodiment;.
[0043] FIG. 13 is a flowchart illustrating a G3 transmission procedure in the second embodiment;
[0044] FIG. 14 is a diagram illustrating a format of address data in the second embodiment;
[0045] FIG. 15 is a diagram illustrating a protocol in the second embodiment;
[0046] FIG. 16 is a flowchart illustrating selection of an Internet FAX mode in the second embodiment;
[0047] FIG. 17 is a flowchart illustrating Internet FAX transmission in the second embodiment;
[0048] FIG. 18 is a flowchart illustrating Internet FAX reception in the second embodiment; and
[0049] FIG. 19 is a flowchart illustrating TIFF conversion in the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] Preferred embodiments of the present invention will now be described with reference to the drawings.
First Embodiment
[0051] FIG. 1 is a block diagram illustrating image communication by an Internet FAX apparatus according to a first embodiment of the present invention.
[0052] In FIG. 1 , an Internet FAX apparatus 1 operates at a side transmitting an image. An Internet FAX apparatus 2 operates at a side receiving the image. The internal structure of the Internet FAX apparatus 2 is not shown because it is the same as the internal structure of the Internet FAX apparatus 1 .
[0053] A telephone network 3 is used for performing facsimile transmission. Reference numeral 4 represents Internet. In the first embodiment, the Internet 4 is used as a network for communicating E-mails.
[0054] A CPU (central processing unit) controls the Internet FAX apparatus 1 . A scanner unit 6 reads an original and converts the read original into image data. A printer unit 7 prints an image represented by image data on a recording sheet as an image.
[0055] A FAX modem (modulator-demodulator) 8 performs communication in a G3 FAX mode, and modulates/demodulates a procedure signal and an image signal in G3 FAX. An NCU (network control unit) 9 is connected to the telephone network (telephone line) 3 , and operates as an interface for call, call-receiving and analog signals.
[0056] An Ethernet interface 10 is connected to the Internet 4 , and exchanges digital signals in the form of TCP (transmission control protocol)/IP(Internet protocol) packets.
[0057] A ROM (read-only memory) 11 stores control programs and control data for the Internet FAX apparatus 1 which are to be executed by the CPU 5 . A RAM (random access memory) 12 is accessed by the CPU 5 when it executes the control programs, and is used by the CPU 5 as a working area, and stores control data and data relating to each address where an image is to be transmitted.
[0058] An operation unit 13 includes one-touch buttons to be used by the operator when instructing a transmission address.
[0059] The Internet FAX apparatus 1 in the first embodiment may include a scanner, a printer, a personal computer and the like which are interconnected via a network.
[0060] First, a description will be provided of basic two communication modes possessed by Internet FAX, i.e., a G3 FAX mode and an Internet FAX mode.
[0061] In the G3 FAX mode, an image is transmitted/received via the telephone network 3 in communication using the Internet FAX apparatus 1 (hereinafter termed a “transmitter 1”) and the Internet FAX apparatus 2 (hereinafter termed a “receiver 2”) shown in FIG. 1 .
[0062] An outline of the user's operation, the operation of the transmitter 1 , and the operation of the receiver 2 in communication in the G3 FAX mode will now be described.
[0063] The operator sets an original on the scanner unit 6 of the transmitter 1 , and depresses an one-touch button on the operation unit 13 .
[0064] The CPU 5 thereby reads address data (shown in FIG. 3 ) from the RAM 12 in accordance with an address instructed through the one-touch button. The CPU 5 selects one of the G3 FAX mode and the Internet FAX mode (in the first embodiment, it is assumed that the simple mode of Internet FAX is used) for transmitting image data, based on information registered in the address data.
[0065] When the G3 FAX mode has been selected, the CPU 5 reads the telephone number registered in address data of the address assigned through the one-touch button from the RAM 12 . The CPU 5 then causes the NCU 9 to call the telephone number read from the RAM 12 . The receiver 2 is thereby called via the telephone network 3 .
[0066] Then, the image of the original is read by the scanner unit 6 of the transmitter 1 . The read image of the original is converted into image data by the CPU 5 according to the control program (control software) stored in the ROM 11 .
[0067] The receiver 2 called from the transmitter 1 starts automatic receiving processing according to an ordinary G3 FAX procedure.
[0068] In communication between the transmitter 1 and the receiver 2 , first initial identification is performed according to an ITU-T T3 procedure. At that time, a procedure signal is modulated/demodulated by the modem 8 , and is transmitted/received between the transmitter 1 and the receiver 2 via the telephone network 3 .
[0069] Upon completion of the initial identification, the CPU 5 of the transmitter 1 encodes image data according to the control program (control software) stored in the ROM 11 and transmits encoded data. In the receiver 2 , received image data is decoded, decoded data is transmitted to the printer, which prints a corresponding image.
[0070] Upon completion of transmission of the image data, the transmitter 1 transmits an end-of-procedure (EOP) signal.
[0071] When a confirmation signal (MCF signal) has been received from the receiver 2 , the transmitter 1 transmits a disconnection signal (DCN signal) and terminates the communication in the G3 FAX mode.
[0072] A description will now be provided of the Internet FAX mode. In the Internet FAX mode (in the first embodiment, the simple mode of Internet FAX), an image is transmitted/received via the Internet 4 in communication using the transmitter 1 and the receiver 2 shown in FIG. 1 .
[0073] In the simple mode, an image file in the form of TIFF (Tag Image Data Format) configured by image data of the A 4 size and 200 dpi which has been encoded by an MH (modified Huffman) encoding method is transmitted by being added to an E-mail.
[0074] An outline of the operator's operation, the operation of the transmitter 1 , and the operation of the receiver 2 in communication in the Internet FAX mode will now be described.
[0075] The operator sets an original on the scanner unit 6 of the transmitter 1 , and depresses an one-touch button on the operation unit 13 .
[0076] The CPU 5 thereby reads address data from the RAM 12 in accordance with an address instructed through the one-touch button. The CPU 5 selects one of the G3 FAX mode and the Internet FAX mode for transmitting image data, based on information registered in the address data.
[0077] When the Internet FAX mode has been selected, the CPU 5 reads an Internet address registered in the address data of the address instructed through the one-touch button from the RAM 12 .
[0078] Then, the image of the original is read by the scanner unit 6 of the transmitter 1 . The read image of the original is converted into image data by the CPU 5 according to the control program (control software) stored in the ROM 11 .
[0079] The image data is converted into an additional file of the E-mail according to the control program (control software) stored in the ROM 11 .
[0080] Upon completion of conversion of the image data into the additional file, the Internet address read from the RAM 12 is set as an address for the E-mail. The E-mail where the additional file of the image data is added is transmitted to the receiver 2 via Internet through Ethernet using SMTP (Simple Mail Transfer Protocol) which is a protocol for transmitting an E-mail.
[0081] The receiver 2 receives the E-mail according to the ordinary SMTP.
[0082] Upon reception of the E-mail, the receiver 2 detects if the additional file is added to the E-mail. When the additional file has been detected, then, it is determined if the additional file is image data.
[0083] If the result of the determination is affirmative, the additional file is converted into image data, which is transmitted to the printer in order to print an image represented by the image data.
[0084] As described above, in the Internet FAX apparatus, the G3 FAX mode and the Internet FAX mode, which are the two basic modes, operate.
[0085] A characteristic operation of the Internet FAX apparatus of the first embodiment will now be described with reference to FIGS. 2 through 7 . In the first embodiment, it is proposed to add a new bit and a new optional frame to each of an initial identification signal, a reception command signal and a transmission command signal conforming to the ITU-T T30 recommendation.
[0086] FIG. 2 is a diagram illustrating an optional signal for notifying an Internet address according to the T30 recommendation. FIG. 3 is a diagram illustrating a format of address data. FIG. 4 is a flowchart illustrating one-touch transmission. FIG. 5 is a flowchart illustrating an image transmission operation of the Internet FAX apparatus 1 . FIG. 6 is a flowchart illustrating TIFF conversion. FIG. 7 is a flowchart illustrating an image reception operation of the Internet FAX apparatus 2 . Since the transmitter 1 and the receiver 2 have the same configuration, the receiver 2 will be described using the block diagram of the transmitter 1 .
[0087] The contents of a DIS signal proposed in the first embodiment will now be described.
[0088] An octet (allocation of a bit of FIF) of the DIS signal is allocated according to ITU-T. In the first embodiment, it is assumed that a bit indicating the capability of Internet FAX is allocated to FIF of the DIS signal. A bit X indicates presence/absence of the Internet FAX function. That is, presence of the Internet FAX function in the receiver is represented by the bit X.
[0089] The contents of a DCS signal proposed in the first embodiment will now be described.
[0090] A bit X indicating whether or not the apparatus is to be switched to Internet FAX is allocated to FIF of the DCS signal. An octet (allocation of a bit of FIF) is allocated according to ITU-T. In the first embodiment, it is assumed that a bit indicating to perform communication by switching the communication mode from the G3 FAX mode to the Internet FAX mode is allocated to FIF of the DCS signal. A bit X indicates instruction to perform communication by switching the mode to the Internet FAX mode.
[0091] One bit or a plurality of bits may be allocated to the bit X.
[0092] It is assumed that, when a bit indicating presence/absence of the Internet FAX function is officially recommended by ITU-T, these bits X correspond to the recommended bits.
[0093] FIG. 2 is a diagram illustrating an optional signal for notifying an Internet address according to the T30 recommendation proposed in the first embodiment.
[0094] Conventionally, CSI, CIG and TSI signals are used as optional signals for notifying a telephone number in the T30 procedure. In the first embodiment, CSE, CIE and TSE signals corresponding to the CSI, CIG and TSI signals, respectively, are newly proposed and used as signals, each for notifying an Internet address. An Internet address is stored in FIF of each of the CSE, CIE and TSE signals.
[0095] As the CSI signal for transmitting a telephone number, the CSE signal, serving as an optional signal, is transmitted while storing the Internet address of the receiver in FIF of the frame. The timing of transmission of the CSE signal according to the T30 procedure is the same as the timing for the CSI signal.
[0096] As the CIG signal for transmitting a telephone number, the CIE signal, serving as an optional signal, is transmitted while storing the Internet address of the poling requesting apparatus in FIF of the frame. The timing of transmission of the CIE signal according to the T30 procedure is the same as the timing for the CIG signal.
[0097] As the TSI signal for transmitting a telephone number, the TSE signal, serving as an optional signal, is transmitted while storing the Internet address of the transmitter in FIF of the frame. The timing of transmission of the TSE signal according to the T30 procedure is the same as the timing for the TSI signal.
[0098] The manner of transmitting/receiving a signal in the G3 FAX mode in the first embodiment will now be desribed with reference to FIG. 8 . Since this processing is performed basically according to the known T30 procedure, only difference from the known T30 procedure will be described.
[0099] First, the transmitter 1 calls the receiver 2 via the telephone network.
[0100] The receiver 2 which has received the call from the telephone network connects the line to the telephone network, and sets and transmits the X bit of DIS signal in accordance with the capability of the Internet FAX of the receiver's apparatus. At that time, the DIS signal notifies not only the function which can be used in the simple mode of Internet FAX, but also the function which cannot be used in the simple mode of Internet FAX.
[0101] Upon reception of the DIS signal from the receiver 2 , the transmitter 1 determines if the Internet FAX mode is present in the receiver 2 according to the X bit of the DIS signal. If the result of the determination is affirmative, the communication mode is determined according to the flowchart for selecting the communication mode shown in FIG. 4 (to be described in detail later). When the Internet FAX mode has been selected, an instruction to switch to the Internet FAX mode is set in the X bit of the DCS signal, the Internet address of the transmitter 1 is set in the optional frame TSE, and the resultant signal is transmitted. The function which cannot be notified in the simple mode of Internet FAX and which has been notified by the received DIS signal is stored in address data.
[0102] Upon reception of the DSC signal, the receiver 2 determines if shift to the Internet FAX mode is instructed according to the X bit of the DCS signal. If the result of the determination is affirmative, a CFR signal is transmitted, the Internet address of the receiver's apparatus is stored in the optional frame CSE, and the resultant signal is transmitted.
[0103] Upon reception of the CFR signal after transmitting the DCS signal, the transmitter 1 transmits a DCN signal in order to shift to the Internet FAX mode, and terminates the communication via the telephone network by disconnecting the line.
[0104] The receiver 2 disconnects the line upon reception of the DCN signal.
[0105] Then, the transmitter 1 shifts to the Internet FAX mode, and transmits an E-mail where an image data file in the form of TIFF is added.
[0106] The receiver 2 converts the image data file added to the E-mail received via Internet into printing data, and records an image represented by the image data on a recording sheet.
[0107] The optional frame CSE transmitted from the receiver 2 may be transmitted together with the DIS signal. In this case, the CSE signal after receiving the DCS signal may or may not be transmitted (see FIG. 9 ).
[0108] FIG. 3 illustrates a format of address data. Each of the address data is provided for the corresponding one of a plurality of one-touch dials or abbreviation dials, and an address table including a plurality of address data is stored in the RAM 12 shown in FIG. 1 . One-touch-dial numbers and abbreviation-dial numbers are generically termed “one-touch numbers”.
[0109] In FIG. 3 , presence/absence of the G3 FAX mode (G3 FAX function), the telephone number, presence/absence of the Internet FAX mode (Internet FAX function), the Internet address, and information relating to the receiver for each one-touch number are stored in the RAM 12 .
[0110] The procedure of one-touch transmission of Internet FAX will now be described with reference to the flowchart shown in FIG. 4 . The flowchart shown in FIG. 4 is a program stored in the ROM 11 , and is executed by the CPU 5 .
[0111] When a one-touch dial button on the operation unit 13 has been depressed, information (presence/absence of the G3 FAX mode, the telephone number, presence/absence of the Internet FAX mode, and the Internet address) relating to the one-touch number corresponding to the depressed button is read.
[0112] When the one-touch dial button has been depressed (input) by the operator, then, in step S 1 , information relating to address data of the one-touch number corresponding to the depressed one-touch dial button is read.
[0113] In step S 2 , it is determined if the Internet FAX mode is present in the input address. If the result of the determination in step S 2 is affirmative, the process proceeds to step S 3 . If the result of the determination in step S 2 is negative, the process proceeds to step S 7 , where it is determined if the telephone number is set in the address table. If the result of the determination in step S 7 is affirmative, transmission is performed in the G3 FAX mode. If the result of the determination in step S 7 is negative, address error processing is performed assuming that address error has occurred.
[0114] In step S 3 , it is determined if information relating to the function of the receiver (receiving-function information) is written in the address data. If the result of the determination in step S 3 is affirmative, the process proceeds to step S 4 , where the receiving-function information is read from the address data and is set for transmission in the Internet FAX mode. Then, transmission in the Internet FAX mode is executed.
[0115] If the result of the determination in step S 3 is negative, the process proceeds to step S 5 , where it is determined if the telephone number is written. If the result of the determination in step S 5 is affirmative, a G3 FAX transmission mode is selected, and communication for receiving the receiving-function information from the receiver 2 is executed.
[0116] If the result of the determination in step S 5 is negative, the process proceeds to step S 6 , where the A4 size, 200 dpi and the MH encoding method are set as the receiving-function information, and transmission is performed in the Internet FAX mode.
[0117] The flow at the transmission side Internet FAX apparatus will now be described with reference to FIG. 5 . The flowchart shown in FIG. 5 is a program stored in the ROM 11 and executed by the CPU 5 .
[0118] Suppose that the operator has set an original and has depressed a one-touch button 01 on the operation unit 13 . According to the flow of one-touch transmission shown in FIG. 4 , the CPU 5 checks address data of the address 01 shown in FIG. 3 , and determines that the Internet FAX function is present, receiving-function information is not stored in the memory, and the telephone number is registered. The address 01 is called via the telephone network based on this information, and communication in the G3 FAX mode is started.
[0119] After the call, in step S 101 , a DIS signal is received from the receiver 2 .
[0120] In step S 102 , it is determined if the Internet FAX function is present in the transmitter's apparatus. If the result of the determination in step 5102 is affirmative, the process proceeds to step S 103 . If the result of the determination in step S 102 is negative, the process proceeds to step S 112 , where image data is transmitted in the G3 FAX mode according to the ordinary T30 procedure.
[0121] In step S 103 , it is determined if the Internet FAX mode is present in the received DIS signal. If the result of the determination in step S 103 is affirmative, the process proceds to step S 104 . If the result of the determination in step S 103 is negative, the process proceeds to step S 112 . In step S 104 , received information relating to the receiver 2 , for example, DIS information indicating the B4 size, 400 dpi and JBIG, is stored in the column of address data for the one-touch number 01 shown in FIG. 3 .
[0122] In step S 105 , the Internet address of the transmitter's apparatus is set in the TSE signal.
[0123] Then, in step S 106 , TSI, TSE and DCS signals are transmitted. When a CFR signal has been received in step S 107 after transmitting the TSI, TSE and DCS signals, then, in step S 108 , it is determined if a CSE signal has been received. If the result of the determination in step S 108 is affirmative, the process proceeds to step S 109 . If the result of the determination in step S 108 is negative, the process proceeds to step S 110 .
[0124] In step S 109 , the Internet address in FIF of the CSE signal is stored in a working area of the RAM 12 and is set in the Internet address of the corresponding one-touch number in the address table.
[0125] Then, in step S 110 , a DCN signal is transmitted. Then, in step S 111 , the NCU 9 disconnects the line.
[0126] Then, in step S 113 , transmission processing in the Internet FAX mode is started.
[0127] Then, in step S 114 , the Internet address of the receiver 2 stored in the working area in step S 109 is set as the address for the E-mail.
[0128] Then, in step S 115 , the image data file is converted into TIFF. At that time, for example, TIFF comprising the B4 size, 400 dpi and JBIG is formed for the image to be transmitted according to the flow of TIFF conversion shown in FIG. 6 .
[0129] In step S 116 , the image data file converted in the form of TIFF is added to the E-mail. Then, in step S 117 , the. E-mail is transmitted with SMTP. Then, in step S 118 , the process returns to a waiting state.
[0130] The flow of TIFF conversion will now be described with reference to FIG. 6 . The flowchart shown in FIG. 6 is a program stored in the ROM 11 and executed by the CPU 5 .
[0131] First, in step S 201 , the resolution of the image to be transmitted is checked. If the resolution is 400 dpi, the process proceeds to step S 202 . If the resolution is 200 dpi, the process proceeds to step 5204 .
[0132] In step S 202 , it id determined if 400 dpi is present in the receiving-function information relating to the address data of the one-touch number depressed by the operator. If the result of the determination in step S 202 is affirmative, the process proceeds to step S 204 . If the result of the determination in step S 202 is negative, the process proceeds to step S 203 , where the resolution conversion into 200 dpi is performed.
[0133] In step S 204 , the size of the image to be transmitted is checked. If the size is B4, the process proceeds to step S 205 . If the size is A4, the process proceeds to step S 207 .
[0134] In step S 205 , it is determined if B4 is present in the receiving-function information relating to the address data of the one-touch number depressed by the operator. If the result of the determination in step S 205 is affirmative, the process proceeds to step S 207 . If the result of the determination in step S 205 is negative, the process proceeds to step S 206 , where the size is converted into A4.
[0135] In step S 207 , the encoding method of the receiving-function information relating to the address data of the one-touch number depressed by the operator is checked, and encoding is performed according to the JBIG, MMR, MR or MH method.
[0136] In step S 212 , image data encoded in each of steps S 208 -S 211 is converted into a file in the form of TIFF.
[0137] The flow at the reception-side Internet FAX apparatus will now be described with reference to FIG. 7 . The flowchart shown in FIG. 7 is a program stored in the ROM 11 and executed by the CPU 5 when the Internet FAX apparatus operates as a reception-side apparatus.
[0138] When there is a call from the telephone network, the NCU 9 performs call-receiving processing, and an automatic reception procedure in the G3 FAX mode is started.
[0139] In step S 301 , it is determined if the Internet FAX mode of the receiver's apparatus is set to be usable. If the result of the determination in step S 301 is affirmative, the process proceeds to step S 302 . If the result of the determination in step S 301 is negative, the process proceeds to step S 314 , where the process returns to the ordinary T30 procedure.
[0140] In step S 302 , the X bit of the DIS signal is set in accordance with the setting of the Internet FAX function of the receiver's apparatus. Then, in step S 303 , a DIS signal is transmitted.
[0141] In step S 304 , it is determined if a DCS signal has been received. If the result of the determination in step S 304 is affirmative, the process proceeds to step S 305 , where it is determined if the X bit of the DCS signal equals 1. If the result of the determination in step S 305 is negative, i.e., if the X bit of the DCS signal equals 0, the process proceeds to step S 314 , where the process returns to the ordinar T30 procedure.
[0142] In step S 306 , it is determined if a TSE signal has been received. If the result of the determination in step S 306 is affirmative, the process proceeds to step S 307 , where it is determined if a TSI signal has been received. If the result of the determination in step S 307 is affirmative, the process proceeds to step S 308 , where the Internet address in the TSE signal is stored in the column of the Internet address of address data corresponding to the telephone number in the TSI signal.
[0143] Then, in step S 309 , the Internet address of the receiver's apparatus is stored in a CSE signal. In step S 310 , CSE and CFR signals are transmitted. Then, in step S 311 , it is determined if a DCN signal has been received. If the result of the determination in step S 311 is negative, the process returns to step S 304 .
[0144] If the result of the determination in step S 311 is affirmative, the process proceeds to step S 312 , where the NCU 9 disconnects the line. Then, the process returns to the waiting state in step S 313 .
[0145] When the process has returned to the waiting state, image data is transmitted from the transmitter in the Internet FAX mode, and the process proceeds to step S 315 , where reception in the Internet FAX mode is started.
[0146] Then, in step S 316 , reception of the E-mail is performed with SMTP.
[0147] In step S 317 , it is determined if an additional file is present in the E-mail. If the result of the determination in step S 317 is affirmative, the process proceeds to step S 318 , where it is determined if the additional file is a TIFF file.
[0148] If the result of the determination in step S 318 is affirmative, the process proceeds to step S 319 . If the result of the determination in step S 317 or S 318 is negative, the process proceeds to step S 321 .
[0149] In step S 319 , the TIFF file is converted into image data. In step S 320 , an image represented by the image data is printed by the printer.
[0150] In step S 321 , an E-mail reception log is formed. Then, the process returns to the waiting state in step S 322 .
[0151] In the simple mode, serving as the ordinary Internet FAX mode, only a TIFF file indicating the A4 size, 200 dpi and the MH encoding method is received. According to the first embodiment, however, the transmitter 1 can transmit a TIFF file indicating the B4 size, 400 dpi and JBIG so as to correspond to the receiving function of the receiver 2 , when the function of the receiver 2 is stored, or after receiving receiving-information information relating to the receiver 2 in the G3 FAX mode when the function of the receiver 2 is not stored.
[0152] The receiver 2 can assuredly convert image data of the B4 size, 400 dpi and JBIG transmitted so as to correspond to the function of the receiver 2 into image data for printing, and can also assuredly perform printing even if image data using a function other than the function usable in the simple mode of Internet FAX is received.
[0153] As described above, in the first embodiment, the Internet FAX function of the receiver is notified to the transmitter using a DIS signal, and the Internet address of the receiver is transmitted using an optional CSE signal. The transmitter instructs communication in the Internet FAX mode with a DCS signal, interrupts the G3 FAX mode, and execute communication in the Internet FAX mode. Hence, it is possible to transmit image data adjusted to the function of the receiver which cannot be transmitted in the simple mode of Internet FAX via Internet.
Modification of the First Embodiment
[0154] In the above-described first embodiment, the mode is switched to the Internet FAX mode by interrupting the T30 procedure. However, it is also possible to transmit image data in the G3 FAX mode at the first communication operation with a communication partner, and transmit image data at subsequent communication operations by directly selecting the Internet FAX mode using the same one-touch number.
[0155] It is determined that the current communication with an address in the Internet FAX mode is the first communication operation when receiving-function information is not stored as in the case of the one-touch number 01 shown in FIG. 1 , when the Internet FAX function is absent as in the case of the one-touch number 04 , when the Internet FAX address is not stored, or when at least one of the above-described conditions is satisfied.
[0156] In the first communication operation with a communication partner, the G3 facsimile transmission mode is selected according to the determination shown in FIG. 4 in the first embodiment.
[0157] The flow shown in FIG. 5 for the first embodiment differs for the modification in the first communication operation. Only difference from the first embodiment will now be described, and description for the same processing will be omitted.
[0158] After NO in step S 108 or after execution of step S 109 shown in FIG. 5 , ordinary T30 image data transmission is performed (image data is transmitted after trasmitting a training/TCF signal and receiving a CFR signal from the receiver 2 ). After transmitting image data for all pages in that communication operation, an ordinary T30 EOM signal is transmitted. Then, the process proceeds to step S 110 , where a DCN signal is transmitted. Then, the first communication operation with the communication partner is terminated.
[0159] In each of subsequent communication operations with the communication partner, as shown in FIG. 4 , address data of the address in the one-touch address table is read. Then, the process proceeds as YES in step S 2 and YES in step S 3 . In step S 4 , receiving-function information relating to address data corresponding to the address stored in the address table is set, and then, transmission in the Internet FAX mode is selected. Then, image data is transmitted via Internet according to the processing from step S 113 to step S 118 shown in FIG. 5 .
[0160] It is also possible to transmit image data stored in the memory during memory transmission in the Internet FAX mode as in the first embodiment.
[0161] When performing a call using a ten-digit key dial instead of a one-touch key, it is also possible to transmit image data in the Internet FAX mode as in the first embodiment by storing the FAX function of the receiver received in the G3 FAX mode together with the telephone number called using the ten-digit key dial in a working area of the RAM 12 .
[0162] According to the first embodiment, in an image communication apparatus and method having the Internet FAX mode and the G3 FAX mode, the FAX function of the communication partner's apparatus is detected during communication in the G3 FAX mode, and the apparatus shifts to communication in the Internet FAX mode by disconnecting communication in the G3 FAX mode based on detection of the FAX function of the communication partner's apparatus. Thus, the apparatus shifts to the Internet FAX mode requiring no communication fee after knowing the function of the communication partner's apparatus in communication in the G3 FAX mode. As a result, it is possible to reduce the communication cost, and transmit optimum image data in accordance with the function of the communication partner's apparatus. Furthermore, the FAX function of the communication partner's apparatus is detected during communication in the G3 FAX mode, and an image is transmitted in the Internet FAX mode in accordance with the detected function of the communication partner's apparatus. Hence, it is possible to detect the function of the communication partner's apparatus in the G3 FAX mode even if the Internet FAX function of the communication partner's apparatus is unknown, and to transmit optimum image data in accordance with the function of the communication partner's apparatus in the Internet FAX mode.
[0163] According to the first embodiment, the detected FAX function of the communication partner's apparatus is stored, and image data is transmitted in the Internet FAX function in accordance with the stored FAX function of the communication partner's apparatus. Hence, when the function of the communication partner's apparatus is stored, it is possible to start to transmit optimum image data adjusted to the function of the communication partner's apparatus in the Internet FAX mode without performing communication in the G3 FAX mode, and therefore to start communication of image data earlier by an amount of omitting the G3 FAX mode for detecting the function of the communication partner's apparatus, and to reduce the communication fee.
[0164] According to the first embodiment, in an image communication apparatus and method having the Internet FAX mode and the G3 FAX mode, the apparatus notifies the communication partner's apparatus of possession of the Internet FAX function, and the Internet FAX address during communication in the G3 FAX mode. Hence, even when the communication partner's apparatus does not know the possession of the Internet FAX function and the Internet address of the image communication apparatus, if communication is performed in the G3 FAX mode with the communication partner's apparatus, the image communication apparatus can notify the communication partner's apparatus of the possession of the Internet FAX function and the Internet FAX address of the image communication apparatus, and can receive image data from the communication partner's apparatus via Internet.
Second Embodiment
[0165] A second embodiment of the present invention will now be described with reference to the drawings.
[0166] The second embodiment is realized in the system shown in FIG. 1 which includes the Internet FAX apparatuses 1 and 2 , the telephone network 3 to which these apparatuses are connected, and the network 4 .
[0167] The Internet FAX apparatus of the second embodiment has the G3 FAX mode, and the simple mode, full mode and real time mode of Internet FAX.
[0168] The G3 FAX mode is the same as that described in the first embodiment.
[0169] The simple mode of Internet FAX (hereinafter abbreviated as the “simple mode”) is the same as that in the first embodiment. In the Internet FAX modes (the simple Mode, full Mode, and real time mode), an image is transmitted/received via the Internet 4 in communication using the transmitter 1 and the receiver 2 shown in FIG. 1 .
[0170] The full mode of Internet FAX (hereinafter abbreviated as the “full mode”) will now be described.
[0171] In the full mode, image data having specifications superior to the A4 size, 200 dpi and the MH encoding method can be used as an additional file added to an E-mail, and the E-mail where the image data is added as a TIFF-format image file is transmitted. The receiver can notify the transmitter that the receiver has processed the E-mail.
[0172] An outline of the user's operation, the operation of the transmitter 1 , and the operation of the receiver 2 in communication in the full mode will now be described.
[0173] The operator sets an original on the scanner unit 6 of the transmitter 1 , and depresses an one-touch button on the operation unit 13 .
[0174] The CPU 5 thereby reads address data from the RAM 12 in accordance with the address instructed through the one-touch button. The CPU 5 selects one of the G3 FAX mode and the three modes of Internet FAX for transmitting image data, based on information registered in the address data.
[0175] When the full mode has been selected, the CPU 5 reads the Internet address registered in the address data of the address instructed through the one-touch button from the RAM 12 .
[0176] Then, the image of the original is read by the scanner unit 6 of the transmitter 1 . The read image of the original is converted into image data by the CPU 5 according to the control program stored in the ROM 11 .
[0177] It is assumed that the capability of the receiver 2 has been checked in advance by an E-mail for exchanging capability and is stored in address data.
[0178] The image data is converted into an additional file of the E-mail in accordance with the control program stored in the ROM 11 .
[0179] Upon completion of conversion of the image data into the additional file, the Internet address read from the RAM 12 is set as the address for the E-mail. The E-mail where the additional file of the image data ia added is transmitted to the receiver 2 via Internet through Ethernet using SMTP which is a protocol for transmitting an E-mail.
[0180] The receiver 2 receives the E-mail according to the ordinary SMTP.
[0181] Upon reception of the E-mail, the receiver 2 detects if the additional file is added to the E-mail. When the additional file has been detected, then, it is determined if the additional file is image data.
[0182] If the result of the determination is affirmative, the additional file is converted into image data, which is transmitted to the printer in order to print an image represented by the image data.
[0183] The receiver 2 notifies the transmitter by the E-mail that the image data has been received and printed.
[0184] When the transmitter 1 has been notified by the E-mail from the receiver 2 that the image data has been received by the receiver 2 and an image represented by the image data has been printed, the transmitter 1 stores the fact that the transmission has been normally completed in a communication history file so as to be able to output a communication control report later.
[0185] A description will now be provided of the real time mode of Internet FAX (hereinafter abbreviated as the “real time mode”).
[0186] The real time mode is a method conforming to the T30 procedure in which the frame of a T30 procedure signal is transmitted/received in the form of TCP packets, and image data is transmitted in the form of TCP packets.
[0187] An outline of the operator's operation, the operation of the transmitter 1 , and the operation of the receiver 2 in communication in the real time mode will now be described.
[0188] The operator sets an original on the scanner unit 6 of the transmitter 1 , and depresses an one-touch button on the operation unit 13 .
[0189] The CPU 5 thereby reads address data from the RAM 12 in accordance with the address instructed through the one-touch button. The CPU 5 selects one of the G3 FAX mode and the three modes of Internet FAX for transmitting image data, based on information registered in the address data.
[0190] When the real time mode has been selected, the CPU 5 reads an Internet address registered in the address data of the address instructed through the one-touch button from the RAM 12 .
[0191] Then, the image of the original is read by the scanner unit 6 of the transmitter 1 . The read image of the original is converted into image data by the CPU 5 according to the control program (control software) stored in the ROM 11 .
[0192] The transmitter 1 notifies the receiver 2 having the Internet address of the address instructed through the one-touch button of call-receiving in the real time mode using TCP packets.
[0193] Upon notification of call-receiving in the real time mode, the receiver 2 transmits a DIS frame in the form of TCP packets.
[0194] By receiving the DIS frame, the transmitter 1 can check the capability of the receiver 2 .
[0195] The transmitter 1 transmits a DCS frame and image data in the form of TCP packets in accordance with the function of the receiver 2 notified by the received DIS frame. At that time, the image data is transmitted in the form of TCP packets formed by the CPU 5 according to the control program stored in the ROM 11 in accordance with the function of the receiver 2 notified in the received DIS frame.
[0196] Upon reception of the DCS frame and the image data in the form of TCP packets, the transmitter 1 prints an image represented by the image data in accordance with information in the received DCS frame.
[0197] After transmitting the image data, the transmitter 1 transmits an EPO frame in the form of TCP packets.
[0198] When the receiver 2 has received the EOP frame in the form of TCP packets, the receiver 2 transmits an MCF frame in the form of TCP packets in response to the reception.
[0199] The transmitter 1 which has received the MCF frame transmits a DCN frame in the form of TCP packets, and terminates the transmission in the real time mode.
[0200] Upon reception of the DCN frame in the form of TCP packets, the receiver 2 terminates reception in the real time mode.
[0201] The operation of the above-described Internet FAX apparatus operating in the G3 FAX mode, or one of the simple mode, full mode and real time mode of Internet FAX will now be described with reference to FIGS. 10-19 .
[0202] FIG. 10 is a diagram illustrating the format of a T30 DIS signal. FIG. 11 is a diagram illustrating the format of a T30 DCS signal. FIG. 12 is a diagram illustrating a T30 optional signal for notifying an Internet address. FIG. 13 is a flowchart illustrating a G3 transmission procedure. FIG. 14 is a diagram illustrating a format of address data. FIG. 15 is a diagram illustrating a protocol. FIG. 16 is a flowchart illustrating processing of selecting an Internet FAX mode. FIG. 17 is a flowchart illustrating the transmission operation of the Internet FAX apparatus. FIG. 18 is a flowchart illustrating the image receiving operation of the Internet FAX apparatus. FIG. 19 is a flowchart illustrating TIFF conversion. Since the transmitter 1 and the receiver 2 have the same configuration, the receiver 2 will be described using the block diagram of the transmitter 1 .
[0203] The contents of a DIS signal proposed in the second embodiment will now be described with reference to FIG. 10 .
[0204] FIG. 10 illustrates a bit indicating the Internet FAX capability of the DIS signal in the format of FIF. An octet (allocation of a bit of FIF) of the DIS signal is allocated according to ITU-T. In the second embodiment, it is assumed that a bit indicating the Internet FAX capabililty of the DIS signal is allocated to FIF of the DIS signal. A bit X indicates presence/absence of the simple mode, full mode or real time mode of Internet FAX. That is, as shown in FIG. 10 , presence/absence of the simple mode, full mode and real time mode of Internet FAX is represented by the patterns of bits X, X+1 and X+2 of the DIS signal.
[0205] FIG. 11 illustrates a bit indicating the Internet FAX capability of the DCS signal in the format of FIF. An octet (allocation of a bit of FIF) of the DCS signal is allocated according to ITU-T. In the second embodiment, it is assumed that a bit instructing to perform communication by switching the communication mode to one of the simple mode, full mode and real time mode of Internet FAX is allocated to FIF of the DCS signal. A bit X indicates a bit for providing the receiver with instruction indicating with which one of the simple mode, full mode and real time mode of Internet FAX communication is to be performed.
[0206] It is assumed that, when bits indicating presence/absence of the simple mode, full mode and real time mode of Internet FAX is officially recommended by ITU-T, these bits X, X+1, X+2 correspond to the recommended bits.
[0207] FIG. 12 is a diagram illustrating an optional signal for notifying an Internet address according to the T30 recommendation proposed in the second embodiment.
[0208] Conventionally, CSI, CIG and TSI signals are used as optional signals, each for notifying a telephone number, in the T30 procedure. In the second embodiment, CSE, CIE and TSE signals corresponding to the CSI, CIG and TSI signals, respectively, are newly proposed and used as signals, each for notifying an Internet address. An Internet address is stored in FIF of each of the CSE, CIE and TSE signals.
[0209] As the CSI signal for transmitting a telephone number, the CSE signal, serving as an optional signal, is transmitted while storing the Internet address of the receiver in FIF of the frame. The timing of transmission of the CSE signal according to the T30 procedure is the same as the timing for the CSI signal.
[0210] As the CIG signal for transmitting a telephone number, the CIE signal, serving as an optional signal, is transmitted while storing the Internet address of the poling requesting apparatus in FIF of the frame. The timing of transmission of the CIE signal according to the T30 procedure is the same as the timing for the CIG signal.
[0211] As the TSI signal for transmitting a telephone number, the TSE signal, serving as an optional signal, is transmitted while storing the Internet address of the transmitter in FIF of the frame. The timing of transmission of the TSE signal according to the T30 procedure is the same as the timing for the TSI signal.
[0212] The manner of transmitting/receiving a signal in the G3 FAX mode in the second embodiment will now be desribed with reference to FIG. 15 . Since this processing is basically according to the known T30 procedure, only difference from the known T30 procedure will be described.
[0213] First, the transmitter 1 calls the receiver 2 via the telephone network.
[0214] The receiver 2 which has receives the call from the telephone network connects the line to the telephone network, and sets and transmits the X, X+1 or X+2 bit of DIS signal in accordance with the Internet FAX capability of the receiver's apparatus.
[0215] Upon reception of the DIS signal from the receiver 2 , the transmitter 1 determines if the simple mode, full mode or real time mode of Internet FAX mode is present in the receiver 2 according to the X, X+1 or X+2 bit of the DIS signal. If it has been determined that the receiver 2 has at least one of the Internet FAX modes, the communication mode is determined according to the flowchart for selecting the communication mode shown in FIG. 16 (to be described in detail later). When one of the Internet FAX modes has been selected, a bit indicating to which of the Internet FAX modes the communication mode is to be switched is set in the X, X+1 or X+2 bit of the DCS signal, the Internet address of the transmitter 1 is set in the optional frame TSE, and the resultant signal is transmitted.
[0216] Upon reception of the DSC signal, the receiver 2 determines if shift to one of the Internet FAX modes is instructed according to the X, X+1 or X+2 bit of the DCS signal. If the result of the determination is affirmative, a CFR signal is transmitted, the Internet address of the receiver's apparatus is stored in the optional frame CSE, and the resultant signal is transmitted.
[0217] Upon reception of the CFR signal after transmitting the DCS signal, the transmitter 1 transmits a DCN signal in order to shift to the Internet FAX mode, and terminates the communication via the telephone network by disconnecting the line.
[0218] The receiver 2 disconnects the line upon reception of the DCN signal.
[0219] Then, the transmitter 1 shifts to the Internet FAX mode, and transmits an E-mail where an image data file in the form of TIFF is added in the case of the simple mode or full mode, and transmits a T30 procedure signal and image data in the form of TCP packets in the case of the real time mode.
[0220] The receiver 2 converts the image data file added to the E-mail received via Internet, or the image data received in the form of TCP packets into printing data, and records an image represented by the image data on a recording sheet.
[0221] FIG. 13 is a flowchart illustrating an outline of the transmission operation in the G3 FAX mode in the transmitter 1 . FIG. 13 illustrates state transition of the transmitter 1 , and the actual flow executed by the CPU during transmission is shown in FIG. 17 . The flowchart shown in FIG. 17 will be described later.
[0222] In FIG. 13 , in step Si, it is determined if an Internet FAX mode (to be described with reference to FIG. 16 ) has been selected.
[0223] If the result of the determination in step S 1 is affirmative, the process proceeds to step S 2 , where TSE and DCS signals are transmitted. The DCS signal transmitted in step S 2 indicates switching to one of the simple mode, full mode and real time mode.
[0224] In step S 3 , it is determined if a CFR signal has been received. When an optional frame CSE has been received in step S 3 , the Internet address of the CSE frame is stored in the address table.
[0225] When a CFR signal has been received in step S 3 , the process proceeds to step S 4 , where a DCN signal is transmitted. Then, in step S 5 , the line is disconnected. Then, in step S 6 , transmission is started in the Internet FAX mode.
[0226] If the result of the determination in step S 1 is negative, i.e., when the G3 FAX mode has been selected, the process proceeds to step S 7 , where a DCS signal which does not indicate switching to the Internet FAX mode is transmitted. Then, in step S 8 , a training signal is transmitted. Thereafter, image transmission is performed according to the ordinary T30 procedure.
[0227] Next, an outline of the receiving operation in the G3 mode in the second embodiment will be described.
[0228] This operation is performed basically according to the known T30 procedure. Hence, only portions which are features of the second embodiment will be described.
[0229] When transmitting a DIS signal, the X, X+1 and X+2 bits of the DIS signal shown in FIG. 10 are transmitted in accordance with the Internet FAX capability of the receiver.'s apparatus. Upon reception of a DCS signal transmitted from the transmitter 1 , it is determined if an instruction to shift to an Internet FAX mode is provided in the received DCS signal based on the X, X+1 and X+2 bits shown in FIG. 11 . If the result of the determination is affirmative, the Internet address of the receiver's apparatus is stored in the optional frame CSE. Then, CSE and CFR signals are transmitted, and the line is disconnected by receiving a DCN signal from the transmitter 1 . Then, image data is received in the Internet FAX mode indicated by the DCS signal. If the result of the determination is negative, a CFR signal is transmitted, and ordinary G3 reception is performed. The Internet address in the optional frame TSE received together with the DCS signal is stored in the address table.
[0230] FIG. 14 illustrates a format of address data. Each of the address data is provided for the corresponding one of each of a plurality of one-touch dials or abbreviation dials, and an address table including a plurality of address data is stored in the RAM 12 shown in FIG. 1 . One-touch-dial numbers and abbreviation-dial numbers are generically termed “one-touch numbers”.
[0231] In FIG. 14 , presence/absence of the G3 FAX mode (G3 FAX function), the telephone number, presence/absence and, in the case of the presence, the name of an Internet FAX mode (Internet FAX function), the Internet address, and abbreviation of the receiver for each one-touch number are stored in the RAM 12 .
[0232] In the Internet FAX apparatus of the second embodiment, when a one-touch button has been depressed on the operation unit 13 , the CPU 5 reads information relating to address data of the corresponding one-touch number (presence/absence of the G3 FAX function, the telephone number, presence/absence of each Internet FAX mode, the Internet address, and abbreviation of the communication partner) from the address table stored in the RAM 12 .
[0233] Processing of selecting an Internet FAX mode will now be described with reference to the flowchart shown in FIG. 16 .
[0234] The flowchart shown in FIG. 16 is a program stored in the ROM 11 , and is executed by the CPU 5 . The flowchart shown in FIG. 16 is a subroutine called from step S 203 shown in FIG. 17 .
[0235] In step S 101 , it is determined if the real time mode of Internet FAX is present, based on a DIS signal from the receiver. If the result of the determination in step S 101 is affirmative, the process proceeds to step S 110 , where it is determined if the transmitter's apparatus can execute the real time mode. If the result of the determination in step S 110 is affirmative, the process proceeds to step S 111 , where the real time mode represented by the X bit of the DCS signal is set.
[0236] In step S 102 , it is determined if the full mode of Internet FAX is present, based on the DIS signal from the receiver. If the result of the determination in step S 102 is affirmative, the process proceeds to step S 108 , where it is determined if the full mode can be executed in the transmitter's apparatus. If the result of the determination in step S 108 is affirmative, the process proceeds to step S 109 , where the full mode represented by the X+1 bit of the DSC signal is set.
[0237] In step S 103 , it is determined if the simple mode of Internet FAX is present based on the DIS signal from the receiver. If the result of the determination in step S 103 is affirmative, the process proceeds to step S 105 , where it is determined if the simple mode can be executed by the transmitter's apparatus. If the result of the determination in step S 105 is affirmative, the process proceeds to step S 106 , where the simple mode represented by the X+2 bit of the DCS signal is set.
[0238] In step S 107 , the selected Internet FAX mode of the address data corresponding to the assigned one-touch number is set.
[0239] When all of the X, X+1 and X+2 bits in the DIS signal equal 0, then, in step S 104 , absence of the Internet FAX function is set in the DCS signal.
[0240] FIG. 17 is a flowchart illustrating the image transmission operation at the transmission-side Internet FAX apparatus. The flowchart shown in FIG. 17 is a program stored in the ROM 11 and executed by the CPU 5 .
[0241] When the operator has set an original and depressed a one-touch dial button on the operation unit 13 , information relating to the one-touch number corresponding to the depressed button (presence/absence of the G3 FAX function, the telephone number, presence/absence of the function of each Internet FAX mode, the Internet address, and abbreviation of the communication partner) is read. It is assumed that a one-touch button 01 has been depressed on the operation unit 13 .
[0242] The address shown 01 in FIG. 14 is checked, and the address 01 determined not to have the Internet FAX capability is called through the telephone network, and transmission in the G3 mode is started.
[0243] In step S 201 , it is determined if a DIS signal has been received from the receiver 2 . If the result of the determination in step S 201 is affirmative, the process proceeds to step S 202 , where it is determined if the transmitter's apparatus has the Internet FAX function and therefore can perform communication in an Internet FAX mode.
[0244] If the result of the determination in step S 202 is affirmative, the process proceeds to step S 203 , where the processing of selecting an Internet FAX mode shown in FIG. 16 is called, and presence/absence of an Internet FAX mode in the received DIS signal is checked.
[0245] In step S 204 , it is determined if the receiver 2 has an Internet FAX mode. If the result of the determination in step S 204 is affirmative, the process proceeds to step S 205 .
[0246] If the result of the determination in step S 202 or S 204 is negative, the process proceeds to step S 206 , where image data is transmitted according to the ordinary T30 procedure.
[0247] In step S 205 , the Internet address of the transmitter's apparatus is set in a TSE frame.
[0248] In step S 206 , TSE and DCS signals are transmitted. Then, in step S 207 , it is determined if a CFR signal has been detected.
[0249] If the result of the determination in step S 207 is affirmative, the process proceeds to step S 208 , where it is determined if a CSE signal has been detected together with the CFR signal. If the result of the determination in step S 208 is affirmative, the process proceeds to step S 209 , where the Internet address in FIF of the CSE frame is stored in a working area, and is set in the Internet-address column of the corresponding one-touch number in the address table.
[0250] In step S 210 , a DCN signal is transmitted. Then, in step S 211 , the line is disconnected.
[0251] In step S 212 , it is determined if the DCN signal instructing shift to the simple mode which has been transmitted in step S 206 has been received. If the result of the determination in step S 212 is affirmative, the process proceeds to step S 219 , where transmission processing in the simple mode of Internet FAX is performed.
[0252] In step S 213 , it is determined if the DCS signal instructing shift to the full mode which has been transmitted in step S 206 has been received. If the result of the determination in step S 213 is affirmative, the process proceeds to step S 217 , where transmission processing in the full mode of Internet FAX is performed.
[0253] In step S 214 , it is determined if the DCS signal instructing shift to the real time mode which has been transmitted in step S 206 has been received. If the result of the determination in step S 214 is affirmative, the process proceeds to step S 218 , where transmission processing in the real time mode of Internet FAX is performed.
[0254] Processing from step S 219 to step S 224 is performed when the mode shifts to the simple mode.
[0255] In step S 219 , transmission processing in the simple mode of Internet FAX is started.
[0256] In step S 220 , the Internet address stored in the working area in the processing of step S 209 is set as the address for the E-mail.
[0257] In step S 221 , the image file is converted into TIFF. At that time, the image to be transmitted is converted into a format of the A4 size, 200 dpi and the MH encoding method so as to conform to the specifications of the simple mode.
[0258] In step S 222 , the TIFF image file is added to the E-mail. Then, in step S 223 , the E-mail is transmitted according to SMTP. Then, in step S 224 , the process returns to a waiting state.
[0259] Processing in the full mode in step S 217 is similar to the processing in the simple mode in step S 219 . The processing in the full mode differs from the processing in the simple mode in that, when converting image data into a TIFF file, a function seperior to the function of the A4 size, 200 dpi and the MH encoding method can be selected.
[0260] FIG. 19 is a flowchart for TIFF conversion in the full mode. The detail of this flowchart will be describe later.
[0261] Processing in the real time mode in step S 218 is a method according to a T30 procedure in which a T30 procedure signal and image data are transmitted in the form of TCP packets. Since this processing has already been described, further description thereof will be omitted.
[0262] The flow at the reception-side Internet FAX apparatus will now be described with reference to FIG. 18 . The flowchart shown in FIG. 18 is a program stored in the ROM 11 and executed by the CPU 5 when the Internet FAX apparatus operates as a reception-side apparatus.
[0263] When there is a call from the telephone network, the NCU 9 performs call-receiving processing, and an automatic reception procedure in the G3 FAX mode is started.
[0264] In step S 301 , it is determined if the Internet FAX mode of the receiver's apparatus is set to be usable. If the result of the determination in step S 301 is affirmative, the process proceeds to step S 302 . If the result of the determination in step S 301 is negative, the process returns to the ordinary T30 procedure in step S 322 .
[0265] In step S 302 , the X, X+1 and X+2 bits of the DIS signal are set in accordance with the setting of the Internet FAX function of the receiver's apparatus. Then, in step S 303 , a DIS signal is transmitted.
[0266] In step S 304 , it is determined if a DCS signal has been received. If the result of the determination in step S 304 is affirmative, the process proceeds to step S 305 , where it is determined if all of the X, X+1 and X+2 bits of the DCS signal equal 0. If the result of the determination in step S 305 is affirmative, the process returns to the ordinary T30 procedure in step S 322 .
[0267] In step S 306 , it is determined if a TSE signal has been received. If the result of the determination in step S 306 is affirmative, the process proceeds to step S 307 , where it is determined if a TSI signal has been received. If the result of the determination in step S 307 is affirmative, the process proceeds to step S 308 , where the Internet address in the TSE signal is stored in the column of the Internet address of address data corresponding to the telephone number in the TSI signal. If the result of the determination in step S 306 or S 307 is negative, the process proceeds to step S 309 .
[0268] In step S 309 , the Internet address of the receiver's own apparatus is stored in a CSE signal. In step S 310 , CSE and CFR signals are transmitted. Then, in step S 311 , it is determined if a DCN signal has been received. If the result of the determination in step S 311 is negative, the process returns to step S 304 .
[0269] If the result of the determination in step S 311 is affirmative, the process proceeds to step S 312 , where the NCU 9 disconnects the line. Then, the process returns to the waiting state in step S 313 .
[0270] When the process has returned to the waiting state in step S 313 , image data is transmitted from the transmitter's apparatus in the Internet FAX mode, and the process proceeds to step S 315 , where reception in the Internet FAX mode is started. Processing from step S 314 to step S 321 will now be described assuming that image data has been transmitted in the simple mode.
[0271] In step S 315 , reception of the E-mail is performed with SMTP.
[0272] In step S 316 , it is determined if an additional file is present in the E-mail. If the result of the determination in step S 316 is affirmative, the process proceeds to step S 317 , where it is determined if the additional file is a TIFF file.
[0273] If the result of the determination in step S 317 is affirmative, the process proceeds to step S 318 . If the result of the determination in step S 316 or S 317 is negative, the process proceeds to step S 320 .
[0274] In step S 318 , the TIFF file is converted into image data. In step S 319 , an image represented by the image data is printed by the printer.
[0275] In step S 320 , an E-mail reception log is formed. Then, the process returns to the waiting state in step S 321 .
[0276] In the foregoing description, reception in the simple mode is started in step S 314 . Even when reception is started in the full mode, the same processing from step S 314 to step S 321 is performed. In this case, however, as for specifications for the size (A4 size or B4 size), the pixel density (200 dpi or 400 dpi) and the encoding method (MH, MR, MMR or JBIG), the TIFF file in step S 318 has specifications superior to the specifications of the A4 size, 200 dpi and the MH encoding in the simple mode.
[0277] When reception is started in the real time mode in step S 314 instead of the simple mode, a T30 procedure signal is transmitted/received in the form of TCP packets, and image data is received in the form of TCP packets.
[0278] The flow of TIFF conversion will now be described with reference to FIG. 19 . The flowchart shown in FIG. 19 is a program stored in the ROM 11 and executed by the CPU 5 .
[0279] First, in step S 401 , the resolution of the image to be transmitted is checked. If the resolution is 400 dpi, the process proceeds to step S 402 . If the resolution is 200 dpi, the process proceeds to step S 404 .
[0280] In step S 402 , it is determined if image data is to be transmitted in the full mode. If the result of the determination in step S 402 is affirmative, the process proceeds to step S 404 . If the result of the determination in step S 402 is negative, i.e., if the image data is to be transmitted in the simple mode, the process proceeds to step S 403 , where the resolution conversion into 200 dpi is performed.
[0281] In step S 404 , the size of the image to be transmitted is checked. If the size is B4, the process proceeds to step S 405 . If the size is A4, the process proceeds to step S 407 .
[0282] In step S 405 , it is determined if image data is to be transmitted in the full mode. If the result of the determination in step S 405 is affirmative, the process proceeds to step S 407 . If the result of the determination in step S 405 is negative, i.e., if the image data is to be transmitted in the simple mode, the process proceeds to step S 406 , where the size is converted into A4.
[0283] In step S 407 , it is determined if the image data is to be transmitted in the full mode. If the result of the determination in step S 407 is affirmative, encoding is performed according to the JBIG, MMR, MR or MH method (step S 408 , S 409 , S 410 or S 411 , respectively), depending on the condition.
[0284] If the result of the determination in step S 407 is negative, i.e., if the image data is to be transmitted in the Simple Mode, the process proceeds to step S 412 , where the MH encoding is performed.
[0285] In step S 412 , image data encoded in each of steps S 408 -S 411 is converted into a file in the form of TIFF.
[0286] As described above, in the second embodiment, the Internet FAX function of the receiver is notified to the transmitter with a DIS signal, and the Internet address of the receiver is transmitted with an optional CSE signal. The transmitter instructs communication in the Internet FAX mode with a DCS signal, interrupts the G3 FAX mode, and execute communication in the Internet FAX mode. Hence, it is possible to transmit image data using one of the real time mode, full mode or simple mode of Internet FAX adjusted to the function of the receiver via Internet.
Modification of the Second Embodiment
[0287] In the above-described second embodiment, the mode is switched to the Internet FAX mode by interrupting the T30 procedure. However, it is also possible to transmit image data in the G3 FAX mode at the first communication operation with a communication partner, and transmit image data at subsequent communication operations by directly selecting the Internet FAX mode using the same one-touch number.
[0288] It is determined that the current communication operation with an address in the Internet FAX mode is the first communication operation when the Internet FAX function is absent as in the case of the one-touch number 01 shown in FIG. 14 , when the Internet FAX address is not stored, or when at least one of the above-described conditions is satisfied.
[0289] In the first communication operation with a communication partner, the G3 FAX transmission mode is selected according to the determination shown in FIG. 16 in the second embodiment.
[0290] The flow shown in FIG. 17 for the second embodiment differs for the modification in the first communication operation. Only difference from the second embodiment will now be described, and description for the same processing will be omitted.
[0291] After NO in step S 208 or after execution of step S 209 shown in FIG. 17 , ordinary T30 image data transmission is performed (image data is transmitted after trasmitting a training/TCF signal and receiving a CFR signal from the receiver 2 ). After transmitting image data for all pages in that communication operation, an ordinary. T30 EOM signal is transmitted. Then, the process proceeds to step S 210 , where a DCN signal is transmitted. Then, the first communication operation with the communication partner is terminated.
[0292] In each of subsequent communication operations with the communication partner, address data of the address in the one-touch address table is read. Then, in the selection of an Internet FAX mode shown in FIG. 16 , one of Internet FAX modes is selected in accordance with information relating to the Internet FAX function of the address data. Then, image data is transmitted via Internet according to the processing from step S 219 to step S 224 shown in FIG. 17 .
[0293] It is also possible to transmit image data stored in the memory during memory transmission in the Internet FAX mode as in the second embodiment.
[0294] When performing a call using a ten-digit key dial instead of a one-touch key, it is also possible to transmit image data in the Internet FAX mode as in the second embodiment by storing the FAX function of the receiver received in the G3 FAX mode together with the telephone number called using the ten-digit key dial in a working area of the RAM 12 .
[0295] According to the second embodiment, in an image communication apparatus and method having a plurality of Internet FAX modes and the G3 FAX mode, the Internet FAX function of the communication partner's apparatus is detected during communication in the G3 FAX mode, and the image communication apparatus shifts to communication in the Internet FAX mode by disconnecting communication in the G3 FAX mode based on detection of the Internet FAX function of the communication partner's apparatus. Thus, the image communication apparatus shifts to the Internet FAX mode requiring no communication fee after knowing the Internet FAX mode of the communication partner's apparatus in communication in the G3 FAX mode. As a result, it is possible to reduce the communication cost, and transmit optimum image data in accordance with the Internet FAX function of the communication partner's apparatus.
[0296] Furthermore, the Internet FAX mode of the communication partner's apparatus is detected during communication in the G3 FAX mode, and an image is transmitted in the Internet FAX mode in accordance with the detected mode of the communication partner's apparatus. Hence, it is possible to detect the Internet FAX mode of the communication partner's apparatus in the G3 FAX mode even if the Internet FAX mode of the communication partner's apparatus is unknown, and to transmit optimum image data in accordance with the Internet FAX mode of the communication partner's apparatus.
[0297] According to the second embodiment, the detected Internet FAX mode of the communication partner's apparatus is stored, and image data is transmitted in the Internet FAX mode in accordance with the stored Internet FAX mode of the communication partner's apparatus. Hence, when the function of the communication partner's apparatus is stored, it is possible to start to transmit image data in an optimum mode adjusted to the Internet FAX mode of the communication partner's apparatus in the Internet FAX mode without performing communication in the G3 FAX mode, and therefore to start communication of image data earlier by an amount of omitting communication in the G3 FAX mode for detecting the Internet FAX mode of the communication partner's apparatus, and to reduce the communication fee.
[0298] According to the second embodiment, in an image communication apparatus and method having a plurality of Internet FAX modes and the G3 FAX mode, the apparatus notifies the communication partner's apparatus of the Internet FAX mode of the image communication apparatus and the Internet FAX address during communication in the G3 FAX mode. Hence, even when the communication partner's apparatus does not know the Internet FAX mode and the Internet address of the image communication apparatus, if communication is performed in the G3 FAX mode with the communication partner's apparatus, the image communication apparatus can notify the communication partner's apparatus of the Internet FAX mode and the Internet FAX address of the image communication apparatus, and can receive image data from the communication partner's apparatus via Internet.
[0299] The individual components desiganated by blocks in the drawings are all well known in the image communication apparatus and method arts and their specific construction and operation are not critical to the operation or the best mode for carrying out the invention.
[0300] While the present invention has been described with respect to what are presently considered to be the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, the present invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
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An image communication apparatus having an Internet facsimile communication device and a G3 facsimile communication device includes a detector for detecting a facsimile function of a communication partner's apparatus during communication by the G3 facsimile communication device, and a controller for performing control of causing the G3 facsimile communication device to disconnect communication in a G3 facsimile mode and shifting to communication by the Internet facsimile communication device, based on the detection of the facsimile function of the communication partner's apparatus by the detector.
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RELATED US PATENT APPLICATION
This patent application claims priority to Utility application Ser. No. 11/333,154, filed Jan. 17, 2006, which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to an apparatus for securing laces of a shoe. The apparatus comprises a folded piece of material that can wrap around adjoined laces to ensure that said laces stay adjoined.
2. Description of the Prior Art
There currently exist several methods for securing adjoined, or tied, laces. Often these methods involve the use of fine motor skills to engage the laces. The problem of laces becoming untied is typical for all shoes containing laces. For most adults this is an annoyance that is easily overcome by the re-tying of the lace. Most adults have life experience that teaches them to retie their laces so that a dangerous accident can be avoided from the tripping over of untied laces. However, children often over look this danger because they lack life experience or the untied lace goes unnoticed. In addition, there are several occasions where adults will also notice that a lace is untied until it is pointed out to them or they trip on the lace. Therefore, there is a need to have an invention that is inexpensive, easy to use and desirable to use to prevent laces from coming untied.
The invention, in its simplest form, must be inexpensive because the use of the lace gripper will be primarily by children and they tend to destroy and lose attachable items. In addition the safety feature has to fit into a family budget.
The invention must be easy to use because the primary market to the lace gripper is going to be small children and adults who will not or cannot retie their laces.
The invention must be desirable to the user because children must want to use the lace gripper in order for it to be an effective safety measure.
The invention must keep laces secured because the safety feature is to eliminate the tripping over of laces.
The invention is also useful for adults that may not be able to tie their laces when they come undone. For example, athletes may not want to interrupt their athletic perform to tie their laces. In addition, adults may have disabilities that make it impossible or difficult to tie or retie their laces. Thus an invention to secure a tied lace is desirable for these individuals.
The invention should have optional features for users who desire more safety and are less concerned about price. These features should include signaling means to both sound and alarm and locate the user.
Past efforts have attempted to solve the problem of untied laces by providing complicated devices that integrate with laces to secure one end of the lace to another. In addition, these methods do not offer interchangeability in design that would make them universally appropriate for securing laces. An example of how these prior inventions are limited are that they require a more complicated securing process and they have only one outwardly appearance that may not be desirable or appropriate for the laces that are being secured.
None of the prior art couple the securing of laces with added security features such as sounds alarms or locating signals to find wayward users. None of the prior art provides a means for presenting interchangeable images onto shoes.
The prior art fails to teach a means for storing a key, or similar object, into a small pocket of an object that secures to one's shoelaces.
The prior art fails to teach the inclusion of an image within a transparent pocket of an object that secures to one's shoelaces. With that, it is further limited by not providing software to create such artwork using a preset image outline for such an insert, further wherein said software is available via the Internet.
Therefore, the present invention addresses the great need to develop an apparatus that is easy to use, inexpensive and desirable to use.
The present invention relates to a lace gripper that wraps around tied laces to secure the tied knot within.
The present invention further discloses an easy to use apparatus that wraps around tied laces to secure the tied knot within.
The present invention further discloses a desirable apparatus that wraps around tied laces to secure the tied knot within that may be changed in appearance to fit the activity being performed or appearance required by the user.
The present invention further discloses a desirable apparatus that wraps around tied laces to secure the tied knot within that may be configured with additional safety features from sounding alarms and locating wearers.
Nothing in the prior art references disclose an apparatus or method that utilizes a combination of these elements to facilitate the securing of tied laces.
SUMMARY OF THE INVENTION
According to the present invention, a lace gripper, or apparatus is disclosed.
An object of the present invention is to disclose an apparatus that is easy to use so that young children or disabled adults can use the present invention.
It is an object of this invention to provide an inexpensive apparatus that wraps around tied laces to secure the tied knot within, said apparatus referred to as a lace gripper.
A second objective is to disclose a desirable to use said apparatus that wraps around tied laces to secure the tied knot within, wherein said apparatus may be changed in appearance to fit the activity being performed or appearance required by the user.
A third objective is to disclose a desirable to use said apparatus that wraps around tied laces to secure the tied knot within, wherein said apparatus may have additional safety features for sounding alarms or locating signals for wayward wearers.
A fourth aspect of the present invention is the application of a fabric as a lace gripper, wherein said fabric comprising an outer surface and a joining surface. Said outer surface would be visible when used, said joining surface would be folded such to contact itself and therefore would not be visible when used.
A fifth aspect of the present invention is the inclusion of a fastener, wherein said fastener would be coupled to said joining surface of said fabric.
A sixth aspect of the present invention is the inclusion of a fastener, wherein said fastener would be coupled to said joining surface of said fabric, wherein said coupler is at least one of: Velcro® (a dense hook and loop fastening system); a snap; a button; a ribbon or string tie, a hook and eye; and a loop and knot.
A seventh aspect of the present invention is the incorporation of a fabric stiffener, wherein said fabric stiffener would be coupled to said joining side of said fabric.
An eighth aspect of the present invention is the incorporation of a member to at least one of to hold and insert flat images.
A ninth aspect of the present invention is the incorporation of a member to at least one of to hold and insert flat images, wherein said member is a clear, flexible material, spanning across an upper, outer surface.
A tenth aspect of the present invention is the incorporation of a member to at least one of to hold and insert an image, wherein said member is narrow frame for containing said image on at least three sides.
An eleventh aspect of the present invention is the incorporation of a charm holder, wherein said charm holder.
A twelfth aspect of the present invention is the incorporation of a charm holder, wherein said charm holder is a charm bar coupled to said top, upper surface of said lace gripper.
A thirteenth aspect of the present invention is the incorporation of a charm holder, wherein said charm holder is a charm bar coupled to said top, upper surface of said lace gripper.
A fourteenth aspect of the present invention is the incorporation of a charm holder, wherein said charm holder is a horizontal strip of fabric incorporated in said top, upper surface of said lace gripper.
A fifteenth aspect of the present invention is the incorporation of a charm holder, wherein said charm holder is a charm chain coupled to said top, upper surface of said lace gripper.
A sixteenth aspect of the present invention is the incorporation of a charm holder, wherein said charm holder is at least one of a tie and ribbon coupled to said top, upper surface of said lace gripper.
A seventeenth aspect of the present invention is the utilization of said invention as a means to hold a daily tasks list.
An eighteenth aspect of the present invention is the utilization of said invention as a means to hold a daily tasks list, wherein said lace gripper is secured to a person's purse.
A nineteenth aspect of the present invention is the utilization of said invention as a means to hold a daily tasks list; wherein said lace gripper is secured to a person's key ring.
A twentieth aspect of the present invention is the utilization of printed fabric as the primary material for said lace gripper. Several examples would be utilization of cartoon characters, sports logos, sports related images, and the like.
A twenty-first aspect of the present invention is the utilization of leather, suede, silk, satin, lace and other materials for said fabric as the primary material for said lace gripper.
A twentieth aspect of the present invention is the utilization of a metal coupling apparatus, wherein said metal coupling apparatus is shaped similar to a clothes hanger and used to couple said lace gripper to another object such as a key-ring.
A twenty-first aspect of the present invention is a lace gripper wherein said lace gripper is of a length to hold a key.
A twenty-second aspect of the present invention is a lace gripper wherein said lace gripper is of a length to hold a key, and further comprising a pocket for holding said key.
A twenty-third aspect of the present invention is a lace gripper wherein said lace gripper is of a length to hold a key, and further comprising a pocket for holding said key, wherein an opening for said key pocket is located on the inside of said lace gripper.
A twenty-fourth aspect of the present invention is a lace gripper wherein said lace gripper is of a length to hold a key, and further comprising a pocket for holding said key, wherein an opening for said key pocket is located on the outside of said lace gripper.
A twenty-fifth aspect of the present invention is software including the outline of said insert, wherein the software provides the process of designing said insert for said lace gripper.
A twenty-sixth aspect of the present invention is software including the outline of said insert, wherein the software provides the process of designing said insert for said lace gripper, wherein said software resides on a website.
A twenty-seventh aspect of the present invention is software including the outline of said insert, wherein the software provides the process of designing said insert for said lace gripper, wherein said software resides on a website, said website further comprising sale of charms, lights, and other accessories.
A twenty-eighth aspect of the present invention is software including the outline of said insert, wherein the software provides the process of designing said insert for said lace gripper, said software comprising all of the standard elements for drawing, editing, importing, text, and the like for design & decorating an image for said insert.
Still further objectives will become apparent from the disclosure herein and are claimed as objects of the invention as if described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, where like designations denote like elements, and in which:
FIGS. 1 a through 1 g presents a detailed view of a lace gripper, further comprising an embodiment allowing for the insert of various images;
FIGS. 2 a through 2 g presents a detailed view of the lace gripper, further comprising an embodiment allowing for the attachment of charms;
FIGS. 3 a through 3 c presents a diagram illustrating the steps of inserting said lace gripper onto footwear and securely fastening said lace gripper around a tied knot;
FIGS. 4 a through 4 d presents various views of said lace gripper, further comprising additional embodiments of the present invention;
FIGS. 5 a through 5 d presents a detailed view of the lace gripper, further comprising an embodiment providing for storage of a key; and
FIG. 6 presents a web page, wherein said web page is representative of software for designing an insert for said lace gripper.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Shown throughout the figures, the present invention is directed towards a lace gripper. Like element references are used through the various figures.
FIGS. 1 a through 1 g illustrates a lace gripper 10 (shown as 10 A- 10 p herein), said lace gripper comprising a lace gripper upper body 20 and a lace gripper lower body 30 . Said lace gripper upper body 20 has an upper body outer surface 40 and an upper body joining surface 50 . Said lace gripper upper body 20 is the portion of said lace gripper 10 that is visible when used. Said lace gripper lower body 30 has a lower body outer surface 60 and a lower body joining surface 70 . Said lace gripper lower body 30 is the portion of said lace gripper 10 that is not visible when used, placed behind said lace gripper upper body 20 . Said upper body joining surface 50 and said lower body joining surface 70 further comprise an interlocking means 80 used as a means for securing said upper body joining surface 50 and said lower body joining surface 70 , forming a loop about an object such as laces. In one embodiment interlocking means 80 is Velcro®. However, any means for joining said upper body joining surface 50 and said lower body joining surface 70 is contemplated herein whereby tied laces may be clamped in between said upper body joining surface 50 and said lower body joining surface 70 , including, but not limited to a snap; a button; a ribbon or string tie, a hook and eye; and a loop and knot.
Optionally, said upper body outer surface 40 may have an attaching means (shown as several members herein) to attach various aesthetic items to make the use of said lace gripper 10 more appealing to the user. Said lace gripper 10 is presented in 4 orientations: an unfolded bottom/joining section view 10 a , an unfolded side view 10 b , an unfolded top/outer section view 10 c , and a folded side view 10 d . In one embodiment, said upper body outer surface may comprise a pocket/channel 100 completely covering (or an image slot 111 disposed around the perimeter of) said upper body outer surface 40 . Said pocket/channel 100 (or said image slot 111 used interchangeably herein) will create an image pocket 112 for holding an insert 110 . Said illustration presents the steps of inserting 114 said insert 110 into said image pocket 112 , said process is detailed via: an orienting step 10 e for orienting said insert 110 and aligning said insert with said pocket/channel 100 ; an insertion step 10 f for inserting 114 said insert 110 into said pocket/channel 100 ; and seating step 10 g , for seating said insert 100 to the base of said pocket/channel 100 . Said insert 110 comprising printed card stock of various pictures to suit the personal preference of the user. For example, as shown in FIGS. 1 a through 1 c , a soccer ball may be imprinted on said insert 110 , which would indicate the users fondness or participation in the activity. Alternatively, said insert 110 can comprise notes for reminding the user of various tasks, inspiration phrases, dates such as a calendar or other such messages. There is no limitation contemplated on the subject matter of printed material on said insert 110 . In fact, said insert 110 may be left blank in which case the user may design their own graphic on said insert 110 . Moreover, there is no limitation on the means of attaching said insert 110 to said upper body outer surface 40 . For example, said insert 110 and said upper body outer surface 40 may also be coupled via Velcro® coupled on opposite joining sides, adhesive, and the like. The configuration of having said attaching means shown herein as a pocket/channel 100 allows the user to change said insert 110 easily to allow several aesthetic themes. Moreover said lace gripper 10 may be used without said insert 110 at all.
Said lace gripper 10 can be fabricated in accordance with the following process. A stiffening material 86 is coupled to said joining side of a sheet of fabric. An outline of said lace gripper 10 is transferred to said stiffened sheet of fabric. One such means to transfer said outline would be to cut the sheet of fabric to shape, including any seam allowance 82 as required. An optional attaching means is then positioned and coupled to said stiffened sheet of fabric. Any seam allowance 82 is folded under as shown in said unfolded bottom side view 10 a . A seam 84 secures said seam allowance 82 . Additionally, said seam 84 can be used to secure said attaching means. Alternatively, the cut edge of the material can be finished to avoid fraying by a process known as surging. Said interlocking means 80 are then coupled to said joining surfaces 50 , 70 . Said lace gripper is then folded along a fold 88 as illustrated in said folded side view 10 d.
FIGS. 2 a through 2 g presents a lace gripper 10 in accordance with an alternate embodiment, wherein said upper body outer surface 40 of said lace gripper 10 incorporates a charm attaching means 120 to attach user-selected charms 130 . Said charms attaching means 120 is preferable a charm bar 140 secured to said upper body outer surface 40 via a charm attaching means coupling apparatus 122 —more specifically, the preferred embodiment is a secured coupling member 122 a at a first end and a removable coupling member 122 b attached to said upper body outer surface 40 at an opposing end of said charm attaching means 120 . By having one end of said charm bar 140 removable secured on one end the user may selectively add or remove said selected charms 130 . Said selected charms 130 can be used for aesthetic appeal or used to convey membership, affiliation or approval of groups and activities symbolic. For example a group of friends can create a group of said selected charms 130 that represent the group of friends. Also, those involved in specific activities can select said charms 130 the represent those activities. In addition, said selected charms 130 can be matched to other jewelry being worn by the user to complete an their outfit. In a modified version, said charm attaching means 120 can be a strip of fabric, string, ribbon, and the like as presented in FIG. 10 j . Said modified charm attaching means could be fabricated by incorporating two horizontal slits into the fabric as shown. It can be recognized that any number of charm attaching scenarios can be incorporated into said lace gripper while maintaining the spirit and intent of the present invention.
FIGS. 3 a through 3 c presents a representative flow for applying said lace gripper to footwear 200 in accordance with the preferred embodiment. The method of using said lace gripper 10 comprising: inserting said lace gripper lower body 30 between the tongue of said footwear 200 (not shown, but widely understood) and laces 202 used to secure said footwear 200 , while leaving said lace gripper upper body 20 extending outwardly from said laces 202 . The preferable insertion location would be about a lace knot 204 to ensure said laces 202 remain tied. The midpoint (fold 88 position) of said lace gripper 10 should be positions at the point where said laces 202 will be tied (lace knot 204 ). Then the user tightens said laces 202 and ties said laces 202 of said footwear 200 as they normally would. It can be recognized that the user may tie said laces 202 prior to inserting said lace gripper 10 . After which, said lace gripper upper body 20 is folded over 208 (along fold 88 ) about the tied laces (lace knot 204 ) until said upper body joining surface 50 and said lower body joining surface 70 are joined securing via said interlocking means 80 . Thus the tied laces (lace knot 204 ) are secured between the two bonded surfaces of said lace gripper 10 . Said inserts 110 or said selected charms 130 may have been previously positioned on said upper body outer surface 40 or may be so positioned or changed at this time.
FIGS. 4 a through 4 d presents additional embodiments not shown in the previous figures. In one such embodiment, said upper body outer surface 40 may incorporate or contain a desired pattern of lights 150 , as illustrated in a lighting embodiment 10 k . Currently, there are many shoes for children that have lights built into the shoes. However, these lights often become non-functioning prior to the useful life of the shoe. However, if said attached desired pattern of lights 150 is used it may be reenergized by the replacement of a battery or replaced altogether. Typically said desired pattern of lights 150 will be activated upon detection of motion. Alternately, said lights can be activated via a switch. Said lights can be incandescent bulbs, LEDs, fiber optics, and the like. Said lights can additionally flash, flash in patterns, etc. to gain attention. Said lights or ends of fibers can be fashioned into images.
In accordance with another alternate embodiment, attached to said upper body outer surface 40 may be a message-recording device 160 , as illustrated in a recording embodiment 10 m . Said message recording device 160 comprising a memory apparatus (not shown), a power source (not shown), a recording transducer 162 , recording play controller 164 , a recording stop controller 166 , and a recording recorder controller 168 . Said message recording device 160 could contain a recorded message from a parent reminding the child user to do something or conveying a message of endearment. Also, said recording device 160 could be used to store critical information like a home address or cell phone number in the event that a child gets lost. Additionally, said recording device could transmit an alarm or locating signal. Typically, said recording device 160 would be activated by depressing a button or remotely by a parent or caretaker.
In accordance with another alternate embodiment, either said lace gripper 10 or any of the said upper body outer surface 40 attachments may be fitted with a location device that allows a parent or caretaker to locate the position of the wearer utilizing wireless locating technology, as illustrated in a signaling embodiment 10 n . This is accomplished through embedding a signaling device 170 in either the lace gripper 10 or any of the said upper body outer surface 40 attachments, and providing a receiving means to said parent or caretaker. Said signaling device 170 can optionally comprise a signaling device controller 172 and a signaling device warning apparatus 174 . The wearer would activate said signaling device 170 via the said signaling device controller 172 . Once activated, said signaling device 170 would transmit a signal back to said parent or caretaker. Optionally, said signaling device 170 would also provide an audible or visual alert via said signaling device warning apparatus 174 .
In accordance with another alternate embodiment, said lace gripper 10 may be fitted with a lace gripper coupling apparatus 180 that provides a means for said lace gripper 10 to be secured to other objects such as a key-ring or purse, as illustrated in a note keeping embodiment 10 p . Said lace gripper coupling apparatus 180 can comprise a lace gripper hanger 182 and optionally a coupling loop 184 . Said hanger comprising a long, strait section for securing said lace gripper 10 and a smaller loop section for coupling to a key ring, loop on a purse, and the like.
Finally, it should be noted that all of the attachable features contained herein can be used in conjunction with each other or separately.
The primary goal of allowing user selection of various methods to display said inserts 110 and said selected charms 130 is to achieve the goal of getting the user to use said lace gripper 10 .
The primary purpose of lace gripper 10 is to provide a means for securing shoe laces to avoid annoyance and provide safety to those would otherwise ignore untied laces and possibly trip over their untied laces.
An alternate purpose of lace gripper 10 is to provide a means for maintaining a task list or other such notes.
FIGS. 5 a through 5 d presents an additional embodiment of the present invention, wherein said lace gripper 10 is illustrated as a key holding lace gripper 300 , further presented in 4 orientations: an unfolded bottom/joining section view 300 a , an unfolded side view 300 b , an unfolded top/outer section view 300 c , and a folded side view 300 d . Said unfolded bottom/joining section view 300 a presents a lace gripper key pocket 306 on the inside of said key holding lace gripper 300 . A user would insert a key 302 in accordance with a key insertion 304 . It is understood that said key pocket 306 could alternately be positioned on the exterior of said key holding lace gripper 300 . Said key 304 is shown in phantom as an inserted key 308 , placed in a stored position.
FIG. 6 presents an insertion design screen view 400 . Said insertion design screen view 400 presents various features representative of software for creating a user-designed image 406 onto an owner designed insert 404 . Said insertion design screen view 400 would comprise at least one of the following elements:
a. software header 402 ; b. file menu 408 for opening, saving, and like functions; c. print menu 410 for printing, print preview, page setup and like functions; d. line drawing function 412 for drawing strait, curved, and multi-point lines; e. select function 414 for selecting one or more elements of said user designed image 406 ; f. rectangle drawing function 416 for drawing square and rectangular shaped elements; g. oval drawing function 418 for drawing circular and elliptical shaped elements; h. polygon drawing function 420 for drawing any shaped polygons, said function may include an option for establishing a number of sides for said polygon shaped elements, as well as inverting said polygon to create stars; i. text insertion function 422 for inserting text into said user designed image 406 ; j. viewing scaling function 424 for zooming in or out of the viewing area; k. rotating function 426 for rotating a selected element or group of elements; l. cropping function 428 for cropping a selected element, group of elements, image, and the like; m. clip art menu 430 for inserting, manipulating, and like functions respective to clip art to be applied to said user designed image 406 ; n. insert image menu 432 for inserting, manipulating, and like functions respective to an image provided by a source other than clip art to be applied to said user designed image 406 ; o. font format menu 434 for modifying the font of selected text within said user designed image 406 ; p. line format menu 436 for modifying the format of selected line(s), including thickness, type, style, curve features, and like functions; q. mirror function 438 for inverting or mirroring one or more selected elements, said inverting can be horizontally, vertically, along a diagonal, along a user generated line, and the like; r. alignment function 440 used for aligning an element or group of elements to another element, a page feature, or any other selectable item; s. color function 442 for inserting, changing, and like functions of colors upon an element; t. pattern function 444 for inserting, changing, and like functions of patterns upon an element, said patterns can be black and white, two-color, multi-color, textured, photo-like, and any other known pattern insertion feature; u. shadow function 446 for creating, changing, directing, shading, and like functions of a shadow projecting from an element or plurality of elements; and v. purchase accessories 448 which forwards the user to a location for purchasing of accessories for said lace gripper 10 .
The software can be provided on a CD, accessible via the Internet, or available via any other manner. The user would operate the software to create said user designed image 406 within an outline of said owner designed insert 404 . The software can optionally crop said user designed image 406 to the outline of said owner designed insert 404 by using said cropping function 428 . It should be noted that additional features could be included to the above software.
It should be noted, that the specific apparatus and method described of utilizing the present invention is only one example and is provided for illustrative purposes only. A wide variety of other applications and uses adaptable and configured for specific conditions are contemplated.
Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.
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A lace gripper having an upper body and a lower body that may be joined together whereby a tied lace is secured between the two bodies. Preferable the upper body is designed to receive inserts, keys, charms, lights, recording devices, alarm and locating audible signals and locating devices, to allow the user to customize the lace gripper to their personal preference. The lace gripper can additionally be utilized to maintain a memo and would be secured to an object of daily use, such as a key ring or purse. Artwork for an image for the insert can be created by using software with a preset outline of the insert. Such software can be provided in softcopy or accessible via the Internet.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The invention described and claimed hereinbelow is also described in German Patent Applications DE 10 2007 049 889.8 filed on Oct. 18, 2007. This German Patent Application, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
[0002] The invention relates to a vibration roller, having a vibration generator that has at least one unbalance shaft.
[0003] Such vibration rollers are used for instance in self-propelled or manually movable trench compactors or in roller trains but are also used as compactor attachments for arms of excavators. To that end, they are moved over the area of soil to be compacted, while the vibration generator generates the vibration necessary for the compaction.
[0004] In most known vibration rollers, the vibration generator is located in the interior of the rollers. This has the disadvantage that in servicing work on the vibration generator, as a rule the removal of the vibration generator from the roller is necessary, which is time-consuming. Moreover, the unbalance shafts become quite hot, which especially with vibration rollers that in their interior contain not only the vibration generator but also a drive unit for their own rotational drive, can lead to problems with temperature-sensitive components, such as electronic components. The hydraulic medium typically used for the drive also heats up severely from a generator unit located on the inside and must be cooled, which is complicated and expensive.
SUMMARY OF THE INVENTION
[0005] The object of the present invention is to furnish a vibration roller in which maintenance work can be done on a vibration generator without problems. It should furthermore be low in height, in order to reduce the lateral tilting moment and to assure good hill climbing capability.
[0006] This object is attained with a vibration roller, having a vibration generator that has at least one unbalance shaft, which is characterized in that the vibration generator is located above the vibration roller.
[0007] It has been demonstrated that when the vibration generator is located above the vibration roller, no disadvantages whatever in terms of the compacting performance arise, yet excellent accessibility to the vibration generator for maintenance work is assured. Since as a rule there is more space available above the vibration roller than in the interior of the roller, larger unbalance shafts can be provided than in the known vibration rollers, so that the generation of the complete vibrating mass and hence the compaction power can even be increased, compared to the known rollers with vibration generators located in the interior.
[0008] Heat dissipation is also markedly simpler with vibration generators located above the roller than with vibration generators integrated with the rollers.
[0009] Further advantages can be attained if the axis of the at least one unbalance shaft is oriented transversely to the axial direction of the vibration roller. The unit comprising the vibration roller and the vibration generator can then be manufactured with a lower height than when the axes of the vibration generator and roller are parallel to one another. Besides the lower height, a downward shift in the center of gravity of the unit is also attained, and as a result the risk of lateral tilting of the vibration roller can be reduced.
[0010] Preferably, the vibration generator can have two axially parallel, contrarily rotatable unbalance shafts, so that directional vibration can be generated with the vibration generator. For that purpose, the drive of the two unbalance shafts can expediently be coupled, and as a result, only one of the unbalance shafts has to be actively driven. The coupling of the unbalance shafts can be effected via a gear or in some other way. It is understood that a separate drive, adapted to one another, of the two unbalance shafts is also conceivable.
[0011] In a preferred embodiment, the at least one unbalance shaft can be provided with one eccentric weight mounted in a manner fixed against relative rotation and with one eccentric weight that is pivotable between two radially oriented stops. Depending on the quality of the soil to be compacted, a greater or lesser amplitude of the vibration generated can thus be selected. In one of the pivoted positions, the movable eccentric weight can reinforce the effect of the fixed eccentric weight, while in the other position it can reduce it. It is understood that naturally, the vibration frequency can be adapted to soil or ground conditions in a manner known per se.
[0012] The direction of rotation of the at least one unbalance shaft can also be reversible. Thus the amplitude of the vibration generated by the vibration generator can also be varied by simply reversing the direction of rotation of the unbalance shafts.
[0013] In principle, the invention also pertains to vibration rollers that are moved by hand. Preferably, however, a drive unit, preferably a hydraulic drive unit, for the rotational drive of the roller may be provided in the vibration roller. Such vibration rollers can be used for instance in remote-controlled, self-propelled equipment.
[0014] The drive direction of the drive unit can be reversible, to enable compacting in both directions of travel even in tight spaces, where there is often no room for turning the roller around.
[0015] Particularly with driven vibration rollers, it is advantageous if the vibration generator is located with its center of gravity in the cross-sectional plane of the vibration roller extending through the center of gravity of the vibration roller. In that case, the straight-ahead travel of the roller can be best assured. If the centers of gravity of the vibration generator and the vibration roller are too far apart, then lateral motions of the roller can occur, especially with vibration generators that generate directional vibration.
[0016] The manifold possibilities for using the vibration roller can be enhanced even more markedly if the vibration generator is supported limitedly movably above the vibration roller in such a way that its center of gravity can be shifted to in front of and/or behind the vertical plane that extends through the axis of the vibration roller.
[0017] If the vibration generator is supported limitedly displaceably horizontally, then by shifting the center of gravity of the vibration generator to in front of or behind the axis, the vibration amplitude can be reduced.
[0018] If the vibration generator is supported limitedly pivotably about the axis of the vibration roller, then by the pivoting motion, the center of gravity of the vibration generator can for instance be shifted somewhat behind the axis and at the same time the vibration generator can be inclined, thus enormously improving the forward motion of the vibration roller and hence its hill climbing capability. The vibration roller can then be used even for compacting sloping terrain or very poorly accessible ground.
[0019] A further way to increase the flexibility of use of the vibration roller is to equip it with replaceable bandages. Either smooth bandages, of the kind required more for compacting sandy soil, or profiled bandages for compacting heavy soils, can then be installed.
[0020] The invention moreover relates to a compacting device or compacting vehicle having at least one vibration roller of the invention.
[0021] The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a perspective view of a vibration roller having a vibration generator in accordance with the present invention; and
[0023] FIG. 2 is a view from the front of the vibration roller in accordance with the present invention of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] FIG. 1 shows a vibration roller 10 , which has a vibration generator 11 that is located above the vibration roller 10 . The vibration generator 11 has two unbalance shafts 12 , 13 , located in separate housings, and the unbalance shaft 13 is driven by a motor 14 . The contrary drive of the unbalance shaft 12 required for driving the unbalance shaft 13 is accomplished by a gear 15 , located on the face ends of the unbalance shafts 12 , 13 . As FIG. 1 shows, the axial direction 16 of the unbalance shafts 12 , 13 extends transversely to the axial direction 17 of the vibration roller. The vibration generator 11 is furthermore located such that its center of gravity is above the center of gravity of the vibration roller 10 , so that the vibration the vibration generator produces does not impair the straight-ahead travel of the vibration roller 10 .
[0025] The amplitude and frequency of the vibration generated by the vibration generator 11 may be variable. For that purpose, the unbalance shafts 12 , 13 may, in a manner known per se and not shown in further detail here, each have one eccentric weight located in a manner fixed against relative rotation and one adjustable eccentric weight. The adjustable eccentric weight can be pivoted between two stops, and in one position, it amplifies the effect of the fixed eccentric weight, and in the other direction, it lessens the effect of the fixed eccentric weight.
[0026] The vibration roller 10 , in its interior, has a drive unit 18 , which can preferably be a hydraulic motor. For supplying oil to the hydraulic motor, in a middle region of the vibration roller 10 connections 19 are provided, to which hydraulic lines from a vehicle or device to which the vibration roller 10 can be attached can be connected. Because of the closed construction of the drive unit 18 , impairment of the drive from being contaminated with dirt is precluded.
[0027] FIG. 2 , in the view from the front of the vibration roller 10 and the vibration generator 11 , clearly shows that the vibration roller 10 is provided with two bandages 20 , 21 of different widths. The hydraulic connections 19 for the drive unit 18 in the interior of the vibration roller 10 are located in the gap 22 between the bandages 20 , 21 . If a device or vehicle is now equipped with two vibration rollers 10 , and for the second vibration roller the bandage 20 on the left is wider than the bandage 21 on the right, so that the gaps 22 between the bandages 20 , 21 of the two vibration rollers are offset from one another, then with such a device or vehicle, streak-free compaction of the soil can be done.
[0028] The bandages 20 , 21 are removable. Thus the profiled bandages 20 , 21 shown here can also be replaced with smooth bandages, of the kind needed for instance for sandy soils.
[0029] The vibration generator 11 can also be limitedly pivotable about the axis 17 of the vibration roller 10 or limitedly displaceable on the vibration roller 10 in the axial direction 16 of the unbalance shafts 12 , 13 . By means of a horizontal displacement of the vibration generator 11 out of the middle position, the amplitude of the vibration exerted on the soil by the vibration roller 10 can be reduced. When the vibration generator 11 is pivoted out of the middle position, the vibration generated by the vibration generator acquires a component that reinforces the forward drive of the vibration roller 10 .
[0030] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
[0031] While the invention has been illustrated and described as embodied in a vibration roller, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
[0032] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A vibration roller includes a roller with a vibration generator that has at least one unbalance shaft. The vibration generator is located above the vibration roller.
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BACKGROUND OF THE INVENTION
This invention relates to die assemblies for extruding liquids and more particularly to a die assembly which is suitable for extruding high viscosity liquids such as magnetic inks onto a moving substrate.
The conventional prior art practice for applying magnetic inks to a flexible substrate for the manufacture of magnetic recording tapes and the like, has been by the gravure coating technique. In the gravure coating technique a pair of rolls are rotated relative to each other and the substrate on which the coating is to be applied is passed therebetween. One of the rolls is rotated in contact with a supply of the coating material and the rotating roll applies this coating material to one side of the substrate as it is passing thereby.
The gravure technique has several disadvantages. First, coating thickness cannot be changed significantly without changing gravure rolls. Further, there has to be a recirculation of the coating material due to the excessive amount of coating applied over and above what is necessary during the coating process. Moreover, the machinery requires constant operator adjustment, and even then precise thickness control of the coating is not always achieved.
Thus, while the gravure process is an acceptable process for coating high viscosity magnetic inks onto flexible substrates, nevertheless there are certain limitations which adversely affect this gravure technique.
The present invention overcomes many of these defects in that it provides a device which will allow a much closer control of thickness without any equipment change and eliminates the need for any recirculation of ink, reduces the amount of adjustment needed in coating and allows for substantially higher coating speeds in the coating process.
SUMMARY OF THE INVENTION
According to the present invention, a die assembly for extruding high viscosity liquids onto a substrate moving relative thereto is provided. The die assembly includes an upstream plate and downstream plate separated by shim means disposed therebetween, which plates together with the shim means and defines a liquid passage terminating with a discharge opening. Each of the plates terminates in a smooth material contacting surface, which surfaces bound the discharge opening. A reservoir is formed in at least the upstream plate adjacent to and communicating with the liquid passage at the discharge opening. The downstream edge of the downstream plate forms an acute angle with the material contacting surface thereof. A source of supply for a viscous fluid communicates with the liquid passage.
The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view, somewhat diagrammatic of a coating line showing the extrusion head of this invention in longitudinal section;
FIG. 2 is a top plan view of the extrusion head assembly of this invention; and
FIG. 3 is an exploded perspective view of the extrusion head assembly of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, an improved extrusion head assembly of this invention is shown and designated generally by the reference character 10. The head assembly is shown in conjunction with the somewhat diagrammatically represented extrusion line which includes an entrance guide roll 12 and an exit guide roll 14 which guide a web of material W on which an extrusion coating of a viscous material is to be applied. In the preferred embodiment the material to be coated onto the web is what is known as magnetic ink which includes a polyurethane isocyanate binder having magnetic particles admixed therewith. The web of material may be any one of a variety of flexible materials such as a polyester plastic sold by E. I. duPont under the name Mylar. However, the invention is not limited to this and can be used to coat other viscous substances onto various substrates.
The head assembly includes plates 16 and 18 and shim 20 which are secured together in any suitable manner such as by bolts 22 and passing through aligned apertures (unnumbered) provided in the plates and shim to form a head, the apertures in plate 18 being tapped to threadably receive the bolts. The plates 16 and 18 and shim 20 define a fluid passage 26 therebetween.
It is also possible to achieve the same "shim" results by actually machining recesses in the interior of one or both of the plates leaving ridges around the peripheries of the interior which will provide the required passage 28. In such a case the shimming function is performed by the ridges formed on the plate or plates themselves.
The plates 16 and 18 are provided with smooth material contacting surfaces 30 and 32, respectively at the ends thereof. The plate 18 also has a rounded edge 34 and the plate 16 is provided with a slanting "V" surface 36. The slanting "V" surface 36 and rounded edge 34 together with the smooth end surfaces 30 and 32 on the plates together define an open ended fluid reservoir 38 at the end of the passage 26.
The upstream plate 16 is provided with an entrance surface 42 which meets with the material contacting surface 30 at an acute angle; similarly the downstream plate 18 is provided with an exit surface 44 which meets with the material contacting surface 32 also to form an acute angle.
A fluid supply plenum 48 is formed in the upstream plate 16 and communicates with the passage 26 to supply fluid thereto. The plenum 48 communicates through an opening 50 and through a flexible conduit 54 with a metering pump 52. The metering pump 52 supplies a constant volume of fluid to the plenum 48.
The head assembly is mounted for both pivotal movement and oscillation movement by means of a mounting mechanism generally designated by the reference character 60. The mounting mechanism includes a threaded stud 62 extending from the plate 16 which is connected to an escillating arm 64 by ball bearing 66. A nut 68 secures the arm 64 to the stud 62, while permitting rocking or pivotal movement of the head assembly 10. An oscillating motor 70 is connected to the oscillating arm 64 and is arranged to provide an oscillating movement of the arm to move the head back and forth across the tape as indicated by the arrows in FIGS. 2 and 3.
As can be seen in FIG. 3 the shim 20 is preferably provided with a plurality of fingers 58 which in effect provide a serrated terminus for the passage 26.
In operation, the web of flexible plastic W is constantly moved across the smooth material contacting surfaces 30 and 32 by any appropriate drive mechanism (not shown). The coating material is provided from the metering pump 52 to the plenum 48 through the passage 26 and to the reservoir 38 and applied to the material therefrom. The thickness of the coating can be closely controlled by varying the delivery of the metering pump 52.
The two essential features of the present invention are the provision of the reservoir 38 and the acute exit angle formed by the surfaces 32 and 44. It has been found that when there is provided this enlarged reservoir adjacent the moving web and an acute exit angle coupled with the smooth material contacting surfaces an extremely smooth coating of controlled thickness can be applied to a web of material as it moves therepast. It is essential that the reservoir 38 be formed at least partially on the upstream side (on the side of the web before it is coated) of the passage 36. It is possible however, to have at least a portion of the reservoir 38 formed on the downstream side which would entail machining both of the plates 16 and 18 to the proper configuration. In any event there must be a reservoir supply of the fluid on the upstream side of the passage 26.
It has been found that in order to obtain a good transfer of the fluid and obtain a smooth final surface of uniform thickness, that it is essential to have smooth flat material contacting surfaces 30 and 32 together with an acute angle trailing edge formed by the surfaces 32 and 44 and the reservoir 38. These features together co-act to provide a uniformly good coating application with respect to uniform thickness and smooth final surface. It has also been found that in order to get uniformly of distribution across the web the gap thickness (i.e., the distance between the plates 16 and 18) must be maintained to a very close tolerance. The distance between the plates which forms the passage 26 may be different to provide different size passages for different applications. However, it has been found that the thickness of between approximately 0.010 and 0.012 of an inch is generally satisfactory for a coating of magnetic inks, according to this invention. Nevertheless, whatever size is selected the tolerance should be maintained to approximately 0.0002 of an inch throughout the entire width thereof, i.e., the distance across the web, to assure uniformity of flow.
It has also been found that the relationship of the thickness of the reservoir 38 to the thickness of the passage 26 is important. The reservoir should be at least about two times the thickness of the passage but no more than about ten times the thickness of the passage.
The rounded edge 34, is a desirable feature which is provided in order to allow for passage of any small foreign particles in the ink. If this edge were sharp, the particles would tend to hang up on this edge and form a barrier. However, by slightly rounding this edge as at 34 it will allow small particles to pass on without hanging up and prevent the build-up of foreign particles at this point. The acute angle formed by the surfaces 30 and 42 is a desirable feature which contributes to the smooth deposition of the coating and the smooth flow of the web. However, this is not critical and merely a desired feature. Also this edge may be beveled, instead of rounded with a radius when machining practice so dictates and the term "rounded" is intended to include such beveling.
The mounting on the ball bearing 66 allows the head to freely pivot thereby being self aligning to the web of material. The oscillation of the head is back and forth across the web transversely on its path of travel. This in conjunction with a post coating smoothing device (not shown) prevents any continuous line defects from forming, which could be caused by particles building up at edge 34 or any minor defects in the structure.
In summarizing, it has been found that the combination of the material contacting surfaces together with a reservoir adjacent these contacting surfaces and an acute angle trailing edge on the downstream side, together form a die assembly that provides a uniformly good coating of a viscous fluid.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. 9n
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A method and apparatus for applying a viscous fluid to a moving substrate is disclosed. The invention includes providing a die assembly formed from a pair of plates which are separated by shim means to define a fluid passage. The fluid passage communicates with a fluid reservoir having an opening bounded by smooth surfaces for contacting the substrate. The supply of ink is metered to the passage. The substrate is moved in contact with the smooth surfaces and the fluid is applied thereto by the reservoir. The trailing or downstream edge of the smooth surface is formed with an acute angle. Other features are also disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to heddles for use in weaving and more particularly to split heddles for use in connection with automated seaming of flat woven fabrics. In particular, the present invention finds use in automatic seaming equipment which utilizes a Jacquard Machine in the shed formation process.
2. Description of the Prior Art
For some time, the art has recognized the advantages to be gained from split heddles. One prior art split heddle used for automatic seaming is comprised of two stainless steel strips which are secured about a stainless steel spacing washer. The two stainless steel strips and the spacing washer are bonded together in a sandwich like arrangement. The assembly of this prior art heddle requires that great care be taken in the positioning and bonding of the individual pieces. Misalignment of the various pieces cannot be tolerated. In addition to problems with misalignment, the prior art device is not tolerant of any curvature in the metal strips. Curvature in the metal strips caused an opening in the washer area and this opening frequently resulted in a failure to retain the strand within the heddle. Although the prior art device was frequently used, the above factors contributed to a high cost of construction, a high rate of rejection during manufacturing of the heddles and high maintenance during weaving.
It is the purpose of the present invention to provide a heddle which eliminates the need for a spacing washer, improves the tolerance of the heddle for curvature in the metal strips and reduces maintenance.
SUMMARY OF THE INVENTION
The heddle is comprised to two superimposed blades. Each blade has an aperture in communication with a slot and an arcuate groove or channel. The blades are superimposed and bonded with the grooves facing in opposite directions and extending through the slot in the opposing blade. The apertures and the opposed grooves define a yarn passage or channel in the heddle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the heddle in accordance with the present invention.
FIG. 2 is a front elevation of a first heddle strip in accordance with the heddle of the present invention.
FIG. 3 is a fragmentary side elevation of the heddle strip of FIG. 2.
FIG. 4 is a front elevation of a second heddle strip in accordance with the heddle of the present invention.
FIG. 5 is a side elevation of the heddle strip of FIG. 4.
FIG. 6 is a front elevation of the heddle strip of FIG. 1 rotated 180° and assembled with heddle leads.
FIGS. 7 , 8 and 9 illustrate the use and rotation of the present heddle as shown in FIG. 6. FIG. 7 represents the zero position; FIG. 8 represents 90° of rotation; and FIG. 9 represents 180° of rotation.
FIG. 10 is a fragmentary section illustrating the position of a yarn as it is placed in the heddle.
FIG. 11 illustrates the capture of the yarn in the heddle channel after a 180° rotation from the position depicted in FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment will be described with reference to the drawings and like elements are identified by the same numeral throughout.
With reference to FIG. 1, the split heddle 20 of the present invention is comprised of two blade or strip members 30 and 40 which are bonded together at their respective ends 31 and 41. The blades 30 and 40 may be of the same or different length. In the preferred embodiment, blade 30 is slightly longer than blade 40. In the preferred embodiment, the blade 30 has an overall length, from end to end, of approximately 5.5 inches and the blade 40 has an overall end to end length of approximately 5.375 inches.
As noted previously with respect to FIG. 1, the heddle 20 is comprised of individual elongate blade members or strips, 30 and 40, which have been superimposed, aligned and bonded. Each blade has an aperture, 32 or 42, through its first end, 31 or 41. While it is preferable that the apertures 32 and 42 be in direct alignment, this is not critical to the invention. The respective heddle members 30 and 40 need only be in sufficient alignment to permit the oppositely facing arcuate grooves or channel portions 35 and 45 to be in sufficient alignment for a channel to be formed across the heddle. The reason for this alignment will become more evident upon reading the description hereinafter.
The preferred material for blades 30 and 40 is stainless steel. The preferred method of bonding is laser welding, however, spot-welding and sonic welding are alternative bonding methods.
In order to more fully understand the invention, each blade 30 and 40, will be desCribed individually. For this purpose, reference will be made to FIGS. 2 through 5.
Referring first to FIG. 2, strip 30 has a first end 31 having two apertures 32 and 34 which are generally on the longitudinal centerline. Aperture 32 has a diameter of approximately 0.065 inches. Aperture 34 has a diameter of approximately 0.128 inches. The aperture 34 is intersected on one side by a horizontal slot 33 which extends through to the edge of the blade member 30. Slot 33 has a width of approximately 0.078 inches. The aperture 34 is also in communication with the arcuate groove or channel portion 35. The groove 35 is on the centerline with the slot 33 and the aperture 34. This may be seen clearly with reference to FIG. 2. Groove 35 is concave with respect to the plane of the blade 30 as shown in FIG. 2; this is evident from FIG. 3. Groove 35 has a radius of approximately 0.009 inches. The blade, 30 has an overall average thickness of approximately 0.018 inches with the thickness at the groove 35, as illustrated by the numeral 38 in FIG. 3, being approximately 0.54 inches.
The blade 40 will be described with reference to FIGS. 4 and 5. The first end 41 of blade 40 is essentially a mirror image of end 31 of blade 30. All of the elements of end 41 correspond with the like element of end 31. However, it should be noted with respect to the groove 45, that it will be convex with respect to the plane of the blade 40. This may be clearly seen with reference to FIG. 1. Blade 30 differs from blade 30 as described hereinafter. As stated previously, the overall length of blade 40 is approximately 0.125 inches less than than that of blade 30. This may be seen with reference to FIG. 6. The aperture 47 in end 46 of blade 40 will be positioned opposite the aperture 37. Aperture 47 is intersected by horizontal slot 48 which extends through the end 46. Slot 48 is approximately 0.040 inches wide. The differential length is believed to make it easier to separate and move the blades during yarn insertion.
With reference to FIG. 1, it can be seen that the grooves 35 and 45 are facing in opposite directions and they cooperate to effectively close the apertures 34 and 44, FIGS. 3 and 4 and define a horizontal channel 68 across the heddle 20, FIGS. 10 and 11. Groove 35 fits through slot 43 and groove 45 fits through slot 33. As a result of their convex-concave configurations the grooves 35 and 45 each form one half of the horizontal channel 68 across the heddle. Channel 68 has a diameter of approximately 0.033 inches but may be dimensioned to accommodate the yarns that are to be controlled.
With reference to FIG. 6, the heddle 20 is assembled with lead lines 22 and 24. The two blade members 30 and 40 are assembled together, such as by sonic or spot welding at the respective ends 31 and 41. The lead line 22 passes through apertures 32 and 42. The lead line 24 passes through apertures 37 and 47. As known by those skilled in the art, the lead lines 22 and 24 provide a means of controlling the heddle during weaving. Other control means may be used. Due to the existence of slot 48 in the end 46, blade 40 may be separated from blade 30 and moved to the side, as indicated by arrow 60, by passing lead 24 through the slot 48. This movement of blade 40 provides a separation between the blades 30 and 40 so that a yarn may be passed between the blades and into the apertures 34 and 44. This positioning of a yarn 70 in the apertures 34 and 44 is shown in FIG. 7. At this point in time, the yarn 70 extends over groove 35 which is convex with respect to the frontal plane of the figure and behind groove 45 which is concave with respect to the frontal plane of the figure. After a rotation of approximately 90°, the yarn 70 will be within the apertures 34 and 44, see FIG. 8. By continuing the rotation through 180°, the yarn 70 will be positioned so that it now extends in a straight line and rests within the cross channel 68 formed by the opposed grooves 35 and 45, see FIG. 9. At this point in time, the yarn 70 is captured by the heddle and will be retained in that position regardless of slight variations or curvatures in members 30 and 40 and/or slight variations with respect to precise alignment of the ends 31 and 41 and/or the arcuate portions 35 and 45.
FIG. 10 illustrates the position of yarn 70 relative to channel 68 prior to rotation and FIG. 11 illustrates the position of yarn 70 in the channel 68 after rotation through 180°.
If desired, the second blade may be shorter and the aperture 47 and the slot 48 may be eliminated. Since there is virtually no space between the blade members 30 and 40, they will be in very close contact. Since the channel 68 is closed, a yarn will not slip between the blades 30 and 40, even if the lead line 24 does not pass through the aperture 47.
As can be seen from the foregoing, a simplified heddle construction with improved yarn control reliability has been disclosed.
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A split heddle for controlling a yarn is particularly useful in automated seaming machines. The heddle is comprised of two blade like members. Each member has an aperture which is intersected on one side by a slot and on the other side by a groove. The members are superimposed with the apertures in alignment and the grooves opposite the slots. The unit is secured by laser, spot or sonic welding. After insertion of the yarn(s) in the aperture, the heddle is rotated 180° with respect to the yarn(s) and the yarn(s) is/are captured in the channel formed by the opposed grooves.
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TECHNICAL FIELD
[0001] This invention relates to CMOS bus pulsing.
BACKGROUND
[0002] CMOS logic buses are generally configured as static or dynamic buses. Static buses consume less power than dynamic buses, because a static CMOS bus consumes power only when data signals are switched and transmitted. The coupling capacitance between CMOS bus lines limits the transmission speed of a static CMOS bus. For example, when one CMOS bus line is switched in the opposite direction from two adjacent bus lines, the coupling capacitance from the first line to each adjacent line is twice as large as the inter-line capacitance, i.e., a coupling factor of two.
[0003] Dynamic CMOS buses generally operate at higher speed but consume more power than static CMOS buses. A dynamic CMOS bus operates by pre-charging a bus line to a voltage level and then conditionally discharging the line based on the data input level. Because the dynamic bus lines are always evaluated in the same direction (either high-to-low or low-to-high), the worst coupling capacitance, and therefore the worst delay, occurs when one line switches and the two adjacent lines remain at the pre-charge level. The resulting worst case coupling capacitance of a dynamic CMOS bus line to each adjacent line is equal to the inter-line capacitance, i.e., a coupling factor of one. This lower coupling capacitance allows a dynamic bus to operate faster than a static bus. However, the power consumption of a dynamic CMOS bus is higher than the static CMOS bus due to the power dissipated during the pre-charging and conditional discharging of the dynamic bus lines.
DESCRIPTION OF DRAWINGS
[0004] [0004]FIG. 1 is a schematic representation of a static CMOS logic bus line;
[0005] [0005]FIG. 2 is a schematic representation of an embodiment of the invention;
[0006] [0006]FIG. 3 is a schematic representation of a pulse generator circuit;
[0007] [0007]FIG. 4 is a timing diagram for the pulse generator circuit of FIG. 3.
[0008] [0008]FIG. 5 is a timing diagram for the embodiment of FIG. 2.
DETAILED DESCRIPTION
[0009] Referring to FIG. 1, a static CMOS logic bus line 100 includes a CLK signal 106 , a data signal D 150 , a flip-flop 130 , a data signal output D 160 , a series of repeaters 110 A- 110 N, and a receiving flip-flop 140 . The CMOS logic bus 100 also includes a series of resistor-capacitor (RC) loads 120 A- 120 C, which represent the load imposed by the interconnections between adjacent repeaters 110 A- 110 N.
[0010] Repeaters 110 A- 110 N are included in CMOS logic bus line 100 in order to regenerate the data signal D 160 as it is transmitted through the RC loads 120 A- 120 C. The number of repeaters 110 A- 110 N included in CMOS logic bus line 100 is determined by the overall length of the bus and the resulting total RC load. In operation, data signal D 150 (which may be at a high or low voltage) is delivered as D 160 from flip-flop 130 when CLK 106 goes high, causing the D 160 signal to be transmitted through repeaters 110 A- 110 N, and to the input 142 of receiving flip-flop 140 (also enabled by CLK 106 ). The period of CLK 106 is set so that D 160 has sufficient time to propagate through repeaters 110 A- 110 N and to the input 142 of receiving flip-flop 140 , at which time the next rising edge of CLK 106 causes the D 160 signal to be latched by flip-flop 140 .
[0011] Referring to FIG. 2, in an embodiment according to the invention, a pulse skewed CMOS logic (PSCL) bus line 200 is shown. PSCL bus line 200 differs from the static CMOS bus line 100 by the inclusion of pulse generator 202 and decoder 204 . The data to be sent on the bus line is received by the pulse generator and converted to pulses that are decoded at the other end of the line in decoder 204 . The PSCL bus line 100 operates by generating a pulse, F 170 , for each incoming edge of data, D 160 .
[0012] All of the pulses, F 170 , are generated in the same direction (either positive or negative) and transmitted through the bus line to decoder 204 . Because all pulses, F 170 , are generated in the same direction, the worst coupling factor between PSCL bus lines is one, which reduces the total line capacitance which must be driven by repeaters 110 A- 110 N and allows the PSCL bus line to operate much faster than the static bus line 100 . Furthermore, the PSCL pulses, F 170 , are generated only when the data signal D 160 makes a transition. Therefore, power is dissipated in the PSCL bus line 200 only when pulses are being transmitted.
[0013] Referring to FIGS. 3 and 4 an exemplary pulse generator circuit 202 receives data signal D 160 , delivers output signal F 170 , and includes transmission gates X 1 and X 2 , and delay block 310 . Transmission gates X 1 and X 2 , inverter 320 , inputs 322 and output 324 are configured to produce an XOR negative-going pulse for each edge of D 160 . For example, pulses 404 and 408 are generated in response to the rising and falling edges 402 and 406 , respectively, of data signal D 160 , as shown in FIG. 4. The width of each pulse generated by pulse generator 202 is controlled by the number of inverters included in delay block 310 .
[0014] Circuit 202 is just one example of a pulse generator circuit, any circuit which produces a pulse for each edge of data signal D 160 could be used. Alternatively, a positive-going pulse generator circuit could be used.
[0015] Referring to FIGS. 2 and 5, PSCL bus line 200 includes a decoder 204 to detect the transmission of pulse F 170 through PSCL bus line 200 . Decoder 204 is configured as a ‘toggle’ flip-flip, in which the output 212 is connected to the input 207 through inverter 206 , such that each pulse F 170 will cause output 212 and input 207 to change voltage level.
[0016] In operation, when CMOS PSCL bus line 200 is powered on, RESET 210 is input to decoder 204 , resetting flip-flop 208 to a known state, in this case resetting output 212 to ‘0’, and inverting input 207 to ‘1’. At the beginning of cycle 1 , signal D 150 has just completed a ‘0’-to-‘1’ transition, CLK 106 goes to ‘1’ at t=0, which causes D 160 to be output from latch 130 and input to pulse generator 202 . Rising edge 402 of D 160 causes pulse generator 202 to produce a pulse 404 at output F 170 which is transmitted through repeaters 110 A- 110 N.
[0017] At the receiving end, transmitted pulse 404 is then delivered to the ‘CK’ input of flip-flop 208 , which causes the ‘1’ at input 207 to be latched through to output 212 and delivered to receiving flip-flop 140 . Pulse 404 also toggles the flip-flop 208 input 207 to a ‘0’. The next rising edge of CLK 106 , at t=1, latches through the ‘1’ at input 212 of receiving flip-flop 140 to the output of flip-flop 140 . The timing in cycle 2 , when D 150 has just completed a 1-to-0 transition, is similar to the timing of cycle 1 , except that the rising edge of CLK 106 at t=2 latches a ‘0’ at the output of receiving flip-flop 140 .
[0018] Thus, the successive pulses F 170 indicate the start and end of the data signal, and the decoder decodes the successive pulses to recover the data signal.
[0019] Decoder 204 circuit, as shown in FIG. 2, is one example of a decoder circuit. Other decoder circuits which can detect pulses could be used. In particular, a PSCL bus which uses positive-going pulses would require a decoder to be reset to ‘1’ at power on, and detect positive-going pulses being transmitted.
[0020] Another advantage of the PSCL bus is that the repeaters can be “skewed” in favor of the “evaluate” transition. This means that the repeaters can be made to have a shorter delay time for a falling edge than for a rising edge, or vice-versa. This cannot be done with a standard CMOS bus because both the rising and the falling edges are transmitted by the repeaters, and so each one is equally important. However for the PSCL bus (as well as for dynamic busses), the bus lines are always evaluated in the same direction, which means the repeaters can be skewed. By skewing the repeaters, the PSCL bus can be made faster.
[0021] Other embodiments are within the scope of the following claims.
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A method and apparatus for transmitting data through a CMOS bus line includes a pulse generator to generate a pulse representing a data signal, and a decoder for receiving the pulse and an output port for delivering the detected signal to a receiving device.
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RELATED APPLICATIONS
[0001] This non-provisional application claims the benefit of U.S. Provisional Patent Application No. 61/072,262 filed on Mar. 31, 2008 and the non-provisional patent application Ser. No. 12/217,415 filed on Jul. 3, 2008.
FIELD OF THE INVENTION
[0002] This invention relates to the patient care monitoring system, associated method and its constituent devices which will provide monitoring, proactive prompts for treatment, recording and reporting of all prescribed actions as well as general care actions, mistakes and corrective measures administered for each patient. The patient care monitoring system matches the identification of the patient to their corresponding prescribed daily treatments, procedures, medications and general care. The system also matches the time frame specified for each of these care actions with the corresponding patient. When a mismatch is detected, the system will sound an alarm, and/or activate a warning display, and prompt any healthcare worker within its radio frequency transmission range to correct the mistake. The system will also sound an alarm or activate a warning display when the prescribed action is not acted upon or corrected within its specified time frame.
[0003] The system will further record and report prescribed treatment, procedure and medication given to a patient throughout the day along with the time of the care action. The system identifies, records and reports which healthcare worker was administering the care action as well as any mistakes and subsequent corrective actions.
BACKGROUND OF THE INVENTION
[0004] To err is human. However, medical errors, according to many research studies, have caused on average some 195,000 deaths in the U.S. annually. These deaths are preventable. The most common type of preventable medical errors are: incorrect administering of drugs (wrong prescription, wrong dosage, given to wrong patient and at wrong time), hospital acquired infections (unclean or improperly cleaned hands of healthcare staff, improperly sterilized equipment), postoperative bloodstream infection (un-sterilized and/or improper handling of sterile equipment, unclean hands), ventilator-associated pneumonia (again, un-sterilized and/or improper handling of sterile equipment, unclean hands) and negligence in basic cares (bed sores, falls, dehydration, malnutrition, etc.). The estimated cost for these medical errors is between $8.5 to $14.5 billion dollars annually. In the current climate of ever escalating healthcare costs, to prevent and reduce medical errors have become an absolute necessity. There is also a moral responsibility to provide quality healthcare to patients.
[0005] Medicare patients (65 years and older) account for 45% of all hospital admissions (excluding obstetric patient) in the U.S. This population suffers much more severe consequences from medical errors due to declining health, decreased immunological resistance and decreased recuperative ability. Consequently, out of the average 195,000 preventable deaths due to medical errors annually, a disproportional number of patients are elderly.
[0006] The latest statistics on U.S. nursing homes stated that there are 1.6 million patients occupying 1.9 million available beds, and the average stay of patients being discharged is over 290 days. For those not being discharged the average stay of patients is over 800 days. This is a clear indication that most patients in nursing homes as well as increasingly in the hospitals are aged and invalid patients (needless to add, many have difficulty in communicating their needs to healthcare staff).
[0007] These aged and invalid patients require additional care such as feeding, changing of bed pans, washing, turning them on their sides periodically, or simply communicating with them. Although each hospital and nursing home has stringent guidelines in how to take care of this type of patient properly, the workload pressure and shortage of nursing staff frequently result in lengthy improper care and further deterioration of the patient's health status. The lack of proper care thus costs the entire healthcare system (patients, their families, taxpayers, insurance companies) much more money, suffering and, in the worst case, unnecessary deaths.
[0008] It is not unusual for a person to observe the foul odor in a hospital wing or nursing home housing mostly aged and invalid patients. Numerous complaints have come from families that the patients frequently have severe skin rashes, lesions and bed sores to the degree of rotting flesh. All these are clear signs that proper patient care are not provided by these healthcare facilities.
[0009] On the other hand, by visiting any hospital or nursing home admission office, one will be bombarded with how well they have cared for their patients as well as shown the reams of patient care guidelines that they adhere to and the records of their adherence. However, there is no unbiased monitoring system that can provide data on: how often each patient is cared for, the percentage of properly carrying out treatment, procedures and medications prescribed by physicians on time and on specification other than what is recorded by nurses or their aids.
[0010] Several U.S. Congressional hearings and subsequent laws and regulations had resulted in the establishment of Federal Minimum Standards for nursing care facilities. Furthermore, each state also sets forth their minimum standards. However, the lack of effective monitoring methods and systems in providing realistic patient care monitoring data is a huge handicap in enforcing the laws and regulations particularly on those facilities supported principally by the Medicare and Medicaid programs.
[0011] Besides medical errors and negligence in providing necessary care actions, another aspect is fraudulent billing, i.e. charges without actually delivery of medical care actions, by not only healthcare facilities, but also increasingly by home care providers. Since the federal government medical insurance (Medicare) and the states' assistances are the biggest payers, they suffer the most financial loss.
[0012] Here we put forward an invention consisting of a method, monitoring devices and a system that does not disrupt the existing work routine of a healthcare facility and does not add any additional work step to the care giver. This system also ensures proper patient care is registered and reported on a daily or periodic basis. This data certainly can be forwarded to the regulatory agencies as well as family members of the patients to ensure proper care is continuously provided to those unfortunately sick, aged and/or invalid on a daily or periodic basis instead of just the period prior to or after an inspection by regulatory agencies. Furthermore, by logging these care actions, it provides a mean to track the accuracy of billing by insurance payers and thus reducing fraud.
[0013] There are numerous prior arts as cited in the Reference Section detailing various patient care monitoring systems and methods. All of them require special adaptations in order to achieve some measure of monitoring patient care. Therefore, not only new procedures must be adopted by a healthcare facility, but also added work steps. For example, added work steps such as: scanning the patient identification band, scanning every treatment/medication identification tag, waiting for remote processors to give an O.K. before proceeding in carrying out the care action, will greatly disrupt the work flow and reduce efficiency. Many of the basic care actions, such as changing a bed pan, bathing, altering a patient's laying position, special diet, etc., are not necessarily codified in most healthcare facilities, other than written in the patient's chart. Therefore, the actions are not monitored or tracked and are ignored in all the prior arts. Furthermore, many of the care actions, prescribed and general, have a timing element associated, such as medications, physiological measurements, altering a patient's laying position. Consequently, the patient care monitoring system must be able not only to record the timing of a care action being executed, but also proactively prompt the care giver to provide the care action within a specified time frame. Again, this aspect has been missing in the prior arts.
[0014] During a standard patient admission process into a healthcare facility, he/she is assigned an identification wrist band (such as a simple printed label with information like name, age, gender to assignment to a specific department/hospital wing and a specific patient room), which will stay with the patient for his/her entire stay in the facility along with a patient chart as well as entry of informational data into the central computer of the facility. During the patient's stay in the facility, a physician or attending care giver will typically examine the patient periodically (daily in hospital) and prescribe specific care actions to the said patient. The daily prescribed care action corresponding to a specific patient is entered into the patient chart as well as into the central computer of the care facility. Furthermore, standard general care actions, such as changing the patient's laying position and bed pans periodically for invalid or aging patients, bathing patients and diet precautions, etc., are also included (automatically or manually by the care giver) into the care instruction set for each patient.
[0015] To identify each patient and the treatments, procedures, medications and care actions prescribed to each patient, many prior arts suggested various approaches other than simple printed label, such as adding bar code, magnetic strip, Infrared (IR) pattern or radio frequency identification device (RFID) to the identification wrist band and to the label attaching to each care action delivery agent, administering devices or paper work as a mean in matching the patient with the care action-prescribed to him/her. U.S. Pat. Nos. 4,857,713 (Brown) and 4,857,716 (Gombrich, et al.) use printed bar code method for patient and care action identifications. Proper patient care monitoring is accomplished by scanning the bar codes of the patient and care action label as well as having a linked processor to conduct the matching. U.S. Pat. Nos. 6,824,052, 6,830,180 and 6,910,626 (Walsh) expanded the identification method to not only printed bar code, but also magnetic strip and/or Infrared (IR) pattern. As mentioned before, these methods and systems create added work steps for typical healthcare facilities as well as new equipment, linkage and installation. Also, the chaos/confusion will occur from the inaccuracy of scanning a bar code, swiping magnetic cards through a reader or line-of-sight requirements to do IR pattern recognition (error rate between 5 to 10%). U.S. Pat. Nos. 5,071,168 and 5,381,487 (Shamos) employ personal characteristics (such as fingerprint, eyeprint, and footprint) as patient identification code. Treatment/care action will only be given based on matched patient identification code. This is an even more tedious and time consuming method of patient identification. Many inaccuracies will result from the arbitrary selection of matching confidence level.
[0016] The RFID approach requires less effort of a care giver to read the identification code of a patient or a treatment/care action label/tag, since it only demands proximity to the reader and without the stringent line-of-sight demanded by optical scanner (bar code and IR methods) or moving the identification band/tag through a contact magnetic strip reader. However, a passive RFID as presented in the U.S. Pat. Nos. 6,671,563 and 6,915,170 (Engleson, et al.) still requires a reader to be placed close to the patient's identification band and to the treatment/care action tag in order to obtain the identification codes. This approach is more suitable for identification of objects rather than persons. The added work steps (placing the reader close to the identification band/label/tag and check whether a reading is made) to accomplish this data acquisition will disrupt the heavy work load of healthcare workers and result in frequent-non-usage.
[0017] Other prior arts, such as U.S. Pat. No. 7,384,410 (Eggers, et al.), use RFID method to identify patients and care delivery devices to achieve error avoidance. However, this approach will not monitor many of the care actions that require no administering devices.
[0018] The system and method stipulated in the U.S. Pat. Nos. 5,883,576, 6,255,951 and 6,346,886 (De La Huerga) as well as U.S. Pat. Nos. 6,961,000, 7,158,030 and 7,382,255 (Chung) employs the approach of reading and sending the identification codes from the patient and the treatment/care action device along with a relational check code (in Chung's patents) to a separate and independent processor for matching to determine the action to be executed corresponds to the patient. A display and alarm will then inform the care giver whether a mismatch exists. This multiple-element system not only produces added work steps (scanning/reading of the identification devices and waiting for direction from the processor), thus discouraging usage by care givers and adoption by healthcare facilities, but will also not monitor those required care actions, such as bathing invalid patients, changing wet clothes, changing bed pan, rotating patient laying/sitting posture, etc., that do not carry identification labels/tags.
[0019] The invention presented here will employ active RFID technique (contains a power source to transmit and receive RF signals for transmitting its stored codes and for receiving external data) in the patient and treatment/care action identification. This approach will provide direct and immediate verification between the patient identification band and the treatment/care action ID tag. The healthcare worker does not take any extra step to facilitate the reading of the RFID tags, thus ensuring the usage of this invention. Active RFID also achieves the determination of a match or mismatch prior to administering care action at the point-of-care. The patient ID band will also (through communication with other sensors) determine whether other general care actions without ID tags have been executed within the prescribed time frame. Furthermore, it will interact with the care giver's identification tag/band to proactively prompt him/her to provide the required care actions as well as record all the care actions given with respect to time and correctness along with the identities of the care givers administered all the care actions.
SUMMARY OF THE INVENTION
[0020] Conforming to the standard practice of a hospital or nursing home, this invention presents a patient care monitoring system and method that employs active RFID integrated with a digital processor as a device (ID band or ID tag) to transmit the programmed identification codes for each patient, care giver and for each treatment, procedure, medication and care action. By having each identification device capable of receiving and deciphering only the signals containing its own unique identification code, the patient identification wrist band will thus determine whether the treatment/procedure/medication/care action label/tag presented to him/her at the point-of-care matches the one prescribed by his/her physician. Equally, the treatment/care action label/tag will match the received patient ID code to its assigned patient code to determine whether it is the correct patient. If there is a mismatch, then a visual or audio alarm integrated into the identification devices will be displayed and/or sounded to alert the care giver of the error. Since the standard routine in a healthcare facility is for an attending physician to examine his/her patient in the morning and entering prescribed care action for the day into the patient's chart and the facility's computer system (typically at the terminals in a nurse station), the present invention will translate the prescriptions into corresponding treatment/procedure/medication/care action codes within its central processor and transmit the daily care actions and schedule via wireless communication through a RF transceiving device within each patient's room to each corresponding patient's identification band. At the same time, the central processor will send the prescribed treatments, procedures, medications and care actions to appropriate departments of the facility to program an active RFID identification tag with the unique code corresponding to the treatment, procedure, medication or care action along with the targeted patient identification code. These ID tags will then be attached to the care delivery device and/or paper work to be presented to the patient at the point-of-care. Each patient ID band and the care action ID tag will interact with each other and cross check with each other to ensure they correspond to each other before the care action is administered. At the time of administering, both the patient ID band and the care action ID tag will record the event and time as well as the ID code of the care giver. The patient ID band can also receive input from other measuring sensors, such as posture position, wetness, body temperature, pulse/heart rate to determine whether an alert to the care giver should be generated. Also, if a prescribed or general care action at a specific time frame was not administered, then, the patient ID band will transmit an alert signal continuously to prompt any care giver to provide the care action as soon as possible. All the care actions administered or non-conformance to the prescription or general care guidelines will be recorded by the patient ID band and transfer through the same RF transceiver device to the central processor to report and alert the quality control personnel of the facility. At the same time, all the treatment/care action ID labels/tags will be returned to the corresponding departments after their usage to download the recorded data and transfer to the central processor. After downloading, the memory of each ID tag can be cleared and reprogrammed for reuse.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 illustrates a wrist band configuration of a patient's identification device where [ 1 ] indicates the housing for battery pack, [ 2 ] is where the RF transceiver and digital processing, memory and timing circuitry is housed, which links to [ 3 ] the capsule for an antenna. FIG. 2 shows a version where it can be the identification device worn by the healthcare giver with [ 7 ] housing the battery pack, [ 9 ] being a combination of a watch module and the RF transceiver/processing/memory/timing circuitry, and [ 10 ] being the capsule for an antenna and visual display.
[0022] FIG. 3 demonstrates a treatment/procedure/medication/care action tag, which is attached to a medicine delivery vessel [ 13 ]. In this drawing, [ 11 ] is an encapsulation of a RF transceiver, digital processing, memory and timing circuitry along with battery pack and an antenna. This waterproof capsule is covered with a printed label stating what the care action is and the patient's name, room number along with other relevant information. The entire capsule is adhered to a disposable tape [ 12 ] which in term adheres to a care action administering device [ 13 ] (such as a medication dispensing vessel in this drawing), or to the treatment/procedure/care action paper work carried by the care giver to the point-of care. The green [ 15 ] and red [ 16 ] LED indicators on each care action tag will flash when there is a match or mismatch between the prescribed care action and the patient's identity.
[0023] FIG. 4 shows a programmer machine for programming a prescribed treatment/procedure/medication/care action identification tag. This device is linked to the central processor of the healthcare facility to download the prescribed care action into a care action identification tag. Care action in code will be programmed into the inserted tag along with the targeted patient identification code. The programmed data will also be shown on the display screen [ 17 ], and an integral printer [ 19 ] will print out the coded care action, patient name, identification characteristics and room number on a visually readable label [ 20 ] that will automatically be attached to the care action identification tag. Manual programming can be done through key pads [ 18 , 21 and 22 ].
[0024] FIG. 5 illustrates how an attending physician per hospital work routine will enter his/her prescribed treatments, procedures, medications and/or care actions as well as timing for a specific patient after a round of examination into the central processor of the healthcare facility. The prescription will then be translated into corresponding care action codes and forwarded to responsible departments to program the care action identification tags and for administering.
[0025] At the same time, the physicians' prescriptions will also be sent via a RF transceiving device in a patient room [ 27 ] to the patient identification band [ 23 ] as shown in FIG. 6 . FIG. 7 demonstrates that the patient's identification band will interact with each care action identification tag [ 26 ] being administered to assure it matches the prescription and timing. The patient identification band [ 23 ] will record all the care actions administered throughout the day, their correctness and timing. The record will be transferred from the patient band [ 23 ] to the central processor again through the [ 27 ] RF transceiving device on daily basis for the central processor to produce a patient care monitoring report as indicated in FIG. 7 .
[0026] FIG. 8 presents one type of sensor network that enables the invention to provide proactive prompts to care givers for prescribed care action or general required care action. In this illustration a thin and flexible pad [ 27 ] consists of a network of pressure transducers [ 29 ], which will be placed underneath the patient's bed sheet. The signals from various pressure transducers will indicate the body movement (or lack of) of a patient as a function of time. For an invalid patient, this pad will signal the patient identification band to prompt any care giver walking into the patient room to alter the patient's body position when required to prevent and eliminate bed sores. Equally, a wetness sensor added to the pad can prompt the care giver to change the bed pan, clothing and bed sheets for the patient.
[0027] FIG. 9 a provides a block diagram and interaction between the various components of the invention, whereas the prescribed care actions are entered into the central computer of a healthcare facility and transmitted through its intranet to the in-patient-room RF Transceiving Device. This relays to the corresponding patient's ID band and to the Care Action ID Tag Programming Device for programming into a Care Action ID along with the targeted patient ID code. FIG. 9 b illustrates the wireless interaction between the patient ID band and a care action ID tag to assure correctness prior to the administering of the care action. FIG. 9 c demonstrates that the patient ID band will proactively prompt the care giver's ID band to furnish needed care action per its sensor network inputs or query from its own stored prescribed care action program.
[0028] FIG. 10 presents a possible daily patient care quality monitoring report generated by this patient care monitoring system and method.
DETAILED DESCRIPTION OF THE INVENTION
[0029] This invention presents a practical and accurate system to monitor patient care to avoid most common medical errors in a healthcare facility while it adheres to the standard healthcare work procedures and routines in administering patient care. The transparency in conducting the monitoring without requiring care givers to perform additional work steps or disrupting the trust between patients and care givers ensures this invention to be adopted and accepted by healthcare facilities. It also differentiates itself from any prior arts.
[0030] The hardware and software detailed in claim 1 consists of the following hardware components along with imbedded operating software to enable each to function as described below:
1. The patient identification device as illustrated in FIG. 1 is in the most commonly employed configuration of a wrist band. This waterproof wrist band contains a battery pack [ 1 ] which can be charged via electrical contacts [ 4 ] or electromagnetically without electrical contacts, a central plastic housing [ 2 ] for the RF transceiving, digital processing, memory and timing circuitry and a separate plastic capsule [ 3 ] for an antenna. With the current integrated circuitries and micro-electronics, all three components can be integrated into a single small housing of 0.5 in (Width)×1.0 in (Length)×0.25 in (Height) or even smaller in size. At the admission of a patient, the admission personnel will enter the relevant patient information, such as name, gender, age, ethnicity, possible illness, physician name(s), hospital room assigned, etc. into the central processor (computer) of the healthcare facility along with generating a unique identification code for the patient. This code will stay with this patient until his/her discharge. The central processor will in turn program a wrist band (as illustrated in FIG. 4 —note: the patient identification wrist band and the prescription care action identification tag programming can be done on a same device linking to the central processor) with this assigned patient code and print the patient information on a label to insert into the transparent pocket on top of the wrist band. The admission personnel will then fasten the identification wrist band on the patient's wrist (or ankle) which will be secured for the duration of the patient's stay. The patient ID band will be continuously in receiving mode to receive RF signals. Upon receiving a RF signal tuned to its receiving frequency, such as 2.3 GHz, it will examine the signal string for its own unique identification code. If the code does not exist in the signal string, then it will ignore the signal. If the code does exist, then it will match its stored care action program codes with the care action code in the signal. If it matches, then it will broadcast an “O.K” signal along with its identification code and flash its green LED indicator [ 5 ] in FIG. 1 for a period of time. If there is no match in the care action code between its stored program and that from the received signal, then it will transmit a “Mistake” signal along with its identification code and flash its red LED indicator [ 6 ] for a period of time. The patient ID band will also transmit a specific prompt signal along with its ID code to alert care giver to correct any mistake or administer the prescribed care action before the specified time period expires. All the signals transmitted by the patient ID band will be in low power range (a few milliwatts) to achieve a short distance (3-10 ft) receiving by other identification devices within a patient room. The patient ID band will record all these interactions and time and date and transmit the record to the central processor of the healthcare facility on daily basis. 2. The care giver identification device as illustrated in FIG. 2 is in a configuration of a fashionable wrist watch. This waterproof wrist watch contains a battery pack [ 7 ], which can be charged via the contacts [ 8 ] or electromagnetically without electrical contacts, a central housing [ 9 ] for the RF transceiving, digital processing, memory and timing circuitry along with the watch mechanism and a separate plastic capsule [ 10 ] for antenna and a display module. This care giver identification wrist watch will contain a unique code assigned to each individual worker during his/her employment in the facility. This care giver ID device will transmit its identification code continuously in burst mode (such as once every second or every other second) and, in between the transmissions, it will receive any RF prompt signals from the patient ID bands and activate its display [ 10 ] to show the nature of the prompt on care action not executed or mistake on care action to be administered as well as starting its built-in vibration device to alert the care giver. 3. Identification device in the configuration of a label or tag for prescribed treatment, procedure, medication and any special care action, as shown [ 11 ] in FIG. 3 , is virtually identical to the patient identification device in terms of RF transceiving, digital processing, memory and timing circuitry except all of them along with battery pack and antenna are contained in a single sealed plastic housing of 0.5 in (Width)×1.0 in (Length)×0.25 in (Height) or even smaller in size. This type of tag will each be programmed by the programming device, shown in FIG. 4 , with the code of a particular prescribed treatment, procedure, medication or care action along with the identification code of the targeted patient. This care action tag will continuously transmit, in burst mode, a signal containing its programmed care action code and the corresponding patient ID code at a cycle of once every second or some other frequency rate. The transmission will be at a specific frequency, such as 2.3 GHz, and at a low power, typically in a few milliwatts range, to affect a short distance signal transmission (3 to 10 ft range). In between transmission, the care action tag will be in receiving mode to receive signals from the patient ID band. It will ignore any signal that does not have the correct patient ID code that it carries in corresponding to the care action code. If an “O.K.” signal is received with correct patient code, then it will flash its green LED indicator [ 15 ] to signal match has been verified. When a “Mistake” signal is received with correct patient code, then it will flash its red LED indicator [ 16 ] and/or audio warning tone to signal error. 4. A central processor can be the central computer of a healthcare facility or it can be a separate personal computer (PC), a server or a combination of multiple PC and servers, which is linked with the central computer of a healthcare facility via intranet such as a wired or wireless large area network (LAN) or wide area network (WAN). This central processor will take the prescriptions issued by attending physicians (typically each morning after their rounds of examination of patients as illustrated by FIG. 5 ) and convert them into alpha-numerical codes corresponding to the specific treatments, procedures, medications (type and dosage) and special care actions along with the identification codes of the targeted patients as well as time frame to be administered. These coded data along with prescriptions entered by the physicians will be transmitted via intranet to each responsible department and/or nursing station to program and prepare the care action tags as well as administering schedule as illustrated in FIG. 9 a. This central processor will also transmit these coded prescribed care actions and time schedule to the corresponding patient's ID band via RF transceiving device, [ 27 ] of FIG. 6 , located in each patient room as shown in interaction block diagram of FIG. 9 a. The same transceiving device [ 27 ] will also relay the daily care administering log recorded by a patient ID band back to the central processor for report presentation and data archiving. 5. A RF transceiving device, [ 27 ] of FIG. 6 , which is linked to the central processor through intranet (e.g. an Ethernet connection) and contains a RF transceiving and digital processing circuitry along with antenna to convert the data strings received from the central processor and to transmit them via RF to the patient ID bands located within the room that this device [ 27 ] is located. It will also receive the daily care administering log from the patient ID bands located within a room via RF and convert them into proper format/protocol (such as TCP/IP) for transmission via intranet to the central processor. FIG. 6 illustrates the transmission and receiving actions taking place between this device [ 27 ] and the patient's ID band [ 23 ] worn by a specific patient [ 24 ]. 6. A care action identification tag programming machine, shown in FIG. 4 , which programs the memory of a care action identification tag placed within it with a set of code corresponding to the type of care action, dosage (in term of medication), delivery mean and time frame for the administering along with the patient's identification code that this care action is prescribed to. It will concurrently print out a readable label [ 19 , 20 ] adhering to the care identification tag for ease and correct delivery to the right patient room and to the right patient. This machine will be used in each department and nurse station of the healthcare facility and is linked to the central processor through intranet for downloading the care action identification codes and corresponding patient's identification code that the department and/or nurse station will be responsible to execute. 7. When a care action delivery device/agent, [ 25 ] of FIG. 7 , or associated paper work is brought to a patient, the care action identification tag [ 26 ] attached to this delivery device/agent or paper work will transmits its stored codes and associated patient's identification code continuously. FIG. 7 shows that the care action tag [ 26 ] attached to an intravenous medication bag [ 25 ] performing this process. Upon receiving this signal string, the patient's ID band [ 23 ] will examine whether its unique identification code is within the signal string. If it is not, then the patient ID band will ignore the signal string. If it is, then the ID band will further examine whether the care action codes match those stored in its memory as part of the care action program prescribed by his/her physician for the day. If it matches, then the ID band will transmit an “O.K.” signal along with its own identification code. Otherwise, it will send a “Mistake” signal with its own identification code. For “O.K.” status, the ID band will also flash the green LED [ 5 ] of FIG. 1 , for a period of time. Red LED [ 6 ] will be flashed when “Mistake” status is determined (audio alarm can also be included in the warning) along with sending out a warning signal to trigger the vibration mode of the care giver's identification band/tag to prompt the stop of administering and examine the mistake. The care action identification tag, upon receiving either the “O.K.” or “Mistake” signal with correct corresponding patient identification code from the patient ID band, will activate the flashing of green LED [ 15 ] or red LED [ 16 ] and/or audio warning on its housing as presented in FIG. 3 . All these interactions described in this section occurring at the point-of-care are illustrated by the block diagram in FIG. 9 b and are immediate as well as transparent to the care giver except when a mistake warning or no indicator/warning (signaling the patient ID code does not match the patient ID code included in the care action tag) happens. 8. The patient ID band will also periodically examine its stored care action program vs. time to determine whether a prescribed action has been administered. If not, then the ID band will issue a prompt signal which can activate the display and vibration of a care giver's identification band/tag [ 10 ] in FIG. 2 and/or transmitted through the RF transceiving device [ 27 ] in FIG. 6 to the central processor for displaying alert status in the nursing station responsible for the patient. 9. The patient ID band will also receives signals from a patient monitoring, sensor network, such as from a pressure transducer pad (as show in FIG. 8 ), wetness sensor, pulse/oximetry sensors and/or heart rate sensors to determine whether specific general care action, such as changing the patient's laying position to prevent bed sores, or changing bed pan, changing clothing or bed sheets is required. If the need is there, then the ID band will issue prompt signals to activate the display and vibration of the identification band/tag [ 10 ] of any care giver within his/her room as well as transmit through the RF transceiving device [ 27 ] to the central processor to display an alert to the care givers in the nursing station responsible for the patient. 10. The patient ID band will also record all the care action administered and time and date as well as verify all the prompts and resulting actions in its memory. At a designated time, it will transmit this log through the RF transceiving device [ 27 ] to the central processor for it to process into a daily or periodic patient care monitoring report as demonstrated in FIG. 9 a and FIG. 10 . 11. The care action identification tag will be returned to the appropriate department after administering for battery charging, disinfecting and reuse (clear codes in its memory and reprogram with a new set of instruction codes). 12. An electromagnetic (non-electrical contact) battery charger can be placed close to the patient ID band to fully charge the band's internal battery pack. Current U.S. Class: 235/437, 472.02; 340/572.1, 573.1, 573.7, 604, 614, 669; 700/108, 109, 226; 705/2, 3, 9 Current International Class: G06F 11/30, 19/00; G06K 5/00, 7/10; G08B 21/02, 04, 20; G08B 25/10, 29/18, 31/00 Field of Search: 235/380, 470, 437, 462.01-.09, .34, .46, 472.02; 340/572.1, 573.1, 573.7, 604, 614, 669; 604/67; 700/108, 109, 226; 705/2, 3, 9, 17; 713/189; 714/752
[0000]
Reference Cited
Related U.S. Patent Documents
4,857,713
Aug. 15, 1989
Brown
4,857,716
Aug. 15, 1989
Gombrich, et al.
5,071,168
Dec. 10, 1991
Shamos
5,381,487
Jan. 10, 1995
Shamos
5,760,704
Jun. 2, 1998
Barton, et al.
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De La Huerga
6,139,495
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6,255,951
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De La Huerga
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Engelson, et al.
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A patient care monitoring system and method employ active RFID devices integrated with digital processing, memory and timing circuitry for patient identification, care giver identification and for identification of each prescribed treatment, procedure, medication and general and/or special care action. At the point-of-care, each care action identity device will match directly with the targeted patient identity device or issue an error warning to prevent mistakes. The patient identity device will also interact with an associated sensor network to proactively prompt care givers to provide general care actions, such as altering a patient's laying position, changing bed pan/clothing/bed sheet, etc. for invalid patients. Also the patient identity tag will furnish periodic records of every care action, mistakes, remedies, care givers' identities and time and date for a central processor of a healthcare facility to monitor the quality of patient care. Such record can also be potentially accessed via the Internet by the responsible regulatory agencies, accreditation associations, insurance firms and even patients' families to ensure patient care is meeting the standards as well as medical billing accuracy.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a U.S. National Stage Application under 35 U.S.C §371 of International Application No. PCT/CN2014/074318, filed Mar. 28, 2014 which claims priority from Chinese patent application No. 201310104162.5 filed on Mar. 28, 2013, the entire content of which is hereby incorporated herein by reference.
FILED OF THE INVENTION
The present invention relates to a polyhydric sterone, in particular 2β,3α,5α-trihydroxy-androst-6-one, and its preparation methods and medical uses.
BACKGROUND OF THE INVENTION
Polyhydric sterones are a group of important compounds that are widely naturally occurred. Many polyhydric sterones isolated from marine organisms and terrestrial plants have important physiological functions such as antineoplastic and immunity enhancement effects. For example, ecdysterones and brassinosteroids are growth-promoting compounds for plants.
However, naturally occurring polyhydric sterones are contained in plants at an extremely low level, the purification procedures of which are thus complicated and time-consuming. In addition, due to structural complexities for example relatively longer and complicated side chains, most compounds of this group are not synthesizable, which restricts their applications. It will be of great significance with respect to the ranges of applications if those naturally occurring compounds are structurally optimized such that they substantially maintain inherent pharmaceutical properties, while having simplified structures to facilitate synthesis.
SUMMARY OF THE INVENTION
The present invention provides a novel polyhydric sterone, i.e., 2β,3α,5α-trihydroxy-androst-6-one (hereinafter referred to as YC-10, compound (I), compound I, as used interchangeably herein), having the structure of formula (I):
The compound of formula (I) was synthesized by the present inventors. The compound has relatively simple structure compared to many naturally occurring polyhydric sterones. For example, it does not contain long or complex side chains, allowing for easy synthesis. In addition, reduced molecular weight and relatively simple stereochemical structure are beneficial to drug delivery. Furthermore, the removal of side chains decreases the possibility that the compound interacts with other substances. Moreover, the absence of side chain at 17-position of the compound (I) may improve in vivo bioavailability of the compound and eliminate hormone-like effects thereof. Further, a unique spatial configuration may improve stereoselectivity of the compound, achieving better biological activity.
The compound of formula (I) has proven to posses specific pharmacological effects. In one aspect, the compound is proved to have anti-tumor activity. In another aspect, the compound is proved to have neuron-protective effect, especially for retinal ganglion cells.
Therefore, in one aspect, the present invention provides a pharmaceutical composition comprising therapeutically effective amount of a compound having structure of formula (I), and pharmaceutically acceptable carriers. “Therapeutically effective amount” means the amount of a compound that, when administered to a subject for treating a disease, is sufficient to effect such treatment for the disease. The “therapeutically effective amount” can vary depending on the compound, the disease and its severity, and the age, weight, etc., of the subject to be treated. “Pharmaceutically acceptable carriers” refers to a diluent, adjuvant, excipient or carrier with which the compound of the invention is administered.
In another aspect, the present invention provides a pharmaceutical composition comprising therapeutically effective amount of a compound having structure of formula (I), and a second neuron-protective agent. The second neuron-protective agent is different from, but can be used in combination with, the compounds provided by the present invention for neuron-protective purpose. In preferred embodiments, the second neuron-protective agent is an agent protecting retinal ganglion cells.
In a further aspect, the present invention provides a pharmaceutical composition comprising therapeutically effective amount of a compound having structure of formula (I), and a second anti-tumor drug. The second anti-tumor drug is different from, but can be used in combination with, the compounds provided by the present invention for anti-tumor applications.
As used herein, “tumor” means malignant or benign growth of cells in skin or body organs, for example, but not limited to breast, prostate, lung, kidney, pancreas, stomach or intestines. Malignant tumors are prone to invade into adjacent tissues and diffuse (metastasize) to far organs such as bones, liver, lung or brain. The term “tumor” as used herein includes metastatic tumor cell type, for example, but not limited to melanoma, lymphoma, leukemia, fibrosarcoma, leiomyosarcoma and mast cell tumor, and tissue carcinoma type, for example, but not limited to colorectal cancer, prostate cancer, small cell lung cancer and non-small cell lung cancer, breast cancer, pancreatic cancer, bladder cancer, kidney cancer, stomach cancer, glioblastoma, primary hepatic carcinoma, ovarian cancer, prostate cancer and uterine leiomyosarcoma.
In a yet another aspect, the present invention provides a use of a compound having structure of formula (I) in the preparation of neuron-protective medicines or anti-tumor medicines. The compounds provided by the present invention have been demonstrated to inhibit tumor cell growth in a does-dependent manner, together with significant neuron-protective effect.
In a further yet aspect, the present invention provides a method for treating or alleviating a disease or condition such as diseases or conditions related to retinal nerve injury or neuron damage of central nervous system caused by multiple factors, including ophthalmic diseases, such as retinal ischemia, trauma and optic nerve injury resulting from acute or chronic glaucoma, hypertensive retinopathy, diabetic retinal damage, retinal pigment degeneration and maculopathy, and central nervous system diseases, such as stroke, brain injury, spinal injury, Parkinson's disease (PD), Alzheimer's disease (AD), Huntington disease (HD), and amyotrophic lateral sclerosis (ALS). The method comprises administering to a subject therapeutically effective amount of the compound of formula (I), a prodrug or solvate thereof, or the pharmaceutical compositions provided by the present invention.
As used herein, “prodrug” refers to compounds, including derivatives of the compounds of the invention, which have cleavable groups and become by solvolysis or under physiological conditions the compounds of the invention which are pharmaceutically active in vivo. Such examples include, but are not limited to, choline ester derivatives and the like, N-alkylmorpholine esters and the like.
“Solvate” refers to forms of the compound that are associated with a solvent, usually by a solvolysis reaction. This physical association includes hydrogen bonding. Conventional solvents include water, ethanol, acetic acid and the like. The compounds of the invention may be prepared e.g. in crystalline form and may be solvated or hydrated. Suitable solvates include pharmaceutically acceptable solvates, such as hydrates, and further include both stoichiometric solvates and non-stoichiometric solvates.
In certain instances the solvate will be capable of isolation, for example when one or more solvent molecules are incorporated in the crystal lattice of the crystalline solid. “Solvate” encompasses both solution-phase and isolable solvates. Representative solvates include hydrates, ethanolates and methanolates.
In a further aspect, a method for preparing the compound of formula (I) is provided. The method uses androst-5-en-3-ol as starting material to obtain compound VI, i.e., 3β-p-toluensulfonyloxy-5α-hydroxy-androst-6-one; Compound VI is then subject to elimination reaction to obtain compound IX, i.e., 5α-hydroxy-androst-2-en-6-one; Compound IX is then subject to oxidation at 2-position double bond and hydrolysis to obtain compound I.
The compound VI can be prepared by a plurality of methods which are exemplified in the following.
(1) Starting material: androst-5-en-3-ol, followed by H 2 O 2 /formic acid oxidation, alkaline hydrolysis, NBS oxidation, and p-toluensulfonyl chloride protection.
Specifically, the method comprises following steps.
(1a) To a reaction flask is added androst-5-en-3-ol and formic acid, and then H 2 O 2 is added dropwise at low temperature. The reaction mixture is allowed to react for 1 to 2 hours and then heated. To the reaction mixture is added water and stirred to disperse. The mixture is filtered and dried to give compound II as a white solid. The starting material:formic acid:H 2 O 2 is 1:10˜30:0.5˜3 (w:v:v);
(1b) To a reaction flask is added alkaline methanol solution and compound II. The reaction mixture is heated at refluxed for 1-2 h, and poured into water to disperse. The mixture is filtered and dried to provide compound III as a white solid. The alkaline methanol solution is selected from a solution of potassium hydroxide, sodium hydroxide or sodium methoxide in methanol. The alkali concentration of the reaction mixture is 2-10%;
(1c) To a reaction flask is added compound III, dioxane and water. NBS is added in batch. The mixture is reacted for 2-4 h, followed by addition of sodium sulfite. The mixture is filtered, washed with water to neutral, and dried to give compound V as a white solid; and
(1d) To a reaction flask is added compound V, pyridine and p-toluensulfonyl chloride. The reaction mixture is stirred for 24-36 h at room temperature and then added to icy hydrochloric acid solution. The mixture is filtered, washed with water to neutral, and dried to give compound VI as a white solid.
(2) Starting material: androst-5-en-3-ol, followed by oxidation with m-chloroperoxybenzoic acid, acidolysis, NBS oxidation and p-toluensulfonyl chloride protection.
Specifically, the method comprises following steps.
(2a) To a reaction flask is added androst-5-en-3-ol and CH 2 Cl 2 . m-Chloroperoxybenzoic acid is added in batch while stirring. The mixture is further stirred for 2-5 h in ice bath. After the reaction was completed, the mixture is washed with Na 2 CO 3 , Na 2 SO 3 and water, dried and concentrated to give compound IV;
(2b) To a reaction flask is added compound IV and acidic acetone aqueous solution and stirred at room temperature for hours. After the reaction was completed, the reaction solution is adjusted to neutral with Na 2 CO 3 solution. The acetone is removed and residue is extracted with ethyl acetate. The organic layer is collected, dried and concentrated to provide compound III. The acid in the acidic acetone aqueous solution is sulfuric acid or periodic acid. Compound IV:acetone:1N acid is 1:20˜30:5˜10 (w:v:v);
(2c) To a reaction flask is added compound III, dioxane and water. NBS is added in batch. The mixture is reacted for 2-4 h, followed by addition of sodium sulfite. The mixture is filtered, washed with water to neutral, and dried to give compound V as a white solid; and
(2d) To a reaction flask is added compound V, pyridine and p-toluensulfonyl chloride. The reaction mixture is stirred for 24-36 h at room temperature and then added to icy hydrochloric acid solution. The mixture is filtered, washed with water to neutral, and dried to give compound VI as a white solid.
(3) Starting material: androst-5-en-3-ol, followed by p-toluensulfonyl chloride protection, oxidation with m-chloroperoxybenzoic acid, and Jones reagent oxidation.
Specifically, the method comprises following steps.
(3a) To a reaction flask is added androst-5-en-3-ol, anhydrous pyridine and p-toluensulfonyl chloride. The reaction mixture is stirred at room temperature. After the reaction was completed, the mixture is poured into icy hydrochloric acid solution, stirred, filtered, washed with water to neutral, and dried to provide compound VII as a white solid;
(3b) To a reaction flask is added compound VII and dichloromethane, and m-chloroperoxybenzoic acid is added in batch while stirring. The reaction mixture is further stirred in ice bath. After the reaction is complete, the mixture is washed with saturated sodium sulphite solution, sodium carbonate solution and distilled water. The organic layer is collected, dried, concentrated and purified by silica-gel column chromatography, providing compound VIII as a white solid;
(3c) To a reaction flask is added compound VIII and acetone, followed by addition of Jones reagent while stirring. The mixture is allowed to react for hours at room temperature. After the reaction is completed, the mixture is quenched with isopropanol and adjusted to neutral. The mixture is concentrated under reduced pressure to remove acetone, extracted with ethyl acetate, washed, dried, and concentrated to give a pale green solid. The solid is purified by silica-gel column chromatography to provide compound VI as a white solid.
In the methods of the present invention, compound IX is for example prepared as follows. To a reaction flask is added compound VI, DMF, Li 2 CO 3 and LiBr. The reaction mixture is heated to reflux and poured into icy aqueous hydrochloric acid solution. The mixture is stirred, filtered, washed to neutral, and dried to give compound IX as a white solid. Preferably, compound VI:DMF is 1:3˜15(w:v); compound VI: Li 2 CO 3 : LiBr is 1:4˜12:4˜12(M:M:M).
In the methods of the present invention, compound I can also be prepared from compound IX by methods exemplified as follows.
(1) Compound I is prepared from compound IX by H 2 O 2 /formic acid oxidation and alkaline hydrolysis.
Specifically, the method comprises the following steps.
(1a) To a reaction flask is added compound IX and formic acid, and then H 2 O 2 is added dropwise at low temperature. The reaction mixture is allowed to react for 1 to 2 hours and then heated. To the reaction mixture is added water and stirred to disperse. The mixture is filtered to obtain a white filter cake. The cake is dried to give compound X as a white solid. The compound X:formic acid:H 2 O 2 is 1:10˜30:0.5˜3 (w:v:v);
(1b) To a reaction flask is added alkaline methanol solution and compound X. The reaction mixture is heated at refluxed for 1-2 h, and poured into water to disperse. The mixture is filtered and dried to provide compound of formula (I) as a white solid. The alkaline methanol solution is selected from a solution of potassium hydroxide, sodium hydroxide or sodium methoxide in methanol. The alkali concentration of the reaction mixture is 2-10%.
(2) Compound I is prepared from compound IX by oxidation with m-chloroperoxybenzoic acid and acidolysis.
Specifically, the method comprises the following steps.
(2a) To a reaction flask is added compound IX and CH 2 Cl 2 . m-Chloroperoxybenzoic acid is added in batch while stirring. The mixture is further stirred for 2-5 h in ice bath. After the reaction was completed, the mixture is washed with Na 2 CO 3 , Na 2 SO 3 and water, dried and concentrated to give compound XI;
(2b) To a reaction flask is added compound XI and acidic acetone solution and stirred at room temperature for hours. After the reaction was completed, the reaction solution is adjusted to neutral with Na 2 CO 3 solution. The acetone is removed and residue is extracted with ethyl acetate. The organic layer is collected, dried and concentrated to provide compound I. The acid in the acidic acetone aqueous solution is sulfuric acid or periodic acid. Compound XI:acetone:1N acid is 1:20˜30:5˜10 (w:v:v).
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows the inhibition of LN18 and DBTRG-50MG cells of compound I of the present invention (n=3*, p<0.05).
FIG. 2 shows compound I protects cerebellar granule neurons from glutamate-induced damage.
FIG. 3 shows that compound I improves survival of cerebellar granule neurons in a dose-dependent manner.
FIG. 4 shows compound I protects cerebellar granule neurons from low potassium induced death.
FIG. 5 shows that RGC is significantly decreased in an optic nerve clamping injury model, while compound I is shown to prevent from RGC decrease.
FIG. 6 is a graph showing RGC statistics in different groups of samples in an optic nerve clamping injury model.
FIG. 7 shows that RGC is significantly decreased in an eye high pressure and ischemia model, while compound I is shown to prevent from RGC decrease.
FIG. 8 a graph showing RGC statistics in different groups of samples in an eye high pressure and ischemia model.
DETAILED DESCRIPTION
The following is provided for illustrative purpose only. It is understood that the scope of the invention shall not be limited to the examples provided below. In the following examples, compound I refers to 2β,3α,5α-trihydroxy-androst-6-one; compound II refers to 3β,6β-diformyloxy-5α-androst-5-ol; compound III refers to androst-3β,5α,6β-triol; compound IV refers to 3β-hydroxy-androst-5β,6β-epoxy; compound V refers to 3β,5α-dihydroxy-androst-6-one; compound VI refers to 3β-p-toluensulfonyloxy-5α-hydroxy-androst-6-one; compound VII refers to 3β-p-toluensulfonyloxy-androst-5-en; compound VIII refers to 3β-p-toluensulfonyloxy-androst-5β,6β-epoxy; compound IX refers to 5α-hydroxy-androst-2-en-6-one; compound X refers to 2β,3α-diformyloxy-5α-hydroxy-androst-6-one; and compound XI refers to 2β,3β-epoxy-5α-hydroxy-androst-6-one.
PREPARATION OF COMPOUND I
Example 1
Step 1—To a 2 L of reaction flask was added compound androst-5-en-3-ol (54.5 g) and formic acid (1 L, 88%). The reaction mixture was cooled to 25° C., and hydrogen peroxide (82.5 mL, 30%) was slowly added. After reaction was completed as evidenced by TLC, the mixture was heated to 75° C. to remove excess hydrogen peroxide. Water (1 L) was added and stirred to disperse. The mixture was filtered to obtain a white filter cake. The cake was immersed into saturated NaHCO 3 solution and filtered. Filter cake was washed to neutral and dried to provide compound II (62.4 g) as a white solid.
Step 2—To a 2 L of reaction flask was added potassium hydroxide (45 g), methanol (1500 mL), water (300 mL) and compound II (60 g). The reaction mixture was heated to reflux. TLC confirmed no residual compound II. The reaction mixture was cooled to room temperature, and poured into water (3 L) to disperse. The mixture was adjusted to pH=7 by concentrated hydrochloric acid and allowed for settlement lamination. The mixture was filtered and filter cake was washed to neutral and dried to obtain compound III (49.6 g) as a white solid.
Step 3—To a 1 L of reaction flask was added compound III (49 g), dioxane (600 mL) and water (200 mL). After compound III was completely dissolved, N-bromo-succinimide (42.5 g) was added in four batches. After compound III was depleted as evidenced by TLC, the reaction was stopped. Sodium sulfite (11 g) was added to reduce excess oxidant. The mixture is dispersed in water (4 L) and filtered. Filter cake was washed to neutral and dried to provide compound V (47.8 g) as a white solid.
Step 4—To a 500 mL of reaction flask was added pyridine (135 mL), compound V (44.3 g) and p-toluensulfonyl chloride (45 g). The mixture was stirred at room temperature. After compound V was depleted as evidenced by TLC, the reaction was stopped. The mixture was poured into icy aqueous hydrochloric acid solution (300 mL, 1:1(V:V)), stirred, and filtered. Filter cake was washed to pH=7 and filtered. Filter cake was washed to neutral and dried to provide compound VI (61.7 g) as a white solid.
Step 5—To a 1 L of reaction flask was added N,N-dimethylformamide (325 mL), compound VI (54 g), Li 2 CO 3 (52.1 g) and LiBr (60.5 g). The mixture is heated to reflux. After compound VI is depleted as evidenced by TLC, the reaction is stopped. The mixture was poured into icy aqueous hydrochloric acid solution (2 L, 1:1(V:V)), stirred and filtered. Filter cake was washed to neutral and dried to provide compound IX (32 g) as a white solid.
Step 6—To a 500 mL of reaction flask was added compound IX (30 g) and formic acid (600 mL, 88%). The mixture was heated to dissolve the solid compound and then cooled to below 25° C. Hydrogen peroxide (24 mL, 30%) was slowly added. After compound IX was depleted as evidenced by TLC, the mixture was heated to 75° C. for 10 minutes to remove excess hydrogen peroxide. Water (3 L) was added and stirred to disperse. The mixture was filtered to obtain a white filter cake. The cake was immersed into saturated NaHCO 3 solution and filtered. Filter cake was washed to neutral and dried to provide compound X (26 g) as a white solid.
Step 7—To a 500 mL of reaction flask was added potassium hydroxide (27 g), methanol (600 mL), water (72 mL) and compound X (23.4 g). The reaction mixture was heated to reflux. TLC confirmed no residual compound X. The reaction mixture was cooled to room temperature, and poured into water (3 L) to disperse. The mixture was adjusted to pH=7 by concentrated hydrochloric acid and allowed for settlement lamination. The mixture was filtered and filter cake was washed to neutral, followed by recrystallization in acetone, and dried to obtain compound I (16 g) as a white solid.
m.p:197˜201° C.; specific rotation:−50° (2 mg/mL, absolute ethanol); 1 H NMR(CDCl 3 , 400 MHz)δ:0.65(s, 3H, 18-CH 3 ), 0.87(s, 3H, 19-CH 3 ), 3.76˜3.83(d, J=28 Hz, 2H, 2-CH and 3-CH); 13 C NMR(CDCl 3 , 400 MHz)δ: 15.52 (CH 3 ), 17.27(CH 3 ), 19.94(CH 2 ), 20.53(CH 2 ), 24.68(CH 2 ), 26.90(CH 2 ), 33.02(CH 2 ), 36.45(CH), 39.72(CH 2 ), 40.92(C), 41.26(CH 2 ), 42.54(C), 44.99(CH), 54.04(CH), 68.94(CH), 70.19(CH), 79.71(C), 210.65(C); IR(KBr, cm −1 ) v:3296, 2937, 1726, 1064; MS(APCI)m/z: 319(M-3).
PREPARATION OF COMPOUND I
Example 2
Step 1—To a 2 L of reaction flask was added compound androst-5-en-3-ol (70 g) and CH 2 Cl 2 (1200 mL). To the mixture was added m-chloroperoxybenzoic acid (105 g, mCPBA) in batch while stirring. The reaction mixture is further stirred in ice bath for 5 h. After the reaction was completed, the mixture was washed with saturated sodium sulphite solution, sodium carbonate solution and distilled water. The organic layer was collected, dried, and concentrated to provide compound IV (62 g) as a yellow solid.
Step 2—Compound IV (60 g) was dissolved in acetone (3 L). To the solution was added 1 N H 2 SO 4 (400 mL) solution. The mixture was stirred at room temperature for 3 h. After the reaction was completed, the mixture was adjusted to neutral with Na 2 CO 3 solution and concentrated under reduced pressure to remove acetone. The mixture was extracted with ethyl acetate, and organic layer was collected and dried over anhydrous sodium sulfate to give a yellow solid (48 g). The solid was recrystallized in acetone to provide compound III (30.5 g).
Steps 3 to 7 were identical with steps 3 to 7 in Example 1.
m.p:197˜201° C.; specific rotation:−50° (2 mg/mL, absolute ethanol); 1 H NMR(CDCl 3 , 400 MHz)δ:0.65(s, 3H, 18-CH 3 ), 0.87(s, 3H, 19-CH 3 ), 3.76˜3.83(d, J=28 Hz, 2H, 2-CH and 3-CH); 13 C NMR(CDCl 3 , 400 MHz)δ:15.52 (CH 3 ), 17.27(CH 3 ), 19.94(CH 2 ), 20.53(CH 2 ), 24.68(CH 2 ), 26.90(CH 2 ), 33.02(CH 2 ), 36.45(CH), 39.72(CH 2 ), 40.92(C), 41.26(CH 2 ), 42.54(C), 44.99(CH), 54.04(CH), 68.94(CH), 70.19(CH), 79.71(C), 210.65(C); IR(KBr, cm −1 ) v:3296, 2937, 1726, 1064; MS(APCI)m/z: 319(M-3).
PREPARATION OF COMPOUND I
Example 3
Steps 1 to 5 were identical to steps 1 to 5 of Example 1.
Step 6—In a 500 mL of reaction flask, compound IX (23 g) was dissolved in CH 2 Cl 2 (600 mL). To the mixture was added m-chloroperoxybenzoic acid (34.6 g, mCPBA) in batch while stirring. The reaction mixture is further stirred in ice bath for 5 h. After the reaction was completed, the mixture was washed with saturated sodium sulphite solution, sodium carbonate solution and distilled water. The organic layer was collected, dried, and concentrated to provide compound XI (20.7 g) as a yellow solid.
Step 7—In a 2 L of reaction flask, compound XI (17.4 g) was dissolved in acetone (900 mL). To the mixture was added 1 N H 2 SO 4 solution (180 mL). The mixture was stirred at room temperature for 3 h. After the reaction was completed, the mixture was adjusted to neutral with Na 2 CO 3 solution and concentrated under reduced pressure to remove acetone. The mixture was extracted with ethyl acetate, and organic layer was collected and dried over anhydrous sodium sulfate to give a yellow solid (14.4 g). The solid was recrystallized in acetone to provide compound I as a white solid.
m.p:197˜201° C.; specific rotation:−50° (2 mg/mL, absolute ethanol); 1 H NMR(CDCl 3 , 400 MHz)δ:0.65(s, 3H, 18-CH 3 ), 0.87(s, 3H, 19-CH 3 ), 3.76˜3.83(d, J=28 Hz, 2H, 2-CH and 3-CH); 13 C NMR(CDCl 3 , 400 MHz)δ: 15.52 (CH 3 ), 17.27(CH 3 ), 19.94(CH 2 ), 20.53(CH 2 ), 24.68(CH 2 ), 26.90(CH 2 ), 33.02(CH 2 ), 36.45(CH), 39.72(CH 2 ), 40.92(C), 41.26(CH 2 ), 42.54(C), 44.99(CH), 54.04(CH), 68.94(CH), 70.19(CH), 79.71(C), 210.65(C); IR(KBr, cm −1 ) v:3296, 2937, 1726, 1064; MS(APCI)m/z: 319(M-3).
PREPARATION OF COMPOUND I
Example 4
Step 1—To a 250 mL of reaction flask was added androst-5-en-3-ol (14.64 g) and anhydrous pyridine (125 mL). To the mixture was added in batch p-toluensulfonyl chloride (26.05 g). The mixture was allowed to react at room temperature for 24 h. After starting materials were depleted as evidenced by TLC, the reaction was stopped. The mixture was poured into icy HCl solution (2000 mL, 17%) under vigorous stirring, and filtered. Filter cake was washed to neutral and dried under vacuum to provide compound VII (22.48 g) as a white solid.
Step 2—To a 250 mL of reaction flask was added compound VII (15.00 g) and CH 2 Cl 2 (200 mL). To the mixture was added m-chloroperoxybenzoic acid (15.12 g, mCPBA) in batch while stirring. The reaction mixture is further stirred in ice bath for 5 h. After the reaction was completed, the mixture was washed with saturated sodium sulphite solution, sodium carbonate solution and distilled water. The organic layer was collected and dried over anhydrous sodium sulfate. Organic solvents were evaporated. The residue was dried under vacuum to provide crude product (14.07 g). The crude product was purified by silica-gel column chromatography to provide compound VIII (12.3 g) as a white solid.
Step 3—To a 1000 mL of reaction flask was added compound VIII (14.07 g) and acetone (750 mL). To the mixture was added Jones reagent (30 mL) while stirring. The mixture was allowed to react at room temperature for 2 h. After the reaction was completed as evidenced by TLC, the mixture is quenched with isopropanol and adjusted to neutral with Na 2 CO 3 solution. The mixture is concentrated under reduced pressure to remove acetone, and extracted with ethyl acetate. The organic layer was collected and washed with distilled water several times, dried over anhydrous sodium sulfate, and concentrated to give a pale green solid. The solid is purified by silica-gel column chromatography to provide compound VI (12.89 g) as a white solid.
Steps 4 to 6 were identical to steps 5 to 7 of Example 1.
m.p:197˜201° C.; specific rotation:−50° (2 mg/mL, absolute ethanol); 1 H NMR(CDCl 3 , 400 MHz)δ:0.65(s, 3H, 18-CH 3 ), 0.87(s, 3H, 19-CH 3 ), 3.76˜3.83(d, J=28 Hz, 2H, 2-CH and 3-CH); 13 C NMR(CDCl 3 , 400 MHz)δ: 15.52 (CH 3 ), 17.27(CH 3 ), 19.94(CH 2 ), 20.53(CH 2 ), 24.68(CH 2 ), 26.90(CH 2 ), 33.02(CH 2 ), 36.45(CH), 39.72(CH 2 ), 40.92(C), 41.26(CH 2 ), 42.54(C), 44.99(CH), 54.04(CH), 68.94(CH), 70.19(CH), 79.71(C), 210.65(C); IR(KBr, cm −1 ) v:3296, 2937, 1726, 1064; MS(APCI)m/z: 319(M-3).
PREPARATION OF COMPOUND I
Example 5
Steps 1 to 4 were identical to steps 1 to 4 in Example 1.
Step 5—To a 1 L of reaction flask was added anhydrous N,N-dimethylformamide (325 mL), compound VI (54 g), dry Li 2 CO 3 (69.5 g), and LiBr (80.6 g). The mixture was heated to reflux. After the compound VI was consumed as evidenced by TLC, the reaction was stopped. The mixture was added to icy HCl aqueous solution (2 L, 1:1 (V:V)), stirred, and filtered. Filter cake was washed with water to neutral and dried to provide compound IX (32.5 g) as a white solid.
Steps 6 to 7 were identical to steps 6 to 7 in Example 1.
m.p:197˜201° C.; specific rotation:−50° (2 mg/mL, absolute ethanol); 1 H NMR(CDCl 3 , 400 MHz)δ:0.65 (s, 3H, 18-CH 3 ), 0.87(s, 3H, 19-CH 3 ), 3.76˜3.83(d, J=28 Hz, 2H, 2-CH and 3-CH); 13 C NMR(CDCl 3 , 400 MHz)δ: 15.52 (CH 3 ), 17.27(CH 3 ), 19.94(CH 2 ), 20.53(CH 2 ), 24.68(CH 2 ), 26.90(CH 2 ), 33.02(CH 2 ), 36.45(CH), 39.72(CH 2 ), 40.92(C), 41.26(CH 2 ), 42.54(C), 44.99(CH), 54.04(CH), 68.94(CH), 70.19(CH), 79.71(C), 210.65(C); IR(KBr, cm −1 ) v:3296, 2937, 1726, 1064; MS(APCI)m/z: 319(M-3).
PREPARATION OF COMPOUND I
Example 6
Steps 1 to 4 were identical to steps 1 to 4 in Example 1.
Step 5—To a 1 L of reaction flask was added anhydrous N,N-dimethylformamide (325 mL), compound VI (54 g), dry Li 2 CO 3 (34.7 g), and LiBr (40.3 g). The mixture was heated to reflux. After the compound VI was consumed as evidenced by TLC, the reaction was stopped. The mixture was added to icy HCl aqueous solution (2 L, 1:1(V:V)), stirred, and filtered. Filter cake was washed with water to neutral and dried to provide compound IX (30.2 g) as a white solid.
Steps 6 to 7 were identical to steps 6 to 7 in Example 1.
m.p:197˜201° C.; specific rotation:−50° (2 mg/mL, absolute ethanol); 1 H NMR(CDCl 3 , 400 MHz)δ:0.65 (s, 3H, 18-CH 3 ), 0.87(s, 3H, 19-CH 3 ), 3.76˜3.83(d, J=28 Hz, 2H, 2-CH and 3-CH); 13 C NMR(CDCl 3 , 400 MHz)δ: 15.52 (CH 3 ), 17.27(CH 3 ), 19.94(CH 2 ), 20.53(CH 2 ), 24.68(CH 2 ), 26.90(CH 2 ), 33.02(CH 2 ), 36.45(CH), 39.72(CH 2 ), 40.92(C), 41.26(CH 2 ), 42.54(C), 44.99(CH), 54.04(CH), 68.94(CH), 70.19(CH), 79.71(C), 210.65(C); IR(KBr, cm −1 ) v:3296, 2937, 1726, 1064; MS(APCI)m/z: 319(M-3).
PREPARATION OF COMPOUND I
Example 7
Steps 1 to 4 were identical to steps 1 to 4 in Example 1.
Step 5—To a 1 L of reaction flask was added anhydrous N,N-dimethylformamide (432 mL), compound VI (54 g), dry Li 2 CO 3 (52.1 g), and LiBr (60.5 g). The mixture was heated to reflux. After the compound VI was consumed as evidenced by TLC, the reaction was stopped. The mixture was added to icy HCl aqueous solution (2 L, 1:1(V:V)), stirred, and filtered. Filter cake was washed with water to neutral and dried to provide compound IX (30.5 g) as a white solid.
Step 6—To a 500 mL of reaction flask was added compound IX (30 g) and formic acid (600 mL, 88%). The mixture was heated to dissolve the solid compound and then cooled to below 25° C. Hydrogen peroxide (20 mL, 30%) was slowly added. After compound IX was depleted as evidenced by TLC, the mixture was heated to 75° C. for 10 minutes to remove excess hydrogen peroxide. Water (3 L) was added and stirred to disperse. The mixture was filtered to obtain a white filter cake. The cake was immersed into saturated NaHCO 3 solution and filtered. Filter cake was washed to neutral and dried to provide compound X (28 g) as a white solid.
Step 7—To a 500 mL of reaction flask was added potassium hydroxide (18 g), methanol (600 mL), water (72 mL) and compound X (25 g). The reaction mixture was heated to reflux. TLC confirmed no residual compound X. The reaction mixture was cooled to room temperature, and poured into water (3 L) to disperse. The mixture was adjusted to pH=7 by concentrated hydrochloric acid and allowed for settlement lamination. The mixture was filtered and filter cake was washed to neutral, followed by recrystallization in acetone, and dried to obtain compound I (8.8 g) as a white solid.
m.p:197˜201° C.; specific rotation:−50° (2 mg/mL, absolute ethanol); 1 H NMR(CDCl 3 , 400 MHz)δ:0.65 (s, 3H, 18-CH 3 ), 0.87(s, 3H, 19-CH 3 ), 3.76˜3.83(d, J=28 Hz, 2H, 2-CH and 3-CH); 13 C NMR(CDCl 3 , 400 MHz)δ: 15.52 (CH 3 ), 17.27(CH 3 ), 19.94(CH 2 ), 20.53(CH 2 ), 24.68(CH 2 ), 26.90(CH 2 ), 33.02(CH 2 ), 36.45(CH), 39.72(CH 2 ), 40.92(C), 41.26(CH 2 ), 42.54(C), 44.99(CH), 54.04(CH), 68.94(CH), 70.19(CH), 79.71(C), 210.65(C); IR(KBr, cm −1 ) v:3296, 2937, 1726, 1064; MS(APCI)m/z: 319(M-3).
PREPARATION OF COMPOUND I
Example 8
Steps 1 to 5 were identical to steps 1 to 5 in Example 7.
Step 6—To a 500 mL of reaction flask was added compound IX (30 g) and formic acid (600 mL, 88%). The mixture was heated to dissolve the solid compound and then cooled to below 25° C. Hydrogen peroxide (36 mL, 30%) was slowly added. After compound IX was depleted as evidenced by TLC, the mixture was heated to 75° C. for 10 minutes to remove excess hydrogen peroxide. Water (3 L) was added and stirred to disperse. The mixture was filtered to obtain a white filter cake. The cake was immersed into saturated NaHCO 3 solution until free of bubbles and then filtered. Filter cake was washed to neutral and dried to provide compound X (24 g) as a white solid.
Step 7 is identical to step 7 in Example 7.
m.p:197˜201° C.; specific rotation:−50° (2 mg/mL, absolute ethanol); 1 H NMR(CDCl 3 , 400 MHz)δ:0.65 (s, 3H, 18-CH 3 ), 0.87(s, 3H, 19-CH 3 ), 3.76˜3.83(d, J=28 Hz, 2H, 2-CH and 3-CH); 13 C NMR(CDCl 3 , 400 MHz)δ: 15.52 (CH 3 ), 17.27(CH 3 ), 19.94(CH 2 ), 20.53(CH 2 ), 24.68(CH 2 ), 26.90(CH 2 ), 33.02(CH 2 ), 36.45(CH), 39.72(CH 2 ), 40.92(C), 41.26(CH 2 ), 42.54(C), 44.99(CH), 54.04(CH), 68.94(CH), 70.19(CH), 79.71(C), 210.65(C); IR(KBr, cm −1 ) v:3296, 2937, 1726, 1064; MS(APCI)m/z: 319(M-3).
PREPARATION OF COMPOUND I
Example 9
Steps 1 to 5 were identical to steps 1 to 5 in Example 7.
Step 6—To a 500 mL of reaction flask was added compound IX (30 g) and formic acid (600 mL, 88%). The mixture was heated to dissolve the solid compound and then cooled to below 25° C. Hydrogen peroxide (45 mL, 30%) was slowly added. After compound IX was depleted as evidenced by TLC, the mixture was heated to 75° C. for 10 minutes to remove excess hydrogen peroxide. Water (3 L) was added and stirred to disperse. The mixture was filtered to obtain a white filter cake. The cake was immersed into saturated NaHCO 3 solution until free of bubbles and then filtered. Filter cake was washed to neutral and dried to provide compound X (23 g) as a white solid.
Step 7—To a 500 mL of reaction flask was added potassium hydroxide (27 g), methanol (300 mL), water (36 mL) and compound X (12.5 g). The reaction mixture was heated to reflux. TLC confirmed no residual compound X. The reaction mixture was cooled to room temperature, and poured into water (3 L) to disperse. The mixture was adjusted to pH=7 by HCl and allowed for settlement lamination. The mixture was filtered and filter cake was washed to neutral, followed by recrystallization in acetone, and dried to obtain compound I (8.0 g) as a white solid.
m.p:197˜201° C.; specific rotation:−50° (2 mg/mL, absolute ethanol); 1 H NMR(CDCl 3 , 400 MHz)δ:0.65(s, 3H, 18-CH 3 ), 0.87(s, 3H, 19-CH 3 ), 3.76˜3.83(d, J=28 Hz, 2H, 2-CH and 3-CH); 13 C NMR(CDCl 3 , 400 MHz)δ: 15.52 (CH 3 ), 17.27(CH 3 ), 19.94(CH 2 ), 20.53(CH 2 ), 24.68(CH 2 ), 26.90(CH 2 ), 33.02(CH 2 ), 36.45(CH), 39.72(CH 2 ), 40.92(C), 41.26(CH 2 ), 42.54(C), 44.99(CH), 54.04(CH), 68.94(CH), 70.19(CH), 79.71(C), 210.65(C); IR(KBr, cm −1 ) v:3296, 2937, 1726, 1064; MS(APCI)m/z: 319(M-3).
Anti-Tumor Activity of Compound I
Cell seeding and treatment: Logarithmic phase of LN18 and DBTRG-50MG cells were prepared to cell suspensions with complete medium. Cells were seeded into a 96-well plate at a density of 100 μl per well, 3×10 4 /ml. 12 h post seeding, full cell adherence was observed. To the wells was added YC-10 to a final concentration of YC-10 being 250, 500, and 1000 μM, with each concentration group having 5 repeats.
Reaction of MTT with succinate dehydrogenase: At 24th h of culturing, 10 μl (5 mg/ml) of MTT was added to each well, followed by 4 h incubation. At this time, granulate violet formazan crystalline can be observed in live cells by microscopy.
Formazan particle dissolution: Supernatant was carefully discharged. To the wells was added DMSO at 100 μl/well to dissolve the crystalline. The mixture was vibrated on a mini oscillator for 5 min and measured for optical density (OD value) at 570 nm for each well by enzyme-linked immunometric assay.
Each group of experiments was repeated 3 times.
Survival (%)=OD value in treatment group/OD value in control group*100%.
All data was presented as mean±SD. SPSS 13.0 statistics package software was used. One-Way ANOVA and t-test were used to analyze the data. Sigmaplot software was used to give FIG. 1 . As can be seen from FIG. 1 , 24 h post treatment with 250, 500, 1000 μM of YC-10, cell survival rates of treatment group were statistically significant in comparison with control group (P<0.05). YC-10 killed tumor cells in a dose-dependent manner.
Neuron Protective Activity of Compound I
The in vivo and in vitro toxicity and pharmacological functions of YC-10 were studied to evaluate its neuron protective activity and possibility to become potential clinical drug. In summary, results showed that no obvious abnormality was observed in mice administered large doses of YC-10 (250 mg/kg). Studies showed YC-10 was significantly effective in improvement of survival rate of cerebellar granule neurons in both glutamate-induced and low potassium induced injury models. YC-10 was also shown to significantly improve survival rate of retinal ganglion cells in an animal model suffering from both optic nerve injury and retinal ischemia. Those results showed that YC-10 had neuron protective activity, without obvious toxic or side effects.
1 Toxicological Study
Maximal Tolerance Dose Test
YC-10 injections at concentration of 25 mg/mL were prepared with 40% hydroxypropyl cyclodextrin, and were injected through tail vein to 30 KM mice (half males and half females, weighted 18-22 g) at does of 0.1 mL/10 g.
The mice were continuously observed. All mice behaved and ate as usual, with bright coat color and fine fur. No abnormal secretions in mouth, eyes, nose, or ears were observed. Mice defecated normally. Mice weights were slighted increase. No mice died. Mice were sacrificed after 14 days, dissected and visual examined on important organs such as heart, liver, spleen, kidney, and gastrointestinal. No abnormal changes were observed. Those results showed that YC-10 was nontoxic to mouse at 250 mg/kg.
2 Pharmacological Studies
2.1 YC-10 Protected Cerebellar Granule Neurons from Glutamate-Induced Damage
Cerebellar granule neurons cultured in vitro for 8 days were grouped. Treatment groups received MK801 or YC-10 at various concentrations, followed by incubation for 30 min. Following that, model group and all treatment groups were replaced with Mg 2+ -free Locke buffer, and added with glutamate (100 μM final concentration), Glycine (10 μM final concentration) and drugs at respective concentrations. Cells were incubated at 37° C. for 30 minutes, replaced with original medium, incubated for further 24 h, followed by FDA staining. Results were shown in FIG. 2 .
The results showed that glutamate can induce injury and death of cerebella granule neurons. MK801 was able to prevent cerebella granule neurons from glutamate-induced injury. YC-10 was also effective in preventing glutamate-induced excitotoxin damage of cerebellar granule neurons in a dose-dependent manner. YC-10 protected cerebellar granule neurons against glutamate-induced damage ( FIG. 3 ).
2.2 YC-10 Protected Cerebellar Granule Neurons from Low Potassium-Induced Death
Cerebellar granule neurons were cultured in vitro for 8 days. Treatment groups received YC-10 at various concentrations and incubated for 30 min. Following that, model group and all treatment groups were replaced with 5K (i.e., 5 mM KCl) BME medium (25K BME for control group), and added with YC-10 at respective concentrations. Cells were incubated at 37° C. for 24 h, followed by FDA staining. Results were shown in FIG. 4 .
As shown in FIG. 4 , low potassium medium can reduce death of cerebellar granule neurons. YC-10 (50 μM) could prevent neuron from low potassium-induced death. YC-10 protected cerebellar granule neurons from low potassium-induced death.
2.3 YC-10 Protected Retinal Ganglion Cell from Optic Nerve Clamping Injury-Induced Death
10% chloral hydrate was used to anesthetize rats. YC-10 (20 mg/kg) or solvents were administered via tail vein 20 min before surgery. Eyes were subject to topical anesthesia. Conjunctiva was cut along limbus cornea with corneal scissors and intraocular microforceps. Lateral rectus was bluntly dissected to fully expose optic nerve. A cross action forceps was used to clamp the optic nerve for 5 seconds at 2 mm posterior to the eyeball, and then released. Antibiotic eye ointment was applied post operation to prevent infection. Drugs were administered at 2 h post operation, Day 2, and Day 3. Eyeballs were obtained for pathological examination at Day 7. As shown in FIG. 5 , pathological examination showed that optic nerve clamping injury can induce death of retinal ganglion cell (RGC). YC-10 was shown to slow down or prevent from clamping injury-induced death, i.e., YC-10 can protect retinal ganglion cell from optic nerve clamping injury-induced death. RGC counts in each group were recorded and reported in FIG. 6 .
2.4 YC-10 Protected Retinal Ganglion Cell from Eye High Pressure and Ischemia Injury-Induced Death
10% chloral hydrate was used to anesthetize rats. Eyes were subject to topical anesthesia. Perfusion apparatus was placed 176 cm above rats' eyeballs (resulting in 130 mmHg intra-ocular pressure). 30 G ½ syringe needle was carefully inserted into anterior chamber. The eyeballs became white and starting time of ischemia was recorded. 1 h post ischemia, the syringe needle was quickly withdrawn and eyes were cared by antibiotic eyedrops. Rats were raised back to cage. Drugs were administered 20 before modeling for solvent group and YC-10 group (20 mg/kg). At 2 h, Day 2 and Day 3 post modeling, rats were treated with YC-10 via tail vein. At Day 7 post modeling, eyeballs were obtained for pathological examination.
As shown in FIG. 7 , pathological examination showed that eye high pressure and ischemia can induce death of retinal ganglion cell (RGC). YC-10 was shown to reduce or prevent from ischemia-induced death, i.e., YC-10 can protect retinal ganglion cell from eye high pressure and ischemia-induced death. RGC counts in each group were recorded and reported in FIG. 8 .
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The present invention discloses compound 2β,3α,5α-trihydroxy-androst-6-one, having the structure of formula (I). The present invention also discloses a plurality of methods for preparing the compound and a use of the compound.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims benefits from U.S. provisional application Ser. No. 60/819,202 filed Jul. 7, 2006, the entire contents of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
This invention is related to the field of monitoring devices and, more specifically, to the field of performance monitoring of concrete structures.
BACKGROUND OF THE INVENTION
Current early-age concrete evaluation devices, such as the maturity meter, cannot be applied for the detection and evaluation of cracks and damage for the maintenance period. Some other early-age concrete evaluation devices, such as ultrasonic wave velocity meters, require bulky equipment and are not suitable for the health monitoring of in-situ, large-scale concrete structures.
The current maturity meter measures the hydration heat of a concrete structure and the hydration time at early-age to estimate the strength development of a concrete structure. An ultrasonic velocity meter evaluates some physical properties of a concrete structure by measuring the velocity of ultrasonic waves propagated inside the concrete structure.
Compressive test equipment determines the compressive strength data of concrete by directly compressing and crushing the concrete specimens (structure) but, due to the press method, equipment and other uncertain factors, large amounts of concrete specimens are needed for the test which is time-consuming and effort consuming.
The present technological methods to evaluate the strength of concrete at early-age can be classified into two categories: (1) destructive method that crushes the concrete for strength testing and (2) non-destructive testing.
Two popular non-destructive methods to evaluate the early-age strength development of concrete are the hydration heat-based method and the ultrasonic wave velocity-based method. Hydration heat-based method evaluates the early-age strength development of concrete by measuring the hydration heat and recording the hydration time. This kind of method cannot be applied to the health monitoring of concrete structure after the concrete strength is fully developed.
The ultrasonic velocity-based method applies an ultrasonic meter on the surface of concrete structure to measure the velocity of the ultrasonic waves from the surface to evaluate the concrete strength. The shortcoming of this method is that the variation of the wave velocity of the ultrasonic waves is not sensitive to the strength of the concrete. A ten percent increment of strength may only result in less than one percent increment of the wave velocity.
Early-age concrete performance is an important and critical issue for the construction of the concrete structures. The construction speed and the quality evaluation of concrete at an early-age are the major concerns for the construction of civil concrete structures. After the concrete is cured, the detection of the existence and growth of cracks and damage is another important issue for the maintenance of civil concrete structures.
It is an object of the present invention, therefore, to extend the lifetime of concrete structures. It is a further object of the invention to enhance the safety of concrete buildings. It is also an object of the present invention to reduce the maintenance effort and cost for concrete structures.
BRIEF SUMMARY OF THE INVENTION
The invention is a novel unified performance-monitoring device (based on piezoelectricity) for concrete structures. A smart aggregate is directly embedded into a concrete structure at the desired location before casting and can be used, not only for early-age strength monitoring of concrete, but also for the health monitoring (crack and damage detection and evaluation) of concrete structure after the concrete strength has been fully developed.
A method for monitoring the health of a structure, comprising the steps of: coating piezoceramic transducers with an insulating material; embedding the piezoceramic transducers into a housing; embedding the housing into the structure; inducing a first waveform from a first piezoceramic transducer; and displaying a second waveform received by a second piezoceramic transducer. The structure of this method is composed of concrete. The step of embedding the housing occurs prior to the curing of the concrete. The piezoceramic transducers are composed of lead zirconate titanate. The housing is a cubic concrete block. The insulating material is composed of water-proof insulating layers.
This invention reduces the maintenance cost and effort of civil concrete structures and is also capable of giving precaution warnings before the failure of concrete structures.
This invention has the advantages of low cost, unified evaluation of concrete from early-age through the life-time, and easy implementation.
This invention has the potential to be manufactured in large quantities of commercial product as a meter for early-age performance evaluation and health monitoring (crack detection and evaluation) for civil concrete structures. The commercial product, based on this invention, will have a very competitive price and offer promising profits for civil construction companies, civil maintenance companies and related industrial companies.
The commercial market for the invented device is an obvious promising one due to the reason that the invented device is a great necessity for the early-age performance evaluation, the health monitoring during the maintenance period of large-scale concrete structures, such as bridges, buildings, and pillars. The safety and the life-time of the concrete structure are greatly improved by using the invented device.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective illustration of the piezoceramic transducer with waterproof coating.
FIG. 2 is an exploded view of smart aggregates embedded in a concrete structure.
FIG. 3 illustrates the experimental setup for strength testing and health monitoring testing.
FIG. 4 shows a concrete bent-cap (structure) with four smart aggregates embedded.
FIG. 5 is a chart illustrating the crack width measured by microscope and LVDT.
FIG. 6 is a chart showing the damage index curve vs. load of PZT 2 .
FIG. 7 is a chart showing the damage index curve vs. load of PZT 3 .
FIG. 8 is a chart showing the damage index curve vs. load of PZT 4 .
FIG. 9 is a photograph of a test frame setup with the reinforced concrete bent-cap specimen.
FIG. 10 is a perspective view of the present invention showing the location of smart aggregates.
FIG. 11 is a chart showing the crack width measured by microscope (MS) and LVDT.
FIG. 12 is a chart of the time response of PZT 10 with PZT 3 as actuator excited by the sweep sine (100-10 k Hz).
FIG. 13 is a chart of the damage index vs. load for PZT 1 with PZT 3 as actuator.
FIG. 14 is a chart of the damage index vs. load for PZT 2 with PZT 3 as actuator.
FIG. 15 is a chart of the damage index vs. load for PZT 5 with PZT 3 as actuator.
FIG. 16 is a chart of the damage index vs. load for PZT 8 with PZT 3 as actuator.
FIG. 17 is a chart of the damage index vs. load for PZT 9 with PZT 3 as actuator.
FIG. 18 is a chart of the damage index vs. load for PZT 10 with PZT 3 as actuator.
FIG. 19 is a photograph of an experimental setup for early-age strength monitoring of concrete specimens.
FIG. 20 is a photograph of a Universal compression testing machine for concrete cylinder compressive testing.
FIG. 21 is a chart showing the compressive strength of the concrete vs. age.
FIG. 22 is a chart showing the amplitude of specimens I, II and III for 60k harmonic response.
FIG. 23 is a chart showing the amplitude of specimens I, II and III for 100k harmonic response.
FIG. 24 is a chart showing the average value of the amplitude of different harmonic excitation.
FIG. 25 is a chart of the average value of the amplitude of different harmonic excitation after the seventh day.
FIG. 26 is a chart of the membership function of the input variable (harmonic amplitude).
FIG. 27 is a chart of the membership function of the output variable (compressive strength).
FIG. 28 is a chart showing the experimental training data and the fuzzy mapping data.
FIG. 29 is a chart showing the experimental compressive strength and the estimated compressive strength.
FIG. 30 is a chart of the experimental data for healthy monitoring of concrete cylinder specimen.
FIG. 31 is a chart of the damage index data for concrete cylinder specimen.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a piezoceramic-based smart aggregate 100 (see FIG. 1 ) for unified performance monitoring of concrete structures 102 and the method of making the smart aggregate 100 . A piezoceramic transducer 104 is formed from a piezoceramic patch 106 with electric wires 108 and a waterproof, insulating coating 110 .
One preferred embodiment of the smart aggregate 100 , as shown in FIG. 1 , contains an 8 mm×8 mm×0.267 mm piezoceramic patch 106 , the waterproof insulating coating 110 , two soldered electric wires 108 on two sides of the piezoelectric patch 106 that are all embedded in a small cubic concrete block 112 . This is meant by way of example and is not intended to limit the scope of the invention.
This smart aggregate 100 of the present invention has three obvious advantages over the current technology for early-age concrete performance evaluation:
(1) The smart aggregate 100 can be applied to the evaluation of concrete performance from the beginning of the hydration period through the life-time maintenance period. Other current, early-age concrete evaluation devices cannot be applied for the health monitoring (crack detection and evaluation) during the maintenance period.
(2) The present invention 100 is suitable for the performance evaluation of the in-situ, large-scale concrete structures 102 which may be inaccessible for other current devices (not shown) to evaluate the early-age concrete performance.
(3) The present invention 100 is very economical. The cost of one invented device 100 is approximately one dollar which is much less than the current transducer (not shown) for early-age concrete performance evaluation.
FIG. 2 shows the smart aggregate 100 embedded in the concrete structure 102 .
FIG. 3 is a preferred embodiment of an experimental testing system 120 for strength testing and health monitoring testing. The system 120 includes two smart aggregates (embedded in a concrete cylinder specimen 306 ) that are attached to industry standard devices (such as a function generator 300 , a power amplifier 302 , and an oscilloscope 304 ) via the electric wires 108 . The smart aggregate 100 can be used as either an actuator 100 a or sensor 100 s as depicted in FIG. 2 . The function generator 300 and the power amplifier 302 generate a signal to the smart aggregate 100 a to induce a mechanical force (shown in FIG. 2 ). The mechanical force is detected by the smart aggregate 100 s and the smart aggregate 100 s provides a signal to the oscillator 304 . The mechanical This test setup is meant by way of example and is not meant to limit the scope of the invention.
Method of Creating
To protect the piezoelectric patch 106 from water and moisture, the patch 106 is coated with waterproof coating layers 110 as shown in FIG. 1 . The smart aggregate 100 , as shown in FIG. 2 , is manufactured by embedding the coated, piezoelectric patch 106 into a small, cubic concrete block 112 . The smart aggregate 100 is then positioned at a pre-determined place in the concrete structure 102 before casting, as shown in FIG. 2 . This invention 100 is then used to conduct early-age strength monitoring and health monitoring after the concrete strength is fully developed.
The present invention uses a novel treatment of the piezoceramic transducer 104 . The piezoceramic transducer can be constructed from various ceramic materials, such as lead (plumbum) zirconate titanate (PZT). The piezoceramic transducer 104 is first coated with water-proof insulating layers 110 and then embedded into a cubic concrete block 112 to form the smart aggregate 100 . The smart piezoceramic-based aggregates 100 are then directly embedded into the concrete structure 102 to evaluate the performance of the concrete in the structure 102 .
Test Results for the Invention
Concrete cylinders with smart aggregates were tested. The strength monitoring experimental data verified the effectiveness of the invention to monitor the strength development of concrete at early ages. The health monitoring experimental data verified the effectiveness of the invention to be applied to the health monitoring of the concrete structure.
The following figures show the results of the testing which are an impressive improvement over current methods:
FIG. 4 shows one test of four smart aggregates 100 embedded into a concrete bent-cap concrete structure 102 . FIG. 5 is a chart of the test results (measured by microscope and LVDT) showing Crack Width vs Load V.
FIGS. 6-8 are charts showing the results of the Damage Index vs. Load for actuator PZT 1 and sensors PZT 2 , PZT 3 and PZT 4 , respectively.
FIG. 9 is a photograph of a test frame setup with the reinforced concrete bent-cap specimen 102 and four hydraulic actuators (A-D).
FIG. 10 is a view of the test frame setup showing the location of the smart aggregates (PZT 1 -PZT 10 ) 100 .
FIG. 11 is a chart of the crack width measured by microscope and LVDT.
FIG. 12 is a graph of the sensor voltage vs. time showing the time response of PZT 10 with PZT 3 as actuator excited by the sweep sine (100-10 k Hz).
FIGS. 13-18 are graphs showing the Damage Index vs. load for PZT 1 , PZT 2 , PZT 5 , PZT 8 , PZT 9 and PZT 10 , respectively, with PZT 3 as the actuator (sweep sine 10-100 Hz).
FIG. 19 is a photograph of an experimental setup for early-age strength monitoring of concrete specimens using an Agilent Function Generator, a Quickpack Power Amplifier, a Multifrequency LCR meter, a LeCroy Digital Oscilloscope and three concrete cylinder specimens.
FIG. 20 is a photograph of a Universal compression testing machine for concrete cylinder compressive strength testing.
FIG. 21 is a graph showing the compressive strength vs age (days) for the testing done on the Universal compression testing machine.
FIGS. 22-23 are graphs showing the amplitudes of specimens 308 a, b, c (see FIG. 19 ) for 60k and 100k harmonic response, respectively.
FIGS. 24-25 are graphs showing the average values of the amplitude of different harmonic excitation for various days.
FIGS. 26-27 are graphs showing the membership function of input (harmonic amplitude) and output (compressive strength) variables, respectively.
FIG. 28 is a graph showing the experimental training data and the fuzzy mapping data and FIG. 29 shows the experimental compressive strength and the estimated compressive strength.
FIG. 30 is a graph of the experimental data for health monitoring of concrete cylinder specimen (sensor voltage vs. time).
FIG. 31 shows the Damage Index data for the concrete cylinder specimen.
The above described embodiments are intended to be illustrative only and in no way limiting. The described embodiments of carrying out the invention are susceptible to many modifications of form, arrangement of parts, details and order of operation. The invention, rather, is intended to encompass all such modification within its scope, as defined by the claims.
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A system for monitoring the health of a structure, e.g., a concrete wall, bridge, pillars, using a smart aggregate is disclosed. The smart aggregate includes a piezoceramic transducer(s) and associated communication links. The transducer is embedded into the structure prior to the manufacture of the structure. The disclosed system can monitor internal stresses, cracks and other physical forces in the structures during the structures' life. The system is capable of providing an early indication of the health of the structure before a failure of the structure can occur.
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This application is a divisional of application Ser. No. 11/269,375 filed on Nov. 8, 2005, now U.S. Pat. No. 7,367,438.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to, in general, an external-control-type fan coupling device adopting a method which controls the rotation of a fan for cooling an engine in an automobile or the like in accordance with a temperature change of an external surrounding or a rotation change.
2. Description of the Related Art
Conventionally, as a fan coupling device of this type, there has been known a fan coupling device which is configured such that an inside of a hermetic housing which is formed of a non-magnetic casing and a cover which is mounted on the casing is supported on a rotary shaft body (a drive shaft) which mounts a drive disc on a distal end thereof by way of a bearing is divided into an oil reservoir chamber and a torque transmission chamber which houses the drive disc therein by a partition plate having an oil supply adjustment hole, and a valve element having magnetic property which opens or closes an oil circulation flow passage which is formed between the torque transmission chamber and the oil reservoir chamber is provided in the inside of the oil reservoir chafer, and an open/close control of the oil circulation flow passage is performed by operating the valve element using an actuator, wherein the rotational torque transmission from a drive side to a driven side is controlled by increasing or decreasing an effective contact area of oil in a torque transmission gap portion defined between the drive side and the driven side.
As this type of external-control-type fan coupling device, there has been known an external-control-type fan coupling device of a system which controls the rotation of a fan from the outside by operating an actuator inside the coupling device by exciting an electromagnetic coil fixed to an engine or vehicle body side. The structure forms a magnetic loop in which a magnetic flux generated by the excitation of the electromagnetic coil is transmitted to the valve element through a magnetic path of a magnetic body (shaft, valve element) having the high permeability, and the magnetic flux is again made to return to the electromagnetic coil, wherein a voltage is applied to the electromagnetic coil in response to an input signal from an ECU, and the valve element in the inside of the coupling device is opened or closed by a generated electromagnetic force thus controlling a flow rate of the torque transmission oil (see U.S. Pat. No. 6,443,283).
However, the above-mentioned conventional external-control-type fan coupling device has following drawbacks.
That is, in the method which operates the fan coupling device by transmitting the magnetic flux which excites the externally fixed electromagnetic coil to the valve element in the inside of the coupling device, it is necessary to form the magnetic loop in which the magnetic flux generated by the excitation of the electromagnetic coil is transmitted to the valve element through the magnetic path of a magnetic body (shaft, valve element) having the high permeability, and the magnetic flux is again made to return to the electromagnetic coil. Accordingly the conventional fan coupling device has a drawback that there exists the restriction on a layout with respect to a positional relationship of the electromagnetic coil and the valve element, a drawback that the casing and the valve structure become complicated, a drawback that there exists a possibility of leaking of oil in incorporating the magnetic parts for constituting the magnetic loop into the inside of the coupling device, a drawback that leaking of magnetism is increased due to the elongated magnetic circuit, a drawback that the general-purpose property of the system to fan coupling devices which differ in size is insufficient and the like.
SUMMARY OF THE INVENTION
The present invention has been made to overcome the above-mentioned drawbacks of the conventional external-control-type fan coupling device, and it is an object of the present invention to provide an external-control-type fan coupling device which receives no restriction on the layout with respect to the positional relationship of an electromagnetic coil and a valve element, achieves the simplification of the casing and the valve structure, the miniaturization and the reduction of weight of the device, and the prevention of the leaking of oil and the leaking of magnetism, and exhibits the sufficient system general-purpose property.
An external-control-type fan coupling device according to the present invention adopts a method in which a power generating part which supplies an electric current by making use of the rotation of a drive shaft (a rotating shaft body) is incorporated in the coupling device so as to drive an actuator which operates a valve element, wherein the gist of the present invention lies in that the fan coupling device is configured such that an inside of a hermetic housing which is formed of a non-magnetic casing which is supported on a rotary shaft body which mounts a drive disc on a distal end thereof by way of a bearing and a cover which is mounted on the casing is divided into an oil reservoir chamber and a torque transmission chamber which houses the drive disc therein by a partition plate which is mounted on the cover, the coupling device includes an oil circulation flow passage which is formed between the torque transmission chamber and the oil reservoir chamber and an oil supply adjustment hole which is formed in the partition plate, the coupling device includes a valve element which opens or closes the oil supply adjustment hole in the oil reservoir chamber, and an open/close control of the oil circulation flow passage is performed by operating the valve element using an actuator, and the rotational torque transmission from a drive side to a driven side is controlled by increasing or decreasing an effective contact area of oil in a torque transmission gap portion defined between the drive side and the driven side, wherein the actuator is mounted on the cover of the hermetic housing, the coupling device includes a primary coil which is fixed to the outside and a secondary coil which is fixed to the hermetic housing and faces the primary coil in an opposed manner, and the actuator which is mounted on the cover of the hermetic housing is driven by an electric current induced to the secondary coil.
Here, in the case of the external-control-type fan coupling device, a valve element open/close mechanism may be constituted by miniaturizing the actuator which operates the valve element and by mounting the miniaturized actuator on the cover of the hermetic housing in a state that the actuator is offset from the rotary shaft body.
Another external-control-type fan coupling device according to the present invention is configured such that an inside of a hermetic housing which is formed of a non-magnetic casing which is supported on a rotary shaft body which mounts a drive disc on a distal end thereof by way of a bearing and a cover which is mounted on the casing is divided into an oil reservoir chamber and a torque transmission chamber which houses the drive disc therein by a partition plate which is fixedly mounted on the drive disc, the coupling device includes an oil circulation flow passage which is formed between the torque transmission chamber and the oil reservoir chamber and an oil supply adjustment hole which is formed in the partition plate, the coupling device includes a valve element which opens or closes the oil supply adjustment hole in the oil reservoir chamber, and an open/close control of the oil circulation flow passage is performed by operating the valve element using an actuator, and the rotational torque transmission from a drive side to a driven side is controlled by increasing or decreasing an effective contact area of oil in a torque transmission gap portion defined between, the drive side and the driven side, wherein the coupling device adopts a method in which the actuator is arranged in the inside of the rotary shaft body, a control rod which is operated by the actuator penetrates the inside of the rotary shaft body in the axial direction so as to control the valve element, the coupling device includes a primary coil which is fixed to the outside and a secondary coil which is fixed to the rotary shaft body and faces the primary coil in an opposed manner, and the actuator which is mounted in the notary shaft body is driven by an electric current induced to the secondary coil.
Further, the coupling device of the present invention may adopt a method which rectifies an AC current induced to the secondary coil into a DC current and drives the actuator using the DC current , while either one of a rotary-type solenoid type actuator or a linear-type solenoid type actuator may be used as the actuator.
The external-control-type fan coupling device of the present invention adopts the method in which the electricity is supplied to the rotating coupling device body in a non-contact manner and the actuator for operating the valve element is driven by the electricity and hence, it is no more necessary to constitute a complicated magnetic circuit (a magnetic loop) adopted by the conventional structure thus simplifying the structure, the leaking of oil is substantially eliminated, and the leaking of magnetism is made extremely small. Further, since the power supply part (transformer part) and the actuator are electrically connected with each other by a lead line, the restriction on the layout with respect to the positional relationship of power supply part and the actuator is extremely small. Further, since the restriction on-size of the actuator portion is small, the general-purpose property is also enhanced. Still further, even when the external-control-type fan coupling device is a large-diameter external-control-type fan coupling device to drive a large-diameter fan for a large-sized vehicle and the position of the oil supply adjustment hole becomes remote from the center of rotation of the coupling device, it is unnecessary to increase a diameter of coils and the coupling device can be operated with the small-diameter coil whereby the coupling device becomes miniaturized and light-weighted thus giving rise to an advantageous effect that the layout property is also enhanced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross-sectional view showing the first embodiment of an external-control-type fan coupling device according to the present invention.
FIG. 2 is a longitudinal cross-sectional view showing the second embodiment of an external-control-type fan coupling device according to the present invention.
FIG. 3 is a longitudinal cross-sectional view showing the third embodiment of an external-control-type fan coupling device according to the present invention.
FIG. 4 is a longitudinal cross-sectional view showing the fourth embodiment of an external-control-type fan coupling device according to the present invention.
FIG. 5 is a longitudinal cross-sectional view showing the fifth embodiment of an external-control-type fan coupling device according to the present invention.
FIG. 6 is a longitudinal cross-sectional view showing the sixth embodiment of an external-control-type fan coupling device according to the present invention.
FIG. 7 is a schematic view showing layout examples of a primary coil and a secondary coil in the external-control-type fan coupling device of the present invention, wherein A and B show the external-control-type fan coupling device of a lateral type and C to F show the external-control-type fan coupling device of a vertical type.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 to FIG. 6 show an example of an external-control-type fan coupling device according to the present invention, wherein FIG. 1 and FIG. 2 are longitudinal cross-sectional views showing an external-control-type fan coupling device which adopts a rotary type solenoid type as an actuator, while FIG. 3 to FIG. 6 are longitudinal cross-sectional views showing an external-control-type fan coupling device which adopts a linear solenoid type as an actuator, and FIG. 7 is a schematic view shoving layout examples of a primary coil and a secondary coil in the fan coupling device according to the present invention. In the drawing, numeral 1 indicates a rotary shaft body (drive shaft), numeral 2 indicates a hermetic housing, numeral 2 - 1 indicates a casing, numeral 2 - 2 indicates a cover, numeral 3 indicates a drive disc, numeral 4 indicates a partition plate, numeral 5 indicates an oil reservoir chamber, numeral 6 indicates a torque transmission chamber, numeral 7 indicates an oil recovery-circulation flow passage, numeral 8 indicates an oil supply adjustment hole, numerals 9 - 1 to 9 - 6 indicate oil-supply valve elements numerals 10 - 1 , 10 - 2 indicates a rotary-type solenoid-type actuator, numerals 10 - 3 to 10 - 6 indicate a linear solenoid-type actuator, numeral 11 indicates a rectifier, numeral 12 indicates a power source supply transformer, numeral 12 - 1 indicates a primary coil (electromagnetic coil), numeral 12 - 2 indicates a secondary coil (electromagnetic coil) , numeral 13 indicates a lead line, numeral 14 indicates a hermetic housing bearing, numeral 15 indicates a primary-coil bearing, and numeral 16 indicates a fan.
That is, in the external-control-type fan coupling device shown in FIG. 1 , on the rotary shaft body (the drive shaft) 1 which is rotated by driving of a drive part (engine), the hermetic housing 2 which is formed of the casing 2 - 1 and the cover 2 - 2 is supported by way of the hermetic housing bearing 14 . The inside of the hermetic housing 2 is divided into the oil reservoir chamber 5 and the torque transmission chamber 6 by the partition plate 4 provided with the oil supply adjustment hole 8 . In the inside of the torque transmission chamber 6 , the drive disc 3 which is fixedly mounted on a distal end of the rotary shaft body 1 is housed in a state that a torque transmission gap is formed between the drive disc 3 and an inner peripheral surface of the torque transmission chamber.
The oil-supply valve element 9 - 1 which opens or closes the oil supply adjustment hole 8 through which the oil recovered by the oil recovering circulation communication passage 7 formed in the cover 2 - 2 flows out to the torque transmission chamber 6 is mounted on a control rod 10 - 1 a of the rotary-type solenoid-type actuator 10 - 1 mounted on a front surface of the cover 2 - 2 . Due to such a constitution, the oil-supply valve element 9 - 1 is tilted above the partition plate 4 due to the rotation of the control rod 10 - 1 a so as to open or close the oil-supply adjustment hole 8 . Here, when the linear solenoid type actuator is used, the oil supply adjustment hole 8 is opened or closed due to the frontward and backward movement of the control rod 10 - 1 a.
The power source supply transformer 12 is constituted of the primary coil 12 - 1 which is fixed to the engine or the vehicle body side and a secondary coil 12 - 2 which is fixed to the casing 2 - 1 of the coupling device. To explain an operational principle of the power source supply transformer 12 , when an AC voltage (a sinusoidal wave or a square wave) is applied to the primary coil 12 - 1 , due to an electric current which flows in the primary coil 12 - 1 , a magnetic flux is generated in a primary coil core due to the Ampere's right-handed screw law, the magnetic flux flows into the rotating secondary coil core, and again returns to the primary coil core thus forming a magnetic loop. Hare, a vector of the magnetic flux which flows in the secondary coil core has the direction thereof changed in synchronism, with an AC frequency applied to the primary coil 12 - 1 . Further, due to an electromagnetic induction action of the magnetic flux (magnetic field) which flows in the secondary coil core, an electric current is induced in the secondary coil 12 - 2 , this AC current flows into the actuator 10 - 1 side through a lead line 13 which is wired in the inside of the hermetic housing 2 , the AC current is rectified into a DC current by the rectifier 11 which is attached to the actuator 10 - 1 , and the DC current is used as a driving power of the actuator so as to operate the oil-supply valve element 9 - 1 . Here, when an AC actuator is used, the rectifier 11 is not necessary.
The external-control-type fan coupling device shown in FIG. 2 adopts a system in which the rotary-type solenoid-type actuator 10 - 2 and the rectifier 11 are arranged in the inside of the rotary shaft body (drive shaft) 1 , and the control rod 10 - 2 a of the actuator 10 - 2 penetrates the rotary shaft body 1 in the axial direction 30 as to operate the oil-supply valve element 9 - 2 . To explain the structure of the system, the inside of the hermetic housing 2 which is constituted of the casing 2 - 1 which is supported on the rotary shaft body (drive shaft) 1 which fixedly mounts the drive disc 3 on a distal end thereof by way of the hermetic housing bearing 14 and the cover 2 - 2 is divided into the oil reservoir chamber 5 and the torque transmission camber 6 which arranges the drive disc therein by the partition plate 4 having the oil supply adjustment hole 8 which is fixedly mounted on the drive disc 3 , and in the inside of the torque transmission chamber 6 , the drive disc 3 which is fixedly mounted on the distal end of the rotary shaft body 1 is housed in a state that a torque transmission gap is formed between the drive disc 3 and an inner peripheral surface of the torque transmission chamber 6 . Further, the control rod 10 - 2 a of the rotary solenoid-type actuator 10 - 2 which is arranged in the inside of the rotary shaft body (drive shaft) 1 axially penetrates the rotary shaft body 1 and projects into the inside of the oil reservoir chamber 5 , the oil-supply valve element 9 - 2 which opens or closes the oil supply adjustment hole 8 formed in the partition plate 4 which is fixedly mounted on the drive disc 3 is fixedly mounted on the distal end of the control rod 10 - 2 a , To explain the manner of operation of this fan coupling device, in the same manner as the fan coupling device shown in FIG. 1 , due to the rotation of the control rod 10 - 2 a of the actuator 10 - 2 , the oil-supply valve element 9 - 2 is tilted on the partition plate 4 so as to open or close the oil supply adjustment hole 8 . Further, in the case of this fan coupling device, the secondary coil 12 - 2 of the power source supply transformer 12 is fixed to the rotary shaft body (drive shaft) 1 . Further, in case of this fan coupling device, the secondary coil 12 - 2 of the power source supply transformer 12 is fixed to the rotary shaft body (drive shaft) 1 . Here, also in the case of this fan coupling device, when the linear solenoid type actuator is used, the oil supply adjustment hole 8 is opened or closed due to the forward and backward movement of the control rod 10 - 2 a.
As shown in FIG. 2 , when the external-control-type fan coupling device adepts the system in which the rotary-type solenoid type actuator 10 - 2 and the rectifier 11 are arranged in the inside of the rotary shaft body (drive shaft) 1 and the control rod 10 - 2 a of the actuator 10 penetrates the rotary shaft body 1 in the axial direction and operates the oil-supply valve element 9 - 2 , it is possible to form the oil reservoir chamber 5 in the inside of the partition plate 4 of the drive disc 3 which is rotated at a speed higher than a speed of the hermetic housing 2 and hence, it is possible to supply the oil by making use of a large centrifugal which is generated by the high-speed rotation of the rotary shaft body (drive shaft) 1 whereby the oil supply ability is enhanced thus also enhancing a fan rotation response. Further, since the actuator which has a large weight is not arranged on the cover side, a moment weight is decreased. Accordingly, compared to the external-control-type fan coupling device shown in FIG. 1 adopting the system which fixes the actuator to the cover 2 - 2 , it is possible to reduce a load of the bearing 14 which supports the follower portion (the hermetic housing 2 constituted of the casing 2 - 1 and the cover 2 - 2 ) and a load of a bearing (not shown in the drawing) of an engine-side drive shaft (not shown in the driving) which drives the rotary shaft body 1 thus enhancing the durability of the bearings and also enhancing the reliability of the whole cooling system of the engine.
Further, in the system which fixes the secondary coil 12 - 2 of the power source supply transformer 12 to the rotary shaft body (drive shaft) 1 , compared to the external-control-type fan coupling device shown in FIG. 1 which adopts the system in which the secondary coil 12 - 2 is fixed to the casing 2 - 1 , in the same manner as the above-mentioned case, it is possible to reduce the weight of the follower portion (the hermetic housing 2 formed of the casing 2 - 1 and the cover 2 - 2 ) and hence, it is possible not only to reduce the load of the bearing 14 which supports the follower portion but also to shift the position of center of gravity of the fan coupling device to the engine side thus bringing about advantages such as the reduction of the moment load on the rotary shaft body (drive shaft) 1 and the lowering of the elevation of the electric resistance attributed to the heat generation of the fan coupling device which is caused by the shortening of the distance of the lead line 13 from, the secondary coil 12 - 2 to the actuator 10 - 2 .
The external-control-type fan coupling device shown in FIG. 3 adopts a system in which the linear solenoid type actuator 10 - 3 is adopted in place of the rotary-type solenoid-type actuator 10 - 1 in the external-control-type fan coupling device shown in the above-mentioned FIG. 1 , and the oil supply valve element 9 - 3 which is formed of a leaf spring 9 - 3 a and an armature 9 - 3 b is used in place of the oil supply valve element 9 - 1 , wherein a drive electricity of the linear solenoid type actuator 10 - 3 is supplied from the power source supply transformer 12 through the lead line 13 .
That is, in the external-control-type fan coupling device which adopts the linear solenoid type actuator 10 - 3 , a proximal end portion of the leaf spring 9 - 3 a is mounted on the partition plate 1 in a state that the armature 9 - 3 b of the oil-supply valve element 9 - 3 which is formed of the leaf spring 9 - 3 a and the armature 9 - 3 b is positioned in the vicinity of the driving portion of the actuator 10 - 3 .
In the external-control-type fan coupling device having the above-mentioned constitution, when the linear solenoid-type actuator 10 - 3 is turned OFF, the armature 9 - 3 b of the oil-supply valve element 9 - 3 is spaced apart from the actuator 10 - 3 due to an action of the leaf spring 9 - 3 a thus opening the oil-supply adjustment hole B formed in the partition plate 4 and the oil is supplied to the torque transmission chamber 5 , while when the actuator 10 - 3 is turned ON, the armature 9 - 3 b is sucked to the actuator 10 - 3 side and hence, the leaf spring 9 - 3 a is brought into pressure contact with the partition plate 4 whereby the oil supply adjustment hole 3 is closed and the supply of the oil to the torque transmission chamber 5 is stopped.
In case of the external-control-type fan coupling device shown in the above-mentioned FIG. 3 , by adopting the linear solenoid-type actuator 10 - 3 having no operating shaft, it is possible to enhance not only the fan rotation response but also the durability of the actuator 10 - 3 and the oil-supply valve element 9 - 3 and the reliability of the whole cooling system of the engine. Further, it is possible to completely eliminate the possibility of leaking of oil.
The external-control-type fan coupling device shown in FIG. 4 relates to a case in which the present invention is applied to an external-control-type fan coupling device in which the partition plate 4 having the oil supply adjustment hole 3 is fixedly mounted on the drive disc 3 and the fan coupling device adopts a system which supplies electricity to the linear-solenoid-type actuator 10 - 4 and is equal to the system shown in FIG. 1 . An operation mechanism of the oil-supply valve element is, in the same manner as the operation mechanism of the oil-supply valve element shown in FIG. 3 , configured such that, in place of the oil-supply valve element 9 - 1 of the external-control-type fan coupling device shown in FIG. 1 , the fan coupling device uses the oil-supply valve element 9 - 4 which is formed of a leaf spring 9 - 4 a and an armature 9 - 4 b , and a proximal end portion of the leaf spring 9 - 4 a is mounted on the partition plate 4 which is fixedly mounted on the drive disc 3 in a state that the armature 9 - 4 b of the oil-supply valve element 9 - 4 is positioned in the vicinity of a drive portion of the actuator 10 - 4 mounted on the cover 2 - 2 of the hermetic housing 2 .
In case of the external-control-type fan coupling device which adopts the linear solenoid-type actuator 10 - 4 , when the actuator 10 - 4 is turned OFF, the armature 9 - 4 b of the oil-supply valve element 9 - 4 is spaced apart from the actuator 10 - 4 due to an action of the leaf spring 9 - 4 a thus opening the oil-supply adjustment hole 8 formed in the partition plate 4 fixed to the drive disc 3 and the oil is supplied to the torque transmission chamber 6 , while when the actuator 10 - 4 is turned ON, the armature 9 - 4 b is sucked to the actuator 10 - 4 side and hence, the leaf spring 9 - 4 a is brought into pressure contact with the partition plate 4 whereby the oil supply adjustment hole 8 is closed and the supply of the oil to the torque transmission chamber 6 is stopped.
In case of the external-control-type fan coupling device shown in FIG. 4 , by adopting the linear solenoid-type actuator 10 - 4 having no operating shaft, it is possible to enhance the fan rotation response. Further, compared to the external-control-type fan coupling device having the structure in which the partition plate 4 having the oil supply adjustment hole 3 is mounted on the cover 2 - 2 of the hermetic housing 2 , the external-control-type fan coupling device shown in FIG. 4 can make use of a centrifugal force of the rotary shaft body (drive shaft) 1 for supplying the oil to the torque transmission chamber 6 and hence, it is possible to further enhance the fan rotation response.
The external-control-type fan coupling device shown in FIG. 5 relates to a case in which the present invention is applied to an external-control-type fan coupling device in which the partition plate 4 having the oil supply adjustment hole 8 is fixedly mounted on the cover 2 - 2 of the hermetic housing 2 and the fan coupling device adopts a system which supplies electricity to the linear-solenoid-type actuator 10 - 5 which is equal to the system shown in FIG. 1 . That is, the fan coupling device shown in FIG. 5 adopts the system in which the linear solenoid type actuator is miniaturized and, at the same time, the miniaturized actuator is neither aligned nor coaxial with the rotary shaft body (drive shaft) 1 but is offset from the rotary shaft body (drive shaft) 1 so as to open or close the oil supply adjustment hole 8 . To explain the constitution of the fan coupling device, the linear solenoid-type miniaturized actuator 10 - 5 is mounted on an end portion of the cover 2 - 2 of the hermetic housing 2 , and the oil-supply valve member 9 - 5 which opens or closes the oil supply adjustment hole B of the partition plate 4 which is fixed to the cover 2 - 2 of the hermetic housing 2 is resiliently supported on the miniaturized actuator 10 - 5 by way of a spring 9 - 5 a.
In case of the external-control-type fan coupling device which adopts the linear solenoid-type miniaturized actuator 10 - 5 , when the actuator 10 - 5 is turned OFF, the oil-supply valve element 5 - 5 is spaced apart from the actuator 10 - 5 due to an action of the spring 9 - 5 a thus opening the oil-supply adjustment hole 3 formed in the partition plate 4 fixed to the cover 2 - 2 and the oil is supplied to the torque transmission chamber 6 , while when the actuator 10 - 5 is turned ON, the oil-supply valve member 9 - 5 is sucked to the actuator 10 - 5 side and hence, the valve member 9 - 5 is brought into pressure contact with the partition plate 4 whereby the oil supply adjustment hole 8 is closed and the supply of the oil to the torque transmission chamber 6 is stopped.
In case of the external-control-type fan coupling device shown in FIG. 5 , by adopting the linear solenoid-type miniaturized actuator 10 - 5 having no operating shaft and by adopting the system which opens or closes the oil supply adjustment hole 8 by offsetting the rotary shaft body (drive shaft) 1 , it is possible to enhance the fan rotation response and, at the same time, it is possible to achieve the miniaturization, the reduction of weight of the fan coupling device and the reduction of the manufacturing cost of the fan coupling device.
The external-control-type fan coupling device shown in FIG. 6 relates-to a case in which the present invention is applied to an external-control-type fan coupling device in which the partition plate 4 having the oil supply adjustment hole 8 is fixedly mounted on the drive disc 3 and the fan coupling device adopts a system in which the linear solenoid-type actuator 10 - 6 is mounted on the drive disc 3 , the oil-supply valve element 9 - 5 which is formed of a leaf spring 9 - 6 a and an armature 9 - 6 b is used, and the drive electricity for the linear solenoid-type actuator 10 - 6 is supplied from the power source supply transformer 12 shown in FIG. 2 through the lead line 13 .
In case of the external-control-type fan coupling device which adopts the linear solenoid-type actuator 10 - 6 , the armature 9 - 6 b of the oil-supply valve element 9 - 6 is formed of the leaf spring 9 - 6 a and the armature 9 - 6 b , the proximal end portion of the leaf spring 9 - 6 a is mounted on the partition plate 4 in a state that the armature 9 - 6 b of the oil-supply valve element 9 - 6 is arranged in the vicinity of the drive part of the actuator 10 - 6 , Further, the fan coupling device adopts a system in which the drive electric power for the actuator 10 - 6 is supplied to the actuator 10 - 6 from the power source supply transformer 12 fixed to the rotary shaft body (drive shaft) 1 through the lead line 13 which is wired in the inside of the rotary shaft body (drive shaft) 1 .
In the external-control-type fan coupling device having such a constitution, when the linear solenoid-type actuator 10 - 6 is turned OFF, the armature 9 - 6 b of the oil-supply valve element 9 - 6 is spaced apart from the actuator 10 - 6 due to an action of the leaf spring 9 - 6 a thus opening the oil-supply adjustment hole 8 formed in the partition plate 4 , and the oil is supplied to the torque transmission chamber 6 , while when the actuator 10 - 6 is turned ON, the armature 9 - 6 b is sucked to the actuator 10 - 6 side end hence, the leaf spring 9 - 6 a is brought into pressure contact with the partition plate 4 whereby the oil supply adjustment hole 8 is closed and the supply of the oil to the torque transmission chamber is stopped.
In case of the external-control-type fan coupling device shown in FIG. 6 , by adopting the linear solenoid-type actuator 10 - 6 having no operating shaft, in the same manner as the fan coupling device shown in FIG. 2 and FIG. 4 , it is possible to enhance the fan rotation response. Further, since the lead line 13 for supplying electricity can be wired in the inside of the rotary shaft body (drive shaft) 1 , compared to the system in which the lead line 13 is wired through the casing 2 - 1 and the cover 2 - 2 of the hermetic housing 2 , it is possible to obtain advantageous effects including an advantageous effect that a centrifugal force which acts on the lead line 13 is small and hence, there is no possibility of the occurrence of disconnection whereby the elevation of the electric resistance attributed to the generation of heat by the fan coupling device can be reduced.
As the layout (arrangement) of the primary coil 12 - 1 and the secondary coil 12 - 2 of the power source supply transformer 12 according to the device of the present invention, six types A, B, C, D, E, F are considered as illustrated in FIG. 7 . To explain the technical features of the respective types, the transformer 12 of the type A has the simple structure and hence, it is possible to achieve the miniaturization and the reduction of weight of the transformer 12 and the reduction of manufacturing cost, the transformer 12 of the type B can achieve the miniaturization and the reduction of weight and, at the same time, exhibits the favorable magnetism transmission efficiency from the primary coil 12 - 1 to the secondary coil 12 - 2 , the transformer 12 of the type C has the simple structure and hence, it is possible to reduce the manufacturing cost and, at the same time, can easily perform the coil fixing method, the transformer 12 of the type D provides the easy coil fixing method and exhibits the favorable magnetism transmission efficiency from the primary coil 12 - 1 to the secondary coil 12 - 2 , and the transformer 12 of the types E and F can realize the miniaturization and the reduction of the weight and, at the same time, and can exhibit the favorable magnetism transmission efficiency from the primary coil 12 - 1 to the secondary coil 12 - 2 .
In the fan coupling device having the above-mentioned constitutions shown in FIG. 1 to FIG. 6 , the rotation of the fan 16 is controlled by following methods (1), (2).
(1) When the ECU determines that the increase of the rotational speed of the fan 16 is necessary in response to the information such as a radiator water temperature, an intake air temperature, an engine rotational speed, a step-in depth of an acceleration pedal, a vehicle speed or the like, an AC voltage (sinusoidal wave or square wave) is applied to the primary coil 12 - 1 of the power source supply transformer 12 and hence, the actuator 10 is operated so as to open the oil supply valve member 3 to elevate the rotational speed of the fan 16 . When it is necessary to lower the rotational speed of the fan 16 , the power source is turned OFF. Here, due to the setting of the actuator 10 , it is possible to adopt either one of an OFF/ON mode with no supply of electricity and an ON/OFF mode with supply of electricity,
(2) When the rotational speed of the fan is to be controlled to an arbitrary rotational speed instructed by an ECU, a feedback control is performed on the fan rotational speed. Further, by changing the primary coil 12 - 1 side power source frequency, an inductive electromotive force amount induced by the secondary coil 12 - 2 is changed so as to control an operational amount of the actuator 10 whereby the rotational speed of the fan is controlled to an arbitrary rotational speed instructed by the ECU.
Here, when the rotary solenoid type actuator is used, by providing the oil supply adjustment holes 8 formed in the partition plate 4 in plural numbers by changing both of the radial directional positions and the circumferential directional positions, it is possible to sequentially form the oil supply adjustment holes 8 starting from the oil supply adjustment holes 8 at the position where the radius is smallest and hence, it is possible to perform the multiple-stage control of the fan rotational speed. Further, by gradually and continuously forming the oil supply adjustment holes 8 , it is possible to perform a linear control of the fan rotational speed. Still further, by forming the oil supply adjustment holes 8 in multiple stages in a state that the diameter of the oil supply adjustment holes 8 is made continuously and gradually smaller, it is possible to perform a finer multiple-stage control of the fan rotational speed.
INDUSTRIAL APPLICABILITY
The external-control-type fan coupling device of the present invention adopts the system in which the power generating part which supplies the electricity by making use of the rotation of the drive shaft (rotary shaft body) is incorporated into the fan coupling device so as to drive the actuator which operates the valve element. Accordingly, even when the external-control-type fan coupling device is a large-diameter external-control-type fan coupling device to drive a large-diameter fan for a large-sized vehicle, it is unnecessary to increase a diameter of coils and hence, it is possible to achieve the simplification, the miniaturization and the reduction of weight of the whole device structure whereby the layout property is enhanced. Further, the power consumption can be reduced. Still further, the present invention is also applicable to the existing external-control-type fan coupling device.
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An external-control-type fan coupling device is provided and has no restriction on the layout or positional relationship of an electromagnetic coil and a valve element of the device. As a result, the casing and the valve structure of the device can be simplified. Additionally, the design prevents leaking of oil and leaking of magnetism without adversely affecting performance.
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TECHNICAL FIELD
[0001] This invention relates generally to consumer goods and more particularly to wearable dispensers and methods for carrying at least one article.
BACKGROUND OF THE INVENTION
[0002] Consumers appreciate conveniences which make the tasks of their daily lives quicker and/or easier. Children in particular are less likely than others to stop an activity to look for a necessary item (e.g., a tissue) and therefore tend to do without such items with predictable consequences. Children also are more likely than others to leave an item (e.g., food, money, clothing, toys) in a quickly forgotten location when they do not deem it important at a specific moment in time.
[0003] There are various types of dispensers and holders to hold such items. However, these holders and dispensers are often easily left behind due to their bulk or size. Additionally, often it may not be convenient to access the contents of such holders and dispensers. For example, pocket-size tissue holders are often used as an alternative to carrying around a standard sized tissue box at times when mobility is required or desired. However, these tissue holders can be easily lost due to their small size. Additionally, they may be too large to fit in a child's pocket and often small childrens' clothing does not include any pockets.
[0004] Thus, there is a need for a wearable dispenser to hold and dispense items, particularly tissues, which is readily available to a user, and in particular to children, at all times to facilitate use of such items and prevent them from being lost.
SUMMARY OF THE INVENTION
[0005] The present invention provides, in a first aspect, a wearable dispenser for enabling a user to carry at least one article. The wearable dispenser includes a container in the form of at least a portion of a three-dimensional shape of a character for containing the at least one article and a connector which is attachable to the container and to the user or the user's clothing.
[0006] The present invention provides, in a second aspect, a wearable tissue dispenser for enabling a user to carry a plurality of tissues. The wearable tissue dispenser includes a container for containing the plurality of tissues and a wristband which is attachable to the container and to a wrist of a user.
[0007] The present invention provides, in a third aspect, a method for enabling a user to carry at least one article. The method includes providing a container in the form of at least a portion of a three-dimensional shape of a character for containing the at least one article, and attaching the container to an outer portion of the user or the user's clothing.
[0008] The present invention provides, in a fourth aspect, a method for enabling a user to carry a plurality of tissues. The method includes providing a container for containing the plurality of tissues, providing a connector, and attaching the connector to the container and to an outer portion of the user or the user's clothing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention will be readily understood from the following detailed description of preferred embodiments taken in conjunction with the accompanying drawings in which:
[0010] [0010]FIG. 1 is a perspective view of a wearable dispenser in accordance with one embodiment of the present invention;
[0011] [0011]FIG. 2 is a front perspective view of the wearable dispenser of FIG. 1;
[0012] [0012]FIG. 3 is another perspective view of the wearable dispenser of FIG. 1;
[0013] [0013]FIG. 4 is a bottom view of the wearable dispenser of FIG. 1;
[0014] [0014]FIG. 5 is a perspective view of another embodiment of a connector in accordance with the present invention; and
[0015] [0015]FIG. 6 is a side elevational view of a second embodiment of a wearable dispenser in accordance with the present invention.
DETAILED DESCRIPTION
[0016] Examples of a wearable dispenser are depicted in FIGS. 1 - 6 and described in detail herein.
[0017] FIGS. 1 - 3 depict one embodiment of a wearable dispenser 10 according to the present invention which includes a container 20 in the form or shape of a fictional character or non-fictional character adapted to hold a variety of items or articles such as gum, tissues, money, paper, food, toys, or other small items, and a connector or wristband 70 which is desirably worn by a user. Advantageously, wearable dispenser 10 may hold various items, thus making them readily available to a user, and in particular to children. In this way, needed items, for example tissues, can be dispensed or removed therefrom when needed without the necessity of searching for the items.
[0018] Container 20 includes a bottom, upwardly extending sides and an aperture or an opening 30 extending through a side thereof, preferably a top side 40 thereof. Opening 30 is adapted to dispense the items therethrough. Preferably, container 20 holds tissues 50 which are dispensed to a user through opening 30 .
[0019] Desirably, container 20 is formed in a three-dimensional shape of a popular children's character which might be drawn, for example, from books, movies, or television programming. Such a character might be, for example, an animal, person, caricature of a person, plant, or portion thereof. An example of container 20 embodying a fictional character is illustrated in FIGS. 1 - 3 and 6 . Opening 30 of container 20 may be formed as the mouth, nose, belly, hand, or other portion of such a character. For example, as illustrated in FIGS. 1 - 3 and 6 , opening 30 is formed as a portion of a belly of the fictional character. By forming container 20 in such a way, the child might more likely want to wear wearable dispenser 10 while storing items in container 20 , such as tissues, and more likely dispense them as needed. Thus, the child is saved the necessity of finding a tissue and a parent is saved the trouble of cleaning any clothing soiled as a result of the child ignoring a need for a tissue.
[0020] In this illustrated embodiment, container 20 includes an openable or a detachable portion 60 (FIGS. 1 and 3) for receiving various items to be contained within container 20 . Items may thus be inserted or removed from container 20 through an opening 62 (FIG. 3). For example, openable portion 60 may be hingedly attached along an edge 73 . As best illustrated in FIG. 3, edges 72 , 75 , and 79 may matingly engage edges 71 and include hook and loop fasteners, for example VELCRO-type fasteners, or other means, allowing openable portion 60 to be readily opened and securely closed. For example, openable portion 60 might include one or more hook portions 77 on edges 71 while container 20 might include one or more loop portions 78 on edges 72 , 75 , and 79 . As an alternative, an openable portion may include a zipper or other releasably closable means. Desirably, openable portion 60 and opening 62 may be sized to allow the insertion of a tissue holder 65 (FIG. 3) into container 20 thus allowing tissues 50 to be dispensed to the user through opening 30 .
[0021] As depicted in FIGS. 1 - 5 , container 20 may be fixedly or removably attachable to a connector which might be a wristband 70 , wrist strap, or bracelet which may be attached to a wrist of the user via fasteners, for example hook and loop fasteners, a buckle, or a zipper, or other suitable fasteners. FIG. 1 depicts a buckle 32 on an end portion 33 of wristband 70 and holes 34 to receive buckle 32 on an end portion 35 of wristband 70 , for example. In addition, as shown in FIG. 4, wristband 70 may be attachable to container 20 , for example, by being threaded through slots 90 in a bottom side 92 of container 20 . Wristband 70 might also be formed in the shape of or might be adorned with images of, for example, the characters described above for container 20 . Wristband 70 and container 20 might also be formed from materials which are soft, such as textiles, so as to be comfortable for the user and easily washable, allowing for convenient care thereof. Various portions of dispenser 10 might also be made of plastic materials. Advantageously, dispenser 10 might be made of materials sufficiently soft to reduce or prevent injury to a child if he were to fall while wearing it.
[0022] As shown in FIG. 5, another embodiment of a connector or wristband 170 may include hook and loop fasteners provided on the ends of wristband 170 . For example, hook portions 80 might be attached to a first end portion 85 of wristband 170 while loop portions 82 might be attached to a second end portion 87 of wristband 170 , thus enabling easy attachment to a wrist of the user. The use of hook and loop fasteners on first end portion 85 and second end portion 87 advantageously allow easy release of wrist band 170 from a user if wrist band 170 was to catch on a foreign object. For example, wrist band 170 might release from a child if it was to be caught on a piece of playground equipment. From the present description, it will be appreciated by those skilled in the art that a wristband might also be a continuous elongatable or stretchable band. A user might stretch such a band to put it on and take it off while it might suitably retract or constrict to a size of a user's wrist when it is worn. The use of such fasteners is particularly useful for those, for example the elderly, who might have difficulty using other fasteners requiring more intricate maneuvering.
[0023] In a further embodiment of a wearable dispenser 110 , illustrated in FIG. 6, container 120 may be fixedly or removably attachable to a connector 193 , a portion of which may be removably or fixedly attachable to a user or directly to the user's clothing. For example, the connector may be releasably attachable to an outer portion of the user or the user's clothing. As shown in FIG. 6, connector 193 might include hook and loop fasteners to connect container 120 to the user's clothing. A hook portion 194 may be connected to container 120 and a loop portion 196 may be connected to the user's clothing 200 , for example an outer portion of the user's clothing such as a shirt or pants. Container 120 is readily attachable to clothing 200 by attaching hook portion 194 to loop portion 196 .
[0024] From the present description, it will be appreciated by those skilled in the art that other forms of connectors for attaching a wearable dispenser to the user or to the user or to the user's clothing may be suitably employed. For example, a container might be attached to a user's clothing using a pin, zipper, spring biased clip or other means. For example, a container might be attached to a shirt pocket of a user using a spring biased clip. These described connectors for attaching the wearable dispenser are in contrast to the user simply carrying tissues in the shirt pocket.
[0025] As discussed above, by attaching container 20 to a user or a user's clothing, the user can easily and conveniently remove the contents of container 20 . For example, if the user is a child and container 20 holds tissues 50 , then a child could conveniently pull tissues 50 from the dispenser for use as needed.
[0026] Although preferred embodiments have been depicted and described in detail herein, it will be apparent to those skilled in the relevant art that various modifications, additions, substitutions and the like can be made without departing from the spirit of the invention and these are therefore considered to be within the scope of the invention as defined in the following claims.
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The present invention provides a wearable dispenser for enabling a user to carry at least one article. The wearable dispenser includes a container having at least a portion of a three-dimensional character for containing at least one article and a connector attachable to the container and to the user or the user's clothing. Desirably, the wearable dispenser is suitable for containing tissues, and the connector is a wristband which can be worn about a wrist of a child.
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GOVERNMENT LICENSE RIGHTS
The United States Government may have certain rights in some aspects of the invention claimed herein, as the invention was made with United States Government support under award/contract number NBCHC010038 for the Department of Interior/National Business Center.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to communications between and transfer of signals between integrated circuit chips, interconnections between such chips and methods of connecting integrated circuit chips for high speed communications therebetween.
2. Description of the Related Art
The coupling of signals between integrated circuit chips, either on the same circuit board or between boards, is of critical interest. Metal interconnections (i.e., metal backplanes) appear to have reached their speed limits, which are estimated to be in the 100s of Giga-bits-per second (Gbps), for each backplane. Discrete channel fiber-optical connections are being incorporated on top of the metal interconnections, but they too are limited to approximately 10 Gbps per channel.
The LVDS standard (Low Voltage Differential Signaling) is currently a popular standard and is based on differential data transmission. This popularity is mainly driven by the ability of LVDS to deliver high speed transmission without large power consumption. LVDS is a differential scheme, which uses two signal lines (traces or conductors) to convey information, with increased noise tolerance in the form of common-mode rejection being achieved. Because of the improvement in signal-to-noise rejection, the signal swing could be dropped to only a few hundred millivolts. Specifications for the LVDS standard may be found in ANSI/TIA/EIA-644-1995 Electrical characteristics standard titled: “Electrical Characteristics of Low Voltage Differential Signaling (LVDS) Interface Circuits.”
In addition, LVDS offers other benefits that include low voltage power supply compatibility, low noise generation, high noise rejection, robust transmission signals, and integration. For these reasons, it has been deployed across market segments wherever the need for speed exists. Even with all these benefits, there are some limitations in certain applications, including support of multipoint bus configurations, operation from still lower power rail voltage, and extended receiver common-mode range.
Of particular interest and need is the ability to increase transmission power efficiency in terms of data transmission speed per unit of power.
SUMMARY OF THE INVENTION
The present invention solves this need by providing a new design for low power, high speed chip-to-chip communication (either on the same circuit board or between boards on a common backplane).
According to the present invention, a very low voltage swing is used to achieve very high data rates (up to 4 Gbps double data rate) at very low power consumption. A differential signaling approach is used for noise rejection, and a constant current approach also is used to minimize switching noise.
The invention provides according to one preferred embodiment a complete link for high speed, low power chip-to-chip communication, including driver and receiver configurations.
According to an embodiment of the present invention, the differential swing and common mode are decreased so as to effectively increase the data speed and lower the power usage of integrated circuit chip I/O cells. To accomplish this, according to one exemplary embodiment of the invention novel designs of amplifier, inverter, ESD (electrostatic discharge) protection, current mirror, and current driver components are provided to achieve the desired data transfer speed and power consumption goals.
In particular, according to one aspect of the invention, an input/output interface circuit for transferring data between integrated circuit chips is provided, which includes a driver circuit including an inverter stage and a constant current driving stage, that receives an input data signal and develops a differential voltage signal corresponding thereto, a receiver circuit that receives the differential voltage signal from the driver circuit, including a differential in/differential out amplifier stage that receives the differential voltage signal and outputs an amplified differential signal, a differential in/single-ended out amplifier stage that receives said amplified differential signal and outputs a voltage swing signal, and an inverter stage for increasing drive strength of said voltage swing signal for transfer into a chip core.
According to a second aspect of the invention, a method of providing low power, high speed data transfer between integrated circuit chips is provided, including the steps of converting data output from an integrated circuit chip to a differential voltage signal having a common mode range of 1 V, and a voltage swing of 100 mV, converting the differential voltage signal to a constant current driving signal and applying said constant current driving signal to a differential receiver circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a chart showing a modified differential voltage swing and common mode range according to one preferred embodiment of the invention;
FIG. 2 is a circuit diagram of a receiver interface according to one preferred embodiment of the present invention;
FIG. 3 is a circuit diagram of a driver interface according to one preferred embodiment of the present invention; and
FIG. 4 is a chart showing input waveform vs. output waveform for the circuit designs of FIGS. 2 and 3 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates the difference between a conventional LVDS signaling standard and the modified design according to one preferred embodiment of the invention. As shown, according to a conventional LVDS standard, a common mode voltage range of 2.4 V, and a differential signal swing of 400 mV at 1.25 V are used. According to one embodiment of the present invention, a modified common mode range of 1 V is used, along with a differential signal swing of 100 mV at 0.55 V. In order to realize the use of such modified levels, new designs of circuit components for both a receiver and driver circuit are provided.
Referring to FIG. 2 , one preferred embodiment of a receiver circuit 20 according to the present invention is disclosed. A first stage of the receiver circuit is an ESD protection stage 21 , including a pair of modified transmission gates, a first of which receives a high differential voltage input Vih, and a second of which receives a low differential voltage input Vil, across a resistor R 1 . A second stage of the receiver is a differential in/differential amplifier stage 22 . Transistor matching was used to increase the circuit's sensitivity to small differential signals. A first input MXP8 of stage 22 receives the high differential voltage Vih from ESD protection stage 21 , and a second input MXP9 of stage 22 receives the low differential voltage Vil from ESD protection stage 21 . Differential voltage signal are outputted at nodes NR 2 and NR 3 .
A third stage of the receiver circuit is a differential in/single-ended out amplifier stage 23 . This stage receives differential voltage inputs at gates MXP 11 and MXP 12 , and outputs a single voltage signal at output node NR 6 . The output voltage signal from amplifier stage 23 is a weak, large swing (i.e. nearly rail-to-rail) signal.
The final stage of the receiver circuit 20 is an inverter series stage 24 , which includes a number of inverters arranged in series to increase the drive strength of the receiver into the core of a chip. While only two inverters are shown in the example of FIG. 2 , it will be recognized by those of skill in the art that a greater or lesser number of inverters also may be used in accordance with specific application/chip design considerations. The inverter stage receives the single voltage output signal from amplifier stage 23 at input X 17 , and outputs a final output voltage signal Dig_Out at output node NR 8 .
Referring now to FIG. 3 , an exemplary embodiment of a driver circuit 30 according to the present invention is described. The driver circuit is composed of three main stages. The first stage is an inverter stage comprised of two groups 31 , 32 of three inverters each. One of the inverters of group 32 is used as a signal delay to compensate for the propagation time required for the data signal to transition to the next state. The inverter stage 31 , 32 receives an input signal Dig_In, processes the signal and provides the signal at each of nodes ND 2 and ND 7 .
The next stage is a current driving stage 33 . The current driving stage 33 provides driver differential voltage signals Vin and !Vin at nodes ND 4 and ND 9 . The final stage is an ESD protection stage 34 formed of modified transmission gates. The ESD protection stage receives the differential voltage signals and passes them through to a receiver. There are two areas of ESD protection in the driver circuit 30 . In addition to the ESD stage 34 , the transistors on either side of nodes ND 4 and ND 9 provide increased ESD protection. The main purpose of these transistors is to modify the DC offset of the output differential signal from the driver.
FIG. 4 is a chart showing input v. output waveforms for the I/O transfer circuit. The input signal to the driver, which typically is from the core of a chip, is indicated by the wave having an arrow pointing to the driver input at the bottom of the figure. The output waveform of the receiver is indicated by the wave having an arrow pointing to the receiver output at the bottom of the figure. The 100 mV differential signal, with a DC offset of approximately 600 mV, is indicated by the arrows pointing to the input of the receiver at the bottom of the figure.
Table 1 below shows the relationship between input signal frequency and average power consumed. As shown, the power requirements of the circuit increase as the frequency (i.e., speed) of the input signal increases. As seen, the circuit exhibits a non-linear increase in efficiency as frequency increases. When the clock rate of the input signal is more than doubled from 0.6 GHz to 2 GHz, the average power increases only slightly, at less than 50%. The Data Rate Per Unit Power column shows the number of bits per second transmitted for each watt of power used. The final column shows the improvement factor of the present invention over existing LVDS designs.
TABLE 1
Simulated I/O power at various speeds.
Data Rate
Data
Per Unit
Average
Clock
Rate
Power
Improvement
Power
Rate
@DDR
@DDR
Over
(mW)
(GHz)
(Gbps)
(Gbps/W)
Existing Cell
Existing LVDS
46.5
0.6
1.2
26
1
(0.18)
MSP cell (0.18)
11.5
0.6
1.2
104
4
MSP cell (0.18)
12.3
1
2
162
6
MSP cell (0.18)
13.3
1.5
3
216
9
MSP cell (0.18)
14.2
2
4
282
11
Table 2 shows simulated I/O power at 2 GHz over three simulated cases of voltage and temperature ranges. In the worst-case conditions, the temperature is high (125 C) and the voltage is low (−10% of normal level), and the transistors do not respond well to stimuli. For the nominal case, all of the parameters remain at normal operating conditions. Finally, in the best case conditions the temperature is low (−55 C), the voltage is high (+105 of normal level), and the transistors respond better than average to stimulus. The simulated average power is lowest for worst-case conditions and increases as conditions improve. The first row results were obtained before the simulated circuit layout was implemented. The second row was collected after insertion of the driver. The extracted driver included metal capacitance and diodes. The last row shows the power required for a design implementing LVDS in 0.25 um technology.
TABLE2
Simulated I/O power at 2 GHz over voltage and temperature ranges
Worst Case
Nominal Case
Best
T = 125° C.
T = 25° C.
T = −55° C.
V −10% = 1.62 V
V −5% = 1.7 V
V −5% = 1.7 V
V = 1.8 V
V +5% = 1.89 V
V +10% = 1.98 V
lo = −4.1 mA
lo = −4.8 mA
lo = −6.5 mA
lo = −7.6 mA
lo = −12.1 mA
lo = −13.6 mA
Diffo = 100 mV
Diffo = 120 mV
Diffo = 180 mV
Diffo = 200 mV
Diffo = 350 mV
Diffo = 375 mV
Ones
Clk
Ones
Clk
Ones
Clk
Ones
Clk
Ones
Clk
Ones
Clk
(mW)
(mW)
(mW)
(mW)
(mW)
(mW)
(mW)
(mW)
(mW)
(mW)
(mW)
(mW)
Latest Design @ 2 GHz
5.69
7.17
6.81
8.52
9.12
11.02
11.17
13.34
18.34
21.43
21.78
25.29
Driver Extract @ 2 GHz
5.28
7.03
6.47
8.27
8.51
10.49
10.43
12.67
17.39
19.73
20.40
23.19
Atmel Driver @ 600 MHz
25.00
45.00
70.00
The invention having been fully described above with reference to the drawing figures, it will be apparent to those of skill in the art that certain modifications, variations, and alternative constructions are possible, while remaining within the spirit and scope of the invention.
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A very low voltage swing is used to achieve very high data rates (up to 4 Gbps double data rate) at very low power consumption. A differential signaling approach is used for noise rejection, and a constant current approach also is used to minimize switching noise.
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FIELD OF THE INVENTION
[0001] The invention relates to an apparatus and methods for thermally processing substrates, such as semiconductor wafers.
BACKGROUND OF THE INVENTION
[0002] Coating/developing units, using photolithography processes for manufacturing semiconductor devices and liquid crystal displays (LCD's), generally coat a resist on a substrate, expose the resist coating to light to impart a latent image pattern, and develop the exposed resist coating to transform the latent image pattern into a final image pattern having masked and unmasked areas. This permits deposition or treatment of selected portions of the surface of the semiconductor wafer. Such a series of processing stages is typically carried out in a coating/developing system having discrete heating sections, such as a post apply baking unit and a post exposure baking unit. Each heating section of the coating/developing system incorporates a hotplate with a built-in heater.
[0003] Feature sizes of semiconductor device circuits have been scaled to less than 0.1 microns. Typically, the pattern wiring that interconnects individual device circuits is formed with sub-micron line widths. Consequently, the heat treatment temperature of the resist coating should be accurately controlled to provide reproducible and accurate feature sizes and line widths. The substrates or wafers (i.e., objects to be treated) are usually treated or processed under the same process (i.e., individual treatment program) in units (i.e., lots) each consisting of, for example, twenty-five wafers. Individual processes define heat treatment conditions under which baking is performed. Wafers belonging to the same lot are heated under the same conditions.
[0004] The post exposure bake (PEB) process serves multiple purposes in photoresist processing. First, the elevated temperature of the bake drives the diffusion of the photoproducts in the resist. A small amount of diffusion may be useful in minimizing the effects of standing waves, which are the periodic variations in exposure dose throughout the depth of the resist coating that result from interference of incident and reflected radiation. Another main purpose of the PEB may be to drive an acid-catalyzed reaction that alters the solubility of the polymer layer used in many chemically amplified resists. PEB may also play a role in removing solvent from the wafer surface.
[0005] Hotplates having uniformities within a range of a few tenths of a degree centigrade are currently available and are generally adequate for current process methods. Hotplates are calibrated using a flat bare silicon wafer with imbedded thermal sensors. However, actual production wafers carrying deposited films on the surface of the silicon may exhibit small amounts of warpage because of the stresses induced by the deposited films. This warpage may cause the normal gap between the wafer and the hotplate (referred to as the proximity gap), to vary across the wafer from a normal value of approximately 100 μm by as much as a 100 μm deviation from the mean proximity gap (normal value).
[0006] This variability in the proximity gap changes the heat transfer into the wafer causing temperature variations on the wafer surface. These temperature differences in a PEB may result in a change in critical dimension (CD) in that area of several nanometers, which can approach the entire CD variation budget for current leading edge devices, and will exceed the projected CD budget for smaller devices planned for production in the next few years.
[0007] What is needed, therefore, is a method for heating a substrate during the pre- and post-exposure bake processes in a thermal processing system that is tolerant of warpage.
SUMMARY OF THE INVENTION
[0008] The invention is premised on the realization that in a post exposure bake the topography of the bottom surface of a semiconductor wafer may be measured prior to the post exposure bake process utilizing an inline metrology unit. The topographical data measured by an inline metrology unit may then be conveyed to a control system for a hotplate as the wafer is transferred to the hotplate in a baking unit. Different heating elements in the hotplate are controlled to compensate for the differences in distances from the hotplate surface to the surface of the wafer, as measured in the inline metrology unit.
[0009] By imbedding proximity sensors into a surface, above which the wafer is positioned prior to the baking step, one can measure the gap at a plurality of points between each individual wafer and a reference plane on the surface containing the sensors prior to baking. This may provide individual profiles of the warpage for each wafer. From the profile data, individual temperature offsets to compensate for the proximity gap variation may be calculated from a reference look-up table, and the appropriate adjustments may be made to the individual heating element zones beneath the areas of proximity variation. In other embodiments, the topography measurements may be taken after the baking step and stored. The stored measurements are used to adjust the heat applied to the wafer in subsequent baking steps.
[0010] Because the ramp up of the temperature of a cold wafer is a dynamic event, small adjustments in control set points may stabilize during the ramp event. By this method, each wafer will see a customized heating event matching the physical shape of that individual wafer. The two primary advantages of this approach are individual wafer physical measurement for custom compensation, and high speed on the fly correction with no loss in production. This same method may be used in other similar wafer heating processes such as the post apply bake.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.
[0012] FIG. 1 is a flow diagram depicting an exemplary processing sequence for a semiconducting wafer.
[0013] FIG. 2 is a diagrammatic view of a thermal processing apparatus including an inline metrology unit and a baking unit.
[0014] FIG. 3A is an isometric view showing a wafer with an alignment notch.
[0015] FIG. 3B is a top view of the wafer in FIG. 3A .
[0016] FIG. 4 is a top plan view of an inline metrology unit of the thermal processing apparatus of FIG. 2 .
[0017] FIG. 5 is a cross-sectional view taken generally along line 5 - 5 in FIG. 4 .
[0018] FIG. 6 is an isometric view showing detail of the base of the inline metrology unit of FIGS. 4 and 5 .
[0019] FIG. 7 is a diagrammatic top view of the base of FIG. 6 .
[0020] FIG. 8 is a top plan view of a baking unit of the thermal processing apparatus of FIG. 2 .
[0021] FIG. 9 is a cross-sectional view taken generally along line 9 - 9 in FIG. 8 .
[0022] FIG. 10 is a detailed view of a portion of FIG. 8 .
[0023] FIG. 11 is an isometric view showing detail of the base of the baking unit of FIGS. 8 and 9 .
[0024] FIG. 12 is a diagrammatic top view of the base of the baking unit showing a representative arrangement for the heating elements.
[0025] FIG. 13 is a top view of a base in an inline metrology unit having an alternative arrangement for the proximity sensors.
[0026] FIG. 14 is a top view of a base of a baking unit with heating elements arranged in correspondence with the proximity sensors in FIG. 13 .
DETAILED DESCRIPTION
[0027] Photolithography processes for manufacturing semiconductor devices are divided into a series of lithography sequences. Each sequence may add a layer on to what may eventually become a multi-layer device. There are many different options that may be contained in any particular sequence. FIG. 1 shows an exemplary lithography sequence that may be used in conjunction with the present invention.
[0028] Referring now to FIG. 1 , a wafer is loaded on to a coating/developing unit, also known as a Track tool, for processing. In block 10 , the wafer may first be transferred to a vapor prime module on the Track tool where the wafer receives a pre-treatment to a surface to improve adhesion of a photoresist coating that will be applied to the wafer. In block 11 , the wafer may then be transferred to a cool plate to stabilize the wafer temperature prior to coating. In block 12 , once stabilized, the wafer may be transferred to a spin coating device where the wafer is coated by spinning the wafer while dispensing a liquid photoresist or other material to an extremely uniform thin film. In block 13 , the wafer may again be transferred to a cool plate to stabilize the temperature of the wafer prior to baking.
[0029] In block 14 , the wafer may then be baked in a post apply bake step where the wafer is baked to drive out any residual solvents, leaving a photosensitive polymer film. In block 15 , after the bake, the wafer may be transfer to a cool plate to cool and stabilize the temperature of the wafer after the bake. In block 16 , in some lithography sequences, a second film coating for a top coat or an anti-reflective film coat may be applied. If the second layer is applied, blocks 11 - 15 are repeated in the sequence shown in FIG. 1 .
[0030] In block 17 , at the completion of the coating process, in some lithography sequences and in accordance with an embodiment of the present invention, the wafer may be evaluated for conformance to parameters. Conventional metrology tools perform their measurements “offline” that is, they are separate units and the production of the wafer must be interrupted for the measurements to be taken, which may introduce delays into the process. For example, a bare wafer thickness measurement may be taken using a metrology unit, preferably in-line with the rest of the process to minimize the wafer being loaded and unloaded from the Track tool. The in-line metrology unit (i.e. IM unit) may provide the thickness measurement to confirm the photoresist film quality, or the IM unit may perform an analysis for patterned wafer defect (macro inspection). In block 18 , after the evaluation of the wafer, the wafer may then leave the Track tool and be transferred to a scanner for pattern exposure. After exposure, the wafer may then be transferred back to the Track tool.
[0031] In block 19 , the wafer may then be transferred to a baking unit for a post exposure bake. This is one of the more critical bake activities, which is sensitive to temperature non-uniformities. The bake activates the chemistry in the exposed regions of the photoresist. In block 20 , the wafer may then be transferred after the bake, to a cool plate to cool and stabilize the temperature of the wafer. In block 21 , once stabilized, the wafer may then be transferred to a develop unit where the exposed pattern regions are rinsed away, typically with an alkaline fluid, followed by a water rinse. In block 22 , the wafer may then be transferred to a bake unit where a post develop bake, or “hard” bake is performed to stabilize the patterned film for resistance to subsequent etching or implant processing.
[0032] In block 23 , the wafer may be transferred after the hard bake to a cool plate to cool and stabilize the temperature of the wafer. In block 24 , after cooling and in some lithography sequences, a metrology unit, in-line or off line, may be used for an After Develop Inspection (ADI) or an Optical Digital Profilometry (ODP) critical dimension measurement. After these measurements, the wafer leaves the Track tool.
[0033] Because of the critical nature of the Post Exposure Bake (PEB) step in a lithography sequence, an embodiment of a thermal processing apparatus 30 may be included in the lithography sequence at the first metrology measurement as indicated above. The thermal processing apparatus 30 may include an inline metrology unit 40 (i.e., IM unit) in combination with a baking unit 80 used for the PEB as shown in FIG. 2 . The topography measurements from the inline metrology unit 40 transfer to a control unit 122 , which may operate baking unit 80 .
[0034] With reference to FIG. 2 and as discussed above, the wafer 70 is processed in the thermal processing apparatus 30 . The wafer 70 is initially transferred to the IM unit 40 , as part of the sequence for processing the wafer 70 as discussed above. A series of proximity sensors obtain a plurality of distance measurements in the IM unit 40 . These measured distances may then be stored in the control unit 122 , or in other embodiments, may be transferred and stored offline. The measured distances may then be used by the control unit 122 to activate and control the heating elements 120 of a hotplate 90 contained in a baking unit 80 as the wafer 70 is being transferred to the baking unit 80 . The control unit 122 controls the power supplied to the heating elements 120 to make adjustments to temperatures of the elements based on the measured distances to account for non-uniformities in the wafer 70 and to provide for a uniform heating of the wafer 70 .
[0035] With reference now to FIGS. 4-7 , the inline metrology unit 40 of the thermal processing apparatus 30 may comprise a series of outer walls 62 which house a cylinder 52 , common base and support arm 56 , a base 60 , and a horizontal support wall 63 . The base 60 is positioned in a circular cut out in the horizontal support wall 63 and is further supported by a horizontal supporting member 61 . An opening 68 in the outer walls 62 allow for the wafer 70 to be transferred to and from the inline metrology unit 40 .
[0036] The base 60 includes through holes 50 that align with lift pins 48 . The lift pins 48 extend from the common base and support arm 56 . The common base and support arm 56 are connected to, and supported by, a rod 54 of a vertical cylinder 52 . When the rod 54 is actuated to protrude from the cylinder 52 , the lift pins 48 protrude from the base 60 , thereby lifting the wafer 70 . Likewise, when the rod 54 is retracted into the cylinder 52 the lift pins 48 recede into the through holes 50 lowering the wafer toward a top surface 60 a of the base 60 . Projections 64 on the top surface 60 a of the base 60 accurately position the wafer 70 . In addition to the projections 64 and as best show in FIGS. 3A , 3 B, the wafer 70 may contain notch 70 n that may be used to position the wafer in the inline metrology unit providing an orientation reference for the distance measurements. The top surface 60 a also includes a plurality of smaller projections (“proximity pins”) 58 adapted to support the semi-conductor wafer 70 from its bottom surface 70 b so that the bottom surface 70 b of a wafer 70 does not contact the top surface 60 a of the base 60 of the inline metrology unit 40 .
[0037] The top surface 60 a of the base 60 includes a plurality of proximity sensors 42 . The number and location of the proximity sensors 42 may be determined by the configuration of the hotplate 90 in the baking unit 80 . A sufficient number of proximity sensors 42 are utilized to provide sufficient data to control heating elements 120 in hotplate 90 . Accordingly, the number of sensors 42 scales with the number of heating elements 120 . In an embodiment in which the hotplate 90 has a series of concentric heating elements 120 , each of the heating elements 120 may be monitored by at least 3 sensors 42 ( FIG. 7 ) and these sensors 42 may be located at the same distance from a center point corresponding to one of the concentric heating elements 120 ( FIG. 11 ). A variety of different types of proximity sensors 42 may be used including but not limited to infrared, acoustic, inductive, eddy current, and capacitive type proximity sensors, as well as laser interferometers.
[0038] The proximity sensors 42 are configured to determine the distances from a reference plane to the bottom surface 70 b of the semiconductor wafer 70 . The distance measurements obtained in the inline metrology unit 40 may be stored in control unit 122 for later use to control the hotplate 90 in the baking unit 80 .
[0039] In addition to measuring the distances, in some embodiments, the IM unit 40 may also make other measurements to evaluate processing properties of the wafer 70 . The IM unit 40 may provide a thickness measurement to confirm the photoresist film quality or the IM unit 40 may perform an analysis for patterned wafer defect (macro inspection). These measurements may be made simultaneously with the distance measurements using measuring device(s) 69 and are conventionally performed by making measurements on a top side of the wafer 70 .
[0040] Wafer 70 may then be transferred to the other intervening modules for processing as illustrated in FIG. 1 and described above. Wafer 70 may then be transferred to a post exposure bake unit (“baking unit”) 80 . As discussed above, the post exposure bake activates the chemistry in the exposed regions of the photoresist. The topography data, which was measured in the inline metrology unit 40 and stored in the control unit 122 , may be retrieved prior to the wafer arriving at the baking unit 80 . In alternative embodiments, the topography data may be stored offline and delivered to the control unit 122 concurrently with the arrival of the wafer 70 at the baking unit 80 . The topography data from the inline metrology unit 40 may be used to control the temperatures of heating elements 120 of the hotplate 90 to compensate for differences in distances of various points between the hotplate 90 and wafer 70 .
[0041] With reference to FIGS. 8-11 , the baking unit 80 of the thermal processing apparatus 30 heats wafers 70 to temperatures above room temperature. Each baking unit 80 may include a processing chamber 82 , a hotplate 90 , and at least one resistance heater forming the heating elements 120 embedded in the hotplate 90 . In some embodiments, the heating elements may be arranged in a concentric ring fashion as best seen in FIG. 11 .
[0042] The hotplate 90 has a plurality of through-holes 108 and a plurality of lift pins 106 inserted into the through-holes 108 . The lift pins 106 are connected to and supported by an arm 104 , which is further connected to and supported by a rod 102 of a vertical cylinder 100 . When the rod 102 is actuated to protrude from the cylinder 100 , the lift pins 106 protrude from the hotplate 90 , thereby lifting the wafer 70 .
[0043] The upper surface of the hotplate 90 includes projections 118 , which facilitate accurate positioning of the wafer 70 . In addition to the projections 118 , the notch 70 n (FIGS. 3 A and 3 B) in the wafer may be used to position the wafer such that the distance measurements obtained in the inline metrology unit 40 correspond to the heating elements 120 , 120 ′, 120 ″ of hotplate 90 . Proximity pins 116 , which are located on the upper surface of the hotplate 90 , support wafer 70 above hotplate 90 . When the wafer 70 is delivered to the hotplate 90 , the proximity pins 116 contact the bottom surface 70 b of the wafer 70 and elevate the wafer 70 above the hotplate 90 forming a gap. The gap is sufficient to expose the bottom surface 70 b of the wafer 70 to the elevated temperatures produced by the hotplate 90 and prevent the bottom surface 70 b of the wafer 70 from contacting the hotplate 90 to prevent contamination and strain.
[0044] As discussed above, the wafers 70 carry a layer of processable material, such as photoresist. The layer contains a substance that is volatized and released at the process temperature. This volatile substance evaporates off of the wafer 70 when the layer is exposed to the heat energy produced by the hotplate 90 at temperatures sufficient to heat the wafer 70 to process temperatures. An exhaust port 98 a at the center of the lid 98 communicates with an exhaust pipe 99 . The waste product generated from the surface of the wafer during the heat treatment is exhausted through the exhaust port 99 a and vented from the processing chamber 82 via exhaust pipe 99 to an evacuation unit (not shown).
[0045] The temperature of each heating element 120 , 120 ′, 120 ″ of hotplate 90 ( FIG. 11 ) is established by control unit 122 . The control unit 122 utilizes the measured distances determined by proximity sensors 42 in the inline metrology unit 40 to establish set temperatures by adjusting the power for the individual heating element 120 , 120 ′, 120 ″ to uniformly heat a wafer 70 during processing. Heating elements 120 , 120 ′, 120 ″ selectively adjust areas on the hotplate 90 to compensate for differences in the measured distances from various points of the semi-conductor wafer 70 to the hotplate.
[0046] The temperature required for each heating element to uniformly heat the bottom surface 70 b of semi-conductor wafer 70 can be determined empirically by testing the hot plate 90 using sensors located at various distances from the surface of the hot plate 90 and storing this data. Alternatively, this can be determined utilizing the following algorithm:
[0000]
ρ
C
p
L
T
t
=
k
air
δ
(
T
-
T
plate
)
-
h
(
T
-
T
ambient
)
[0000] where ρ is the density of silicon; C p is the heat capacity of silicon; L is the thickness of the wafer; T is the temperature of the resist-coated wafer, K air is the thermal conductivity of air, δ is the thickness of the gap between the hot plate 90 and the wafer 70 ; and h is a coefficient for heat lost from the top surface of the wafer to the surroundings. Thus, the control unit 122 can either utilize stored empirical data or the algorithm in order to determine the set point for each heating element 120 on the hotplate 90 .
[0047] With reference to FIGS. 13 and 14 and in an alternative embodiment, a hotplate 90 ′ may include a plurality of heating elements 126 , 126 ′, 126 ″, 126 ′″ with each one of these elements having a plurality of individual segments. The number of individual segments in each of the heating elements 126 , 126 ′, 126 ″, 126 ′″ may increase with increasing radius. Each of the heating element segments 126 , 126 ′, 126 ″, 126 ′″ may be selectively activated by the control unit 122 responsive to distances measured from the proximity sensors 42 located in the top surface 60 a ′ of the base 60 ′ of the inline metrology unit 40 . To provide the measured distances needed to control these heating element segments 126 , 126 ′, 126 ″, 126 ′″, the top surface 60 a ′ may include at least one proximity sensor 42 for each of the heating element segments 126 , 126 ′, 126 , 126 ′″. The particular arrangement of the heating element segments 126 , 126 ′, 126 ″, 126 ′″ may vary depending upon the desired application.
[0048] Adjusting the heating elements 120 of the hotplate 90 allows the baking unit 80 to uniformly heat the wafer 70 compensating for irregularities or warpage of the wafer 70 . Heating elements 120 may be adjusted for a wafer 70 prior to the wafer 70 arriving at the baking unit 80 so that the time required for the hotplate 90 to come to the proper temperature for each wafer 70 being processed may be minimized. Making topography measurements of the wafer 70 in the inline metrology unit 40 maintains efficiency, as the wafer 70 does not need to leave and be returned to the Track tool during processing. This invention addresses the uneven heating problem due to variability in the proximity gap with the prior art, while maintaining efficient processing of the wafer 70 .
[0049] While the present invention has been illustrated by a description of various embodiments and while these embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicants' general inventive concept.
|
A thermal processing apparatus and method with predictive temperature correction. Distances are measured from a backside of the wafer relative to a reference plane. Heat is transferred to the backside of the substrate in relation to the measured distances. This allows a baking unit to uniformly heat the substrate to compensate for irregularities or warpage.
| 5
|
CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] This patent application is based on Taiwan, R.O.C. patent application No. 098125837 filed on Jul. 31, 2009.
FIELD OF THE INVENTION
[0002] The present invention relates to the channel estimation technology, and more particularly, to a channel estimation method and apparatus applied to an orthogonal frequency division multiplexing (OFDM) communication system.
BACKGROUND OF THE INVENTION
[0003] In a wireless communication system, the inter-symbol interference (ISI) exists in received signals due to the common multi-path fading effect. To remove the ISI, a receiver is generally provided with an equalizer that needs information of channel impulse response (CIR) to operate, and therefore estimation of the CIR plays an important character in a mobile radio system.
[0004] In addition, OFDM, an important communication technology in the wireless communication field, is mainly for increasing the data transmission rate. For example, the data transmission rate in IEEE 802.11a using the OFDM technology reaches up to 54 Mbps, compared to the transmission rate of only 11 Mbps in IEEE 802.11b without the OFDM technology. Therefore, it is an important subject as how to effectively estimate CIR of an OFDM system to remove ISI, so as to fully exert a characteristic of high transmission rate of the OFDM technology. In the OFDM system, channel estimation, i.e., CIR estimation, is normally realized via pilot symbols that are known to a transmitter and a receiver.
[0005] Refer to FIG. 1 showing a block diagram of a conventional OFDM channel estimation apparatus comprising a 4096-sampling-point inverse fast Fourier transformation (IFFT) unit 101 , a mirror image rejection unit 102 , a 4096-sampling-point fast Fourier transformation (FFT) unit 103 , and a frequency-domain response smoothing unit 104 .
[0006] The 4096-sampling-point IFFT unit 101 performs 4096-sampling-point IFFT operation on a preliminary frequency channel response {tilde over (H)}(k) to generate a time-domain CIR {tilde over (h)}(n). Refer to FIG. 2 showing a frequency and time distribution comprising 4096 symbols {tilde over (h)}(0), {tilde over (h)}(1), {tilde over (h)}(2), . . . , {tilde over (h)}(4095). The conventional OFDM channel comprises 4096 sub-carriers, of which one in every 8 sub-carriers comprises a pilot sub-carrier for carrying a pilot symbol, and the remaining sub-carriers (other than the pilot sub-carriers) referred to as data sub-carriers are for carrying data symbols. That is, in the 4096 sub-carriers, there are 512 pilot sub-carriers for carrying pilot symbols, and there are 3584 data sub-carriers for carrying data symbols. FIG. 3 shows a time-frequency plane of 17×4096 symbols transmitted in a conventional OFDM channel. Estimation of a preliminary frequency-domain channel response {tilde over (H)}(k) is obtained by performing the least square difference algorithm on a frequency-domain transmitting value and a frequency-domain receiving value of a pilot symbol. That is, the preliminary frequency-domain channel response {tilde over (H)}(k) only has algorithm values at a frequency k corresponding to pilot sub-carries, and frequency channel response values corresponding to the remaining data sub-carriers are equal to zero. The 512 pilot symbols in the 4096 sub-carriers are distributed in two types, an even type and an odd type, alternatively. Please refer to FIG. 3 , the even type is the horizontal row with a leading black circle as the following:
[0000] ◯◯◯◯◯◯◯◯◯◯◯◯◯◯xxxx,
and the odd type is the horizontal row with a leading while circle as the following:
◯◯◯◯◯◯◯◯◯◯◯◯◯◯xxxx.
The black circle represents pilot symbols. Pilot sub-carriers corresponding to the pilot symbols are at positions 0, 8, 16, 24 . . . 4088 in the even type and 4, 12, 20, 28 . . . 4092 in the odd type. The while circle ◯ represents data symbols, and the mark x represents repeating symbols as the left side. Therefore, the preliminary frequency-domain channel response {tilde over (H)}(k) may be an even frequency-domain channel response or an odd frequency-domain channel response according to the distribution of pilot symbols in 4096 sub-carriers. The even frequency-domain channel response and the odd frequency-domain channel response are alternatively transmitted to the 4096-sampling-point IFFT unit 101 .
[0007] The mirror image rejection unit 102 maintains first and last 256 time-domain CIR values of the 4096 time-domain CIR {tilde over (h)}(n), and filters the mirror image signals, i.e., the remaining 3584 time-domain CIR values, to generate a time-domain CIR {tilde over (h)} w (n) as:
[0000]
h
~
w
(
n
)
=
{
h
~
(
n
)
,
n
=
[
0
,
255
]
⋃
[
3840
,
4095
]
0
,
n
=
[
256
,
3839
]
[0000] The FFT unit 103 performs 4096-sampling-point FFT operation on the time-domain CIR {tilde over (h)} w (n) to generate a frequency-domain channel response Ĥ(k), where k is equal to 0 to 4095.
[0008] The frequency-domain response smoothing unit 104 performs arithmetic averaging operation according to 17 groups of the frequency-domain channel responses, i.e., Ĥ 1 (k), Ĥ 2 (k), . . . , Ĥ 17 (k), to generate a re-estimated frequency-domain channel response Ĥ S (k) represented by:
[0000]
H
^
S
(
k
)
=
1
17
(
H
^
1
(
k
)
,
H
^
2
(
k
)
,
…
,
H
^
17
(
k
)
)
,
[0000] where k is equal to 0 to 4095.
[0009] In the conventional OFDM channel estimation apparatus, only 512 sampling values of the 4096-sampling-point IFFT operation are non-zero, and others are equal to zero. Therefore, the 4096 IFFT operation is in fact large in scale that lacks of efficiency and needs to be improved. According to the present invention, a low-cost solution for reducing IFFT operation scale according to characteristics of China multimedia mobile broadcasting (CMMB) OFDM systems is provided to maintain a same channel estimation efficiency as when the operation scale is small.
[0010] In view of the problem, a novel algorithm for channel estimation is provided by the invention. The algorithm implements smaller scale IFFT operation to adaptively adjust operation formulas for processing the preliminary frequency-domain channel response to reach the same performance, so as to significantly reduce the overall operation scale.
SUMMARY OF THE INVENTION
[0011] One object of the present invention is to provide a channel estimation method having low cost and low power consumption to adaptively estimate CIR to be provided to a receiver for performing compensation.
[0012] Another object of the present invention is to provide a channel estimation apparatus having low cost and low power consumption to adaptively estimate CIR to be provided to a receiver for performing compensation.
[0013] Yet another object of the present invention is to provide a low operation complexity channel estimation solution capable of adaptively adjusting operation formulas according to sampling types of the preliminary frequency-domain channel response, so as to complete CIR estimation using IFFT operation of a smaller scale.
[0014] In order to achieve the foregoing objects, a channel estimation method, applied to an orthogonal frequency division multiplexing (OFDM) communication system, is provided in the invention. The method comprises performing a first number of sampling points inverse fast Fourier transformation (IFFT) operation on a preliminary frequency-domain channel response having a second number of response values to generate a first time-domain channel impulse response (CIR), the second number being greater than the first number; performing a time-domain windowing operation on the first time-domain CIR to generate a second time-domain CIR; performing a smoothing operation on a plurality of second time-domain CIRs of successive time points to generate a smooth time-domain CIR; and performing FFT operation on the smooth time-domain CIR to generate a frequency-domain channel response.
[0015] In order to achieve the foregoing objects, a channel estimation apparatus, applied to an OFDM system, is disclosed in the invention. The channel estimation apparatus comprises an IFFT unit, for performing a second number of sampling points IFFT on a preliminary frequency-domain channel response having a first number of response values to generate a first time-domain CIR, the second number being greater than the first number; a windowing unit, for performing time-domain windowing on the first time-domain CIR to generate a second time-domain CIR; a smoothing unit, for performing smoothing operation on a plurality of groups of second time-domain CIRs of successive time points to generate a smooth time-domain CIR; and a FFT unit, for performing a first number of sampling points FFT operation on the smooth time-domain CIR to generate a frequency-domain channel response.
[0016] Following description and figures are disclosed to gain a better understanding of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a block diagram of a conventional OFDM channel estimation apparatus.
[0018] FIG. 2 is a schematic diagram of a time-domain CIR generated by performing IFFT operation by the conventional OFDM channel estimation apparatus illustrated in FIG. 1 .
[0019] FIG. 3 is a schematic diagram of a pilot sampling distribution of a conventional CMMB OFDM preliminary frequency-domain channel response in time-frequency plane.
[0020] FIG. 4 is a schematic diagram of pilot symbol distribution of a CMMB OFDM system in accordance with an embodiment of the present invention.
[0021] FIG. 5 is a flow chart of a channel estimation method in accordance with an embodiment of the present invention.
[0022] FIG. 6 is a schematic diagram of a time-domain windowing flow in accordance with an embodiment of the present invention.
[0023] FIG. 7 is a block diagram of a channel estimation apparatus in accordance with an embodiment of the present invention.
[0024] FIG. 8 is a block diagram of a 512-sampling-point IFFT unit illustrated in FIG. 7 in accordance with an embodiment of the present invention.
[0025] FIG. 9 is a block diagram of a 512-sampling-point IFFT unit illustrated in FIG. 7 in accordance with another embodiment of the present invention.
[0026] FIG. 10 is a block diagram of a time-domain CIR smoothing unit illustrated in FIG. 7 in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Refer to FIG. 4 showing a schematic diagram of pilot symbol distribution of a CMMB OFDM system In a CMMB OFDM system, a guard band is provided among the 4096 sub-carriers, and sub-carriers within the guard band are not utilized to avoid the signal interference. Therefore, only 192×2 of pilot sub-carriers are actually utilized and distributed within two inconsecutive intervals. In addition, two (i.e., an even type and an odd type) pilot symbol distributions of the CMMB OFDM system are alternately arranged in the time axis. Accordingly, 4096-sampling-point IFFT operation of a preliminary frequency-domain channel response {tilde over (H)}(k) is simplified below.
[0000] An even type operation formula is:
[0000]
h
~
(
n
)
=
∑
k
=
0
4095
H
~
(
k
)
j
2
π
nk
4096
=
∑
k
=
8
m
+
2
m
∈
[
0
,
191
]
H
~
(
k
)
j
2
π
nk
4096
+
∑
k
=
8
m
+
1536
+
1020
+
3
m
∈
[
0
,
191
]
H
~
(
k
)
j
2
π
nk
4096
=
∑
m
=
0
191
H
~
(
8
m
+
2
)
j
2
π
n
(
8
m
+
2
)
4096
+
∑
m
=
0
191
H
~
(
8
m
+
1536
+
1020
+
3
)
j
2
π
n
(
8
m
+
1536
+
1020
+
3
)
4096
=
j
2
π
n
(
2
)
4096
[
∑
m
=
0
191
H
~
(
8
m
+
2
)
j
2
π
nm
512
]
+
j
2
π
n
(
1536
+
1020
+
3
)
4096
[
∑
m
=
0
191
H
~
(
8
m
+
1536
+
1020
+
3
)
j
2
π
nm
512
]
=
j
2
π
n
(
2
)
4096
[
∑
m
=
0
511
A
(
m
)
j
2
π
nm
512
]
+
j
2
π
n
(
1536
+
1020
+
3
)
4096
[
∑
m
=
0
511
B
(
m
)
j
2
π
nm
512
]
where
A
(
m
)
=
{
H
~
(
8
m
+
2
)
,
m
=
0
~
191
0
,
m
=
192
~
511
,
B
(
m
)
=
{
H
~
(
8
m
+
1536
+
1020
+
3
)
,
m
=
0
~
191
0
,
m
=
192
~
511.
[0000] These two groups, each having 192 pilot sub-carriers, are distributed within intervals of nε[0,255] and nε[3840,4095], and {tilde over (h)}(n) is calculated with respect to the two intervals.
An odd type operation formula is:
[0000]
h
~
(
n
)
=
∑
k
=
0
4095
H
~
(
k
)
j
2
π
nk
4096
=
∑
k
=
8
m
+
6
m
∈
[
0
,
191
]
H
~
(
k
)
j
2
π
nk
4096
+
∑
k
=
8
m
+
1536
+
1020
+
7
m
∈
[
0
,
191
]
H
~
(
k
)
j
2
π
nk
4096
=
∑
m
=
0
191
H
~
(
8
m
+
6
)
j
2
π
n
(
8
m
+
6
)
4096
+
∑
m
=
0
191
H
~
(
8
m
+
1536
+
1020
+
7
)
j
2
π
n
(
8
m
+
1536
+
1020
+
7
)
4096
=
j
2
π
n
(
6
)
4096
[
∑
m
=
0
191
H
~
(
8
m
+
6
)
j
2
π
nm
512
]
+
j
2
π
n
(
1536
+
1020
+
7
)
4096
[
∑
m
=
0
191
H
~
(
8
m
+
1536
+
1020
+
7
)
j
2
π
nm
512
]
=
j
2
π
n
(
6
)
4096
[
∑
m
=
0
511
A
(
m
)
j
2
π
nm
512
]
+
j
2
π
n
(
1536
+
1020
+
7
)
4096
[
∑
m
=
0
511
B
(
m
)
j
2
π
nm
512
]
where
A
(
m
)
=
{
H
~
(
8
m
+
6
)
,
m
=
0
~
191
0
,
m
=
192
~
511
,
B
(
m
)
=
{
H
~
(
8
m
+
1536
+
1020
+
7
)
,
m
=
0
~
191
0
,
m
=
192
~
511.
[0000] In the invention, the 512-sampling-point IFFT, replaced to the 4096-sampling-point IFFT in the prior art, is used to process 512 sampling points within intervals of nε[0,255] and nε[3840,4095]. And that time-domain CIR values outside intervals of nε[0,255] and nε[3840,4095] are filtered as mirror image signals after the IFFT operation is performed.
[0028] According to the foregoing formulas, the invention is able to provide a channel estimation method capable of substantially reducing the circuit cost. Refer to FIG. 5 showing a flow chart of a channel estimation method in accordance with an embodiment of the present invention. The method comprises generating a first time-domain CIR {tilde over (h)}(n) by performing a first number of sampling points IFFT operation on a preliminary frequency-domain channel response {tilde over (H)}(k) having a second number of response values (Step a); performing time-domain windowing operation on the time-domain CIR {tilde over (h)}(n) to generate a second time-domain CIR {tilde over (h)} w (n) (Step b); performing smoothing operation on a plurality of groups of the second time-domain CIR {tilde over (h)} w (n) of successive time points to generate a smooth time-domain CIR ĥ s (n)(Step c); and performing a third number of sampling points FFT operation on the smooth time-domain CIR ĥ s (n) to generate a frequency-domain channel response Ĥ s (k) (Step d). The foregoing steps are described below in detail.
[0029] In Step a, the first number of sampling points IFFT operation is performed on the preliminary frequency-domain channel response {tilde over (H)}(k) having the second number of response values to generate the first time-domain CIR {tilde over (h)}(n). In the preferred embodiment, it is obtained that the 512-sampling-point IFFT operation achieves a same effect as using 4096-sampling-point IFFT, and thus the first number is 512 and the second number is 4096. The 512-sampling-point IFFT operation can be showed as the even type formula and the odd type formula. The even type formula has non-zero sampling values at 384 sampling points where k=8m+2, k=8m+2599, and m=0˜191, and sampling values at the remaining sampling points are zero. The odd type formula has non-zero sampling values at 384 sampling points where k=8m+6, k=8m+2563, and m=0˜191, and sampling values at the remaining sampling points are zero. The first number of sampling points IFFT operation comprises
[0000]
∑
m
=
0
511
A
(
m
)
j
2
π
nm
512
[0000] part and
[0000]
∑
m
=
0
511
B
(
m
)
j
2
π
nm
512
[0000] part, and 512 sampling values are
[0000]
A
(
m
)
=
{
H
~
(
8
m
+
2
)
,
m
=
0
~
191
0
,
m
=
192
~
511
(
the
even
type
)
,
B
(
m
)
=
{
H
~
(
8
m
+
1536
+
1020
+
3
)
,
m
=
0
~
191
0
,
m
=
192
~
511
(
the
even
type
)
;
or
A
(
m
)
=
{
H
~
(
8
m
+
6
)
,
m
=
0
~
191
0
,
m
=
192
~
511
(
the
odd
type
)
,
B
(
m
)
=
{
H
~
(
8
m
+
1536
+
1020
+
7
)
,
m
=
0
~
191
0
,
m
=
192
~
511
(
the
odd
type
)
.
[0000] That is, the sampling values are non-zero when m is between 0 to 191 and are equal to zero when m is between 192 to 511. Therefore, the 512-sampling-point IFFT operation is performed only on 512 sampling points within intervals of nε[0,255] and nε[3840,4095], and the response values of other 3584 sampling points outside intervals of nε[0,255] and nε[3840,4095] and are filtered as mirror image signals after the IFFT operation.
[0030] In Step b, the time-domain windowing operation is performed on the first time-domain CIR {tilde over (h)}(n) to generate the second time-domain CIR {tilde over (h)} w (n). The time-domain windowing operation is used for filtering out noises. Referring to FIG. 6 , the time-domain windowing operation filters the sampling points of the first time-domain CIR {tilde over (h)}(n) not in the window and lower than the threshold value to generate the second time-domain CIR {tilde over (h)} w (n). The length of the window is decided by a function of echo delay and is associated with multi-path signals, and the threshold value is a weighted value of time-domain CIR values within the window.
[0031] In Step c, the smoothing operation is performed on a plurality of groups of the second time-domain CIR {tilde over (h)} w (n) distributed in successive time points to generate a smooth time-domain CIR ĥ s (n). In this embodiment, 17 groups of the second time-domain CIRs of successive time points include a present second time-domain CIR, and 8 groups of CIRs respective before and after the time of the present second time-domain CIR in the time axis. The smoothing operation is a weighted average operation. That is, in Step c, the smoothing operation is performed on the 17 groups of the second time-domain CIR {tilde over (h)} w (n) to respectively generate 512 response values within intervals of nε[0,2551] and nε[3840,40951], and the remaining 3584 response values within an interval of nε[256,3839] are assigned to zero, so as to generate a smooth 4096-points time-domain CIR ĥ s (n). In particular, when the weighted average operation may be described as:
[0000]
when
n
∈
[
0
,
255
]
or
n
∈
[
3840
,
4095
]
,
h
^
S
(
n
)
=
1
17
(
h
~
w
1
(
n
)
,
h
~
w
2
(
n
)
,
…
,
h
~
w
17
(
n
)
)
;
when
n
∈
[
256
,
3839
]
,
h
^
s
(
n
)
=
0.
[0032] When the weighted average operation is implemented, channel variation in the time axis is taken into consideration to determine weight values. When the channel dramatically changes in the time axis, a weight value of the present second time-domain CIR is bigger and weight values of the CIRs before and after the time of the present second time-domain CIR are smaller, so that weight values of the second time-domain CIRs far from the present time are decreased. Accordingly, by weighted averaging the second time-domain CIRs with the weight values, the smooth time-domain CIR ĥ s (n) having response values at 512 points within intervals of nε[0,2551] and nε[3840,4095] and zero at 3584 points within the interval of nε[256,3839] is generated.
[0033] In Step d, the third number of sampling points FFT operation is performed on the smooth time-domain CIR ĥ s (n) to generate a frequency-domain channel response Ĥ s (k). The third number is 4096, which is the same as the second number of the preliminary frequency-domain channel response {tilde over (H)}(k), i.e., in Step d, the frequency-domain channel response value Ĥ s (k) is generated at all sub-carriers with frequency k within 0 to 4095.
[0034] Compared to the prior art, the 512-sampling-point IFFT operation implemented according to the present invention, with proof demonstrated via the even type formula and the odd type formula, is capable of achieving the same effect as implementing 4096 IFFT sampling points. Therefore, according to the present invention, computing demands of the IFFT operation, the time-domain windowing and the smoothing operation are substantially reduced.
[0035] Refer to FIG. 7 showing a block diagram of a channel estimation apparatus in accordance with an embodiment of the present invention. In this embodiment, the channel estimation apparatus comprises a 512-sampling-point IFFT unit 701 , a time-domain windowing unit 702 , a time-domain smoothing unit 703 , and a 4096-sampling-point FFT unit 704 .
[0036] The 512-sampling-point IFFT unit 701 performs 512-sampling-point IFFT operation on a preliminary frequency response {tilde over (H)}(k) having 4096 response values according to the even type formula or the odd type formula to generate a first time-domain CIR {tilde over (h)}(n). The even type formula only has non-zero sampling values at 384 sampling points (positions of pilot symbols) where k=8m+2, k=8m+2599, and m=0˜191 and has sampling values of zero at the remaining sampling points. The odd type operation formula only has non-zero sampling values at 384 sampling points (positions of pilot symbols) where k=8m+6, k=8m+2563, and m=0˜191 and has sampling values of zero at the remaining sampling points. The 512-sampling-point IFFT operation comprises
[0000]
∑
m
=
0
511
A
(
m
)
j
2
π
nm
512
[0000] part and
[0000]
∑
m
=
0
511
B
(
m
)
j
2
π
nm
512
[0000] part, and 512 sampling values are:
[0000]
A
(
m
)
=
{
H
~
(
8
m
+
2
)
,
m
=
0
~
191
0
,
m
=
192
~
511
(
even
type
)
,
B
(
m
)
=
{
H
~
(
8
m
+
1536
+
1020
+
3
)
,
m
=
0
~
191
0
,
m
=
192
~
511
(
even
type
)
;
or
A
(
m
)
=
{
H
~
(
8
m
+
6
)
,
m
=
0
~
191
0
,
m
=
192
~
511
(
odd
type
)
,
B
(
m
)
=
{
H
~
(
8
m
+
1536
+
1020
+
7
)
,
m
=
0
~
191
0
,
m
=
192
~
511
(
odd
type
)
.
[0000] That is, the sampling values are non-zero when m=0 to 191, and the sampling values are equal to zero when m=192 to 511. For that time-domain CIRs outside intervals of nε[0,255] and nε[3840,4095] are mirror image signals to be filtered after the IFFT operation is performed, the 512-sampling-point IFFT operation is performed on 512 sampling points within intervals of nε[0,255] and nε[3840,4095] but not on the remaining 3584 sampling points.
[0037] The time-domain windowing unit 702 for removing noises from the first time-domain CIRs {tilde over (h)}(n) according to a threshold value and a window length. The time-domain windowing unit 702 filters the sampling points of the first time-domain CIR {tilde over (h)}(n) not in the window and lower than the threshold value to generate the second time-domain CIR {tilde over (h)} w (n). The length of the window is decided by a function of echo delay and is associated with multi-path signals, and the threshold value is a weighted value of time-domain CIR values within the window.
[0038] The time-domain smoothing unit 703 performs smoothing operation on a plurality of groups of the second time-domain CIR {tilde over (h)} w (n) distributed in successive time points to generate a smooth time-domain CIR ĥ s (n). In this embodiment, 17 groups of the second time-domain CIR of successive time points correspond to a present second time-domain CIR, and 8 groups of CIRs before and after the time point of the present second time-domain CIR in the time axis. The smoothing operation is a weighted average operation to respectively generate smooth response values within intervals of nε[0.255] and nε[3840,4095], and the remaining 3584 response values within an interval of nε[256,3839] assigned as zero, so as to generate a smooth 4096-point time-domain CIR ĥ s (n). In particular, when the weighted average operation is described as:
[0000]
when
n
∈
[
0
,
255
]
or
n
∈
[
3840
,
4095
]
,
h
^
S
(
n
)
=
1
17
(
h
~
w
1
(
n
)
,
h
~
w
2
(
n
)
,
…
,
h
~
w
17
(
n
)
)
;
when
n
∈
[
256
,
3839
]
,
h
^
s
(
n
)
=
0.
[0039] When the weighted average operation is implemented, channel variation in the time axis is taken into consideration to determine a weight value. When the channel dramatically changes in the time axis, a weight value of the present second time-domain CIR is bigger and weight values of the CIRs before and after the time of the present second time-domain CIR are smaller, so that weight values of the second time-domain CIRs far from the present time are decreased. Accordingly, by weighted averaging the second time-domain CIRs with the weight values, the smooth time-domain CIR ĥ s (n) having response values at 512 points within intervals of nε[0,255] and nε[3840,4095] and zero at 3584 points within the interval of nε[256,3839] is generated.
[0040] The 4096-sampling-point FFT unit 704 performs 4096-sampling-point FFT operation on the smooth time-domain CIR ĥ s (n) to generate a frequency-domain channel response Ĥ s (k), which has frequency-domain channel response values at all sub-carriers with frequency k within 0 to 4095.
[0041] Refer to FIG. 8 showing a block diagram of the 512-sampling-point IFFT unit 701 illustrated in FIG. 7 in accordance with an embodiment of the present invention. In this embodiment, the IFFT unit 701 comprises two 192-sampling-point buffers 801 and 802 , two 512-sampling-point IFFT calculators 803 and 804 , two multipliers 805 and 806 , and an adder 807 .
[0042] The 192-sampling-point buffers 801 and 802 are for storing the preliminary frequency-domain channel responses {tilde over (H)}(k). When sampling points of the preliminary frequency-domain channel response {tilde over (H)}(k) are distributed in an even type, the 192-sampling-point buffers 801 and 802 respectively store the preliminary frequency-domain channel response, A(m)={tilde over (H)}(8m+2), m=0˜191 and B(m)={tilde over (H)}(8m+1536+1020+3), m=0˜191, in two inconsecutive ranges. When the sampling points of the preliminary frequency-domain channel responses {tilde over (H)}(k) are distributed in an odd type, the 192-sampling-point buffers 801 and 802 respectively store the preliminary frequency-domain channel response, A(m)={tilde over (H)}(8m+6), m=0˜191 and B(m)={tilde over (H)}(8m+1536+1020+7), m=0˜191 in two inconsecutive ranges.
[0043] The 512-sampling-point IFFT calculator 803 , coupled to the 192-sampling-point buffer 801 , performs first IFFT operation on 512 sampling points to generate a first IFFT values
[0000]
∑
m
=
0
511
A
(
m
)
j
2
π
nm
512
,
[0000] where nε[0,255] or nε[3840,4095].
[0044] The 512-sampling-point IFFT calculator 804 , coupled to the 192-sampling-point buffer 802 , performs second IFFT operation on 512 sampling points to generate a second IFFT values
[0000]
∑
m
=
0
511
B
(
m
)
j
2
π
nm
512
,
[0000] where nε[0,255] or nε[3840,4095].
[0045] The multiplier 805 multiplies a first phase variable e j2πn(2+4i)/4096 with the first IFFT value
[0000]
∑
m
=
0
511
A
(
m
)
j
2
π
nm
512
[0000] to generate a first part of the first time-domain CIR. A parameter i of the first phase variable e j2πn(2+4i)/4096 has two situations—i=0 means the even type, and i=1 means the odd type.
[0046] The multiplier 806 multiplies a second phase variable e j2πn(2559+4i)/4096 with the second IFFT value
[0000]
∑
m
=
0
511
B
(
m
)
j
2
π
nm
512
[0000] to generate a second part of the first time-domain CIR. A parameter i of the second phase variable e j2πn(2+4i)/4096 has two situations—i=0 means the even type, and i=1 means the odd type.
[0047] The adder 807 integrates the first part of the first time-domain CIR and the second part of the first time-domain CIR to generate a first time-domain CIR {tilde over (h)}(n).
[0048] Refer to FIG. 9 showing a block diagram of the 512-sampling-point IFFT unit 701 illustrated in FIG. 7 in accordance with another embodiment of the present invention. In this embodiment, the 512-sampling-point IFFT unit 701 comprises a 192-sampling-point buffer 901 , a 512-sampling-point IFFT calculator 902 , a multiplier 903 , a switch 904 , a time-domain CIR buffer 905 , and an adder 906 .
[0049] The 192-sampling-point buffer 901 is for storing the preliminary frequency-domain channel response {tilde over (H)}(k). When sampling points of the preliminary frequency-domain channel response {tilde over (H)}(k) are distributed in an even type, the 192-sampling-point buffer 901 buffers A(m)={tilde over (H)}(8m+2), m=0˜191 and B(m)={tilde over (H)}(8m+1536+1020+3), m=0˜191 in sequence. When sampling points of the preliminary frequency-domain channel response {tilde over (H)}(k) are distributed in an odd type, the 192-sampling-point buffer 901 buffers A(m)={tilde over (H)}(8m+6), m=0˜191 and B(m)={tilde over (H)}(8m+1536+1020+7), m=0˜191 in sequence. In this embodiment, the IFFT operation only needs to be completed before a next set of 192 preliminary frequency-domain channel responses is transmitted to the 192-sampling-point buffer 901 , so that the 192-sampling-point buffer 901 is allowed to store each 192-sampling-point preliminary frequency-domain channel response values.
[0050] The 512-sampling-point IFFT calculator 902 , coupled to the 192-sampling-point buffer 901 , performs IFFT operation on 512 sampling points to generate an IFFT value
[0000]
∑
m
=
0
511
A
(
m
)
j
2
π
nm
512
or
∑
m
=
0
511
B
(
m
)
j
2
π
nm
512
,
[0000] Where nε[0,255] or nε[3840,4095].
[0051] The multiplier 903 multiplies a phase variable e j2πn(2+4i)/4096 (or e j2πn(2559+4i)/4096 ) and the IFFT values
[0000]
∑
m
=
0
511
A
(
m
)
j
2
π
nm
512
or
∑
m
=
0
511
B
(
m
)
j
2
π
nm
512
[0000] to generate a first part of the first time-domain CIR (or a second part of the first time-domain CIR).
[0052] The switch 904 is for selecting one phase variable from a first phase variable and a second phase variable. The first phase variable is e j2πn(2+4i)/4096 , where i=0 means the even type, and i=1 means the odd type. The second phase variable is e j2πn(2559+4i)/4096 , where i=0 means the even type and i=1 means the odd type.
[0053] The time-domain CIR buffer 905 , coupled to the multiplier 903 , is for storing a first part and a second part of the first time-domain CIR.
[0054] The adder 906 is for integrating the first part of the first time-domain CIR and the second part of the first of time-domain CIR to generate a first time-domain CIR {tilde over (h)}(n).
[0055] Refer to FIG. 10 showing the time-domain CIR smoothing unit 703 illustrated in FIG. 7 in accordance with an embodiment of the present invention. In this embodiment, the time-domain CIR smoothing unit 703 comprises a time-domain CIR storage unit 1001 and a smoothing calculator 1002 .
[0056] The time-domain CIR storage unit 1001 is for storing 17 groups of the second time-domain CIRs {tilde over (h)} w1 (n), {tilde over (h)} w2 (n), . . . , {tilde over (h)} w17 (n). The 17 groups include a present second time-domain CIR, and 8 groups before and after the time of the present second time-domain CIR. For that only 512-sampling-point IFFT operation is utilized, the time-domain CIR storage unit 1001 needs only storage space for 17*512 points and thus significantly reducing requirements of storage units.
[0057] The smooth calculator 1002 , coupled to the time-domain CIR storage unit 1001 , performs smoothing operation on the 17 groups of the second time-domain CIR {tilde over (h)} w1 (n), {tilde over (h)} w2 (n), . . . , {tilde over (h)} w17 (n). The smoothing operation implements weighted average operation to calculate 17 groups of the second time-domain CIR {tilde over (h)} w (n) so as to respectively generate response values of 512 sampling points within intervals of nε[0,255] and nε[3840,4095], and assigns zero as response values of other 3584 sampling points within an interval of nε[256,3839], so as to generate 4096 smooth time-domain CIR ĥ s (n). In particular, when the weighted average operation is implemented, following operations are performed.
[0000] when nε[0,255] or nε[3840,4095],
[0000]
h
^
S
(
n
)
=
1
17
(
h
~
w
1
(
n
)
,
h
~
w
2
(
n
)
,
…
,
h
~
w
17
(
n
)
)
;
[0000] when nε[256,3839], ĥ s (n)=0, so as to generate the smooth time-domain CIR ĥ s (n). When the weighted average operation is implemented, channel variables in the time axis are taken into consideration to determine weight values. When the channel dramatically changes in the time axis, a weight value of the present second time-domain CIR is bigger and weight values of the CIRs before and after the time of the present second time-domain CIR are smaller, so that weight values of the second time-domain CIRs far from the present time are decreased. Accordingly, by weighted averaging the second time-domain CIRs with the weight values, the smooth time-domain CIR ĥ s (n) having response values at 512 points within intervals of nε[0,255] and nε[3840,4095] and zero at 3584 points within the interval of nε[256,3839] is generated.
[0058] Therefore, according to the foregoing embodiments of the present invention, a channel estimation solution with low complexity, low cost and low power consumption is provided to overcome disadvantages of the prior art.
[0059] While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not to be limited to the above embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. For example, modifications of arrangement patterns of pilot sub-carriers, sampling points, buffer size, the number of average groups, smoothing processing approaches are included within the spirit and scope of the appended claims.
|
A channel estimation method, applied to an orthogonal frequency comprises performing a first number of sampling points inverse fast Fourier transformation (IFFT) operation on a preliminary frequency-domain channel response having a second number of response values to generate a first time-domain channel impulse response (CIR), the second number being greater than the first number; performing a time-domain windowing operation on the first time-domain CIR to generate a second time-domain CIR; performing a smoothing operation on a plurality of second time-domain CIRs of successive time points to generate a smooth time-domain CIR; and performing FFT operation on the smooth time-domain CIR to generate a frequency-domain channel response.
| 7
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an apparatus for dispensing a filled, or threaded, bobbin when an empty bobbin is deposited into the apparatus.
[0003] 2. Description of the Related Art
[0004] Bobbins are used in the sewing industry to supply thread to a sewing machine. Thread is pre-wound onto the bobbin, and the bobbin is then placed on the sewing machine. The thread is pulled from the bobbin as the machine functions. Bobbins are useful in that the amount of thread and type of thread can be controlled. Specifically, a bobbin can be pre-wound with a pre-determined quantity of thread to minimize waste, and make changing a machine from one sewing job to another more efficient.
[0005] A problem associated with the use of bobbins in this manner is controlling the inventory of new and used bobbins. As known in the art, when the thread on a bobbin is exhausted, the empty bobbin may be re-used. Specifically, new thread may be wound onto the used, empty bobbin and the bobbin can then be re-circulated with a different type and/or amount of thread. Empty bobbins, however, are sometimes carelessly discarded or lost, thereby depleting the supply of empty bobbins to be re-used.
[0006] Therefore, it is desirable to provide an apparatus for dispensing a filled, or re-threaded, bobbin, once an empty bobbin has been exhausted and deposited into the apparatus.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the invention, an apparatus is provided for dispensing a fully threaded bobbin to an operator upon the depositing of an empty bobbin into the apparatus. The apparatus comprises a housing defining a storage compartment for storing the bobbins. The housing has a first opening for depositing the empty bobbins therein and a second opening for dispensing the full bobbins therefrom. A tray is mounted to the housing within the storage compartment for orienting and feeding fully threaded bobbins. At least one slide is provided for transporting the full bobbins from the tray to the second opening. An actuator lever is slidably coupled to the housing for activating the apparatus. A release hinge is mounted to a portion of the slide and operatively coupled to the actuator lever for releasing a single full bobbin from the slide and the second opening in response to the actuator lever being activated from a fully extended position to an actuated position and an empty bobbin being deposited into the first opening. An accommodator is operatively coupled between the actuator lever and the tray for orienting the bobbins for transportation in the slide for cooperation with the release hinge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
[0009] [0009]FIG. 1 is a perspective view of a bobbin dispenser in accordance with the present invention;
[0010] [0010]FIG. 2 is a perspective view of a center divider;
[0011] [0011]FIG. 3 is another perspective view of the bobbin dispenser shown with a tray removed;
[0012] [0012]FIG. 4 is a perspective view of the tray;
[0013] [0013]FIG. 5 is an exploded perspective view of a top slide and related components;
[0014] [0014]FIG. 6 is a perspective view of a bottom slide; and
[0015] [0015]FIG. 7 is an exploded perspective view of a lever channel and related components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a bobbin dispenser apparatus of the present invention is generally shown at 10 in FIG. 1.
[0017] The dispenser 10 includes a housing 12 that defines a storage compartment 14 . The housing 12 can be made from any material such as steel, plastic, wood, or the like. The housing 12 includes a top 16 which is either removable, or in the alternative, hinges in such a way that the top 16 can be opened up to allow access to the compartment 14 . A center divider 18 is disposed in the compartment 14 and is supported by the housing 12 such that the compartment 14 is divided into an upper compartment 20 and a lower compartment 22 .
[0018] Referring to FIG. 2, the center divider 18 includes a full bobbin opening 24 for allowing bobbins to fall from the upper compartment 20 into the lower compartment 22 as will be discussed below. The center divider 18 further includes an empty bobbin opening 26 located adjacent to the full bobbin opening 24 , the function of which is discussed below.
[0019] As best shown in FIG. 3, the housing 12 further includes a first planar wall 28 and a second planar wall 30 opposite the first wall 28 . The first 28 and second 30 walls are interconnected by a third planar wall 32 and an opposite fourth planar wall 34 . The walls 28 , 30 , 32 , 34 define the storage compartment 14 and support the center divider 18 between the upper and lower compartments 20 , 22 . A first opening 36 and a second opening 38 are formed in the first wall 28 . The first opening 36 communicates with the upper compartment 20 of the compartment 14 and the second opening 38 communicates with the lower compartment 22 of the compartment 14 . A third opening 40 and a fourth opening 42 are formed in the fourth wall 34 and are in communication with the upper compartment 20 and the lower compartment 22 , respectively.
[0020] As discussed in the background section, bobbins as shown at 8 , which are pre-wound with thread, are used in the sewing industry to supply thread to a sewing machine. The dispenser 10 is designed to accept a used bobbin, i.e. a bobbin without thread, and dispense a new or full bobbin, i.e. a bobbin with thread. In particular, the used bobbin is inserted into the third opening 40 and the full bobbin is dispensed out the second opening 38 . The specifics of how the bobbin is dispensed and the working components of the dispenser 10 are discussed in greater detail below.
[0021] Referring again to FIG. 1, the dispenser 10 includes a tray 44 that holds and orients the full bobbins 8 in the upper compartment 20 . The tray 44 is mounted above the divider 18 and supported by the side walls 28 , 30 , 32 , 34 . As best shown in FIG. 4, the tray 44 includes a reservoir 46 defined by sidewalls 48 and a bottom 50 for holding the full bobbins. The bobbins 8 are placed to move in a rolling orientation in order to be easily dispensed from the tray 44 . The reservoir 46 is tilted to cause the full bobbins 8 to roll along the bottom 50 toward a release channel 52 . The release channel 52 runs along one side of the tray 44 and includes an angled, or ramped, sidewall 54 to assist in aligning the full bobbins in a manner to be dispensed. The tray 44 also includes an opening 56 in the sidewall 48 adjacent the end of the release channel 52 for insertion of an accommodator 58 . The accommodator 58 is a wedge shaped block slidably supported by the housing 12 for movement in and out of the opening 56 so as to assist in orienting the dispensing of the bobbins as is further discussed below.
[0022] Referring also to FIG. 5, full bobbins are fed from the tray 44 to a top slide 60 . An upper guide 62 is mounted to an upper end 64 of the top slide 60 to assist in guiding the full bobbins from the release channel 52 to within the top slide 60 . A lower end 66 of the top slide 60 is mounted to the center divider 18 over the full bobbin opening 24 .
[0023] The top slide 60 , including the attached upper guide 62 , includes a generally U-shaped channel 68 defined by first and second side walls 70 , 72 and a floor 74 extending between the side walls 70 , 72 . The floor 74 is slightly wider than the thickness of a bobbin standing on edge. In particular, the floor 74 is wide enough to allow the bobbin to freely roll thereon and is narrow enough to prevent the bobbin from toppling over so as to keep the bobbin on its edge, thereby allowing the bobbin to roll. The full bobbin opening 24 , show in FIG. 2, is of a complementary width to the floor 74 such that a bobbin can fall through the opening 24 and into the lower compartment 22 while maintaining its rolling orientation.
[0024] The top slide 60 further includes an arcuate groove 76 formed in each of the side walls 70 , 72 approximately half way between the upper end 64 and the lower end 66 of the top slide 60 . A release hinge 78 is disposed in the groove 76 perpendicular to the longitudinal length of the top slide 60 . The release hinge 78 includes a lateral bar 80 having a pair of spaced apart bushings 82 . The bar 80 is seated in the groove 76 with the bushings 82 straddling the side walls 70 , 72 so as to limit lateral movement of the release hinge 78 .
[0025] A valve 84 is mounted to the lateral bar 80 between the bushings 82 . The valve 84 is an arcuate shaped member made of metal, plastic or the like. The valve 84 has a major portion 86 that hangs from the lateral bar 80 towards the lower end 66 of the top slide 60 , and a minor portion 88 that hangs from the lateral bar 80 towards the upper end 64 of the top slide 60 . As is discussed below, the valve 84 is used to control the movement of the bobbins in the channel 68 .
[0026] An actuation rod 90 extends downwardly from the lateral bar 80 and outside of the channel 68 and along side of the side walls 70 , 72 . The actuation rod 90 is used to rotate the lateral bar 80 and valve 84 to facilitate releasing the bobbins one at a time from the top slide 60 .
[0027] Referring to FIGS. 1 and 3, a bottom slide 92 is mounted within the lower compartment 22 of the dispenser 10 . As best shown in FIG. 6, an upper end 94 of the bottom slide 92 includes a lower guide 96 for connecting the bottom slide 92 to the center divider 18 opposite the lower end 66 of the top slide 60 . The lower guide 96 is therefore aligned with the full bobbin opening 24 in the center divider 18 . The bottom slide 92 includes a channel 98 defined between spaced apart sidewalls 100 , 102 , similar to the channel 68 within the top slide 60 , for maintaining the bobbin on its edges and thus allowing the bobbin to roll downward.
[0028] A lower end 104 of the bottom slide 92 extends through the second opening 38 within the second wall 30 . The lower end 104 includes U-shaped cutouts 106 in each sidewall 100 , 102 to allow an operator to retrieve a full bobbin that has been dispensed.
[0029] As shown in FIG. 1, the dispenser 10 includes an actuator lever 108 to facilitate the release of a bobbin from the dispenser 10 once an empty bobbin has been inserted into the third opening 40 . As best shown in FIG. 7, the actuator lever 108 rests within a lever channel 110 , defined by spaced apart and parallel sidewalls extending between a front end 112 and rear end 113 . As shown in FIG. 3, the lever channel 110 is supported by the divider 18 within the upper compartment 20 . Referring to FIGS. 3 and 7, the front end 112 of the lever channel 110 mates with the inside of the first wall 28 and aligns with the first opening 36 therein. The actuator lever 108 is slidably disposed into the upper compartment 20 through the first opening 36 for movement between a fully extended position and an actuated position. A lever spring 114 is disposed about the lever 108 and between opposite ends thereof for biasing the lever 108 outwardly from the compartment 14 to the fully extended position. The actuator lever 108 also includes a forked end 116 defined by spaced apart and parallel fingers 118 , 120 that is located within the lever channel 110 .
[0030] An accommodator bracket 122 including opposing L-shaped ends 124 , 126 is mounted to the top side of the actuator lever 108 by the end 124 . The accommodator 44 is mounted to the other end 126 of the accommodator bracket 122 opposite the actuator lever 108 , and aligns with the accommodator opening 56 in the tray 44 , as shown in FIG. 4.
[0031] An actuation spring support bracket 128 is fixedly mounted to the sidewalls of the lever channel 110 . The actuation spring support bracket 128 straddles the lever channel 110 and includes a mounting clip 130 . An actuation spring 132 , such as a compression coil spring, interconnects the clip 130 and the distal end of the actuation rod 90 opposite the lateral bar 80 , as shown in FIG. 3. The actuation spring 132 biases the release hinge 78 to a starting position where the major portion 86 of the valve 84 is rotated downwardly into the channel 68 of the top slide 60 . When hinge 78 is in the starting position, the actuation rod 90 extends into the lever channel 110 .
[0032] An empty bobbin slide 134 attaches generally perpendicularly to the lever channel 110 . The empty bobbin slide 134 includes spaced apart and parallel sidewalls 136 , 138 extending between first and second ends 140 , 142 defining a channel 144 therebetween for receiving a bobbin. The first end 140 is connected to the sidewall of the lever channel 110 adjacent the rear end 113 and the opposite second end 142 is connected to the fourth wall 42 and aligned with the third opening 40 therein. The rear end 113 of the lever channel 110 ends directly aligned with the empty bobbin opening 26 in the center divider 18 .
[0033] In operation, the tray 44 of the dispenser 10 is initially filled with full bobbins 8 . At least a few of the full bobbins fall into the release channel 52 and subsequently roll down the top slide 60 until stopped by the major portion 86 of the valve 84 . Specifically, when a bobbin rolls down the channel 68 , the bobbin rolls under the minor portion 88 and is stopped by the major portion 86 .
[0034] A user may deposit an empty bobbin 146 through the third opening 40 and into the empty bobbin slide 134 such that the bobbin is standing on an end face. When the actuator lever 108 is in the fully extended position, the forked end 116 is biased to a position closest to the front wall 28 which is behind the point where the empty bobbin slide 134 mates with the lever channel 110 . In addition, the release hinge 78 is in the starting position with the distal end of the actuation rod 90 extending into the lever channel 110 in front of the point where the empty bobbin slide 134 mates with the lever channel 110 . Therefore, when the empty bobbin is deposited to the empty bobbin slide 134 , the bobbin will slide downward on its end face and topple over on its edges into the lever channel 110 in front of the forked distal end 116 and behind the distal end of the actuation rod 90 . The channels and intersection of the empty bobbin slide 134 and the lever channel 110 are configured such that when the empty bobbin reaches the lever channel 110 , the bobbin is positioned in a rolling orientation.
[0035] To receive a new full bobbin, the operator activates the actuator lever 108 to move the lever 108 to the actuated position. Specifically, the operator pushes the actuator lever 108 toward the first wall 28 against the bias of the lever spring 114 . As the actuator lever 108 advances, the forked end 116 slides forward to contact the empty bobbin that is standing in the lever channel 110 . Upon further advancement of the lever 108 , the forked end 116 extends to the rear end 113 of the lever channel 110 , thereby pushing the empty bobbin past the rear end 113 and causing the empty bobbin to fall through the empty bobbin opening 26 and into the lower compartment 22 .
[0036] As the empty bobbin is pushed along the lever channel 110 toward the rear end 113 , the empty bobbin contacts the distal end of the actuation rod 90 and causes the release hinge 78 to rotate counter-clockwise as viewed by FIGS. 3 and 5. The counterclockwise rotation rotates the lateral bar 80 such that the major portion 86 of the valve 84 is rotated upward and out of the channel 68 . Simultaneously, the minor portion 88 is rotated downward into the channel 68 . The minor portion 88 lowers into the channel 68 in front of a subsequent full bobbin directly behind the bobbin held by the major portion 86 of the valve 84 . After the major portion 86 is rotated fully upward and out of the channel 68 , a single full bobbin will roll freely down the channel 68 while all the other full bobbins stacked behind are being held by the minor portion 88 of the valve 84 .
[0037] The single full bobbin rolls forward down the remainder of the top slide 60 , until the bobbin falls downward through the full bobbin opening 24 . The bobbin is then caught by the lower guide 96 which delivers the bobbin further downward into bottom slide 92 . The bobbin rolls down through bottom slide 92 and exists out the first opening 36 into the cutouts 80 for retrieval by an operator. The remaining full bobbins continue to be held in place by the minor portion 88 of the valve 84 .
[0038] Once the empty bobbin has been pushed beyond the rod 90 , the actuation spring 134 causes the actuation rod 90 to snap back to the starting position. Hence, the lateral bar 80 rotates clockwise back to the starting position. The major portion 86 of the valve 84 will rotate back downward into the channel 68 , and the minor portion 88 will rotate upward out of the channel 68 . The subsequent full bobbins within the channel 68 will roll forward until the first bobbin rests against the major portion 86 of the valve 84 .
[0039] Simultaneously with the actuation of the actuator lever 108 , the accommodator 58 is forced into the accommodator opening 56 and into the supply of bobbins. The accommodator 58 helps to shift the bobbins so the bobbins may fall within the release channel 52 and become correctly oriented such that they may roll forward to the top slide 60 .
[0040] The actuation of the actuator lever 108 therefore deposits an empty bobbin into the lower compartment 22 while simultaneously releasing a single full bobbin for retrieval by the operator. Actuation of the actuator lever 108 without first depositing an empty bobbin will not release a full bobbin. Without an empty bobbin placed in the lever channel 110 , the forked distal end 116 will pass underneath the actuation rod 90 . Hence, the empty bobbin acts as a coupler to couple the forked distal end 116 to the actuation rod 90 .
[0041] Once the actuator lever 108 has been fully actuated, the empty bobbin has dropped into the empty bobbin opening 26 , and the fill bobbin has been dispensed, the operator will release the actuator lever 108 . The lever spring 114 automatically biases the lever 114 to the original starting position such that the dispensing operation may be repeated.
[0042] The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.
[0043] 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 practised other than as specifically described.
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An apparatus for dispensing a fully threaded bobbin to an operator upon the depositing of an empty bobbin into the apparatus. The apparatus comprises a housing defining a storage compartment for storing the bobbins. The housing has a first opening for depositing the empty bobbins therein and a second opening for dispensing the full bobbins therefrom. A tray is mounted to the housing within the storage compartment for orienting and feeding fully threaded bobbins and a top and bottom slide are provided for transporting the full bobbins from the tray to the second opening. An actuator lever is slidably coupled to a lever channel for activating the apparatus. A release hinge is mounted to the top slide and operatively coupled to the acutator lever for releasing a single full bobbin from the top slide and to the second opening in response to the actuator lever being activated from a fully extended position to an actuated position and an empty bobbin being deposited into the first opening and lever channel. An accommodator is operatively coupled between the actuator lever and the try for orienting the bobbins for transportation in the top slide for cooperation with the release hinge.
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This application is a continuation of application Ser. No. 07/604,466, filed on Oct. 29, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a track jump control circuit used in an optical record and playback apparatus or the like.
2. Description of the Related Art
Generally, in an optical record and playback apparatus such as a compact disc player (CD player), or compact disc ROM (CD-ROM), information stored on a disc is read by a pick-up.
In such an optical record and playback apparatus, when reading information by means of the pick-up, the pick-up is moved at a low speed so as to follow tracks. When placing the pick-up to a desired position, the pick-up is moved at a high speed so as to jump tracks.
A track jump control circuit for conducting such a track jump operation is disclosed in Japanese Patent Application Serial No. SHO 60-117203.
With the track jump control circuit, in the track jump state, the moving speed of the pick-up is detected. The completion of the track jump operation is determined by the moving speed.
However, with the aforementioned track jump control circuit, if a vibration is applied to the optical record and playback apparatus, the vibration component is added to the speed signal of the pick-up. Thus, the completion of the track jump cannot be precisely determined.
In addition, the speed signal of the pick-up is obtained only after the pick-up is moved. Thus, the response of the early stage of the track jump is slow.
SUMMARY OF THE INVENTION
An object of the present invention is to solve such problems and to provide a track jump control circuit for determining the completion of the track jump operation.
To accomplish such an object, the first embodiment of the present invention is a track jump control circuit comprising a pick-up for reading information stored on a disc, moving means for moving the pick-up in a radial direction of the disc, speed detecting means for detecting the moving speed of the pick-up and for outputting a speed signal, moving amount computing means for generating a signal according to the moving amount of the pick-up according to the speed signal, means for generating a reference signal according to a distance for which the pick-up is moved in a track jump mode, comparing means for comparing the reference signal with a signal according to the moving amount and for sending a difference signal to the moving means, and stopping means for stopping sending the difference signal to the moving means when the difference signal is in a predetermined range.
To accomplish such an object, the second embodiment of the present invention is a track jump control circuit comprising a pick-up for reading information stored on a disc, moving means for moving the pick-up in a radial direction of the disc, speed detecting means for detecting the moving speed of the pick-up and for outputting a speed signal, moving amount computing means for generating a signal according to the moving amount of the pick-up, means for generating a reference signal according to a distance for which the pick-up is moved in a track jump mode, comparing means for comparing the reference signal with a signal according to the moving amount and for sending a difference signal to the moving means, and addition means for adding the difference signal and the speed signal, and stopping means for stopping sending the difference signal to the moving means when the difference signal is in a predetermined range.
In the first embodiment, when the difference signal between the position signal of the pick-up and the reference signal is in a predetermined range, the completion of the track jump operation is determined. Since the completion of the track jump operation is determined in accordance with the position signal, even if a vibration is applied to the apparatus, the completion of the track jump can be precisely determined.
The position error signal is lesser affected by an external vibration frequency than the speed signal.
In the second embodiment, both the position signal of the pick-up and the speed signal can be controlled.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram showing the structure of a track jump control circuit of a first embodiment of the present invention;
FIG. 2 is a circuit diagram of the track jump control circuit of the first embodiment of the present invention;
FIG. 3 is a wave form schematic of each signal of FIG. 2;
FIG. 4 is a block diagram showing the structure of a track jump control circuit of a second embodiment of the present invention; and
FIG. 5 is a circuit diagram showing the track jump control circuit of the second embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
By referring to the accompanying drawings, embodiments of the present invention will be described in the following.
FIG. 1 is a block diagram showing the structure of a track jump control circuit. FIG. 2 is a circuit diagram of the track jump control circuit.
FIG. 1 includes circuits which are not illustrated in FIG. 2. In contrast, FIG. 2 includes circuits which are not illustrated in FIG. 1.
The track jump control circuit comprises a switch 1, a phase compensation circuit 3, an amplifier circuit 5, a tracking actuator 7, a low pass filter 9, a controller 11, a reference voltage generation circuit 13, a comparator 15, a switch 17, a comparator 19, a amplifier circuit 21, a motor 23 a speed detector 25, an integration circuit 27, and a window comparator 31.
The switch 1 sends a tracking error signal ER to the phase compensation circuit 3 in accordance with a command issued by the controller 11. The phase compensation circuit 3 converts the phase of the tracking error signal ER.
The amplifier circuit 5 amplifies an output signal of the phase compensation circuit 3 and sends the resultant signal to the tracking actuator 7 and the low pass filter 9 so as to form a tracking servo loop. The low pass filter 9 sends a low frequency component of an output signal of the amplifier circuit 5 to the switch 17.
The switch 1, the phase compensation circuit 3, the amplifier circuit 5, the tracking actuator 7, the low pass filter 9, and the switch 17 are omitted in FIG. 2.
The controller 11 controls the switches 1 and 17 and sends a particular signal to the reference voltage generation circuit 13 and a reset signal RST to the integration circuit 27, respectively. The reference voltage generation circuit 13 consists of a ladder resistor, which converts track jump data portions D0 to D7 which are sent from the controller 11 into an analog signal. An arithmetic amplifier 105 converts an impedance to another one.
A direction switching device 107 outputs a signal according to the direction where the pick-up is moved by means of a signal F/R which is sent from the controller 11. The direction switching device 107 consists of an arithmetic amplifier 109, transistors 111 and 113, and resistors 115, 117, 119, 121, and 123, the resistance of the resistors 115 being the same as that of the resistor 117.
When the signal F/R is set to "1", the transistor 111 is turned off. Thus, the arithmetic amplifier 109 functions as a non-inverting amplifier whose gain is "1". In contrast, when the signal F/R is set to "0", the transistor 111 is turned on. Thus, the arithmetic amplifier 109 functions as an inverting amplifier whose gain is "-1". In other words, when the signal F/R is set to "1", the direction switching device 107 outputs an output of the arithmetic amplifier 105 as it is. When the signal F/R is set to "0", the direction switching device 107 outputs the inverted signal which is output from the arithmetic amplifier 105.
The comparator 15, which consists of resistors 75 and 77, compares an output signal S5 of the direction switching device 107 with an output signal S3 of the integration circuit 27 and sends a difference signal (position error signal) S4 to the window comparator 31 and the comparator 19.
The switch 17 selects one of output signals of the low pass filter 9 and the comparator 15 according to a command from the controller 11 and outputs the selected signal. The speed detector 25 detects the moving speed of a pick-up (not shown in the FIGURES) and outputs a speed signal S1. An arithmetic amplifier 33 amplifies the speed signal S1 and output a signal S2.
The comparator 19, which consists of registers 41 and 43, compares the signal S2 with an output of the comparator 15.
The amplifier circuit 21, which consists of an arithmetic amplifier 45, a register 47, and condensers 49 and 51, amplifies an output signal of the comparator 19. The condensers 51 and 53 and the resistors 47 and 55 are used to compensate the phase.
The motor 23 moves the pick-up according to an output signal of the amplifier circuit 21.
The integration circuit 27 integrates the speed signal S1 from the speed detector 25, obtains the output signal S3, and outputs it to the comparator 15. The integration circuit 27 consists of an arithmetic amplifier 57, transistors 59 and 61, resistors 63, 65, 67, and 69, and a condenser 71.
When the reset signal RST, which is sent from the controller, is set to "1", the transistor 59 is turned off and thereby the arithmetic amplifier 57 functions as an integration circuit. In contrast, when the reset signal RST is set to "0", the transistors 69 and 59 are turned on. Thus, since both the ends of the condenser 71 are shortcircuited, an output of the arithmetic amplifier 57 is "0" and thereby an initial value is set.
The window comparator 31 consists of comparators 85 and 87 and resistors 89, 91, 93, and 95. When the position error signal S4 is in a voltage range determined by the resistors 89, 91, 93, and 95, an output signal TAC is set to 1. When the position error signal S4 is out of such a range, the output signal TAC is set to "0".
A resistor 103 is a pull-up resistor. A diode 101 is a protection diode for preventing a negative voltage from being applied to the controller 11. A condenser 99 is a noise arrester condenser.
Then, by referring to FIG. 1, an outline of the operation of the track jump control circuit will be described in the following.
In track following state (position control state) where the pick-up is followed to a particular track so as to read information, the controller 11 causes the switch 1 to be closed and the switch 17 to be placed in the low pass filter 9 side. In this state, the tracking error signal ER and the output signal S1 of the speed detector 25 are input to the comparator 19. The comparator 19 compares these signals and sends the difference signal to the motor 23.
In track jump state (speed control state), the controller 11 causes the switch 1 to be opened and the switch 17 to be placed on the comparator 15 side. The controller 11 sends data equivalent to the distance over which the pick-up is moved to a desired position to the reference voltage generation circuit 13. The integration circuit 27 outputs the position signal of the pick-up. The comparator 15 compares these signals and sends the resultant signal to the motor 23 so as to move the pick-up to the desired position.
The completion state of the track jump is determined in the following manner.
Since the output signal of the comparator 15 is input to the window comparator 31 as shown in FIG. 2, when the output signal of the comparator 15 is in the voltage range determined by the resistors 89, 91, 93, and 95, the output signal of the window comparator 31 is set to "1". Thus, the controller 11 determines that the track jump operation was completed.
Then, by referring to FIGS. 2 and 3, the operation in the track jump state of the track jump control circuit will be described in detail.
FIG. 3 is a wave form diagram of each signal of FIG. 2.
In the track jump state, the controller 11 determines the track jump direction and sets the signal F/R to "0" or "1". When the signal F/R is set to "1", the direction switching device 107 functions as a non-inverting amplifier whose gain is "1". In contrast, when the signal F/R is set to "0", the direction switching device 107 functions as an inverting amplifier whose gain is "-1".
Then, the controller 11 sets the reset signal RST to "1". At that time, the transistor 59 is turned off and the arithmetic amplifier 57 is in an integration state. At that time, since the output signal of the speed detector 25 does not take place, the signals S1, S2, and S3 are kept to "0".
Then, the controller 11 sends data equivalent to the difference between the present position and the desired position of the pick-up to the reference voltage generation circuit 13. The reference voltage generation circuit 13 converts the received signal into an analog signal. The direction switching device 107 multiplies the analog signal by 1 or -1 and outputs the resultant signal S5 to the comparator 15.
At that time, since both the signals S2 and S3 are set to "0", the signal S5 is input to the motor 23 as it is and thereby the pick-up is fully accelerated in the predetermined direction.
When the motor 23 is being started, a signal proportional to the speed is output from the speed detector 25.
When the motor 23 rotates, the output signal S3 of the integration circuit 27 is output in the negative direction.
The comparator 15 compares the signal S3 with the signal S5. The comparator 19 also compares the position error signal S4 with the signal S2. When the signal S4 is equal to the signal S2, the motor 23 is decelerated. The level of the signal output from the comparator 15 is reduced to zero as the pick-up reaches to the desired position as shown in FIG. 3.
When the pick-up is placed in the desired position, since S4=0 and S2=0, the motor 23 is stopped. At that time, the position error signal S4 is in the range determined by the window comparator 31 and the output signal TAC of the window comparator 31 is set to "1". Thus, the controller 11 detects that the track jump operation was completed. After a predetermined time elapsed, the controller 11 sets both the signal DATA and the reset signal RST to "0" so as to complete the track jump operation.
At that time, the controller 11 turns on the switch 1 and places the switch 17 in the low pass filter 9 side. Thus, the apparatus enters the track following mode.
In this embodiment, the position error signal S4 is input to the window comparator 31. When the position error signal S4 is in the predetermined range, the controller 11 determines that the track jump operation was completed.
As was described above, since the position error signal S4 is used to determine whether or not the track jump operation was completed, an effect of an external vibration against the apparatus can be reduced.
During the track jump state, since the position control loop is structured, the suppression degree against vibrations in low frequency range is high. In other words, the position error signal S4 is less affected by an external vibration frequency than the speed signal.
In addition, since the position error signal S4 is output just when a desired position is set, the response in the track jump initial state of the TAC signal can be improved.
Then, by referring to FIGS. 4 and 5, a second embodiment of the present invention will be described in the following. FIGS. 4 and 5 are a block diagram and a circuit diagram showing the structure of a track jump control circuit of the second embodiment of the present invention. The portions which are same as those in the first embodiment have the same numerals and the description thereof will be omitted.
In the second embodiment, an addition circuit 29 is used to add the position error signal S4 and the speed signal of the pick-up. The added signal is input to the wind comparator 31 so as to determine whether or not the track jump operation was completed. In this embodiment, the position error signal S4 is added to the speed signal of the pick-up in the ratio of 5 to 1.
According to the second embodiment, the controller 11 can monitor the speed state and the position error state by means of one wind comparator 31.
In the CD-ROM drive apparatus, CD player, or the like, when the power is turned on, information at the first position of the disc named TOC should be verified. However, since this information is recorded at the most inner peripheral position, the controller 11 moves the pick-up to the inner peripheral direction of the disc in a method other than the track jump method until the pick-up contacts the stopper.
At that time, even if no special switch is provided at the stopper portion, since the speed signal is monitored, the contact of the pick-up to the stopper can be readily detected.
In addition, the addition ratio of the position error signal S4 and the speed signal can be set in various manners according to applications.
Moreover, in the second embodiment, it is possible to provide a potentiometer for detecting the pick-up position instead of the integration circuit 27 so as to input an output signal of the potentiometer to the comparator 15.
It should be understood that the present invention can be applied to other record and playback apparatuses besides the optical record and playback apparatus.
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A track jump control circuit having a pick-up for reading information stored on a disc, a motor for moving the pick-up in a radial direction of the disc, a speed detector for detecting the moving speed of the pick-up and for outputting a speed signal, an integration circuit for generating a signal according to the moving amount of the pick-up according to the speed signal being detected, a reference voltage generation circuit for generating a reference signal according to the distance for which the pick-up is moved in a track jump mode, a comparator for comparing the reference signal with the signal according to the moving amount and for sending a difference signal to the motor, and a controller for stopping sending the difference signal to the motor when the difference signal is in a predetermined range. When the difference signal between the reference signal and the signal according to the moving amount is in the predetermined range, the completion of the track jump operation is determined. Thus, the determination of the completion of the track jump operation is not much affected by an external vibration.
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TECHNICAL FIELD
The present invention relates to a data logger for a measurement device such as an electronic balance, and particularly, to a data logger for a measurement device that manages measured values and installation environmental data of the measurement device.
BACKGROUND ART
Conventionally, in laboratories and production sites where measurement devices such as electronic balances are used, monitoring (recording over time) of installation environmental conditions (temperature, humidity, air pressure, etc.) that affect the performance of the measurement devices in parallel with measured values has been commonly performed. In this case, due to the demand for freedom of data processing in data analysis, data loggers capable of digitally recording measurement data and installation environmental data have been often used. For example, as regards the measurement data, a digital measurement data logger that receives measurement data from a measurement device, digitally records numerical values, and enables output of the same to a personal computer (hereinafter, a PC) via a USB terminal (Patent Literature 1) has been provided, and as regards the installation environmental data, a digital environmental data logger capable of receiving environmental data from respective environmental measuring instruments, digitally recording numerical values, and displaying such environmental data on its own display section (Patent Literature 2) etc., has been provided.
CITATION LIST
Patent Literature
Patent Literature 1: Japanese Published Unexamined Patent Application No. 2011-8572 (paragraphs 0027 to 0028, FIG. 1, etc.)
Patent Literature 2: Japanese Published Unexamined Patent Application No. 2009-257927 (paragraphs 0002 and 0008, FIG. 1, etc.)
SUMMARY OF INVENTION
Technical Problem
However, at the site of measurement, there has been a problem of how to manage in a centralized manner installation environmental data and measurement data recorded in different instruments in order to link acquired installation environmental data and measurement data to be graphed and numerically process the data.
In contrast thereto, because only measurement data is acquired from the data logger of Patent Literature 1 described above and installation environmental data is merely acquired from the data logger of Patent Literature 2 described above, centralized management of these data causes a difficulty of transferring both data to other equipment. Moreover, use of a PC as a recording medium allows easy centralized management of measurement data and installation environmental data, but causes trouble such as securing a space to dispose a PC around the measurement device or environmental measuring instrument and installing dedicated software. Moreover, it is first of all wasteful to occupy a PC for this purpose, and realization of centralized management has involved many inconveniences, such that PCs cannot be brought into a clean room or the like, and bringing in general-purpose recording media such as USB memories is also prohibited for reasons of security.
The present invention has been made in view of the problems of the conventional techniques mentioned above, and an object thereof is to provide a data logger exclusively for a measurement device capable of easily managing measurement data and installation environmental data in a centralized manner, and further provide a data logger for a measurement device that allows a user to recognize through a certain type of peripheral equipment how the installation environment affects the measured values in real time at the site of measurement.
Solution to Problem
In order to achieve the above-mentioned object, a data logger for a measurement device according to a first aspect of the invention is to be used for a measurement device that measures a mass of a measuring object, includes in its own structure any of the sensors for temperature, humidity, air pressure, and acceleration as an environmental sensor that detects a physical quality of an environment where the measurement device is installed, data recording means that records installation environmental data detected by the environmental sensor and measurement data detected by the measurement device on the basis of time, and data processing means that displays the recorded installation environmental data and measurement data in whole or selectively, as numerical values or graphs of changes over time, with time axes aligned, and includes one or more external equipment terminal connectors that exchange signals with external equipment such as the measurement device.
A second aspect of the invention is the data logger for a measurement device according to the first aspect of the invention, in which a humidity sensor and a temperature sensor among the environmental sensors are configured as a temperature/humidity sensor unit arranged so as to be attachable to and detachable from the data logger main body incorporating another environmental sensor, the data recording means, and the data processing means, and the temperature/humidity sensor unit includes a temperature/humidity data output terminal to transmit data to the data logger main body.
A third aspect of the invention is the data logger for a measurement device according to the second aspect of the invention, in which by connecting the temperature/humidity data output terminal to a temperature/humidity terminal connector of the data logger main body, the temperature/humidity data output terminal is made airtight and the temperature/humidity sensor unit is integrated in external appearance with the data logger main body.
A fourth aspect of the invention is the data logger for a measurement device according to the second or third aspect of the invention, in which a case of the temperature/humidity sensor unit is formed into a waterproof and dustproof structure that completely seals the temperature/humidity sensor with a filter made of a waterproof and moisture-permeable material being disposed over a position to dispose the humidity sensor and the waterproof and moisture-permeable filter being exposed to external ambient air, and a case of the data logger main body is formed into a waterproof and dustproof structure that completely seals the other environmental sensor, the data recording means, and the data processing means, and at the external equipment terminal connector, and a watertight cap to seal the connector part is attached.
Advantageous Effects of Invention
Based on the above, according to the first aspect of the invention, by providing an exclusive product capable of monitoring (recording over time) measurement data from the measurement device while also simultaneously monitoring environmental data of the temperature, humidity, air pressure, and vibration that affect measurement results, and managing both of the installation environmental data and measurement data in a centralized manner and then linking the installation environment and measurement data to be numerically displayed or graphed inside the single equipment, the difficulties regarding data processing associated with an environmental improvement for data acquisition, centralized data management, and data processing (numerical display, graphing) are eliminated.
Moreover, because of an exclusive product that is free to be carried around, no PC is required, so that trouble for a user at the site of measurement where data acquisition, centralized data management, and data processing have conventionally been difficult can also be eliminated.
Moreover, because data processing (numerical display, graphing) is possible in real time at the site of measurement and it is also further possible to pick up and selectively display only data desired by a user, environmental changes and a correlation between the environmental changes and measurement data are visually disclosed to the user, which allows the user to grasp that poor performance of the device is due to a change in the environment promptly and easily during measurement. Consequently, the reliability of the measurement device from the user is increased, and a guide for the user to improve the installation environment by him/herself can be provided.
According to the second aspect of the invention, as a result of configuring a humidity sensor that is a sensor particularly poor in durability as compared with other sensors as an attachable and detachable separate unit without incorporating into the data logger main body, among a wide variety of environmental sensors, because of the principle of measurement using changes in electrical conductivity with water absorption, because it suffices to replace only the temperature/humidity sensor unit in the case of a malfunction of the humidity sensor, maintenance of the data logger can be performed easily and at low cost.
Moreover, as a result of providing a temperature/humidity sensor unit into which a temperature sensor is also unitized, the temperature/humidity sensor unit can measure a temperature and humidity environment in another area separated from the data logger main body, and therefore can also be used as a temperature/humidity observing instrument of a device different from the logger concerned.
According to the third aspect of the invention, because the temperature/humidity sensor unit is not arranged to be externally attached to the data logger main body, but is housed so as to be integrated in external appearance with the data logger main body, the temperature/humidity sensor unit does not easily contact a person or object and physical damage is less likely to occur because of being covered with the data logger main body case. Moreover, the temperature/humidity sensor unit is less likely to be splashed with water drops and a malfunction due to liquid entry is also less likely to occur because of the covering.
According to the fourth aspect of the invention, because environmental measuring instruments are often used around water, conventionally, an environmental data logger having a waterproof and dustproof structure has existed. However, because it is necessary for the environmental data logger including a humidity sensor that the humidity sensor has a structure to allow water absorption of its humidity sensing body, the environmental data logger has a structure in which only the humidity sensor is in direct contact with external ambient air, and thus has not been a waterproof and dustproof structure. Therefore, by disposing a filter made of a waterproof and moisture-permeable material at the part that needs to permeate ambient air in the temperature/humidity sensor unit case, that is, the position for the humidity sensor so that only the filter made of a waterproof and moisture-permeable material contacts ambient air and the temperature sensor and humidity sensor are completely sealed by the case, a dustproof and waterproof structure can be provided despite inclusion of a humidity sensor.
On the other hand, also for the data logger main body, because a watertight cap is attached to its external equipment connector and the body case is constructed as a sealed structure, dust or liquid never enters the case in a state other than where the data logger main body is connected with external equipment.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a front view of the data logger.
FIG. 2 is a right side view of the data logger.
FIG. 3 is a plan view of the data logger, and is a view showing a state in which a temperature/humidity sensor unit is attached.
FIG. 4 is a front view of the temperature/humidity sensor unit.
FIG. 5 is a back view of the data logger, and is a view showing a state in which the temperature/humidity sensor unit is detached.
FIG. 6 is a conceptual view showing Usage Example 1 of the data logger.
FIG. 7 is a full trend display example of the data logger.
FIG. 8 is a selective numerical display example of the data logger.
FIG. 9 is a selective trend display example of the data logger.
FIG. 10 is a conceptual view showing Usage Example 2 of the data logger.
FIG. 11 is Selective Trend Display Example 1 of the analyzer.
FIG. 12 is Selective Trend Display Example 2 of the analyzer.
FIG. 13 is Selective Trend Display Example 3 of the analyzer.
FIG. 14 is Correlation Analysis Example 1 of the analyzer.
FIG. 15 is Correlation Analysis Example 2 of the analyzer.
FIG. 16 is a conceptual view showing Usage Example 3 of the data logger.
FIG. 17 is a full trend display example of the data logger.
FIG. 18 is a block diagram of the data logger.
DESCRIPTION OF EMBODIMENTS
A configuration of a data logger 1 according to the present invention will be described using FIGS. 1 to 5 . FIG. 1 is a front view of the data logger, FIG. 2 is a right side view of the data logger, FIG. 3 is a plan view of the data logger, and is a view showing a state in which a temperature/humidity sensor unit is attached, FIG. 4 is a front view of the temperature/humidity sensor unit, and FIG. 5 is a back view of the data logger, and is a view showing a state in which the temperature/humidity sensor unit is detached. In addition, FIG. 4 shows the transparent interior of a case.
The illustrated data logger 1 for a measurement device is used for a measurement device 100 , and consists of a data logger main body 20 and a temperature/humidity sensor unit 30 that can be attached and detached with respect to the data logger main body 20 .
The data logger main body 20 is palm sized with 80 mm in length, 120 mm in width, and 30 mm in depth, and is provided at the front surface with a display section 21 and a key operation section 22 . Moreover, in a central portion of the right side surface, an external equipment terminal connector group 23 of a measurement device connector 23 a for RS232C to receive measurement data from the measurement device 100 , an external equipment connector 23 b which can communicate with external equipment such as an external water temperature sensor 200 , and a USB mass storage device class connector 23 c capable of transferring data to a PC is disposed. In a position facing the right side surface, upper surface, and back surface of the data logger main body 20 , a temperature/humidity sensor unit housing recess portion 2 d that substantially matches the outline of a temperature/humidity sensor unit 30 to be described later is formed. At a right side wall in a back view of the temperature/humidity sensor unit housing recess portion 2 d , a temperature/humidity terminal connector 28 connectable with a temperature/humidity data output terminal 31 to be described later is provided.
The data logger main body 20 incorporates an electronic substrate mounted with an air pressure sensor 24 , an acceleration sensor 25 , and related ICs of these, and which can detect air pressure variations and vibration. Moreover, the electronic substrate is also mounted with a data memory (data recording means) 26 that records, on the basis of time, air pressure and vibration data detected by the built-in sensors 24 and 25 , temperature and humidity data detected by the temperature/humidity sensor unit 30 to be described later, and measurement data detected by the external measurement device 100 and taken in via the measurement device connector 23 a and a CPU (data processing means) 27 that displays the temperature, humidity, air pressure, and vibration data and the measurement data recorded in the data memory 26 , as numerical values or graphs of changes over time, with the time axes aligned.
The data logger main body 20 includes a front case 2 a including the display section 21 and the key operation section 22 and opened rearward and a rear case 2 b having the built-in electronic substrate mounted with the air pressure sensor 24 , the acceleration sensor 25 , the data memory 26 , and the CPU 27 and opened forward, and the cases 2 a and 2 b are closely fitted by fitting engaging pawls extending from the opening portion of the rear case 2 b with engaging recess portions provided in the opening portion of the front case 2 a with an O-ring interposed in a joint portion between the rear case 2 b and the front case 2 a , and the data logger main body 20 thus is a structure having a dustproof and waterproof function equivalent to IP65. The external equipment terminal connector group 23 is a dustproof and splashproof structure in a state other than where there is a connector connection, due to attachment of three watertight cap portions 4 a , 4 b , and 4 c integrally molded with a main body protective cover 4 to be described later. Moreover, in a central portion of the back surface of the rear case 2 b , there is a cavity portion in which a battery of the data logger 1 is stored, and the battery housed in the battery cavity portion is sealed by a sliding battery lid 2 e . FIG. 18 is a block diagram illustrating the relationship between the air pressure sensor 24 , acceleration sensor 25 , and data memory 26 with the CPU 27 contained with the main body 20 , and the measurement device 100 and temperature/humidity sensor unit 30 that are disposed outside of the main body 20 .
The temperature/humidity sensor unit 30 is in a rectangular-parallelepiped shape that is 20 mm in length, 50 mm in width, and 20 mm in depth, and in a back view of the data logger 1 , is housed in the data logger main body 20 so as to fill up the recess of the temperature/humidity sensor unit housing recess portion 2 d in a state covered at its lower surface, back surface, and right side surface with the temperature/humidity sensor unit housing recess portion 2 d when attached.
The temperature/humidity sensor unit 30 incorporates an electronic substrate mounted with a temperature sensor 32 , a humidity sensor 33 , and related ICs of these, and can detect temperature and humidity variations. Moreover, the temperature/humidity sensor unit 30 includes, in a central portion of the right side surface, a temperature/humidity data output terminal 31 connected to the temperature/humidity terminal connector 28 of the data logger main body 20 to send temperature/humidity data to the data logger main body 20 .
The temperature/humidity sensor unit 30 includes a lower case 3 b having the built-in electronic substrate mounted with the temperature sensor 32 and the humidity sensor 33 and opened upward and an upper case 3 a to serve as a lid portion thereof, and the cases 3 a and 3 b are closely fitted by fitting engaging pawls extending from an opening portion of the upper case 3 a with engaging recess portions provided in the opening portion of the lower case 3 b with an O-ring interposed in a joint portion between the lower case 3 b and the upper case 3 a , and the temperature/humidity sensor unit 30 thus is a structure having a dustproof and waterproof function equivalent to IP65. Moreover, the lower case 3 b is opened laterally at the right, and the temperature/humidity data output terminal 31 is circumferentially surrounded and protected at a right side end portion of the lower case 3 b while being connectable with the temperature/humidity terminal connector 28 . Moreover, at a left side of the upper surface of the upper case 3 a , sliding pawls 3 c that provide excellent finger retention during sliding are formed, and at a central portion of the upper surface of the upper case 3 a , a filter-use window portion 3 d for a waterproof and moisture-permeable filter 34 to be described later is provided.
By sliding the temperature/humidity sensor unit 30 in the right direction and fitting the temperature/humidity data output terminal 31 by insertion into the temperature/humidity terminal connector 28 , the air tightness of the temperature/humidity data output terminal 31 is secured and the temperature/humidity sensor unit 30 reaches an attached state where it is integrated in external appearance with the data logger main body 20 . In the attached state, the temperature/humidity sensor unit 30 does not easily contact a person or object and physical damage is also less likely to occur because of being covered with the data logger main body 20 (temperature/humidity sensor unit housing recess portion 2 d ). Moreover, the temperature/humidity sensor unit 30 is also less likely to be splashed with water drops and a malfunction due to liquid entry is also less likely to occur because of the covering.
On the other hand, by sliding the temperature/humidity sensor unit 30 in the left direction and removing the temperature/humidity data output terminal 31 from the temperature/humidity terminal connector 28 to bring about a cable-connected state between the terminal 31 and the connector 28 , the temperature/humidity sensor unit 30 reaches a detached state in which a temperature and humidity environment in another area separated from the data logger main body 20 can be measured.
Moreover, the electronic substrate mounted with the temperature sensor 32 , the humidity sensor 33 , and ICs for these is horizontally arranged inside the lower case 3 b , and over a position to dispose the humidity sensor 33 , a filter 34 made of a waterproof and moisture-permeable material is adhered to the inside of the sensor upper case 3 a , and a waterproof and moisture-permeable filter 34 is adhered also to the inside of the lower case 3 b . Further, only the part of the waterproof and moisture-permeable filters 34 is in contact with external ambient air via the filter-use window portion 3 d of the upper case 3 a and a filter-use window portion 3 e of the lower case 3 b , and other parts, that is, the electronic substrate mounted with the temperature sensor 32 , the humidity sensor 33 , and related ICs of these is prevented from hindering water absorption of a humidity sensing body of the humidity sensor 33 by providing a packing for a fitting portion between the upper case 3 a and the lower case 3 b , and thus a temperature/humidity sensor unit 30 that has a dustproof and waterproof structure despite including a humidity sensor is provided.
Moreover, among a wide variety of environmental sensors, humidity sensors 33 are particularly poor in durability, but in the data logger 1 , because it suffices to replace only the temperature/humidity sensor unit 30 in the case of a malfunction of the humidity sensor 33 , maintenance is easy and low cost.
The entire data logger main body 20 is covered at its upper surface and lower surface, circumferentially at its right side surface, circumferentially at its left side surface, circumferentially at its front surface, and circumferentially at its back surface with the main body protective cover 4 (indicated by thick lines in FIGS. 1 to 3 and FIG. 5 ) which is an integrated molding made of a viscoelastic material having a thickness of approximately 3 mm. Four corner positions of the main body protective cover 4 are extended upward/downward and laterally in trapezoidal shapes, and as a result of the main body protective cover 4 being fitted, the data logger main body 20 has a self-standing capability and has shock resistance strong enough for a fall of the main body from 1.5 m. In a right side surface portion of the main body protective cover 4 , for respective connector positions of the measurement device connector 23 a , the external equipment connector 23 b , and the USB connector 23 c , the watertight cap portions 4 a , 4 b , and 4 c molded integrally with the cover 4 are formed by extension from the rearward side toward the forward side of the right side surface portion of the main body protective cover 4 . By opening and closing the respective watertight cap portions 4 a , 4 b , and 4 c , a necessary connector (s) of the external equipment terminal connector group 23 can be opened, and other connector (s) can be sealed for protection (dustproofed and splashproofed).
Next, usage examples and function of the data logger 1 will be described.
Usage Example 1 of the data logger 1 will be described using FIGS. 6 to 9 . Usage Example 1 is a common usage example of the present data logger 1 in which the data logger 1 is used for an analytical balance that has reading accuracy (minimum display) of a measured value of 0.1 mg or less as the measurement device 100 , and the temperature/humidity sensor unit 30 is used in an attached state. In addition, in the drawings in the following usage examples, description of the main body protective cover 4 will be omitted.
First, at the site of measurement, an output connector of the target measurement device 100 and the measurement device connector 23 a of the data logger 1 are connected by a terminal cable for RS232C for installation. Next, when a measurement is started at the measurement device 100 , a zero point being measurement data under no load and a weight being measurement data under load are output from the measurement device 100 to the data logger 1 , triggered by a command issued from the measurement device 100 , and simultaneously, four types of environmental data detected by the air pressure sensor 24 and the acceleration sensor 25 in the data logger main body 20 and the air pressure sensor 32 and the humidity sensor 33 in the temperature/humidity sensor unit 30 are stored in the data memory 26 together with date/time information. The environmental data of the temperature, humidity, air pressure, and acceleration and the weight measurement data recorded in the data memory 26 are promptly read out to the CPU 27 , and are subjected to data processing so as to be numerically displayed ( FIG. 1 ) on the display section 21 in a manner unified in time and correlated with each other. Alternatively, it is also possible to carry out a full trend display consisting of graphs of changes over time of correlation with a time axis set on the horizontal axis and variations of all types of data shown on the vertical axis by an operation of the key operation section 22 ( FIG. 7 ). Alternatively, a selective numerical display ( FIG. 8 ) or selective trend display ( FIG. 9 ) that picks up only data on which a user wishes to focus, for example, only the temperature and humidity can also be performed by an operation of the key operation section 22 . In addition, in a trend display, it is possible for a user to carry out automatic scaling to a desired time duration by an operation of the key operation section 22 .
The data logger 1 can perform all such processing that is required at the site of measurement of data acquisition, centralized data management, and data processing (numerical display, graphing) in the single equipment without using a general-purpose PC. Accordingly, not only the trouble of using a plurality of various data loggers at the same time and compiling respective data into other equipment is eliminated, but also at the site of measurement, such as areas including a clean room where bringing in PCs is prohibited and areas where general-purpose USB memories cannot be brought in for reasons of security, where data acquisition, centralized data management, and data processing have conventionally been difficult, easy adaptation is enabled.
Next, Usage Example 2 of the data logger 1 will be described using FIGS. 10 to 15 . Usage Example 2 includes a measurement analyzer 40 connected to the USB connector 23 c in addition to Usage Example 1.
The measurement analyzer 40 is characterized by including in its own structure a measurement data computing and recording means which is connectable with the data logger 1 via an external terminal connector (USB connector 23 c ) or directly connectable with the measurement device 100 , which computes, from measurement data of a zero point and weight read out of the data logger 1 or the measurement device 100 , at least a span value and a standard deviation of the span value or a standard deviation of the zero point or weight, and records the same data on the basis of time, a data processing means 43 which displays installation environmental data (temperature, humidity, air pressure, and acceleration) read out from the data logger 1 and the computed measurement data (span value and various standard deviations) computed by the measurement data computing and recording means in whole or selectively, in an identical screen of its own display section 42 , as numerical values or graphs of changes overtime, with the time axes aligned, and a data analysis means 44 which analyzes and displays correlations between the above-mentioned installation environmental data and the above-mentioned measurement data and the above-mentioned computed measurement data.
In addition, it is also possible to connect the measurement analyzer 40 with the measurement device connector 23 a by a terminal cable for RS232C.
At the site of measurement, besides linking acquired installation environmental data and measurement data (weight) to be graphed, an operation is also performed such as calculating from acquired measurement data (zero point and measurement) indices that allow for grasping the performance of the measurement device, such as a span value being a difference between the zero point being measurement data under no load and the weight being measurement data under load, a standard deviation of the above-mentioned span value determined by repeatedly measuring the above-mentioned load the mass of which is already known a plurality of times, and a standard deviation of the above-mentioned zero point or the above-mentioned weight determined by repeatedly measuring the above-mentioned zero point or the above-mentioned weight, managing these computed measurement data (span value and various standard deviations (repeatabilities)) and the installation environmental data in a centralized manner and subjecting said data to data processing (numerical display, graphing) and correlation analysis.
The measurement analyzer 40 is an exclusive product capable of, inside the single equipment, managing in a centralized manner measurement data (zero point and weight) and installation environmental data acquired from the measurement device 100 or the data logger 1 and also computed measurement data (span value and various standard deviations) calculated by itself and installation environmental data and subjecting said data to data processing (numerical display, graphing) and data analysis (collation analysis without time display).
Computed measurement data computed and recorded by the measurement data computing and recording means 41 of the measurement analyzer 40 is promptly linked with installation environmental data read out by the data processing means 43 , and a display is carried out with automatic scaling on the display section 42 , examples of which include, as shown in FIG. 11 , a selective trend display consisting of graphs of changes over time of variations correlated with a time axis selected for the horizontal axis and the temperature (right axis), span value (left axis), and zero point (left axis) selected for the vertical axis, and as shown in FIG. 12 , a selective trend display consisting of graphs of changes over time of variations correlated with a time axis selected for the horizontal axis and the humidity (right axis), span value (left axis), and zero point (left axis) selected for the vertical axis, and as shown in FIG. 13 , a selective trend display consisting of graphs of changes over time of variations correlated with a time axis selected for the horizontal axis and the temperature (right axis) and span value standard deviation (left axis) selected for the vertical axis.
Furthermore, a display is carried out by the data analysis means 44 with automatic scaling on the display section 42 , such as, as shown in FIG. 14 , correlated analysis graphs of the zero point/span value with respect to temperature changes with the temperature displayed on the horizontal axis and the zero point/span value displayed on the vertical axis by eliminating the time axis from the data shown in FIG. 11 , and as shown in FIG. 15 , correlated analysis graphs of the zero point/span value with respect to humidity changes with the humidity displayed on the horizontal axis and the zero point/span value shown on the vertical axis by eliminating the time axis from the data shown in FIG. 12 .
Accordingly, even at the site of measurement such as a clean room, numerical processing of measurement data, centralized management of the data including computed measurement data, graphing, etc., are possible in real time and easily even without installing a PC, so that troublesome work for a user that has conventionally been performed to realize these data processing is eliminated. Further, it can be understood at a glance by a user referring to the correlated analysis graphs of FIG. 14 and FIG. 15 prepared from FIG. 11 and FIG. 12 of a simultaneous measurement that the zero drift is greatly affected by changes in temperature and humidity, and it becomes possible to promptly judge by the user him/herself what degree of environmental setting allows achieving a required measurement accuracy.
Specifically, adding a measurement analyzer 40 to the data logger 1 makes the data logger 1 serve as not only a recording medium but also a tool capable of actively evaluating the environment. That is, having once recognized that, as shown in FIG. 13 , the span value standard deviation that was on the order of 3 μg on average at the start of measurement has gradually degraded to 14 μg on average by performing monitoring with the data logger 1 for monitoring while also performing data processing by the measurement analyzer 40 in parallel, a user can perform an operation such as finding out which data of the temperature, humidity, air pressure, and vibration is in the closest conjunction with the span value standard deviation from a trend display. If it is revealed as a result thereof that acceleration data shows conjunction, the user can recognize that the cause is vibration of the building with the passage of a low pressure area, and the user him/herself can appropriately improve the surrounding environment such as installing an anti-vibration platform for the measurement device 100 . Consequently, the reliability of the measurement device 100 from the user is further increased.
Next, Usage Example 3 of the data logger 1 will be described using FIG. 16 and FIG. 17 . Usage Example 3 is an example in which the data logger 1 is used for an analytical balance to be used as the measurement device 100 for a capacity tester to serve mainly for confirmation of the ejection performance of a micropipette, and uses the temperature/humidity sensor unit 30 in a detached state.
To the measurement device connector 23 a of the data logger 1 , a measurement analyzer 40 is connected by a terminal cable for RS232C, and the measurement analyzer 40 is connected directly to the measurement device 100 via a display section 102 by a terminal cable for RS232C. On the upper surface of the measurement device 100 , a measuring vessel 104 is placed at a position over a measuring section, and the measuring vessel 104 is covered at a position other than the measuring section with a humidity retaining vessel 103 to prevent liquid evaporation of a sample in the measurement vessel 104 .
Further, the temperature/humidity sensor unit 30 is introduced into the inside of the humidity retaining vessel 103 in a state detached from the data logger main body 20 and extended by a cable. Specifically, in Usage Example 3, the temperature/humidity sensor unit 30 is used as an instrument to measure a temperature and humidity environment in the humidity retaining vessel 103 located at the position separated from the data logger main body 20 . Thus, the temperature and humidity environment in the humidity retaining vessel 103 that can be high humidity due to evaporation of the sample can be monitored, and is managed with measurement data (measurement value) in a centralized manner by the data logger 1 , and similar to Usage Example 1, displayed numerically ( FIG. 16 ) or as a full trend display ( FIG. 17 ).
Moreover, to the external equipment connector 23 b of the data logger 1 , an external water temperature sensor 200 is connected. The external water temperature sensor 200 is installed for measuring the temperature of water to serve as a sample in order to correct the density of water at calibration of a micropipette. Water temperature data detected by the external water temperature sensor 200 is stored in the data memory 26 similar to Usage Example 1, and can be displayed numerically or as a full trend display by the CPU 27 (Temp2). In this manner, for the data logger 1 , another sensor may be externally connected to the external equipment connector 23 b to expand the application of the data logger 1 to meet user specifications.
In addition, the data logger 1 and the measurement analyzer 40 are characterized by being exclusive products capable of centralized data management and data processing even without requiring a PC, but can also transmit data to a PC via the USB connector 23 c , and therefore may be used in a system where data processing is performed by a PC.
REFERENCE SIGNS LIST
1 Data logger
3 d , 3 e Filter-use window portion
4 Main body protective cover
4 a , 4 b , 4 c Watertight cap portion
20 Data logger main body
21 Display section
23 External equipment terminal connector group
23 a Measurement device connector
23 b External equipment connector
23 c USB connector
24 Air pressure sensor
25 Acceleration sensor
26 Data memory
27 CPU
28 Temperature/humidity terminal connector
30 Temperature/humidity sensor unit
31 Temperature/humidity data output terminal
32 Temperature sensor
33 Humidity sensor
34 Waterproof and moisture-permeable filter
40 Measurement analyzer
100 Measurement device
200 External water temperature sensor
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For easy centralized management of measurement data and installation environmental data and user's real-time recognition through a certain type of peripheral equipment of how the installation environment affects the measured values at the site of measurement, a data logger for a measurement device includes in its structure any of the sensors for temperature, humidity, air pressure, and acceleration as an environmental sensor that detects a physical quality of an environment where the measurement device is installed, a data recording unit that records installation environmental data detected by the environmental sensor and measurement data detected by the measurement device on the basis of time, and a data processing unit that displays the installation environmental data and measurement data in whole or selectively, as numerical values or graphs of changes over time, with the time axes aligned, and includes one or more external equipment terminal connectors that exchange signals with external equipment.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to an impulse type shock wave flash dyeing machine, which is abbreviated as a shock wave dyeing machine. The dyeing machine of the present invention is an improved version of the spray dyeing apparatus with breadth expansion and vibration-enhanced dyeing operation and is a machine that may be used to carry out the dyeing process and other processes and that is characterized with high efficiency, multiple functions, multiple applications and environmental friendliness.
[0003] 2. Description of the Prior Art
[0004] To slow down the global warming and climate change, many processing technologies have been used in the processing of fibrous fabric. These technologies include shock wave technology, electrochemistry, low-temperature plasma technology, carbon dioxide supercritical fluid technology, biological enzyme technology, supersonic technology, radioactive energy technology, microwave technology, etc. These technologies are characterized with convenience, swiftness, effectiveness, a wide range of applications, environmental friendliness, being able to save dyes and energy and being able to be used with automated computer control devices. Therefore, these technologies have been developed swiftly in many places of the world. However, most dyeing machines of the prior art have only a single application and there has not been any dyeing machine that has multiple functions and multiple applications and that is environmental friendly on the market. In light of the above, the invention with the title of “Spray dyeing apparatus with breadth expansion and vibration-enhanced dyeing operation” has been patented in more than 20 countries: Taiwan (date of application: Feb. 25, 1997; application no.: 86,102,237), China (date of application: Apr. 29, 1997; application no.: ZL97 1 82145.3) the US (date of application: Mar. 31, 1997; application no.: 828,884), Canada (date of application: Apr. 29, 1997; application no.: 2,288,214), EU (date of application: Apr. 29, 1997; application no.: 97917988.4), India (date of application: May 28, 1997; application no.: 1126/MAS/97), Japan (date of application: Apr. 29, 1997; application no.: 10546452), Korea (date of application: Oct. 28, 1999; application no.: 997009996), etc. To reach the goal of clean processes and to save energy and reduce carbon footprint, the inventor has put a lot of effort into the subject and has successfully come up with the dyeing machine of the present invention by employing new technologies and new approaches.
[0005] Because water has been used as the medium in the wet type process of textile products, the textile dyeing and finishing industry has been discharging a lot of contaminated water. The global textile market has been forced to provide green products under the pressure from global warming. Such trend is a tough challenge to the textile dyeing and finishing industry. To reach the goal of continuous development of the textile dyeing and finishing industry, the adoption of clean processing technologies has been regarded as the only solution.
[0006] In fact, global warming and climate change have become urgent issues. The textile dyeing and finishing industry should speed up in the adoption of new thinking and employ new processes, use new processing facilities and adopt new methods.
[0007] In the dyeing machine of the present invention, to make the machine that saves energy and water and that can carry out processes in a clean manner, fibrous fabric, dyes and processing agents are placed in a high-energy wave field to reach the goal of fast and efficient processes through the wave field. In addition, low-temperature plasma technology is used to reach the goals of waterless process, innovative approach and optimal effect.
[0008] As of now, most of the dyeing and finishing machines are wet type machines that can be used for only one purpose at a time. Therefore, they consume an excessive amount of water and energy and seriously pollute the environment. Also, their processing costs are too high and they seriously damage the eco system.
[0009] As of now, clean processes in which small amount and many types of fabric may be processed and that is multifunctional are the preferred choice of the textile dyeing and finishing industry. Therefore, green dyeing machines with these three advantages would be the main production facilities in the industry. Many problems and disadvantages still can not be solved in the dyeing machines of the prior art (including the spread-out type and non-spread-out type air flow dyeing machines and the traditional injection type dyeing machine). Such problems and disadvantages include the right portion of the fabric having a different color from that of the left portion, the inconsistency in color for the same patch of fabric, uneven application of the dyes, the fabric circulation wheel being unable to move in sync with the nozzles, the fabric not able to move fast enough, damages caused by friction and collision, the fibers of the fabric being broken by the excessive amount of force exerted by the nozzles, the clogging of the nozzles and the filtering units, the fabric unable to have a pleasant feel, the low efficiency in the bio enzyme process, processes being carried out too slowly, the machine not having enough functions and hence the processes being limited, excessive use of energy and water, etc. Therefore, the cost for the treatment of contaminated water skyrockets. Also, the fabric circulation wheel poses a danger to the users. In addition, finished fabric may not have a good feel. Poor design is the main reason for all of the aforesaid problems. An example would be the uneven heat transfer among the fabric and the dyes, processing fluids and air flow. For example, the inconsistency in color is caused by the more-than-one processing tanks and the uneven division or distribution of the dyes and air flow. It is difficult to equally divide the fluid or flow in a tube into two exactly equal parts (in the prior art, a single tube is divided into two tubes, two tubes are then divided into four tubes and four tubes are divided into eight tubes), resulting the inconsistency in color. To reach the goal of clean processes, the aforesaid problems must be solved simultaneously. In addition, a modification or re-dyeing may be needed when there is an unsatisfactory result and such modification or re-dyeing would be a waste of energy and water and increase the production cost.
[0010] There are four stages in the dyeing process:
1. Dye approaches the surfaces of fabric. In this stage, the dyeing process does not correlate with the quality of the dye and the condition that the dye is in. In this stage, the dye molecules dissolved in the solution or fluid or larger pieces or particles of the dye suspended in the fluid or solution move with the dyeing fluid. Also, the speed of the dye depends on the speed of the flow of the dye. 2. A stagnant layer exists between the fabric and the surface. As the dye reaches the stagnant layer, the dye may get closer to the surface via diffusion. In this stage, the speed of the dye depends on the flow of the dye and the diffusion speed of the dye. Dye in a dissolved condition diffuses much faster than dye in a suspension condition does. Therefore, the solubility of the dye determines the speed of the dye. 3. At a certain distance between the dye and the surface of the fabric, the dye would swiftly attach to the surface as the molecular attraction between the dye and surface becomes sufficiently large. In this stage, the speed of the dye is determined by the interaction between the dye and the fabric and the solubility, which plays a more important role. Therefore, the speed of the dye is greater if the interaction is greater or the solubility is higher. 4. After the dye attaches to the surface of the fabric, the difference in concentration level between the inside of the fabric and the outside of the fabric occurs. By the Fick's law, the dye would move from the surface to the interior of the fabric. Now, the speed of the dye is determined by the molecular structure and physical structure as well as the concentration level of the dye. The greater total area of non-crystalline areas is, the greater the speed of the dye moving toward the interior of the fabric is. The greater the pore size is, the greater the speed of the dye is. The greater the concentration level of the dye at the surface is, the greater the speed of the dye is. In this stage, the speed is determined by the levels of expansion and plasticization of the fibers and the concentration level of the dye at the surface.
[0015] From the above, we can see that the dyeing speed is determined by the levels of expansion and plasticization of the fabric. In fact, we do not need a large amount of the operating solution to dissolve the dye. If the dye dissolves in an excessive amount of the operating solution in the dyeing process, the operating solution may reduce the contact and interaction between the dye or processing fluid and the fabric. In addition, the majority of the input energy would be absorbed by the operating solution. After the operating solution absorbs the energy, the energy would be used for the revolution of the molecules of the operating solution, the vibration of the atoms of the operating solution and the interactions (between the molecules of the operating solution) that are not correlated to the dyeing process and other process.
[0016] To increase the level of solubility of the dye, a certain amount of polar radicals is usually added into the dye. The addition of polar radicals may increase the interaction between the dye and the fabric in few cases. However, it is difficult to process and purify the residual solution after the dyeing process.
[0017] Regarding dispersal dye, which has a level of solubility, because it does not have ion radicals, the dyeing process is quite difficult to carry out. A large amount of dispersion agent has to be used to make it suspending in the operating fluid and the state of such suspension is difficult to maintain. In addition, the residual solution is difficult to purify. Therefore, a good way would be to increase the solubility of the dispersal dye to facilitate the dyeing process (reducing the amount of the dispersion agent or not using the dispersion agent).
[0018] Regarding synthetic fiber, because it is difficult for such fiber to dissolve in water, it is difficult for the dye to diffuse inside the synthetic fiber. The dyeing process for such fiber usually requires a higher temperature. For example, the temperature has to be raised to 130 degree C. to carry out the dyeing process on the polyester fiber. Such temperature may be lowered if the levels of expansion and plasticization of such fiber are enhanced (the diffusion speed of the dye in such fiber would be increased).
[0019] With regard to natural fiber, it has a complicated structure and many cavities, which are filled with air. Therefore, it is difficult for the dye to enter the fibers and dyeing process takes a longer time. With regard to wool, a scale layer exists on the surface of wool and can hinder the entry of dyes. In the past, dyeing at the boiling point is used for the dyeing of wool and such dyeing takes a longer time. Therefore, such dyeing consumes more energy and wool fiber can be damaged. In addition, because reactive dye may react with water at high temperatures and in alkaline solution, the efficiency of dyeing is reduced. Also, after the dyeing process, both the residual solution of the dyeing and the unfixed dyes in the post-treatment are highly polluted solutions.
[0020] An important factor in dyeing is that the dyes must first dissolve in the operating solution to become single molecules because only such single molecules can swiftly attach to the fibers and enter into the interior of the fibers. If the physical mechanism generated by waves and high-energy particles of the present invention is used, the solubility of a dye with a lower solubility may be enhanced in an operating solution that has a high level of concentration and is in a small amount; therefore, dyes may be attach to the fiber swiftly, the levels of solubility and plasticization of the fiber may be enhanced and dyes may diffuse swiftly in the fiber. Hence, the overall dyeing speed is enhanced. If a dye having a stronger bonding force with the molecules of the fiber is chosen, the dyeing process may be carried out easily and such dye has a higher level of attachment.
[0021] To increase the dyeing speed, we can decrease the amount of water, select an appropriate dyeing machine, enhance the interaction between the dye and fabric, choose dyes suitable for the fabric and use dyeing assisting agent and dyeing medium; in addition, the molecular structure and physical structure of the fiber plays a crucial role. If the fiber undergoes a proper pre-treatment or a pre-treatment that can change the quality of the fiber or the fiber's quality is changed in the dyeing process, the dye may attach to the surface of the fiber more quickly and may diffuse inside the fiber more swiftly; in addition, less time is needed in the dyeing process and a lower temperature is needed. Therefore, the goals of high energy efficiency, carbon footprint reduction and clean processes may be achieved.
SUMMARY OF THE INVENTION
[0022] In the impulse type shock wave flash dyeing machine of the present invention, dyes, processing fluids, low-temperature plasma and other media may be spread out in high speed air flow via the acceleration effect of the joint nozzles. These dyes, processing fluids, low-temperature plasma and other media are present with fibrous fabric in a high-energy wave field. Therefore, each of them is imparted with a sufficient amount of activation energy. Whence, the goal of most economical process may be reached within the shortest period of time.
[0023] In use, the fast moving air, steam, dyes, processing agents and low-temperature plasma blast the fibrous fabric. As the fibrous fabric turns or descends, energy transfer may be carried out efficiently from the fast moving air, steam, dyes, processing agents and low-temperature plasma to the fibrous fabric. In addition, the dyes and processing agents are imparted with a high amount of kinetic energy and are in the form of fine mist or individual molecules as they flow in the air flow. The fine mist of dyes and processing agents violently collide with the direction-changing fibrous fabric in the manner of elastic collision (the collision between air or gas and the fibrous fabric) or inelastic collision (the collision between processing agents, dyes or plasma and the fibrous fabric). The inelastic collision results in highly efficient transfer of kinetic energy and hence the fibrous fabric would move faster. The inelastic collision also supplies sufficient amount of fluid to generate the effect of cavitation. In addition, a reflective motion plate can generate a high-speed wavy motion on the fibrous fabric. The air pressure of the upper portion of the fibrous fabric is greater than the air pressure of the lower portion of the fibrous fabric. The difference in air pressure prompts the fibrous fabric to move in a violent high-frequency wavy motion and to spread out as the fibrous fabric passes the reflective motion plate.
[0024] In a wet type process, if there is enough amount of fluid attached to the surfaces of the fibrous fabric and the air flow has enough amount of speed or kinetic energy, a large amount of cavities may be generated in the peripheral portions of the surfaces of the fibrous fabric and shock waves may be generated in the peripheral portions. In a dry type process, the air molecules contained in the fast-moving air flow may be ionized via corona discharge or glow discharge to become fast-moving low-temperature plasma. Therefore, such high-energy plasma may be used to process the fibrous fabric and the goal of waterless process, which is environmentally friendly, may be achieved.
[0025] In use, the swift closures and openings of the air pathway would occur. Such effect makes the fibrous fabric wiggling violently as it passes the fabric accumulator to make the operating solution, loose fibers and solid objects detach from it. In the mean time, the fibrous fabric is folded up. Also, after the operating solution, loose fibers and solid objects detach from it, they would flow to the outlet and then to the solution gathering tank. Then, the solution is filtered out to remove the operating solution, loose fibers and solid objects. Therefore, the solution is purified and may be used for the next cycle of operation. Dyes and processing agents, that have a high concentration level and have been dissolved into the liquid form, may be replenished via the pump-less content adding device. Therefore, the dyes and processing agents may be mixed well with the operating solution to enable the processes to be carried out with a small amount of operating solution. Therefore, as the fibrous fabric has contact with the dyes or processing fluids, the fabric may have a higher level of potential energy and kinetic energy and the dyes and processing agents may have a higher level of concentration gradient, temperature gradient and chemical affinity so that the dyes and processing agents may diffuse in the fabric swiftly. In addition, the effect of several pieces of fabric squeezing each other in the fabric accumulator is reduced to a minimal level and the tension of the fabric is reduced to a minimal level as it moves swiftly in the fabric guiding tube. In use, dyes and processing agents go through the circulation pump; the fluid cross flow distributor can convert the dyes and processing agents into fine mist and the spray coming out from each spraying nozzle has the same pressure, amount, temperature and speed.
[0026] After the air flow is compressed by the blower, it will be distributed by the air cross flow distributor into the distributing tubes. The expansion effect of the air cross flow distributor can covert the kinetic energy of the air flow into static pressure; therefore, as the air flow comes out from each air nozzle and joint nozzle, its speed increases and it will come out from each of these nozzles with the same pressure, amount, temperature and speed. Therefore, dyes and processing agents may be sprayed out evenly on the fabric. In addition, backflow air may flow back to the air backflow unit and hence disturbance may be removed and the goal of stable cyclic air flow may be achieved.
[0027] In particular, the dyeing machine of the present invention further comprises a plurality of air nozzles, a row of joint nozzles and a U-shaped circumrotating plate. The air nozzles are provided along the upstream and midstream of the surface on the lower side of the fabric guiding tube. The joint nozzles are provided on the two sides of the pathway and these nozzles are configured in a linear manner. The U-shaped circumrotating plate is disposed and fixed in the downstream portion of the joint nozzles. A reflective motion plate, which is a flat plate, is formed on the upstream portion of the U-shaped circumrotating plate. An outer separating net barrier is provided in the upstream fabric flop portion. Therefore, in use, the air and operating solution in the processing tank and the dyes and processing fluid in the reserve tank may enter the blower and circulation pump through the pipelines so that the air, fluid and dyes may be compressed and sprayed out of the joint nozzles and a part of the compressed air may be sprayed out from the air nozzles. In use, the compressed air sprayed out from the air nozzles may enable the fibrous fabric to float in the tank. Most of the compressed air is sprayed out from the joint nozzles. The direction of the air coming out from the joint nozzles is changed by the U-shaped circumrotating plate and then the air flow acts on the fibrous fabric. Therefore, in use, most of the kinetic energy of the fibrous fabric is provided by the joint nozzles. Whence, in the dyeing machine of the present invention, the fabric circulation wheel of the prior art is not needed and the spraying nozzles of the prior art may be removed because the kinetic energy is overly spread out and hence processes requiring higher energy can not be carried out. In addition, the effect of plasma (generated by the device of corona discharge or glow discharge) may be used with the mist converting device to achieve the goals of waterless processes and innovative process.
[0028] An object of the present invention is to provide an impulse type shock wave flash dyeing machine in which, in use, high-speed wet or dry hot air injected out of the joint nozzles, fast-moving and evenly spread out dyes, fast-moving and evenly spread out processing fluids, fast-moving low-temperature plasma and other types of mist may be imparted with sufficient amount of kinetic energy (activation energy) and repeatedly collide with the fibrous fabric in a high energy wave field. Therefore, kinetic energy may be transferred from the air, dyes, processing fluids, etc. to the fabric in a very short period of time. Whence, dyeing and other processes may be done in a manner that is the most efficient in terms of energy consumption, water consumption, dye consumption and processing agent consumption.
[0029] Another object of the present invention is to provide an impulse type shock wave flash dyeing machine in which a mixture, which consists of dyes and processing agents, is formed in the tank and such mixture has a low level of viscosity and resistance and a high level of potential energy, diffusion and expandability via the violent high-frequency wavy motion or the effect of shock wave, which is caused by the wavy motion, so as to be used to carry out wet type process on the fibrous fabric in the manner that only a small amount of fluid is needed and has a high level of concentration and efficiency. With respect to the effect of shock wave, shock wave is a high-energy wave motion generated by the high-speed air flow. A compressed area is formed in the peak area and a decompressed area is formed in the trough area. In the compressed area, air is compressed (because the distances between air molecules become smaller) and the density of air is increased. In the decompressed area, air is decompressed (because the distances between air molecules become larger) and the density of air is decreased. If the fabric moves fast enough in the form of wave motion, the molecules of the operating fluid are affected by the effects of compression and decompression. When the negative pressure of decompression is lower than the critical pressure of the saturated vapor pressure, the average distance between the molecules of the operating fluid would exceed the critical distance, destroying the attraction between the fabric and these molecules and creating cavities in the surfaces of the fabric or in the space inside or outside the fabric. Once such cavities occur, they keep on growing until their negative pressure reaches a maximal value. Therefore, a large amount of cavities (i.e., steam bubbles or air bubbles with a very low density) would be brought into existence. When the compressed areas reach these cavities, these cavities would be squeezed and burst. Therefore, the effect of shock wave takes place. Whence, the shock wave is created by the burst of the cavities and is generated by the cavities and the energy contained in the compressed areas. As the cavities burst, a shock wave pointing at the center of the bubble would occur. When such shock wave reaches the fibrous fabric, temperature and pressure would rise substantially in a small area or in the non-crystalline areas in a very short period of time. Therefore, in use, the shock waves generated by the burst of cavities can accelerate the entry and diffusion of the dyes and processing agents into the fibrous fabric and impart kinetic energy to the molecules of the fibrous fabric (to become activated molecules) and generate the effect of plasticization to these molecules and enhance the solubility of the molecules. Therefore, the goal of swift dyeing process and other processes may be reached.
[0030] A third object of the present invention is to provide an impulse type shock wave flash dyeing machine in which, the effect of shock wave, which is generated in the high-energy wave field, may be used to change the innate quality of the fibrous fabric during the dyeing process or other processes.
[0031] On the molecular level, either natural fiber or synthetic fiber consists of molecules that are in the form of long chain and are made of the atoms of carbon (as the skeleton), hydrogen, oxygen (as the ornament) and nitrogen (as the ornament). Either type of fiber comprises crystalline areas and non-crystalline areas. In a crystalline area, molecules are arranged in an orderly fashion and the bonding forces between the molecules are stronger; also, it would be difficult for the molecules of a dye to enter a crystalline area. On the other hand, in a non-crystalline area, molecules are arranged in a disorderly fashion and the bonding forces between the molecules are weaker. In dyeing or other process, the molecules of dyes or processing agents can only enter such non-crystalline area; however, these molecules can not enter such non-crystalline area in a dry condition or under the room temperature.
[0032] According to the dyeing theories, to enable dyeing to be carried out smoothly, the aim is to enlarge the gaps in the non-crystalline areas or to enlarge the surface ratio (between the interior and the exterior of the fabric). Also, the gaps are the origin of the damage of the fabric according to the theories of material mechanics. When the fibrous fabric undergoes violent wave motion and is affected by the burst of cavities, the crystalline structure of the fabric may be changed into a disorderly configuration and some molecules of the fabric may be broken or rearranged. Also, the surface ratio would increase and the gaps in the non-crystalline areas would be enlarged. Whence, the innate quality of the fibrous fabric may be changed and such change may be carried out during the dyeing process.
[0033] A fourth object of the present invention is to provide an impulse type shock wave flash dyeing machine in which fast-moving low-temperature plasma is used to carry out waterless removal of processing fluids or to remove impurities or to change the innate quality of the fibrous fabric before dyeing. Plasma is generated by the tip of an electric discharge rod portion, which is centrally disposed in the central pathway of the mist nozzle, under an atmospheric pressure (fast-moving air or other gas is used as the medium). The electric discharge rod portion is connected with a high voltage source. During discharge, electrons are released from the tip and move toward a circular target. As the electrons move toward the target, they collide with the fast-moving air flow. Because these electrons have a high level of kinetic energy, such collision can ionize the air molecules. Therefore, during a waterless process, electrons, ions, free radicals and energized atoms and molecules may be released from the joint nozzles and then violently collide with the surfaces of the fibrous fabric. In the collision process, free radicals are generated and the surfaces of the fibrous fabric would be oxidized. Also, natural impurities of the fibrous fabric, processing fluids and grease may be removed to enhance the fabric's capacity in water absorption and diffusion. In the pre-treatment of the prior art, a big amount of chemical fluid and a lot of water are used; therefore, such pre-treatment has a low level of efficiency, consumes more energy and generates more waste water. Therefore, the use of low-temperature plasma can remove impurities and such use may the wet type pre-treatment. Also, such application can shorten the time of processes, reduce the amount of chemical agents and lower the necessary temperature in the processes. Therefore, such application can increase the efficiency in production, lessen the consumption of water and the amount of contaminated water generated in the processes and reduce the carbon footprint. Whence, the use of fast-moving low-temperature plasma is economical and environmentally friendly.
[0034] A fifth object of the present invention is to provide an impulse type shock wave flash dyeing machine, which has multiple functions and may be used to carry out dyeing, quality changing processes, removal of processing fluids, refining processes, whitening process, biological enzyme treatment, loose part treatment, discolored part treatment, disheveled part treatment, softening treatment, expansion and contraction treatment, wrinkle treatment, color modification treatment, etc. on various types of fibrous fabric. Therefore, the goals of processes that are swift, easy to carry out, effective and safe and the goals of the saving of dyes, processing fluids, energy and water may be reached. Furthermore, processes may be carried out in a clean manner (to lower the pollution to the environment) and the goal of automation may be achieved.
[0035] A sixth object of the present invention is to provide an impulse type shock wave flash dyeing machine in which a row of joint nozzles supply all the kinetic energy needed by the fabric to move around in the processing tank (as so to remove the use of the fabric circulation wheel in the prior art) and the fast-moving air flow sent from these joint nozzles can enable the fabric to fold up automatically (as so to remove the use of the fabric flop wheel in the prior art). Therefore, the fabric would not be damaged by the circulation wheel and fabric flop wheel and the discontinuity in revolution of these wheels of the prior art may be eliminated. Consequently, the goals of easy control and stable motion may be achieved.
[0036] A seventh object of the present invention is to provide an impulse type shock wave flash dyeing machine in which, in use, the wiggling of the fibrous fabric can make the operating solution remaining on the surface of the fibrous fabric, loose fibers, unneeded dyes and solid objects detach from the fibrous fabric thanks to the direction-changing air flows. Therefore, only a minimal amount of the residual operating fluid remains on the fabric and the process may be carried out with a minimal amount of the operating fluid. Whence, the goals of minimal amount of operating solutions and a high level of concentration may be achieved.
[0037] An eighth object of the present invention is to provide an impulse type shock wave flash dyeing machine in which fast-moving low-temperature plasma is used to carry out removal of processing fluids, refining, quality changing of the surfaces of the fabric and combination. Therefore, the goals of waterless processes and an additional innovative approach may be achieved.
[0038] A ninth object of the present invention is to provide an impulse type shock wave flash dyeing machine in which dyes and processing agents may be added into the content adding tank before the start of the dyeing process or other processes. In this way, electric consumption may be reduced.
[0039] A tenth object of the present invention is to provide an impulse type shock wave flash dyeing machine in which the circulation wheel of the prior art is not needed at the front entry of the fabric guiding tube and the fabric flop wheel of the prior art is not needed at the outlet of the fabric guiding tube. Therefore, safety may be enhanced and a user would not be affected by the presence of the circulation wheel. In addition, the fabric would not be damaged by the fabric circulation wheel and the jamming. Also, the speed at which the fabric moves would not be limited by the fabric flop wheel as the fabric passes the fabric guiding tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] The drawings disclose an illustrative embodiment of the present invention which serves to exemplify the various advantages and objects hereof, and are as follows:
[0041] FIG. 1 is a sectional view showing the impulse type shock wave flash dyeing machine of the present invention.
[0042] FIG. 2 is a sectional view showing the dyeing machine of the present invention with an additional height.
[0043] FIG. 3 is a sectional view showing the dyeing machine of the present invention with an additional length.
[0044] FIG. 4A is a sectional view of the joint nozzles.
[0045] FIG. 4B is a sectional view of the joint nozzles with a replaceable electric discharge rod portion.
[0046] FIG. 5 is a perspective view of the air cross flow distributor.
[0047] FIG. 5A is a sectional view of the air cross flow distributor.
[0048] FIG. 5B is a sectional view of the air cross flow distributor that comprises a left manifold and a right manifold.
[0049] FIG. 6 is a sectional view of the fluid cross flow distributor.
[0050] FIG. 7 is a perspective view of the air backflow unit.
[0051] FIG. 7A is a sectional view of the air backflow unit.
[0052] FIG. 7B is a sectional view of the air backflow unit that includes two tubes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0053] Please see FIGS. 1 to 7 , which illustrate the impulse type shock wave flash dyeing machine of the present invention. The dyeing machine of the present invention includes the following parts and components: a processing tank 1 , fabric accumulator 2 , fibrous fabric 3 , fabric guiding tube 11 , doorway 12 , reflective motion plate 13 , U-shaped circumrotating plate 14 , direction guiding plate 15 , blower 16 , fluid gathering plate 18 , reserve tank 19 , pump-less content adding device 20 , inner separating net barrier 21 , outer separating net barrier 22 , slider 23 , net-holed plate 24 , upstream fabric flop portion 31 , a row of slits 42 , entry 43 , backflow entrance 46 , arc-shaped distributing tube portion 61 , tube 62 , air transporting pipeline 71 , circulation pump 72 , content adding pump 73 , upstream inlet 111 , downstream outlet 112 , a row of joint nozzles 121 , air nozzles 122 , narrow passage 151 , air backflow tube 160 , air heat exchanger 161 , air filtering unit 162 , air cross flow distributor 163 , right manifold 164 , left manifold 165 , converging outlet 166 , distribution tube 167 , distributing tube 168 , air flow regulating valve 169 , dye solution backflow tube 170 , a row of inlets 172 , fluid cross flow distributor 173 , right manifold 174 , left manifold 175 , equal pressure distributing tube 176 , a row of fluid distributing slits 178 , fluid injecting entry 179 , fluid gathering channel 181 , liquid fluid guiding tube 182 , operating solution gathering plate 184 , air backflow unit 190 , diverging tubes 191 , T-shaped backflow tube 192 , exhaust outlet and control valve 200 , flesh air inlet and control valve 201 , flow regulating valve 202 , pressurized circulation fluid transporting tube 210 , steam input and control valve 211 , gas inlet and control valve 212 , operating solution recovery and outlet 214 , broad air flow circulative pathway 221 , Circular target 12111 , jet injecting tube 12121 , replaceable electric discharge rod portion 12122 , high voltage connector 12123 , grounding terminal 12124 , mist converting nozzle 1216 , mist nozzle 12161 , sliding rod portion 12164 , seat portion 12165 , spring piston 12167 and operating solution inlet 12169 .
[0054] Please see 1 to 3 , which illustrate the structure of the processing tank 1 . The processing tank 1 may be a single tank or several tanks arranged in a parallel configuration. The processing tank 1 is usually a sphere when it is used for processes under high temperature and high pressure. The processing tank 1 may have a different shape when it is used for processes under room temperature and one atmospheric pressure. In FIG. 2 , the processing tank 1 has an extra height so that it can process more fabric. In FIG. 3 , the processing tank 1 has an extra length so as to be used to process the fibrous fabric 3 that wrinkles easily and so that the fibrous fabric 3 can move around easily. In FIG. 1 , the processing tank 1 is suitable to be used for either high or low temperature and for either high or low pressure and has an oval shape. The fabric accumulator 2 and the fabric guiding tube 11 may be formed along the wall in the processing tank 1 and form a circular circulative pathway. The fabric guiding tube 11 is disposed directly above the fabric accumulator 2 . For the sake of description, we suppose the fibrous fabric 3 moves in the clockwise direction; the 9 o'clock direction is defined as the front portion of the processing tank 1 and the 3 o'clock direction is defined as the rear portion of the processing tank 1 . A dye solution backflow tube 170 is disposed in the lowest portion (in the 6 o'clock direction) of the processing tank 1 . An air backflow tube 160 is centrally disposed in the processing tank 1 . A doorway 12 is provided by the front portion of the processing tank 1 .
[0055] The upstream inlet 111 of the fabric guiding tube 11 is provided near the front portion of the processing tank 1 and abuts on the doorway 12 . The upstream inlet 111 is in fluid communication with the downstream outlet 112 . The downstream outlet 112 is located in the rear portion of the processing tank 1 and is in fluid communication with the upstream inlet 111 . Therefore, the fabric guiding tube 11 is in fluid communication with the fabric accumulator 2 to form a broad circulative pathway, which allows the fibrous fabric 3 to move along the pathway in a spread-out manner in a dyeing process or other processes. A plurality of air nozzles 122 are provided along the upstream and midstream of the surface on the lower side of the fabric guiding tube 11 . A row of joint nozzles 121 is provided on the two sides of the pathway and these nozzles are interconnected in parallel. Please see FIGS. 4A and 4B for the structure of the joint nozzles 121 . A mist converting nozzle 1216 is disposed at the upstream portion of the acceleration injecting tube of the joint nozzles 121 and consists of a seat portion 12165 and a sliding rod portion 12164 . The amount of the spray is determined by the cross-sectional area between the seat portion 12165 and the sliding rod portion 12164 and the fluid pressure. A spring piston 12167 is disposed on the sliding rod portion 12164 . When the mist converting nozzle 1216 is clogged by fabric or a solid object, compressed air or fluid may enter into the chamber of the spring piston 12167 through an operating solution inlet 12169 . When the pressure of the chamber is greater than the force of the spring, the sliding rod portion 12164 moves rearwards. Now, the cross-sectional area increases and hence the fabric or solid object may be removed. In use, if we want to increase the amount of the mist or spray, we can increase the pressure of the chamber.
[0056] Please see FIGS. 1 and 4A . The mist converting nozzle 1216 is connected with the pipelines 210 and 170 at the circulation pump 72 via a fluid cross flow distributor 173 . Therefore, dye or processing agent may be pressurized by the circulation pump 72 and then may be converted into fine mist by a mist nozzle 12161 . Pressure equal or more than 5 Kg/square cm can convert the dye or processing agent into fine mist. The level of such conversion would be enhanced if the pressure or temperature increases. To impart greater kinetic energy to the dye or processing agent, the angle of the spray is controlled within a range to make the dye or processing agent thoroughly spread out in a jet injecting tube 12121 and then the mist may be mixed with the high speed air flow so that the mist may become fine mist as the dye or processing agent passes the joint nozzles 121 . Therefore, the dye or processing agent can have enough amount of kinetic energy when blasting the fibrous fabric 3 . As illustrated in FIG. 4B , to reach the goal of clean processes, a replaceable electric discharge rod portion 12122 may be centrally disposed in the central pathway of the mist nozzle 12161 . A high voltage connector 12123 is provided at one end of the electric discharge rod portion 12122 and may be connected with a high voltage source 5 outside the processing tank 1 via a wire. The wall of the jet injecting tube 12121 is made of an insulating material. Therefore, a circular target is formed at the joint nozzle outlet 1211 . A grounding terminal 12124 is provided on the circular target. Therefore, the circular target may be grounded via a wire.
[0057] A distributing tube 168 is provided at the lower portion of the fabric guiding tube 11 and along the upstream and midstream portions of the pathway. An air flow regulating valve 169 is provided at the upstream entry of the distributing tube 168 . A distribution tube 167 is provided at the entry of the joint nozzle 121 . An air cross flow distributor 163 is provided at the entry of the distribution tube 167 and in the path linking the distribution tube 167 and the air transporting pipeline 71 . As illustrated in FIGS. 1 , 5 , 5 A and 5 B, the air cross flow distributor 163 comprises a left manifold 165 and a right manifold 164 . The width of the left manifold 165 or the right manifold 164 is equal to the width of the fabric guiding tube 11 . If the fabric guiding tube 11 is in the form of two tubes, the same applies. If the fabric guiding tube 11 is in the form of four tubes, the same applies. Also, the length of the left manifold 165 or the right manifold 164 may be increased or decreased according to the form of the fabric guiding tube 11 . A row of slits 42 are provided on a wall of either manifold 165 or 164 . An arc-shaped distributing tube portion 61 is provided on either manifold 165 or 164 . The row of slits 42 provided on the left manifold 165 are not aligned with the row of slits 42 provided on the right manifold 164 . The air flow may flow through the slits and then to the arc-shaped distributing tube portion 61 and the converging outlet 166 . A tube 62 is connected to the downstream end of the converging outlet 166 . The inlet at the upstream end of the tube 62 is in fluid communication with the converging outlet 166 and the outlet at the downstream end of the tube 62 is in fluid communication with the distribution tube 167 and the distributing tube 168 .
[0058] Please see FIG. 6 . The fluid cross flow distributor 173 is provided under the operating inlet 12162 and in the path linking with the compressed circulation fluid transporting tube 210 . Please refer to FIGS. 1 and 6 for the structure of the fluid cross flow distributor 173 . The fluid cross flow distributor 173 comprises a left manifold 175 , a right manifold 174 and an equal pressure distributing tube 176 . The width of the left manifold 175 or the right manifold 174 is equal to the width of the fabric guiding tube 11 . If the fabric guiding tube 11 is in the form of two tubes, the same applies. If the fabric guiding tube 11 is in the form of four tubes, the same applies. Also, the length of the left manifold 175 or the right manifold 174 may be increased or decreased according to the form of the fabric guiding tube 11 . A row of fluid distributing slits 178 are provided on the wall of either manifold 175 and 174 . The slits provided on either manifold 175 and 174 are spaced apart and the slits provided on the left manifold 175 point at a direction different from the direction in which the slits provided on the left manifold 175 point or the slits provided on the left manifold 175 are not aligned with the slits provided on the left manifold 175 , and wherein a row of inlets 172 are provided in the upper wall of the equal pressure distributing tube 176 to allow the fluid cross flow distributor 173 to be connected with the mist converting nozzle 1216 via tubes.
[0059] Please see FIGS. 1 , 2 and 3 . An air backflow unit 190 is provided in the central portion of the processing tank 1 and above the operating solution gathering plate 184 . Please refer to FIGS. 7 , 7 A and 7 B for the structure of the air backflow unit 190 . Its structure is quite similar to that of the air cross flow distributor 163 . The air backflow unit 190 comprises two diverging tubes 191 and a T-shaped backflow tube 192 . The width of the two tubes 191 is equal to the width of the fabric guiding tube 11 . If the fabric guiding tube 11 is in the form of two tubes, the same applies. If the fabric guiding tube 11 is in the form of four tubes, the same applies. Also, such width may be increased or decreased according to the form of the fabric guiding tube 11 . A row of backflow slits 193 are provided on the wall of the underside of either tube 191 . Two connective tube portions 194 with the shape of a bending arc of 180 degree connect the two tubes with the T-shaped backflow tube 192 . Therefore, air flow may flow through the air backflow unit 190 and a backflow tube 160 , which is provided in the middle portion of the T-shaped backflow tube 192 , and then back to the blower 16 .
[0060] In use, the fluid cross flow distributor 173 can make the same amount of flow coming out of each of the mist converting nozzles 1216 . Also, the fluid cross flow distributor 173 can make the amount of flow coming out of each of the joint nozzles 121 equating the amount of flow coming out of each of the air nozzles 122 . In use, the joint nozzles 121 impart most of the kinetic energy to the fabric 3 so that the fabric 3 may move around cyclically. The revolving speed of the propeller of the blower 16 may be increased or decreased according to the actual processing needs to achieve the proper amount of air flow. In addition, an air flow regulating valve 169 provided at the entry portion of the distributing tube 168 may be adjusted according to the weight per unit area of the fabric 3 so that proper amount air flow may come out from the air nozzles 122 to make the fabric 3 afloat and moving in a stable manner so that no contact and no friction would occur between the fabric 3 and the wall of the processing tank 1 to minimize the friction as the fabric 3 moves quickly in the processing tank 1 . The joint nozzles 121 can make high-speed air flow, high-speed mist of dyes or processing agents, high-speed low-temperature plasma, high-speed vapor flow or high-speed gas or fluid blasting the fabric 3 . In addition, a reflective motion plate 13 can generate wavy motions on the fibrous fabric 3 . Air flows are guided by the reflective motion plate 13 and make the lower portion of the fibrous fabric 3 moving in the downstream direction. The difference in pressure prompts the fibrous fabric 3 to accelerate and move in the wavy motion. As the fibrous fabric 3 moves along the upstream and midstream of the pathway, a vertical downward pull would repeatedly exert on the upper portion of the fibrous fabric 3 . The repetitive pulls prompt the fibrous fabric 3 to expand as it passes the downstream of the joint nozzles 121 and it moves in a spread-out, floating manner along the lower wall of the pathway as it quickly passes the upstream and midstream portions of the fabric guiding tube 11 .
[0061] Please see FIGS. 1 , 2 and 3 . A U-shaped circumrotating plate 14 is provided between the lower side of the fabric guiding tube 11 and the entry portion of an upstream fabric flop portion 31 of the fabric accumulator 2 . The upstream portion of the U-shaped circumrotating plate 14 is fixed to the lower side of the joint nozzles so that the reflective motion plate 13 may be formed near the upstream portion of the U-shaped circumrotating plate 14 . An inner separating net barrier 21 and an outer separating net barrier 22 are provided in the upstream fabric flop portion 31 . A direction guiding plate 15 is provided in the downstream portion of the fabric guiding tube 11 and directly over the joint nozzles 121 . The upstream end of the direction guiding plate 15 is connected with the upper wall of the fabric guiding tube 11 and the downstream end of the direction guiding plate 15 is connected with the outer separating net barrier 22 . With the presence of the direction guiding plate 15 , a narrow passage 151 may be formed at the downstream portion of the fabric guiding tube 11 . As the fibrous fabric 3 passes the narrow passage 151 , air is squeezed and a downward pull would exert on the fibrous fabric 3 . The high-speed air flow coming out of the joint nozzles may blast the fibrous fabric 3 and provides a continuous static pressure on the side of the fibrous fabric 3 . Therefore, more energy may be transferred to the fibrous fabric 3 to strengthen the wavy motion of the fibrous fabric 3 .
[0062] A solution removing mechanism is provided in the downstream exit portion of the fabric guiding tube 11 and in the upstream fabric flop portion 31 . The fluid solution removing mechanism consists of the U-shaped circumrotating plate 14 , the direction guiding plate 15 , the inner separating net barrier 21 , the outer separating net barrier 22 , a fluid gathering plate 18 and an operating solution gathering plate 184 . The inner separating net barrier 21 and the outer separating net barrier 22 are disposed in the upstream fabric flop portion 31 . The inner separating net barrier 21 runs from the portion where the U-shaped circumrotating plate 14 is connected with the fluid gathering plate 18 and the inner separating net barrier 21 is disposed inside the upstream fabric flop portion 31 in a vertical or substantially vertical position. The downstream end of the inner separating net barrier 21 is connected with the upstream end of the operating solution gathering plate 184 . A fluid gathering channel 181 is provided in the downstream end of the fluid gathering plate 18 . A fluid guiding tube 182 is provided on the downstream wall of the fluid gathering plate 18 and the lowest portion of the operating solution gathering plate 184 and can guide the operating solution to the outlet located on the lower portion of the fabric accumulator 2 . The upstream end of the outer separating net barrier 22 is connected with the downstream end of the direction guiding plate 15 . The downstream end of the outer separating net barrier 22 is connected with a slider 23 and a net-holed plate 24 provided on the lower side of the fabric accumulator 2 . Therefore, a broad air flow circulative pathway 221 is formed between the fabric accumulator 2 and the wall of the processing tank 1 to guide the air flow from the outer separating net barrier 22 to enter the fabric guiding tube 11 . The solution, fibers and other solid objects gathered by the outer separating net barrier 22 may go through the wall of the processing tank 1 to enter the outlet 170 and the operating solution gathering tank 213 . In use, the high-speed air flow sent out from the joint nozzles 121 would flow above the upper portion of the inner separating net barrier 21 due to the interaction between the underside of the fibrous fabric and the reflective motion plate 13 and the interaction between the underside of the fibrous fabric and the U-shaped circumrotating plate 14 . In the mean time, the fibrous fabric 3 would be moved by the air flow toward the inner separating net barrier 21 and hence the air pathway toward the inner separating net barrier 21 would be blocked. Therefore, the fibrous fabric 3 would be moved toward the outer separating net barrier 22 and the lower portion of the upstream fabric flop portion 31 . Therefore, the fibrous fabric 3 would move by the downward expanding air flow from the upper portion of the inner separating net barrier 21 toward the lower portion of the inner separating net barrier 21 . As the fibrous fabric 3 leaves the upper portion of the inner separating net barrier 21 , the air pathway re-opens and the air flow would flow toward the inner separating net barrier 21 and then flow out of the inner separating net barrier 21 . Such process would keep on repeating itself, making the fibrous fabric 3 wiggling violently as the fibrous fabric 3 passes the U-shaped circumrotating plate 14 . During the process, the operating solution attached to the surface of the fibrous fabric 3 would detach from the fibrous fabric 3 thanks to the direction-changing air flow. The operating solution would then flow through the inner separating net barrier 21 and the outer separating net barrier 22 and then leaves the upstream fabric flop portion 31 . In the mean time, the fibrous fabric 3 entering the fabric accumulator 2 may be folded up thanks to the wiggling motion.
[0063] Please see FIGS. 1 , 2 and 3 . An air filtering unit 162 , an exhaust outlet and control valve 200 and a flesh air inlet and control valve 201 are provided on the backflow tube 160 . A flow regulating valve 202 is provided between the exhaust outlet and control valve 200 and the flesh air inlet and control valve 201 . A steam input and control valve 211 and a gas inlet and control valve 212 are provided on the pressurized circulation fluid transporting tube 210 . An operating solution gathering tank 213 and a recovery and outlet 214 are provided on the lowest portion of the processing tank 1 . The aforesaid valves may be adjusted according to the actual need.
[0064] The dyeing machine of the present invention further comprises an air heat exchanger 161 and an air filtering unit 162 . The air heat exchanger 161 is provided on the air transporting pipeline 71 . The air filtering unit 162 is provided on the air backflow tube 160 . Therefore, the air heat exchanger 161 and the air filtering unit 162 form a pathway with the blower 16 .
[0065] Therefore, in the dyeing process or other processes, the air and operating solution in the processing tank 1 and the dyes and processing agents in the pump-less content adding device 20 and the reserve tank 19 may be in fluid communication with the blower 16 and the content adding pump 73 via several pipelines so that compressed air and compressed dyes and processing agents may be injected out of the joint nozzles and a part of the compressed air may be injected out of the air nozzles 122 .
[0066] Many changes and modifications in the above described embodiment of the invention can, of course, be carried out without departing from the scope thereof. Accordingly, to promote the progress in science and the useful arts, the invention is disclosed and is intended to be limited only by the scope of the appended claims.
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An impulse type shock wave flash dyeing machine is disclosed. A row of joint nozzles can send out high-speed air flows to prompt fibrous fabric to spread out and move in the dyeing machine through the effect of impulse. Dyes or processing agents may be converted into fine mist and is carried by the high-speed air flows to blast the fibrous fabric ( 3 ). Therefore, the dyes or processing agents can enter the fibrous fabric ( 3 ) quickly and can diffuse or spread out in the fibrous fabric ( 3 ) swiftly through strong elastic and inelastic collisions as well as the effect of shock wave. Such collisions and effect can impart enough energy to the dyes or processing agents and convert non-activated molecules into activated molecules. In addition, the effect of corona discharge may be used to generate high-energy particles and hence the goals of clean and swift processes may be achieved.
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RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional Application No. 60/200,113, filed on Apr. 27, 2000, the entire teachings of which are incorporated herein by reference.
NOTICE OF COPYRIGHT
[0002] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
[0003] Lithographic processes are known for semiconductor fabrication which employ an actinic light source focused through a mask onto a substrate, or resist, through a lens. The mask has a predetermined pattern which selectively passes the actinic light source to produce a desired image on the resist. However, the light is subject to interference, such as diffraction, as it passes from the mask to the resist surface. The diffraction pattern contains all the information about the predetermined pattern but passes through a lens of finite size and some of the information contained within the diffraction pattern is filtered out. Accordingly, the image on the resist can become slightly distorted from the predetermined image on the mask. In semiconductor fabrication, however, it is desirable to minimize such distortion to enable a smaller minimum feature size on the substrate. Since the minimum feature size defines the density of the electronic elements on the substrate, a smaller minimum feature size allows more elements to be placed per unit area on the substrate or for the same density to make a electronic element faster.
[0004] [0004]FIG. 1 shows a prior art conventional and phase-shift mask for use in a lithographic process. Referring to the mask cross-sectional views in FIG. 1, a conventional mask 2 has opaque chrome 8 or other light blocking regions, which define a predetermined pattern to be formed. Actinic light 6 is directed at the mask 2 to form an image on a wafer (not shown) or other substrate according to the predetermined pattern. A phase-shift mask 4 further includes a shifter layer 9 according to the predetermined pattern. The shifter layer 9 shifts the phase of the actinic light 6 180 degrees to produce the light amplitude shown in graph 3 . The light amplitude results in a light amplitude distribution shown in graph 5 , which results in the light intensity distribution shown in graph 7 .
[0005] Phase-shift masks may be employed to reduce the distortion caused from loss in information due to diffraction by creating destructive interference on the resist plane between the light of opposite phases. However, the actinic light 6 source generates an electric field between light beams of different phases of zero magnitude and elimination of zero-frequency light, or zero-order light, between the beams of different phases by balancing the opposing electric fields reduces phase error between the diffracted beams and allows a smaller minimum feature size.
[0006] It would be beneficial, therefore, to provide a system and method for providing a photolithographic phase-shift mask which balances the energy between electric fields of opposed phase to substantially reduce or eliminate zero-frequency energy to produce a strong phase-shifted, dual beam to reduce diffraction and reduce the minimum feature size on a substrate to which the dual beam is directed.
SUMMARY OF THE INVENTION
[0007] A system and method of strong phase-shifting a beam from an actinic light source in a lithographic process includes focusing a beam from an electromagnetic beam source onto a mask adapted to selectively phase-shift at least a portion of the beam according to a predetermined pattern. The beam is passed from the actinic light source through the mask producing a phase-shifted beam, and the phase-shifted beam is directed at a substrate such as a semiconductor wafer adapted to be selectively etched according to the predetermined pattern. The strong phase-shift serves to substantially eliminate zero-order light in the phase-shifted beam. Strong phase-shift mask techniques, through a two electromagnetic beam interference imaging process, are known in the art of microlithography to form imaging results for an isolated primary feature of a size well below the limit of conventional prior art imaging.
[0008] The use of sub-resolution assist features in the field of microlithography is known to provide optical proximity compensation, reduce the mask error enhancement factor (MEEF), minimize the effect of aberrations and boost isolated line performance with off-axis illumination. Assist features such as scattering bars are opaque or semitransparent features that are offset from primary features in the bright field and anti-scattering bars are their dark field analogues. They were first used as an optical proximity correction technique; or, if phase-shifted, as a weak phase-shift mask technique. Later, it was shown that they could reduce MEEF and aberrations. Finally, they have been shown to boost the performance of isolated line features using off-axis illumination. The invention as defined by the present claims is based on the use of phase-shifted assist features to improve the imaging capability of an isolated, or primary feature by balancing the opposing electric fields of the primary and assist features to minimize or eliminate the electric field at the zero frequency of the primary features. In the art, when the electric field is eliminated at zero frequency, the imaging is said to be strong phase-shifted and the image is constructed using a two-beam imaging technique. Two-beam imaging is better than conventional imaging because it restricts interference angles needed to reconstruct the image in a way where their phase relationship is maintained to improve resistance to change in focus and exposure, as well as, to provide improved performance in the presence of other aberrations. Most phase-shifting techniques used for imaging isolated features are not strong. This is because properly balanced features would be large enough to print an unwanted pattern in the resist, and as a result, the microlithography community did not actively pursue this technique.
[0009] The invention as defined by the present claims provides a method to design and fabricate a strong phase-shift mask for use in the imaging of a photoresist material during the fabrication of semiconductor devices. This invention is not limited only to the fabrication of semiconductors, but also extends to the manufacture of other elements that use the microlithography imaging technique. The method has special application to isolated or semi-isolated clear field features placed on a dark background. The method works by determining the layout and fabrication requirements of a photomask such that as actinic energy is passed through the mask forming a diffraction pattern, the electric fields that form of opposite phase are equal, and thus balanced in strength with respect to their average integrated amplitudes. By balancing the energy between electric fields of opposing phase, this method eliminates zero-frequency energy and makes a strong phase-shifted, two-beam imaging system. Thus, it works much in the fashion of a strong phase-shift mask but is not limited to the normal methods of making a strong phase-shift mask and can use most any phase-shifter technique that is known in the imaging arts. The invention provides a method for layout and fabrication of a strong phase-shift feature that takes into account the final size of the feature, the ability of a photoresist not to image assist features, the capability of the projection printer, and the phase-shift mask's topographical modification of the electric field.
[0010] The method as disclosed herein is not limited to making isolated or semi-isolated clear features on a dark background, but alternatively can be used for other feature density as long as the electric field between regions of opposing phase can be balanced to give the desired result. Examples of using this type of imaging technique would be the fabrication of discrete semiconductor devices such as is common, but not restricted to gallium-arsenic technology and to CMOS microprocessor gates. The invention also claims that the technique for making a strong phase-shift mask can be used to make a weak phase-shift mask. A weak phase-shift mask is a mask that has some electric field strength at the zero frequency of the diffraction pattern. This field at the zero frequency allows the image to be formed using a technique that requires a zero frequency component to form the image. An example of this would be the formation of a small square aperture using an exposure tool with off-axis illumination.
[0011] The isolated feature can be strong phase-shifted by making the strength of the electrics fields of a primary feature and that of the sum of assist features equal but of opposite phase. The desired phase-shift can be made by an additive or subtractive etch process of the assist features or the primary feature, and may employ using a material of transmittance greater than 0 and less than or equal to one for the assist features. Large assist features improve image quality and the ability to fabricate said features, and may be employed by reducing the transmission of assist features by a subtractive process, and may employ a material with transmission greater than zero but less than 1.0, whereby an effective phase-shift of 180 degrees is maintained, but the trench depth is an odd multiple of the thickness required to attain the 180 degree phase and the multiple is greater than one. Mask fabrication specification and design methodology may employ an EMF simulator to find the complex transmittance and phase of a given design scheme that provides the strong phase-shifter result. Further, the fabrication may be applied to multiple pairs of assist features and to two dimensional primary features, and may also be employed in the case of a dark phase-shifted surrounded on two or more sides such that the electric fields are to be balanced between the two regions of opposing phase, and in the case where the overall field intensity needs to be increased so that the feature is easier to print amongst the plurality of other features found on the same mask.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0013] [0013]FIG. 1 shows a prior art phase-shift mask;
[0014] [0014]FIG. 2 shows a cross section of a mask with an isolated space defining an isolated primary feature;
[0015] [0015]FIG. 3 shows an isolated space with assist features;
[0016] [0016]FIG. 4 shows a graphical representation of a phase-shift;
[0017] [0017]FIG. 5 shows a graphical representation of a strong phase-shift;
[0018] [0018]FIG. 6 shows percent exposure latitude for different amounts of depth of focus (DoF) from 0.000 microns to 0.576 microns;
[0019] [0019]FIGS. 7 a - 7 i show a variety of embodiments including various combinations of primary and assist features;
[0020] [0020]FIG. 8 shows a top-down view of an isolated primary feature with phase-shifted halftone assist features;
[0021] [0021]FIGS. 9 a and 9 b show cross-sections of an isolated feature with the trenches of the phase-shift assist features; and
[0022] [0022]FIG. 10 shows a flowchart of strong phase-shift mask fabrication as defined by the present claims.
DETAILED DESCRIPTION OF THE INVENTION
[0023] A description of preferred embodiments of the invention follows.
[0024] Recent advances in resist chemistry and resist processing prevents the resist from imaging the assist features within the critical sizing regime of the primary feature. The invention as defined by the present claims utilizes this resist capability to not print the assist features and tuning the complex transmittance of the phase-shift features on the mask to produce a strong phase-shift mask for imaging the primary feature using a strong phase-shifting technique. In a particular embodiment, several techniques and combinations thereof adjust the complex transmittance of the features, and is based on producing the highest fidelity and most robust image in the photoresist while maintaining design rules so that the photomask can be manufactured in a reliable fashion. An alternate embodiment uses the same techniques to produce an image that is optimal for use with off-axis illumination of the photomask by the exposure tool. The diffraction patterned formed by this mask has a component of nonzero magnitude electric field at zero frequency and is said to be weak phase-shifted.
[0025] Phase-shift mask fabrication techniques in conjunction with the invention as defined by the present claims include Petersen, Analytical Description of Anti - scattering and Scattering Bar Assist Features, Optical Microlithography XIII, Volume 4000, © 2000, Society of Photo-Optical Instrumentation Engineers; Gerold et al., Multiple Pitch Transmission and Phase Analysis of Six Types of Strong Phase - Shifting Masks, Petersen Advanced Lithography, Inc., Austin, Tex. 78579, http://www.advlitho.com: and Gordon et al., Design and Analysis of Manufacturable Alternating Phase - Shifting Masks, 18th Annual BACUS Symposium on Photomask Technology and Management, Volume 3546, © 1998, Society of Photo-Optical Instrumentation Engineers; all co-authored by the applicant of the present application and incorporated herein by reference in their entirety.
[0026] [0026]FIG. 2 shows a cross sectional view of an isolated primary feature on a photomask. Referring to FIG. 2, an isolated primary feature 10 defined on a photomask 12 of width, w P , centered about x−0, shown by dotted line 14 . The shape of the electric field that is formed when coherent energy is passed through the slot is shown at the mask plane 16 and at the pupil or Fourier plane 18 . At the mask plane 16 the electric field can be described as a rect function of the horizontal distance, x. Rect(x) is zero every where except in the region between the edges of the space where it is not zero and there, is proportional to the complex transparency of the mask. In the pupil plane 18 of the lens, the isolated feature has a diffraction pattern that is described by the Fourier transform M(v) or F{m(x)} of rect(x) which is sin(x)/x and is called sinc(x) 20 . The Fourier analysis transforms x-dimensional space to frequency space, v. The Fourier transform is shown in Equation 1.
M ( v ) = F { m ( x ) } = ∫ - ∞ + ∞ m ( x ) - 2 π vx x Equation 1
[0027] In this work, frequency is normalized to the range −nNA/λ to +nNA/λ, where n is a factor that typically ranges from one to ten, NA is the numerical aperture of the pupil and λ is the actinic wavelength incident on the mask. Unless otherwise stated herein, the solutions are based on coherent imaging. However, to see what might affect the image formation at the wafer, it is useful to set n=1+σ, where σ is the partial coherence of the imaging system. In this way, only the range that can be accepted by NA is observed. The sinc function is everywhere in phase and can interfere to form the final image using any or all of the available interference angles contained within the sinc function envelope.
[0028] [0028]FIG. 3 shows the isolated space 10 with assist features 22 a, 22 b added symmetrically about x=0, shown by dotted line 14 . In this figure the width of the left and right assist features, 22 a, 22 b, w L and w R , respectively, are equal in size and transmittance. Like the primary features, the assist features can be described by their own sinc functions. They however are placed equidistant from the center of the primary feature by Δx.
[0029] To derive the analytic solution for the assisted feature use superposition to solve M(v) Total by setting it equal to the sum of the individual transforms of M(v) Primary , M(v) Left and M(v) Right ; where the assists are phase-shifted relative to each other proportional to Δx, as defined by the shift theorem of Fourier analysis. Mathematically, this sum is Equation 2.
M ( v )= F{m ( x )}= F{P ( x )}+ F{A Left ( x+Δx )}+ F{A Right ( x−Δx )}Equation 2
[0030] where v is frequency.
[0031] For the primary feature 10 , centered at x=0, with width w P and complex transmittance T P , Equation 3:
F { P ( x ) } = ∫ - w p / 2 + w p / 2 P ( x ) - 2π vx x = T p sin ( π vw P ) π v
multiply w P w P to get sin c ( π x ) to yield :
F { P ( x ) } = T P w P sin c ( π vw P ) Equation 3
[0032] Now apply the shift theorem to the assist features 22 a and 22 b, centered at x=−Δx and +Δx, Equation 4a and 4b:
F{A Left ( x+Δx )}= T A L w A L e +i2πvΔx sinc(π vw A L ) Equation 4a
F{A Right ( x−Δx )}= T A R w A R e −i2πvΔx sinc(π vw A R ) Equation 4b
[0033] Then using superposition add all three spaces for a binary mask. If the assist features are asymmetric in w A , T A , or Δx, the solution is complex as shown in Equation 5:
F{m ( x )}= F{P ( x )}+ F{A Right ( x−Δx )}+ F{A Left ( x+Δx )} if assists features are different= T P w P sinc(π vw P )+ T A L w A L e +i2πvΔx sinc(π vw A L )+ T A R w A R e −i2πvΔx sinc(π vw A R ) Equation 5
[0034] If the assist features are not asymmetric the solution is shown in Equation 6:
F{m ( x )}== T P w P sinc(π vw P )+ T A w A sinc(π vw A )( e =i2πvΔx +e −i2πvΔx ) Equation 6
[0035] Using Euler's equation, Equation 6 is simplified to Equation 7:
= T P w P sinc(π vw P )+2 T A w A cos(2π vΔx )sinc(π vw A ) Equation 7
[0036] Phase-shifting can be examined simply by subtracting either the primary, Equation 8, or of the combined assist feature term, Equation 9.
F{m ( x )}=− T P w P sinc(π vw P )+2 T A w A cos(2π vΔx )sinc(π vw A ) Equation 8
[0037] or
= T P w P sinc(π vw P )−2 T A w A cos(2π vΔx )sinc(π vw A ) Equation 9
[0038] [0038]FIG. 4 shows a graphical representation of the binary solution for Equation 7, and FIG. 5 shows a phase-shift solution for Equation 9. Referring to FIG. 4, a plot of relative electric field amplitude and the square of the amplitude versus relative frequency is shown for n=10 for an 130 mm isolated space with 65 nm assists and complex transmittance of one. The amplitude is relative to the maximum amplitude of the primary, F{m(x)}^ 2=(F{P(x)}+F{A(x)})^ 2. The curves are: the primary sinc, F{P(x)} 24, the cosine of the combined assist features that are shaped by the assist feature sinc F{A(x)} 26, the sum of the Fourier transforms, F{P(x)}+F{A(x)} 28, and the square of that sum (F{P(x)}+F{A(x)})^ 2 30. FIG. 5 shows a strong phase-shift result using similar parameters, thereby reducing or eliminating zero-frequency light including the primary sinc, F{P(x)} 32, the cosine of the combined assist features that are shaped by the assist feature sinc F{A(x)} 34, the sum of the Fourier transforms, F{P(x)}+F{A(x)} 36, and the square of that sum (F{P(x)}+F{A(x)})^ 2 38.
[0039] FIGS. 4 and 5 both disclose dark field solutions. To convert them to bright field simply subtract the dark field solution from a delta function, Equation 10.
F{m ( x )} Bright-field =δ( v )− F{m ( x )} Dark-field Equation 10
[0040] The examination of the analytic solutions will be restricted to the dark field cases in Equations 7, 8 and 9.
[0041] An understanding of the diffraction pattern that forms when the features all have the same phase relationship on the mask may prove beneficial in light of the invention disclosed herein. That is, the features have not been modified by introducing a phase relationship to either the primary or the assist feature that arises from using a material of selected transmittance that also has a 180 degree phase difference from the other features.
[0042] For binary masks, the dark field solution is shown by its components in FIG. 4. This is a plot of relative electric field amplitude and the square of the amplitude versus relative frequency, for n=10 for a 130 nm isolated space with 65 nm assists and complex transmittance of one. The amplitude is relative to the maximum amplitude of the primary, F{m(x)} 2 =(F{P(x)}+F{A(x)}) 2 . FIG. 4 has four curves, the primary sinc 24 , the cosine of the combined assist features that are shaped by the assist feature sinc 26 , the sum of the all Fourier transforms 28 and the square of that sum 30 . Note that all sinc functions have a maximum at zero frequency and that the sum of all the transforms is a function that has side-lobes symmetrically placed around a strong central-lobe centered at zero frequency. While this function looks somewhat like the diffraction pattern of discrete orders formed by an infinite series of lines and spaces it is not discrete, it is still a sinc, albeit modified. This means that even if the modified sinc function matches the frequency and amplitude of a diffraction pattern of a dense line, it still contains the information of the isolated feature 10 (FIG. 5) and will print as such.
[0043] Although this is true, the space does print differently, and when used properly, it prints better. First, with proper tuning of all the lobes the feature can be made to print the same size as the dense feature, thus its use as an OPC structure. Second, image printability improves because the trimming of the primary sinc reduces the set of non-optimal angles that interfere to form the image at the image plane of the wafer. In the bright field, this improvement gives rise to an increase in depth of focus, and the reduction of MEEF. For the same reason, modifying the sinc reduces sensitivity to aberrations by decreasing the effects of aberrated beams with non-optimal interference angles.
[0044] Finally, it improves the performance of off-axis illumination, not only by reducing non-optimal interference but also by maximizing the interference that does occur by setting the frequency to match the frequency of the dense line diffraction pattern that the illuminator was designed to enhance. These attributes make scattering and anti-scattering bars important image process integration tools for extending production resolution.
[0045] For phase-shift masks, the dark field solution is shown by its components in FIG. 5. This is a plot of relative electric field amplitude and the square of the amplitude versus relative frequency, for n=10 for a 130 nm isolated space with 65 nm assists and complex transmittance of one. The amplitude is relative to the maximum amplitude of the primary, F{m(x)} 2 −(F{P(x)}+F{A(x)}) 2 . FIG. 5 has four curves, the primary sinc 32 , the cosine of the combined assist features that are shaped by the assist feature sinc 34 , the sum of the all Fourier transforms 36 and the square of that sum 38 . The sum of all the transforms is a function that has side-lobes symmetrically placed around zero frequency with amplitude that is generally less than its binary mask analog. As shown in FIG. 5, in this design, the electric field of the assists can be manipulated to be equal but opposite of the primary, thus zeroing the amplitude of the central lobe. Under these conditions, the modified sinc function matches the frequency and amplitude of a strong phase-shifted feature.
[0046] At first glance this diffraction patterns looks like the discrete diffraction pattern of a infinite series of lines and spaces whose zero order has been removed by an opaque aperture in the pupil plane of the lens. This type of imaging is known as dark field. If this was really dark field imaging only the edges of the feature would be resolved and we would not know if this image was a series of small spaces and large lines or the other way around. However, this is not the discrete diffraction pattern of a series of lines and spaces but a modified sinc diffraction pattern of an isolated line described by Equation 9. For that reason, it still contains information about being an isolated space and produces the corresponding photoresist image.
[0047] Strong phase-shift formation of the image does so by interfering the two lobes of the modified sinc function when they are brought back together at the image plane. Because the lobes are symmetric about the center of the optical axis the beams maintain a uniform interference relationship when equally aberrated, as in the case where the imaging material is moved in or out of the best image plane. This movement from the image plane is called changing the focus setting from optimum or best focus. This invariance in the interference relationship with focus gives rise to better stability of the size and shape of the final resist image. In fact, with respect to spatial coherence, if the lobes were points with no radial distribution about their nodal centers, the depth of focus would be infinite. However, since the nodes are not points and energy distribution exists away from the nodal center, the interference from these off center components reduce the focus tolerance to something less than infinite, but one that is still significantly better than the depth of focus of an unmodified sinc function or of a modified function whose phase-shifted electric fields are not perfectly balanced. The nodal center frequency is also important. This is because there are some complex phase relationships about the center of each node that are best trimmed out using the numerical aperture of the lens as a low frequency filter to get the best performance.
[0048] The frequency where the center of each node is located is driven by the distance Δx. The smaller this value, the greater the absolute frequency value. FIG. 6 shows how the focus tolerance changes with nodal position in frequency space. Referring to FIG. 6, the vertical axis 40 shows the percent exposure range about the dose to size a 130 nm clear isolated feature with respect to frequency for varying amounts of defocus. Typically, for an exposure tool with 0.70 numerical aperture 248 nm exposure wavelength and partial coherence of 0.3, a process is said to be production worthy if the exposure latitude, shown by axis 44 is greater than or equal to 5% and has a focus tolerance of more than 0.4 microns. In FIG. 6, this occurs when the normalized frequency is larger than 0.6, with optimum performance at frequencies between 0.8 and 1.2. Below the frequency of 0.6, , shown by axis 42 , from 0 to 0.3 the performance is the same as an unmodified sinc function and the phase-shifter provides no enhancement. Between frequencies 42 of 0.3 and 0.6, the performance is worse than if no phase-shifting was used. This degradation appears to be related to the introduction of 180-degree phase component of the node and the width of this phase region defined by the partial coherence of the imaging system. This phase component is not observed at frequencies 42 greater than 0.92 for coherent light, but with partially coherent illumination it would be first introduced at 0.92 minus the coherence, 0.3 in this example for a value of 0.62. This means that not only does zero frequency need to be reduced to zero for the best imaging to occur but that the phase-shifted assist feature must be placed properly to remove any unwanted phase component.
[0049] The invention as defined by the present claims provides a phase-shift mask design for optimizing the imaging performance of a discrete isolated space. In this invention the sum of the complex transmittance and the width for the assist features is fabricated to cancel the electric field of the primary feature so that the amplitude at zero frequency is zero within the manufacturing tolerances of the fabrication process used to make the phase-shift mask. Equation 11 shows that for the simple case of one pair of assist features this occurs when:
T P ·w P =2· T A ·w A Equation 11
[0050] Further, the assist features are placed close enough to the primary feature to place the side-lobes of the Fourier transform at frequencies greater than 0.6 and less than or equal to a frequency that is equal to Equation 12:
v ≤ ( 1 + α · σ ) · Δ x · NA λ Equation 12
[0051] Where σ and NA equal the partial coherence and numerical aperture of the exposure tool, respectively, and α is a factor bigger than one that takes into account that the side-lobe has a width that is defined by the variables in Equations 8 and 9. Multiple pairs of assist features can be used, as long as the sum of the Fourier transform of all features still yields zero amplitude at zero frequency within manufacturing tolerances.
[0052] [0052]FIGS. 7 a - 7 i show different embodiments of the invention for a primary feature with a single pair of assist features. FIG. 7 a shows a trench 50 cut into a transparent material 52 such as glass or chrome to define the assist features 22 a and 22 b. The layer beneath the transparent material 52 is an opaque material 54 also cut according to the predetermined pattern defining the assist features 22 a and 22 b. FIG. 7 b shows the trench 50 cut into the primary feature 10 . FIG. 7 c shows the embodiment of FIG. 7 b with the assist features 22 a, 22 b positioned adjacent to the primary feature 10 . FIG. 7 d shows an embodiment similar to FIG. 7 a with the assist features 22 a, 22 b adjacent to the primary feature 10 . FIG. 7 e shows an attenuated phase-shift material 56 that has an opaque layer 54 beneath it to define the assist features 22 a, 22 b. FIG. 7 f shows a similar embodiment as FIG. 7 e where the assist features 22 a, 22 b are adjacent to the primary feature 10 . FIG. 7 g shows the attenuated phase-shift material 56 beneath the opaque layer 54 . FIG. 7 h shows an alternative embodiment in which the opaque layer 54 forms all the features then a layer of the appropriate phase and transmission is deposited on top of the film and the selectively removed from the primary feature 10 . FIG. 7 i shows a similar embodiment as FIG. 7 h wherein the material is removed from the assist features 22 a, 22 b rather than the primary.
[0053] Note that the foregoing embodiments illustrated in FIGS. 7 a - 7 i represent varying complexity in the required fabrication techniques, and the particular fabrication technique chosen depends on the availability of fabrication resources and does not deviate from the scope of the invention as defined by the present claims. Referring to Equations 8 and 9 and to FIGS. 7 a - 7 i, when the assist feature is separated from the primary feature (FIGS. 7 a, 7 b, 7 e, 7 h ), the preferred embodiment is Equation 9 where the assist features are used to make the relative phase-shift with the primary feature (FIGS. 7 a, 7 e and 7 h ). This is because cutting trenches or using attenuated phase-shift material, reduces the complex transmittance of the modified feature, making it possible to increase the size of w A . Since the assist features are the smaller than the primary feature, making it bigger makes it easier to fabricate because the width of the assists and the primary begin to approach each other. Secondly, since the width of the sinc function is equal to 1/w A , bigger features will decrease the width of the side-lobe that forms in Equation 9.
[0054] [0054]FIG. 8 shows a top-down view of an isolated primary feature 10 with phase-shifted halftone assist features 22 a, 22 b of the embodiments of FIGS. 7 a - 7 i. FIGS. 9 a and 9 b show cross-sections of an isolated feature 10 with the trenches of the phase-shift assist features 22 a, 22 b. FIG. 9 a shows a trench 50 ′ which represents a 180 degree phase-shift. FIG. 9 b shows a trench 50 ″ which represents a 540 degree phase-shift, and is three times deeper than the trench 50 ′. Deeper trenches provide assist features 22 a, 22 b which are less transmissive, thereby allowing a larger width and facilitating fabrication.
[0055] [0055]FIG. 10 shows a flowchart of strong phase-shift mask fabrication as defined by the present claims. Referring to FIG. 10, to determine the proper electric field balance between the primary and the assist features, the invention uses the following method. An optical lithography simulator such as PROLITH (available commercially from FINLE Technologies, Austin, Tex.) is employed to determine the best layout for the primary and assist features for the imaging conditions, as shown at step 100 . Consider all the variables in Equations 8, 9, 11 (remember the transmittance equals the square of the complex transmittance) and 12 plus photoresist and exposure tool performance, substrate conditions and requirements for pattern transfer, and the mask fabrication capability.
[0056] The depth of trench or thickness of material needed to produce an odd multiple of a 180-degree phase-shift is calculated, as depicted at step 102 . The multiple is typically one but can be any odd number as long as the fabrication process is capable of producing it in a final product. To this end, making the trench in the subtractive process as deep as possible will reduce the complex transmittance making it possible to make w A larger.
[0057] A pattern layout based on equations 11 and 12 is created, as disclosed at step 104 . For a trench into the material underlying the opaque layer such is common in the art, like, but not limited to quartz, or for a non-absorbing deposited material, assume 100% transmittance. Thus T P =T A =1.0 and w A =0.5w P . If using an attenuated phase-shift material use Equation 11 to determine the first w A to try.
[0058] A simulation of the effect of the mask topography is performed using an electromagnetic simulator designed for such purposes, like, but not limited to, TEMPEST (UC Berkeley, Berkeley, Calif., and more recently from Panoramic Technology, Berkeley, Calif.) and ProMax (FINLE Technologies, a division of KLA-Tencor, Austin, Tex.), as shown at step 106.
[0059] The mask topography of step 106 is employed to determine the complex transmission and phase of the phase-modified features, as disclosed at step 108 . This can be done a number of ways, but one method is to generate a grayscale mask of phase and complex transmission relative to the horizontal position on the mask, and input this mask into a lithography simulator. Then determine the aerial image produced through the desired imaging tool for varying degrees of focus and also its diffraction pattern.
[0060] The complex transmission and phase are invoked to adjust the mask and correlate the results, as shown at step 110 . Control reverts to step 104 until the desired diffraction pattern of zero energy at zero frequency is attained. If adjustments in the vertical direction, z, do not yield an optimum condition, then additional assist features of same phase, but of smaller size, by 1/n where n equals the number of assists, or of alternating phase can be added, but if alternating phase structures are used the last set of assists should mach the phase of the assists nearest the primary feature to maintain zero electric field at zero frequency. Referring again to FIG. 8, alternatively or in combination with the multiple features, the assist features 22 a and 22 b can use subresolution halftoning of the assists to make them have lower transmittance as shown by 22 a and 22 b. In this case the size and pitch must be small enough to diffract all of the halftone information outside of the lens leaving only zero diffraction order energy so that the individual components of the halftone features do not print, while maintaining the requirement that these features too can be manufactured.
[0061] As a final refinement, the actual lens and illuminator aberrations are refined so that the mask design can account for them, as shown at step 112 . Control then reverts to step 104 until a refinement threshold of zero-frequency energy is attained.
[0062] The mask may then be fabricated, as shown at step 114 , employing the information from above to design the mask and its fabrication requirements. Fabrication of the phase-shift mask involves employing metrology to determine if structural requirements are met to within the capabilities of the fabrication process. Exposure of the mask and tuning of the exposure tool, resist and pattern transfer processes are performed to achieve optimal results. Compare to expected results and fine-tune the layout and fabrication process to further improve the results. The fabrication of the mask may be performed iteratively as required to account for lack of metrology accuracy and/or mask fabrication biases such as differences between test structure phase-trench depths.
[0063] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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A system and method of strong phase-shifting a beam from an actinic light source in a lithographic process includes focusing a beam from the electromagnetic beam source onto a mask adapted to selectively phase-shift at least a portion of the beam according to a predetermined pattern. The beam is passed from the actinic light source through the mask producing a phase-shifted beam, and the phase-shifted beam is directed at a substrate such as a semiconductor wafer adapted to be selectively etched according to the predetermined pattern. The strong phase-shift serves to substantially eliminate zero-order light in the phase-shifted beam. Strong phase-shift mask techniques, through a two electromagnetic beam interference imaging process, are known in the art of microlithography to form imaging results for features of a size well below the limit of conventional prior art imaging.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. application Ser. No. 111,315, filed on Jan. 11, 1980, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to vehicle transmissions and, more particularly, to a transmission of the multi-range, multi-speed type commonly used in large off-road vehicles.
Current multi-range transmissions used on large off-road vehicles utilize a high/low synchronizer for gear shifting. However, reverse gear shifting is exacted using a conventional gear clutch because of space and cost considerations. When the main clutch assembly is released, the main clutch assembly being the means of transmitting torque to the transmission from the vehicle engine, a resulting drag causes the input shaft to experience a continued torque which in turn causes the reverse gear and reverse clutch to rotate out of synchronization. Therefore, upon shifting the conventional gear clutch to the reverse gear, clashing between the clutch and reverse gear pin results, especially when the vehicle engine is running at a high R.P.M.
This invention provides a means of stopping the reverse gear and gear pin from rotating to prevent clashing when shifting the transmission from neutral to reverse.
SUMMARY OF THE INVENTION
A transmission of the type used on large off-road vehicles generally includes an input shaft or an output shaft, a gear shaft and one or more countershafts. The input shaft carries a high and low gear separated by a high/low synchronizer clutch. Also, carried on the input shaft is a reverse gear and conventional clutch therefor. The gear shaft contains a plurality of gears and clutching means therefor.
Customarily, prior to shifting the vehicle transmission to reverse gearing, the vehicle will be stopped resulting in the output shaft being stopped. Since the gear shaft is in communication with the output shaft, the gear shaft will also be stopped. By momentarily engaging the high gear on the input shaft and, thereby, communicating the input shaft to the gear shaft, the input shaft is stopped. Also, the reverse gear is stopped by motion transmission through the transmission countershafts. The reverse clutch can now engage the reverse gear without clashing between the reverse gear pin and clutch.
To accomplish the desired reverse clutching action, a first shift rod carries a first shift collar in shifting communication with the high/low synchronizer clutch, and a second shift collar in communication with the reverse clutch. Each shift collar includes a travel pin which is placed in a corresponding travel groove on a cam such that movement of the cam dictates the clutching action of the high, low and reverse gears. By proper definition of the travel grooves the desired clutching action can be achieved, gear engagement of the gear shaft being accomplished in the conventional manner.
It is an objective of the present invention to achieve reverse gear synchronizing in a multi-range transmission of the type used in large off-road vehicles without the use of additional synchronizers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary elevational view, partly in section, illustrating a transmission.
FIG. 2 is a fragmentary elevational view, partly in section, of the transmission reverse countershaft.
FIG. 3 is a fragmentary elevational view, party in section of the transmission and shifting means.
FIG. 4 is an elevated view of a shifting cam.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Illustrated in FIg. 1 is the parallel shaft portion of a multi-range transmission representative of the type used on off-road vehicles. A transmission housing 11 includes a forward and rear wall 13 and 15, respectively. Rotatably mounted to the forward wall 13 and inner wall 17 is an input shaft 19. The input shaft 19 is splined to an input feed shaft 21 at 23. Conventionally, the input feed shaft 21 communicates with a main clutch assembly (not shown) to receive torque from an engine (not shown). It is sometimes customary to communicate the input feed shaft 21 with a planetary gear section to increase the range capability of the transmission.
Carried on the input shaft 19 is a low range or speed input pinion gear 25, and a high range speed or input pinion gear 27. For the purpose of selectively establishing either a low or high range positive engagement between the input shaft 19 and pinions 25 and 27, the transmission includes a dual speed or range selector clutch 29 located between the input pinions 25 and 27. The dual range clutch 29 includes a pair of synchronizer rings 31 located at opposite sides of the synchronizer member 33, the later being splined to a hub 35 as at 37. One of the synchronizer rings 31 is splined as at 39 to the input pinion 25 while the other synchronizer ring 31 is splined as at 41 to the input pinion 27. When the synchronizer rings 31 are shifted in the direction of an arrow L, synchronization occurs between the rear ring 31 and the synchronizer member 33, after which the splined connection at 39 is carried over the spline 37 on the hub 35. Thus, the hub 35, the low range pinion 25 and a rear synchronizing ring 31 are connected for the rotation in unison. This positively connects the low range pinion 25 to the input shaft 19. Shifting the synchronizer ring 31 in the opposite direction, in the direction of an arrow H, first synchronizes the first ring 31 and the synchronizer member 33 and causes positive engagement between the high-range pinion 27 and input shaft hub 35 by means of carrying over the splined connection at 41 to hub splines 37.
Also, carried on the input shaft 19 is a reverse pinion gear 43. A reverse clutch 45 is located on the input shaft 19 between the low speed input pinion 25 and the reverse pinion 43. The reverse clutch 45 includes an internal ring 47 keyed to the shaft 19. An external ring 49 is axially shiftably splined, as at 51 to the interior ring 47 and is shiftable in the direction of the arrow R to drivingly engage teeth 53 located on the hub of the reverse pinion 43.
A main countershaft 55 is rotatably mounted to walls 13 and 17. Main countershaft 55 is shown displaced from its true position in order that the structure thereof may be more readily perceived. Main countershaft 55 carries a small countershaft gear 57, a large countershaft gear 59, a first intermediate countershaft gear 61, and a second intermediate countershaft gear 63, the gear 61 being smaller than the gear 63. The countershaft gear 59 is in constant mesh with the low range pinion 25, and the countershaft gear 63 is in constant mesh with the high-range pinion 27.
A gear shaft 65 is rotatably mounted to walls 13 and 17. Gear shaft 65 has journalled thereon a large gear 67, a small gear 69, and an intermediate gear 71, these gears being respectively in constant mesh with the countershaft gears 57, 59, and 61. The gear shaft 65, also, has an output gear 73 in constant mesh with a gear 75 fixably mounted by any conventional means to a shaft 77 rotatably mounted between wall 17 and interior wall 79, gear 75 being in constant mesh with a gear 81 fixably mounted by any conventional means to a output shaft 83 rotatably mounted between walls 17 and 79. For selectively establishing a positive engagement between the gears 67, 69, 71, and gear shaft 65, gear shaft 65 carries a first and second clutch 85 and 87, which are of similar construction as reverse clutch 45. Specifically, the clutches 85 and 87 include an interior ring 89 keyed to the gear shaft 65 at 91 and 92, respectively. An external ring 93 of clutch 85 is axially slidably splined to the interior ring 89. The external ring 93 is shiftable in the direction of the arrow A to bring the internal splines thereof into driving engagement with teeth 95 of the gear 67. If the exterior ring 93 is shifted to the direction of the arrow D the external ring 93 will drivingly engage teeth 97 of gear 69. Similarly, an external ring 99 is axially shiftably splined to the internal ring 89 of clutch 87 and when shifted in the direction of arrow C will engage teeth 101 to drivably engage gear 71.
Referring to FIG. 2, a reverse countershaft 103 is rotatably mounted between walls 17 and internal wall 105 parallel to and behind input shaft 19. Countershaft 103 carries a first and second gear 107 and 109, respectively. The first gear 107 is in constant mesh with the reverse gear 43 on the input shaft 19 and the second gear 109 is in constant mesh with the gear 59 on the main countershaft 55.
Forward gear selection is attained in the conventional manner well known in the art. By way of illustration, first gear is obtained by sliding external ring 93 in the direction of arrow A to engage teeth 95 of gear 67 and shifting synchronizer 29 in the direction of arrow L, second gear being obtained by shifting synchronizer 29 in the direction of arrow H. It is observed that gear 67 represents first and second gears; gear 71 represents a third and fourth gear; and, gear 69 represents a fifth and sixth gear.
It is observed that, when a vehicle carrying the transmission is stopped, the output shaft 83 will be stopped, thereby bringing the gear shaft 65 to a stop because of the communication between gears 73, 75, and 81. The input shaft 19, even with the main clutch assembly disconnected (clutch assembly not shown), will have a drag effect produced from the engine so that the input shaft 19 remains rotating when the engine is idling. It is customary to have either gear 67, 69, or 71 in engagement to shaft 65 prior to shifting to reverse, therefore countershaft 55 will be stopped. Therefore, motion between gears 59, 109, and 107, and reverse gear 43 is stopped. Because the input shaft 19 experiences a degree of rotation, drag forces will cause the reverse clutch 45 to rotate such that direct shifting of the reverse clutch 45 in the direction of arrow R to engage teeth 53 will produce clashing between the reverse gear teeth 53 and the reverse clutch 45. To eliminate clashing, shifting the synchronizer 29 in either the direction of arrows H or L will cause the input shaft 19 to stroke down by creating a positive communication between input shaft 19 and stopped shaft 55. Once the input shaft 19 has been stroked down, the reverse clutch 45 can be shifted without clashing.
Referring to FIG. 3, a transmission will further include a shift synchronizer clutch collar 108 having a linking arm 109. The collar is placed around synchronizer clutch 29. A shift collar 111 having a linking arm 113 is placed around clutch 45. A shift rod 115 is passed through a hole in linking arms 109 and 113 and fixably mounted in the transmission by any conventional means parallel to the input shaft 19 such that collars 107 and 109 can slidably move thereon. Third and fourth shift collars 117 and 119, similar to shift collar 111, are slidably mounted on a second shift rod 121 fixably mounted in the transmission by any conventional means mounted parallel to said gear shaft 65, shift collar 117 being placed around clutch 93 and the shift collar 119 being placed around clutch 87.
Referring to FIG. 3, and more particularly to FIG. 4, a first cam 123 is rotatably mounted to the transmission at 124. Cam 123 has a first groove or cam track 125 in which the track rider 137 of linking arm 109 can slidably move therein and a second groove or cam track 127 in which the track rider 135 of linking arm 113 can slidably move therein. The contour of cam tracks 125 and 127 upon rotation of cam 123 defines the clutching action of clutches 29 and 45. Similarly, a cam 131 controls the clutching action of clutches 85 and 87.
Referring to FIG. 4, tracks 125 and 127 of cam 123 are contoured to define a track for clutch riders 135 and 137 to achieve the desired reverse clutching without clashing. The intersection of track 125 and 127 with line 1--1 indicates the location of riders 135 and 137, respectively, to place the transmission in reverse; the intersection of tracks 125 and 127 with line 5--5 indicates the location of riders 135 and 137, respectively, to engage the low gear pinion 25 to shaft 19, the reverse clutch 45 being disengaged; and the intersection of tracks 125 and 127 with line 9--9 indicates the location of followers 135 and 137, respectively, to engage the high gear pinion 27 to shaft 19, the clutch 45 being disengaged. The intersection of tracks 125 and 127 with lines 3--3 and 7--7 indicates a neutral transmission mode. The course of cam track 125 experiences a lateral deformation at 133 of sufficient magnitude to cause the clutch collar 108 to shift the high/low synchronizer clutch 29 to momentarily engage and disengage the high gear 27 just prior to engaging the reverse clutch 111, thereby, deriving the aforedescribed clutching action to eliminate reverse gear clashing.
It is noted that the present invention has been described in reference to a particular transmission, which should be understood as not limiting the scope of the invention. The scope of the present invention is defined by the following claims.
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Reverse gear synchronizing for a transmission of the type commonly used on large off-road vehicles is accomplished without the use of a reverse gear synchronizing clutch. The input shaft of the transmission carries a high and low gear separated by a high/low synchronizer clutch. Also, carried on the input shaft is a reverse gear and conventional clutch. A shift rod has a first shifting collar in shifting communication with the high/low synchronizer clutch and a second shifting collar in communication with the reverse clutch. A cam containing travel channels is in linked communication with the shifting collars such that movement of the cam produces clutch movement to engage the high, low, or reverse gear. The travel channels of the cam are so defined to enable relative movement between the high/low synchronizer and reverse clutch, whereby clashing between the reverse clutch and pin of the reverse gear is eliminated when the transmission gearing is changed from neutral to reverse.
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The present invention provides the novel compounds WBI-3001 having antibiotic and antineoplastic activities. The present invention also provides methods for the production of WBI-3001 sereis, comprising the step of cultivating the microorganism Xenorhabdus species. The present invention further provides antibiotic and antineoplastic compositions comprising WBI-3001, the salts thereof, and methods of using the inventive compounds as antibiotic and antineoplastic agents.
BRIEF DESCRIPTION OF THE DRAWING
The following figure represents the structural formula of WBI-3001 series, a novel group of compounds,
Wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 5 ′, R 6 , R 6 ′, R 7 , R 7 ′, R 8 , R 8 ′, R 9 and R 9 ′ are independently selected from the groups consisting of H, unsubstituted or substituted alkyl, cycloalkyl, alkenyl, alkynyl, aryl or aralkyl group, halo, nitro, CN, hydroxyl, amino, COR 10 , NR 11 R 12 , S(O) 2 NR 11 R 12 , S(O) n R 11 , n=0-2, OR 13 , and heterocyclic group. R 5 and R 5 ′; R 6 and R 6 ′; R 7 and R 7 ′; R 5 and R 5 ′; R 9 and R 9 ′ can not be nitro, CN, hydroxyl, amino, COR 10 , NR 11 R 12 , S(O) 2 NR 11 R 12 simultaneously.
R 10 is selected from H, unsubstituted or substituted alkyl, cycloalkyl, aryl, or aralkyl, or NR 11 R 12 , or OR 11 ; R 11 and R 12 are selected from H, unsubstituted or substituted alkyl, cycloalkyl, aryl or aralkyl; R 13 is selected from H, unsubstituted or substituted alkyl, cycloalkyl, aryl, aralkyl or acyl.
BACKGROUND
It has become increasingly apparent in recent years that the problems of pests and diseases of man, domestic animals and crops that were once controlled by the use of synthetic pesticides and chemotherapeutic agents have re-emerged in many parts of the world, due to social, legislative and biological change. In both medicine and agroforestry, the development of resistance to pesticides and chemotherapeutic drugs in many micro-organisms is becoming progressively more challenging to humans. As well, treatment of human and animal neoplastic diseases remains to be a great task. There is, therefore, an urgent need for new agrochemicals and new drugs to control diseases effectively. The diversity of microbial products from soil inhabiting microorganisms has been a traditional source for the discovery of new pharmaceuticals and agrochemicals.
One of the recent developments has been the commercialization of a nematode-bacteria combination as biological control agents against insect pests. A crucial feature of this biocontrol agent is that the bacterial symbiont ( Xenorhabdus spp. or Photorhabdus spp.) of the nematode produces a wide range of bioactive metabolites including antimicrobial substances that inhibit the growth of bacteria, fungi and yeasts (Webster et al., 2002).
Although there are a limited number of publications on this aspect of the biology of Xenorhabdus spp. and Photorhabdus spp., it has been recognized that bioactive substances are produced by these bacteria. Some of these specific compounds have been isolated, identified and their structures elucidated (Forst and Nealson, 1996). Recently, the cell-free culture broths of Xenorhabdus species and Photorhabdus luminescens were found to be active against many fungi of agricultural and medicinal importance (Chen et al., 1994). Two new classes of antimicrobial substances, nematophin (Webster et al., U.S. Pat. No. 5,569,668) and xenorxides (Webster et al., U.S. Pat. No. 6,316,476), were found from these bacterial cultures. As well, xenorxides have been shown to have very strong antineoplastic activity (Webster et al., U.S. Pat. No. 6,020,360). As part of the ongoing investigation of these bacteria, the WBI-3001 series, a novel group of chemicals have been found to have extremely potent antibiotic and antineoplastic activities and are the subjects of this invention, Prior art references have not shown the existence of WBI-3001 and the use of WBI-3001 or any operable aspects as antibiotic and/or antineoplastic agents.
DETAILED DESCRIPTION OF THE INVENTION
The Microorganisms
Xenorhabdus bovienii and its nematode symbiont Steinernema feltiae used in this study were collected from soil in British Columbia, Canada and maintained in culture in Dr. J. M. Webster's laboratory in the Department of Biological Sciences, Simon Fraser University, Burnaby, B.C., Canada V5A 1S6. Briefly, last instar larvae of the Greater Wax Moth, Galleria mellonella , were infected with infective juvenile (IJ) nematodes, carrying the X. bovienii A21 strain, at a rate of 25 IJs/larvae. After 24 to 48 h the dead insect larvae were surface disinfected by dipping them into 95% EtOH and igniting them. The cadavers were aseptically dissected, haemolymph was streaked onto an agar culture medium and incubated in the dark at room temperature. The bacterial strain from which the compounds of this invention were isolated was deposited under the Budapest Treaty in the American Type Culture Collection, Rochville, Md. with a designation number of ATCC 55743. The procedure of isolation and the characteristics of this bacterial strain are fully described in Webster et al., U.S. Pat. No. 6,583,171.
Production of WBI-3001
Cultivation of the microorganism X. bovienii yields the novel substances, WBI-3001. To prepare WBI-3001 , X. bovienii may be cultivated (fermented), for example, at about 25° C. under submerged, aerobic conditions in an aqueous, nutrient medium containing assimilable carbon (carbohydrate) and nitrogen sources until antibiotic activity due to WBI-3001 is imparted to the medium. The fermentation may be carried out for a time period such as approximately 48 to 96 hours, at the end of which time the antibiotic WBI-3001 have been formed, and may be isolated from the fermentation medium and purified.
After the fermentation has been completed, the fermented broth may be filtered or centrifuged and the pH of the filtrate adjusted to about 7.0 by the addition of hydrochloric acid or kept as it was. The filtrate may then be extracted with a water immiscible organic solvent, for example, with ethyl acetate or chloroform. The combined organic layers (e.g. pooled ethyl acetate or chloroform extracts) may be concentrated under vacuum (e.g. at about 30° C.) to an oily residue (“syrup”). The oil may be mixed with a small amount of organic solvent and chromatographed on a silica gel column. After introduction of the sample, chloroform or other organic solvent may be applied to elute the bioactive fraction. The bioactive fraction may be purified further by high performance liquid chromatography (HPLC) with organic and/or aqueous solution.
The compounds of the present invention include WBI-3001 and salts thereof. The term “salts”, as used herein, denotes acidic and/or basic salts, formed with inorganic and/or organic acids and bases. Suitable acids include, for example, hydrochloric, sulfuric, nitric, benzeenesulfonic, acetic, maleic, tartaric and the like which are pharmaceutically acceptable. While pharmaceutically acceptable salts are preferred, particularly when employing the compounds of the invention as medicaments, other salts find utility, for example, in processing these compounds, or where non-medicament-type uses are contemplated.
The WBI-3001 and Use Thereof
As WBI-3001 possess antibiotic activity against micro-organisms pathogenic to animals and plants, they can be used for the treatment and prophylaxis of infections caused by such organisms, particularly, infection caused by antibiotic-resistant bacteria such as bacteria of the genus of Staphylococcus . Hosts treatable include plants and animals, particularly mammals such as dogs, cats and other domestic animals and, especially, humans.
WBI-3001 has also strong antineoplastic activity against several human cancer cell lines. Most importantly, WBI-3001 inhibited the growth of human lung cancer as well as the growth of human cervical and breast cancers.
The dosage form and mode of administration, as well as the dosage amount, may be selected by the skilled artisan. Exemplary daily dosages for an adult human are those within the range of about 2.5 mg to about 2,000 mg/day. Administration to a mammalian host may, for example, be oral, parenteral, or topical. Administration to a plant host may be accomplished, for example, by application to seed, foliage or other plant part, or to the soil.
When WBI-3001 or the salts thereof are used as therapeutics, they can be administrated alone or in a pharmaceutically suitable formulation containing, in addition to the active ingredient, one or more conventional carrier. Depending on the nature of the disease and/or route of administration, the composition of this invention can be formulated by known means.
Examples of pharmaceutical compositions include any solid (tablets, pills, capsules, granules, powder etc.) or liquid (solutions, suspensions or emulsions) compositions suitable for oral, topical or parenteral administration, and they may contain the pure compound or a salt thereof or in combination with any carrier or other pharmaceutically active compounds. These compositions may need to be sterile when administered parenterally.
The dosage administered will depend upon the identity of the diseases, the type of host involved including its age, health and weight; the kind of concurrent treatment, if any; and the frequency of treatment and therapeutic ratio. Illustratively, dosage levels of the administered active ingredients are intravenous, 0.1 to about 200 mg/kg; intramuscular, 1 to about 500 mg/kg; orally, 5 to about 1000 mg/kg; intranasal instillation, 5 to about 1000 mg/kg; and aerosol, 5 to about 1000 mg/kg of host body weight. Expressed in terms of concentration, an active ingredient can be present on the compositions of the present invention for localized use about the cutis, intranasally, pharyngolaryngeally, bronchially, intravaginally, rectally, or ocularly in a concentration of from about 0.01 to about 50% w/w of the composition, preferably about 1 to about 20% w/w of the composition. Also, similarly for parenteral use the invention can be used in a concentration of from about 0.05 to about 50% w/v of the composition and preferably from about 5 to about 20% w/v. The WBI-3001 or the salts thereof, used as active ingredients to be employed as antibiotic and/or antineoplastic agents for treatment of animal and human illness can be easily prepared in such unit dosage form with the employment of pharmaceutical materials which themselves are available in the art and can be prepared by established procedures. The appropriate solid or liquid vehicle or diluent may be selected, and the compositions prepared, by methods known to the skilled artisan.
For agricultural application, the antibiotic compositions may be formed using one of the active ingredients in an inert carrier. If formulated as a solid, the ingredients may be mixed with typical carriers such as Fuller's earth, kaolin clays, silicas or other wettable inorganic diluents. Free-flowing dust formulations may also be utilized by combining the dry active ingredient with finely divided solids such as talc, kieselguhr, pyrophyllite, clays, diatomaceous earth and the like.
The powders may also be applied as a suspension or solution, depending on the solubility in the liquid carrier. Pressurized sprays, typically aerosols with the active ingredient dispersed in a low-boiling dispersant solvent carrier, may be used. Percentages of weight may vary according to the manner in which the composition is to be applied, and formulation used. In general, the active ingredient will comprise 0.005% to 95% of the active ingredient by weight in the antibiotic composition. The antibiotic composition may be applied with other ingredients, including growth regulators, insecticides, fertilizers, and the like. Formulation of the active ingredients to assist applicability, ease handling, maintain chemical stability and increase effectiveness may require addition of various materials. Solvents may be chosen on the basis of affecting the solubility of the active ingredient, fire hazard and flash point, emulsifiability, specific gravity and economic considerations. Adjuvants may be added to enhance the active ingredients, and can include surfactants which are anionic, cationic or nonionic. Stabilizers and antifreeze compounds will prolong storage. Additionally, synergists, stickers, spreaders and deodorant compounds can be added to improve the handling characteristics of the commercial formulation. Alternatively, the active ingredient can be combined with an inert carrier, such as calcium carbonate, and formed into a pill or other consumable delivery device, including controlled release devices intended to deliver metered doses of the active ingredient.
The inventive compounds may be employed also as antibiotic agents useful in inhibiting the growth of microorganisms present or eradicating microorganisms on a surface or in a medium outside a living host. The inventive compounds and/or their salts thereof may be employed, for example, as disinfectants for a variety of solid and liquid media susceptible to microbial growth. Suitable amounts of the inventive compounds may be determined by methods known to the skilled artisan.
The following examples are provided to further illustrate the invention, and are not intended to in any way limit the scope of the instant claims.
Example 1
Production and Isolation of WBI-3001 from the Culture Broth of X. bovienii
The primary form of X. bovienii was maintained and subcultured at 14 d intervals. Inocula of the primary form were prepared by adding one loopful of the culture to 50 ml of tryptic soy broth (TSB) in a 100 ml Erlenmeyer flask. Cultures were shaken at 120 rpm on an Eberbach gyrorotary shaker for 24 h at 25° C. Bacterial fermentation was initiated by adding 100 ml of this bacterial culture to 900 ml of TSB in a 2,000 ml flask. The flask was incubated in the dark at 25° C. on an Eberbach gyrorotary shaker. After 96 h, the culture was immediately centrifuged (12,000×g, 20 minutes, 4° C.) to separate the bacterial cells. Twenty litres of media was inoculated by X. bovienii . The inoculated media was incubated at 37° C. for 3 days. Then media was grinded and extracted with 20 L of ethyl acetate three times. Extracts were combined and evaporated under vacuum. About 20 gram of oily stuff was obtained after the evaporation. To this oily stuff, 100 ml of hexanes was added and the resulted mixture was stirred for half an hour. Solid precipitate appeared after this treatment. About 10 grams of solid was collected by filtration. The solid was redissolved in 20 ml of chloroform and loaded upon a column of silica gel for separation by chromatograph. Mixture of chloroform and methanol (9:1) was used as eluent. The separation of chemicals was test by TLC. Chemicals purified by chromatograph were submitted for antibacterial activity test. One chemical with significant antibacterial activity was found and was identified by NMR and MS. The structure of this chemical is showed as below:
Example 2
Identification of WBI-3001
NMR spectra were recorded on a Bruker WM600 spectrometer in C 5 D 5 N 5 . Low resolution MS were obtained on a Hewlett-Packard 5985B gc/ms system operating at 70 eV using a direct probe. CIMS spectra were obtained with isobutane on the same instrument as described above. High resolution MS were recorded on a Kratos MS80 instrument. HPLC and UV analysis was performed on Waters 2695 with a Waters 996 PDA detector.
1 H NMR(C5D5N) (600 Hz) δ0.87 (dd, 6H, J=7.2 Hz), 1.42(mult., 1H), 1.83(mult., 2H), 1.92(mult., 2H), 2.21(mult., 1H), 2.35(mult., 1H), 2.94(dd, 1H, J=16 Hz, J=3 Hz), 3.21(dd, 1H, J=16 Hz, J=13 Hz), 3.41(mult., 1H), 4.40(mult., 1H), 4.66(mult., 1H), 4.72(dd., 1H, J=16 Hz, J=3 Hz), 4.88(d, 1H, J=6 Hz), 5.02(dd, 11H, J=6 Hz, J=3 Hz), 6.62(d, 1H, J=7 Hz), 6.97(d, 1H, J=8 Hz), 7.35(t, 1H, J=8 Hz), 8.78(d, 1H, J=9 Hz).
13 C NMR(C5D5N) (600 Hz) δ21.76(C-1), 23.41(C-1′), 24.70(C-8), 24.94 (C-2), 25.91(C-7), 30.10 (C-6), 39.93(C-3), 45.53(C-12), 49.39(C-4), 62.46(C-9), 71.78(C-11), 74.16(C-10), 81.77(C-5), 109.07(C-18), 115.95(C-20), 118.67(C-19), 136.50(C-17), 140.78(C-15), 162.40 (C-16), 170.01(C-13), 173.99(C-14).
MS: 408(CI) (M+1)
UV (CH 3 CN:H 2 O=2:8): Dmax (log ε) 314.8 nm (3.7).
Example 3
WBI-3001 as Antibiotic Agents
The following experiments were conducted, demonstrating the antibiotic properties of WBI-3001. To determine minimum inhibitory concentration (MIC) of the WBI-3001, the standard dilution method was used. The tests were conducted at 35° C. and the MICs were determined after 24 h incubation.
Table 1 shows the MICs determined for the compounds against each microorganism. In conclusion, it is shown that WBI-3001 isolated from Xenorhabdus have potent antibiotic properties, particularly against some antibiotic resistant Staphylococcus strains.
TABLE 1
MICs of WBI-3001 and Erythromycin in Tryptic
Soy Broth at 24 hr and 48 hr time points (Note:
MIC values given in units of μg/ml).
Bacteria Sample
WBI-3001
Erythromycin
Escherichia coli
4
1
Staphylococcus epidermidis
8
0.25
S. aureus MSRA*
4
>32
Enterococcus faecalis
32
>32
Streptococcus pyogenes
4
0.03
Pseudomonas aeruginosa
>32
>32
*clinical isolates of methicillin-resistant strain.
Example 4
WBI-3001 as Antineoplastic Agents
The antineoplastic activities of WBI-3001 have been determined in vitro in cell cultures of human lung cancer H460, breast cancer MCF-7 and cervical cancer Hela. The tests were carried out using the method described by Skehan et al. (1990). Both WBI-3001 exhibit very strong antineoplastic activity against these cancer cells.
TABLE 2
Antitneoplastic activity of WBI-3001 in three cancer cell lines.
IC 50 (μg/ml)
Compound
H460
MCF-7
Hela
WBI-3001
0.1
0.81
0.24
While our above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as examples of preferred embodiments. Accordingly, the scope of the invention should not be determined by the embodiments presented, but by the appended claims and their legal equivalents.
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The invention is drawn to novel macrolide compounds of formula I having antibiotic and antineoplastic activities, useful as medicaments and/or agrochemicals for microorganism infections, in particularly for infectious diseases involving drug-resistant Staphylococcus , and for treatment of human and animal cancers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a power line pylon and a lamp post and, more particularly, to a power line pylon and a lamp post which are adapted to support a load.
2. Description of the Prior Art
Posts, or masts, are to be found in many different forms and for many different purposes, ranging from lattice-work mast structures for carrying 400 kV overhead power lines down to fencing posts of 50 mm in diameter. The posts may be grouted in the ground or simply secured by burying one end of the post in a pit or hole formed in the ground and by compacting natural stone around the post, so as to hold the post firmly. Flag posts and sign posts can be said to constitute particular examples of the posts referred to here.
The economic significance of a novel type of post depends upon the cost of and the type of post the novel post is intended to replace and the number of posts involved. In Sweden, more than eight million wooden posts are used today for supporting overhead power lines and telecommunication lines. By present day standards, an impregnated wooden post of this kind is estimated to have an active useful life of 40 years. There exist today overhead power line installations which are 50 years old and in which not a single post has needed to be replaced, although 40 years is the recognized useful life span of a wooden post. The mechanical strength of the post is calculated to be so impaired after this length of time as to render the post unsuitable and in need of replacement. It will be appreciated that the useful life span of such posts will be progressively shorter in the future, since the wood from which present day posts are produced and the wood from which posts have been recently produced is not of the same quality as that upon which present day standards have been based.
In addition to the scarcity in modern forests of rooted trees, which are suitable to be used for wood for posts for overhead power lines in excess of 10 kV, the impregnation of such now available wood has presented pronounced problems. The impregnating agent used hitherto, i.e. creosote tar, has been classified as toxic by the authorities. Consequently, anyone working with creosote impregnated posts must wear special protective clothing. Another drawback with creosote impregnated posts is that they may not be stored in the open air, due to the fact that the impregnation methods used result in moist posts, caused by incomplete absorption of the creosote tar and manifested in sticky wood surfaces.
Arsenic-copper salt solutions are alternative impregnating agents to creosote tar but, since these solutions have a shorter effective life span than creosote, they are not as economically viable. When considering the problems represented by the deterioration in the natural surroundings when facilities for impregnating wood are present which use such impregnating solutions, it is seen that the increased use of such solutions is counterproductive to the endeavor to provide improved environmental conditions.
Overhead power lines intended for more than 70 kV are supported by lattice-work posts or masts. In addition to being expensive to manufacture, such masts are highly unaesthetic and present an ugly feature in the surrounding landscapes. The need for power lines is increasing with the increasing need for electrical energy from progressively increasing production units to progressively higher consumer concentrations. In many areas or districts, this has resulted in multiple power cables or lines being erected in parallel. The posts or masts involved herewith detract greatly from the surrounding countryside and, in addition, present obstacles to agricultural machines working in the area. The same applies to posts used to carry telecommunication lines, although in this case the posts are not as high as the masts used to carry power lines and are not, therefore, as equally discernible to the eye.
Attempts, to reduce the extent to which such posts or masts encroach upon cultivated agricultural land, have resulted in power lines being run across land which is not used for agricultural purposes or across marshy territory. However, the erection of power or telecommunication line masts or posts in this latter territory is both difficult and laborious. Certain posts need to be anchored with the aid of dolphin-like shoring structures, and sometimes with the aid of some twenty or so auxiliary supportive posts.
Because of the limited flexibility of a wooden post, it is necessary to shore the post when a change in power or telecommunication line direction is effected, even though this directional change may be only moderate. The costs involved include the cost of the shores and tensioning devices required, e.g., bottle screws, and also the additional cost of the necessary concrete foundations or horizontal subsoil anchoring posts and the excavation work that needs to be undertaken in conjunction therewith.
The method used hitherto for erecting wooden posts for different purposes is one in which a pit is dug to a prescribed depth, in the case of posts for carrying 10 kV cables, a depth of 1.40 m, whereafter the root end of the post is placed in the pit and the post is lifted to a vertical position. The pit, or hole, is then fitted with available screened aggregate and the post is brought to a truly vertical position prior to filling in the pit and finally consolidating the packing material. The work of preparing post pits has been facilitated for many years by the use of earth drills and tractor carried vertical diggers. However, the ground surrounding the pits is often uneven or is inclined, which results at times in incomplete compaction of the aggregate intended to anchor the posts.
Another drawback with known wooden post support structures is that when two such posts are used to support a transformer, and even when four such posts are used for this purpose, and when one of the posts used becomes defective and must be changed, it is necessary to disconnect the transformer and lower it to ground level before the post can be changed. Subsequent to replacing the defective post, the transformer has to be lifted back into position and reconnected. Even though it is possible to plan the work involved, it necessitates an interruption in the power supply, which may be troublesome. As will be understood, it is necessary to restrict the future use of wooden posts, not only because of the aforementioned toxic risk presented by impregnated posts, but also because wooden posts are attacked by insects, or pests, other than those normally classified as infestants, or parasites, even though the posts have been thoroughly impregnated. It has been found in recent years that wooden posts are attacked by the black housefly (Campanatus liquiperda) and the red ant (Formica nufa), to an extent which is on a par with the damage caused by woodpeckers, fungi and mold. The latter cause mainly superficial damage, whereas the ants attack the core of the wood itself. The reason for this is probably because the core of the post is unable to absorb the impregnating agent used, since the wood resin is impregnable and impermeable to the impregnates used, and secondly because the natural habitats for ants have been greatly restricted by modern forestry. This, together with clear cutting of entire forests and subsequent ground preparation, has decimated all protective locations where ants may build their stacks. Ants, which live in stacks, and also horse flies to some extent, normally lay their eggs in tree stubs and dry furrows. When the ground is finally cleared and such stubs and furrows can no longer be found in the area, power line posts become the natural habitat of the ants.
The problems recited in the aforegoing with regard to cable or wire carrying posts apply with varying degrees to all types of wooden posts, irrespective of whether they are used to support lamps, cableways, ski lifts, fences, road signs, advertising signs, or flag poles.
OBJECT OF THE INVENTION
One object of the present invention is the provision of a post or like structure which, when dimensioned for its intended function, is able to carry the load involved, irrespective of whether this load is represented by a road safety fence, which extends less than one meter above road level, a lamp or by a high-tension power line supported at a height of more than 20 meters above ground level.
SUMMARY OF THE INVENTION
An aspect of the invention resides in a post construction kit for constructing a post implanted in a base terrain. The post construction kit includes at least a first post section adapted for implantation in the base terrain, at least a second post section, at least one of the second post sections being adapted for interconnection with at least one first post section and an interconnecting arrangement for interconnecting at least one first post section to at least one second post section.
The object is achieved with a post constructed in accordance with the invention. When seen from the aspect of the costs involved in erecting a post according to the present invention, one important feature of the inventive post is that no pit or hole is required. Instead, a first section of the post, which forms a post foundation, is hammered or likewise driven into the ground. In the case of posts which are 50 mm in diameter, the posts may be continuous, single piece structures and are preferably driven into the ground to a depth of about 50 cm. In the case of posts which are intended to support overhead power lines and which are to be erected on marshy ground, this first post section may not be long enough to achieve firm frictional engagement with the surrounding soil or earth and, consequently, it may be necessary to drive a further post section into the ground in order to achieve the requisite degree of friction. Thus, this obviates the need of pile driving to refusal.
Shorter posts may be driven into the ground with the aid of hydraulically operated drivers. In the case of posts of the very largest dimensions, the aforesaid first post section can be driven into the ground with the aid of a tractor carried, pneumatic or hydraulic high speed hammer. It has been found in practice that this method can be applied also with respect to frozen ground and that the first or foundation-forming post section can be driven into such ground in a matter of only a few minutes.
Because the various post sections of a multisection post, according to the invention, are preferably of tubular configuration and provided with a socket coupling at one end and a conically tapered spike at the other end, the sections can be readily assembled to form a continuous post. The conicity of the tapered, spiked end of respective post sections is preferably such that the joint formed between two mutually adjacent post sections is self-locking, such that the post will withstand relatively large loads, more specifically both the load exerted axially by the object carried by the post and also the bending stresses created, e.g., at the juncture where a change in cable direction is made. The post sections may also be made of ductile iron, thereby improving the flexural strength of the post still further. Ductile iron is relatively resistant to corrosion, and by coating the hollow tubular posts with asphalt, both internally and externally, to a thickness of at least 50 microns, in accordance with one preferred embodiment of the invention, the posts can be given a useful active life of more than 100 years.
Since that section of the post which is driven into the ground is the section which is most subjected to corrosion, it may suffice in some cases to produce solely this section of the post from ductile iron. In certain instances it may be desirable, for environmental reasons, that the part of the post which is visible above the ground has a particular configuration. One conceivable instance in this regard is when a public thoroughfare is to be provided with new lamp posts which are required to conform to or blend with the existing character of nearby buildings. In this case, the advantages afforded by the novel post construction can be fully utilized, because of the inclusion of the aforesaid drivable first post section of said construction. In the case of this particular embodiment of the inventive post, there is fitted to the first or foundation-forming post section at ground level, an auxiliary or transition post section to which the remainder of the post structure can be fitted. The remaining part of the post structure which extends above ground can be intentionally designed to suit prevailing aesthetic requirements. When newly manufacturing such parts, they are provided with a spiked end portion which fits at ground level into the socket of the first post section located in the ground and which is selflocking in said socket. This enables the inventive concept to be applied in respect of posts which are especially molded for use in highly exclusive environments.
The post section, which, in accordance with the invention, is driven into the ground, can be used as a foundation for other types of post. For example, that part of the post, which extends above ground level, may consist of a continuously tapering, or step-wise tapering galvanized steel tube. Wooden posts may also be fitted to the ground-located first post section. Furthermore, there is no restriction to posts of round cross-section, since it suffices that the connecting end of the overlying post section has a configuration which conforms to the configuration of the socket connector of the ground-located post section.
In the case of high posts which comprise a plurality of separate post sections, and particularly when an assembled post is to be erected with the aid of a tractor-carried digger, it may be beneficial to ensure that the various post sections are securely locked to one another prior to lifting the post. This can be effected by drilling a slightly conical hole through a connecting socket and the tapered end of an adjoining post section fitted thereinto, and by subsequently driving a lock pin into the hole.
In the case of inventive post constructions intended for supporting overhead power lines, an advantage is afforded when the ground-located first post section is fitted with a post shoe prior to being driven into the ground, the size of the post shoe used being dependent on the nature of the ground into which said post part is driven. The function of the post shoe is to form in the ground a hole whose transverse dimension is greater than the transverse dimension of the ground-located post section. This hole enables an erected post to be vertically aligned whereafter the hole can be filled with loose aggregate in the vicinity of the ground-located post section. This will further reduce the risk of corrosion.
The ground-located part of the post may also be provided with, preferably, axially extending elongated slots. Subsequent to having driven the ground-located post section to the intended ground depth, concrete is pumped therein to and exits through the slots. When a sufficiently large post shoe is used, the ground-located post section will be surrounded by concrete, thus creating a firm foundation.
Ductile iron, such as nodular iron, is well suited for the manufacture of post sections by centrifugal casting methods. The above-ground post sections can therewith readily be given a configuration which tapers towards the spiked ends of respective sections. Since the ground-located post section is normally driven into the ground with its spiked end facing downwards, the connecting socket of this post section is fitted with an auxiliary, transition post section which is spiked at both ends. This enables the above-ground sections of a multiple section post assembly to be assembled with the connecting sockets facing downwards. Furthermore, the auxiliary post part may comprise a multiple of very short post sections which are used between two mutually adjacent above-ground post sections for dimension changing purposes. This enables very high post constructions to be given a diameter which decreases with each further post section above ground level; normally with each five meters of post length.
Since the post is of hollow tubular construction, the upper end of the post will be open. It is, therefore, preferred to fit to the end of the top post section a cap or like cover member, preferably a capping sleeve. In the case of posts which are intended to carry overhead electrical conductors, the capping sleeve is made of the same material as the post, since materials of mutually different electropotential in the electrochemical series of metals are liable to induce corrosion in the magnetic field surrounding the conductors, particularly in the presence of rain water and a contaminated atmosphere.
When the inventive posts are used in groups of twos or threes, for example, to support high tension lines and larger ski lifts, it is preferable to connect together the tops of the respective posts or masts with the aid of connecting elements. These elements may consist of lengths of conventional angle iron secured to respective posts with the aid of conventional fasteners, such as nuts and bolts. The connecting elements or attachment devices therefore may also be welded to respective iron parts. An alternative solution, however, is to place over the tops of respective posts a tubular post section, which lacks the provision of connecting sockets and has a larger diameter than the tops of said posts, and which is provided with at least two apertured recesses at a mutual distance apart equal to the distance between the tops of the posts. This hollow tubular connecting element may, of course, be secured to respective posts with the aid of suitable fasteners. Alternatively, the apertured recesses may be given the same configuration as the top ends of the post, so as to engender a self-locking effect. It will be understood that if the posts are inclined towards one another, the apertures must be formed at an angle of less than 90° to the longitudinal axis of the connecting element.
The surfaces of the posts will normally be treated with an asphalt emulsion, although they may, alternatively, be painted in any desired color.
In general, the invention features a post construction kit for constructing a post implanted in a base terrain, the post construction kit including a first post section adapted for implantation in the base terrain, a second post section adapted for interconnection with the first post section, and interconnecting means for interconnecting the first and second post sections.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail with reference to a number of exemplifying embodiments thereof and with reference to the accompanying drawings, in which:
FIG. 1 illustrates a post or mast construction intended for supporting overhead high-tension power lines;
FIG. 2 illustrates a lamp post construction;
FIG. 3 illustrates a post construction for supporting power lines;
FIG. 4 illustrates the spiked portion and the socket portion between post sections: and
FIG. 5 shows a post section which includes a slotted surface.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The illustrated post construction includes a tubular post section 1 which is hollow and cylindrical and which is intended to be driven into the ground so as to provide a post foundation therein and to which there is fitted a pole shoe 2. One end 3 of the foundation-forming post section 1 is spiked and the pole shoe is fitted to this spiked end with the aid of a connecting socket which embraces said spiked end 3. The opposite end of the foundation forming post section 1 is provided with a conical connecting socket 4 into which there is inserted an auxiliary or bridging post section 5, the two ends of which have a spiked configuration which corresponds to the conicity of the socket 4. The socket 4 is located at the upper end of the post section 1. The socket 4 has a portion with an outer diameter which is greater than the diameter of the cylindrical portion of the post section 1. The outer surface of the socket 4 is flaringly outwardly and upward so that the diameter at an upper portion is greater than the diameter of the lower portion of the outer surface of the socket 4. Fitted to the spiked end of the auxiliary post section 5 distal from the foundation forming post section 1 is the connecting socket 7 of a first above ground post section 6.
Alternatively, two post sections may be connected directly together without the use of a bridging post section 5. As shown in FIG. 1, post sections 60 and 62 are directly connected together through connecting socket 64. In this embodiment, the end of post section 60, which is engaged by socket 64, is configured in the same shape as either end of bridging post section 5 so as to properly be engaged by socket 64. Socket 64 may form an integral part of post section 62 or may be welded or otherwise attached to post section 62 in a manner well known to those of ordinary skill in the art.
The socket 7 on the first above ground post section 6 has an internal conicity which coincides fully with the conicity of the upper spiked end of the auxiliary section 5. This conicity has a tapering ratio of at least 1:14 and at most 1:20, i.e. the diameter decreases one length unit in an axial direction over a maximum of 20 length units.
As illustrated in FIG. 1, a second, and optionally several, post sections 8 and 9 can be fitted consecutively above the first above ground post section 6, the number of sections fitted being dependent on the desired height of the post assembly. When the load to be supported permits, the higher post section 8 and 9 may have a diameter which decreases in relation to the underlying post section 6. This is achieved in accordance with the invention with the aid of adapters 10 and 11 which are fitted between respective post sections 6, 8 and 9 and which also serve to stabilize the joint between mutually adjacent post sections. The adapters have the form of very short post sections, of which the conicity and dimension of the connecting socket coincide with the conicity and the dimension of the connecting socket 7 of the first above ground post section 6, the adapter 10 being fitted to the spike end of said post section. In addition to length, a further difference between a diameter reducing adapter and a post section is that the spiked end of the adapter has a diameter which corresponds to the inner diameter of the connecting socket on the post section to be placed above the diameter decreasing adapter. The diameter-reducing adapters are preferably placed approximately 10 meters apart, even though shorter post sections may be used.
When erecting posts intended for supporting high tension power lines, it may be necessary to drive two or more foundation-forming post sections 60 and 62 into the ground. These foundation-forming post sections are preferably configured in a similar manner to the aboveground post sections, i.e., each have mutually corresponding connecting sockets 4 and spiked ends 3 with self-locking facilities, as described above. These foundation-forming sections can be driven straight into the ground to provide a stable foundation at a requisite depth so as to provide the necessary support, even in ground which would not otherwise be considered suitable for the erection of such posts or masts.
Trestle-like post configurations are used for supporting high tension power lines of 130 kV. The supporting trestles comprise at least two posts which extend vertically or are inclined toward each other and which are interconnected at the tops of their respective sections by means of a horizontal connecting bridge 12, which may comprise either a single post section or a number of interfitted post sections. The post section or sections forming the connecting bridge 12 must have a larger diameter than the post sections forming the limbs of the trestle-like structure. The holes required in the connecting bridge 12 to enable the bridge to be fitted over the pointed ends of the uppermost post sections can be formed with the aid of a conical boring tool provided in the high tension power line construction equipment and which has the same cutting angle as the spiked ends of respective post sections 9. The connecting bridge 12 can be anchored to the top post elements 9 with the aid of a vibrating device. Attachment devices for the insulators from which the high tension power lines are to be suspended are screwed firmly into the connecting bridge 12.
When it is necessary to further support a post, for example due to its height, a guy arrangement 13, 14 and 15 may be used, as shown in FIG. 1. The guy peg used to this end may comprise a foundation-forming post section 1, which may or may not be fitted with a driving shoe 2, or may comprise a post element of desired diameter which is driven into the ground at an acute angle to the surface thereof. Concrete is then poured into the hollow guy peg 13 and an eye bolt 14 is secured in the concrete. A guy wire 15, connected to the post at a suitable height thereon, is then connected to the eye bolt 14 and tensioned, e.g., through the provision of an appropriate tensioning device 27. Alternatively, the eye bolt may comprise a guy wire which is wound around the post section beneath the connecting socket, therewith eliminating the need of filling the post section with concrete.
Referring now to FIG. 2, when the inventive post is to be used as a lamp post, the foundation-forming post section 1 is driven into the ground in the aforedescribed manner. Subsequent to fitting the auxiliary post section 5 into the connecting socket 4, the connecting socket 17 of a lamp post 16 is fitted over the upper spiked end of the auxiliary section 5. The post 16 preferably tapers continuously upwards and may consist of a single piece structure to a height of 5 meters. Fitted to the upper spiked end of the post 16 is a single arm or double arm element 18 which carries a lamp 19 at the extremity or extremities of its arm or arms 18. The electric wires required for connecting the lamp or lamps can be readily drawn through the hollow post as the post is being erected.
Referring now to FIG. 3, in the case of high lamp posts, there is applied the same technique as that applied when erecting, for instance, posts which are to support 20 kV power lines. The foundation-forming post section 1 is driven into the ground in the manner aforedescribed, whereafter a post section 20 is fitted over the auxiliary post section 5. The post section 20 of this embodiment differs from the aforementioned post sections, in that the spiked end 21 of the post section 20 decreases in diameter stepwise at the location where its cone begins to converge. The post section 20 has fitted thereto an overlying post section 22 which is provided with a connecting socket which has an outer diameter adapted for making a fitting relationship by having a dimension which is equal to the outer diameter of the post section 20. The post section 22 tapers upwards from the connecting socket to a given point on said section, whereafter the diameter of the section remains constant. Connected to a provided upper spiked end of the post section 22 is a T-piece 23, the vertical leg of which is configured as the connecting socket on one of the aforedescribed post sections. The horizontal part of the T-piece 23 has the form of a hollow sleeve of uniform diameter. Extending through the horizontal sleeve is a smooth iron tube which forms a crosspiece 24, which is secured to the T-piece 23 by means of a preferably conical locking pin which is driven into a hole drilled through the T-piece 23 and into the crosspiece 24. The crosspiece 24 is intended to support lamp fittings or power line insulators 25, whichever are required.
In the majority of cases, it is preferred to assemble at least the aboveground post sections on the ground. The post is assembled by placing the connecting socket 7 of the first above ground post section 6 against a firm abutment, whereafter the diameter reducing adapter 10 is fitted to the spiked end of the post section 6. The connecting socket of the second post section 8 is then fitted onto the adapter 10 and an annular vibrating device is placed around the connecting socket of the post section 8 (for example, around the top thereof) and the parts are hammered together. As an additional safety measure, a conical locking pin or like device can be driven into a hole drilled through each connecting socket and into the spiked end of a post section located in said socket. Assembly of the post is continued until the requisite number of post sections have been fitted together, whereafter the post is erected.
The assembled post can be raised with the aid of a relatively powerful tractor carried digger. The ground around the post has been highly compacted during the driving in of the foundation-forming section 1, which in itself contributes towards firming the support of the post. The use of a tractor carried digger affords a practical solution both when erecting a single post and when erecting a complete power line installation.
Referring now to FIG. 4, the socket 7 on the first aboveground post section 6 has an internal conicity 30 which coincides fully with the conicity 32 of the upper spiked end of the auxiliary section 5. The other sockets in the configuration and the other spiked ends have similar internal conicities and spiked ends.
FIG. 5 shows an alternate embodiment of a below ground post section 40. Post section 40 includes a plurality of slots 42 which are formed in surface 44. With this embodiment, post section 40 may be driven into the ground as hereinbefore described. Shoe 46, which is positioned adjacent the end of post section 40 which is to be driven into the ground, forms an opening in the ground which is of a larger diameter than post section 40 itself, as post section 40 and the attached shoe 46 are being driven into the ground. The large diameter ground hole allows post section 40 to be pivoted, somewhat, about spiked end 48 along arcs 50 so that post section 40 may be vertically aligned with respect to the ground surface.
Once such alignment is completed, flowable ballast material, for example concrete, may be poured into top open end 52 of post section 40, thereby filling the hollow interior of post section 40. The flowable ballast material will then escape from the interior of post section 40 through slots 42 thereby filling the space between the sidewalls of the ground hole and surface 44 of post section 40. This ensures that post section 40 is securely anchored in the ground.
In view of their very long useful life, posts constructed in accordance with the invention afford an economically advantageous alternative, particularly with regard to their reusability.
The invention as described hereinabove in the context of the preferred embodiments is not to be taken as limited to all of the provided details thereof, since modifications and variations thereof may be made without departing from the spirit and scope of the invention.
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A post construction kit for constructing a post implanted in a base terrain which includes a first post section adapted for implantation in the base terrain, at least one other post section adapted for interconnection with the post section to be implanted underground, and an interconnecting arrangement for interconnecting the underground section and at least one other post section.
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BACKGROUND OF THE INVENTION
The present invention relates to a device for operating guiding tongues of a product diverter for use, for example in polygraphic machines. The product diverter of this kind is designed for diverting a stream of sheets to be folded, for example, or diverting singular sheets to different paths.
From DE-PS No. 1,044,589 a device for sorting out defective sheets is known wherein a cam disk driven synchronously with a cross cutter moves via a lever system the guiding tongues of the diverter until the movements of the cam disk are inactivated by means of an electromagnetic locking mechanism. This known device, however, enables the sorting of sheets having predetermined fixed characteristics but cannot selectively divide the entire stream of sheets or alternately divert selected sheets from the stream to different directions.
Known are also devices which divide a stream of products or sheets in such a manner that one product is diverted in one direction and the next product is diverted in another direction. For example, DE-AS No. 25 59 138 discloses a diverter for directing flat workpieces from a conveyor belt onto two subsequent conveyor belts. The guiding tongues in this prior art device alternately receive driving impulses through springs activated upon the release of locking pawls or catches tensioned in reciprocating cycles by means of a crank drive of a sliding wedge mechanism which also releases the locking pawls. It is true that devices of this kind are suitable for dividing a stream workpieces. Nevertheless, their main disadvantage is the inability to alternate the division of the stream of the workpieces or to divert at a predetermined time point the entire stream to one or other direction. Another disadvantage of these known devices is a high noise level during operation.
Another device of this kind is known from DE-AS No. 22 29 286 which serves for sorting out defecting pieces in paper processing machines and offers the possibility to divert after a predetermined number of pieces, the path of their transportation. A synchronized locking mechanism cooperates with a pneumatic double-acting locking cylinder controlled by different signals. By means of the working cylinder a pressure accumulator is created for an instantaneous switchover when a gap in the product stream occurs. This mechanism which is advantageous for a synchronized control is also unable to solve the problem of an alternating switchover at a high frequency because the relatively high inertia of the pneumatic drive and the numerous additional control members prevent such fast changes.
SUMMARY OF THE INVENTION
It is, therefore, a general object of this invention to provide a device for actuation of guiding tongues of a product diverter which is versatile in application and can be employed both in connection with rotary folders, for example for dividing a stream of sheet shaped products, or with cross cutters, for example for a non-stop operational program, and also in sheet fed printing machines, for example in sheet sorting devices. Another object of this invention is to provide such an improved diverting device which is reliable in operation and inexpensive to manufacture.
Still another object of this invention is to provide such an improved device which enables an exact division of a stream of products following rapidly one after the other at a high frequency either at a certain time or to control the division in such a manner that after a certain time point either one or the other direction is selected.
In keeping with these objects and others which will become apparent hereafter, one feature of this invention resides in a combination including the mounting of the guiding tongues on a tiltably supported shaft which is directly connected to one end of a cam follower arm which by means of a first biasing spring is urged into engagement with a cam disk, the cam disk being rotatable in a bearing and driven by a driving gear in synchronism with the machine cycles. The bearing of the cam disk and of the driving gear being mounted on the free end of a rocking arm whose other end is supported for rocking movement in a pivot point on the machine frame. The rocking arm is linked to a central portion of a rocker bar whose ends are linked to armatures of two solenoids acting in opposite directions relative to each other to move stepwise the rocking arm into different positions.
In a modified embodiment of this invention the movement of the rocking arm is limited by an abutment on the machine frame. The arm is spring loaded against the abutment by a second spring which is weaker than the spring of the cam follower lever. A spring loaded first pawl is linked to an armature of one solenoid and cooperates with a free end portion of the rocking arm to limit is movement away from to the fixed abutment. A second spring-loaded pawl is linked to the other solenoid and cooperates with an abutment provided on the free end of the cam follower lever to lock the same in predetermined positions.
In the preferred embodiment of this invention, the cam disk is firmly connected to an intermediate gear which meshes with a driving gear connected to a main driving shaft of the machine which is coaxial with the pivot axis of the rocking arm.
The advantages of the solution according to the invention reside particularly in the fact that the sheet-like products or sheets supplied in a processing machine at a high feeding rate at regular time intervals can be either alternately diverted in different feeding directions or after a certain time point diverted into one of two feeding directions. It is of particular advantage that in any application it is possible to achieve an exact kinematic synchronization for the actuation of the rocker bar. The switchover of operating conditions is performed in concert with this synchronization and is not limited to the time period of a gap between the supplied sheets. Moreover, the start of the switchover process can begin at a time point at which the trailing edge of the preceding sheet-shaped product has not yet reached the diverting edge of the guiding tongue when viewed in the intended new direction of transportation.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic side view of one embodiment of the device of this invention; and
FIG. 2 is a schematic side view of another embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A series of sheet-shaped products or sheets arrive in the direction of arrow Z from a non-illustrated processing machine in a conventional manner, for example conveyed on non-illustrated conveying bands, rollers or on a transfer cylinder. Depending on the position of the diverting edge of the guiding tongue 1 relative to the stream Z of conveyed products, namely whether the diverting edge is below or above the conveyed products, the latter are diverted to run either in the direction A along the guiding side 1A or in the direction B along the guiding side 1B and are conveyed in the diverted directions by conventional means. In practice, a plurality of guiding tongues 1 are fixed side by side on a pivot shaft 2 which is supported for rotation on a machine frame 3. A cam follower lever 4 is rigidly connected at one end thereof to the pivot shaft 2 and is spring-loaded by a pressure spring 5 to resiliently engage at its free a cam disk 6. The cam disk 6 is fixed to a side of a gear 7 and rotates jointly with the latter in a pivot bearing 8. It will be seen from FIGS. 1 and 2, the pivot bearing 8 is mounted on a free end portion of a rocking arm 9 whose other end is secured to a pivot joint 10 supported for rotation on the machine frame 3. The pivot joint is coaxial with the axis of rotation of the driving gear 11 meshing with the main driving gear of the machine and with the gear 7 of the cam disk 6. The shaft of the driving gear 11 is also supported for rotation on the machine frame and the gear 11 thus drives the cam disk 6 in synchronism with the machine cycles. The cam disk 6 is shaped with high and low camming surfaces whose sizes depend respectively on the time of passage of a product or sheet over the diverting edge of the guide tongue and whose ascending or descending surfaces are designed to match the gaps between the products. Subject to the selection of the operational mode "feeding direction A" or "feeding direction B", or "alternate feeding directions A and B", the working arm 9 which supports the cam disk 6 keeps taking such positions at which the guiding tongues 1 are oriented relative to the product stream in the directions corresponding to the selected operational mode.
For the positioning of the rocking arm 9 various constructions of the device of this invention are possible of which only two are illustrated and described.
Referring to FIG. 1, the rocking arm 9 is linked at the joint 12 with a central part of a rocker arm 13 whose ends are linked via additional joints 12' and 12" and connected rods 14' and 14 to armatures of control solenoids 15 and 16 acting in opposite directions relative one to another. The positions of solenoids 15 and 16 are electrically adjustable and determine the position of the free end of the rocking arm and hence the position of the cam disk 6 relative to the cam follower lever 4.
In the operational mode "alternate feeding of sheets in directions A and B" the armatures of respective solenoids 15 and 16 are electrically set to positions n and m by applying voltage to coil terminals (n) and (m). The pivot bearing 8 of the cam disk 6 in this case is situated in a central position (n-m) indicated by full lines in FIG. 1 and accordingly the diverting edge of guiding tongues 1 reciprocates in synchronism with the machine cycles between positions m' and n'. If it is desired to divert the entire product stream in the direction A, solenoid 16 is switched over into position o indicated by dash and dot lines. Accordingly, the pivot bearing 8 of the cam disk 6 is displaced into right hand position (o-m) indicated by dashed lines and the guiding tongues 1 move back and forth between the points m' and o'. As a consequence, the stream Z of the conveyed products runs on the upper guiding side 1A of the tongues and all products are diverted in a single direction A only. In analogous fashion all products can be diverted in the direction B when armatures of solenoids 15 and 16 are simultaneously displaced into positions n and p. The switchover of solenoids 15 and 16 is accomplished by conventional switching means which need not be described in detail for the purposes of this invention.
In a modification, instead of changing the angular position of the pivot bearing 8 it is possible to change the position of the pivot shaft 2 while the position of the pivot bearing 8 remains constant.
In a second embodiment of this invention illustrated in FIG. 2 the arrangement of driving members and machines elements 1 through 11 is substantially the same as in the embodiment of FIG. 1. The principal difference is in the modification of the locking arm 9 and of the cam follower lever 4 and also in the provision of electromagnetically activated locking pawls 17 and 18 for determining the selected operational modes.
In the operational mode "alternate feeding in directions A and B" the stop pawl 17 is brought by tensioning spring 17' into a position illustrated in full line in FIG. 2 in which it locks the rocking arm against the fixed abutment 19. The second locking or stop pawl 18 is tilted by tensioning spring 18' into the position illustrated in full line in which it disengages the cam follower lever 4 thus permitting its free movement. Accordingly, the cam disk 6 moves the cam follower lever 4 back and forth in synchronism with the machine cycles between the positions r and s of the diverting edge of the guiding tongue 1 and the stream of products is alternately diverted in directions A and B. If it is desired to retain the guiding tongues in the position s in order to divert the entire product stream in the direction A, the solenoid 23 is energized. Due to the force of pressure spring 5 acting via the cam follower lever 4, the cam disk 6 and the rocking arm 9 on the first stop pawl 17, the latter can switch over from its illustrated position when the force of spring 5 is taken up by an adjustable limit stop 20 cooperating with the cam follower lever 4 in such a manner that the latter abuts against the stop in an intermediate position of the cam disk. The low cam surface only slightly releases the cam follower lever from the limit stop 20. In the intermediate cam disk position, the first stop pawl 17 releases the rocking arm 9 which springs under the action of pressure spring 21 from position t to position t'. The strength of pressure spring 21 is less than that of the pressure spring 5 so that the cam follower lever 4 remains on the limit stop 20 and consequently the guiding tongues 1 remain in the position s.
In the alternating mode of operation the synchronized switchover of the tongues into the original position can be enforced only then when the rocking arm 9 is in position t at which the first stop pawl 17 is allowed by the action of tension spring 17' to lock the rocking arm on the abutment 19. In all other positions, a stop surface 24 formed at right angles at the free end of the rocking arm prevents the pawl 17 to move into its locking position. Similarly, the fixation of the guiding tongues in the diverting position r is effected by the stop pawl 18. The high camming surface of the cam disk 6 moves the cam follower lever 4 in a position in which the second stop pawl 18 when actuated by the second solenoid 22 can rotate against the force of spring 18' into engagement with the right-hand side of the cam follower lever. In all preceding positions, this locking engagement was prevented by the stop surface 25 formed at right angles at the free end of the cam follower lever.
The force of pressure spring 5 which holds the cam follower lever in engagement with the second pawl 18 can be overcome by the biasing spring 18' upon inactivation of solenoids 22 only at the time point at which the high camming surface of cam disk 6 moves the cam follower lever away from the second stop pawl 18 thus guaranteeing that the diverting edge of tongue 1 is moved in synchronism with the occurrence of gaps between the conveyed series of products. Among others it is also conceivable in a further modification of this invention to design a first stop pawl 17 so as to act immediately on the cam follower lever 4.
From the above described operation of the two embodiments of this invention it is evident that the diverting device provides both high switching frequency and well defined switching cycles accurately correlated to the feeding rate of the processed sheets in any selected operational mode. The embodiment of FIG. 1 shows a design in which the swinging of the cam is controlled substantially electrically whereas in the embodiment of FIG. 2 a mechanical adjustment for controlling the product diverting positions is of greater importance.
While the invention has been illustrated and described as embodied in specific examples of a sheet diverting device, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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In a rotary machine for processing a series of sheet-shaped products supplied at a rate which is synchronized with the machine cycles, a device for diverting the stream of products to processing directions in accordance with a desired mode of operation. The device includes at least one guiding tongue pivotably supported in the path of movement of the products. A cam disk attached to a driven gear is supported for rotation at a free end of a rocking arm whose other end is pivotably supported on the machine frame. A cam follower lever is spring biased into engagement with the cam disk and at its end is fixedly connected to the pivot shaft of the guiding tongue. The rocking arm is linked to a control device which either electrically or electromechanically by means of two solenoids sets the rocking arm in at least three different angular positions in dependency on the selected mode of stream diverting operation.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention generally relates to a single lens reflex camera having an improved high-speed film exposure rate. In particular, the invention relates to an autofocus single lens reflex camera in which the main mirror is controlled to decrease the time between film exposures.
2. Description of Related Art
When the film is not being exposed in a conventional autofocus single lens reflex camera, the light entering the camera lens is reflected by a mirror positioned between the film and the camera lens. The light reflected by the mirror is directed to a view finder and other devices in the camera, such as a range measuring device. The range measuring device uses the light to detect the distance from a photographic subject to the camera, i.e. the subject range. The subject range is then used to control the focus lens in the autofocus camera to focus an image of the subject on the film. Therefore, light must be directed to the range measuring device between each film exposure so the focus lens can be controlled to focus the image of the subject. If light is not directed to the range measuring device between film exposures, the focus lens cannot be controlled and the image is very likely to be out of focus.
When the conventional single lens reflex camera exposes the film, the mirror is raised to allow the light to pass toward the film. After the mirror is raised, a shutter, which is positioned between the mirror and the film, opens and then closes to expose the film to the light. After the film is exposed, the mirror is lowered, again reflecting the light entering the camera lens toward the view finder, the range measuring device and other devices.
The shutter in a single lens reflex camera has a front blind and a rear blind. Before the film exposure begins, the front blind is closed and the rear blind is open. As the front blind opens to expose the film to the light, the light passes through the shutter. At the end of the film exposure, the rear blind closes, stopping the passage of light to the film.
Conventional single lens reflex cameras, as disclosed in Japanese Unexamined Patent Publication 58-1136, initiate the lowering of the mirror after the film exposure after the rear blind of the shutter closes.
However, in the conventional single lens reflex camera, the mirror does not actually start moving downward immediately after the single lens reflex camera initiates lowering of the mirror. The time delay between initiating lowering of the mirror and actual mirror movement is due to the time constant of the motor which drives the mirror downward and the clearance or play between the mechanical parts in the mirror drive linkage. The time delay in lowering the mirror is particularly problematic during high-speed autofocus photography.
During high-speed autofocus photography, a short time interval between consecutive film exposures is desired. As outlined above, the film exposure cycle starts with measuring the subject range. Then, the focus lens is controlled to focus the image. Next, the mirror is raised, the shutter opens and closes and the film is exposed. The mirror is lowered and the next film exposure cycle is ready to begin. The time delay in lowering the mirror in the conventional single lens reflex camera delays the start of the range measurement during the next film exposure cycle. The start of the range measurement is delayed because the mirror is delayed in reaching the down position, the position where the mirror reflects the light to the range measuring device.
Therefore, an autofocus single lens reflex camera is needed which eliminates the effect of the time delay in lowering the mirror.
SUMMARY OF THE INVENTION
This invention therefore provides a single lens reflex camera which initiates lowering of the mirror such that the effect of the time delay present in conventional single reflex cameras is eliminated.
In a preferred embodiment of this invention, a start signal is sent to the motor which lowers the mirror before the action of the shutter blinds is complete. In other words, the motor and mirror drive linkage are activated before the rear blind closes and may be activated even before the front blind opens. This decreases the time interval between the point in time when the rear shutter closes and the point in time when the mirror reaches the down position, enabling the range measurement to begin for the next film exposure cycle. Therefore, the time between consecutive film exposures is decreased, since, in the preferred embodiments of this invention, the subject range is measured more quickly or sooner after the previous film exposure is completed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in reference to the following-figures, in which like reference numerals refer to like elements, and;
FIG. 1 is a plan side view of the mirror in the down position in a preferred embodiment of the invention;
FIG. 2 is a plan side view of the mirror in the up position in the preferred embodiment of the invention;
FIG. 3 is a block diagram of the mirror drive control system of the preferred embodiment of the invention;
FIG. 4 is a timing diagram showing when the elements in the preferred embodiment the invention are activated in response to a first exposure condition;
FIG. 5 is a timing diagram showing when the elements in the preferred embodiment of the invention are activated in response to a second exposure condition;
FIG. 6 is a timing diagram showing when the elements in the preferred embodiment of the invention are activated in response to a third exposure condition;
FIG. 7 is a flowchart outlining a first preferred embodiment of the method for controlling the preferred embodiment of the invention; and
FIG. 8 is a flowchart outlining a second preferred embodiment of the method for controlling the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a plan side view showing a mirror and a mirror drive apparatus in the preferred embodiment of this invention. The main mirror 52 is shown in a down position resting against the position determining pin 24, which is fixed to a camera body 1 (shown in FIG. 3). The light 45 from the photographic subject (not shown) is reflected by the main mirror 52 to a view finder. The main mirror 52 rotates around a shaft 23, which is also fixed to the camera body 1. A spring 20 urges the main mirror 52 to rotate in a counterclockwise direction around the shaft 23. An auxiliary mirror 53 rotates around a shaft 31, which is fixed to the main mirror 52. A torque spring 34 engages pins 32 and 33 fixed to the main mirror 52 and the auxiliary mirror 53, respectively. The torque spring 34 biases the auxiliary mirror 53 relative to the main mirror 52 by urging the auxiliary mirror 53 to rotate counterclockwise around the shaft 31 relative to the main mirror 52. A position determining pin 25 fixed to the camera body 1 contacts the auxiliary mirror 53 and resists the biasing force of the torque spring 34 on the auxiliary mirror 53.
A mirror up lever 51 rotates around a shaft 22, which is fixed to the camera body 1. A spring 19 urges the mirror up lever 51 to rotate clockwise around the shaft 22. The mirror up lever 51 also has a wheel 46 mounted on an end of the mirror up lever 51 opposite a mirror end 51b of the mirror up lever 51. A hook 50a on a stop lever 50 engages a stop arm 51a of the mirror up lever 51 and resists the force of the spring 19 on the mirror up lever 51. The stop lever 50 rotates around a shaft 21, which is fixed to the camera body 1. A spring 18 urges the stop lever 50 to rotate clockwise around a shaft 21 which is fixed to the camera body 1. A position determining pin 26 contacts the stop lever 50 and resists the force of the spring 18 on the stop lever 50. A release magnet 13 is capable of rotating the stop lever 50 in a counterclockwise direction by magnetic attraction sufficient to overcome the force of the spring 18 on the stop lever 50.
The mirror drive apparatus shown in FIG. 1 also includes a motor 10 which has a motor shaft 35. A pinion 58 is fixed to the motor shaft 3S. A pin 27 fixes a cam 55 to a gear 54, which rotates around a shaft 28 mounted to the camera body 1. The motor 10 drives the pinion 58, which in turn drives the gear 54, and thus the cam 55, through gears 57 and 56. The gears 57 and 56 rotate around shafts 30 and 29, respectively. The shafts 30 and 29 are mounted to the camera body 1.
To raise the main mirror 52 from the down position where it rests against the position determining pin 24 to an up position, a release signal (Mg1) is sent to the release magnet 13. When the release magnet 13 is engaged by the release signal (Mg1), it causes the stop lever 50 to rotate counterclockwise against the force of the spring 18, disengaging the hook 50a a from the stop arm 51a of the mirror up lever 51. The force of the spring 19 rotates the mirror up lever 51 clockwise around the shaft 22. The mirror end 51b of the mirror up lever 51 contacts and pushes on a back surface 52a of the main mirror 52. The force of the mirror up lever 51 against the main mirror 52 causes the main mirror 52 to rotate clockwise about the shaft 23 until the main mirror 52 contacts a stopper 17 which is fixed to the camera body 1.
As the main mirror 52 begins to rotate toward the up position where it rests against the stopper 17, a fork 53a on the auxiliary mirror 53 engages a pin 40 which is fixed to the camera body 1. As the main mirror 52 continues to rotate toward the up position, the auxiliary mirror 53 rotates clockwise relative to the main mirror 52 against the force of the torque spring 34.
FIG. 2 shows the main mirror 52 in the up position. When the main mirror 52 is in the up position, the light 45 is not reflected by the main mirror 52 or the auxiliary mirror 53. The main mirror 52 is held in the up position by the mirror up lever 51. The mirror up lever 51 is rotated in the clockwise direction by the spring 19 which provides sufficient force to overcome the restoring force of the spring 20 on the main mirror 52. The auxiliary mirror 53 is held in the up position by the force of the torque spring 34, which biases the auxiliary mirror 53 toward the main mirror 52. The torque spring 34 biases the auxiliary mirror 53 and the main mirror 52 together by now urging the auxiliary mirror 53 to rotate in the clockwise direction around the shaft 31.
To return the main mirror 52 to the down position, a mirror down signal MD is sent to the motor 10. In response to the mirror down signal MD, the motor 10 rotates the pinion 58, which is mounted on the motor shaft 35 of the motor 10. The motor 10 thus drives the cam 55 in a counterclockwise direction through the gears 57, 56 and 54. The cam 55 engages the wheel 46 mounted on the mirror up lever 51. The cam 55 forces the mirror up lever 51 to rotate in a counterclockwise direction around the shaft 22 until the stop arm 51a engages the hook 50a the stop lever 50. The main mirror 52 returns to the down position due to the force of the spring 20 as the mirror up lever 51 is rotated in the counterclockwise direction by the cam 55.
FIG. 3 shows a block diagram of a control system for controlling the preferred embodiment of the camera shown in FIGS. 1 and 2. A controller 3 communicates with and controls the operation of a photography mode setting device 4, a photometry device 5, a film speed detection device 6, a display 7, a memory 8, a range measurement device 9, the motor 10, the release magnet 13, a front blind magnet 14 and a rear blind magnet 15. A release button 2 mounted to the camera body 1 activates a first release button switch 11 and a second release button switch 12 when the release button 2 is depressed.
In this preferred embodiment, the controller 3 is implemented as a single special purpose integrated circuit (e.g., ASIC) having a main or central processor section for overall, system-level control, and separate sections dedicated to performing various different specific computations, functions and other processes under control of the central processor section. It will be appreciated by those skilled in the art that the controller 3 can also be implemented using a plurality of separate dedicated or programmable integrated or other electronic circuits or devices (e.g., hardwired electronic or logic circuits such as discrete element circuits, or programmable logic devices such as PLDs, PLAs, PALs or the like). The controller 3 can also be implemented using a suitably programmed general purpose computer, e.g., a microprocessor, microcontroller or other processor device (CPU or MPU), either alone or in conjunction with one or more peripheral (e.g., integrated circuit) data and signal processing devices. In general, any device or assembly of devices on which a finite state machine capable of implementing the flowcharts shown in FIGS. 7 and 8 can be used as the controller. A distributed processing architecture is preferred for maximum data/signal processing capability and speed.
The photography mode setting device 4 outputs a selection signal to the controller 3 indicating a selected photography mode in which the camera should operate. The photography mores generally include one or more of an automatic photography mode, a manual photography mode, a stop-priority automatic photography mode and a shutter-speed priority automatic photography mode. The photography modes can also include any other known photography mode.
The photometry device 5 can be any one of the many photometry devices known in the art. The photometry device 5 measures a brightness of the light 45 from the photographic subject and outputs a brightness signal to the controller 3. The film speed detection device 6 detects the speed of the film in the camera and outputs a film speed signal to the controller 3.
Based on the photography mode signal, brightness signal and the film speed signal, the controller 3 determines an exposure time and an f-stop value for the film exposure cycle. The controller 3 displays the determined exposure time and the determined f-stop value to the operator on a display 7. The controller 3 also receives range signals from a range measurement device 9 indicating the subject range of the photographic subject. The range measurement device 9 can be any one of the many range measurement devices known in the art. The controller 3 controls the focus lens (not shown) based on the range signals to focus an image of the photographic subject on the film (not shown).
The controller 3 controls the release magnet 13 to disengage the stop lever 50 from the mirror up lever 51, thus causing the main mirror 52 to move from the down position to the up position. The controller 3 also controls the front blind magnet 14 to release the front blind of the shutter (not shown). The front blind opens to expose the film to the light 45 when released by the front blind magnet 14. To stop exposing the film, the controller 3 controls the rear blind magnet 15 to release the rear blind of the shutter. When the rear blind is released by the rear blind magnet 15, the rear blind closes and stops the light 45 from reaching the film.
To expose the film, an operator partially depresses the release button 2 mounted to the camera body 1 to close the first release button switch 11. The controller 3 starts a film exposure cycle and receives signals from the photography mode setting device 4, the photometry device 5 and the film speed detection device 6. The exposure time and the f-stop values are then displayed on the display 7.
As shown in FIG. 4, when the operator further depresses the release button 2 at a time T 0 , the second release button switch 12 is closed and a second release button switch signal SW2 goes high. FIG. 4 is a timing diagram indicating when the various signals are output by or input to the controller 3 in response to a first exposure condition. An exposure condition is represented by the amount of time the film is exposed to the light 45, or the exposure time. The exposure time is affected by many factors including the film speed, ambient light conditions, camera shutter speed, whether a flash is used or not, the type and magnification of the lenses in the camera, and the like. In the first exposure condition shown in FIG. 4, the time interval T is the exposure time.
The controller 3 inputs the high second release button switch signal SW2 from the second release button switch 12 and sends the release signal Mg1 (not shown in FIG. 4) to the release magnet 13, which releases the main mirror 52 to the up position as described above. Range measurements are no longer sent to the controller 3 by the range measurement device 9 since the main mirror 52 is in the up position and the light 45 is no longer reflected to the range measurement device 9.
Before the second release button switch 12 is closed, the front shutter blind and the rear shutter blind are mechanically held in a closed position and open position, respectively, by mechanical engagement stops (not shown). As shown in FIG. 4, after the second release button switch signal SW2 goes high, the controller 3 sets the signals to the front blind magnet 14 and the rear blind magnet 15 to high after first and second time delay intervals Δt1 and Δt2, respectively. The controller 3 sets the front blind magnet signal Mg2 and the rear blind magnet signal Mg3 to high, thus energizing the front and rear blind magnets 14 and 15. When energized, the front blind magnet 14 and the rear blind magnet 15 bind the respective front and rear shutter blinds. Once the front shutter blind is held in place by the front blind magnet 14 and the rear shutter blind is held in place by the rear blind magnet 15, the controller 3 releases the mechanical engagement stops.
At a time T FB , which is after a first time interval t1 has elapsed since the second release button switch signal SW2 went high at the time T 0 , the controller 3 releases the front blind by setting the front blind magnet signal Mg2 to the front blind magnet 14 low. The front blind magnet 14 thus releases the front blind. In response, the front blind opens the photo field, starting the film exposure. The photo field is the shutter opening, which is equivalent to the area of the film exposed to the light 45.
At a time T MS , which is after a fifth time interval t5 has elapsed since the second release button switch signal SW2 went high, the controller 3 sets the mirror down signal MD high. In response to the mirror down signal MD going high, the motor 10 begins to drive the main mirror 52 from the up position to the down position.
At a time T RB , which is after a second time interval t2 has elapsed since the controller 3 set the front blind signal Mg2 low at time T FB , the controller 3 releases the rear blind by setting the rear blind magnet signal Mg3 low. The rear blind magnet 15 releases the rear blind and the rear blind closes, ending the film exposure. The exposure time interval T is equal to the second time interval t2 plus the difference between third and fourth time delay intervals Δt3 and Δt4. The third time delay interval Δt3 is the time delay between the time T FB when the controller 3 sets the front blind magnet signal Mg2 low and when the front blind actually begins to move. Likewise, the fourth time delay interval Δt4 is the time delay between the time T RB when the controller 3 sets the rear blind magnet signal Mg3 low and the time when the rear blind actually begins to move.
The third time interval t3 is the time interval between the time T RB when the controller 3 sets the rear blind magnet signal Mg3 low and a time T SC when the rear blind actually closes the photo field. The fifth time delay interval Δt5 is a time interval or cushion between the time T SC when the rear blind closes the photo field and a time T MM when the main mirror 52 actually starts to move downward. The fifth time delay interval or cushion Δt5 ensures that the main mirror 52 does not interfere with the light 45 during the film exposure. A fourth time interval t4 is the time interval from the time T MS when the controller 3 sets the mirror down signal MD high to the time T MM when the main mirror 52 actually starts moving downward.
At a time T MD , the main mirror 52 reaches the down position. After a sixth time interval t6 elapses since the second release button switch signal SW2 went high, the controller 3 sets the range measurement start signal high. In response to the range measurement start signal going high, the range measurement device 9 starts measuring the range to the subject. The sixth time delay interval Δt6 is a time cushion which ensures that the range measurement device 9 does not start measuring the subject range before the main mirror 52 reaches the down position.
As discussed above, the time interval t5 is the time interval between the time T 0 when the second release button switch signal SW2 goes high and the time T MS when the controller 3 sets the mirror down signal MD high, and is determined by Equation (1):
t5=t1+t2+t3+Δt5-t4 (1)
Setting the mirror down signal MD low at the time T MS which occurs only after the time interval t5 elapses from when the second release button switch signal SW2 goes high, ensures that the main mirror 52 actually starts moving downward after the time cushion Δt5 has passed after the rear blind closes the photo field. Therefore, the main mirror 52 starts to move downward as soon as possible after the film exposure is completed.
FIG. 4 shows a first example, where the photographic conditions require the controller 3 to set the mirror down signal MD high at the time T MS , which is after the time T FB when the controller 3 sets the front blind magnet signal Mg2 low and before the time T RB when the controller 3 sets the rear blind magnet signal Mg3 low. FIG. 5 shows a second example, where the photographic conditions require the controller 3 to set the mirror down signal MD high at time T MS , which is before both the time T FB when the controller 3 sets the front blind magnet signal Mg2 low and before the time T RB when the controller 3 sets the rear blind magnet signal Mg3 low. FIG. 6 shows a third example, where the photographic conditions require the controller 3 to set the mirror down signal MD high at the time T MS , which is after the time T FB when the controller 3 sets the front blind magnet signal Mg2 low and after the time T RB when the controller sets the rear blind magnet signal Mg3 low.
Regardless of the photographic conditions, however, the controller 3 outputs the front and rear blind magnet signals Mg2 and Mg3 to the front blind magnet 14 and the rear blind magnet 15 and outputs the mirror down signal MD to the motor 10 such that the main mirror 52 always starts to move downward at time T MM , which is no later than the fifth time delay interval Δt5 after the rear blind closes the photo field at time T SC . This assures that the controller 3 is able to set the range measurement start signal high as soon as possible after the film exposure is completed.
FIG. 7 is a flowchart outlining a first preferred method for controlling the preferred embodiment of the camera of this invention. In step S10, the film exposure cycle starts when the first release button switch 11 closes and the first release button switch signal SW1 goes high. In step S20, the controller 3 starts a timer. In step S3O, the controller 3 inputs the film speed signal detected by the film speed detection device 6. In step S40, the controller 3 inputs the photography mode signal, which indicates the photography mode selected using the photography mode setting device 4. In step S50, the controller 3 inputs the brightness signal detected by the photometry device 5. In step S60, the controller 3 determines the shutter speed, the f-stop value and the time intervals t1, t2, t3, t4 and Δt5 based on the film speed signal, the photography mode signal and the brightness signal. The shutter speed, the f-stop value and the time intervals are determined by methods well known in the art. In step S70, the time intervals tl, t2 t3, t4 and Δt5 are stored in the memory 8.
In step S80, the controller 3 displace the shutter speed and the f-stop value on the display 7. In step S90, the controller 3 determines if the timer has reached a time t0. If time t0 has been reached, the control jumps to step S100 and the controller 3 enters a wait state. If time t0 has not been reached, the controller 3 determines in step S110 if the second release button switch signal SW2 is high. If the second release button switch signal SW2 is not high, control Jumps back to step S30. Otherwise, control proceeds to step S120.
In step 8120, the controller 3 retrieves the time intervals t1, t2, t3, t4 and Δt5 from the memory 8. In step S130, the controller 3 determines the time interval t5 as described above, and the time interval (t1+t2). In step S140, the controller 3 compares the time intervals t1 and t5. If the time interval t1 is greater than the time interval t5, control continues to step S150. Otherwise, control jumps to step S180. The condition where the time interval tl is greater than the time interval t5 is shown in FIG. 5.
In step S150, the controller 3 sets the mirror down signal MD high after the time interval t5 elapses after the second release button switch signal SW2 goes high. In step S160, the controller 3 sets the front blind magnet signal Mg2 low after the time interval tl elapses after the second release button switch signal SW2 goes high at the time T 0 . In step S170, the controller 3 sets the rear blind magnet signal Mg3 low after the time interval (t1+t2) elapses after the second release button switch signal SW2 goes high at the time T 0 . Control then jumps to step S210
If the time interval tl is not greater than the time interval t5, i.e. the condition shown in FIG. 4, control jumps from step S140 to step S180. In step S180, the controller 3 sets the front blind magnet signal Mg2 low after the time interval tl elapses after the second release button switch signal SW2 goes high at the time T 0 . In step S190, the controller 3 sets the mirror down signal MD high after the time interval t5 elapses after the second release button switch signal SW2 goes high at the time T 0 . In step S200, the controller 3 sets the rear blind magnet signal Mg3 low after the time interval (t1+t2) elapses after the second release button switch signal SW2 goes high at time T 0 . Control then continues to step S210. In step S210, the controller 3 outputs the range measurement start signal after the time interval t6 elapses after the second release button signal SW2 goes high at the time T 0 . In response, the range measurement device 9 begins measuring the range of the subject. Following step S210, the control of the single lens reflex camera continues according to well known methods.
FIG. 8 is a flowchart outlining a second preferred method for controlling of the preferred embodiment of the camera of this invention. Steps S10 through S130 are identical to steps S10 to S130 of the first preferred embodiment of the method, except after step S130, control jumps to step S300. In step S300, the controller 3 compares the sum of the time interval t1 and the time interval t2 (t1+t2) to the time interval t5. If the sum (t1+t2) of the time intervals t1 and t2 is greater than the time interval t5, control continues to step S310. Otherwise, control jumps to step S340. The exposure condition where the sum (t1+t2) of the time intervals t1 and t2 is greater than time t5 is shown in FIG. 5.
in step S310, the controller 3 sets the mirror down signal MD high after the time interval t5 elapses after the second release button switch signal SW2 goes high at the time T 0 . In step S320, the controller 3 sets the front blind magnet signal Mg2 low after the time interval t1 elapses after the second release button switch signal SW2 goes high at the time T 0 . In step S330, the controller 3 sets the rear blind magnet signal Mg3 low after the time interval (t1+t2) elapses after the second release button switch signal SW2 goes high at the time T 0 . Control then Jumps to step S370.
If the sum (t1+t2) of the time intervals t1 and t2 is not greater than the time interval t5, i.e. the condition shown in FIG. 6, control Jumps from step S300 to step S340. In step S340, the controller 3 sets the front blind magnet signal Mg2 low after the time interval t1 elapses after the second release button switch signal SW2 goes high at the time T 0 . In step S350, the controller 3 sets the rear blind magnet signal Mg3 low after the time interval (t1+t2) elapses after the second release button switch signal SW2 goes high at the time T 0 . In step S360, the controller 3 sets the mirror down signal MD high after the time interval t5 elapses after the second release button switch signal SW2 goes high at the time T 0 . Control then continues to step S370. In step S370, the controller 3 outputs the range measurement start signal after the time interval t6 elapses after the second release button signal SW2 goes high at the time T 0 . In response, the range measurement device 9 begins measuring the range of the subject. Following step S370, the control of the single lens reflex camera continues according to well known methods.
While this invention has been described above with reference to specific embodiments, this description of the specific embodiments is illustrative only and is not to be construed as limiting the scope of the invention. Various other modifications and changes may occur to those skilled in the art without departing form the spirit and scope of the invention as set forth in the following claims.
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A single lens reflex camera which has improved high-speed photography operation. The mirror in the single lens reflex camera is controlled to reduce the time delay between a first time when the rear shutter blind closes the photo field and a second time when the mirror reaches the down position. The time delay is reduced by initiating the mirror down movement at least before the rear shutter blind closes the photo field and possibly before the front shutter blind even opens the photo field, depending on the exposure conditions.
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CROSS REFERENCE TO RELATED APPLICATION
The present application claims the priority benefits of International Patent Application No. PCT/EP2011/064242, filed on Aug. 18, 2011, and also of German Patent Application No. DE 10 2010 037 229.3, filed on Aug. 30, 2010, which are hereby incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
The invention relates to a suspension device for a rail, in particular a rail of an overhead conveyor or a lifting gear, having a tensile element which includes a threaded rod and at least one connection part screwed thereto, and having a securing element which prevents the screw connection between the threaded rod and the connection part from being loosened.
A suspension for a crane rail on a supporting mechanism in the form of a cover or a cover profile is known from German patent document DE 10 2005 040 421 B4. A crane can travel along the crane rail via travelling mechanisms. The crane rail is attached to the supporting mechanism via several suspensions spaced apart from each other in the longitudinal direction of the crane rail. Each of the suspensions consists essentially of an upper attachment part having a first threaded sleeve, a threaded rod and a lower attachment part having a second threaded sleeve. The upper attachment part is attached to the supporting mechanism and the lower attachment part is attached to the rail to be suspended. The lower attachment part is suspended on the upper attachment part via the threaded rod whose opposite ends are screwed into the first threaded sleeve and second threaded sleeve. By using a threaded rod in conjunction with the threaded sleeves, the vertical length of the complete suspension can easily be adapted to the local conditions in order to thus suspend the crane rail in the desired orientation and to distribute the load on the suspensions. In order to protect the connection between the threaded rod and the lower attachment part and the upper attachment part against unscrewing, a spring connector is provided in each case and comprises a pin part and a spring part. For this purpose, the pin part is inserted through a through-going elongate mounting hole in the respective threaded sleeve and a through-going elongate mounting hole in the threaded rod, whilst the spring part lies against the respective threaded sleeve on the outside. The pin part is thus prevented from sliding out of the elongate mounting holes. These suspensions are also configured to swing since this ensures that the crane rails are oriented automatically or come into the condition of equilibrium, i.e., there is no substantial bending load in the tensile element. The swinging suspension is effected via ball-and-socket joint bearings.
So-called turnbuckles are known from the German utility model DE 299 14 578 U1 and from the German laid-open document DE 101 31 183 A1 and are also used for the suspension of rails of overhead monorails in the mining industry. These turnbuckles consist essentially of a central turnbuckle sleeve and two tensioning eyelets laterally connected thereto. The tensioning eyelets each consist of an eyelet to accommodate hooks, bolts or cables, and a shaft, disposed on the eyelet, having an outer thread. The turnbuckle sleeve is formed either as an elongate frame or as a sleeve, on the opposite ends of which are disposed inner threads in the form of nuts. The shafts of the tensioning eyelets are screwed into these nuts. The outer thread of the shafts run in opposite directions which means that the eyelets of the tensioning eyelets can be moved towards each other or away from each other by rotating the turnbuckle sleeve relative to the two tensioning eyelets. In the case of one of the two turnbuckles, provision is also made that the two tensioning eyelets can be blocked with respect to the turnbuckle sleeve. For this purpose, several grooves are disposed in the shafts which extend in each case in the longitudinal direction of the shafts. Mounted on the tensioning eyelets is in each case a resiliently biased pin which can be moved from a pulled-back rest position into a blocking position to block the turnbuckle, the pin protruding into one of the grooves in this blocking position. Such turnbuckles are fundamentally different from the design of the previously described suspension devices since these do not comprise a central threaded rod but rather only two tensioning eyelets having threaded shafts.
SUMMARY OF THE INVENTION
The present invention provides a suspension device for a rail, in particular a running rail of an overhead conveyor or a lifting gear, which allows simplified and secure assembly.
In accordance with an embodiment of the invention, in the case of a suspension device for a rail, in particular a rail of an overhead conveyor or a lifting gear, having a tensile element which includes a threaded rod and at least one connection part screwed thereto, and having a securing element which prevents the screw connection between the threaded rod and the connection part from being loosened, simplified and secure assembly is achieved by virtue of the fact that the securing element engages with a pin part into a groove in the assembled state, said groove being disposed in the threaded rod. The groove in the threaded rod results in considerably simpler assembly since the securing element can be easily inserted after the groove has been aligned flush with the opening, without a bore in the threaded rod and/or the connection part having to be provided. There is no need for any length-dependent mechanical working during assembly. The groove results only in a small reduction in cross-section in the threaded rod and barely reduces its strength.
In terms of the invention, a threaded rod is understood to mean a bar having an outer thread which has no specially shaped surfaces or regions for engaging a tool, such as for example a hexagonal head. The outer thread is provided at least in the region of the opposite ends of the threaded rod but typically extends over the entire length of the threaded rod. The outer thread also has just one pitch direction. Since the threaded rod is simply designed in this manner, it is particularly suitable for use in the suspension device since the length of the threaded rod to be used can frequently only be determined on site when suspending the rails. A threaded rod can then be simply shortened to the required length on site. The threaded rods can thus be produced in an advantageous manner in graded standard lengths. An appropriate simple length adjustment can not be effected in the case of turnbuckles since the lengths of the shafts of the tensioning eyelets are adapted to the length of the turnbuckle sleeve.
The securing element acts and is supported in a reliable manner by virtue of the fact that the securing element engages into the groove with the pin part through an opening in the connection part in the assembled state.
From a manufacturing point of view, it has proven to be convenient for the groove to extend in the longitudinal direction of the threaded rod.
Shortening the threaded rods and also procuring the threaded rods is facilitated by virtue of the fact that the groove extends in the longitudinal direction of the complete threaded rod.
In a particular embodiment, provision is made that the securing element is formed in the manner of a two-spring connector having two opposing limbs. In this case, the pin part is shortened compared with a commercially available two-spring connector, since it only has to be inserted into the groove in the assembled state. The securing element is thus formed in a manner allowing it to be produced simply and the sleeve-shaped connection parts only need to be provided with the bores for use of the two-spring connector and do not have to be subjected to any additional, costly, mechanical working.
The pin part is secured in the groove via the limbs of the two-spring connector which, in the assembled state of the securing element, engage behind the sleeve-shaped connection part, as seen in the direction of the pin part.
In a particular manner, provision is made that the opening is formed as an elongate hole, whose longitudinal extension is oriented in the longitudinal direction of the threaded rod, and the pin part is formed in a u-shaped manner such that a plane spanned by the pin limbs is oriented at right angles to a plane spanned by the limbs of the securing element and includes the longitudinal axis of the threaded rod. In other words, the pin part is formed in a u-shaped manner as seen transversely with respect to its insertion direction and as seen transversely with respect to the longitudinal direction of the threaded rod. The securing element, in particular its pin part, is hereby prevented from being able to rotate in the opening and in the groove. Therefore, the limbs also do not slide down from the threaded sleeve portion even when there is a mechanical influence from the outside.
In a particular embodiment, provision is made that the tensile element includes, in addition to the threaded rod, a lower connection part and an upper connection part.
In a typical usage mode, in the assembled state the rail is suspended on the lower connection part and the upper connection part is attached to a supporting element.
Further features, details and advantages of the invention are provided in the subordinate claims and the following description of exemplified embodiments shown in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a single girder suspension crane,
FIG. 2 shows an enlarged portion of the region Z of FIG. 1 ,
FIG. 3 shows an enlarged portion of FIG. 2 , taken from the region of a securing element in the manner of a two-spring connector,
FIG. 4 shows a sectional view of FIG. 3 ,
FIG. 5 shows a perspective view of the securing element of FIG. 3 ,
FIG. 6 shows a front view of the securing element of FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a plurality of suspension devices 1 in conjunction with a single girder suspension crane. By means of the suspension devices 1 , rails 2 , which extend substantially horizontally and are profiled in a downwardly open c-shape, are suspended on supporting elements 3 or further rails 2 . The supporting elements 3 are formed as I-beams. Since the present exemplified embodiment relates to a single girder suspension crane, two first rails 2 a , which extend in a substantially horizontal manner in parallel with and at a spaced disposition with respect to each other, are provided and are used as running rails of the single girder suspension crane, and a second rail 2 b , which forms a crane rail, which is oriented substantially transversely with respect to the first rails 2 a and can travel along the first rails 2 a . For this purpose, the second rail 2 b is suspended via two suspension devices 1 in each case on a travelling mechanism which is not shown and can travel along the first rails 2 a . A lifting gear 4 such as a chain or cable hoist is generally suspended on the second rail 2 b and can travel along the second rail 2 b by means of a further travelling mechanism, not shown. The lifting gear 4 can be controlled by a pendant switch 5 suspended on the lifting gear 4 .
FIG. 2 shows an enlarged portion of the region Z of FIG. 1 which relates to a suspension device 1 . The suspension device 1 consists essentially of a lower attachment part 6 , a tensile element 7 and an upper attachment part 8 . The rail 2 a is suspended on the tensile element 7 of the suspension device 1 by means of the lower attachment part 6 . The tensile element 7 is attached to the supporting element 3 , which is formed in this case as a concrete slab, via the upper attachment part 8 . In order to be able to provide the rail, which is C-shaped and open at the bottom, with suspension devices 1 at any location in its longitudinal direction, it comprises in the upper region an upwardly protruding web 2 c extending in the longitudinal direction of the rail 2 a , which web extends away from the rail 2 a and thus upwards in a v-shaped manner. The lower attachment part 6 is formed in a clamp-like manner and engages around the upwardly widening web 2 c . The tensile element 7 is attached to the upper end of the lower attachment part 6 opposite the web 2 c . Depending upon the local conditions and the manner of using the rail 2 a , this attachment can be formed in a rigid or swinging manner. A rigid connection can be effected for example via a corresponding screw connection; a swinging connection can be provided via a ball coupling in the region of the end of the tensile element 7 and a corresponding receptacle in the region of the lower attachment part 6 .
The rod-shaped tensile element 7 includes a lower connection part 7 a , a threaded rod 7 b and an upper connection part 7 c . The lower and upper connection parts 7 a , 7 c are formed substantially as threaded sleeves 7 d at their end facing the threaded rod 7 b and are provided at their opposite ends for example with an outer thread in the case of a rigid attachment or with a half-ball coupling part 7 e (see FIG. 3 ) for the articulated connection to the lower attachment part 6 or upper attachment part 8 . Designing the tensile element 7 with a threaded rod 7 b is advantageous in that depending upon the local conditions the threaded rods 7 b can be shortened to the desired suspension length and then assembled into the required length by screwing the lower connection part 7 a and the upper connection part 7 c to the tensile element 7 . In order to secure the screw connection between the lower connection part 7 a and the threaded rod 7 b as well as the upper connection part 7 c and the threaded rod 7 b , an upper securing element 9 b and a lower securing element 9 a are provided. The lower and upper securing elements 9 a , 9 b are formed in each case in the manner of a two-spring connector.
FIG. 3 shows an enlarged view of an upper connection part 7 c which is engaged with a threaded rod 7 b and is secured via an upper securing element 9 b . The upper connection part 7 c is divided into a lower threaded sleeve portion 7 d and an upper half-ball coupling part 7 e . The half-ball coupling part 7 e and the threaded sleeve portion 7 d are formed in one piece and the curved surface of the half-ball coupling part 7 e faces the threaded sleeve portion 7 d . The half-ball coupling part 7 e is part of a ball-and-socket joint bearing whose complementarily formed reception shell is disposed in the upper attachment part 8 of the suspension device 1 . The threaded sleeve portion 7 d is provided with an inner thread, into which the upper end of the threaded rod 7 b is screwed with its outer thread. In order to secure the threaded rod 7 b in the threaded sleeve portion 7 d , the wall of the threaded sleeve portion 7 d is provided with an opening 10 , into which a pin part 9 c of the upper securing element 9 b can be inserted. The opening 10 passes through the wall of the threaded sleeve 7 d which means that the pin part 9 c of the upper securing element 9 b impinges upon the outer periphery of the threaded rod 7 b . Furthermore, the threaded rod 7 b comprises a groove 11 extending in its longitudinal direction L, wherein the pin part 9 c of the upper securing element can be inserted into this groove. The threaded rod 7 b and the upper connection part 7 c are hereby effectively prevented from rotating with respect to each other.
It can also be seen that, in a configuration typical for a two-spring connector, the pin part 9 c becomes two helical regions 9 d disposed in a symmetrical manner with respect to each other, and is formed in this case to increase the spring force as a double coil having two windings. Each of the two helical regions 9 d becomes a limb 9 e , as seen starting from the pin part 9 c , which limb abuts against the peripheral surface the cylinder-shaped threaded sleeve portion 7 d from the outside when the upper securing element 9 b is in the assembled state. As seen from the helical region 9 d , each of the limbs 9 e becomes a curved region 9 f , wherein the curved region 9 f follows the peripheral surface of the threaded sleeve portion 7 d and then curves inwards. Since the curved region 9 f lies against the peripheral surface of the threaded sleeve portion 7 d in the region of approximately one eighth of the periphery of the threaded sleeve portion 7 d and, as seen from the direction of the pin part 9 e , resiliently engages behind the threaded sleeve portion 7 d and the two curved regions 9 f form a counter-bearing for the pin part 9 c inserted in its longitudinal direction into the opening 10 and groove 11 and thus in the radial direction of the threaded rod 7 b . The longitudinal extensions of the pin part 9 c and the limb 9 e extend substantially in parallel with and at a spaced disposition with respect to each other. It can also be seen from FIG. 3 that the pin part 9 c is formed as a whole in a U-shaped manner since there follows two helical regions 9 d each in the manner of a two-spring connector.
The above description also applies to the identically formed lower connection part 7 a and the associated lower securing element 9 a.
FIG. 4 illustrates a sectional view of FIG. 3 , taken from the region of the threaded sleeve 7 d with a threaded rod 7 b also screwed-in. It can be seen that the pin part 9 c protrudes through the opening 10 in the threaded sleeve portion 7 d into the groove 11 in the threaded rod 7 b . Only a single groove 11 is provided in the threaded rod 7 b . It would also be fundamentally possible to provide several grooves in order to achieve a more precise adjustment of the length of the tensile element 7 . However, practice has shown that one groove 11 is sufficient since length adjustments of the tensile element 7 in the millimeter range are already possible using this one groove. FIG. 4 also shows that the limb 9 e of the upper securing element 9 b in a curved region 9 f follows the contour of the peripheral surface of the threaded sleeve portion 7 d . This curved region 9 f is then followed by an approximately 90° bend outwards which issues into an opening region 9 g . By way of these two opening regions 9 g , extending in opposite directions, it is easier to fit the securing element onto the threaded sleeve portion 7 d against the spring force of the helical regions 9 d.
The securing element 9 is also dimensioned such that it can be fitted onto the threaded sleeve portion 7 d laterally and in this case the pin part 9 c then already protrudes into the opening 10 but not yet into the groove 11 , since this is not yet aligned with the opening 10 . Upon rotation of the threaded rod 7 b relative to the threaded sleeve portion 7 d , the result—when the groove 11 is aligned with the opening 10 —is that the pin part 9 c slides automatically into the groove 11 by reason of the spring force of the securing element 9 . This is a great advantage during assembly and reduces the assembly time.
FIG. 5 shows a perspective view of a lower or upper securing element 9 a , 9 b . The u-shaped formation of the pin part 9 c can be seen particularly clearly in this view. In a corresponding manner, the opening 10 in the threaded sleeve 7 d is not formed as a circular bore but rather as an elongate hole. The u-shaped region of the pin part 9 c thus comprises a web part 9 i , which in the assembled state rests in the base of the groove 11 , and respectively opposing lower and upper web limbs 9 h and 9 j adjoining thereto and extending in a substantially mutually parallel manner.
It is also fundamentally possible for the opening 10 to adjoin the edge facing the threaded rod 7 b and thus to have only the form of a recess open in the direction of the threaded rod 7 b.
FIG. 6 shows a view from FIG. 5 in the direction of the free end of the pin part 9 c . It can be seen in particular that the doubled helical regions 9 d are to be wound starting from the U-shaped pin part 9 c from the top or bottom inwardly and towards each other so that despite the doubled helical regions 9 d , the limbs 9 e which are oppositely arranged in relation to the threaded sleeve portion 7 d , lie in a plane and thus the pin part 9 e is securely held in the opening 10 and groove 11 . It can also be seen that the pin part 9 c is formed to be shorter than a commercially available two-spring connector since it is inserted only into a groove 11 and does not have to be inserted through the through-going bore—otherwise typically provided—in the threaded rod.
In this exemplified embodiment, the suspension device 1 is described in conjunction with a single girder suspension crane. Of course, this new suspension device 1 is also suitable for suspending rails 2 , 2 a , 2 b of double girder suspension cranes and monorails as well as rails 2 , 2 a , 2 b on which travelling mechanisms of overhead conveyors or lifting gears can travel. The securing element is also described as a two-spring connector. It is by all means possible also to form this as a single spring connector. Typically, the threaded rod 7 b has an outer thread over its entire length. It is also feasible for the threaded rod 7 b to have an outer thread only at its opposite end regions. Of course, it is also feasible to provide, in addition to the single groove 11 , a second groove 11 opposite thereto. Third and fourth grooves distributed evenly over the periphery are also feasible. Increasing the number of grooves 11 means that the effective length of the threaded rod 7 b can be adjusted in a more precise manner.
LIST OF REFERENCE NUMERALS
1 Suspension device
2 Rail
2 a First rails
2 b Second rails
2 c Web
3 Supporting element
4 Lifting gear
5 Pendant switch
6 Lower attachment part
7 Tensile element
7 a Lower connection part
7 b Threaded rod
7 c Upper connection part
7 d Threaded sleeve portion
7 e Half-ball coupling part
8 Upper attachment part
9 a Lower securing element
9 b Upper securing element
9 c Pin part
9 d Helical region
9 e Limb
9 f Curved region
9 g Opening region
9 h Lower pin limb
9 i Pin web
9 h Upper pin limb
10 Opening
11 Groove
L Longitudinal direction
Z Enlargement region
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A suspending device for a rail, in particular a rail of an overhead conveyor or lifting gear, with a tensile element, which comprises a threaded rod and at least one connecting part that is screwed to the latter, and with a securing element, which secures the screw connection between the threaded rod and the connecting part against loosening. The suspending device for a rail, in particular a running rail of a suspended conveyor or lifting gear, allows simplified and secure mounting in that the securing element engages in a groove with a pin part in the assembled state, with the groove being disposed in the threaded rod.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains generally to lubrication of specified substrates and, more particularly, to an improved lubrication composition and method of its application. The improved, wear-resistant, low friction substrates have a coating provided by such composition, said substrates including sound and video recordings such as gramophone or phonographic records, video discs and the like.
2. Description of the Prior Art
Lubrication of various substrates, and particularly of substrates upon which recorded signals have been stored and from which said signals can be recalled by dynamic means, has not been generally recognized and where attempts have been made to lubricate such substrates they have not proven fully satisfactory. In particular, substrates possessing this special problem include synthetic, natural and combinations of thermoplastic materials and include resins, shellac, polyvinyl acetate, polyvinyl chloride, cellulose acetate, cellulose nitrate and their derivatives as well as numerous other compositions that are generally formed through various press moulding means into photographic records or discs as well as similar thermoplastic structures having trackable groove contours and reproducing recorded monaural and stereophonic and video signals therefrom.
As is generally known, a phonograph cartridge serves to convert the variations on the walls of the grooves of a phonograph record into electrical signals whereby the variations or wavy pattern on the grooves determine the frequency and the amplitude of the sound vibrations. The cartridge includes a stylus or pickup needle usually in the form of a diamond of sapphire which generally has a hemispherical or ellipsoidal tip which rides or dips into the record groove and moves in response to variations of the pattern of said groove. The stylus, in turn, is generally attached to an armature which moves with the stylus to induce variations in an electrical or magnetic field in response to the stylus movement. This generates an electrical signal representative of the groove configuration which may then be amplified and used to drive speakers. Again, the stylus is caused to mechanically vibrate in response to the variations in amplitude and frequency of the undulations of the record groove wall which comprise the recorded signal.
A stylus has to track a plurality of evenly spaced groove contours with recorded signals on the order of between 15-20 and 20,000 Hz. Moreover, with the introduction of discrete four-channel record systems or quadrasonic systems, a stylus must faithfully track grooves with recorded signals to cause vibrations of up to 50,000 Hz. As the stylus rides in the record groove, the relatively hard stylus wears away the relatively soft thermoplastic material of the record forming the groove. There has been heretofore no easy solution to alleviate the problem of record wear caused by the stylus riding in the groove contour of such recordings.
The deterioration of the sound quality of records with increase in the number of plays through wear of their tracks by repeated uses results in records becoming unusable and often being discarded within a short period of time. A number of factors are responsible for wear including the general wear through abrasive and adhesive wear mechanisms to an extent proportional to stylus loading. This loading is not only the deadweight stylus load on the record which may range from about 1 gram to 4 grams but also includes dynamic inertial forces caused by stylus mass and the frequency of stylus directional changes as it tracks the groove undulations. As known, reduction of deadweight load and stylus mass lowers the rate of groove wear but wear and the consequent loss of playback fidelity cannot be entirely eliminated. At any rate, most attempts of the prior art via record cleaners or alleged lubricates have simply resulted in cleaning only or depositing chemical films onto records without being successful in that such materials generally reduce the record fidelity due to rapid groove wear if cleaned or to hydrodynamic damping of the stylus tracking if oily substances are deposited. Further, it is often observed in the use of these materials that the noise level is increased due mainly to dust captured along with the formation of a tacky deposit upon the stylus. Moreover, it has been observed that attempts to use powdered solid lubricants such as graphite, molybdenum disulfide and the like have several disadvantages for they do not only reduce fidelity but also increase noise due to particulate interference in the record grooves.
In general, various silicones and hydrocarbon waxes and certain fluorinated telomeric compositions have been used as lubricants in sundry applications. U.S. Pat. Nos. 3,067,262 and 3,345,424 discuss the manufacture of such fluorinated telomers. U.S. Pat. No. 3,067,262 discloses tetrafluoroethylene telomerized with trichlorotrifluoroethane whereby moderately high molecular weight products are produced. The patent discloses further that in order to obtain a wax-like product, a second active telogen must be included in the telomerization process. In general, such active telogens are hydrogen-containing compounds including tertiary hydrocarbons, aliphatic alcohols, divalent sulfur compounds, aliphatic tertiary amines, aliphatic ethers, carbonyl compounds and dialkyl phosphites. Since these active telogens contain hydrogen, the telomer products contain significant amounts of hydrogen, e.g., from 0.05 to 2% by weight.
U.S Pat. No. 3,345,424 discloses an improvement over the telomeric compositions of U.S. Pat. No. 3,067,262 in that the improved compositions have no hydrogen and are of a lower melting point. In effect, the improved compositions are derived from the products obtained by telomerization of tetrafluoroethylene with certain haloalkanes. In fact, the compositions are made by the chlorination or fluorination of certain fractions of telomer iodide mixtures whereby the iodine is replaced by chlorine or fluorine. The utility of these compositions is found in their application as a general dry lubricant, protective surface treatment, oil and water repellents, and a mold release and antistick composition.
In U.S. Pat. No. 3,652,314 to Castner, a method is disclosed for renewing, resurfacing and preserving a phonograph record by the steps of coating the record with a composition consisting essentially of acrylic polymer, polyethylene emulsion, a detergent, an ether and water, brushing the composition into the grooves, removing any excess, drying and playing the phonograph record.
In U.S. Pat. Nos. 3,862,860 and 3,954,637, a method and composition are disclosed for improving lubricity, abrasion resistance, and lowering the coefficient friction of substrates such as photographic films, magnetic surfaces and other recording elements by applying to such substrates a solution comprising tetrafluoroethylene telomer and a copolymer of vinyl chloride and trifluorochloroethylene in a volatile solvent, drying and removing the excess, and substrates so lubricated. In effect it was shown that the combination of a lubricant, viz., tetrafluoroethylene telomer and non-lubricant, viz., poly(trifluorochloroethylene-co-vinyl chloride) provides a coefficient of friction below that of the lubricant per se.
SUMMARY OF THE INVENTION
The present invention, which provides a wear-resistant lubricous coating for phonograph records and the like is a solution consisting essentially of low-molecular weight fluorocarbon telomers, an antistatic agent, and a volatile solvent therefor. Generally, the telomers have a maximum average molecular weight of about 3700. The composition can be easily applied to any number of thermoplastic substrates generally used in the record or gramophone trade, upon which are recorded signals in the form of undulations or grooves, to provide a glossy coating that promotes a marked increase in lubrication properties thereof.
Accordingly, an object of the present invention is to provide a method which produces a phonograph record element having low friction characteristics.
An object of this invention is to provide a method and phonograph record article or similar plastic substrate having a greater extension of its playing life without any initial significant loss of frequency response or amplitude fidelity.
Another object of the present invention is to provide a composition and method which impart wear resistance to phonograph elements through a protective coating capable of bearing a momentary high load without any significant reduction in playing functionalities throughout a substantial number of plays.
Yet another object of the present invention is to provide a composition and method which produce a coating film on phonographic recording elements and the like which enhance the surface qualities of such elements, such as static discharge and appearance.
Still another object of the present invention is to provide a method by which the composition of the instant invention may be conveniently applied.
Another object of this invention is to produce a treated phonograph record or disc which after a large number of plays does not result in any substantial particle build-up on the stylus.
Still another object of the present invention is to provide a coated record surface having long life, great wear resistance and low surface friction.
Yet still another object of the present invention is to provide a phonograph record having both high lubricity and resistance to increase in noise and harmonic distortion through normal playings.
A further object of the present invention is to provide an improved, thin lubrication system for groove-tracking record elements having recorded audio and/or video signals stored thereon and which can be subjected to dynamic tracking means to render the signals recorded thereon.
These and other objects of the present invention will become apparent from the following description and discussion.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, a composition is formed and is capable of imparting to various substrates, including a phonograph record, a low coefficient of friction, said composition consisting essentially of low-molecular weight telomers of fluorocarbons, and especially telomers of tetrafluoroethylene, an antistatic agent, and a solvent therefor. The telomers of the preferred embodiment to be hereinafter described are soluble in the organic solvent and for the most part do not exist in the composition herein contemplated as particles or as colloidal suspensions. In effect, the composition of the present invention is generally an essentially homogeneous solution, that is, it exhibits a uniform composition throughout its entire volume.
As used herein the term "telomers" include homotelomers and cotelomers and the term "telomerization" includes homotelomerization, cotelomerization, and the term "low molecular weight telomers" means telomers having a maximum average molecular weight of about 3700.
The term "substrate" as used herein embraces various surfaces of articles to be treated by the compositions and refer to plastic substrates, metal substrates, combination of plastic and metallic substrates, and in particular to playing elements of synthetic, natural and combinations of thermoplastic materials and include resins, shellac, polyvinyl esters such as polyvinyl acetate, polyvinyl benzene, polyvinyl chloride, cellulose acetate, cellulose butyrate, cellulose nitrate, their derivatives as well as copolymers and blends thereof. In particular, the term "substrates" include those surfaces which are made of numerous compositions that are generally formed through various press molding means into phonographic records or discs as well as similar thermoplastic structures having trackable groove contours thereon which when used in conjunction with certain dynamic means such as styli are capable of following said contours and reproducing recorded monaural and stereophonic and video signals therefrom.
One group of preferred telomers of this invention may be represented by the general structural formula:
R--(CF.sub.2 CF.sub.2).sub.a X (I)
wherein R is a haloalkyl containing one to four carbon atoms, X is a member selected from the group consisting of chlorine, iodine, and fluorine and a is an integer from about 6 to about 16. A preferred composition of the present invention is one where X is chlorine or fluorine and the radical R is a group having the structural formula: ##STR1## wherein R 1 and R 2 each independently represent perfluoroalkyl and monochloroperfluoroalkyl wherein each alkyl moiety has one to four carbon atoms. This tetrafluoroethylene telomer has been available commercially under the trade name MP-51. In general, these telomers are completely halogenated telomers, in that they do not contain hydrogen, and have a molecular weight range of about 800 to about 1800. A fuller description of these particular telomer compositions is given in U.S. Pat. No. 3,345,424.
Other groups of related and preferred telomers are those that have the formula:
R'(CF.sub.2 --CF.sub.2).sub.b Y (II)
wherein R' is a hydrogen-containing moiety of a telogen, said telogen being a member selected from the group consisting of tertiary hydrocarbons, aliphatic alcohols, divalent sulfur compounds, aliphatic tertiary amines, aliphatic ethers, aliphatic carbonyl compounds, dialkylamides, and dialkyl phosphites, and Y is chlorine or a chlorofluoroalkyl wherein the alkyl portion has one to two carbon atoms and where b is an integer from about 3 to about 50. In general, these tetrafluoroethylene telomers, as distinguished from the telomers mentioned above, contain hydrogen, e.g., from 0.05 to 2% by weight.
Hydrogen-containing tetrafluoroethylene telomers are available under the trademark Vydax AR. These telomers have a maximum average molecular weight of about 3700, a specific gravity of about 2.16, a melting point of 300° C., and are generally furnished at various concentrations including a 20% solid suspension in trichlorotrifluoroethane. These particular telomer compositions are generally described in U.S. Pat. Nos. 2,540,088 and 3,067,262.
It has been found possible to separate from Vydax AR a somewhat lower molecular weight fraction by the conventional expedients of extracting, decanting, filtering, or centrifuging. By such methods, a selected fraction is obtained where, in the above-mentioned structural formula II, b has a value of about 3 to about 8. In general, lack of turbidity or presence of clarity of the solution is found to be a good indication of such a selected fraction. The average molecular weight of this lower fraction is between about 400 and 900, the fraction being readily soluble in the herein described organic solvents. The melting point of this fraction is generally less than 120° C.
For the hydrogen-containing telomers, such as Vydax AR, it has been found, for certain preferred embodiments that the use of the lower molecular weight fraction, that is, the fraction having a molecular weight below about 900, results in favorable properties for certain end uses herein disclosed. Thus, during stylus tracking on a stereo or quadraphonic record coated with a composition of the present invention, there is observed no substantial wear particle build-up on the stylus as compared to an untreated record. Further, there is no actual clogging or interference of the groove undulations even in a single alternation with a record at frequencies up to and including 45,000 Hz., which may occupy no more than about 0.0008 linear inches of space along the record groove.
In general, the concentration of the above-mentioned telomers can vary over a relatively broad range, but a range of about 2.0 weight percent to about 0.001 weight percent of the total weight of the composition has been found most effective. In practice, a concentration of between about 0.15 to about 0.005 weight percent has been found to be satisfactory for treating phonograph records.
The use of an antistatic agent renders the solutions herein effective from a practical standpoint in that such compositions eliminate or substantially reduce the electrostatic charge on phonograph record surfaces to which said compositions are applied, thereby reducing the attractive forces which induce the migration of dust and other undesirable foreign particles to the record surface. The electrostatic charge can result from several causes, but is especially noticeable upon removing a record from its protective jacket, wiping its surface with cloth or brush, and otherwise contacting or buffing the record surface. Representative of one group of preferred antistatic agents found highly effective in the compositions herein are the tertiary amines, including the dialkanolamines. These amines have been found to be compatible in terms of solubility with the solvents herein disclosed.
The particular dialkanolamines found highly suitable for the herein described composition may be represented by the general structural formula: ##STR2## wherein R" is an alkyl having about four to about twenty carbon atoms. These dialkanolamines have a molecular weight of about 150 to about 400. Illustrative of such dialkanolamines are N,N-bis(2-hydroxyethyl)dodecylamine, N,N-bis(2-hydroxyethyl)tetradecylamine and N,N-bis(2-hydroxyethyl)tetradecylamine. The dialkanolamines may be readily made by conventional chemical techniques known in the art. A process for preparing various N-alkyl substituted N,N-dialkanolamines is desclosed in U.S. Pat. No. 2,541,088.
Other suitable and preferred antistatic agents may be readily incorporated into the compositions herein. Such agents should be soluble in the solvent employed. Thus other antistatic agents include fatty quaternary ammonium compounds, fatty esters, phosphate esters and polyethylene glycols. The concentration of the antistatic agent can vary over a wide range so long as it is effective in reducing or removing electrostatic charge. In general, a concentration of about 1.0 to about 0.001 weight percent based on the total composition has been found to be most effective.
The solvents utilized with the compositions of the present invention are essentially organic and are generally halogenated. While certain solvents are useful, provided there is no adverse effect upon the substrate, trichlorotrifluoroethane is particularly desirable as having suitable organic dissolution powers, high volatility, and essentially no physical or chemical effect on the substrate. The trichlorotrifluoroethane can be either isomer, i.e., it may be 1,1,1-trichloro-2,2,2-trifluoroethane or 1,1,2-trichloro-1,2,2-trifluoroethane. Certain other solvents can also be incorporated with trichlorotrifluoroethane to the extent that the combination has no more adverse effect on the substrate than does trichlorotrifluoroethane alone. Such other solvents include, for example, 1,1,1-trichloroethane, benzotrifluoride, perfluorodimethylcyclobutane, chloroform, tetrachloroethylene, trichloroethylene, methylene chloride, carbon tetrachloride, dichloroethylene, dichloroethane, and mixtures thereof.
A preferred composition of the present invention consists of low-molecular weight fluorocarbon telomers having a maximum average molecular weight of about 3700, an organic solvent and an antistatic agent which is, preferably, a tertiary amine as defined above.
Lubrication of susbstrates herein contemplated can be accomplished by applying the herein-described composition wherein the low-molecular weight telomers are generally present in an amount less than two weight percent to a given substrate, evaporating the solvent therefrom and lightly buffing, if desired, the thus-coated substrate to provide a clear coating. Application of the composition can be accomplished by numerous means including spraying, dipping, brushing, swabbing, flowing and doctoring. For most purposes, spraying and swabbing are preferred because of the complete and uniform coverage these methods afford.
There can be added to the composition of the present invention minor amounts of various conventional components including antioxidants, pigments, hardeners, fillers, binders, odorants, dyes and the like if there is need to do so and to the extent that such ingredients are soluble or dispersible in the solvent and do not degrade the performance characteristic of the present compositions.
A more detailed appreciation of the invention will be gained with reference to the following examples. It is to be understood that the following examples are for the purpose of illustration and the invention is not to be regarded as limited to any one of the specific compositions or processes recited therein.
EXAMPLE I
A lubricating composition was prepared by adding 594 grams trichlorotrifluoroethane (Freon TF) to 6 grams Vydax AR, a 20 weight percent dispersion of tetrafluoroethylene telomers in 80 weight percent trichlorotrifluoroethane so as to provide about a 0.2 weight percent concentration of said telomers in the final concentration. Generally, the average particle size of the telomers in said dispersion is about five microns. The resulting mixture was thoroughly agitated and allowed to settle for about 168 hours. The upper clear solution was then removed from the relatively fluffy, white sediment to yield about 570 grams of clear solution. About 0.53 ml of Anti-Stat 273C, a commercial N,N-bis(2-hydroxyethyl)alkylamine was added for each liter of clear solution to provide in a concentration of approximately 0.03 weight percent. The alkyl percent. The alkyl moiety of said alkylamine ranges from about dodecyl to tetradecyl. This resulting clear composition was applied to a National Association of Broadcasters (NAB) No. 12-5-98 phonograph test record by gently spraying over the surface thereof whereby evaporation removes the solvent at room temperature and results in an almost instantaneous deposition upon the record surface of a practically invisible coating thereon. The thus-treated record was thereafter carefully buffed by rubbing in the direction of the grooves employing a velvet buffing pad so as to provide a bright, lustrous finish thereon.
In order to determine both reduction of distortion and background noise of treated as compared with untreated records, tests were conducted and were determined by using a Hewlett-Packard Wave Analyzer (Model No. 3590A with a 3594A attachment). The studies which were made over the frequency range of about 500 Hz. to about 13 KHz. employed a "window" bandwidth of about 100 Hz. The sweep rate was set at 100 Hz., per second, the meter damping being set at a "medium" setting. The maximum input voltage was set at 0.1, reference adjustment to relative and the meter to Linear DB, with a frequency range of 62 KHz. After 50 plays, noise in the 3 KHz. band had increased by an average of 1.4 dB compared with an average increase of 3.7 dB for an untreated record subjected to the same test, and the second harmonic had changed by an average of 2 dB compared with an average change of 8 dB for an untreated record. Thus, the composition of the present invention when applied to the record surface demonstrates that there is a significantly lower increase in the background noise and a significantly smaller change in harmonics as compared with an untreated record surface when both records are subjected to the same number of playings.
EXAMPLE II
A lubricating composition according to the instant invention was prepared by adding 598.8 grams of trichlorotrifluoroethane solvent (Freon TF) to 1.2 grams of MP-51, a tetrafluoroethylene telomer, so as to provide a 0.2 weight percent concentration of telomers in the final composition. The resulting mixture was carefully stirred for about 30 minutes and only a few insoluble particles remained which were then removed by filtering through filter paper No. 3. To the resulting clear solution there was added Anti-Stat 273C, described in Example I in an amount equivalent to 0.53 ml per liter of solution, so as to provide a concentration of about 0.03 weight percent thereof in the final composition. This composition was sprayed upon a phonograph record surface and carefully buffed after evaporation of solvent.
The phonograph record test equipment described in Example I was again employed. The mean noise level on the treated record was measured at 59.3 dB below reference level compared with 60 dB below reference for an untreated record; and the second harmonic of the 3 KHz. fundamental test frequency for the treated record was measured at a mean peak height of 29 dB below reference level compared with 30.3 dB below reference for the untreated record. Thus, it was demonstrated that there is no significant increase in background noise or change in harmonics due to the application of the lubricating composition of the present invention to a new record.
EXAMPLE III
Using a paper clip friction test method as recited in "Processed Film Lubrication: Measurement by Paper Clip Friction Test and Improvement of Projection Life" by T. Anvelt, J. F. Carroll, and L. J. Snyder, "Journal of the Society of Motion Picture and Television Engineers," Vol. 80, pp. 734 to 739 (1971), it was found that the standard NAB vinyl phonograph test records which were treated by the method disclosed in Example I exhibit coefficients of friction which were significantly lower than the coefficient of friction for a record merely cleaned with the solvent, trichlorotrifluoroethane. This is shown in the following tabulation:
______________________________________Phono-graphRecordSpeci- Paper Clipmen Composition of Record Treating Friction Test,Identi- Solution: Trichlorotrifluoroethane Coefficientfication plus the following (Wt. %) of Friction______________________________________A 1.0% tetrafluoroethylene telomer concentrate (20% solids), Vydax AR, (decanted) plus 0.024% N,N-bis(2- hydroxyethyl)alkylamine; (alkyl = C.sub.12 -C.sub.14), Anti-Stat 273C 0.13B 0.2% tetrafluoroethylene telomer, MP-51, plus 0.03% N,N-bis(2-hydroxy- ethyl)alkylamine, (alkyl = C.sub.12 -C.sub.14), Anti-Stat 273C 0.15C None 0.22______________________________________
EXAMPLE IV
Accelerated phonograph record wear tests were conducted on NAB test records which had been treated with the composition of the subject invention. The results achieved from the treated records were compared with the results of the wear test conducted on a cleaned test record which had not been treated in accordance with the present invention. The test utilized a standard type automatic record turntable rotating at 331/3 rpm with the stylus on the tone arm adjusted to 9.5 grams load on the record surface. This high stylus load was used in order to accelerate the wear process and thereby provide better discrimination among record treatments. Various compositions of the present invention were applied to the record surfaces in accordance with the procedures described in Example I.
The untreated test record was cleaned by gently washing the surface with a disposable wiper soaked with mild dish detergent, then rising with lukewarm tap water, and drying with an absorbent disposable towel. Test results after 125 to 128 playing cycles are presented in the tabulation below:
______________________________________Phono-graph Record SurfaceTest Appearance atRecord Composition of Record Treating Test Termina-Identi- Solution: Trichlorotrifluoroethane tion and Rela-fication plus the following (wt. %) tive Rating______________________________________ (0 = clean, 100 = heavily covered with wear debris)D 1.0% tetrafluoroethylene telomer concentrate (20% solids), Vydax AR, Randomly scat- (decanted), plus 0.024% N,N-bis(2- tered wear hydroxyethyl)alkylamine, (alkyl = particles. C.sub.12 - C.sub.14), Anti-Stat 273C Rating = 4E 0.2% tetrafluoroethylene telomer, MP-51, plus 0.03% N,N-bis(2-hy- Scattered wear droxyethyl)alkylamine, (alkyl = particles. C.sub.12 -C.sub.14), Anti-Stat 273C Rating = 6F Record cleaned with mild deter- Heavily cov- gent ered with various sized particles of wear debris. Rating = 100______________________________________
Comparison of the above test results reveals that the two records treated with the compositions of the present invention were worn to only a small fraction of the extent of wear experienced on the cleaned-only record, as judged by visual observations of the accumulation of wear particles on the test record surfaces.
EXAMPLE V
A solution was prepared by combining 99.0 weight percent trichlorotrifluoroethane (Freon TF) with 0.1 weight percent tetrafluoroethylene telomer concentrate (20% solids), Vydax AR, allowing the solution to settle and thereafter decanting. To 99.98 weight percent of the clear, decanted solution, which contained about 0.03 weight percent of said telomer, was added 0.02 weight percent N,N-bis(2-hydroxyethyl)alkylamine, (alkyl = C 12 -C 14 ), Anti-Stat 273C. A clear solution resulted and was sprayed onto a test phonograph record (NAB 12-5-98), the trichlorotrifluoroethane was allowed to evaporate, and the playing surface was lightly buffed to leave a thin coating. The record was then subjected to playing and compared with an untreated record to determine changes in any surface noise. For this purpose, the signal from the stylus, tracking at one gram load in the record grooves, was fed to a Tektronix 5100 Series Storage Oscilloscope for display. During the first number of playings, the coated record showed significantly less surface noise than did an identical uncoated record; and progressively throughout some 120 playings, the level of surface noise of the coated record ultimately reached the background or noise level that the uncoated record showed on its first playings.
The above examples show that compositions of the subject invention markedly reduce phonograph record wear, lower the coefficient of friction, and preserve the original recorded fidelity; and the compositions significantly reduce or at least do not cause background or surface noise when applied to a record and effectively retard the rate of noise increase over a large number of actual playings.
Although the several specific embodiments of the present invention have been illustrated, it is apparent that those skilled in the art will recognize numerous changes and modifications within the scope of the invention without departing therefrom.
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An article of manufacture and a method are disclosed herein for improving lubricity and wear resistance of a given substrate by applying thereto a composition consisting essentially of low-molecular weight tetrafluoroethylene telomers, an antistatic agent, preferably in the form of a tertiary amine, and a volatile organic solvent, and removing the volatile solvent to produce a thin, dry coating upon said substrate. The compositions herein disclosed have been found to be most effective as preservatives for coating gramophone or phonograph records which provide marked reduction of record groove wear while substantially minimizing noise and harmonic distortion.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to liquid drainage systems used on site for footings, open trenches, or nitrification fields used as discharge points for septic tanks, and more particularly to a novel flexible preassembled drainage line unit which is an improvement over the flexible preassembled drainage line units illustrated in FIGS. 2 and 3 of U.S. Pat. No. 5,015,123 (the “'123 patent”, owned by the assignee of this invention), the disclosure of which is incorporated herein by reference in its entirety.
[0002] The preassembled drainage line unit illustrated in FIG. 2 of the '123 patent constitutes loose aggregate in the form of lightweight materials such as polystyrene beads provided in surrounding relationship to a perforated conduit and bound thereto by a perforated sleeve member such as plastic netting. These units, used in combination with preassembled units illustrated in FIG. 3 of the '123 patent which do not include the perforated pipe, provide a storage chamber or area for example for effluent from a septic tank until it can be absorbed by the surrounding soil as illustrated in FIGS. 4 b and 4 c of the patent and replaces the conventional gravel drainage system illustrated in FIG. 1 of the patent. Drainage systems employing the preassembled drainage line units of the '123 patent represent a substantial improvement over prior conventional gravel systems for reasons set forth in the '123 patent and have enjoyed substantial commercial success.
[0003] While those preassembled drainage line units have enjoyed commercial success, in certain applications problems have presented themselves. For example depending on the type of fill soil placed on top of the preassembled units, solids such as sand or dirt may pass downwardly through the netting into the void area between adjacent aggregate, clogging that area and causing an undesirable reduction in liquid flow through the aggregate. In other applications it is sometimes desirable that the pre-assembled units which are normally very flexible along their length possess greater rigidity along that length and still in other applications it is sometimes beneficial to provide structure as part of those units which promotes the growth of microorganisms within the drainage units.
[0004] The improved drainage products of the invention as described hereinbelow have been developed to overcome the problems associated with the units described in the '123 patent and to fulfill the needs described above.
SUMMARY OF THE INVENTION
[0005] Accordingly, a primary object of the invention is to provide a preassembled drainage line unit in which loose aggregate in the form of lightweight materials is contained within and bounded by a perforated conduit such as a plastic mesh tube of construction netting and wherein a barrier material overlies at least a portion of the aggregate to prevent solids from passing through the netting and entering the storage area defined by the aggregate.
[0006] Another object of the invention resides in the provision of the above novel preassembled drainage unit which further includes a perforated conduit wherein the loose aggregate surrounds the conduit and is bounded thereby by the perforated sleeve member.
[0007] Depending upon the type of drainage application in which the novel preassembled units are to be used, the material from which the barrier is constructed may vary. For example, it may be paper, cloth, geo-textile such as nylon, or any other suitable pliable sheet material that can be inserted between the netting and the aggregate. The thickness of the sheet material can be varied. For example the thickness of the material may be thin so as to conform to the preferred cylindrical shape of the units or may be thicker to provide rigidity along the length of the units. In addition, the barrier material may extend around the aggregate through an angular distance of about 10 degrees through full coverage of 360 degrees.
[0008] The provision of the barrier material within the above described novel preassembled drainage units can be tailored to block the infiltration of outside media such as sand, dirt and soil through the net into the aggregate, to provide rigidity to the drainage units along their length and to provide structure which promotes the growth of microorganisms within the drainage unit.
[0009] It is also an object of the invention to provide a method and apparatus for manufacturing the novel drainage units.
[0010] Further objects and advantages of the invention will become evident from the reading of the following detailed description of the invention wherein reference is made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 illustrates a preassembled drainage line unit constructed according to the invention which includes a plurality of lightweight aggregate surrounding a perforated conduit and bounded thereto by an outer perforated sleeve member, with a barrier material overlying at least a portion of the aggregate to prevent outside media such as sand, dirt or soil from infiltrating into the liquid storage area defined by the aggregate;
[0012] [0012]FIG. 2 is a cross-sectional view of the unit taken along line 2 - 2 of FIG. 1;
[0013] [0013]FIG. 3 illustrates a preassembled drainage line unit similar to FIG. 1 with the perforated conduit removed;
[0014] [0014]FIG. 4 is a cross sectional view of the conduitless unit taken along line 4 - 4 of FIG. 3;
[0015] [0015]FIG. 5 is a cross-sectional schematic view illustrating an alternative construction of the unit illustrated in FIG. 1.
[0016] [0016]FIG. 6 is a fragmentary front perspective view of apparatus for manufacturing the novel drainage units of the invention;
[0017] [0017]FIG. 7 is a side view of the apparatus of FIG. 6 illustrating the manner in which the rolls of barrier material are supported on the mandrel.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Referring now to the drawings, the longitudinally extending, flexible preassembled drainage line unit 20 illustrated in FIG. 1 includes a corrugated PVC perforated vent pipe 10 encased by an outer perforated sleeve member 22 of tubular nylon netting or mesh which is filled with an aggregation of discrete water impervious crush resistant lightweight plastic elements 21 and is secured to the pipe ends 24 and 25 by means of suitable conventional wires or tie fasteners 26 which prevent the escape of the loose aggregates 21 .
[0019] Unit 20 as described thus far corresponds to the drainage unit illustrated in FIG. 2 in U.S. Pat. No. 5,015,123 and the detailed description set forth therein is incorporated herein by reference.
[0020] As mentioned hereinabove, in some applications employing the flexible drainage line units illustrated in the '123 patent, outside media solids such as sand, dirt or local soil placed on top of the units can penetrate into the units and thereby reduce the void space between the aggregates 21 , clogging the units and reducing the fluid flow through the units.
[0021] To alleviate this problem a liquid or water permeable barrier material 28 is placed between aggregates 21 and netting 22 , the barrier 28 extending longitudinally along unit 20 between ends 24 and 25 of the pipe and being secured at its ends to the pipes by fasteners 26 along with the netting 22 .
[0022] As shown n FIG. 2 the barrier 28 extends through a predetermined desired angular distance across the top portion of unit 20 and depending upon the application it may extend through an angular distance within the range of 10 degrees to a complete 360 degrees of the unit.
[0023] Barrier 28 may be constructed of any suitable pliable water permeable sheet material such as paper or cloth, but is preferably a geo-textile material such as nylon having a fine weave to block the passage of the sand or dirt but sufficiently open to permit the passage of water therethrough.
[0024] Preferably barrier 28 is very thin so as to readily conform to the shape of the flexible unit 20 which is preferably generally cylindrical but it may be thickened as desired to provide rigidity to the unit if desired.
[0025] In operation water collected at one end of pipe 10 passes into the pipe and outwardly through the perforations of the pipe into the chamber defined by aggregates 21 and barrier 28 blocks infiltration of sand or dirt placed on top of units 20 into the void space containing the aggregates.
[0026] Referring now to FIG. 3 the generally cylindrical drainage unit 30 is the same as unit 20 described in FIG. 1 except that it has no conduit passing therethrough. The end of the netting 22 and barrier 28 are tied together at the ends of unit 30 to hold aggregates 21 in place within the units. The units illustrated in FIG. 3 in this application containing the barrier 28 constitute an improvement over the conduitless units illustrated in FIG. 3 of the '123 patent and described therein.
[0027] [0027]FIG. 5 an alternative construction to that illustrated and described above with respect to FIG. 1. In the FIG. 5 embodiment, a pipe 10 a is surrounded by aggregate 21 a which is bounded to the pipe by a first perforated net 22 a , with this structure described so far being essentially identical to the prior art unit illustrated in FIG. 2 of the '123 patent. A barrier 28 a extends longitudinally along the length of the unit outside of net 22 a and around the unit through a predetermined angular distance and is fastened thereto by suitable means such as a second outer tubular nylon net or mesh 40 fastened at its ends along with the ends of barrier 28 a to the ends of pipe 10 in the same manner as the unit of FIG. 1. Instead of the tubular net 40 , barrier 28 a may, for example, be fastened to the outside surface of net 22 a by rope or cord at various locations along the length of the unit.
[0028] Another embodiment constructed according to FIG. 5 but without the conduit 10 a may be provided as an alternative to the conduitless unit illustrated in FIGS. 3 and 4.
[0029] From the description herein above it is apparent that the provision of the barrier 28 in the preassembled drainage line units advantageously prevents the passage of outside media such as sand, dirt or soil into the void space defined by the lightweight plastic aggregates; the barrier provides structure for the growth of microorganisms within the drainage unit; and the barrier may be constructed to provide rigidity to the unit when desired. The flexible pliable barrier material may extend a varying angular distance around the unit. For example, it may extend through a small angular distance of about 10 degrees to full circumferential coverage of 360 degrees of the unit depending upon the application in which the unit is to be used.
[0030] The apparatus shown in FIGS. 6 and 7 is of the type illustrated and described in detail in U.S. Pat. No. 6,173,483 which is owned by the assignee of this application, and the disclosure of U.S. Pat. No. 6,173,483 is incorporated herein by reference in its entirety. The apparatus is used to make both of the units of FIGS. 1 and 2.
[0031] Briefly, the apparatus includes a tubular mandrel 50 having an inner bore or cavity, a rear opening, a front opening, and an upper opening, with each opening communicating with the inner cavity.
[0032] A pipe feeder is positioned for feeding a predetermined length of perforated length pipe through the inner cavity of the mandrel 50 in a direction of manufacture from the rear opening to the front opening and therethrough. As it is fed into the mandrel 50 the vent pipe is positioned within the inner cavity so as to define a void space between the pipe and the inner wall of the mandrel.
[0033] A hopper assembly containing the plastic aggregate bodies is connected via conduit 52 to the upper opening in the mandrel to feed the plastic aggregates into the cavity.
[0034] A blower 54 is positioned in communication with the inner cavity of the mandrel for producing the sufficient air flow therethrough for moving the aggregate from conduit 52 through the inner cavity to substantially fill the void space between the vent pipe and the wall of the mandrel so that the pipe is surrounded by the aggregate as it emerges from the from opening of the mandrel.
[0035] A sleeve feeder is connected to the front end of the mandrel for feeding a continuous sleeve of netting 22 over the plastic aggregate and the vent pipe emerging through the front opening of the mandrel. As it is fed the continuous sleeve of netting 22 substantially encases the plastic aggregate around the vent pipe thereby forming a drainage unit.
[0036] The apparatus operates substantially the same for producing the conduit units of FIG. 3 but with no perforated vent pipe being fed through the unit.
[0037] For a more detailed description of this type of apparatus, reference is made to the specification of U.S. Pat. No. 6,173,483.
[0038] In accordance with the invention one or more rolls 56 of barrier sheet material 28 are mounted on top of mandrel 50 , the leading end 58 of which is located underneath the netting 22 in contact with the mandrel and is fed with the netting over the plastic aggregate and is fastened with the netting around the vent pipe for manufacturing the units of FIG. 1, or is simply tied together with the end of the netting for producing the conduitless units of FIG. 3. The apparatus as illustrated in FIGS. 6 and 7 is producing conduitless units. When drainage units larger in diameter for example, 10 inches, 12 inches, 14 inches, etc. are being produced instead of using a single roll 56 of barrier material it is better to use a plurality of rolls which are angularly offset as shown in FIGS. 6 and 7 with overlapping side edges so that the barrier material is able to extend for a larger angular distance, for example approximately 180 degrees in the unit shown in FIG. 6.
[0039] The operation illustrated in FIGS. 6 and 7 produces the units of FIGS. 1 and 2 and FIGS. 3 and 4 wherein the barrier material 28 is placed between netting 22 and aggregates 21 .
[0040] To produce the embodiments illustrated in FIGS. 5 and 6, the operation of FIGS. 6 and 7 may be modified by placing the leading edges of barrier material 28 on top of the netting 22 on mandrel 50 and then placing a second netting 40 around barrier 28 and the first netting 22 and continue the operation as described above.
[0041] The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A pre-assembled drainage line unit includes a flexible longitudinally extending perforated sleeve member and a loose aggregation of lightweight elements contained within the sleeve member. A pliable, water permeable barrier material extends along the sleeve member and overlies at least a portion of the aggregation to prevent the passage of solid materials, such as sand and dirt, into the aggregation.
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This invention relates to a bore plug and to a bore plugging method, usually but not necessarily for tubes, and has particular (but not exclusive) application for the isolation of defective heat exchanger tubes.
Thus we believe that a bore plug according to the invention will find its greatest utility for the temporary plugging of an end of a defective tube of a land or marine heat exchanger, and it is to such use that the following description is directed.
BACKGROUND TO THE INVENTION
Heat exchangers are widely used, for instance in the power supply and chemical industries, and for marine applications. A plurality of tubes, typically linear, are mounted in tube plates, being connected in parallel between "headers" so as to carry heat exchanger fluid, though heat exchangers are known with a single header and "U" shaped tubes.
Generally, the tubes will carry the coolant, typically air or water (perhaps sea water), and the fluid which is to be cooled is circulated around the tubes,.
If one or more of the tubes develops a leak, with leakage of the fluid being cooled, for example hot oil, into the coolant, then to prevent the oil being discharged with the coolant e.g. for marine applications into the sea, each defective tube needs to be taken out of service (by being "plugged"), for instance until the ship reaches port and the tube can be replaced.
Heat exchanger tubes conventionally have thin walls in order to maximise heat transfer. Such thin walls require special care to prevent damage by the fitted tube plug. Following prolonged heat exchanger use, the terminal end of a tube (and the area immediately inwards of this terminal end) can become non-uniform, by one or more of erosion, corrosion and contaminant build-up, making it difficult to ensure effective sealing.
DISCLOSURE OF THE PRIOR ART
It has long been known to isolate a tube in a heat exchanger by the insertion of a plug into one or both ends of the defective tube.
One arrangement uses a tube plug of frusto-conical form, perhaps a tapered wedge of metal or other rigid material, the plug having at least one peripheral surface of a size to span the tube i.e. so that when forced into the tube the plug will grip an inner terminal surface of the tube; when so gripping, the plug can act both to seal the "outer" leakage path between an outer periphery of the plug and the inner terminal surface of the tube, and to provide a frictional resistance to ejection of the plug from the tube --for instance upon an increase in the internal pressure in the tube. However, the force necessary for effective securement of the plug can damage the tube end (and specifically the terminal surface), especially if this terminal surface is not supported by a tube plate. The plug is usually "hammered home" and thus requires sufficient space for the hammering action, since if the plug is not firmly secured, or if it can work loose e.g. under marine vibrations, the plug can be ejected from the end of the tube, and this may not be noticed until there has been substantial leakage of the fluid being cooled.
An arrangement using a resilient plug (of plastics material) and having a separate holding means for the plug inwardly of the tube terminal surface is disclosed in British Patent 1,593,379. The arrangement is not intended as a tube plug, but may in certain circumstances function as such. The holding means is a nut of special form which accepts a threaded bolt; once inserted into the tube the nut may be difficult or even impossible to remove, so presenting a permanent flow restriction if the tube is subsequently repaired. In addition, the plug is annular, with therefore an additional potential leakage path for pressurised fluid to escape from within the tube.
A number of plug designs have been taught in which the sealing means is fitted inwards of the terminal end of the tube to be sealed, with holding means to secure the tube plug within the tube. Amongst these are the plugs as disclosed in GB patents 1,518,425 and 1,563,762. In these designs, a sleeve is firstly positioned within the bore, after which a sealing material is injected; the effectiveness of the sealing is in part dependent upon the flowability of the sealant and in part upon the provision of an adequate flow path for the sealant. The requirement for the additional step of sealant injection is time consuming and awkward, and this step may therefore not always be carried out correctly. The plugs have an annular holding sleeve, with therefore an additional "inner" internal leakage path.
Another arrangement is that of U.S. Pat. No. 4,600,036 disclosing embodiments wherein sealing members in the form of resiliently deformable O-rings providing "small area" sealing, and combination sealing and holding. In the latter of these designs there is disclosed an annular tube plug embracing a spindle, part of the spindle being threaded to receive a nut, such that upon rotation of the nut and consequent axial movement of the nut along the threaded spindle, the holding means is expanded into secure engagement with an internal bore of the tube.
It will be understood that the tube plugs according to these prior patents, and other similar designs utilising holding means and annular selling members, suffer from the disadvantage that there is a potential leakage path for pressurised fluid both to the outside of the annular sealing member (i.e. between the sealing member an the inner surface of the tube), and also to the inside of the sealing member (i.e. between the sealing member and the spindle). Furthermore, such tube plugs are more expensive to manufacture than the solid frusto-conical tube plug and yet may not always provide adequate sealing, requiring axial compression of the sealing member to cause its radial expansion into engagement with the tube. In order to ensure effective sealing, the inside of the tube typically initially requires cleaning, e.g. with a wire brush, to remove any contaminants which might otherwise interfere with the sealing member. Clearly, the requirement for a clean and uniform inner surface of the tube is greater for tube plugs employing "small area" sealing members. The known designs described above require the tube to be cleaned for a considerable length (corresponding to the length of the fitted tube plug), increasing the time and difficulty of fitting such a tube plug. Sometimes, the tube is inadequately cleaned, or is cleaned for an insufficient length, so that the tube plug provides only a partial seal, or provides an effective seal for only a short period of time, in both cases requiring further remedial work once the continued leakage is discovered.
UK patent application 2,218,177A teaches a tube plug comprising a sealing member adapted to span the tube, and a holding means comprising an eccentic ring engageable with the inner surface of a tube upon relative rotation of the sealing member and the ring. However, the ring is indicated to be partially effective only, so that further holding means are required, both to prevent rotation of the plug within the bore on tightening of the plug, and also to prevent ejection of the plug from the tube. The second holding means is provided by the sealing member which is forced into engagement with the tube as a threaded tapered holding member is screwed into a threaded opening in the sealing member. A first disadvantage of this design is that the ring is positioned inwardly of the tube relative to the sealing member, and the sealing member can be engaged with the tube bore only after the ring has itself been engaged. The sealing member can only be engaged with the tube if rotation of the ring is resisted by the tube, specifically by a tube internal irregularity such as a build-up of scale at the holding position(s) within the tube, so that operation of the plug may be unreliable. In particular, it is necessary to clean the tube adjacent the position at which the sealing member (the further holding means) engages the tube, but to leave the tube relatively uncleaned adjacent the position at which the ring engages the tube, so that considerable care in cleaning the tube prior to fitment of this particular tube plug is required. Another disadvantage is that the sealing member is desired to deform to provide an effective seal and yet be sufficiently rigid to receive the threaded holding member. The need for the sealing member to receive and cooperate with the threaded holding member requires it to be made of a substantially rigid material; a resiliently deformable material more suited to sealing cannot be used, so that sealing performance is impaired.
SUMMARY OF THE INVENTION
We seek to provide a bore plug and especially a tube plug which avoids or reduces the disadvantages of the above mentioned designs. Our bore plug has a sealing member which is continuous across the bore to be sealed and so does not share the major disadvantage of the prior designs in which an annular sealing member provides a second leakage path. Our design requires fewer components than the prior designs, and thus can be easier and cheaper to manufacture. Furthermore, our design is of smaller axial length than many of the prior designs and so a shorter length of the tube requires to be cleaned prior to insertion of the plug.
In addition, our bore plug can provide more effective and reliable bore sealing than is often achieved with the frusto-conical plug relying upon the friction grip of a tightly fitted sealing member. Furthermore, our bore plug can utilise a sealing member of a resiliently deformable material chosen for its sealing properties i.e. the sealing member is not required to be rigid to receive a threaded holding member or the like. Our design has been shown to be holdable securely in position against internal tube pressures exceeding those required in most land and marine heat exchanger applications.
Thus according to one feature of our invention we provide a bore plug comprising a sealing member and a holding member, the sealing member being adapted to span the bore, the sealing member having a longitudinal axis and an axial opening to receive the holding member, the holding member being insertable into the opening solely by axial movement.
The sealing member is initially a sliding or interference fit within the bore; the holding member expands the sealing member into sealing engagement with the bore. Because the sealing member is urged into sealing engagement with the bore for approximately the full length of the holding member, the area of sealing contact between the sealing member and the bore is significantly greater than the prior art designs incorporating small area sealing.
Thus, we have realised that it is possible to achieve good bore sealing, capable of withstanding high pressures, without the need for large holding forces which are achievable only with threaded connections. The holding member according to the invention is not threaded, and is inserted into the opening of the sealing member by axial movement alone; accordingly, the sealing member is not required to be threaded, and the material of which it is made can be readily deformable and chosen for its ability to provide a good seal.
According to a further feature of the invention, therefore, we provide a method of plugging a bore such as a tube including the steps of {i} pushing the sealing member of a bore plug as defined herein axially into the bore, the sealing member having an exposed opening, and {ii} pushing a holding member axially into the opening so as to urge part of the sealing member into sealing engagement with an inner surface of the bore.
The sealing member has a first end and a second end and preferably has a transverse partition between its ends, the sealing member having a first opening to one side of the partition (to receive the holding member) and usefully a second opening to the other side of the partition. The second opening is open to the interior of the bore or tube in the fitted condition of the plug.
Since the second opening is open to the tube in the fitted condition it becomes filled with fluid at the pressure within the tube; the wall of the sealing member surrounding the second opening is thus urged into engagement with the tube, adding to the effectiveness of the seal therebetween.
Preferably, the partition is not planar, and includes an upstand projecting into the second opening. Pressure from within the tube upon the upstand acts to urge the sealing member (and in particular the periphery of the sealing member adjacent the partition) into greater engagement with the tube wall, so increasing the effectiveness of the seal therebetween.
Usefully, the upstand is on or close to the longitudinal axis of the sealing member. Usefully also, the area of the partition surrounding the upstand is concave towards the second opening. It has been found that such a concave partition increases the sealing effectiveness of the bore plug.
Preferably, the wall surrounding the second opening is externally tapered, to assist with insertion of the plug into the bore. Preferably also, when the plug has been fitted into the bore of a heat exchanger tube, the wall surrounding the second opening will extend beyond the expanded end portion of the tube, so that the tapered exterior of the wall surrounding the second opening is in engagement with the (narrowed) tube wall.
Preferably, the wall surrounding the second opening terminates in a sharp edge at the second end of the sealing member, so that the second end provides a small area against which the pressure of fluid within the bore can act.
Usefully, the sealing member is resilient.
The first opening may be tapered. The first opening may also have a number of indentations and receive a holding member having at least one projection. The projection can locate in an indentation to provide a detent position for the holding member relative to the sealing member, resisting any tendency of the holding member to be urged out of the opening.
Desirably, the holding member has a threaded aperture to receive a threaded tool adapted to remove the holding member from the sealing member.
A particular advantage of our design is its relatively short length. Typically, all the tubes of the heat exchanger will have had at least one end mechanically expanded into tight contact with a common tube plate, and being of relatively short length the bore plug of the invention can be mostly accommodated in such expanded end i.e. typically only the wall surrouding the second opening will need to accommodate the reduction in diameter of the tube which occurs inwardly of the expanded portion. As above indicated, however, the fact that the wall can extend into the non-expanded part of the tube is an advantage in that the tapered outer wall can engage the tube beyond the expanded portion. Also, prior to fitment of a bore plug according to the invention, only the expanded portion and a short length of the tube therebeyond needs to be cleaned, so considerably reducing the time and difficultly of the tube plugging operation.
Another advantage of our invention is that the sealing member can be effective for substantially its full length. Thus, part of the sealing member is expanded into sealing contact with the bore by the holding member; part is in sealing contact by virtue of the action of the partition, and part is in sealing contact because of the pressure of fluid within the second opening. Accordingly, the sealing member is better able to accommodate any imperfections which remain on the tube wall after the cleaning operation.
Holding members with different outside diameters can be provided to take account of slightly different bore internal diameters, perhaps caused by differing amounts of erosion and/or corrosion of the bore. Thus, the bore plug manufacturer does not need to know the precise inside diameter of the bore, since a given sealing member is sufficiently deformable (expandable) to seal bores of slightly differing inside diameters depending upon the outside diameter of the holding member which is pushed thereinto, i.e. the bore plug fitter can choose to fit the holding member required to provide the desired sealing for the particular bore.
Additionally therefore, there is provided a sizing ring having a number of differently sized projections thereon. In one method of fitment according to the invention, a sealing member as herein defined is chosen for the size of bore, and is fitted into the bore. Respective projections of the sizing ring are sequentially pushed manually into the first opening until the projection causing an interference fit is determined. The projections will correspond to certain diameter holding members, so that the holding member corresponding to the determined projection can thereafter be inserted into the opening to seal the bore.
It will be understood that the bare plug according to the invention does not require the large positioning forces which in certain of the prior art tube plugs was provided by rotation of a nut on the threaded spindle; rather, the bore plug of the invention can be inserted into the bore in its unstressed condition, and then be clamped in position inside the tube simply by pushing manually a holding member axially into the sealing member. Thus, cooperating threads are not required, so saving on manufacturing cost. Also, fitment tools (perhaps specialised) are not required, so saving on fitting time and difficulty.
Notwithstanding the ease of fitment, analysis has demonstrated that the bore plug of the invention when fitted into a tube of a heat exchanger can seal against and hold against internal tube pressures in excess of 1000 p.s.i. (approximately 7×10 6 Pa).
Tests have also shown that removal of the the holding member permits the bore plug readily to be removed from the bore, so that the bore plug according to the invention is generally re-usable.
Usually the bore is circular in cross-section (which is typically the case for the tubes of land and marine heat exchangers, for example), so that the outer surface of the sealing member is also circular, but other bore cross-sections can be accommodated by sealing members with correspondingly shaped outer surfaces.
As above indicated, whilst it has been found that the engagement between the (deformable) material of the sealing member and the tube is sufficient to resist forcing out of the tube plug under the pressures typically acting in land and marine heat exchangers, additional holding means can be provided if required. Thus, alternatively the sealing member can carry a holding means, the holding means being of a different material to the sealing member and being movable into a bore-engaging condition by the holding member.
The holding means can be of a harder material than the sealing member, and thus be suited to holding engagement with the bore so as to resist movement of the plug along the longitudinal axis of the bore.
Usefully, the holding means comprises a plurality of independent holding plates. In one embodiment the holding plates can move relative to the sealing member, but in another embodiment will be fixed thereto such as to be movable into holding engagement with the tube simultaneously with sealing engagement with the tube by the sealing member.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a sectional side view of the parts of a bore plug according to the invention, the sealing member being fitted into the end of a heat exchanger tube;
FIG. 2 is a sectional side view of part of the sealing member of FIG. 1;
FIG. 3 is a sectional side view of the parts of another embodiment of bore plug;
FIG. 4 is a view of a sizing ring; and
FIG. 5 is a sectional side view of an alternative embodiment of bore plug.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The bore plug 10 of FIG. 1 comprises a sealing member 12, holding member 14, and protective cap 16.
The sealing member 12 is of resiliently deformable material, chosen for its sealing properties. In this embodiment the sealing member 12 is of "Hysil", chosen for its ability to withstand operating temperatures in the range encountered in the application concerned, though other elastomeric materials including fluoro-elastomers, polyurethane, rubber, "Nulex", "Nitrile", or "Viton" could be used, suited to the particular application and the range of temperatures which the bore plug will encounter in use; for land and marine heat exchangers, the bore plug should be able to withstand operating temperatures typically up to 150° C., and perhaps up to 200° C.
The sealing member 12 is selected to be of an outside diameter which is a sliding or interference fit in the expanded and 20 of the tube 22 into which it is adapted to be secured, so that it can be manually pushed into the tube until its second part or flange 26 abuts the tube annular end surface 24. The spacing between the outer surface 28 (FIG. 2) of the sealing member 12 and the inner surface of the enlarged portion 20 of the tube is exaggerated in FIG. 1, for clarity; in practice the sealing member will preferably be a sliding or interference fit within the tube, so that there will be little or no gap between these parts.
In practice, the degree of expansion utilised by heat exchanger manufacturers is approximately consistent, so that the manufacturer of the bore plug will know the size of bore plug which is necessary if he is told the nominal (i.e. unexpanded) diameter and wall thickness of the tube.
As shown in FIG. 2, the sealing member 12 has a partition 30 arranged between its ends. To one side of the partition 30 is the first opening 32 which is adapted to receive the holding member 14. To the other side of the partition 30 is second opening 34 which in the fitted condition of FIG. 1 is open to the interior of the tube 22.
Surrounding the second opening 34 is an annular wall 36. The wall 36 has an outer surface which tapers towards the second end 38 of the sealing member. The tapering outer surface facilitates ease of insertion of the sealing member 12 into the tube end 20.
Notwithstanding the tapered outer surface of the wall 36, however, the outer surface is sized to engage the tube for which it is intended beyond the enlarged region 20, as seen in FIG. 1, and is thus able to provide a seal therewith.
Tube plate 40 of a heat exchanger supports a number of heat exchanger tubes in parallel, each tube 22 during manufacture of the heat exchanger having had its end 20 mechanically expanded in known fashion so as to form a tight mechanical bond with the tube plate 40. A particular advantage of the bore plug 10 is its relatively short axial length, so that when its flanged end 26 engages the end 24 of the tube the body of the bore plug is accommodated in the enlarged portion 20 of the tube 22 and only the wall 36 extends therebeyond.
The annular wall of the opening 32 has an inside surface 42 which is smooth, and which in this embodiment is parallel to the longitudinal axis A of the sealing member. Thus, the opening can receive smooth-sided holding member 14. The outer diameter of the holding member 14 is slightly larger than the diameter of the surface 42, so that on pushing of the holding member 14 fully into the opening 32 part of the sealing member is expanded so that its outer surface 28 is forced into greater engagement with the expanded end 20 of the tube, to form a seal therewith.
Despite the holding member 14 being of greater outer diameter than the diameter of the surface 42 of the opening 32, the holding member can usually be pushed thereinto by hand or finger pressure with sufficient force to expand the sealing member as required. Thus, it is foreseen than no tools will be required to fit the bore plug.
The holding member 14 has a threaded aperture 44, adapted to receive a threaded tool to assist in the removal of holding member 14 from the sealing member 12, as may be required when the defective tube 22 is to be replaced. The aperture receives cap 16 which prevents the ingress of dirt and debris into the aperture (prior to removal being required). The aperture 44 is continuous through the holding member, the aperture thus allowing the egress of air from within the opening 32 as the holding member is pushed thereinto.
Thus, our bore plug requires a minimum of tube cleaning prior to fitment. Furthermore, because our design requires only the axial insertion and removal of the holding member, there results both the quick and easy fitment of the bore plug and also the quick and easy removal and (subsequent reuse) of the plug, without loss of performance and with a saving in cost.
The partition 30 in this embodiment has an upstand 46 which projects into the second opening 34 of the sealing member 12. Surrounding the upstand, the partition is concave towards the second opening. It has been demonstrated that this form of partition provides enhanced sealing as compared to a planar partition, for example. Thus, when the tube 22 is fitted with a bore plug 10 and the tube is subsequently pressurised, the pressure acting on the partition 30 and upon the upstand 46 urges the sealing member, and in particular the outer surface 28 surrounding the partition, into greater contact with the tube, so increasing the effectiveness of the seal.
It has been shown in tests that a bore plug of this design, in which the holding member 14 is merely manually pushed into the opening 32, is nevertheless retained in the tube (and provides an effective seal) despite the pressure within the tube 22 being 1000 p.s.i. (approximately 7×10 6 Pa) greater than the pressure outside the tube. Such a pressure differential far exceeds the pressure differentials existing in most land and marine heat exchangers.
In an alternative embodiment, the flange 26 is omitted, so that the bore plug can be located fully within the tube and does not; protrude therefrom. This embodiment may be desirable for those applications in which for example a protruding flange may foul a part of the heat exchanger or adjacent component, or it may be desirable for aesthetic reasons. In such embodiments, it can be arranged that the bore plug is inserted until it is flush with the end of the tube, or until the wall surrounding the partition reaches the end of the expanded region of the tube and the force to insert the plug further increases noticeably.
FIG. 3 shows an alternative design of bore plug 50. The bore plug 50 is generally similar to the bore plug 10 of FIGS. 1 and 2, and fits into the enlarged end 20 of a tube of a heat exchanger tube 22 in the same way. However, the first opening 52 of the sealing member 54 is tapered, and includes three circumferential indentations 56a,b,c. The indentations are adapted to receive a circumferential projection 58 of the holding member 60, to provide three detent positions for the holding member.
When using the bore plug 50 of FIG. 3, the sealing member 54 is first inserted into the tube until its enlarged end 62 engages the end of the tube. The holding member 60 is then pushed into the opening 52 until the projection 58 locates in indentation 56a. If greater sealing pressure between the sealing member and the tube is required, or if the sealing member needs to be expanded more, e.g. because of extra erosion of its respective tube, the holding member 60 can be pushed further into the opening, so that the projection 58 locates in the indentation 56b or 56c. It is believed that with sufficient experience in fitting bore plugs of this type, a fitter would become aware of the manual pressure needed to insert the holding member 60 to achieve the required sealing, so that the fitter would know whether the holding member is correctly located with the projection within the indentation 56a, or whether it is necessary to push the holding member further into the opening 52. A skilled fitter would thus not need to pressurise the tube and check for any leakage in order to determine the correct relative position of the holding member 60.
In embodiments similar to FIG. 3, more or fewer indentations can be provided, as required. It may also be acceptable to have just one indentation, with the variation in the sealing force applied being provided by differently sized holding members (as is also the case with the embodiment of FIGS. 1 and 2); clearly, in such an embodiment the opening would not need to be tapered.
FIG. 4 shows a sizing ring 62, adapted to determine the size of the holding member 14 required to be fitted into the first opening 32 of the sealing member as more fully described below. Thus, for a given tube, the actual internal diameter will be determined partly by the degree of expansion involved (which is usually fairly consistent throughout the heat exchanger industry), and also by the (variable) amount of erosion and corrosion which the tube has suffered. A given sealing member 12,50 will be able to accommodate fairly large variations in the tube inside diameter, perhaps of the order of 0.5 mm on a nominal 19.05 mm (3/4 inch) tube. The expansion of the sealing member which is needed to achieve the sealing required will, however, depend upon the actual tube diameter, and in accordance with the invention this is achieved by the fitment of an appropriately sized holding member into the opening 32.
Accordingly, for use with a heat exchanger tube having a nominal outer diameter of 19.05 mm, it is envisaged that the sealing member 12 would have a first opening 42 with a non-stressed diameter of approximately 13 mm; holding members having outer diameters in the range 13.5 mm to 15 mm would be used with such a sealing member, there being many differently-sized holding members possible within this range, preferably varying by diameters of 0.5 mm, but perhaps varying by diameters of 0.2 mm if desired.
In order to determine which holding member to fit within the opening 42 to achieve the required sealing, there is provided a sizing ring 62. The sizing ring 62 has eight projections 64a-h, each differing in diameter by 0.5 mm. The sealing member 12 is fitted into the tube, and the smallest projection 64a is inserted into the opening 32. If the sealing member is expanded but does not form a tight seal with the tube, the projection 64a will slide easily in and out of the opening. Progressively larger projections 64b,64c etc. are subsequently pushed into the opening, until a projection is determined which gives an interference fit. Experience or instruction can teach a fitter the fit required so that with the determined projection the sealing member is being forced into sealing engagement with the tube.
Usefully, the projections are coded, preferably colour coded, and correspond to differently sized holding members. When the correct projection 64 has been determined, the corresponding holding member 14 can be inserted into the opening to achieve the required seal. If desired, or necessary in certain applications, the corresponding holding member can have a slightly larger diameter than the projection, so that the force necessary to push it into the opening 32 is greater than that required to push in the determined projection. Accordingly, the corresponding holding member will provide a greater seal than did the projection.
Sizing rings with more or fewer projections 64 can be provided as desired, and the size difference of the projections can vary in accordance with the variation in the diameters of the holding members, e.g. by 0.2 mm if desired. In addition, it may be necessary to provide two or more sizing rings which together have projections corresponding to all of the holding members within the range of sizes provided.
The tube plug 70 of FIG. 5 comprises a sealing member 72, holding means comprising separate holding plates 74 (only one of which is shown in FIG. 5), a holding member 76, and protective cap 16.
Fitment of the tube plug 70 is similar to that described for the plug 10.
The holding means in this embodiment comprises three separate holding plates 74 arranged at approximately 120° separation around the longitudinal axis "A" of the sealing member 72. Each holding plate 74 is substantially flat, and is mounted in a suitably sized opening in the sealing member 72.
In the absence of a holding member, the holding plates 74 each have a part 80 which projects into the opening 82, and the outer edge 84 thereof is approximately flush with the outer surface of the sealing member 72. When the holding member 76 is inserted into the opening 82, however, the plates 74 are pushed outwardly so that their outer edges 84 engage the inner surface of the tube.
In this embodiment the outer edges 84 are sharpened and formed into two "teeth" adapted to become slightly embedded in the tube wall, so as firmly to retain the bore plug 70 in position in the tube.
As in the embodiments of FIGS. 1, 2 and 3, the outer diameter of the holding member 76 is slightly larger than the diameter of the first opening 82 in the sealing member 72, so that on forcing of the holding member fully into the first opening, not only are the holding plates 74 forced into engagement with the inner surface of the tube, but also the sealing member is expanded so that its outer surface engages the inner surface of the tube and forms a seal therewith.
When it is desired to remove the bore plug 70 from the tube, for instance whilst the heat exchanger is being repaired, the protective cap 68 can be removed and a bolt or the like can be screwed into the bore 92 of the holding member 76 to pull the holding member 76 out of the sealing member 72. When the holding member 76 has been removed, the force with which the holding plates 74 engage the inner surface of the tube is much reduced, permitting the sealing member 72 and its holding plates 74 to be withdrawn from the tube.
It will be understood that in other embodiments more than three holding plates can be used; we have found that a greater number of holding plates increases the pressure differential which the tube plug can withstand before being forcibly ejected from the tube, so that the number of holding plates can be determined in part by the pressure differential which the tube plug will be required to withstand. In addition, the plates can be replaced by pins or fingers, having a shape and construction suited to the particular application.
The bore plug 70 differs slightly from the bore plug 10 in that the partition 86 between the first opening 82 and the second opening 90 is concave (towards the bore when fitted, i.e, the left of FIG. 5 as viewed), and does not have an upstand such as that referred to by numeral 46. In some applications, the additional security provided by the holding plates can overcome the requirement for an upstand. Clearly, however, in other embodiments a sealing member having the form of that of FIGS. 1 and 2 could incorporate holding plates such as those of FIG. 5; alternatively, in some applications it may be acceptable to use a sealing member simiar to that of FIG. 5 but without the holding plates.
The holding member 76 is longer (in the direction of the axis A) as compared to its diameter than the holding member 14 of FIG. 1; this need not be so, and in an alternative embodiment the holding member 14 can be used with a bore plug having holding means such as the plates 74.
A bore plug would typically be fitted to both ends of a leaking tube, to prevent flow both into and out of the tube. A bore plug according to the invention can be used whether it is the coolant or the working fluid which flows through the tubes. Also, the bore plug can be effective at sealing a bore carrying a gas or a liquid.
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This invention relates to a bore plug and to a bore plugging method, usually but not necessarily for tubes, and has particular (but not exclusive) application for the isolation of defective heat exchanger tubes. The bore plug comprises a sealing member and a holding member, the sealing member being adapted to span the bore, the sealing member having a longitudinal axis and an axial opening to receive the holding member, the holding member being insertable into the opening solely by axial movement. The method includes the steps of {i} pushing the sealing member axially into the bore, and {ii} pushing a holding member axially into the opening so as to urge part of the sealing member into sealing engagement with an inner surface of the bore.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No. 10/971,349, filed on Oct. 22, 2004, which is a division of U.S. Ser. No. 09/665,669, filed on Sep. 20, 2000 and issued as U.S. Pat. No. 6,902,482 on Jun. 7, 2005, which is a continuation of U.S. Ser. No. 08/977,806, filed on Nov. 25, 1997 and issued as U.S. Pat. No. 6,162,123 on Dec. 19, 2000.
FIELD OF THE INVENTION
[0002] The present invention relates to interactive electronic games. More specifically, the present invention provides an apparatus in which a participant may input velocity and position information into an electronic game and receive physical feedback through the apparatus from the electronic game.
BACKGROUND OF THE INVENTION
[0003] The electronic game industry has seen a dramatic evolution from the first electronic ping-pong game (“pong”) to the state of modern games and consumer home electronics. In general, hardware advances that have increased processing power and reduced cost have fueled this evolution. The increased availability of low cost processing power, as well as consumer expectation for improved game content, demands that new games be developed to take advantage of this processing power. This can be seen especially in the new 64-bit processing devices such as the Nintendo 64™ and the processing power available in home personal computer games and/or in arcade game platforms. These new hardware platforms are so powerful that a whole new genre of games has to be developed in order to fully utilize the hardware.
[0004] Electronic game input, traditionally, has been limited to joy sticks, button paddles, multi-button inputs, trackballs and even a gyro mouse that has a gyroscope means for determining the orientation of the mouse. Recently, Nintendo has deployed a “rumble” device to provide vibratory feedback to game console users. Traditional computer input means are well know to those in the arts and require no further discussion. The gyro-mouse, in the context of the present invention, however, deserves some further discussion.
[0005] The gyro-mouse, provided in U.S. Pat. No. 5,138,154 to Hotelling, the relevant portions herein incorporated by reference in their entirety, provides a means for using the gyroscopic effect in a computer input device to recover user input. The gyro-mouse provides a gyroscope contained within a ball so that ball may be rotated. This rotation translates into two-dimensional or three-dimensional motion for software receiving the gyro-mouse input to display on a computer screen. Thus, the gyro-mouse is somewhat an extension of the track ball paradigm for a computer input device.
[0006] The gyroscopic effect has also been harnessed for practical commercial applications. One of the more interesting gyroscopic effects is brought about through the principal of conservation of angular momentum. As witnessed in gyroscopic phenomena, a gyroscope creates a force at right angles to a force that attempts to “topple” the gyroscope. Thus, a gyroscope when left alone or mounted in a double gimbal arrangement allowing the gyroscope to move freely in both axes, will resist movement and/or attempt to hold its own angular position. Gyroscopes are also known to have precession due to the earth's effect on the gyroscope. Gyroscope precession is not especially pertinent to the present invention; however, its principles and mathematical proofs and formula are herein incorporated by reference.
[0007] The navigational arts also provide a means for harnessing gyroscopic phenomena to determine the inertial position of a vehicle such as an aircraft. In an inertial navigation system, the gyroscope is mounted in a double gimballed arrangement and allowed to rotate without resistance in all directions. As the aircraft turns, rotates, and/or changes direction the gyroscopic effect keeps the inertial navigation gyroscope at the same angle. High precision means are used to determine how much the gyrostat has rotated, in actuality the aircraft rotating around the gyroscope, and this measurement in combination with high precision accelerometers provides a means for tracking the change in an aircraft direction. This instrumentality in conjunction with precision timing and velocity measurements provides a means for continuously determining an aircraft navigational position.
[0008] In another application of the gyroscopic effect, a large gyroscope can be used to create an effect that in some aspects is the reverse that of an inertial navigation system. Here, a large gyrostat mass (the flywheel) can be use to stabilize or position certain objects such as spacecraft. In the spacecraft application, such as in U.S. Pat. No. 5,437,420, the relevant portions herein incorporated by reference in their entirety, large flywheels and high torque motors and brakes are used to topple the flywheel. The spacecraft then feels a moment of thrust at right angles to the torque that is applied to the gyrostat. This way, and in others such as the “pure” inertia of rotation of causing a flywheel mass to accelerate or decelerate rotation, spacecraft attitude may be changed through gyrostatic means. In other stabilization applications, gyrostats are used to stabilize platforms such as cameras and other precision instruments, in general by attaching a gyrostat to the instrument platform.
[0009] Gyrostats have been used in conjunction with wheels to provide linear propulsion. Through a systems of gears and linkages, U.S. Pat. No. 5,090,260, incorporated herein by reference in its entirety, provides a means for translating the gyrostatic toppling effect into a linear force for propulsion.
SUMMARY OF THE PRESENT INVENTION
[0010] The present invention is an electronic game with interactive input and output through a new, novel and non-obvious player interface apparatus. The new player interface apparatus may be a hand held apparatus that may use sensors to determine the position of the apparatus and the gyrostatic effect to provide tactile feedback to the user. More particularly, in one embodiment of the present invention, the apparatus may be used in conjunction with software to create an electronic interactive sword game. In the sword type embodiment of the present invention, the hand held apparatus is preferably about the size of a three and/or four D-size cell battery flashlight and is adapted to be held by either one and/or two hands. The sword type device may be ornamentally, decorated to resemble the hilt and/or handle part of a traditional and/or futuristic sword. Contained within the sword housing is a gyrostatic propulsion device from which the gyrostatic toppling effect is utilized to create a torque and/or the feel of sword blows on the sword handle and, thus, on the player holding the sword apparatus.
[0011] In overview, one or more gyrostat(s) inside the sword apparatus may be used as the “propulsion” gyrostat, hereinafter, the “propulsion gyrostat.” The propulsion gyrostat may be configured with a relatively “large” mass flywheel and a high speed electric motor to spin the flywheel and, thus, provide a source of gyrostatic power. The flywheel of the propulsion gyrostat may be configured in a double gimbal housing wherein each axis of freedom, for example, the pitch and yaw of the flywheel, may be controlled by high torque electric motors. By applying the appropriate voltage to the high torque motors, the propulsion gyrostat may be “toppled” in such a way as to create a calibrated torque on the whole sword apparatus, e.g., the sword housing. This calibrated torque may be used to simulate, inter alia, a sword blow as felt at a sword's handle. Through the interaction of successive sword blows, e.g., torque provided by the propulsion gyrostat to provide the “feel” of sword blows, and interactions with virtual swordsman opponents, the present invention provides a novel and exciting interactive sword game that physically involves the player interactivity with the game.
[0012] In the preferred embodiment, the present invention works in conjunction with an electronic game and/or under the control of the electronic game. Thus, game “play” and/or plot features can be used to enhance the effectiveness of the present invention in creating the illusion of sword fighting. For example, game “play” and/or plot elements may be used to encourage the player to conserve the rotational energy stored in the propulsion gyrostat. This conservation of energy may be rewarded in the game interaction by producing more “powerful” sword strikes when the propulsion gyrostat of the sword apparatus is at full power storage, e.g., optimal rotational speed and/or a large flywheel in the sword apparatus. Keeping the propulsion gyrostat at full and/or near full power storage allows the sword apparatus to create the maximum impulse torque available thereby creating the most effective and powerful sword illusion.
[0013] It is understood that the sword apparatus of the present invention may not need a blade but the blade may be represented in the virtual space in the game itself. This may be done either on the computer screen or through the use of virtual reality glasses and/or other display apparatus. Thus, in the virtual reality domain, the computer may generate a sword blade that appears to extend from the hand held sword apparatus of the present invention. However, a plastic blade and/or other ornamental blade extending from the apparatus are within the scope of the present invention.
[0014] In another embodiment of the present invention, other virtual representations of the virtual instrument that is representative of the object held by the player are within the scope of the present invention such as a gun, bazooka, knife, hammer, axe and the like and the gyrostat propulsion instrumentality of the present invention may be controlled accordingly to provide the appropriate feedback to simulate the virtual instrument. For example, in the gun and/or pistol embodiment of the present invention the gyrostat feedback means may be used to simulate events such as the “kick” from a gun, or the “crush” of a hammer blow.
[0015] Another feature of the present invention is to have a macro gyroscopically powered inertia navigational means on-board the hand held device. Such a small apparatus is available from Sony Corporation. The gyroscopic inertial positioning system may keep the computer game apprised of the spatial attitude and/or location of the sword apparatus in such a way that the game may provide the proper moments of torque on the motors to provide feedback to the player.
[0016] Yet another feature of the present invention is to use sensors, e.g., a receiver and/or a transmitter, on the sword apparatus and an array of sensors, e.g., receivers and/or transmitters, external and/or internal to the sword apparatus to determine the spatial attitude and/or location of the sword apparatus. In the preferred embodiment of the present invention, the sword apparatus uses infrared blasters, e.g., high output infrared transmitters such as those found on modern universal remote television controls, to output a pulse and/or timed emission of infrared light which may then be received at the remote sensors, which in the preferred embodiment are infrared receivers, whereupon the timing and/or phase differential of the received signals may be used to triangulate and determine the spatial position of the sword apparatus. An infrared output at both the top and the bottom of the sword apparatus may be used to determine the attitude of the sword apparatus and is within the scope of the present invention.
[0017] Game play and/or game plot may be used to encourage the player to maintain the sword apparatus within a predetermined field of play. For example, if the gaming program determines that the sword apparatus is positioned near the edge of a predetermined game field, the game software of the present invention may produce a virtual attack and/or event on the player from the center and/or opposite side of the game field to encourage the player to move the sword apparatus toward the “center” of the predetermined game field. It is understood that the game of the present invention may also use a “mysterious” force feature, discussed further below, to encourage the player to move the sword apparatus toward the center of the predetermined game field.
[0018] Economical high torque motors are found in many common children's toys such as radio controlled cars and other devices. It is understood, that the present invention may have a gyrostat of sufficiently high mass and may be “spun” at a sufficiently high speed in order to convey to the player, through the gyrostatic toppling effect, the desired tactile-game effect and/or torque on the player. The torque on the propulsion gyrostat may be a calibrated and/or variable force and, therefore, the effect may be a calibrated and/or variable force imparted to the player. It is understood that the fictitious “light saber” sword as popularized in the Star Wars™ fictionalized universe may be an appropriate metaphor for the game of the present invention. In the light saber metaphor, because a light saber is a fictional device, the game effects and/or game plot may be optimized to work in conjunction with the sword apparatus of the present invention. For example, the blow of crossing swords may use a calibrated and/or variable tactile feedback to the player where low energy storage in the propulsion gyrostat may be coordinated with game interaction such as allowing an opponent's sword to partially and/or completely pass through the players “light saber” defense. In another example, the light saber metaphor may allow the light saber virtual blade to strike through objects and, thus, may require a relatively small tactile feedback amount, thus, creating the illusion of a powerful virtual sword that can strike through objects. In contrast to a virtual medieval sword, wherein the steel blade cannot strike through all objects and, therefore, the striking of an object, such as a virtual tree, may require a massive tactile feedback response in order to “stop” the sword blow cold. Thus, the illusion of the medieval sword may be lost because of overloading, e.g., over draining of the rotational gyrostatic energy, the propulsion gyrostatic tactile feedback means of the present invention. That is not to say, of course, that a medieval sword embodiment is not within the scope of the present invention, for indeed it is as well as swords and blades of all types and sizes.
[0019] The light saber metaphor may be most appropriate, here, because the light saber metaphor may allow a player to strike through walls, e.g., the light saber may cut through the virtual walls. However, the player may still feel feedback as the sword passes through a virtual reality object, e.g. walls. Allowing the object to pass through the virtual reality object without stopping it “cold,” thus, allows the system to conserve its rotational energy for other interactions with the game.
[0020] Another interesting aspect of the present invention is the ability of the software to lead a player's movements, as well as provide impact feedback. A good example of this would be, again, the Star Wars™ metaphor where the player is told to “feel the force.” The game of the present invention may apply a “mysterious force,” discussed further below, which is essentially a small torque from the propulsion gyrostat whereby the sword device may “lead” the player's sword blows and/or movement.
[0021] Another aspect of the present invention is the ability to network multiple game play stations to allow virtual sword fights between multiple players and/or the coordinated efforts of multiple participants. In a two player mode, conventional modem means may be used to connect game stations in a back-to-back configuration. Telemetry between the game stations may be used to convey positional, attitudinal and inertial mass, explained further below, of the respective sword devices between game stations. In another configuration, multiple players may-network together with a server computer acting as the communication hub between multiple game stations. A low cost network such as the interne may be used as the network transport protocol. Alternatively, one game station may be configured as a master station, acting as a communication master and other game stations may be networked to the master station.
BRIEF DESCRIPTION OF THE FIGURES
[0022] FIG. 1 shows a cross sectional profile of one configuration of the sword game of the present invention. Sword housing 200 , power supply 900 , power supply cord 910 , data link to game controller 510 , control logic 499 , voltage control circuits for the motors and sensor inputs 400 , gyrostat position detector circuit and positional gyroscope 600 , safety switch 201 , safety switch lever 202 , propulsion gyroscope device 500 , Speaker 203 , infrared receivers and/or blasters 300 , 302 and 304 . It is understood that the infrared detectors and blasters are interchangeable into different operable configurations.
[0023] FIG. 2 shows a detailed diagram of control circuit 400 and the propulsion gyrostat device 500 .
[0024] FIG. 3 shows a configuration of the present invention showing the game controller remote infrared blasters, television display, game controller and the sword device 200 of the present invention.
[0025] FIG. 4 shows a block diagram of control circuit 400 , showing the controller output and sensor input.
[0026] FIG. 5 shows a block diagram of the calculate blow routine which among other things, is a routine called from the game software to calculate the severity of a sword blow.
[0027] FIG. 6 shows a block diagram of a procedure for outputting the sword blow to the propulsion gyrostat 500 .
[0028] FIG. 7 shows a block diagram of the gyro position control procedural loop which controls the position and the torque on the propulsion gyrostat.
[0029] FIG. 8 is a block diagram showing the mysterious force procedure which is a part of the integration between the game software and the sword hardware apparatus of the present invention.
[0030] FIG. 9A is a block diagram showing a networked application of the present invention.
[0031] FIG. 9B shows a message protocol format that may be used in a multiplayer configuration.
[0032] FIG. 10 shows a depiction of the sword apparatus in sword contact with a virtual opponent.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Turning now to FIG. 1 , the sword game of the present invention has a sword housing 200 not to scale which is preferably made of a plastic material that is light weight yet strong enough to handle the forces imparted by the propulsion gyrostat. The torque forces from the present invention may be able to approximate the feel of a real sword battle, therefore, the material for the housing, 200 , should be of sufficient strength to safely handle the torque imparted by the torque propulsion system 500 . It is understood that the sword housing 200 may be made of metal, cast aluminum, plastic or other materials known to those in the art, for handling this amount of torque. It should be noted that the housing 200 may also serve as a safety enclosure if the propulsion gyrostat contained in block 500 were to have catastrophic failure and become free of its bearings. This may be accomplished by lining the inside and/or outside of housing 200 with Kevlar® or other highly impact resistant material to contain the flywheel of the propulsion gyrostat within the housing. However, in the preferred embodiment housing 200 may be sufficiently strong so as to contain the propulsion gyrostat in the event of catastrophic failure while maintaining a means for low cost plastic injection molding manufacturing techniques. Housing 200 may also be configured with shock absorbing material on the exterior of the housing to cushion impact should the housing contact physical objects. Block 900 represents an external power supply. The power supply 900 may be used to rectify household voltage into usable voltages for the sword game of the present invention. The sword apparatus of the present invention may have sufficient current draw to require a separate power supply and this current draw may not be available from the voltage outputs from a standard personal computer and/or game controller device. The high current draw of the present invention may be due to the high torque motors of propulsion gyrostat 500 necessary for the torque propulsion. However, it is understood to those skilled in the arts, that power supply line 910 may be coupled into the data line 510 to integrate power lines 910 and 510 into a single cord for data controls and power to the sword apparatus. Moreover, it is within the scope of the present invention to draw power from batteries, the game controller 240 and/or from a computer peripheral interface port if sufficient power is available. The sword housing 200 may be adapted to receive a speaker 203 to provide an audio output for game sounds. Speaker 203 may be connected by line 204 to control circuits 400 . Control circuits 400 may contain a digital to analog converter to generate game sounds.
[0034] Block 499 may represent the circuit board for the control circuits of the present invention. Control circuits 499 may have a suitable communication means such as a USART and/or ethernet and/or universal serial bus interface to receive data signals from the game controller 240 . It is within the scope of the present invention to use external circuits and use analog controls signals and/or wireless analog and/or digital control signal to provide an interface between the sword apparatus and the game controller 240 . In the preferred embodiment of the present invention, circuits 499 may contain a suitable protocol communications device or procedure to establish communications between the sword device and game controller 240 . Circuits 499 may also contain the processing elements necessary for control and/or execution of software and/or software elements to effect control of the sword apparatus of the present invention. The control functions and/or part or parts of the control function may be moved into the game controller 240 .
[0035] Block 400 may represent the control circuits necessary for the analog drive voltages for the propulsion gyrostat means 500 . It is understood that because of the high torque available from is the propulsion gyrostat 500 separate control circuits such as high powered transistors and/or FETs may require separate circuits 400 to generate sufficiently large drive currents and/or voltages. The control circuits 400 and the digital control circuits, and/or microprocessor circuit 499 may be placed into a single integrated circuit, group of circuits and/or on the same circuit board.
[0036] Block diagram element 600 may represent a gyrostat positioning system to determine the attitude of the sword apparatus of the present invention. One such miniature device is commercially available from Sony Electronics and or functionally as the device employed in U.S. Pat. No. 4,959,725, the relevant herein incorporated by reference. Positional device element 600 may be used to determine the position of the sword and the attitude of the sword in the X, Y and Z axes. Switch 201 and switch arm 202 may be a safety switch, in the “deadman” circuit configuration, held in place by the player's grip on the apparatus. Because of the high torque available in this game it be desirable to have a kill switch connected to the sword apparatus 200 requiring that the user keep the switch depressed in order for power to be imparted to the torque propulsion unit. The game may be equipped with suitable straps, such as Velcro® straps and/or gloves, to maintain the sword within a player's hands and not allow the sword to flip out of a sword player's hands, much like a hand guard served in part, on traditional swords. The circular devices depicted at 300 , 302 and 304 may be either infrared receivers or infrared blasters or transmitters. These sensors and more, not shown, may extend around housing 200 to detect the position of a sword and/or the spatial coordinates of X, Y and Z as is denoted and further discussed in FIG. 3 .
[0037] Turning now to FIG. 2 , which shows a detailed mechanical diagram; not to scale, of one configuration of the gyrostat of the present invention, block 400 may contain the drive circuits necessary to drive the analog motors 20 , 22 (not shown), 30 , 35 , 40 and 50 . It is understood that motors 30 , 35 , 40 , 50 , 20 and 22 may be high torque motors such as those available from the radio controlled model cars and/or other devices from the hobby arts. It is understood that motors 20 and 22 may be high velocity motors capable of spinning the main propulsion flywheel 10 up to a sufficient velocity to impart the necessary torque to the player. The energy stored in the propulsion gyrostat is a factor of rotational velocity and the mass of the flywheel 10 . Spoke 15 shows one of the spokes connecting the main body of propulsion flywheel 10 , along axis 60 to motor 20 and 22 . As known to those skilled in the mechanical arts, motors 20 and 22 may have mechanical assistance, e.g., gears, in rotating flywheel 10 and may also include a small transmission to help the motors 20 and 22 initially start the flywheel 10 and then shift gears into higher speed to impart a greater rotation to flywheel 10 . In as much as flywheel 10 and motors 20 and 22 are the main inertial drives of the apparatus, it is understood that a suitable high speed motor may be obtained from the disk drive technology arts wherein a very flat motor is available to spin a disk at a very high rotational speed.
[0038] The main flywheel 10 is shown mounted in a double gimballed configuration. The first gimbal is along an axis between motors 30 and 35 . The second gimballed axis is between motors 40 and 50 . This is a (two axes of freedom) double gimballed apparatus meaning that both “pitch” and “yaw” of the main propulsion flywheel 10 may be controlled in two axes of freedom. Other mechanical configurations of double gimballed gyroscopic apparatus are known to those skilled in the art and are within the scope of the present invention. It is also understood that a single gimballed embodiment is within the scope of the invention that may utilize two and/or more gyrostats. Two propulsion gyrostats in a single gimballed configuration may be utilized by coordinating the toppling force on the two gyrostats to create the necessary torque action on the player desired by the present invention. It is also within the scope of the present invention to utilize two double gimballed gyrostats, one at the top of the sword and one at the bottom of the sword (not shown) in a “bar bell” like configuration. Such a dual gyrostatic propulsion configuration may be used to impart additional torque on the sword housing 200 to provide amore realistic simulation of the sword battle.
[0039] Sensors 37 and 38 are positional sensors that may be infrared and/or light-based sensors which may reflect off disks 100 and 90 , respectively. Disk 90 and disk 100 may be reflectively “bar coded” to indicate the position of the flywheel within the gimbals via the coding of the reflected light from sensors 37 and 38 off of the disks. These positional sensors may be necessary to obtain the position of the flywheel 10 , e.g., the pitch and yaw position, in order to calculate which way the propulsion gyrostat should be toppled to create the desired torque. Contacts 110 and 95 are shown as a means for transferring power and signals from the outer gimbal to the inner gimbal. Such power transfer may be accomplished by utilizing conductive metal ring fixated to disk 100 and disk 90 and pressure contacts at 110 and 95 keeping in contact with the conductive metal rings.
[0040] The main propulsion gyrostat is shown at 10 . Spokes 15 hold the propulsion gyrostat to the axis 60 of the main drive motor 20 . It is understood that an additional drive motor 22 may also be used. Housing 70 shows the housing of the first gimbal securing motor 20 and 22 and flywheel 10 to the first gimbal housing 70 . The first housing 70 extends around to the mounting axles 31 and 32 , connected to toppling motors 35 and 30 respectively. Drive motors 35 and 30 may impart the toppling torque in the first gimballed axis. It is understood that motors 30 and 35 may be replaced with a single motor and that configuration is within the scope of the present invention. Configurations that give the toppling motors 30 and 35 a mechanical advantage, such as with a mechanical gear arrangement, are also within the scope of the present invention. Circular ring 80 depicts the second gimbal housing holding motors 30 and 35 to a second gimbal arrangement. The second gimbal housing 80 connects the inner gimbal and motor drives 30 and 35 to the outer gimbal 80 through axles 81 and 82 . Axles 81 and 82 are connected to the second gimbal drive motors 40 and 50 . Once again, a two motor configuration is shown as a means for imparting the maximum torque available from small electric motors such as those available from the hobby and toy arts. It is understood that these toppling motors may work in tandem to impart a toppling torque in the same direction; likewise motors 35 and 30 may also work in tandem to impart the maximum toppling effect on the drive gyrostat, the drive flywheel 10 . It is understood that motors 50 and 40 may be replaced by a single suitably high torque motor. It is also within the scope of the present invention to use configurations that give motors 40 and 50 a mechanical advantage for toppling the drive flywheel 10 via the inner gimbal. Inner and outer gimbal brakes and/or clutches (not shown) may be used to temporarily lock a gimbal axis which a toppling force is applied to the second gimbal axis, such as disclosed in U.S. Pat. No. 5,437,420, the relevant portions herein again incorporated by reference. Function circuit board 400 is shown as providing the analog drive voltages for the motors described above.
[0041] FIG. 3 shows the present invention in a deployment perspective showing a television and/or display 205 in a virtual reality and/or the game reality space can be projected 205 from game controller 240 in conjunction with sword housing 200 . Note the configuration of remote infrared transmitter and/or receivers 210 , 220 and 230 . This configuration, after a suitable calibration within the scope of the present invention, may be used to triangulate the position of sword apparatus 200 using signal phase delay and/or time delay calculations between the remote elements 210 , 220 , 230 and the housing sensors 300 , 302 and 304 . It is understood that television 205 may be replaced with a suitable display such as a high definition television and/or a computer display and game controller may be embodied in personal computer software and/or a personal computer hardware apparatus and/or dedicated hardware. Infrared blaster and/or receivers 210 , 220 and 230 may work in conjunction with infrared receivers and/or blasters 300 , 302 and 304 to determine the position of the sword in real coordinates. The real coordinates may be determined by a timed burst from infrared blasters 210 , 220 and 230 and the time delay of the burst received at any one of the sensors 300 , 302 or 304 which may then be used to triangulate the position of the sword in real coordinates. Although shown in an infrared embodiment, other remote triangulation techniques are known to those in the navigational arts, such as through the use of radio frequency and ultra-violet frequencies. Television and/or display 205 may be replaced with virtual reality glasses and/or helmet arrangement. The virtual reality glasses and/or helmet may use two displays stereoscopically disposed in front of a player's eyes to give a three dimensional representation of the virtual playing field. In such a virtual reality embodiment in using virtual reality glasses it is understood that infrared sensors 210 , 220 and 230 may be supplemented with additional infrared sensors to provide suitable determination of the real positional coordinates of the sword 200 and/or players head attitude and/or real position in respect to the virtual reality game. It is understood that this positioning information may be used by the game to encourage the player to re-center the sword 200 and/or to keep the sword 200 in a predetermined playing field of the game. Infrared blasters, shown at 210 , 220 and 230 may be reversed; that is, they may be infrared receivers and the infrared blaster may be located at 300 , 302 and 304 . In such a configuration a single and/or multiple infrared burst(s) may be output from 300 , 302 and 304 and the timing of receiving or reception could be determined at 210 , 220 and 230 in order to triangulate the real position of the sword 200 . It is understood that the game has a suitable calibration mode for configuring the sensor array.
[0042] FIG. 4 shows a block diagram of the control circuits 400 of the present invention. A controller 401 may be used in conjunction with drive circuits at 402 , 404 and 406 to provide the voltages and currents necessary to provide the energy for rotation of the propulsion gyrostat motor 20 and/or 22 (not shown) and toppling motors 30 , 35 , 40 and 50 . Block 402 may depict the main drive circuit for the rotation of the propulsion drive motor 20 and/or 22 . Block 404 may depict the drive circuitry for toppling motors 30 and 35 . Block 406 may depict the drive circuitry for toppling motors 40 and 50 . It is understood that blocks 404 and 406 are representative of circuitry necessary to drive the high torque motors for the tumbling action of the present invention; these circuits may be incorporated into an application specific integrated circuit and/or incorporated with controller 401 . They may also be discrete high current components such as MOSFET devices. Blocks 408 and 410 are representative of the circuits necessary to determine the position of the propulsion drive 10 from sensors 37 and 38 , respectively. Such sensors may include, as previously noted, sensors 37 and 38 as optical sensors that reflect off disks 100 and disk 90 respectively to determine the pitch and yaw position of propulsion drive 10 . The circuits of blocks 408 and 410 may work in conjunction with controller 401 to determine the propulsion drive 10 position. Block 414 may represent the circuitry necessary to work in conjunction with sensor 21 to determine the rotational velocity of propulsion drive 10 . The rotational velocity of the propulsion drive motor 10 may vary as game play ensues. Determining the rotational frequency of propulsion flywheel 10 , may also be accomplished by measuring the reflected voltage from motor drive 20 and/or 22 . The reflected voltage, current and/or power factor vector may be used to determine an approximate rotational velocity and/or speed of propulsion drive 10 . Blocks 416 , 418 and 420 may represent the circuitry necessary for positional sensors 602 , 604 and 606 to determine the pitch, yaw and/or attitude of the sword 200 when a mini-gyroscope is used to determine the position of the sword 200 . Sensors 602 , 604 and 606 may be incorporated into functional block 600 .
[0043] FIG. 5 shows a block diagram representing a procedure that may be used to calculate a simulated sword blow. This routine may make the initial calculation for the torque force to be applied to the pitch and yaw motor drives at outputs 404 and 406 . The calculate blow routine 520 may be called when an “attacking” sword and/or other virtual object(s) comes into contact with the calculated position for the player's virtual embodiment of the sword. The calculate blow routine 520 routine may receive an impact point in the x, y, and z coordinates of the virtual space and when applicable the attacking sword velocity. Block 522 labeled “get position sword hilt” is a routine that may retrieve the actual position of a player's sword apparatus 200 from sensor 600 and/or by the other means of sensors 300 , 302 and 304 . The retrieved hilt point may be used to determine the distance from the sword hilt that a sword impact occurred. This distance may, in turn, be used to determine the amount of leverage, e.g., the amount of “twisting force,” that the attacking sword blow may have on the sword apparatus 200 . The next block 524 may calculate the sword's idealized mass. It is understood that more than one type of sword apparatus may be utilized, e.g., sword apparatus with different mass flywheels and/or rotational frequency; thus, the sword's idealized mass may be derived, at least in part, from a variable mass M, which may be the actual mass of the propulsion gyrostat and the variable omega which may be the instantaneous and/or present angular velocity and/or rotational frequency of the propulsion gyrostat. These two parameters may be used to determine the idealized mass and/or angular momentum of the propulsion gyrostat at any give time. Block 526 labeled “get sword velocity vector” may determine the sword velocity vector, e.g., the direction and speed of the sword, by successively determining the position of the player's sword and then determine from the change in position the velocity of the sword apparatus 200 . The virtual sword may have an idealized and/or virtual mass that is different from the actual mass and/or inertial mass of the actual apparatus 200 . For example, in one configuration the virtual mass may be represented and/or idealized as a heavy broad sword. Since a real broadsword may be a very heavy instrument, its virtual mass may also have a certain amount of momentum because of its idealized weight and velocity. The resultant of procedural blocks 524 and 526 is a vector providing the player's virtual sword direction and force at the impact point. The next procedural block 528 “get game sword position” yields a value from the game software, much like the resultant from procedural blocks described above, which provides the position of the sword hilt from the attacking virtual sword. Block 530 labeled “get game sword velocity vector” is a vector, from the game software, providing the velocity and virtual mass of the attacking sword, similar to procedural blocks 524 and 526 described above. Again, for example only, the virtual attacking sword may also have a virtual mass idealized from a fictionalized attacking broad sword. That is, once the heavy broad sword is in “motion,” it may have a momentum from its mass and velocity. Procedural block 532 labeled “get game sword blow intensity” is the force of the attacking blow at the position of the strike. This may be calculated by the well known equation that force equals mass times acceleration and/or kinetic energy equals one half the mass times velocity squared. The results of procedural blocks 528 , 530 and 532 is a vector providing the direction and force at the impact point of both the attacking virtual sword and the virtual sword projected from the player's sword apparatus 200 . By taking the cross product of these vectors, the factors such as angle of the sword attack, how far from the hilt the strike may be taken into account when calculating the resultant vectors. Thus, procedural block 534 labeled “calculated blow/return blow torque vector” is a product of the two vectors; that is, the vector providing the player's sword direction and force at the impact point and the attacking sword vector providing the direction and force of the impact point idealized at right after impact. The product of the two vectors may provide the resulting direction and speed of the two swords by the calculation between two idealized objects when the equation for the conservation of momentum and/or energy is applied. That is m1y1+m2v2=m1y1(t+1)+m2v2(t+1). Thus, in this exemplary embodiment of the present invention the two swords may “bounce” off each other with an idealized impact. That is, there is no cushion or elasticity loss in the impact of the two idealized swords. However, elasticity factors as well as other means for calculating the resultant torque from a sword blow are within the scope of the present invention and may be accommodated by the insertion of loss constants in the energy conservative equations.
[0044] FIG. 6 shows the call sword blow procedure which is used in conjunction with the procedures of FIG. 5 to calculate the actual values of the torque outputs for the pitch and yaw gyrostat toppling motors that provides the simulated impact of the sword at the player's sword apparatus 200 . Procedural block 540 labeled “call sword blow” may denote the name of the software routine to perform the aforementioned torque output calculations. Turning now to the step by step procedural blocks, 542 labeled “get gyro position” may be from sensors 408 and 410 and may determine the attitude of the position of the propulsion gyrostat 10 . This calculation may be important for the torque calculation because the gyrostatic force acts at a right angle to which the toppling force is applied. Thus, given that the desired torque effect for the sword apparatus is known from the calculation above, in general terms, the toppling torque applied to the propulsion gyrostat may be applied at a right angle to the propulsion gyrostat to achieve the desired torque effect. The next block 544 labeled “get gyro rotation” may be from sensor 418 and may indicate the angular velocity and/or rotational speed of the propulsion gyrostat 10 . The next procedural block 546 labeled “get calibration factors” may provide operating parameters for the particular sword apparatus for which the torque output calculation is being determined. For example, as discussed above, a sword apparatus with two or more propulsion gyrostats is within the scope of the present invention. Also the mass of the propulsion gyrostat may be different for different sizes and models of the sword apparatus. Thus, block 546 may be utilized to retrieve the particular calibration factors for the particular sword apparatus for which the torque calculations are being calculated. It is understood that the calibration parameters may be encoded in a memory location associated with and/or within controller 401 . It is also understood that in the preferred embodiment of the invention the actual inertial mass of the sword, which is the rotational frequency of the propulsion gyrostat times the mass of the propulsion gyrostat, may be greater than the virtual mass and/or idealized mass of the sword in order to provide excess torque and game action capacity for sword blows, e.g., at any given moment in game play the rotational frequency of the propulsion gyrostat may not be at the maximum rotational frequency and, therefore, the maximum torque effect on the sword apparatus may not be instantaneously available. The next procedural block 548 may calculate the value of the torque for output to controllers 404 and 406 . This calculation may use the instantaneous inertial mass available, the desired torque amount and a compensating factor to resolve any non-linearities in the toppling motor response, as determined by conventional control systems principals, to calculate the output value. The sum of these torques may provide a toppling force at a right angle to the desired torque for the sword apparatus 200 . The next procedural block 550 labeled “output impulse torque 1 and torque 2 ” are numerical value that may represent a value for eventual output to the toppling motors. In the preferred embodiment, these torque values are output to a predetermined memory location in controller 401 that, as will be discussed further below, are accessed by the gyrostat position control routine detailed in FIG. 7 . It is understood that torque 1 and torque 2 may be a vector and/or an angular equation that takes into account the rotation of the propulsion gyrostat as torque is applied in order to translate what may be an angular torque output, due to the change in the angular position of the propulsion gyrostat, to translate the toppling force into a linear and/or straight line torque effect on the sword apparatus 200 . Procedural block 552 labeled “gyro position control” denotes that the values of block 550 may be output to a memory location and/or data buffer and/or queue that will be accessed by the gyrostat position control routine detailed in FIG. 7 . Procedural block 552 also provides that the call sword blow routine 540 may then terminate normally and exit and/or return.
[0045] FIG. 7 shows the gyrostat position control procedure 560 . The gyrostat position control procedure may be the control loop that controls the output to torque control 404 and 406 and governs the position and/or toppling of the propulsion gyroscope 10 . The gyrostat position control procedure may operate in a continuous loop and may be the master routine that takes into account the sword blow torque and the “mysterious force factor,” as will be discussed below, and the torque output required to cancel the force of a player rotating the sword apparatus 200 when no torque and/or tactile feedback or output on the sword apparatus 200 is desired. Taking each step in turn, procedural block 562 labeled “initialize position” may provide that when the sword is initially powered on this procedure moves the propulsion gyrostat to an initial position. For example, “toppling” or rotating the propulsion gyrostat to top dead center while it initially spins up. This may be used to initially provision software variables in the game controller 240 . Procedural block 564 “get sword position” may be the sword position from block 600 and/or sensors array in the 300 series which may be used to determine the sword device 200 position. Block 566 may be a wait state that may be used to pause the procedural loop. Procedural block 568 labeled “get sword position” which may be a routine that may be identical to block 564 and may be used to get a second sword position. Procedural block 570 may use the first position from procedural block 564 and the second sword position 568 to calculate the change and/or delta in the sword apparatus 200 position, that is, the change and/or attitude in the position of the sword apparatus 200 . Procedural block 572 “get gyro position” may determine, from sensors 408 and 410 , the position of the propulsion gyrostat 10 . Procedural block 574 may be used to calculate the tracking torque 1 and torque 2 , although it is labeled “tracking torque” it may actually be a tracking voltage that topples the propulsion gyrostat to compensate for the change in the sword position from the first sword position calculated at 564 and the second sword position determined at 568 . The tracking voltage may be used to topple the propulsion gyrostat in such a way as to track the position of the sword apparatus 200 so as to minimize the torque felt at the sword apparatus 200 in response to movement of the apparatus, e.g., by the player, when no torque is desired. Alternatively, the toppling motors in the relaxed and/or non-energized state in conjunction with any mechanical advantage mechanism used to couple the toppling motors to the propulsion gyrostat flywheel 10 , may allow the propulsion gyrostat sufficient freedom of rotation so as to not require the tracking voltage output. However, in certain situations and/or configurations, it may be that if the propulsion gyrostat were to remain fixed and the player moved and/or changed the attitude of the sword apparatus 200 , the player may feel an undesired torque at a right angle to the rotational force applied by the player. In this instance, the mechanical linkage, generally denoted in FIG. 2 , may provide a predetermined mechanical degree of freedom in the coupling of the toppling motors with the propulsion flywheel 10 . The predetermined degree of freedom may be used by the gyrostat position control routine 560 to provide a delay and/or predetermined degree of mechanical freedom to allow the calculation of the tracking voltages from block 574 to rotate and/or to allow the propulsion gyrostat to rotate and track the player's movement of the sword apparatus 200 without the player receiving an untoward amount of undesirable tactile feedback. The tracking voltage calculation may only be an approximate calculation and yet be a mitigating factor for undesirable torque effect, e.g., some residual torque felt by the player may actually add a desirable strangeness of the tactical feel of the sword apparatus 200 . The next procedural block 580 labeled “get gyro effects” accesses the torque calculated for the sword blow, from FIG. 6 , at the circular block 576 and accesses the mysterious force torque, as will be discussed below in FIG. 8 , at block 578 . Procedural block 580 “get gyro effects” calculates the sum of the tracking voltages from block 574 , the sword blow torque from FIG. 6 and the mysterious force torque from FIG. 8 to combine these three torque vectors to determine a tracking voltage and/or voltages to create the toppling torque for the propulsion gyrostat 10 . Block 582 outputs torque voltages 1 and torque voltages 2 to torque motor controllers 404 and 406 . These torque voltages are used to topple the propulsion gyrostat 10 of the present invention to provide the gyrostatic effect of the sword apparatus 200 . Thus, for example, when the virtual sword is not impacting on a virtual object the output at block 582 may merely be the tracking torques from block 574 that attempts to topple the propulsion gyrostat so as to track the player's movement of sword apparatus 200 . Thus, for example, when a sword blow torque is generated from the procedure described in FIG. 6 , the dominant factor in the gyro effects calculation 580 and, therefore, the output at 582 may be the sword blow providing a strong output providing a strong torque at the sword apparatus 200 . In a third example situation, the dominant force may be the “mysterious” force from FIG. 8 , which will be discussed further below, which attempts to lead the player's sword movement through what may be subtle torque on the sword apparatus 200 . The “mystery” torque may be strong or subtle on sword apparatus 200 depending on pre-programmed parameters.
[0046] Procedural block 584 checks whether the controller 401 has issued a shut down command, if yes, the gyrostat position control loop exits at 586 , if no, the procedure is passed to sword position routine 564 and the control loop goes on continuously (that is, until a shut down command is received). The check shutdown routine 584 may check the dead-man switch shown as FIG. 1 , switch 201 , as to whether the player still has a sword in his hands and whether the controller may continue to output torque.
[0047] FIG. 8 shows the “mysterious” force calculation at procedural block 590 . For example, the mysterious force in the light saber metaphor may be a fanciful force as fictionalized in the Star Wars™ story line that the sword apparatus 200 will actually lead the player to a future sword impact. Another use of the “mysterious” force may be for a swordsman training mode to teach sword fighting techniques. The mysterious force calculation may be performed at procedural block 591 by first getting a desired virtual x, y, and z point for the virtual sword. Thus, the game software provides this coordinate as it, by definition, is a point and/or coordinate wherein a game event will occur within the game domain's future. Procedural block 592 may determine the sword apparatus 200 base point, as discussed above, from sensors 600 gyrostatic determination and/or sensors 300 external determination. The base point is understood to be the hilt of the sword apparatus 200 and/or the sword handle of sword apparatus 200 . Procedural block 593 may get the sword position or attitude, e.g., the angular position of the sword apparatus 200 and, thus, may determine the virtual location of the virtual sword blade extending from the sword apparatus 200 . Procedural block 594 may calculate the smallest change in position of the virtual sword location to the game provided X, Y and Z coordinates, e.g., some “future event.” Procedural block 595 may calculate a torque for the necessary pitch and yaw for the propulsion gyrostat, which may calculate a torque to move the virtual sword to intersect the desired X, Y and Z coordinate and/or provide a torque in the direction of the desired X, Y, and Z coordinates. Block 596 is the mysterious force factor parameter which may be a constant that is multiplied by the torque from block 595 to provide a mysterious force that is either strong, if the mysterious force factor is a large number, or subtle if the mysterious force factor is a small constant. The game metaphor and/or plot line may be adapted to provide the player additional incentive to have a subtle mysterious force factor, again, to coordinate the game play and/or the plot with the conservation of the angular momentum of the propulsion gyrostat. The next procedural block 597 may output a torque for controllers 404 and 406 to the gyro position control procedure depicted in FIG. 7 . It is understood that this torque calculation may take into account the position of the propulsion gyrostat from sensor circuits 408 and 410 as well as the angular momentum of the propulsion gyrostat from sensor circuit 414 and as well as taking into account the mass factors from the controller for the particular propulsion gyrostat used by the particular sword apparatus 200 . Procedural block 597 may output the mysterious force torque via a memory location or other suitable buffer structure back to FIG. 7 as previously discussed.
[0048] Turning back to FIG. 5 , this routine may be configured so as to accept other factors that may effect the sword blow calculation, such as to accommodate for when the sword apparatus 200 for the virtual sword apparatus passes through an object in the game domain such as a tree or wall that as previously discussed in the light saber metaphor and thereby may allow the sword to pass through or strike through while providing some tactile feedback to the sword apparatus 200 denoting the striking through of an object. This may be accomplished by reducing the sword blow intensity factor to provide an impulse from an object, e.g., idealized as a very small virtual mass, that may allow the sword apparatus idealized momentum to strike through the object. That is, the conservation of momentum equations may allow the virtual sword to follow through an object when the object struck has a small mass relative to the virtual sword mass.
[0049] Through the interactions of the procedures outlined in FIGS. 5 , 6 and 7 a comprehensive output for motor controller 404 and 406 to control the propulsion gyrostat may be accomplished through these inter-related demands on the sword movement and/or interactions with the game plot and/or game play metaphor to give a player the incentive to conserve angular momentum of the sword apparatus 200 . A comprehensive controller output is disclosed and allows sword apparatus 200 to be completely controlled by the game controller 240 at FIG. 3 .
[0050] FIG. 9A shows the game controllers of the present invention in a network configuration. Game controller 702 may be configured as the master and game controllers 704 and 706 may be in a slave configuration.
[0051] A network 708 is shown which may be a TCP/IP network such as the Internet. In the master configuration, the game station programmed as the master sends, receives and coordinates the information transfer from the “slave” configured stations. Information may be transferred between the stations using the communication data packet shown in FIG. 9B . The communication packet provides a terminal identification 750 , position information for a sword apparatus 752 , attitude information for a sword apparatus 754 , velocity information for a sword apparatus 756 , resultant force vector information 758 and sword parameter information 760 . The slave configured game station may periodically send this information packet to the master configured game controller. The master configured game controller may in turn, use this information to generate a virtual opponent having a virtual sword representation that is mapped into the game space. The master configured game station may relay the information from a first slave configured game terminal to a second slave configured game terminal. The master configured game station coordinates the calculation of the resultant force vector for the slave configuration game station's control output. It is understood that data packet shown in 9 B may be framed with the suitable protocol overhead and transparent bits.
[0052] Turning now to FIG. 10 , sword apparatus 200 is shown in a player's hand 1000 in combat with a virtual sword 1002 and virtual opponent 1004 . A virtual sword blade is shown at 1006 as idealized as extending from the sword apparatus 200 as may be viewed through virtual reality goggles on a player's 1000 eyes. The opponent's sword 1002 opponent 1004 and opponent sword blade 1008 are, in this example, a virtual representation. The game controller 240 may track the position and attitude of sword apparatus 200 . The positional and attitude information may be used by the game controller software to project and track the virtual blade 1006 . The game controller software 240 may determine and track the velocity of the blade 1006 by using the differential positioning method described above. The game controller 240 software may also create and track the position of blade 1006 in the game space coordinate system. The game controller 240 may create and track the position of blade 1008 . The game controller software may determine when the position information of blade 1006 and the position information of blade 1008 indicates a collision of the blades by tracking the area from line 1014 which has a radius 1018 and the area from line 1016 which has a radius 1020 and logically comparing the points to determine whether there is an intersection. When the game controller software determines there is an intersection the intersection point may be passed to the procedures described above in FIGS. 5 , 6 and 7 . In summary, a vector 1012 is determined that provides the force of the sword blow, for blade 1006 , at the point of intersection. A vector 1010 is also determined providing the force of the attacking sword at the point of intersection. Through the use of the conservation of energy equations provided above, a resultant vector 1022 may be determined to provide the force vector for the resultant force at the point of intersection. The vector 1024 may also be calculated with the conservation of energy equations to provide the resultant force at the intersection point for the attacking sword 1002 . The resultant force vector 1022 may be used in conjunction with the distance between the point of intersection and the sword hilt 1026 to approximate the torque generated at the point the player 1000 is gripping the sword apparatus 200 . The torque is the distance times the force vector 1022 . This torque output approximation may be used, inter alia, by the procedures described above to calculate the output torques and/or toppling force for the propulsion gyrostat. The above described procedures often use vectors and cartesian coordinates to describe the present invention. Other coordinate systems such as spherical and cylindrical are also within the scope of the present invention.
[0053] The above described invention and modifications and alterations thereto will are within the scope of the present invention and will provide those skilled in the arts and the general public with a new, novel and non-obvious electronic feedback apparatus and electronic sword game.
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Systems, methods, and apparatus for communicating information regarding movement of a gaming device are presented herein. A gaming device can include at least one sensor configured to measure information associated with at least one of a position of the gaming device or an attitude of the gaming device. Further, a communications interface component can be configured to communicate the information to a controller. A method can detect, via sensors of a handheld gaming device, information related to a movement of the handheld gaming device; and transfer the information to a controller communicatively coupled to the handheld gaming device. A system can include means for receiving information related to a position of a gaming device or an attitude of the gaming device, and means for predicting an anticipated position of the gaming device based on the means for receiving the information.
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TECHNICAL FIELD
This invention provides a mechanism to improve the performance of parallel applications running on S-COMA (Simple Cache-Only Memory Architecture) computer systems as well as other DSM (Distributed Shared Memory) systems by dynamically migrating the home node of any global page to a more suitable node.
DESCRIPTION OF THE PRIOR ART
In the targeted architecture, any coherence-related access or other access that cannot be serviced at the client node results in a request for service to be sent to the home node of a globally shared page. This may result in a significant amount of traffic between the client nodes and the home node, resulting in slow effective bandwidth and latency for the system. Also excessive paging pressure at a home node can cause the system to halt. The following lists some of these circumstances in more details.
1. The home node does not participate in the sharing of the global page:
Two or more client nodes frequently share lines of a global page whose home node does not participate in this sharing. The hardware coherence protocol will require one extra trip through the home node for every coherence/data movement. This extra trip involves time consuming communication through the network, thereby slowing down the shared memory system.
One client node may frequently access a global page whose home node does not even access the global page (perhaps by bad assignment of static home node initially, or when the memory access pattern changes after a migration). This access by the client node will unnecessarily tie up a frame at the home node.
2. Too much paging activity at a home node may force the page replacement algorithm to replace a global page in order to service a request of an additional global page from a client node--a very time expensive operation.
In U.S. Pat. No. 5,535,116, each page has a plurality of data-items, and each data-item has a statically assigned home node which maintains its directory. The directory identifies all the sharing nodes as well as a single master node that is supposed to hold the master copy of the data-item. Each time a read request comes to the home node, it asks the master node to forward a copy of the data-item. When a write request comes, the home node asks all sharers to invalidate the data-item and asks the master to send the data (to the requester) and to give up mastership. The requester becomes the new master. The home node never changes in their patent.
REFERENCES
1. U.S. Pat. No. 5,535,116 "Flat Cache-Only Multiprocessor Architectures" by Anoop Gupta et al.
2. Computer Architecture A Quantitative Approach, 2nd edition, 1996 by D. Patterson & J. L. Hennessy (Morgan Kaufmann Publishers Inc) ISBN 1-55860-329-8 describes cache coherence in various computer architectures.
References 1-2 above are hereby incorporated herein by reference.
SUMMARY OF THE INVENTION
Our proposed solution to the problem involves 2 components:
1. A mechanism involving information maintained in network adapters and a protocol to enable migration.
2. Migration policies employing counters maintained in network adapters, and their interactions with OS to achieve efficient operation of the above migration mechanism.
Home node migration is important in the performance of DSM systems because the shared-memory access pattern of parallel applications is often hard to predict in advance, and may change during program execution. This invention provides a mechanism to dynamically migrate the home node of a global page to a more suitable node for improving performance of parallel applications running on an S-COMA and other DSM systems. In this invention, information is maintained in the shared memory adaptor (SMA) at each node, and this information is used in a protocol which enables migration. More specifically, information on the static home node and the dynamic home node of a global page is maintained at the static home node, the dynamic home node, and each client node of a global page. Also, at the SMA of each client node, a consultation count of the latest dynamic home node is maintained. This consultation count indicates the number of times the client node has consulted the dynamic home node for lines of the page. Also, at the SMA of the dynamic home node, a short list of the top N nodes, together with their consultation counts to the dynamic home node, is maintained. This information is then used (possibly with additional information e.g. paging pressures at the current and the potential new dynamic homes) to decide whether to change the dynamic home to a more suitable node. For example, if the consultation count exceeds a threshold, the dynamic home starts migrating to a more suitable node. With this invention, a message from a client node's SMA to another node's SMA always includes the static home node information and its consultation count to the dynamic home node. When a home node sends a reply, it always sends the dynamic home node information, and the recipient updates it dynamic home information.
It is an object of this invention to minimize time consuming communications between the SMA's of a shared memory system.
It is also an object of this invention to reduce paging activity at a home node.
Accordingly, this invention provides a method of migrating the dynamic home node of a global page to reduce time consuming communication between the SMAs of shared memory system. With this invention consultation counts are maintained, where each of the counts indicates the number of times a respective client node has consulted the dynamic home node of a global page, where the dynamic home node is the node at which the consultation counts are maintained. If the consultation count of a client node for the global page is greater than a selected threshold, then the dynamic home node is migrated to the client node.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a distributed shared memory system having a plurality of nodes interconnected through a network.
FIG. 2 schematically illustrates the flowchart for the basic home node migration protocol according to the invention.
FIG. 3 schematically illustrates the request and reply messages sent between nodes.
FIG. 4 graphically illustrates the home migration mechanism in accordance with this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Our scheme assumes that the S-COMA system contains hardware to support cache coherency amongst the nodes, to implement a directory-based coherence protocol. In this application, this extra hardware is referred to as a Shared Memory Adapter (SMA), and there is an SMA at each node. We now define a few terms that are used in the sequel:
Node-set: A job in this system consists of a set of processes running on a set of nodes, called its node-set. Each node may be a uniprocessor or a multiprocessor.
In this application a page is chosen as the unit for a home and for home migration. Other units may also be possible.
Static home node: Each global page is assigned a static home node at its initialization. This is done by using a simple distribution function (e. g. successive pages are assigned to the nodes in the node-set in a round-robin manner, to get even distribution). The static home node of a global page does not change during the life of the application program. The static home is responsible for bringing pages in and out of the backing store. (Although this function can be performed by other nodes as well, we restrict it to the static home node for simplicity).
Dynamic home node: Each global page has a dynamic home node. The dynamic home for a page may change from time to time under the control of the algorithms described later. Sometimes (e.g. at job start time) the static home node itself may act as the dynamic home. The dynamic home node keeps track of the node-level directory information for cache lines in that global page. It enforces the Invalidation Protocol (a well-known art, summarized later) to maintain the coherence of each line.
Client node: Any node that is accessing one or more lines of a global page is considered as a client node for that global page. In an S-COMA system, a client node allocates a frame in the node's memory to hold lines of a global page.
Invalidation Protocol When a client node does not have a valid copy of a line that it needs, it sends a REQUEST message to the dynamic home node of that page. A request specifies the line address and indicates whether the client needs a shared or exclusive copy of the line.
If the request is for a shared copy, the dynamic home responds with a copy of the line. If the line is held by another client in an exclusive state, the dynamic home first retracts the exclusive state (by communicating with that client) and then sends the data to the requester. In either case, the new client is added to the directory.
If the request is for an exclusive copy, the dynamic home first invalidates copies of the line in all clients, by communicating with them. It then sends the data to the requester in exclusive mode. It updates the directory to reflect this state.
Shown in FIG. 3 are the two types of messages that are transmitted between nodes to implement cache coherence and home node migration. Request messages (30) are sent by client nodes to a home node. The operation and line address fields are used as described above. The static home node and consultation count fields are added as part of the mechanism in this invention and are described later. The REPLY message (35) also has the operation and cache line address fields as described above, and the cache line data corresponding to the cache line address. The dynamic home node field is added as part of the mechanism in this invention and is explained later.
Shown in FIG. 1 is a typical distributed shared memory system in which this invention is implemented. Shown are nodes N1 through N3 interconnected to each other through network (100). Each node is shown as having memory (10), a plurality of processors (16), and a shared memory adaptor (15), connected to each other through bus (5).
According to this invention, a request message, which may be a request for an update of a cache line of a global page in a node, is sent from a shared memory adaptor (15) of one of the nodes to another shared memory adaptor of another of the nodes. This message typically includes static home node information and a consultation count to the dynamic node.
Mechanism--Information maintained per global page
At Client Node: A client node maintains the following information about a global page that is mapped into its memory:
1. The static and dynamic home nodes for the page,
2. The number of requests sent to the dynamic home thus far. This is called the Consultation Count of this client.
At Static Home: The static home always remembers the dynamic home node for the page. Any changes to the dynamic home are performed by coordination with the static home.
Dynamic Home: The dynamic home keeps the following information:
1. The static home node for this page,
2. The directory of all the lines in this page, containing the state of each line and the list of nodes sharing the line,
3. Its own consultation count (i.e. access by processors within the dynamic home node needs consultation of the directory),
4. The highest N consultation counts and the corresponding client node numbers, for this page. N is a hardware parameter and is typically 4.
Mechanism--Protocol
Page Fault: The first time a processor accesses a line in a global page, a page-fault (well-known art) occurs and the operating system allocates a frame in the memory and maps the global page to that frame. At this time, the SMA is informed of the corresponding static and dynamic home nodes of the page. The SMA stores this information into its tables and resets its consultation count for this page to zero. The adapter also marks all the lines in the memory frame as invalid.
Client Sends Request to Dynamic Home: When a processor at the client node accesses an invalid line, a request message is composed for the corresponding line. The consultation count for the page is incremented. The request (see FIG. 3) includes the line address, operation, the static home node of the line, and the current consultation count.
A Node Receives a Request: Referring to FIG. 1 and FIG. 2, with this invention, when a arbitrary node (say N3) receives a message (21) from the requesting node (say N1), node N3 does the following:
1. If node N3 is the dynamic home node for that page (22), then node N3 processes the message (23), as described later.
2. If node N3 is the static home and not the dynamic home for that page (24), it forwards the message to the current dynamic home node (25). Recall that the static home node always knows the correct dynamic home.
3. If node N3 is neither the static nor dynamic home for that page, it picks up the static home node number contained in the request and forwards the message to the static home (26).
The situation in which a node N3 (which is neither the dynamic home nor the static home) is being sent a request arises when it has been the dynamic home for a while and other nodes (such as N1) have recorded this information. But after some time, the dynamic home has been changed to some other node, and the requester (such as N1) still has the outdated information i.e. thinks that N3 is still the dynamic home. Typically N3 has deleted the page and the associated information (including the static home node number) from its tables. Hence N3 uses the static home node number contained in the message and forwards it.
Dynamic Home receives a Client Request: When a dynamic home node receives a client request message, it services the request as per the invalidation protocol described earlier. In addition, it also updates its list of consultation counts. That is, if this client's consultation count passed in the message is one of the highest N counts, it is inserted into the sorted top list of N items, and causes the bottom list-item to drop out. For best performance, it may be necessary to make such updates less frequently than on the receipt of every message.
Client Node Receives Reply from Home: When a dynamic home node services a request, it sends a reply message to the requesting client. As part of the reply, the line number, operation and line data are supplied. In addition, the new dynamic home node number is also supplied, and the client updates its dynamic home node number. This way, stale information is automatically updated based on need. Update information is not sent when there is no further activity from a client, and this is harmless.
Use of Consultation Counts: The consultation count of a client node reflects the amount of traffic between the client and the dynamic home. The counts are maintained by all client nodes, including the dynamic home nodes. Thus, for instance, suppose there are 4 nodes, N1,N2,N3,N4, where N4 is the dynamic home. Suppose all the nodes access lines from the page and the consultation counts for them are 5, 10, 2, 3, respectively. This implies that N2 is consulting the directory more heavily than other nodes. If the home is moved to N2, it would reduce messages between nodes N2 and N4. Thus, a criterion for causing a change in the dynamic node is that the consultation count of some client is greater than the consultation count of the dynamic home itself by a predefined margin. When the dynamic home observes this situation, it communicates with the static home, supplying the node number of the client that has the maximum consultation count. The static home then arranges for the migration as described later.
Page Pressure at Dynamic Home: When page pressure builds up, the operating system at the dynamic home may decide to evict a page. It then communicates this to the SMA. The SMA picks up the node that has the highest consultation count (besides itself) and sends the migration request to the static home node. After the migration is completed, the page eviction can take place.
Coordination for Migration: In either of the above two cases, the static home node receives a migration request along with the prospective candidates for a new dynamic home. The static home node communicates with the SMAs in the candidate nodes, gets confirmation and then initiates the migration to the most suitable candidate.
The migration involves the following steps:
1. The old dynamic home node sends a copy of the directory for all the lines in the page to the new candidate home.
2. The new home stores the directory into its tables.
3. The static home node updates its entry for dynamic node.
4. The old dynamic home deletes the directory for the page. It may then push out any modified lines to the new dynamic home node and delete the page from its memory thereafter.
Illustration: The following series of figures illustrate how the mechanism described above normally works:
FIG. 4A shows the Operating System in each of three nodes A through C that share a particular global page initially allocating a frame for the page and specifying node A as the static home (44) and dynamic home (45).
FIG. 4B shows that after some amount of network traffic, nodes A and B negotiate (See description of coordination for migration above.) and decide to make node B the dynamic home (46). After B becomes the dynamic home, node C is still unaware of it (47).
FIG. 4C--Node C now requests (51) node A for a line in the global page, as it thinks A is the dynamic home. Node A then forwards the request (52) to the dynamic home B, which sends the line data and informs C that the dynamic home is now B (53). Node C then updates its dynamic home information (54).
FIG. 4D--Node D now also brings in this page and goes through similar steps, i.e. initially it is set up with A as static home (44) and dynamic home. Then on its first read operation, it is informed that the dynamic node is B. It then updates its information as shown (46).
FIG. 4E--Node B later negotiates with A and C, transfers the dynamic home of the global page to C (56) and drops the page from its memory (55).
FIG. 4F
1. Node D requests (51) a line in the global page. It sends the request to B as it thinks B to be the dynamic home.
2. Node B has dropped all information on this page (55), and hence forwards the line request (52) to the static home (A) contained in the message.
3. Node A forwards the request (52) to the dynamic home C.
4. Node C then sends line data and the up-to-date dynamic home (53) information to node D.
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A mechanism to dynamically migrate a home node of a global page to a more suitable node for improving performance of parallel applications running on a S-COMA and other DSM systems. More specifically, consultation counts are maintained at each client node of a shared memory system, where the consultation count indicates the number of times the client node has consulted the dynamic for lines a page. This information is then used along with other information to decide on whether to change the dynamic home node to a more suitable node.
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FIELD OF THE INVENTION
The present invention relates to solid compositions which release a vapour containing at least one essential oil when exposed to effective air flow. The present invention also relates to methods of producing the solid compositions; and to methods of disinfecting air conditioning systems using the solid compositions.
BACKGROUND OF THE INVENTION
Tea tree oil is a natural essential oil from a tree of the class Myrtenceae, especially of Melaleuca. Tea tree oil has been used as a broad spectrum topical antiseptic for more than 70 years. In recent times, the anecdotal evidence as to the antimicrobial efficacy of tea tree oils has been substantiated by scientific evidence. Such evidence can be found in the work of Carson, C. F. and Riley, T. V, Antimicrobial activity of the Major Components of the essential oil of Melaleuca Alternifolia, Journal Applied Bacteriology, 78, 264-269 (1995); C. F. Carson, B. D. Cookson, H. D. Farrelly and T. V Riley, Susceptibility of methicillin-resistant Staphylococcus aureaus to the essential oil of Melaleuca Alternifolia, Journal Antimicrobial Chemotherapy, 35, 421-424 (1995); and Carson, C. F., Hammer, K. A. and Reiley, T. V. (1996) In vitro activity of the essential oil of Melaleuca Alternifolia against Streptococcus spp. Journal of Antimicrobial Chemotherapy 37: 1177-1178.
It is well recognised that commercial, industrial and hospital air conditioning ducting can be a major source of infection and re-infection in public and private buildings. The World Health Organisation (WHO) reported its findings on this subject in 1988. This report in brief stated that biological air contaminants in indoor air have been associated with half of all absenteeism and reduced worker efficiency discovered in the report.
International publication No. WO 88/10122 (Commonwealth Industrial Gases Ltd) describes the use of a biocidal composition comprising an oil of Melaleuca in disinfecting air conditioning systems. This procedure involves solubilising the tea tree oil in both ethanol and carbon dioxide and delivering the solubilised tea tree oil by gaseous carbon dioxide into air conditioning ducting. The procedure therefore requires a constant supply of carbon dioxide by way of carbon dioxide gas cylinders. Specialised equipment such as a high pressure rated gun, hoses and other automatic delivery apparatus are also required. In addition to the fact that this procedure requires specialised equipment and highly trained personal, the possible hazards associated with the use of carbon dioxide in these procedures are well documented. A safer and more cost effective procedure for disinfecting air conditioning systems is therefore desirable.
The positive effects of dispersing pleasant aromatic essential oil odours into public building air space are now well described in the medical literature. The traditional manner for achieving this is by the use of either electric diffusers or by candle warmed water or oil dispersed essential oil burners.
At the Plane Tree Public Hospital in California patients are given a choice of fragrances. In the St Croix Valley Memorial Hospital, Wisconsin, natural fragrances are used to counteract unpleasant odours and to generally improve the atmosphere of all patient care and amenity rooms. The Sloane Kettering Institute in New York has reported that the use of Heliotropin, a vanilla like perfume, has significantly reduced stress in cancer patients. Lavender and Camomile essential oils are now in regular use in hospitals in the United Kingdom. Where elderly patients have demonstrated a tendency to insomnia the use of lavender has been found to lead to less restlessness and an actual increase in the number of hours sleep.
At the Japan School of Medicine the worker Sagano has reported that the use of natural fragrance will help both in the relaxation of staff and patients. International Airlines as Virgin Airlines and New Zealand Airlines are using pure essential oils to assist customers overcome travel fatigue and jet lag. International Hotel Groups as the Marriott Chain use essential oil odours in the lobby areas of many of their hotels.
In all of the examples cited above traditional methods of dispersing the natural essential oil odours are employed. It is desirable to develop a method of dispersing essential oils which eliminates the need for electrical or candle or other such diffusers.
SUMMARY OF THE INVENTION
The present inventors have now developed a solid composition which releases microscopic essential oil vapour when exposed to an effective flow of gas such as that generated by an air conditioning system. When placed in air conditioning ducts, solid compositions of the present invention release an essential oil vapour. In cases where the essential oil used in the solid composition exhibits antimicrobial activity, such as tea tree oil, the solid compositions release a germicidal oil vapour. These compositions therefore provide a relatively safe and inexpensive means for dispersing essential oils in a given environment or for disinfecting air conditioning systems.
Accordingly, in a first aspect the present invention provides a solid composition including a gum material and tea tree oil wherein the solid composition releases vapour containing the tea tree oil when exposed to an effective flow of gas.
The gum material may be any material classified as a gum or hydrocolloid including proteins, polysaccharides (for example, microbial polysaccharide exudates), carbohydrates and celluloses or mixtures thereof.
In a preferred embodiment, the gum material includes carrageenans extracted from red seaweeds. Rhodophyeae-Gigartinales, families Gigartinaceae and Solieriaceae and example species Eucheuma coltinii, Chondrus crispus, Eucheuma spinosan and Gigarta stellata are suitable red seaweeds for a source of primary gum materials.
In a further preferred embodiment the carrageenans include kappa, iota or lambda fractions or mixtures thereof.
In another preferred embodiment the gum material includes a galactomannan. Preferably, the galactomannan has a molecular weight of approximately 300.000 and is non-ionic. The galactomannan may be locust bean gum derived from the legume Ceratonia siliqua.
In another preferred embodiment the gum material includes a microbial exudate. The exudate may be derived from a bacterium such as Xanthomonas campestris. The microbial exudate may be Xanthan gum.
In a more preferred embodiment the gum material includes a mixture of two or more materials selected from carageenans, locust bean gum and Xanthan gum.
Preferably, the gum material is present in the solid composition at a concentration of between 2 and 10 wt %, more preferably between 3 and 6 wt %.
In a further preferred embodiment deionised water is used to prepare the gum material solution. Preferably, the pH of a 1% solution of the gum material solution is in the range of 7 to 9.
The term "essential oil" when used herein encompasses both synthetic essential oils and naturally occurring essential oils. Non-limiting examples of essential oils are oils of various fruits such as apple, cherry, pineapple and the like, oils of various woods such as cedar, pine, briar and the like, oils of various flowers or herbs such as ruses, violets, tobacco flowers and the like, and other such fragrances such as peppermint, menthol, camphor, methyl salicylate, eucalyptus, parachlor benzene, acetates and in general essential oils such as alcohols, aldehydes, esters, terpenes, tars, phenols, thaymols and the like.
In one preferred embodiment the essential oil exhibits antimicrobial activity. Non-limiting examples of oils which exhibit antimicrobial activity include oils obtained from tea trees, thyme, lemongrass, lemons, oranges, anise, clove, roses, lavendar, citronella, eucalyptus, pepermint, camphor, sandalwood and cedar and combinations thereof.
In a preferred embodiment the essential oil is an aromatic oil or a tea tree oil or a mixture thereof.
The aromatic oil may be selected from one or more of the group consisting of heliotropin, lavender, camomile, a lemon scented oil (such as the oil of Leptospermum liversidgeii), sandalwood and jasmine.
The essential oil of the species Leptospermum liversidgeii has a unique and long lasting natural lemon odour. The present inventors have found that compared to other lemon scented species (notably Leptospermum petersoni) this species delivers the most pleasant of lemon odours and does so for the longest duration.
In a further preferred embodiment, the solid composition also includes a fixative. By "fixative" we mean a component which prolongs the evaporation rate of an aromatic oil.
The fixative may be selected from the group consisting of musk ketone, coumarin, eugenol and vanillin. The natural hydrocarbon component eugenol is a preferred fixative for fragrant materials.
In the oil of Leptospermum liversidgei, eugenol is present in relatively high amounts. This factor combined with the other constituents such as citronellal, alpha pinene, linalool and thymol work together to produce naturally a long lasting pleasant lemon aroma. The present inventors have found that by combining the natural fixative elements present in the oil of Leptospermum liversidei, unique and pleasant long lasting aromatic blends containing lavender or camomile can be produced. The finished aroma can have a lemon scent or it can display the fragrance of lavender or camomile. These examples are non-limiting and any combination of fragrances that can be incorporated into solid gum compositions are encompassed by the present invention.
Preferably, the essential oil is present in the solid composition at a concentration of between 5 and 20% v/v, more preferably between 10 and 15% v/v.
The essential oil may be solubilised by any known means such as by admixture with an alcohol or a surfactant or a mixture thereof. The alcohol may be ethanol, propan-2-ol (isopropyl alcohol), propylene glycol or methanol.
In a preferred embodiment, the essential oil is solubilised by admixture with a non-ionic surfactant which allows a low weight surfactant to weight of tea tree oil composition. Preferably, the surfactant is an alcohol ethoxylate. In a more preferred embodiment, the alcohol ethoxylate is polyoxyethylene (2) oleyl ether.
In a second aspect the present invention provides a method of solubilising an essential oil which includes
i) heating a predetermined amount of an alcohol ethoxylate to a temperature of between 25° C.-45° C.; and
ii) adding a predetermined amount of the essential oil to the heated alcohol ethoxylate.
The preferred method of solubilising essential oil provided by the present invention is advantageous in that it results in an essential oil solution wherein the weight to weight ratio of surfactant to tea tree oil is relatively low. Weight to weight ratios of less than 1 to 1 can be achieved by following the solubilisation method of the present invention.
The low weight to weight surfactant to essential oil solutions are preferable for the following reasons:
i) High weight to weight surfactant to essential oil mixtures often give rise to solutions which are hazy, cloudy or opalescent. These cloudy or opalescent solutions are generally not desirable for commercial reasons. The low weight to weight surfactant to essential oil solutions can be diluted with water to produce bright clear solutions.
ii) A relatively high mass of surfactant can inhibit the broad spectrum germicidal efficacy of an essential oil such as tea tree oil. The lower the weight surfactant the higher the efficacy of natural oil as measured by standard Minimum Inhibitory Concentration (MICS) analysis.
In a further preferred embodiment of the present invention, the solid composition is in the shape of a disc.
In a further preferred embodiment the disc is a flat discus shape with a base surface and a top surface and a side wall connecting the base surface to the top surface. Preferably, the diameter of the top surface is less than the diameter of the base surface.
In a preferred embodiment the ratio of the height of the side wall to the width (circumference) of the top surface is between 1:10 and 1:11.5. For example, a preferred disc may have a side wall height of 20 mm and a top surface width (circumference) of 230 mm. A disc of the present invention may, for example, have the following dimensions:
Base surface: 250 mm
Top surface: 210 mm
Height: 40 mm.
In a further preferred embodiment the side wall is shaped in a camber. Preferably, the angle of connection between the base and top surfaces is equal to or less than 65 degrees and more preferably equal to or less than 62 degrees and 57 minutes.
In a further preferred embodiment the solid compositions of the present invention have a total weight of between 0.5 and 5 kg. More preferably, the solid compositions have a total weight of between 0.9 and 3 kg.
The preferred dimensions of a disc according to the present invention provide an advantage in that a slow and even diffusion of natural oil from the disc occurs in the presence of air flow.
In a third aspect the present invention provides a method of preparing a solid composition which method includes
i) dissolving a gum material in an aqueous solution:
ii) heating the gum material solution to a temperature of between 60° C. and 95° C.;
iii) admixing the heated gum material solution with a tea tree oil/surfactant solution; and
iv) placing the admixed solution from step iii) into a mould.
It will be appreciated that the present invention provides a simple and cost-effective means for dispersing essential oils in a given environment. The solid compositions of the present invention can be simply placed in air conditioning ducts by unskilled labour so as to diffuse essential oils into the air stream.
Accordingly, in a fourth aspect the present invention provides a method of diffusing tea tree oil into the atmosphere which method includes exposing a solid composition including a gum material and the tea tree oil to an air flow such that the solid composition releases vapour containing the tea tree oil.
In a preferred embodiment the solid composition is exposed to an air flow by placing the solid composition in an air conditioning duct.
It will be appreciated that the preferred solid compositions of the present invention also provide a simple and cost effective means of disinfecting air conditioning systems. Unlike systems described in the prior art, the preferred compositions of the present invention do not rely on solubilising the essential oil in alcohol or gaseous carbon dioxide. The preferred non toxic water-based gum disc-shaped compositions allow germicidal oil vapour to diffuse slowly and constantly in the presence of the air flow generated in air conditioning ducting.
Accordingly, in a fourth aspect the present invention provides a method of disinfecting an air conditioning system which method includes placing a solid composition in a duct of the air conditioning system, the solid composition including a gum material and tea tree oil, wherein the composition releases antimicrobial vapour containing the tea tree oil when exposed to an effective flow of gas.
In a preferred embodiment, the essential oil is tea tree oil.
The term "air conditioning system" as used herein refers collectively to ducts, fans, filters, humidifiers, coolers and other plant and equipment assembled for air conditioning to parts of such systems.
DETAILED DESCRIPTION OF THE INVENTION
In order that the nature of the present invention may be more clearly understood preferred forms thereof fill now be described with reference to the following Examples.
EXAMPLE 1
Tea Tree Oil Compositions
In a preferred embodiment of the invention the tea tree oil is manufactured in accordance with the ISO 4730 standard. Preferably, the tea tree oil is a pharmaceutical grade material. Table 1 describes the characteristics of an ISO 4730 standard tea tree oil. In a most preferred embodiment the tea tree oil conforms with the ISO 4730 standard prescribed in Table 1 but with component values in respect to 1,8 cineol less than 4% and preferably 2.2-3.0%; and terpinen-4-ol values greater than 37% and preferably 39-41%. Table 2 shows results of gas chromatic analysis for two batches of the preferred TEETEEOH! brand pharmaceutical grade tea tree oil.
TABLE 1__________________________________________________________________________The ISO Standard 4730 prescribes the following physical and componentdetails for Australian Single Distilled Tea Tree Oil -Oil of MelaleucaAlternifoliaPhysicalState Liquid__________________________________________________________________________Colour Visually colourless to pale yellowOdour Typically MyristicSpecific Method ISO 279 20 Degrees C/20 degrees C 0.885-0.906GravityRefractive Method ISO 280Index 1.475 to 1.482Optical Method ISO 592Rotation +5 degrees to +15 degreesSolubility In 85% V/V Ethanol at 20 Degrees C the Miscibility should be such that one volume of the oil shall require not more than two volumes of 85% ethanol to give a clear solution This is tested in accordance with ISO Method 875Flash Point Penskey Martens Closed Cup IP 34 In typical Range 57 degrees C to 60 Degrees CFire Point Cleveland Open Cup IP 36-72 Degrees C.Component There are 15 components determined by gas chromatographicRange analysis in accordance with method ISO 7609-1985 which are identified as being truly representative of genuine oil of melaleuca alternifolia in the TSO 4730 standard. These are listed below. The components described as Ledene (Viridiflorene), delta-Cadinene, Globulol and Viridiflorol are each components found only in the prescribed rations in genuine oil of melaleuca alternifolia and are said to be "genuine marker components for tea tree oil (oil of melaleuca alternifolia)."Component ISO 4730 Range %alpha-Pinene 1-6Sabinene Trace-3.5alpha-Terpinene 5-13Limonene 0.5-4para-Cymene 0.5-121,8 Cineole 0-15gamma-Terpinene 10-28Terpinolene 1.5-5Terpene-4-ol 30 plusalpha-Terpineol 1.5-8Aromadendrene Trace-7Ledene (Viridiflorene) 0.5-6.5delta-Cadiuene Trace-8Globulol Trace-3Viridiflorol Trace-1.5__________________________________________________________________________
TABLE 2______________________________________Teeteeohl Brand Pharmaceutical Single Distilled Australian Tea Tree Oil(Oil of Melaleuca Alternifolia) ISO 4730COMPONENT VALUE % STANDARD %______________________________________Batch Number 1029alpha-Pinene 0.7 1-6Sabinene 0.5 Trace-3.5alpha-Terpinene 9.7 5-13Limonene 1.0 0.5-4para-Cymene 2.7 0.5-121,8 Cineole 2.8 0-15gamma-Terpinene 20.9 10-28Terpinolene 3.4 1.5-5Terpinen-4-ol 40.0 30 plusalpha-Terpineol 2.5 1.5-8Aromadenedrene 1.3 Trace-7Lendene (Viridiflorene) 1.1 0.5-6.5delta-cadinene 1.1 Trace-8Globulol 0.4 Trace-3Viridiflorol 0.2 Trace-1.5BATCH 1021alpha-Pinene 2.4 1-6Sabinene 0.6 Trace-3.5alpha-Terpinene 10.1 5-13Limonene 1.0 0.5-4para-Cymene 2.3 0.5-121,8 Cineole 3.0 0-15gamma-Terpinene 20.8 10-28Terpinolene 3.4 1.5-5Terpinen-4-ol 41.4 30 plusalpha-Terpineol 2.6 1.5-8Aromadenedrene 1.1 Trace-7Lendene (Viridiflorene) 0.9 0.5-6.5delta-cadinene 0.9 Trace-8Globulol 0.3 Trace-3Viridiflorol 0.2 Trace-1.5______________________________________
EXAMPLE 2
Tea tree oil solid composition
A carrageenan locust bean gum mixture is selected which has been standardised with the addition of appropriate salts and polysaccharides so the mixture possesses the following characteristics: Viscosity: 400 to 600 centipoises measured as a 2.5% aqueous solution on a Brook field RVT Viscometer, operating at 20 revolutions per minute and with solution heated to 70 degrees centigrade.
The pH of the Carrageenan, locust bean gum mixture is in the range 7-9% when a 1% solution of the mixture is measured.
The particle size of the combined dried mixture is such that more than 98% is finer than 250 microns. The total moisture content of the mixture is not greater than 14%. The gel strength of the mixture is between 1800 and 2200 measured in a Kobe tester a solution strength of 2.5%. The carrageenans are a mixture of kappa and iota component containing types.
The water for first dispersing the carrageenan and locust bean gum mixture and then heating to gelatinisation is de-ionised water.
The carrageenan locust bean gum mixture is first wetted to aid dispersion with ethanol. A mixture of pure tea tree oil and surfactant is made. The tea tree oil is as described above and conforms with ISO 4730. The actual tea tree oil used is TEETEEOH! Brand Australian Single Distilled Pharmaceutical Grade with the following important component values; the 1, 8 cineole is in the range 2.2-2.5% and the Terpinene-4-ol in the range 39-41%.
The surfactant used is polyoxyethylene (2) oleyl ether. The surfactant is measured so that sufficient is available to solubilise the tea tree oil. The measured surfactant is heated approximately 37 degree C. The carefully measured tea tree oil is poured into the heated surfactant and stilled vigorously. The finished solution is bright and clear. Sufficient de-ionised water is added to the surfactant-tea tree oil mixture as is required. This bright clear mixture is set aside.
The wetted carrageenan-locust bean gum mixture described above is mixed with sufficient cold water. The water temperature is no greater than 12 degrees C. The well dispersed carrageenan-locust bean gum mixture is gradually heated with vigorous stirring to 90 degrees C. The mixture is held at 90 degrees C. for several minutes. The mixture is allowed to cool to 70 Degrees C. To the cooled carrageenan-locust bean gum mixture is added the tea tree oil-surfactant solution. This has the immediate effect of rapidly cooling the mixed solution further. The cool mixture is poured carefully into rubber moulds. The moulds are formed so that the finished gel has a distinctive flat discus shape as described previously. The surface area of the top of the discus shape is preferably less than the surface area of the bottom of the discus shape. The ratio of the height (side wall) of the discus to its surface is preferably of the order of 1:10 or 1:11.5 but this ratio is not essential. The edge of the discus shape is preferably carefully shaped so as to provide a gradual camber. This is preferable so that even air diffusion takes place with the finished Tea Tree Gel Disc. The mixture can be de-moulded with 30 minutes. The Tea Tree Gel-Discs so formed are allowed to cool completely.
Upon complete cooling the discs may be packed in suitable plastic and further packed in recyclable cardboard cartons. The plastic may be polyethylene-plastics does type 4, polypropylene-plastics code type 5, or preferably Fluorinated--High density Polyethylene-plastics code type 2-modified. No colouring matter is used in the manufacture of any type of Tea Tree Gel-Disc. The final Tea Tree Gel Disc in this example contains 10% tea tree oil. The Tea Tree Gel Disc in this example has a shelf life of 12 months wrapped and packaged. The tea Tree Gel Disc in this example has an unwrapped normal room air circulation life of between 30 and 45 days.
When installed into an air conditioning ducting this Tea Tree Gel Disc may have a life of between 7 and 10 days. The Gel Disc life in an air conditioning system is dependent on the systems air flow and air temperature. The tea tree gel disc manufactured in accordance with this method can be described as having low to very low syneresis.
EXAMPLE 3
Tea tree oil solid composition
A carrageenan locust bean and xanthan gum mixture is selected which has been standardised with the correct addition of salts and saccharides. The carrageenan has a viscosity of 400 to 600 centipoises as measured in a 2.5% solution on a Brookfield RVT viscometer at 20 revolutions per minute and solution heated to 70 degrees C. The pH of the carrageenan in a 1% solution is between 7 and 9. The total moisture of the powder is 14%. The carrageenan tests to a gel strength of 1800 to 2200 in a Kobe test measured at 2.5% in de-ionised water. The carrageenan selected is a mixture of carrageenans containing kappa and iota component carrageenans. This mixture is dry mixed with a selected xanthan gum. The dry blended mixture is carefully weighed. To this weighed mixture is added sufficient ethanol to aid dispersion in cold de-ionised water. The mixture is slowly dispersed in di-ionised water with a commencement temperature of 12 degrees C. The water is added so that the final gel mixture contains 3.8% selected hydrocolloids. The mixture is gradually heated to 90 degrees C. under constant stirring. The heated mixture is held at 90 degrees C. under constant stirring for several minutes. To this mixture is added pre-prepared tea tree oil--surfactant solution of sufficient strength so that the final gel-disc contains no less than 10% v/v tea tree oil. The Tea Tree Oil in Pharmaceutical Standard Material conforming with ISO 4730.
The tea tree oil surfactant mixture is added to the hydrocolloid solution which has been cooled to 70 degrees C. The mixture is carefully stirred and allowed to cool further. It is then poured carefully into rubber moulds designed in accordance with disc specifications previously described. The moulds are released within 30 minutes. The gel discs are allowed to cool. Once cooled the Tea Tree Gel Discs may be packed in suitable plastic film and packed in recyclable fibreboard.
The Tea Tree Gel Discs manufactured in accordance with the method may have an air conditioning air diffusion life of between 7 and 10 days. The Gel Discs so produced are bright, shiny and almost transparent. No colouring material is used. The tea tree gel disc is manufactured in this manner can be described as having low syneresis.
EXAMPLE 4
Tea tree oil solid composition
In this example only pure kappa component type carrageenan from the family Solieriaceae species Eucheuma cottonii is used. Further, the ethanol alcohol which is used to aid dispersion of the carrageenan is also co-used to solubilise the pharmaceutical grade tea tree oil. No surfactants are used in this example. To the carrageenan as selected is added dextrose monohydrate and maltodexterin with a dextrose equivalent of between 17 and 21. The dry powder is carefully wetted with a proportion of the ethanol and mixed. To this wetted mixture is added cold water with a temperature of 12 degree C. The mixture is heated to 85 degrees C. and held for exactly 2 minutes. This solution is cooled to 70 degrees C. To the cooled mixture is added a pre mixed solution of ethanol and pharmaceutical grade tea tree oil. The tea tree oil conforms with ISO 4730 standard. The mixture is stirred vigorously. The rapidly cooling mixture is poured into suitable rubber mould prepared in accordance with the disc specification described previously. Within 15 minutes the moulds are released and the Tea Tree Gel Discs removed. The Tea Tree Gel Discs are allowed to cool completely. They may be packed in suitable plastic film as described previously. The plastic wrapped tea tree gel discs may be packaged in recyclable fibreboard boxes. The tea tree gel discs manufactured in this manner are preferably bright and clear and have reasonably hard finished surface. The tea tree gel disc made in the manner in this example have a tea tree oil content of 15%. The solid hydrocolloid matter is 4.8% and the weight of the finished tea tree gel discs is 900 grams. The air diffusion life in standard air conditioning ducting for this example was between 7 and 10 days. These discs can be described as having low to very low syneresis.
EXAMPLE 5
Tea tree oil solid composition
Pure kappa component carrageenan derived from Eucheuma cottonnii was used in this example. No additional salts or saccharides were used. The weighted carrageenan was wetted only with commercial methylated spirits. The wetted kappa carrageenan was thoroughly mixed and admixed with cold water at 20 degrees C. The mixture was well dispersed. A pre-prepared mixture of pharmaceutical grade tea tree oil and ethanol was then added to the cold kappa carrageenan mixture. The proportion of ethanol to tea tree oil in the pre-prepared mixture was approximately 2 parts ethanol to 1 part tea tree oil. The complete mixture was stirred vigorously and heated slowly to 85 degrees C. The mixture was kept at 85 degrees C. for approximatley 45 seconds. By way of a jacketed mixer cold water with temperature of between 12 and 14 degrees C. was introduced into the jacket as a cooling medium. The mixture was rapidly cooled to below 70 degrees C. and poured directly into suitable moulds as previously described. The moulds were released in 12 minutes. The tea tree gel discs allowed to cool. The Tea Tree gel discs made in this manner contained 15% tea tree oil v/v and were carried by a total dry hydrocolloid matter of 5%. The tea tree gel disc were packed as previously described. These discs were found to have an air conditioning diffusion life of between 7 and 10 days. They can be described as low syneresis.
EXAMPLE 6
Tea tree oil solid composition
A dry mixture of selected kappa and iota component carrageenans together with locust bean gum, xanthan gum, dextrose monohydrate, 17 DE maltodextrin, and cations including Sodium salts, Potassium salts and Calcium salts is carefully prepared. The weight of this mixture is such that the weight of mixed hydrocolloid in the final preparation is 3%. This mixture is wetted with ethanol. The mixture is carefully dispersed in cold water of a temperature between 8 and 12 degrees C. The mixture is mixed in a jacketed vessel with accurately controlled heating and cooling capabilities. The stirred mixture is carefully heated to 86 degrees C. and held at this temperature for 2 minutes. To this mixture is added a surfactant solubilised pharmaceutical grade tea tree oil mixture. The tea tree oil mixture is such that in the finished gel disc the tea tree oil content will be 10% v/v. The tea tree oil surfactant mixture is added when the hydrocolloid solution is at 65 degrees C. The total mixture is stirred carefully so as to minimise formation of air bubbles. The cooling mixture is carefully poured into the rubber moulds as previously described. Within 30 minutes the mould can be released. The Tea Tree Gel Discs are left to cool for 24 hours prior to packing. The gel discs made in this manner have very low syneresis. After 24 hours the tea tree gel discs are packed in selected plastic film. The plastic film wrapped tea tree gel discs are placed into recyclable fibreboard for storage and shipping. No colouring matter is used and the tea tree gel discs have a pleasant opaque creamy to light brown colour. The Tea Tree Gel Discs made in this way have very low syneresis. The rate of diffusion in standard air conditioning systems may be 7 to 10 days depending on air flow and temperature range. The net weight of tea tree gel disc made in this manner is 900 grams each. The total volume of tea tree oil dissipated in 168 hours is approximately 90 grams. In the first 24 hours 18 grams of tea tree oil is dissipated. This is an approximate equivalent of 0.75 grams per hour in a typical air flow situation. This is relatively low yet as per the experimental results described herein is highly effective in the disinfecting of air conditioning ducting.
EXAMPLE 7
Tea tree oil and lavender solid composition
A carrageenan locust bean gum mixture is selected which has been standardised with the addition of appropriate salts and polysaccharides so the mixture possesses the following characteristics;
Viscosity; 400 to 600 centipoises measured as a 2.5% aqueous solution on a Brookfield RVT Viscometer, operating at 20 revolutions per minute and with solution heated to 70 degrees centigrade.
The pH of the Carrageenan locust bean gum mixture is in the range of 7-9 when a 1% solution of the mixture is measured.
The particle size of the combined dried mixture is preferably such that more than 98% is finer than 250 microns, the total moisture content of the mixture is preferably less than 14%. The gel strength of the mixture is between 1800 and 2200 measured in a Kobe tester at solution strength of 2.5%. The carrageenans are a mixture of kappa and iota component containing types.
The carrageenan locust bean gum mixture is first wetted to aid dispersion with ethanol. A mixture of pure tea tree oil, oil of Leptospermum Liversidgeii, oil of Lavendula angustifolia (lavender) and surfactant is made. The tea tree oil is as already described and conforms with ISO 4730. The additional oils are pure as defined by the Australian Standards.
The surfactant used is polyoxyethylene (20) oleyl ether. The surfactant is measured so that sufficient is available to solubilise all the essential oils described.
The measured surfactant is heated to 37 degrees C. The measured essential oils are poured into the heated surfactant and stirred vigorously. The finished solution is preferably bright and clear. Sufficient water is added to the surfactant--essential oil mixture as required. This bright highly fragrant mixture is set aside.
The wetted carrageenan--locust bean gum mixture described above is mixed with sufficient cold water. The water temperature is no greater than 12 degrees C. The well dispersed carrageenan-locust bean gum mixture is gradually heated with vigorous stirring to 90 degrees C. and held at this temperature for several minutes. The mixture is allowed to cool to 70 degrees C. To the cooled carrageenan-locust bean gum mixture is added the essential oil--surfactant solution. This has the immediate effect of rapidly cooling the mixed solution further.
The cooled mixture is poured into suitable moulds. The cooled discs are packed in such a way as to have a shelf life of 12 months wrapped. Unwrapped discs have been found to have an operational air conditioning ducting lift up to 30 days.
When installed into an air conditioning ducting the discs release a pleasant lavender fragrance.
EXAMPLE 8
Fragrant tea tree oil solid composition
In this example, custom made and chosen fragrant essential oil blends are selected, so that when incorporated with polysaccharides as previously described, the fragrance will diffuse into air conditioning ducting. Firstly, the fragrant essential oils are selected and blended so that the chosen fragrance is the most powerful of all fragrances present in the mixture. This blend of essential oils is then solubilised in a selected volume of polyoxyethylene (20) oleyl ether. This mixture is then added to a pre-prepared complex polysaccharide mixture which may comprise both kappa and iota type carrageenans and locust bean gum and guar gum.
In this example the most dominant fragrance is that of German Camomile essential oil derived from the species Matricaria recutica.
The method of preparation is similar to other examples described herein.
EXAMPLE 9
Tea tree oil and sandalwood solid composition
In this example and by way of demonstration that a single essential oil fragrant note could be achieved, by combining only one other essential oil with the oil of Melaleuca alternifolia (tea tree oil) as previously described. In this example only the oil of Santalum album (sandalwood) was added to that of the tea tree oil.
Whilst maintaining the broad spectrum antimicrobial characteristics of tea tree oil this example shows that the highly aromatic and myrsitic odour of tea tree oil can be simply masked and overpowered by an essential oil such as sandalwood. This is surprising given that sandalwood is described generally in essential oil and perfumery literature as the base note essential oil having an evaporation rate of 100 according to the index ascribed to Poucher. This index asserts that an oil with a maximum score of 100 has the slowest evaporation rate. By way of comparison, an oil such as lavender which is given an index number of 4, is considered to be a top note essential oil.
The sandalwood tea tree oil mixture is combined with a sufficient amount of polyoxyethylene (20) oleyl ether for solubilisation and the mixture added to a cooled mixture of complex polysaccharides. The combined mix is then poured into a suitable mould to form a disc shape as previously described.
The unwrapped discs so produced can deliver a pleasant fragrance when installed into air conditioning ducting. In circumstances where the air conditioning fans are operating (not necessarily the refrigeration) the sandalwood--tea tree oil solid composition discs may last for up to 30 day.
EXAMPLE 10
Summary of test results from trials conducted in air conditioning systems in a hospital in New South Wales, Australia
The experimental parameters for establishing the broad spectrum germicidal efficacy of the air diffused water gel tea tree oil solid compositions is described below;
An air conditioning ducting system was chosen in a major New South Wales Australia Public Hospital.
This system operated on refrigerated air and the the refrigerant was of a non CFC type. The air flow was variable to suit and was measured typically as cubic metres per minute.
The temperature range of the air flow was measured and automatically controlled so that at ducting inspection points the air temperature ranged between 11 degrees C. and 21 degrees C.
Specially adapted ease of access inspection ports were installed at the selected air conditioning ducting.
Ducting with identical geometry was selected in two separate floors-nominated as level 3 and level 4.
Only active air diffused water gel blocks containing water miscible tea tree oil weer installed on level 3. On level 4 either no gel discs or only placebo gel discs were installed for control purposes.
Installation was in the manner that two tea tree oil solid compositions were installed within 600 mm either side of the inspection ducting, so that one solid composition was up airstream and one down airstream from the inspection port.
The solid compositions were placed on the flat floor of each ducting either side of the inspection port as described above.
The width of the ducting floor was at point 1 level 3 approx 600 mm. The width of the ducting floor at point 2 level 3 was approximately 350 mm.
The ducting floor widths at identical inspection points on level 4 were approximately the same as those on level 3.
The air flow into the ducting selected had an airstream which has been HEPA micro filtered (High Efficiency Particulate Air Filtered).
The ducting systems on both level 3 and level 4 were carefully sampled for both air and surface microbiological samples as per the accompanying table/s.
The sampling was carried out by independent Air Quality Surveyor using the most modern air and surface sampling methods and equipment.
The sampling was further supervised by a qualified and practising microbiologist.
The solid compositions were produced by the method described in example 2 and were installed on level 3 at 1 inspection point approximately 1 hour after this initial sampling.
Further sampling was performed on the same active sites described as inspection points 1 and 2 on level 3 approximately 21 hours later.
Approximately 72 hours after the insertion of the first two solid compositions, which were only installed at inspection point 1, an additional four solid compositions were installed on level 3.
Two solid compositions were installed at inspection point 1 on either side of the inspection port. Two solid compositions were installed at inspection point 2 level 3 on either side of the inspection port-in floor of the ducting.
The distance between inspection point 1 and 2 is approximately 20 metres.
First Microbiological samplings were taken prior to installation of the first two solid compositions; further samplings were taken after the installation of the additional four solid compositions; installed as two at each inspection point.
The results obtained from these samplings show clearly the microbiological efficacy of the solid compositions.
The reduction in Fungal count within the first 21-24 hours was particularly significant as fungal contamination of air conditioning ducting is of major concern to health and sanitation authorities. The results show a greater than 100 fold reduction after 48 hours. In fact in the first 21 hour period the fungal reduction was greater than 800 fold being reduced from greater than 3200 colony forming units (CFU) to less than 4 CFU.
The rate of diffusion of the solid compositions was as predicted by small scale experimental programmes and indicated as 20% within the first 24 hours, 20% in second 24 hours, approximately 20% in the third 24 hour period. Thereafter the rate of diffusion was at around 10% in each 24 hour period and reducing so that the total solid composition had air diffused within the air conditioning ducting by the action of the air flow existing within the system in a period of between 120-168 hours.
The results obtained from the trials above are further confirmation of the well published efficacy data for tea tree oil which shows the Minimum Inhibitory Concentrations of Australian Tea Tree oil for some organism as per the table below:
______________________________________ MIC %______________________________________GRAM POSITIVE BACTERIABacillus cereus 0.3Bacillus subtilus 0.3-0.4Corynebacterium spp 0.2-0.3Micrococcus luteus 0.2-0.3Propionibacterium acnes 04-0.5Methicillin resistant Staphylococcus 0.2-0.3aureusStaphylococcus epidermis 0.5Enterococcus faecalis 0.5-0.75GRAM NEGATIVE BACTERIAEnterobacter aerogenes 0.3Eschericia coli 0.2Klebsiella pneumoma 0.3Proteus vulgaris 0.2-0.3Pseudomonas putida 0.5Serratia marcescens 0.2-0.3FUNGI AND YEASTSAspergillus niger 0.3-0.4Aspergillus flavus 0.4-0.5Candida albicans 0.2Piryrosporum ovales 0.2Trychophyton mentagrophytes 0.3-0.4Trychophyton nibrum 1.0______________________________________
EXAMPLE 11
Summary of test results from trials conducted in air conditioning system in a public hospital in New South Wales, Australia
Sampling performed by Air Quality Services Pty Ltd and Microbiological examination of the samples performed by Biotech Laboratories Pty Ltd Queensland.
Test Area
Air conditioning air ducting system. The system comprises straight ducting with two in--place inspection points at approximately 25 metres apart.
Air Supply
The system is refrigerated and works on constant supply 24 hours 7 days per week. The air is HEPA filtered.
Microbiological Sampling
Sampling for airborne bacteria, airborne fungi and mould, surface bacteria and surface yeast and mould was performed by sterile swab and automatic air sampling apparatus.
Solid Composition Tea Tree Oil Gel Discs
Solid compositions for this test were produced according to the method described in Example 2. Two each with a total mass of 2.2 kilograms were placed at each inspection point. The water solubilised tea tree oil content in each gel disc was 12% v/v.
Sampling Procedure
Samples were taken prior to installing the gel discs. The gel discs were installed either side of the inspection hatch and placed directly on the floor of the air conditioning ducting.
Bacteria
Both surface and airborne bacteria levels tested were shown to be so insignificant as unnecessary to be reported in these results.
Surface Yeast and Mould and Airborne Fungi and Mould
These tests indicated very high microbiological contamination.
RESULTS
__________________________________________________________________________ Date 05/11/96 06/11/96 13/11/96 19/11/96 SURFACE YEAST AND MOULD CFU/cmLEVEL 3 24 Hour Result Final Result__________________________________________________________________________ACCESS POINT 1 Temp/C 12 Temp/C 20 Temp/C 15 Temp/C 13Against Flow 44 36 160 20With Flow 8 120 100 8Hatch >1200 4 <4 <4Hatch 8 <4 <4 <4ACCESS POINT 2Against Flow >1200 <4 12 8With Flow 16 8 8 4Hatch <4 <4 <4 <4Hatch <4 16 <4 <4__________________________________________________________________________
AIRBORNE FUNGI AND MOULD CFU/cm
______________________________________ACCESS POINT 1Against Flow 150 50 <50 <50With Flow 100 150 <50 100ACCESS POINT 2Against Flow 150 50 <50 <50With Flow <50 200 50 >50______________________________________
The tea tree oil solid compositions were installed on Nov. 5, 1996 (after initial samples taken). These results show significant surface yeast and mould at the start of the trial. The 24 hour reduction (as measured on Nov. 6, 1996) of the greater than 1200 CFU values indicate the efficacy of the solid tea tree oil gel discs. The final 14 day results further indicate this efficacy.
Airborne Fungi and Mould can be described as insignificant levels. A statistical reduction is observed.
EXAMPLE 12
Test conditions and results obtained from trials conducted in a major public Bowling Club in Northern New South Wales--Australia.
Sampling performed by Air Quality Services Pty Ltd and Microbiological examination of the samples performed by Biotech Laboratories Pty Ltd Queensland.
Test Area
Air conditioning air ducting system/s. The system is a mixed one. One air handler supplying quite direct air flow to destination terminals. Another had a split air flow system and ducting constructed with large curvature in many places.
Sampling was also performed in a public area access site at the point furthest from the air handler. This site was at a point in a bistro area--in the ceiling close to a window. Sampling was also performed at a public point described as cashier.
Air Supply
The system is refrigerated. The system is idyll for up to 11 hours daily. For part of these trials one air handler was re-set so that the fans worked continuously for 24 hours each day for 7 days. The refrigeration unit was maintained as operational for between 9 and 11 hours. The air is filtered prior to entry into the ducting.
Microbiological Sampling
Sampling for airborne bacterium, airborne fungi and mould, surface bacteria and surface yeast and mould was performed by sterile swab and automatic air sampling apparatus.
Solid Tea Tree Oil Compositions
In order to fully test the efficacy of the solid composition a number of compositions made according to Example 2 were employed.
Sampling Procedure
Samples were taken prior to installing the gel discs. The gel discs were installed either side of the inspection hatch and placed directly on the floor of the air conditioning ducting.
Bacteria
Surface bacteria valued found are insignificant. Airborne values are higher--but may be considered also to be unimportant so far as building health is concerned.
Surface Yeast and Mould and Airborne Fungi and Mould
These are considered high. Species are identified but not described in detail.
Airborne Fungi and Mould
Generally not considered excessive. Results for the public area are indicated for interest.
Temperature and Relative Humidity
Temperatures fluctuated considerably. The relative humidity was high but in line with local atmospheric conditions for the summer period in northern New South Wales.
RESULTS
TEST SITE A--UPPER CASINO
______________________________________YEAST AND MOULD CFU/cm2 04/02/97 11/02/97 18/02/97______________________________________ACCESS POINT 1Hatch Door 20 <4 4Hatch Door <4 <4 <4Ducting Floor 640 320 160Ducting Floor 960 640 440ACCESS POINT 2CASHIER-PUBLIC PLACEDuct wall - side 510 240 330Duct wall - rear 180 200 92______________________________________
On the start date, Feb. 4, 1997, one composition (10% v/v tea tree oil) was installed after sampling. At the test time Feb. 11, 1997 there were only a few grams of the single 10% tea tree oil discs remaining in the ducting.
On the Feb. 18, 1997, two further 10 % v/v tea tree oil compositions were installed. These discs were designed to have slow diffusion rates.
______________________________________ACCESS POINT 1 25/02/97 04/03/97______________________________________Hatch Door 4 8Hatch Door <4 <4Ducting Floor <1200 140Ducting Floor <1200 220______________________________________
At test Feb. 25, 1997 it was found that the solid compositions had diffused slowly and were greater than 80% intact. Following sampling, two further 15% v/v tea tree oil solid compositions were installed. These compositions had a gel type as described in Example 2 and allowed for greater diffusion rate to compensate for the limited air flow in the system.
The results on Mar. 4, 1997 confirm positively this course of action with a reduction in CFUs from <1200 to 140 and 220.
The trials generally indicated a highly contaminated ducting environment and continued as follows.
______________________________________ACCESS POINT 1 11/03/97 18/03/97 25/03/97______________________________________Hatch Door <4 4 <4Hatch Door <4 <4 <4Ducting Floor 380 120 220Ducting Floor 570 1200 84______________________________________
After Mar. 11, 1997 no further solid compositions were installed. The air flow was very poor during week of Mar. 18, 1997. At Mar. 25, 1997 the compositions had diffused by about 95%.
These tests confirm that the air conditioning fan system is preferably running fully for each 24 hour period to fully maximise the solid composition potential. The refrigeration may be employed only for the commercial times required by the operator--in this instance 9-13 hours daily. Running the fans is a low energy cost. The general benefits of moving large air mass around public facilities irrespective of tea tree oil gel solid composition disinfection are considerable.
Species of micro-organisms were identified during these trials. No conclusive evidence was obtained to indicate the tea tree oil disinfection process is more specific for the elimination of any particular type.
The most dominant species present was Cladosporium herbarium, with Penicillium species the next most dominant. Aspergillus and Candida were also observed. It was noted that the Aspergillus only appeared after human intervention with the installation of a new inspection hatch at one ducting site.
TEST SITE B--TERRACE BISTRO
ACCESS POINT 4
Adjacent to a Window in the public bistro area. This area is some 70 metres from the insertion point of the Tea Tree Oil Solid Compositions in the ducting. For four weeks in the trial sampling was conducted as shown below:
______________________________________ CFU/cm 04/02/97 11/02/97 18/02/97 25/02/97______________________________________Duct Wall-Side >1200 >1200 >1200 >1200Duct Wall-Rear >1200 >1200 >1200 >1200______________________________________
On the Mar. 4, 1997, one solid composition of the present invention was installed. The count was more fully enumerated following this installation.
______________________________________ 04/03/97 11/03/97 18/03/97 25/03/97______________________________________Duct Wall-Side 12000 2700 18400** 2600Duct Wall-Rear 6800 2100 1900 1400______________________________________ **This anomalous result may be due in part to the reduction in air flow that week. No further compositions were placed in this area after 04/03/97. It is noted that the extremely high counts at this point were effectively reduced over 4 weeks by the insertion only of one 2.2 kilogra tea tree oil solid composition. The significant reduction within one week of these trails 04/03/97 to 11/03/97 indicate that in an area of high # infection such as this, solid compositions can be applied at more regular intervals, or in greater mass per composition.
Test Conclusions
Air flow is preferably continuous. Fans can be left running at low cost. Refrigeration can be employed as required. High relative humidity values are conducive to formation of surface yeast and moulds constant air flow reduces this risk. Tea tree gel discs are preferably moderate release type. Optimum tea tree level found to be 15% v/v. Split air flow ducting--generally considered outdated--must be clearly identified and cycles shown so that tea tree oil disc insertion points can be clearly determined. Tea tree oil gel disc are clearly effective in the elimination of fungus, moulds and yeasts and the maintenance of low bacteria counts in commercial air conditioning ducting.
These examples demonstrate that the Tea Tree Oil Solid Composition of the present invention is highly effective and safe air conditioning ducting system sanitiser. The composition is particularly effective against high mould, fungus and yeast microorganism numbers. The presence of such high levels of micro-organisms is now recognised as posing a serious health risk to the buildings occupants.
The composition is particularly effective in well controlled refrigerated air conditioning systems which run continuously. The constant air flow in such systems allows for even diffusion rates of the solid composition tea tree oil gel discs.
The composition was found to be effective in commercial systems which operated fully for only limited times during any 24 hour period. The trials demonstrated a low cost way for such facilities to further improve the general air quality of their systems. By limiting the generation of refrigerated air to the times selected and at other times running the fans only, the solid composition worked more effectively and the overall air quality improved.
In badly infected systems, the solid composition can return the system to normal and accepted base line values for resident fungal microorganisms. By thereafter employing regular placement of the solid composition in air conditioning facilities these levels are economically and efficiently maintained.
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 described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
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Solid composition including a gum material and an tea tree oil and optionally another essential oil wherein the solid composition releases vapor containing the essential oil when exposed to an effective flow of gas. A method of diffusing tea tree oil into the atmosphere and a method of disinfecting air conditioning systems are also provided.
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RELATED APPLICATION
[0001] This patent is a continuation of U.S. patent application Ser. No. 12/494,760, entitled “High Chairs and Methods to Use High Chairs,” filed on Jun. 30, 2009, which is a continuation of U.S. patent application Ser. No. 11/968,526, entitled “High Chairs and Methods to Use High Chairs,” filed on Jan. 2, 2008, which claims priority to U.S. Provisional Patent Application No. 60/883,277, entitled “High Chairs and Methods to Use High Chairs,” filed on Jan. 3, 2007, all of which are hereby incorporated by reference in their entireties.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates generally to child care products, and, more particularly, to high chairs and methods to use high chairs.
BACKGROUND
[0003] Small children are typically placed into high chairs that secure and support the child when, for example, the child is being fed. Such high chairs typically include a seat attached to a frame and a tray attached to either the seat or the frame. The seats in conventional high chairs are typically fixed in one position so that the seat is elevated above a floor to a level that is convenient for an adult to feed the child from the adult's sitting position. At times it would be convenient for a parent or other caretaker to adjust the position of the seat on a high chair. Prior attempts at creating adjustable chairs have focused on making the height of the seat variable with respect to the floor.
[0004] Conventional high chairs also include trays that can be affixed and removed from the front of the seat. The trays provide a serving surface for providing the child with food, drinks and other items such as eating utensils and/or toys. In addition, the trays may include a tray insert that can be easily removed to clean spills that end up on the tray.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a front perspective view of an example high chair showing the chair in an upright position with an example headrest in an extended position.
[0006] FIG. 2 is a side view of the example high chair of FIG. 1 .
[0007] FIG. 3 is a side view of the example high chair of FIG. 1 with the example tray extended away from the example seat and the example headrest in a retracted position.
[0008] FIG. 4 is a partial cross-sectional view of an example slidable connector used to change the distance between the example seat and the example tray of FIG. 1 .
[0009] FIG. 5 is a front perspective view of an alternative example high chair with an example threaded connector to change the distance between the example seat and the example tray.
[0010] FIG. 6 is a rear view of the high chair of FIG. 1 .
[0011] FIG. 7 is an exploded view of the example seat of FIG. 1 .
[0012] FIG. 8 is a bottom view of the example seat showing an example catch basin.
[0013] FIG. 9 is a partial perspective bottom view of the example highchair of FIG. 1 .
[0014] FIG. 10 is a side view of the high chair of FIG. 1 , showing the example seat and example tray in a lower position closer to the support surface.
[0015] FIG. 11 is a partial cross-sectional view of an example connector used to change the distance between the example seat and tray of FIG. 1 and the support surface.
[0016] FIG. 12 is a side view of the high chair of FIG. 1 showing the chair in a reclined position with the headrest in a retracted position.
[0017] FIG. 13A is an exploded, left perspective view of an example rotating joint used to recline the example seat of FIG. 1 .
[0018] FIG. 13B is an exploded, right perspective view of an example rotating joint used to recline the example seat of FIG. 1 .
[0019] FIG. 14 is a side view of the high chair of FIG. 1 , showing the chair in a folded position.
DETAILED DESCRIPTION
[0020] FIGS. 1-14 illustrate an example high chair 100 that is adjustable in several respects. The example high chair 100 of FIG. 1 may be fit to a child of virtually any size, and may be adjusted to a child as he/she grows over time. For example, a seat 102 and a tray 104 of the high chair 100 are adjustable along a frame 106 of the high chair 100 . In addition, the distance between the seating surface of the seat 102 and the tray 104 is adjustable. Furthermore, the seat 102 may be reclined with respect to the frame 106 . The high chair 100 also includes an adjustable headrest 108 and an adjustable footrest 110 . The tray 104 is laterally adjustable with respect to a back 112 of the seat 102 . The seat back 112 may be raised or lowered to properly position the headrest 108 relative to the child. In addition, the frame 106 may be collapsed into a folded position, as shown in FIG. 14 .
[0021] More specifically, FIGS. 1 and 2 show the example high chair 100 with the tray 104 positioned a first distance above the seating surface of seat 102 . The distance between the tray 104 and the seat 102 as can be seen by comparing FIGS. 2 and 3 (the tray 104 is at a higher position above the seat 102 in FIG. 3 ). In the illustrated example, the tray 104 is coupled to the seat 102 through a first side post 114 and a second side post 116 . Each side post 114 , 166 is located toward a side of the seat 102 and tray 104 . The seat 102 and tray 104 also are coupled through a crotch post 118 . The crotch post 118 serves as a child restraint. Each of the first side post 114 and the second side post 116 includes a plurality of indentations, apertures or holes 120 . A first connector 124 slidably couples the first side of the tray 104 to the first post 114 . A second connector 128 slidably couples the tray 104 to the second post 116 . A first actuator 122 is located on the first slidable connector 124 , and a second actuator 126 is located on the second slidable connector 128 . Each actuator 122 , 126 is capable of selectively releasing a corresponding pin 130 ( FIG. 4 ) from one of the holes 120 . When both actuators 122 , 126 are actuated, the first slidable connector 124 and the second slidable connector 128 are free to slide along the first side post 114 and the second side post 116 , respectively. Although two actuators are shown in the illustrated example, any number of actuators may be used (e.g., only one of the first actuator 122 or the second actuator 126 may be included). A cross-sectional view of one of the connector 128 is shown in FIG. 4 . In the illustrated example, the connectors 124 , 128 are identical or mirror images of each other and, thus, only one connector 128 is shown and described in detail.
[0022] To move the seat 102 with respect to the tray 104 , the first actuator 122 and the second actuator 126 are depressed against the force of a spring 129 (see FIG. 4 ) to cause a side pin 130 to disengage a respective one of the plurality of indentations or holes 120 of the posts 114 , 116 . In the illustrated example, a flange 131 of the actuator 126 is moved to engage (e.g., cam) the side pin 130 when the actuator 126 is depressed to thereby cause the pin 130 to rotate out of engagement with the hole 120 .
[0023] As noted above, the connectors 124 , 128 and the actuators 122 , 126 are substantially identical, thus, there is a side pin 130 associated with each of the first and second actuators 122 , 126 . With the side pins 130 disengaged from holes 120 , the first and second slidable connectors 124 , 128 may be moved along the first and second posts 114 , 116 , respectively to a desired position. Movement of the first and second slidable connectors 124 , 128 along the first and second posts 114 , 116 changes the distance between the seat 102 and the tray 104 . The first and second slidable connectors 124 , 128 may be moved to a lower position on the first and second side posts 114 , 116 to fit a larger and/or older child in the high chair 100 , and the first and second slidable connectors 124 , 128 may be moved to a higher position on the first and second side posts 114 , 116 to fit a smaller and/or younger child in the high chair 100 .
[0024] Furthermore, as the first and second slidable connectors 124 , 128 move along the first and second side posts 114 , 116 , the seat 102 moves along the crotch post 118 . In some examples, the crotch post 118 may telescope. When the seat 102 is in a desired position with respect to the tray 104 , the first and second actuators 122 , 126 are released such that the pins 130 move under the influence of their respective springs 129 and engage with respective ones of the plurality indentations or holes 120 to fix the seat 102 at a distance below the tray 104 . In the example of FIGS. 1 , 2 and 4 , the tray 104 is fixed at the top of the posts 114 , 116 and the seat 102 is adjustable to different positions along the posts 114 , 116 .
[0025] In an alternative example shown in FIG. 5 , the seat 102 is height adjustable relative to the tray 104 in a different manner. In the example of FIG. 5 , the tray 104 of the illustrated high chair 500 is fixed on the top of the side posts 514 , 516 . The seat 102 is slidably mounted to the crotch post 518 via the alternative actuator 135 . In this example, the actuator 135 is a knob that is threaded on the crotch post 518 . By rotating the actuator 135 (i.e., the threaded knob 135 shown in FIG. 5 ) beneath the seat 102 at the center of the chair 500 , the seat 102 is moved up or down (depending on the direction of rotation of the knob 135 ) relative to the crotch post 518 and, thus, relative to the tray 104 to thereby adjust the distance between the seat 102 and the tray 104 . As a result of this structure, one control is used to threadingly adjust the position of the seat 102 relative to the tray 104 . The range of travel of the seat 102 relative to the tray 104 in the example of FIG. 5 is may be about one inch, although other ranges of travel would likewise be appropriate.
[0026] Referring back to FIGS. 1 and 2 , the example high chair 100 also includes the adjustable footrest 110 . The footrest 110 of the illustrated example is coupled to one or more extension posts 132 . The footrest 110 is couplable to the extension posts 132 at different positions. As a result, the distance between the seat 102 and the footrest 110 is variable and may be changed to accommodate children of varying heights. The footrest 110 may be coupled to the extension posts 132 through any type of fasteners including, for example, Valco® pins and/or actuators and pins similar to the first and second actuator 122 , 126 and pins 130 described above. In the illustrated example, springs loaded pins are used to engage apertures or holes 137 found in the posts 132 . Four height adjustment positions 137 are shown in the illustrated example. However, any number of height adjustment positions may be included. In addition, the distance of travel between each height adjustment and/or the overall range of travel of the footrest may be any desired distance. For example, each height adjustment position may be an inch from an adjacent height adjustment, and the overall range of travel may be, for example, four inches.
[0027] As shown in FIGS. 1-3 and 6 , the example high chair 100 also includes the adjustable bolster or headrest 108 . FIGS. 1 and 2 show the headrest 108 in a deployed or extended position (i.e., with the bolster wings 134 of the headrest 108 at least partially pivoted forward). FIG. 3 shows the headrest 108 in a retracted position (i.e., with the wings 134 of the head rest 108 pivoted flat against the back 112 ). The foldable wings 134 pivot outward (away from the seat back) to support a small child's head, for example, during feeding, etc. In the illustrated example, at least a portion of the wings 134 extends to a rear of the seat 102 . A bolster actuator 136 ( FIG. 6 ) located on the rear of the seat 102 is used to retract and/or extend the one or more wings 134 . In the illustrated example, the bolster actuator 136 is an elongated lever or paddle, which, when moved to a deployed position, forces (e.g., cams) the one or more wings 134 outward to an extended position in which the one or more wings 134 are folded outward and able to support the head of a child. The bolster actuator 136 may also be moved to a retracted position to pull the wings 134 to an unfolded position in which the wings 134 are flattened against the front of the seat 102 . In the illustrated example, the bolster actuator 136 may be moved to one or more intermediate positions between the deployed position and the retracted position to move the wings 134 to semi-folded positions.
[0028] The illustrated example includes an upholstered the headrest 108 . The headrest 108 also includes padding to form a cushion or pillow. Alternatively, the headrest 108 may be un-upholstered and/or may be upholstered together with the seat 102 . Also, in some examples, the headrest 108 may not include foldable wings.
[0029] In the illustrated example high chair 100 as shown in FIGS. 2 , 3 , 7 an 8 , the seat 102 includes a seat pan 138 , a seat support structure 139 , a seat back 112 , and a seat frame 142 . The seat support 139 may be a fabric seat support such as, for example, mesh, or the seat support 139 may be a plastic component or any other suitable material. The seat support 139 of the illustrated example is fabric and includes a seat support frame 141 . In some examples only the seat support frame 141 supports the seat 102 , and no fabric support 139 is included. In this example, the frame 141 is implemented as a metal tube frame. The seat support 139 may be coupled to the seat frame 142 via any suitable mechanical or chemical fasteners.
[0030] In the example of FIGS. 7-8 , the seat pan 138 is supported in the seat support 139 via a lip 143 that is integrally formed with the seat pan 138 . The lip 143 is sized to fit over and support the seat pan 138 on the seat support frame 141 of the seat support 139 . In the illustrated example, the seat pan 138 is removably coupled to the seat support 139 . Therefore, the seat pan 138 may be removed from the high chair 100 for cleaning, storage or the like.
[0031] The seat pan 138 of the illustrated example high chair comprises a slick polyurethane foam seat. The seat pan 138 is molded as a unitary structure and forms a slick, spill resistant, surface during the molding process. The seat pan 138 is easy to clean and is soft to the touch.
[0032] In the illustrated example, the height of the seat back 112 is adjustable. As shown in FIGS. 2 , 3 and 6 , there is a clamp 144 disposed on the rear of the seat back 112 to slidably couple the seat back 112 to the seat frame 142 , a portion of which, as shown in FIG. 6 , forms a U-shaped post. This portion may be a separate component from the remainder of the frame 142 , i.e., not integrally formed therewith. The clamp 144 includes a seat back actuator 146 , which may be implemented by any suitable actuating device such as, for example, a knob, push button, lever, etc. When the seat back actuator 146 is activated, the clamp 146 is released from the seat frame 142 and the seat back 112 may be raised or lowered with respect to the seat pan 138 to accommodate children of varying sizes. When the seat back 112 has been moved to a desired position, the seat back actuator 146 is returned to a locked position to fix the position of the seat back 112 to a particular position relative to the seat frame 142 . In some examples, the seat back actuator 146 may causes the clamp 144 to engage one or more of a plurality of holes (not shown) on the frame 142 via a pin and spring connection similar to the other pin and spring connections described herein. In other examples, the clamp 144 maybe slidably moved to any of an infinite number of positions along the frame 142 and secured to the frame 142 via a friction fit. Adjusting the position of the seat back 112 enables the headrest 108 to be positioned to suit the child. The chair 100 , thus, can grow with the child. In addition, adjusting the height of the seat back 112 adjusts the position of the child restraint 210 to properly conform to the height of the shoulder of a child seated in the chair 100 .
[0033] As shown in FIGS. 2 , 3 , and 9 , the example tray 104 includes a base tray 148 and top tray 150 . The base tray 148 , which is only exposed when the top tray 150 is removed, is permanently affixed to the posts 114 , 116 adjacent the front of the seat 102 and may be used in the same manner as the top tray 150 when the top tray 150 is removed (e.g., for holding a child's snacks, meals, drinks, toys, etc.). In addition, the base tray 148 acts as a passive restraint to retain the child in the seat.
[0034] The top tray 150 of the illustrated example is laterally adjustable or slidable with respect to the base tray 148 . Consequently, the top tray 150 is laterally adjustable with respect to the seat back 112 . Therefore, the top tray 150 may be adjusted to accommodate children of varying sizes and/or to provide additional room that may be needed, for example, to remove a child occupying the high chair 100 . To adjust the top tray 150 with respect to the base tray 148 , a tray actuator 152 is activated. In the illustrated example, the tray actuator 152 is a push button, but any suitable actuating device may alternatively be used. The tray actuator 152 is depressed to disengage the top tray 150 from the base tray 148 . The example top tray 150 includes one or more cables or tethers 154 (see FIG. 9 ). Each tether 154 has a first end and a second end. The first ends of the tethers 154 are coupled to the tray actuator 152 . The second ends of the tethers 154 are coupled to a respective clasp 156 (one of which is shown in FIG. 9 ). Each clasp 156 includes teeth 158 to engage corresponding detents (not shown) on the base tray 148 . When the tray actuator 152 is depressed, the tethers 154 move to retract the clasps 156 to thereby cause the teeth 158 to disengage the detents and allow the top tray 150 to slide relative to the base tray 148 and/or to be removed therefrom. The top tray 150 is moveable fore/aft to any number of different positions. In the illustrated example, there are four different positions at which the top tray 150 may be laterally secured relative to the seat back 112 . However, other numbers of positions would likewise be appropriate. To fix the top tray 150 in a position relative to the base tray 148 , the tray actuator 152 is released to move the tethers 154 , extend the clasps 156 , and engage the teeth 158 with the detents in the base tray 148 .
[0035] The tray 104 of the illustrated example also includes a removable insert or liner (not shown) that can be removed for cleaning. Furthermore, the entire top tray 150 may be completely removed from the base tray 148 to, for example, place the top tray 150 and the insert in a dishwasher for cleaning.
[0036] As shown in FIGS. 1-3 and 10 , the seat 102 and the tray 104 may be moved together to different heights along the frame 106 . In the illustrated example, the frame 106 includes one or more front legs 160 and one or more rear legs 162 . The front legs 160 and rear legs 162 are coupled via hubs 164 and, in the illustrated example, form an A-frame structure. In the illustrated example, a crossbar 166 couples the front legs 160 to provide lateral stability. Similarly, a second crossbar 166 joins the rear legs 162 . Each front leg 160 and rear leg 162 of the illustrated example high chair 100 includes a wheel 170 depending from a foot 168 .
[0037] To moveably cantilever the seat 102 and tray 106 assembly from the frame 106 , the first side post 114 is coupled to a third slidable connector 172 , and the second side post 116 is coupled to a fourth slidable connector 174 . In the illustrated example, the third and fourth slidable connectors 172 , 174 are coupled to the front legs 160 . However, in other examples, the third and fourth slidable connectors 172 , 174 may be coupled to the rear legs 162 . Each of the third slidable connector 172 and the fourth slidable connector 174 of the illustrated example includes a height actuator 176 . A cross-section of the fourth slidably connector 174 and the height actuator 176 is shown in FIG. 11 . In the illustrated example, the height actuators 176 are identical or mirror images of each other. As with the posts 114 , 116 , each of the front legs 160 includes a plurality of indentations, apertures or holes 178 .
[0038] To move the seat 102 and the tray 104 with respect to the frame 106 , the height actuator(s) 176 are depressed against the force of a bias spring 177 to cause a locking pin 179 to disengage a corresponding one of the plurality of holes 178 . The height actuator(s) 176 may operate in a similar manner as the first and second actuators 122 , 126 described above. Thus, after the third and fourth slidable connectors 172 , 174 are moved to a desired position to adjust the overall height of the seat 102 relative to the floor or other support surface, the height actuator(s) 176 are discharged to engage or reengaged the pin 179 with a corresponding one of the plurality of holes 178 to thereby fix the seat 102 and tray 104 at a position on the frame 106 with respect to a ground or floor upon which the high chair 100 is placed. Four height adjustment positions are shown in the illustrated example. However, any number of height adjustment positions may be included. In addition, the distance of travel between each height adjustment and the overall entire range of travel may be any suitable distance. In the illustrated example, each height adjustment position is one inch from an adjacent height adjustment, and the overall range of travel is ten inches.
[0039] As shown in FIG. 1 , the seat 102 of the illustrated example is coupled to the first side post 114 via a first joint 180 and also is coupled to the second side post 116 via a second joint 182 . In the illustrated example, the first and second joints 180 , 182 are coupled to the first and second slidable connectors 124 , 128 , respectively. In other examples, the first joint 180 and/or the second joint 182 may be coupled to the first side post 114 and/or the second side post 116 directly, indirectly or otherwise. The joints 180 , 182 are also coupled to opposite ends of a crossbar 184 upon which the seat 102 is mounted. The joints 180 , 182 enable the seat 102 to recline or rotate with respect to the cross-bar 184 , first side post 114 , second side post 116 , frame 106 , tray 104 , etc., as shown in FIG. 12 .
[0040] The joints 180 , 182 are substantially identical or mirror images of each other. Thus, in the interest of brevity, only one joint 182 will be described. An exploded view of the joint 182 is shown in FIGS. 13A and 13B . The joint 182 includes an outer, non-rotating or fixed end 186 (also referred to as an outer gear wheel), a cam 188 , an inner gear or lock 190 and a rotating-end 192 . The non-rotating end 186 includes fixed teeth 194 , and the lock 190 includes rotating teeth 196 . The rotating end 192 also has complementary teeth 197 (see FIG. 13B ). A lever 198 ( FIGS. 2 , 3 , 6 and 12 ) on the rear of the seat 102 is operatively coupled to the joint 182 by, for example, a cable (not shown) threaded through one or more components of the chair 100 to the joint 182 . The lever 198 and/or the cable of the illustrated example is spring loaded. To change the tilt angle of the seat 102 , the lever 198 is actuated, which pulls the cable and causes the cam 188 to remove the lock 190 from engagement with the non-rotating end 186 of the joint 182 and move more deeply into the rotating end 192 . When the locking rotating teeth 196 are disengaged from the fixed teeth 194 , the lock 190 and the rotating end 192 , which are coupled via the rotating teeth 196 and the complementary teeth 197 , are freely rotatable relative to the fixed end 186 . The seat 102 , thus, may be moved to a desired angled position. Once the seat 102 is reclined or raised to the desired angle, the lever 198 may be released, which allows a spring 199 to move the lock 190 back into engagement with the non-rotating end 186 . In this position, the rotating teeth 196 of the lock 190 engage both the complementary teeth 197 of the rotating end 192 and the fixed teeth 194 of the non-rotating end. This engagement prevents the rotating end 192 from rotating relative to the fixed end 186 and locks the seat 102 in the desired position.
[0041] In the illustrated example, the seat 102 has a large number of reclined positions over approximately 32.5° of rotation. The maximum angle of recline for the seat back of the illustrated example is approximately 43°±5°. However, other numbers of positions, other ranges of rotation and/or other maximum angles of recline would likewise be appropriate.
[0042] The example high chair 100 also includes a slot 200 in the seat pan 138 as shown in FIGS. 1 , 7 and 8 . The seat pan 138 is shaped to funnel spilt food, liquids and/or other items to the slot. A catch basin 202 ( FIGS. 2 , 3 , 6 , and 8 ) is removably secured beneath the slot 200 to collect the food, liquid and/or other items that funnel into the slot 200 . The catch basin 202 may be removed, emptied and reassembled around the slot 200 . Funneling spills through the slot 200 into the catch basin 200 increases the efficiency of cleaning the high chair 100 as less food, liquid and other items are likely to end up on the floor and/or remain in contact with a child seated in the chair 100 . The catch basin 202 may be secured adjacent the slot 200 via any suitable means. In the illustrated example, the catch basin 202 is secured to the seat 102 by engaging a ridge 203 that circumscribes at least a portion of the slot, as shown in FIG. 8 .
[0043] As shown in FIG. 6 , the example high chair 100 also includes fold actuators 204 , 206 . The fold actuators 204 , 206 are shown as push buttons but any suitable actuating device may be used as well. The fold actuators 204 , 206 are depressed to enable the chair 100 to be folded ( FIG. 14 ) for storage. In the illustrated example, the fold actuators 206 , 204 are spring biased to the locked position. Depressing the fold actuators 204 , 206 against the force of the springs dislocates corresponding pins (not show) carried by the rear legs from bores (not shown) in the hubs 164 to enable the rear legs 162 to pivot forward. The fold actuators 204 , 206 , pins and springs may be implemented by, for example, Valco® pins. As shown in FIG. 14 , the example high chair 100 is proportioned such that the example high chair 100 stands without assistance, even when the high chair 100 is in the folded position. In the illustrated example, the top tray 150 is removed and attached to the rear of the high chair 100 to make the folded high chair 100 more compact.
[0044] The illustrated example high chair 100 includes a restraint or harness 210 , as shown in FIGS. 1-3 . The harness 210 is shown as two straps that are coupled to the seat back 112 via the headrest 108 . In other examples, the harness 210 may be coupled to other portions of the seat back 112 . In addition, the straps of the harness 210 may be secured to the seat back via a ring such as, for example, a D-ring or 0 -ring or via any other suitable mechanical or chemical fasteners. In such an example, D-rings are passed through the openings in the seat back 112 in a first orientation and positioned in a second orientation behind the seat to prevent removal of the harness straps from the seat back 112 . In the illustrated example, the material of the harness 210 is sewn onto itself, for example, in the shape of a ‘T’ on the rear side of the seat back 112 to prevent retraction through the opening. Because the seat back 112 is height adjustable and the harness 210 passes through the seat back 112 , the position of the harness 210 can be easily adjusted by adjusting the height of the seat back 112 . The harness 210 in the illustrated example is attached to the crotch post 118 via a clip to form a three-point harness. In other examples, the harness 210 may be coupled to the crotch post 118 via a T- or Y-shaped shield or plate to form a five-point harness.
[0045] In an alternative example a three point harness that acts like a five point harness is provided. This harness (referred to as a pseudo 5-point harness) includes three solid points and two soft points of attachment. The three solid points are the fixed connections between the belts of the harness and the seat 102 of the high chair 100 at the seat back 112 with the D-rings and the crotch post 118 . Thus, two of the fixed points are located above the shoulders of the child. The third fixed point is located at the crotch post 118 . A Y-shaped connector is included in the pseudo 5-point harness. The Y-shaped connector has a latch on the bottom of the Y that secures into a latch fixed to the crotch post 118 . The wings of the Y-shaped connector are positioned and dimensioned to resiliently engage opposite side walls of the slick foam seat 102 to form two friction fit locks—one on each side of the child, thereby forming the two soft attachment points noted above. The two soft points are friction fit points.
[0046] Returning to the example of FIG. 1 , as a result of the adjustability of the seat back 112 , the seat back 112 need only be provided with two shoulder apertures or holes 212 for the harness 210 , instead of a series of holes to raise or lower the harness 210 as the child grows. Instead, the height of the seat back 112 can be adjusted so that the shoulder belts of the harness 210 are positioned properly relative to the child. The shoulder height of the child harness 210 is automatically adjusted as the seat back 112 is moved to properly locate the headrest 108 for the child, so there is no need for multiple openings on the seat back for the harness 210 to pass through. In the illustrated example the height of the seat back 112 is infinitely adjustable within an approximately 6 inch range of travel. Other approaches such as employing a number of fixed positions and/or other ranges of travel would likewise be appropriate.
[0047] Although certain example methods and apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
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High chairs and methods to use high chairs are disclosed. An example high chair includes a frame and a seat, wherein the seat defines a slot and is shaped to funnel spills toward the slot.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an improved system for protecting finished flooring over on-grade concrete floors from damage from water vapor penetration and for insulating them from the cool earth temperatures. Concrete floors particularly concrete floors installed or poured over the dirt surfaces of sub-terrainean rooms such as basement living spaces of homes or the ground-level rooms or work spaces of slab-homes or buildings, are particularly susceptible to water vapor penetration. Conventionally, such concrete floors are covered with plastic tiles or carpeting to improve their appearance and make them more comfortable to the feel.
[0003] However, concrete floors are relatively porous and also conduct the cold temperature of the ground, which can result in water vapor penetration and condensation at the interior surface of the concrete floor, causing separation of floor tiles adhered thereto or causing a moisture accumulation in carpeting adhered thereto or applied thereover, resulting in mold or mildew. Water vapor and water can penetrate and diffuse through the porous concrete floor from the dampness of the soil or ground beneath the concrete, and also through cracks which can develop in the concrete and/or also can penetrate through interfaces between the floor and the walls and/or footings.
[0004] 2. State of the Art
[0005] It is known to build a sub-floor over concrete floors using wooden studs as spacers and covering them with plywood to form an interior floor surface which is then covered by floor tile or carpeting. Such a system is an insulation improvement, but takes up to 2″ of headroom or more. Water vapor can be absorbed by the wooden studs and plywood, resulting in mold, mildew, rot and odors, and separation of tiles from the plywood floor.
[0006] An improved flooring system is commercially-available from applicant's company, Basement Systems, Inc., under the trademark ThermalDry® Flooring System. Such system involves interposing an embossed insulating, thermal air-gap, high density plastic barrier sheet between the concrete floor and a plywood or chipboard floor, the barrier sheet being embossed to form rear-surface projections and front surface depressions, to space the concrete floor from the plywood or chipboard floor. The ThermalDry® Flooring System produces excellent results but has the disadvantage that it still incorporates a plywood or chipboard floor, which can absorb water or water vapor which might penetrate from below the plywood or from above the plywood, due to plumbing leaks or flooding. In addition to ground water vapor, water heater leaks and plumbing leaks are common and this water ends up on the basement floor. Therefore, it is imperative to install an insulating flooring system that uses no organic materials. Plywood and chipboard absorb water and water vapor which can cause them to swell and delaminate and can support mold, requiring complete replacement of the flooring system. Another important disadvantage of this system and of systems such as disclosed in U.S. Pat. Nos. 5,052,161; 5,489,462 and 5,619,832 is that an embossed plastic barrier sheet does not have a solid, planar or flat upper surface to support a carpet as an outer covering, if desired.
[0007] Another flooring system is commercially-available for the insulation of concrete basement floors, comprising 24″ square wood tiles having bonded to the undersurface thereof a backing layer of water-resistant plastic molded with a plurality of spaced water-resistant studs or spacers which provide an air gap between the concrete floor and the wood tiles. Such system is unsatisfactory since the wood tiles, formed from “chipboard”, warp and delaminate in the moist atmosphere and/or when wet from above, and support mold and the consequences thereof. Water vapor can penetrate from the porous concrete up through the joints between the wood tiles and the plastic backings and be absorbed, causing swelling of the wood, particularly along the joints. Also a water leak or flood in the basement can saturate the wooden tiles and also can penetrate between the tiles and under the plastic backing, making it impossible to dry or remove the water without ripping up the floor.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a water-resistant flooring system for insulating against dampness and cold penetration from concrete sub-floors, and which will not be damaged by water penetration from any direction or source, including above-floor plumbing problems or flooding.
[0009] The present flooring system comprises a thermally-insulating water-vapor-proof, air-gap, solid plastic barrier tile layer system comprising a strong rigid flat solid layer of water-resistant plastic, such as ABS, polyvinyl chloride, polyethylene, polypropylene or polycarbonate, which is either molded with integral spaced plastic legs or spacers such as studs or slots or other raised areas on the underside thereof, or is laminated or bonded to a separate water-resistant solid plastic barrier sheet which is molded with integral spaced plastic legs or spacers such as studs or slots or other raised and/or depressed areas on the underside thereof, to provide spaced leg portions which contact the surface of the concrete floor and which space and support the underside of the flat plastic tile from the surface of the concrete floor to provide an insulating thermal air gap barrier space between about ⅛″ and 1″ high, preferably about {fraction (3/8)} inch high, to admit and circulate any water vapor penetrating up through the concrete floor beneath the entire barrier tile layer system. The air gap barrier space provides a space network within which the water vapor circulates and comes into equilibrium with the water content of the porous concrete floor. Water condensation, which will occur if you lay a flat sheet of plastic against a concrete floor, is avoided or substantially reduced by the present plurality of spacers which create the air gap barrier space. Water vapor from the concrete floor cannot condense within the air gap, and humid air from the basement living space cannot penetrate the interlocked plastic tiles to condense on the concrete floor.
[0010] The flat plastic barrier tile layer preferably comprises a plurality of square or rectangular solid tiles, such as 6″, 12″, 17″, 24″ square or 48″ or even 4′×8′ rectangular sheets, about ⅜″ to ¾″ thick, which fit or interlock together such as with tongue-and-groove sides like parquet flooring. As mentioned, the plastic tiles may be formed or molded with the spaced legs or studs on the underside thereof. The top surfaces of the solid plastic tiles are planar and may have a decorative design formed thereon, or the planar upper surface of the plastic barrier tile layer may have a color which is aesthetic, or the tile layer may be after-covered with a conventional ceramic or plastic tile layer or with carpeting or a vinyl surface such as linoleum or vinyl flooring.
DRAWINGS
[0011] FIG. 1 is a perspective view of the undersurface of a section of a moisture-resistant floor tile for covering a concrete floor, such as a basement floor;
[0012] FIG. 2 is a plan view of the uppersurface of a complete floor tile of the type illustrated by FIG. 1 , showing the network of spaced, raised water-resistant studs or legs at the undersurface thereof by means of broken lines;
[0013] FIG. 3 is a cross-sectional view of the floor tile of FIG. 2 taken along the line 3 - 3 thereof;
[0014] FIGS. 4 ( a ) and 4 ( b ) are isometric and plan views, respectively, illustrating the use of spaced integral studs having rectangular cross-sections;
[0015] FIGS. 5 ( a ) and 5 ( b ) are views corresponding to FIGS. 4 ( a ) and 4 ( b ) but illustrating the use of spaced integral studs having open square cross-sections, and
[0016] FIGS. 6 ( a ) and 6 ( b ) are views corresponding to FIGS. 5 ( a ) and 5 ( b ) but illustrating the use of spaced integral studs having open tubular circular shapes having slots.
DETAILED DESCRIPTION
[0017] Referring to FIG. 1 , the underside 11 of a corner section of a solid water-resistant plastic floor tile 10 is illustrated, the tile 10 having groove or slot means 12 along two edges thereof and tongue means 13 along the other two edges, as shown in FIGS. 2 and 3 , for mating with corresponding complementary means on adjacent tiles to lock the tiles to each other and produce a substantially-continuous, smooth plastic floor surface which is water impervious.
[0018] The plastic tile 10 of FIGS. 1 to 3 is molded to have integral spaced plastic support studs or legs or wall sections 15 projecting a maximum distance from the underside 11 thereof, and intermediate plastic network sections 16 of intermediate height. The legs or wall sections 15 project down a uniform distance to contact the concrete floor 11 , a distance of about {fraction (5/16)}″, to form an interconnected insulation airspace image network 17 between the upper surface of the concrete floor and the underside of the network sections 16 of the tile 10 , which airspace network 17 is continuous and open, and provides a thermal break and reservoir for water vapor which may enter.
[0019] As previously disclosed, the present plastic tiles 10 preferably are molded as a unitary plastic tile element, or plastic tiles can be formed with planar upper and lower surfaces and thereafter a plurality of individual plastic studs or spacers and network walls, similar to 15 and 16 in FIG. 1 , can be adhered to the planar lower tile surface 11 .
[0020] An essential requirement is that the studs or legs or wall sections 15 are spaced from each other to provide therebetween an interconnected airspace network such as 16 and 17 shown in FIG. 1 to prevent water vapor passing up through the floor from being isolated in any chambers created by the tile legs or standoffs 15 , so that said water vapor does not condense into water under the tile 10 . In addition, this interconnected airspace 17 under the plastic floor tile will allow the drying of any water that may temporarily collect under the tiles, such as water from an above-floor plumbing leak, water heater leak, etc. or water from a periodic groundwater leak such as from the floor-wall joint of the foundation. Any collected water vapor is isolated from any organic material by which it can be absorbed, such as wood which when wet nourishes the growth of mold. The isolated water vapor will eventually come into equilibrium with the water vapor content of the concrete floor. Another embodiment of the invention is an option to vent the space 17 between the concrete floor surface and the underside of the tiles. This can be done passively at the edge of the floor or actively with a fan to blow air under or to drawn air from under the floor and exhaust it into the interior room or outside of the building to dry the space under the floor either continuously or only when necessary.
[0021] Referring to FIGS. 4 ( a ) and 4 ( b ), 5 ( a ) and 5 ( b ), and 6 ( a ) and 6 ( b ), these figures illustrate just some of the possible cross-sections for spaced studs or legs 18 / 19 / 20 which can be used in association with intermediate network sections 16 and in place of the studs 15 of the water-resistant plastic tile layer 10 of FIGS. 1 to 3 .
[0022] The studs 18 of FIGS. 4 ( a ) and 4 ( b ) are rectangular in cross-section and in staggered or offset rows, relative to adjacent rows, as shown.
[0023] The studs 19 of FIGS. 5 ( a ) and 5 ( b ) are hollow notched squares in cross-section and in staggered rows, as shown, and the studs 20 of FIGS. 6 ( a ) and 6 ( b ) are circular in cross-section, similar to studs 15 of FIG. 2 , but are hollow and have an opening 21 giving them the appearance of a raised letter “C”. The studs 19 and 20 are notched to permit water vapor circulation from within the hollow interiors thereof.
[0024] The studs 15 , 18 , 19 and 20 may have any desired height such as ⅛″ up to about 1″, most preferably about ⅜″ and are closely spaced and staggered in rows, as shown, for maximum tile support and stability.
[0025] FIG. 7 illustrates a plastic tile board 21 which may be in the form of a 17 inch square tile board having opposed tongue and groove edges. The undersurface comprises a gridwork of repeating raised square outlines 22 or studs or stand-offs which contact the concrete basement floor as do the plurality of raised diagonal “X” studs 23 , one within each raised square outline 23 . This design provides a multiplicity of insulation aerospaces 24 between the underside of the tile board 21 and the surface of the concrete basement floor over which is laid and held in place by the tongue-and-groove engagement.
[0026] The preferred tiles 10 for use according to the present invention, as illustrated by FIGS. 1 to 3 of the drawings, have a solid planar upper surface 14 and a discontinuous under surface comprising spaced support studs or legs and wall sections 15 which project a maximum uniform distance from the undersurface 11 of the tile 10 to contact the supporting surface, such as a concrete basement floor. The undersurface 11 also comprises spaced intermediate network sections 16 which project a lesser distance from the undersurface 11 of the tile 10 and do not contact the surface of the supporting floor. The space therebetween enables any water vapor which enters from the concrete floor to circulate through the airspace 17 network beneath the tiles and come into equilibrium with the water vapor content of the concrete floor.
[0027] The tile design of FIGS. 1 to 3 comprises horizontal walls and vertical walls 15 which intersect to form square compartments enclosing diagonal, intermediate height, X-shaped walls 16 and a central post or support leg 15 of maximum height corresponding to the height of the horizontal and vertical walls 15 . In order to provide a circulation airspace 17 beneath the tiles 10 of FIGS. 1 to 3 it is necessary to provide openings or ports in the vertical and/or horizontal walls to reduce sections thereof from a maximum height 15 to an intermediate height 16 and to enable any water vapor to circulate or be moved through an air circulation network 17 beneath all areas of each tile 10 .
[0028] Air circulation spaces are provided between adjacent tiles 10 between the groove or slot means 12 along two adjacent edges of each tile, and under the elongate tongue means 13 along the other two adjacent edges of each tile. Referring to FIG. 2 of the drawing, each groove or slot means 12 has a maximum height corresponding to the height of the spacers 15 so as to provide therebetween an air port. Also the elongate tongue means 13 along the other edges of the tile 10 comprises a plurality of spaced stop support members 25 which limit the extent of entry of the tongue means 13 into the slot means 12 , provide space between the members 25 to enable the circulation of water vapor beneath the tiles, and make contact with the basement floor to further support the tile thereon.
[0029] The studs 15 , 18 , 19 , 20 , 23 and 24 may have any desired height such as ⅛″ up to about 1″, most preferably about ⅜″ and are closely spaced and staggered in rows, as shown, for maximum tile support and stability.
[0030] It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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A thermally insulating tile floor covering system comprising a water resistant, inorganic, thermal air-gap plastic barrier tile layer which is provided with a network of integral spaced plastic studs, legs or wall sections on the underside thereof, to form an interconnected space network between the undersurface of the flat plastic tile and the surface of a concrete floor supporting the tile. The space network provides an insulating thermal air gap barrier space to receive and circulate any water vapor penetrating up through the concrete floor.
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This application is a continuation application of U.S. patent application Ser. No. 07/972,164 filed Nov. 5, 1992 titled DISPENSING CONTAINER, issued as United States Letters Patent No. 5,277,340.
The present invention relates to a dispensing container for storing and dispensing liquids, and more specifically, relates to the pump dispenser for storing and dispensing samples and other small volumes of liquid from a compact container.
BACKGROUND OF THE INVENTION
It is often desirable to dispense small quantities of liquid from a disposable container. For example, in the fragrance industry, it is desirable to provide sample products for testing of perfume by potential customers. In the fragrance industry, samples are often contained in vials that are broken open or plastic sealed packets that are torn open to dispense the perfume. It is widely recognized that in order for the potential customer to fully appreciate the perfume, the perfume should be dispensed in a mist, preferably through a pump dispenser of the type that is used on bottles of perfume. In order to produce a package suitable for samples for perfume, the package should be compact, inexpensive to produce, and relatively inexpensive so that it is disposable. Further, it would be desirable to provide dispensing through an atomizing pump so that the consumer can ascertain the essence of the perfume when it is atomized during application.
One prior art sample pump dispenser is disclosed in U.S. Pat. No. 5,102,018 issued Apr. 7, 1992. This pump dispenser comprises a conventional pump that is sealed with respect to a container by a conventional compressed gasket seal. The seal is held in a place by a multi-part sealing mechanism. This design has several disadvantages including the cost and manufacturing problems associated with multiple parts to be manufactured and assembled, and an awkward external appearance due to the structure needed to accommodate the multiple parts.
It is an object of the present invention to provide a pump dispenser that has the advantages of being disposable, made from very few parts, and easily assembled. The further object of the invention is to provide a sample pump dispenser that provides an excellent liquid seal between the pump and the reservoir containing the liquid. It is a further object of the invention to provide a pump dispenser wherein the exterior appearance of the reservoir is simple and elegant, and has a clean, unbroken silhouette, which is important when a dispenser is used for consumer sampling of products such as fragrances, as well as in other industries wherein the appearance of the container is important.
SUMMARY OF THE INVENTION
In accordance with the present invention a dispensing container for storing and dispensing liquid such as perfume, medicine, and the like is disclosed. The dispensing container includes a reservoir for the liquid and the reservoir includes an opening at the top thereof and a tubular package between the opening and the reservoir. In a preferred form of the invention, the reservoir comprises a cylindrical tube having the opening at one end and which is closed at the other end.
A conventional dispenser is utilized such as a pump of the type described in U.S. Pat. No. 4,606,479 issued Aug. 19, 1986 and U.S. Pat. Application No. 5,192,006 issued Mar. 9, 1993, or other conventional pump assemblies for dispensing liquid.
In order to provide a seal between the pump assembly and the reservoir, the sealing collar is provided. The collar comprises a resilient deformable polymeric material which provides a seal between the collar and the reservoir. The sealing collar has a frustoconical outer wall separated from a main body of the sealing collar. The top of the outer wall has a diameter which is greater than the diameter of the bottom of the wall to provide a taper angle of the frustoconical outer wall. The outer wall is deformable to permit the wall to flex radially inwardly.
The tubular passage of the reservoir has an interior wall that has a recess sized to receive the outer wall of the collar. The recess has a floor for retaining the bottom of the outer wall of the collar against vertical downward movement, and at a ledge for retaining the top of the outer wall of the collar against vertical upward movement.
The tubular passage has a diameter at the upper ledge of the recess that is smaller than the diameter of the top of the sealing collar. After liquid such as perfume or other dispensable liquid is placed in the reservoir, the sealing collar and pump assembly are inserted through the opening from above. During insertion, the outer wall of the sealing collar flexes radially inwardly as it passes the ledge. Once the top of the frustoconical wall passes the ledge it snaps radially outwardly into contact with the sidewall of the recess to form a liquid seal between the outer wall and the sidewall of the recess.
In accordance with one aspect of the invention, the dispensing container consists of only two subassemblies: (1) the reservoir and (2) the sealing collar and the pump assembly. Preferably, the reservoir consists of a polymeric material which is formed in a single integral part. Also, preferably, the sealing collar consists of a polymeric material which is formed in a single integral part. The pump is drawn from a variety of conventionally manufactured pump assemblies that are readily available. Thus, a dispensing pump and container in accordance with this aspect of the invention has a unique advantage of utilizing only two subassemblies to provide a dispensing pump and container which is easily manufactured and assembled. Further, the unique manner in which the sealing collar engages and seals with the tubular passage of the reservoir provides for an aesthetically pleasing external appearance wherein the dispenser has a clean, uncluttered silhouette.
In accordance with another aspect of the invention, the conventional pump assembly has a cylindrical actuator button from which liquid is dispensed. The button has a top surface for application of finger pressure. The actuator button has a diameter that is slightly less than the diameter than the opening of the reservoir. Thus, the actuator button is movable between a rest position downwardly through a pump stroke wherein the actuator button moves within the tubular package of the reservoir. This provides the advantage that the pump mechanism and the sealing collar is located internal of the actuator button and the reservoir. Thus, only the actuator button and the outer surface of the reservoir are visible by a person using the dispenser.
Other advantages of a dispensing container in accordance with the present invention will be apparent from the detailed description of the invention which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the dispensing pump and container in accordance with the present invention;
FIG. 2 is a partial sectional view through the reservoir shown in FIG. 1 and through a sealing collar shown in FIGS. 3 and 4;
FIG. 3 is a perspective view of the sealing collar shown in FIG. 2;
FIG. 4 is a sectional view of the sealing collar along the lines 4--4 of FIG. 3;
FIG. 5 is a perspective partial sectional view of the inside of the reservoir with the recess shown in detail; and,
FIG. 6 is an expanded sectional view along the lines 6--6 of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, a dispensing pump and container in accordance with the present invention is shown. The dispensing pump includes a reservoir 10, a sealing collar 12, and a conventional pump assembly 14 having an actuator button 16.
Referring to FIGS. 1, 2, 5 and 6, the reservoir 10 includes an opening 18 for receiving the sealing collar 12 and the pump assembly 14. A tubular passage 20 extends between the opening 18 and the reservoir 22 which contains the liquid to be dispensed. In accordance with a preferred aspect of the invention, the reservoir comprises a cylinder that includes opening 18 at the top thereof and a bottom 24 that closes the reservoir. The exterior surface of reservoir 10 preferably comprises a smooth unbroken finish which provides an aesthetically pleasing dispensing container.
Referring in particular to FIGS. 3 and 4, the sealing collar includes a main body 26 having a generally cylindrical peripheral wall 28. Peripheral wall 28 has a bottom 30 that is attached to the bottom 32 of outer wall 34. The outer wall is frustoconical in shape. The outer wall has a top 36 that has a diameter 38 which is greater than the diameter 40 of the bottom 32 of the outer wall 34 to provide the desired frustoconical taper. The outer wall 34 preferably has a predetermined thickness that is deformable to permit the wall 34 to flex radially inwardly.
In accordance with a preferred aspect of the invention, the sealing collar is formed from a flexible polymeric material in a single integral part. More preferably, the part is molded from polyethylene.
As shown in FIG. 2, the pump assembly 14 is secured to the sealing collar 12 in a conventional fashion. The pump can be secured to the sealing collar in a number of different fashions, one of which is disclosed in U.S. Pat. No. 5,108,013 issued Apr. 28, 1992 which is incorporated by reference herein. The sealing collar 12 and pump assembly 14 are assembled and inserted through opening 18 in the reservoir to secure the pump assembly 14 in place and to seal the pump assembly with respect to the tubular passage of the reservoir.
Referring to FIGS. 5 and 6, recess 42 for receiving the frustoconical outer wall 34 of the sealing collar 12 will now be described. Recess 42 has a floor 44 for retaining the bottom 32 of the sealing collar 12 against vertical downward movement. More specifically, the diameter 46 of the tubular passage 20 is less than the diameter 62 of the recess 42, and is also less than the outer diameter 40 of the sealing collar 12. Thus, when the sealing collar 12 is inserted into the tubular passage 20, it comes to rest against floor 44, and can proceed no further into the tubular passage 20.
The recess 42 also has a ledge 48 for retaining the top 36 of the outer wall 34 against vertical upward movement. The diameter 50 of the tubular passage just above the ledge 48 is less than the diameter 66 of the recess 42, and is also less than the diameter 38 of the top 36 of the sealing collar 12. When the sealing collar 12 is inserted into the tubular passage 20, the collar outer wall 34 flexes radially inwardly as it passes the ledge 48 and then moves radially outwardly once it has passed the ledge 48 to position the outer wall 34 adjacent the circumferential sidewall 52 of the recess. The outer wall 34 of the sealing collar 12 forms liquid seal with the circumferential sidewall 52 to retain liquid in the reservoir 10.
In accordance with one aspect of the invention, the outer wall 34 of the sealing collar 12 is frustoconical and has a taper angle 54 of between about 5 to about 10 degrees with respect to vertical. The circumferential sidewall 52 of the recess also has a taper angle 56 with respect to vertical, such taper angle being in the range between about .5 and about 3 degrees. The taper angle 54 of the sealing collar should be greater than a taper angle 56 of the recess sidewall. Thus, when the sealing collar 12 is seated in the recess 42, the pressure between the sidewall 52 and the outer wall 34 increases along the height of the outer wall 34 from the bottom 30 to the top 36.
In addition, the outer wall 34 of the sealing collar 12 has a height 58 that is slightly less than the height 60 of the recess 42 to permit a snug fit of the outer wall 34 into the recess 42.
The floor 44 of the recess 42 has a diameter 62 which is preferably greater than the diameter 40 of the bottom 30 the sealing collar 12. Thus, when the sealing collar 12 is positioned on floor 44, there is a close fit between the sidewall 52 and the outer wall 32 at the bottom thereof. The top diameter 66 of the recess 42 at the ledge 48 is smaller than the top diameter 38 of the sealing collar 12 to provide an interference fit and an annular area of contact as best illustrated in FIG. 2.
In accordance with another aspect of the invention, the circumferential sidewall 52 of the recess 42 has a plurality of spaced apart ridges 68, 70 and 72. Each ridge includes a sharpened edge 73 that cuts into the outer wall 34 of the sealing collar 12. Because the sealing collar outer 34 wall has a greater taper angle than the taper angle of the circumferential sidewall 52 of the recess 42, the pressure of the outer wall 34 against ridge 68 is greater than the pressure of the outer wall 34 against ridge 70. Thus, ridge 68 digs further into the surface of the outer wall 34 than ridge 70. Likewise, ridge 70 digs further into the outer wall 34 than does ridge 72. The deformation of the outer wall 34 of the sealing collar by the ridges 68, 70, 72 provides a liquid seal that extends around the circumference of the ridges. In particular, a first seal is provided by ridge 72, a second seal is provided by ridge 70, and a third seal is provided by ridge 68. The triple seal is effective to minimize any leakage of liquid from the reservoir 10.
In accordance with one aspect of the invention, the dispensing container has two subassemblies for ease of manufacture and for reduction in costs of parts. More specifically, the first subassembly is the reservoir 10, the second subassembly is the sealing collar 12 and the pump assembly 14.
The pump assembly 14 with the sealing collar 12 is assembled with the actuator 16 in advance. The reservoir 10 is then separately filled, and the sealing collar 12 is fitted into the reservoir 10 until the outer wall 34 is snap fitted into the recess 42 in reservoir 10.
In accordance with one aspect of the invention, the actuator button 16 has a generally cylindrical shape and has a diameter 74 that is slightly less than the diameter of opening 18. Thus, as shown in FIG. 1, once the dispensing pump and container are assembled, one only sees two parts: the reservoir and the actuator button. The actuator button is movable between a rest position downwardly through a pump stroke wherein the actuator button moves internal to the reservoir. Thus, a very simple outward appearance is provided without an aesthetically detracting pump/reservoir fastener or other break line that is visible to the user.
It should be understood that although specific embodiments of the invention have been described herein in detail, such description is for purposes of illustration only and modifications may be made thereto by those skilled in the art within the scope of the invention.
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A method for assembling a dispensing container of the type as used for storing and dispensing liquid such as perfume, medicine and the like. The method comprises a forming a reservoir in a single integral part with an exterior surface being smooth and unbroken, assembling an actuator, a pump mechanism and a seal for sealing the pump mechanism with respect to the reservoir into a subassembly, and then inserting the subassembly into the opening of the reservoir to a predetermined distance to locate the seal and the pump mechanism completely internal of the actuator button and reservoir wherein only the actuator button and the reservoir are visible external to said dispensing pump and container.
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TECHNICAL FIELD
[0001] The present invention is related to a heat exchange system and assembly for use in a cryogenic air separation plant, and more particularly, to a sub-cooler assembly comprising at least two separate heat exchange segments within the same housing or shell and configured to concurrently cool two or more upward flowing cryogenic liquids using nitrogen-rich streams from the lower pressure distillation column.
BACKGROUND OF THE INVENTION
[0002] In a typical air separation unit, saturated kettle liquid and shelf liquid from the higher pressure distillation column are sub-cooled in a heat exchanger against a nitrogen stream from the lower pressure distillation column (lower pressure column) before the sub-cooled streams are sent to the lower pressure distillation column. Sub-cooling the kettle liquid and shelf liquid streams prior to introduction into to the lower pressure distillation column tends to minimize flashing of such liquid streams in the column, thereby maximizing liquid reflux in the lower pressure column which enhances the recovery of oxygen product and argon product. In addition, sub-cooling of the kettle liquid and shelf liquid streams aids in the recovery of refrigeration from the nitrogen streams, namely the nitrogen product stream and/or the waste nitrogen reducing the external refrigeration requirements for the air separation plant. Sub-cooling the kettle liquid and shelf liquid streams is preferably targeted at temperatures very close to the temperatures of nitrogen product stream and/or the waste nitrogen stream in order to recover most of the refrigeration and maximize refrigeration recovery from the nitrogen streams.
[0003] Usually, such exchange of heat between the nitrogen streams from the lower pressure column and the kettle liquid and shelf liquid streams from the higher pressure column is carried out using a Brazed Aluminum Heat Exchanger (BAHX), commonly referred to as a sub-cooler. This sub-cooler could be a separate, stand-alone heat exchanger or may be packaged within the primary heat exchanger shell and integrated therewith.
[0004] Both the external sub-cooler and the integrated sub-cooler have selected advantages and shortcomings. For example, an external or separate sub-cooler typically would involve higher capital costs as well as packaging challenges and may also result in higher pressure loss or pressure drops of the cooling nitrogen streams. However, the external or separate sub-cooler typically offers more design flexibility in terms of selection of the quantity, dimensions, and number of layers, and flow direction for each stream traversing through the sub-cooler.
[0005] On the other hand, an integrated sub-cooler typically has the advantage of lower capital costs, lower pressure drops and easier or more simplified packaging. Disadvantages of the integrated sub-cooler is the reduced design flexibility as most of the sub-cooler design parameters are dictated or fixed by the design decisions associated with the primary heat exchanger. An example of an integrated sub-cooler is disclosed in U.S. Pat. No. 6,044,902.
[0006] Use of these prior art integrated sub-coolers in heat exchange systems within large-scale, higher pressure air separation units has also resulted in creation of inactive zones within the primary heat exchanger, where little or no heat exchange takes place. The presence of inactive zones at any place where liquid oxygen is present poses a potential safety risk, which is typically mitigated by forcing an active stream to flow through such zones without taking advantage of effective heat exchange, resulting in performance and cost disadvantages. Also, the sub-cooler designs and associated liquid stream flow directions within such integral sub-coolers is often dictated by the design specifications for the primary heat exchanger resulting in inflexible and ineffective sub-cooler design, which tend to make integrated sub-cooler designs more expensive than separate, stand-alone sub-cooler heat transfer assemblies.
[0007] Some of the root causes of the sub-optimized performance of the conventional sub-coolers include: (i) uneven distribution of flows entering and exiting multiple sub-coolers due to the physical arrangement of the sub-cooler manifolds and associated piping; (ii) flow deviations of kettle liquid and shelf liquid streams from layer to layer within any given sub-cooler due in part to sub-cooler design, low flow velocities and inability of the liquid streams to fill the entire layer volume; and (iii) existence and variability of two phase flows of kettle liquid directed to and within the sub-coolers. As a result of these problems, there appears to be an under utilization of available heat transfer area within the sub-coolers. Such underperformance of the sub-cooler assemblies could adversely impact argon recovery in the air separation unit.
[0008] What is needed therefore, is an improved sub-cooler heat transfer assembly and an improved heat transfer system for a cryogenic air separation plant that mitigates the above-identified problems.
SUMMARY OF THE INVENTION
[0009] The present invention may be characterized as a heat exchanger assembly for a cryogenic air separation unit, comprising: (i) a sub-cooler housing having a shell, at least two cryogenic liquid inlets, at least two cryogenic liquid outlets, at least one nitrogen-rich stream inlet and at least one nitrogen-rich stream outlet, the housing configured to receive a flow of a nitrogen-rich stream at the nitrogen-rich stream inlet(s) and separate or distinct flows of at least two cryogenic liquids at the cryogenic liquid inlets; (ii) a first heat exchange segment disposed within the housing and configured for receiving a first flow of cryogenic liquid of an air separation unit and for channeling the first flow of cryogenic liquid in a cross flow orientation or a counter-cross flow orientation from the cryogenic liquid inlets to one of the cryogenic liquid outlets; and (iii) a second heat exchange segment unit disposed within the housing and configured for receiving a second flow of cryogenic liquid and for channeling the second flow of cryogenic liquid within the second heat exchange segment from another of the cryogenic liquid inlets to another of the cryogenic liquid outlets. The first heat exchange segment is configured for receiving a portion of the flow of nitrogen-rich stream and for channeling that flow in a first direction within the first heat exchange segment from the nitrogen-rich stream inlet to the nitrogen-rich stream outlet(s) to sub-cool the first flow and wherein the first direction is generally orthogonal to the first flow of the cryogenic liquid. The second heat exchange segment is further configured for receiving a portion of the flow of the nitrogen-rich stream and for channeling the flow in a second direction within the second heat exchange segment from the nitrogen-rich stream inlet to the nitrogen-rich stream outlets to sub-cool the second flow of the cryogenic liquid.
[0010] The present invention may also be characterized as a heat exchanger system for an air separation unit, comprising: (a) a primary heat exchanger having a plurality of heat exchanging units, the primary heat exchanger configured to cool a compressed and purified incoming air stream to temperatures suitable for cryogenic rectification of the air stream in distillation columns via indirect heat exchange with return streams from the air separation unit; and (b) a sub-cooling heat exchanger fluidically coupled to one or more of the heat exchanging units in the primary heat exchanger, the sub-cooling heat exchanger configured to sub-cool at least two cryogenic liquid streams via indirect heat exchange with a nitrogen-rich stream selected from the group comprising a waste nitrogen stream, a product nitrogen stream, or other nitrogen-containing return stream, wherein the sub-cooling heat exchanger is separated and disposed apart from the primary heat exchanger.
[0011] Within the present heat exchanger system, the sub-cooling heat exchanger further comprises: (i) a sub-cooler housing having a shell, at least two cryogenic liquid inlets, at least two cryogenic liquid outlets, at least one nitrogen-rich stream inlet and at least one nitrogen-rich stream outlet, the housing configured to receive a flow of the nitrogen-rich stream at the nitrogen-rich stream inlet and separate flows of at least two cryogenic liquids at the cryogenic liquid inlets; (ii) a first heat exchange segment disposed within the housing and configured for receiving a first flow of cryogenic liquid and for channeling the first flow of the cryogenic liquid in a cross flow orientation or a counter-cross flow orientation from one of the cryogenic liquid inlets to one of the cryogenic liquid outlets; the first heat exchange segment further configured for receiving a portion of the nitrogen-rich stream and for channeling the portion of the nitrogen-rich stream in a first direction within the first heat exchange segment from the nitrogen-rich stream inlet to the nitrogen-rich stream outlet to sub-cool the first flow of cryogenic liquid and wherein the first direction is generally orthogonal to the first flow of cryogenic liquid; and (iii) a second heat exchange segment unit disposed within the housing and configured for receiving a second flow of cryogenic liquid and for channeling the second flow of cryogenic liquid within the second heat exchange segment from another of the cryogenic liquid inlets to another of the cryogenic liquid outlets; the second heat exchange segment further configured for receiving a portion of the nitrogen-rich stream and for channeling the portion of the nitrogen-rich stream in a second direction within the second heat exchange segment from the nitrogen-rich stream inlet to the nitrogen-rich stream outlet to sub-cool the second flow of the cryogenic liquid.
[0012] The heat exchanger system also may include or comprise an inlet manifold disposed upstream of the sub-cooling heat exchanger and fluidically coupled thereto and configured to deliver the nitrogen-rich stream from a lower pressure distillation column of the air separation unit to the at least one nitrogen-rich stream inlet. In addition, the heat exchange system may include one or more exhaust manifolds disposed downstream of the sub-cooling heat exchanger and fluidically coupled thereto, the one or more exhaust manifolds configured to deliver the warmed nitrogen-rich stream from the sub-cooling heat exchanger to one or more of the heat exchanging units of the primary heat exchanger as a portion of the return streams.
[0013] Additional features and elements associated with the present inventions may include arrangements where the first flow of cryogenic liquid and second flow of cryogenic liquid may comprise one or more of the following flows: a flow of kettle liquid from the higher pressure column; a flow of shelf liquid from the higher pressure column; a flow of liquid oxygen; or a flow of liquid air. Advantageously, some or all of the first flow and/or second flow of cryogenic liquids within the sub-cooler assembly flow in a cross-counter flow or serpentine path and in a generally upward flow orientation through the sub-cooler assembly.
[0014] The nitrogen-rich stream may comprise waste nitrogen and/or product nitrogen from the lower pressure column of the air separation unit and the flow of the nitrogen-rich stream is a gravity assisted flow in a generally downward orientation. The flow of the cryogenic liquids may be in a counter flow or cross-counter flow path generally orthogonal to the flow of the nitrogen-rich stream. Alternatively, flows of the cryogenic liquids may be in a direction generally parallel to and counter to flow of the nitrogen-rich stream. Still other embodiments of the heat exchanger assembly contemplate splitting the nitrogen-rich stream into two or more exit streams.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above and other aspects, features, and advantages of the present invention will be more apparent from the following, more detailed description thereof, presented in conjunction with the following drawings, in which:
[0016] FIG. 1 shows a general schematic illustration of a portion of a heat exchange system within a cryogenic air separation unit in accordance with the present invention;
[0017] FIGS. 2A and 2B show an exterior planar view of the sub-cooler type heat exchanger assembly in accordance with one embodiment of the present invention;
[0018] FIGS. 3A and 3B show a cross sectional view of the sub-cooler type heat exchanger assembly depicting the individual heat exchange layers and internal flow paths of the cryogenic liquids and nitrogen-rich stream in accordance with the embodiment of FIG. 2A ;
[0019] FIGS. 4A and 4B show a cross sectional view of the sub-cooler type heat exchanger assembly depicting an alternate arrangement of individual heat exchange layers and internal flow paths of the cryogenic liquids and nitrogen-rich stream;
[0020] FIGS. 5A and 5B show an exterior planar view of the sub-cooler type heat exchanger assembly in accordance with an alternate embodiment of the present invention;
[0021] FIGS. 6A and 6B show a cross sectional view of the sub-cooler type heat exchanger assembly depicting the individual heat exchange layers and internal flow paths of the cryogenic liquids and nitrogen-rich streams in accordance with the embodiment of FIGS. 5A ; and
[0022] FIGS. 7A and 7B show a cross sectional view of the sub-cooler type heat exchanger assembly depicting an alternate arrangement of individual heat exchange layers and internal flow paths of the cryogenic liquids and nitrogen-rich streams.
[0023] For the sake of avoiding repetition, some of the common elements in the various Figures utilize the same numbers.
DETAILED DESCRIPTION
[0024] Turning now to FIG. 1 , there is shown a general schematic illustration of a portion of a heat exchanger system 10 within a cryogenic air separation unit. The illustrated heat exchanger system 10 includes a primary heat exchanger 12 having a plurality of heat exchanging units 14 and one or more sub-cooling heat exchanger assemblies 20 coupled to one or more of the heat exchanging units 14 in the primary heat exchanger 12 .
[0025] The illustrated embodiment also includes a first inlet manifold or conduit 15 disposed upstream and coupled to the sub-cooling heat exchanger assembly 20 . This inlet conduit 15 is configured to deliver a stream of waste nitrogen from the lower pressure distillation column of the air separation unit to one of the sub-cooling heat exchanger assemblies 20 . A second inlet manifold or conduit 17 is configured to deliver a stream of nitrogen product from the lower pressure distillation column of the air separation unit to another sub-cooling heat exchanger assembly 20 . The waste nitrogen stream and nitrogen product stream are used to sub-cool one or more cryogenic liquids within the sub-cooler heat exchanger assembly 20 . Although not shown, the cryogenic liquids may be selected from the one or more of the following streams: a kettle liquid stream, a shelf liquid stream, liquid air stream and liquid oxygen stream. The present system further includes one or more exhaust manifolds 16 , 18 , 19 coupled to the sub-cooling heat exchanger assemblies 20 . The one or more exhaust manifolds 16 , 18 , 19 are configured to deliver the effluent waste nitrogen stream or the effluent nitrogen product stream from the sub-cooling heat exchanger assembly 20 to one or more of the heat exchanging units 14 of the primary heat exchanger 12 as a portion of the return streams. The primary heat exchanger 12 receives these effluent streams and uses excess refrigeration in such effluent streams to cool a compressed and purified incoming air stream to temperatures suitable for cryogenic rectification of the air stream in distillation columns.
[0026] Turning to FIGS. 2A and 2B there is shown exterior planar views of the sub-cooler type heat exchanger assembly 20 . As seen therein, the sub-cooler type heat exchanger assembly 20 includes a housing or shell 22 containing a main heat exchange body 30 that is split into two separate heat exchange segments 32 , 34 and separated by a divider 35 . While the divider 35 is shown at the midpoint of the main heat exchange body 30 such that the two heat exchange segments 32 , 34 are of generally equal width, the actual location of the divider 35 may be altered to vary the widths of the two heat exchange segments 32 , 34 depending on the cooling requirements for each heat exchange segment within the sub-cooler type heat exchanger assembly 20 . Adjusting the location of the divider 35 and thus the widths and spatial volumes of the heat exchange segments 32 , 34 provides enhanced design flexibility which is particularly useful in applications requiring the sub-cooling of liquid oxygen from the lower pressure column or liquid air. In addition, by adjusting the widths of the heat exchange segments 32 , 34 one can reduce the pressure drop across the sub-cooler type heat exchanger assembly 20 .
[0027] The illustrated sub-cooler type heat exchanger assembly 20 includes a nitrogen-rich stream inlet 24 , two or more nitrogen-rich stream outlets 26 , a full dome inlet distributing manifold 27 configured to receive the nitrogen-rich stream (shown as arrow C), and a full dome collection manifold 29 configured to collect the nitrogen-rich stream (C) from within the heat exchanger assembly 20 and distribute the nitrogen-rich stream (C) to the nitrogen-rich stream outlets 26 . A flow splitter (not shown) may optionally be disposed within the full dome outlet header or collection manifold 29 to evenly distribute the effluent nitrogen-rich streams (C) to the plurality of nitrogen-rich stream outlets 26 .
[0028] The illustrated sub-cooler type heat exchanger assembly 20 further includes a plurality of cryogenic liquid inlets and cryogenic liquid outlets. In the illustrated embodiment, the first heat exchange segment 32 includes a cryogenic inlet 42 for a first cryogenic liquid flow (shown as arrow A) and a cryogenic inlet 44 for a second cryogenic liquid flow (shown as arrow B). The first heat exchange segment 32 also includes a cryogenic outlet 46 for the first cryogenic liquid flow (A) and a cryogenic outlet 48 for the second cryogenic liquid flow (B). The second heat exchange segment 34 also includes a cryogenic inlet 52 for another first cryogenic liquid flow (shown as arrow A) and a cryogenic inlet 54 for another second cryogenic liquid flow (shown as arrow B) as well as corresponding cryogenic outlet 56 for the first cryogenic liquid flow (A) and cryogenic outlet 58 for the second cryogenic liquid flow (B). The illustrated design contemplates the first cryogenic liquid flow (A) as being kettle liquid from the high pressure distillation column, and second cryogenic liquid flow (B) as being shelf liquid from the higher pressure column which are sub-cooled against a flow of a waste nitrogen stream (C).
[0029] Turning now to FIGS. 3A and 3B , there is shown a cross sectional view of an embodiment of the main heat exchanger body 30 depicting the individual heat exchange layers 40 A, 40 B and internal flow paths of the cryogenic liquids and nitrogen-rich stream. As in many heat exchangers, there are a plurality of each type of layers. In the present embodiment of the sub-cooler type heat exchanger assembly 20 there are 66 layers of the type shown in FIG. 3A and a corresponding number of layers or more of the of the type shown in FIG. 3B arranged in an alternating pattern or sandwich pattern. The minimum number of FIG. 3A type layers 40 A required to ensure complete filling of the passages 45 , 47 , 55 , 57 with kettle liquid and shelf liquid could be determined and implemented independently of number of FIG. 3B type layers 40 B for the nitrogen-rich streams required to achieve the desired sub-cooling of the cryogenic liquid streams.
[0030] As illustrated, the flow of the nitrogen-rich stream (C) within each FIG. 3B type layer 40 B is a gravity assisted flow in a generally downward orientation from the nitrogen-rich stream inlet 62 to one or more nitrogen-rich stream outlets 66 . Conversely, the flows of the kettle liquid (A) and shelf liquid (B) within each FIG. 3A type layer 40 A are against gravity in a generally upward orientation through the heat exchanger main body 30 in both heat exchanger segments 32 , 34 . Note the cryogenic liquid inlets 42 , 44 , 52 , and 54 are disposed vertically below the corresponding cryogenic liquid outlets 46 , 48 , 56 , and 58 such that the overall flow of the cryogenic liquids is in an upward flow orientation in both heat exchanger segments 32 , 34 . In addition, the cryogenic liquid passages 45 , 47 within each of the FIG. 3A type layer 40 A in the first heat exchange segment 32 and the passages 55 , 57 within each of the FIG. 3A type layer 40 A in the second heat exchange segment 34 are configured in a cross-counter or serpentine path orthogonal to the path of the nitrogen-rich stream (C) in the adjacent FIG. 3B type layers 40 B. Perforated fins are preferably used with the serpentine flow paths to effect the transfer of heat.
[0031] FIGS. 4A and 4B show an alternate arrangement of individual heat exchange layers 40 A, 40 B and internal flow paths of the cryogenic liquids and nitrogen-rich stream. In this embodiment, the first heat exchange segment 32 includes a cryogenic inlet 42 for the first cryogenic liquid flow (shown as arrow A) and a cryogenic inlet 44 for the second cryogenic liquid flow (shown as arrow B). As with the embodiment of FIG. 3A , the first heat exchange segment 32 also includes a cryogenic outlet 46 for the first cryogenic liquid flow (A) and a cryogenic outlet 48 for the second cryogenic liquid flow (B). The second heat exchange segment 34 however, includes a cryogenic inlet 52 for a cryogenic liquid flow (shown as arrow E) and a corresponding cryogenic outlet 56 for the cryogenic liquid flow (E). The illustrated design contemplates the first cryogenic liquid flow (A) as being kettle liquid from the high pressure distillation column, the second cryogenic liquid flow (B) as being shelf liquid from the higher pressure column, and the cryogenic liquid flow (E) as being liquid oxygen from the lower pressure distillation column, all of which are sub-cooled against a flow of waste nitrogen stream (C). Passages 65 within each of the FIG. 4A type layer 40 A in the second heat exchange segment 34 are configured in a counter flow arrangement in a direction generally parallel to the path of the nitrogen-rich stream (C) in the adjacent FIG. 4B type layers 40 B. Perforated fins or hardway fins are preferably used with the counter flow paths to effect the required heat transfer.
[0032] FIGS. 5A and 5B show exterior planar views of an alternate embodiment of the sub-cooler type heat exchanger assembly 20 . Similar to the embodiment of FIGS. 2A and 2B , the illustrated heat exchanger assembly 20 includes housing or shell 22 and a main heat exchange body 30 that is split into two separate heat exchange segments 32 , 34 separated by a divider 35 . The illustrated sub-cooler type heat exchanger assembly also includes two nitrogen-rich stream inlets 23 , 24 ; two or more nitrogen-rich stream outlets 25 , 26 ; split dome inlet distributing manifolds 27 configured to receive flows of the nitrogen-rich streams (shown as arrow C and arrow D), and split dome collection manifolds 29 configured to collect the flows of nitrogen-rich streams (C), (D) from within the heat exchanger assembly 20 and distribute the nitrogen-rich streams to the corresponding nitrogen-rich stream outlets 25 , 26 .
[0033] The illustrated sub-cooler type heat exchanger assembly 20 further includes a plurality of cryogenic liquid inlets and cryogenic liquid outlets. In the illustrated embodiment, the first heat exchange segment 32 includes a cryogenic inlet 42 for the first cryogenic liquid flow (shown as arrow A) and a cryogenic inlet 44 for the second cryogenic liquid flow (shown as arrow B). The first heat exchange segment 32 also includes a cryogenic outlet 46 for the first cryogenic liquid flow (A) and a cryogenic outlet 48 for the second cryogenic liquid flow (B). The second heat exchange segment 34 includes a cryogenic inlet 52 for a cryogenic liquid flow (shown as arrows E and/or F) as well as a corresponding cryogenic outlet 56 for the cryogenic liquid flow (E/F). The illustrated design contemplates the first cryogenic liquid (A) as being kettle liquid and the second cryogenic liquid (B) as being shelf liquid which are sub-cooled against a waste nitrogen stream (C). In addition, cryogenic liquid flow (E/F) is either a flow of liquid oxygen from the lower pressure column or a flow of liquid air which are sub-cooled against a nitrogen product stream (D).
[0034] Turning now to FIGS. 6A and 6B , there is shown a cross sectional view of the embodiment of the main heat exchanger body 30 depicting the individual heat exchange layers 40 A, 40 B and internal flow paths of the cryogenic liquids and nitrogen-rich streams. As illustrated, the flows of the waste nitrogen stream (C) and product nitrogen stream (D) within each FIG. 6B type layer 40 B is a gravity assisted flow in a generally downward orientation through their respective heat exchanger segments 32 , 34 . Conversely, the flow of the kettle liquid (A) and shelf liquid (B) within each FIG. 6A type layer 40 A and the flow of cryogenic liquid (E/F) are against gravity in a generally upward orientation through the heat exchanger main body 30 in their respective heat exchanger segments 32 , 34 . As discussed above, the cryogenic liquid inlets 42 , 44 , and 52 are disposed vertically below the corresponding cryogenic liquid outlets 46 , 48 , and 56 such that the overall flow of the cryogenic liquids is in an upward flow orientation in the heat exchanger assembly 20 . Similar to the embodiment of FIG. 4A , the cryogenic liquid passages 45 , 47 within each of the FIG. 6A type layer 40 A in the first heat exchange segment 32 are configured in a cross-counter or serpentine path orthogonal to the path of the waste nitrogen stream (C) in the adjacent FIG. 3B type layers 40 B. Passages 65 within each of the FIG. 6A type layers 40 A in the second heat exchange segment 34 are configured in a counter flow arrangement generally parallel to the path of the nitrogen product stream (D) in the adjacent FIG. 6B type layers 40 B.
[0035] FIGS. 7A and 7B show yet another alternate arrangement of individual heat exchange layers and internal flow paths of the cryogenic liquids and nitrogen-rich streams. Again, the flows of the waste nitrogen stream (C) and product nitrogen stream (D) within each FIG. 7B type layer 40 B is a gravity assisted flow in a generally downward orientation through their respective heat exchanger segments 32 , 34 while the cryogenic flows (A), (B), (E) and (F) are against gravity in a generally upward orientation through the heat exchanger main body in their respective heat exchanger segments 32 , 34 . In this embodiment, the cryogenic liquid passages 45 , 47 , 55 , 57 within each of the FIG. 7A type layers 40 A in the heat exchange segments 32 , 34 are configured in a cross-counter or serpentine path generally orthogonal to the path of the nitrogen-rich streams (C), (D) in the adjacent FIG. 7B type layers 40 B.
[0036] The present heat exchange system described above provides some power savings for the air separation unit through reduced pressure drops in the present sub-cooler type heat exchanger assembly compared to conventional integrated sub-cooler assemblies as well as conventional separate sub-cooling assemblies. In addition, the present heat exchange system can realize potential sub-cooling performance enhancements due to elimination of inactive zones in a primary heat exchanger with integrated sub-cooler assemblies and utilization of the full heat transfer area within the present sub-cooler heat transfer assemblies. Such sub-cooling performance enhancements translate into improved argon recovery within the air separation unit.
[0037] The present heat exchange system also provides some capital cost savings associated with the primary heat exchanger compared to conventional primary heat exchangers with an integrated sub-cooler. The reduction in capital costs is partially offset by the added equipment costs for the separate sub-cooler heat exchange assemblies. Specifically, the capital cost savings associated with reduction in primary heat exchanger length and complexity.
[0038] While the present invention has been described with reference to selected preferred embodiments, numerous additions, modifications, and variances can be made without departing from the spirit and scope of the present invention as set forth in the appended claims.
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A sub-cooler type heat exchanger assembly and system for use in a cryogenic air separation plant is provided. The sub-cooler type heat exchanger includes at least two separate heat exchange segments within the same housing or shell and is configured to concurrently cool two or more upward flowing cryogenic liquids using nitrogen-rich streams from the lower pressure distillation column.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of co-pending Canadian patent application No. 2,571,538 filed Dec. 19, 2006 and Canadian patent application No. 2,571,398 filed Dec. 20, 2006, both of which are incorporated herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention pertains to the field of pharmaceutical compositions and methods of preparation thereof and, more particularly, to pharmaceutical compositions comprising a bisphosphonate and a vitamin D compound, and to method of preparation thereof.
BACKGROUND OF THE INVENTION
[0003] Bisphosphonic acids are important in the treatment of bone diseases as well as problems with calcium metabolism such as osteoporosis, Paget's disease, and hypercalcaemia. Bisphosphonates, i.e. bisphosphonic acids or soluble, pharmaceutically acceptable salts thereof, are synthetic analogs of the naturally occurring pyrophosphate. Due to their marked affinity for solid-phase calcium phosphate, bisphosphonic acids bind strongly to bone mineral. Pharmacologically active bisphosphonic acids are well known in the art and are potent inhibitors of bone resorption and are therefore useful in the treatment and prevention of diseases involving abnormal bone resorption. Bones serve as support structures but are also involved in various body stimuli signaling and response mechanisms. Therefore simple prosthetics to support the damaged bone do not give a patient the proper active effect that repairing the bone itself would do.
[0004] Bisphosphonic acids as pharmaceutical agents are described, for example, in U.S. Pat. Nos. 4,687,767, 4,666,895, 4,927,814, 4,942,157, and 4,777,163. Pharmaceutical forms of marketed bisphosphonic acids are oral composition (tablets or capsules) or solutions for intravenous injection or infusion. Many bisphosphonic acids, including alendronic acid, sodium ibandronate, risedronate, pamidronate and clodronate, are currently under clinical development or marketed for the treatment of osteoporosis and metastatic bone diseases (Muhlbauer R. C., Bauss R., Schenk R., Janner M., Bosies E., Strein K., and Fleisch H. BM21.0955 A Potent New Bisphosphonic acid to Inhibit Bone Resorption. J. Bone Miner. Res. 6:1003-1011 (1991)).
[0005] Vitamin D3 (Cholecalciferol) is a non-activated form of Vitamin D. It is a precursor of the hydroxylated, biologically active metabolites and analogues of Vitamin D3. Generally cholecalciferol may be activated by hydroxylation into 25-hydroxy-cholecalceiferol, and 25-hydroxy-cholecalciferol may be further hydroxylated at the 1-alpha-position to 1,25-dihydroxy-cholecalciferol (an active form of Vitamin D3). Active forms of Vitamin D can not be given in large dosages due to their toxicity to mammals, whereas the inactive Vitamin D3 form may be given in higher dosages. Vitamin D insufficiency is recognized as causes of metabolic bone disease in adults, characterized by the impairment of calcium and phosphate absorption. Vitamin D deficiency is also characterized by impaired bone mineralization. Sustained vitamin D insufficiency and deficiency are thought to be an important cause of gradual bone loss.
[0006] Vitamin D insufficiency can be age related, or due to geographical and seasonal causes. While exposure to sunlight provides most of the vitamin D required for children and young adults, the body can deplete its stored vitamin D because of lack of exposure to sunlight combined with dietary deficiency. However, vitamin D supplementation in food goods fails to ensure adequate intake at times, especially among the elderly who do not frequently consume these foods or where intestinal absorption of calcium is less efficient or where low sunlight exposure is common (thus depletion occurs rapidly).
[0007] U.S. Pat. No. 4,230,700 issued Oct. 28, 1980 discloses the conjoint administration of certain polyphosphonate compounds, in particular bisphosphonic acids and vitamin D-like anti-rachitic compounds for inhibition of the anomalous mobilization of calcium phosphates in animal tissue. U.S. Pat. No. 4,330,537 issued May 18, 1982 claims the compositions used in the methods of U.S. Pat. No. 4,230,700. In subjects undergoing bisphosphonic acid therapy, and in particular those subjects with inadequate dietary calcium intake or inadequate calcium absorption, there is a need for supplemental Vitamin D nutrition to facilitate bone formation and mineralization. A single product or preparation comprised of metabolites of Vitamin D and a bisphosphonic acid address this need by ensuring that patients receiving bisphosphonic acid also receive sufficient vitamin D.
[0008] Pharmaceutical preparations can be problematic because sometimes they are associated with compression and flowability issues during processing. The increased stickiness and resulting hardness of the granules inhibit the processing, resulting in a retarded dissolution profile and friability problems when excipients are manipulated to improve lubrication or flowability. Thus pharmaceutical preparations have been known to require a “glidant” such as, but not limited to, colloidal silicon dioxide, talc and the like, which improve the flow characteristics of a powder mixture during processing as in patent application WO2005/117906A1. Normally, the glidant makes up between 0.5 and 5.0% of the composition.
[0009] This background information is provided for the purpose of making known information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.
SUMMARY OF THE INVENTION
[0010] The present invention provides a composition containing a bisphosphonic acid in combination with a vitamin D compound.
[0011] In particular, one aspect of the invention provides a pharmaceutical composition comprising: (a) an active pharmaceutical ingredient (API), pharmaceutically acceptable salts thereof, derivatives or hydrates of the API, or mixtures thereof; (b) a vitamin D compound; and (c) one or more excipients selected from fillers, diluents, binders, lubricants or disintegrants, wherein said composition does not include a glidant.
[0012] Another aspect of the invention provides a pharmaceutical composition comprising: (a) an active pharmaceutical ingredient (API), pharmaceutically acceptable salts thereof, derivatives or hydrates of the API, or mixtures thereof; (b) a vitamin D compound; (c) lactose; (d) microcrystalline cellulose; and (e) one or more excipients selected from fillers, diluents, binders, lubricants, disintegrants or glidants, wherein the glidant is present at a concentration of from 0 to 0.5% w/w
[0013] According to a specific embodiment of the invention the API is a bisphosphonic acid or a pharmaceutically acceptable salt thereof. In a particular embodiment, the bisphosphonic acid is Alendronic acid or a pharmaceutically acceptable salt thereof, for example, alendronate monosodium, alendronate monosodium monohydrate or alendronate monosodium trihydrate.
[0014] Further, according to a preferred embodiment of the invention the Vitamin D compound is cholecalciferol. The cholecalciferol in the composition is preferably in an amount of from about 2,800 IU to about 5600 IU while the API or pharmaceutically acceptable salt thereof is in a preferred amount of about 70 mg. In a particularly preferred embodiment, the cholecalciferol in the composition is in an amount of about 2,800 IU or about 5600 IU.
[0015] A particularly preferred embodiment of the invention provides a composition as described above, which comprises Alendronic acid as the bisphosphonic acid, Cholecalciferol as the Vitamin D compound, microcyrstalline cellulose (Avicel 302 grade) and an anhydrous form of Spray Dried Lactose. The flow improving excipient such as a glidant, most preferably colloidal silicon dioxide, is either not required or is required at low concentration (i.e., no more than 0.5% by weight).
[0016] An advantage of such compositions is that the stickiness typically associated with bisphosphonic acids, in general, seems to have been surprisingly overcome simultaneously along with the improved flowability when the microcyrstalline cellulose (e.g., Avicel 302) and the Lactose Anhydrous (e.g., Spray Dried) are used. Such compositions allow for hardness or dissolution time (DT) levels of the preparation to be sufficient low to reduce or eliminate friability issues, and prevent the composition from crumbling away or not ejecting properly during processing.
[0017] Another advantage is that fewer excipients are required to improve flowability of the composition, more specifically the need for a glidant is either removed entirely, or reduced significantly.
[0018] Overall, there is the advantage that the compositions herein do not show a retarded dissolution profile in comparison to compositions containing a glidant in the standard amount (typically from greater than 0.5% to 5.0% by weight), as would be expected with such a drastic change in composition even with the complete absence or reduced concentration of glidant.
[0019] Another aspect of the present invention provides a process for preparing a pharmaceutical composition as described above, which method comprises the steps of: (a) blending the active pharmaceutical ingredient (API), pharmaceutically acceptable salts thereof, derivatives or hydrates of the API, or mixtures thereof with a vitamin D compound; and (b) adding one or more excipients selected from the group comprising fillers, diluents, binders, lubricants, disintegrants and glidant, wherein said glidant is added so that the final concentration of glidant is from 0 to 0.5% w/w in the final pharmaceutical composition.
[0020] According to a further embodiment of the invention the pharmaceutical compositions herein are formulated into solid oral pharmaceuticals or dosage forms, such as, tablets or capsules.
[0021] Another aspect of the present invention provides a method for treating a disorder associated with increased bone resorption comprising administering to a patient using a pharmaceutical composition comprising: (a) a bisphosphonic acid, a pharmaceutically acceptable derivative thereof, or mixtures thereof; (b) a vitamin D compound; and (c) one or more excipients selected from fillers, diluents, binders, lubricants, disintegrants or glidants, wherein said glidant is present at a concentration of from 0 to 0.5% w/w. Bone resorption disorders include, but are not limited to osteoporosis, hypercalcaemia, tumour osteolysis and or Paget's disease. The composition for use in this method optionally comprises lactose and microcrystalline cellulose.
BRIEF DESCRIPTION OF THE FIGURES
[0022] FIG. 1 depicts the results of testing the dissolution time of tablets prepared without glidant, according to one embodiment of the present invention.
[0023] FIG. 2 depicts the results of testing the dissolution time of tablets prepared with a low concentration of glidant, according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention relates to the preparation of pharmaceutical compositions containing an active pharmaceutical ingredient (API), or a pharmaceutically acceptable derivative thereof, including salts, esters and solvates thereof, which composition does not include a glidant or includes only a low concentration (i.e., no more than 0.5% by weight) of glidant, but that retains friability, flowability, hardness and DT levels sufficient permit further processing, for example into an oral dosage form. The composition does not crumble away and is ejected properly during processing.
[0025] Surprisingly the current inventors have found that high concentrations of excipients are not required in order to improve or allow for an increased flow characteristic of the mixture used in the preparation of the pharmaceutical compositions of the present invention. By utilizing an improved composition, the requirement of a “flow improving” specific excipient, such as a glidant, is no longer necessary or can be included at a low concentration. The combination of alternative excipients, such as, a dense grade of Microcrystalline Cellulose (MCC) and a Spray Dried Lactose anhydrous have surprisingly shown an improved flow of the mixture and resulting in no compression problems during processing.
[0026] As used herein, the term “active pharmaceutical ingredient” (API) means a therapeutic compound. When API granules are formulated into tablets, such tablets can also contain coloring agents, lubricants and the like. The granules of the invention can be formulated in a variety of forms such as a tablet, capsule, suspension, reconstitutable powder and suppository.
[0027] The therapeutic compound(s) contained within a composition containing the granules of said invention can be formulated as its pharmaceutically acceptable salts thereof. As used herein, “pharmaceutically acceptable salts thereof” refer to derivatives of the disclosed compounds wherein the parent pharmacologically active compound is modified by making acid or base salts thereof. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids; and the like. The pharmaceutically acceptable salts include the conventional non-toxic salts or the quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include those derived from inorganic acids such as hydrochloric, hydrobromic, sulfuric, sulfonic, sulfamic, phosphoric, nitric and the like; and the salts prepared from organic acids such as amino acids, acetic, propionic, succinic, glycolic, stearic, lactic, malic, tartaric, citric, ascorbic, pamoic, maleic, hydroxymaleic, phenylacetic, glutamic, benzoic, salicylic, sulfanilic, 2-acetoxybenzoic, furnaic, toluenesulfonic, methanesulfonic, ethane disulfonic, oxalic, isethionic, and the like.
[0028] The pharmaceutically acceptable salts of the API used in the compositions of the present invention can be synthesized from the parent API which contains a basic or acidic moiety by conventional chemical methods. Generally, such salts can be prepared by reacting the free acid or base forms of these compounds with a predetermined amount of the appropriate base or acid in water or in an organic solvent, or in a mixture of the two. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa., 1985, the disclosure of which is hereby incorporated by reference.
[0029] The phrase “pharmaceutically acceptable” is employed herein to refer to those compounds, materials, compositions, and/or dosage forms which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of human beings and animals without excessive toxicity, irritation, allergic response, or other problem or complication, commensurate with a reasonable benefit/risk ratio.
[0030] The API used in the formulation of the present invention can be a bisphosphonic acid, or a derivative thereof, such as, but not limited to, Etidronate, Clodronate, Tiludronate, Pamidronate, Neridronate, Olpadronate, Alendronate, Ibandronate, Risedronate, Zoledronate or a pharmaceutically acceptable salt, ester or solvate thereof. Such compositions are useful for the treatment of disorders characterized by pathologically increased boned resorption, especially for the treatment of osteoporosis.
[0031] According to a particular embodiment of the present invention, the API is [4-Amino-1-hydroxybutylidene]-bisphosphonic acid (alendronic acid).
[0032] More specifically, the present invention includes compositions containing a combination of a bisphosphonic acid with a Vitamin D compound. The term “vitamin D” or “vitamin D compound” refers to a group of fat-soluble prohormones, the two major forms of which are vitamin O 2 (or ergocalciferol) and vitamin O 3 (or cholecalciferol). The term “vitamin D” or “vitamin D compound” as used herein also refers to metabolites and other analogues of these substances.
[0033] Disintegrants that can be included in the composition of the invention comprise starches such as corn starch, potato starch, pregelatinized and modified starches thereof, sweeteners, clays, such as bentonite, microcrystalline cellulose, alginates, sodium starch glycolate, gums such as agar, guar, locust bean, karaya, pecitin and tragacanth. Disintegrants can comprise up to about 20 weight percent and preferably between about 2 and about 10 percent of the total weight of the composition. The microcrystalline cellulose used in the compositions of the present invention is preferably in a dense form. For example, the microcrystalline cellulose used has a density of no less than 0.4 g/ml, such as 0.45 g/ml.
[0034] Examples of fillers that can be incorporated in the composition of the present invention include calcium carbonate, calcium phosphate, calcium sulphate, carboxymethylcellulose calcium, carboxymethylcellulose sodium, compressible sugar, confectioner's sugar, dextrates, dextrin, dextrose, dibasic calcium phosphate dihydrate, dibasic calcium phosphate, fructose, glyceryl palmitostearate, glycine, hydrogenated vegetable oil-type 1, kaolin, lactose, maize starch, magnesium carbonate, magnesium oxide, maltodextrin, mannitol, microcrystalline cellulose, polymethacrylates, potassium chloride, powdered cellulose, pregelatinised starch, sodium chloride, sorbitol, starch, sucrose, sugar spheres, talc, tribasic calcium phosphate, and xylitol. When lactose is included in the composition, it is preferably a spray dried lactose, an anhydrous lactose or a spray dried anhydrous lactose. Preferably the lactose has a density of no more than 0.5 g/ml. Specifically, the lactose can be a spray dried anhydrous lactose having a density of 0.67 g/ml.
[0035] The composition of the present invention can also include a lubricant. “Lubricant,” as used herein, means a material which can reduce the friction arising at the interface of the tablet and the die wall during compression and ejection thereof. Lubricants may also serve to prevent sticking to the punch and, to a lesser extent, the die wall as well. The term “antiadherents” is sometimes used to refer specifically to substances which function during ejection. As used in the present disclosure, however, the term “lubricant” is used generically and includes “antiadherents.” Tablet sticking during formation and/or ejection may pose serious production problems such as reduced efficiency, irregularly formed tablets, and non-uniform distribution of intended agents or ingredients to be delivered thereby. These problems are particularly severe with high speed tableting approaches and methods.
[0036] Lubricants may be intrinsic or extrinsic. A lubricant which is directly applied to the tableting tool surface in the form of a film, as by spraying onto the die cavity and/or punch surfaces, is known as an extrinsic lubricant. Although extrinsic lubricants can provide effective lubrication, their use requires complex application equipment and methods which add cost and reduce productivity.
[0037] Intrinsic lubricants are incorporated in the material to be tableted. Magnesium, calcium and zinc salts of stearic acid have long been regarded as the most efficient intrinsic lubricants in common use. Concentrations of two percent or less are usually effective.
[0038] Other traditional intrinsic lubricants include hydrogenated and partially hydrogenated vegetable oils, animal fats, polyethyleneglycol, polyoxyethylene monostearate, talc, light mineral oils, sodium benzoate, sodium lauryl sulphate, magnesium oxide and the like. See U.S. Pat. No. 3,042,531.
[0039] Lubricants, according to the present invention, can be used in an amount of up to 1.5 weight percent and preferably between about 0.25 and about 1.0 weight percent of the total composition.
[0040] Intrinsic lubricants pose certain serious difficulties when used in conventional tablets. Many lubricants materially retard the disintegration of tablets.
[0041] Coloring agents that can be included in the composition of the present invention include titanium dioxide, and dyes suitable for food such as those known as F.D. & C. dyes and natural coloring agents such as grape skin extract, beet red powder, beta-carotene, annato, carmine, turmeric, paprika, etc. The amount of coloring used can range from about 0.1 to about 3.5 weight percent of the total composition.
[0042] Flavors incorporated in the composition may be chosen from synthetic flavor oils and flavoring aromatics and/or natural oils, extracts from plants, leaves, flowers, fruits and so forth and combinations thereof. These may include cinnamon oil, oil of wintergreen, peppermint oils, clove oil, bay oil, anise oil, eucalyptus, thyme oil, cedar leave oil, oil of nutmeg, oil of sage, oil of bitter almonds and cassia oil. Also useful as flavors are vanilla, citrus oil, including lemon, orange, grape, lime and grapefruit, and fruit essences, including apple pear, peach, strawberry, raspberry, cherry, plum, pineapple, apricot and so forth. Flavors which have been found to be particularly useful include commercially available orange, grape, cherry and bubble gum flavors and mixtures thereof. The amount of flavoring may depend on a number of factors, including the organoleptic effect desired. Flavors may be present in an amount ranging from about 0.5 to about 3.0 by weight based upon the weight of the composition. Particularly preferred flavors are the grape and cherry flavors and citrus flavors such as orange.
[0043] The pharmaceutical composition of the present invention can be processed into a unit dosage form (e.g., tablet, capsule or sachet) and then packaged for distribution. The processing step will vary depending upon the particular unit dosage form. For example, a tablet is generally compressed under pressure into a desired shape and a capsule or sachet employs a simple fill operation. Those skilled in the art are well aware of the procedures used for manufacturing the various unit dosage forms.
[0044] Materials incorporated in the pharmaceutical composition of the present invention can be pretreated to form granules that readily lend themselves to tableting. This process is known as granulation. As commonly defined, “granulation” is any process of size enlargement whereby small particles are gathered together into larger, permanent aggregates to yield a free-flowing composition having a consistency suitable for tableting. Such granulated compositions may have consistency similar to that of dry sand. Granulation may be accomplished by agitation in mixing equipment or by compaction, extrusion or globulation.
[0045] Tablets according to this aspect of the present invention can be manufactured by well-known tableting procedures. In common tableting processes, material which is to be tableted is deposited into a cavity, and one or more punch members are then advanced into the cavity and brought into intimate contact with the material to be pressed, whereupon compressive force is applied. The material is thus forced into conformity with the shape of the punches and the cavity. Various tableting methods are well known to those skilled in the art and not detailed herein.
[0046] When a pharmaceutical composition of the present invention is processed to form a tablet, the tablet's size and shape can be adapted for direct oral administration to a patient, such as a human patient.
[0047] The amount of therapeutic compound incorporated in each tablet may be selected according to known principles of pharmacy. An effective amount of therapeutic compound is specifically contemplated. By the term effective amount, it is understood that, with respect to for example pharmaceuticals, a pharmaceutically effective amount is contemplated. A pharmaceutically effective amount is the amount or quantity of a drug or pharmaceutically active substance which is sufficient to elicit the required or desired therapeutic response, or in other words, the amount which is sufficient to elicit an appreciable biological response when administered to a patient.
[0048] The following example is given for the purpose of illustrating the present invention and should not be considered as limiting the scope or spirit of the invention in any way.
EXAMPLES
Example 1
Composition Containing No Glidant
[0049] The composition described below was characterized in that the combination of Spray Dried Lactose Anydrous together with a denser Microcrystalline Cellulose (Avicel 302) provided sufficient flowability such that, surprisingly, a glidant was no longer required.
[0000]
Amt
Composition (without glidant)
Req'd in
Quantity per Unit
Description
Grams
mg
%
Alendronate Sodium Trihydrate
91.37
91.37
28.55
Lactose Anydrous Spray Dried
99.98
99.98
31.24
Plasdone
12.80
12.80
4.00
Croscarmellose Sodium
13.20
13.20
4.13
Microcrystalline Cellulose (NF PH 302)
74.90
74.90
23.41
Cholecalciferol Vitamin D
26.00
26.00
8.13
Magnesium Stearate
1.75
1.75
0.55
Total Tablet Weight (Core)
320.00
320.00
100.00
[0050] The process used to prepare the tablet described above was as follows:
[0051] A Prescreen Alendronate Sodium Trihydrate, Lactose Anhydrous NF, Plasdone S630, and Croscarmellose Sodium NF through a #20 mesh and blend for 10 minutes.
[0052] B Prescreen Microcrystalline Cellulose PH302 through a #30 mesh and blend for 10 minutes.
[0053] C Prescreen Magnesium Stearate Non Bovine through a #60 mesh and blend for 3 minutes.
[0054] D Tablet at 15-18 Kp.
[0055] The dissolution times of resulting tablets were tested and compared to dissolution times for tablets of a commercially available alendronate/Vitamin D tablet (Fosamax D). Dissolution was tested in water using the procedure as set out in USP 23 third supplement.
[0056] The results depicted in FIG. 1 demonstrate that there was essentially no difference between the dissolution profiles of the tablets of the present invention and of the commercially available tablets. Further, the dissolution profiles were compared as prescribed in the Guidance for Industry: Immediate Release Solid Oral Dosage Forms, Scale-Up and Postapproval Changes: Chemistry, Manufacturing, and Controls, In Vitro Dissolution Testing, and In Vivo Bioequivalence Documentation, published by the U.S. Center for Drug Evaluation and Research (CDER), under the heading “In vitro Dissolution”. In the present study, the similarity factor, f 2 was calculated to be 54.9. Dissolution profiles are recognized to be similar if 50f 2 <100.
Example 2
Composition Comprising Low Concentration of Glidant
[0057] The composition described below was characterized in that the combination of a densely Spray Dried Lactose Anydrous together with a dense Microcrystalline Cellulose (Avicel 302) provided an unexpected increase in flowability.
[0000]
Amt
Req'd in
Quantity per Unit
Description
Grams
mg
%
Alendronate Sodium Trihydrate
91.37
91.37
28.55
Lactose Anhydrous Spray Dried
98.38
98.38
30.74
Plasdone
12.80
12.80
4.00
Croscarmellose Sodium
13.20
13.20
4.13
Microcrystalline Cellulose (NF PH 302)
74.90
74.90
23.41
Cholecalciferol Vitamin D
26.00
26.00
8.13
Colloidal Silicion Dioxide
1.60
1.60
0.50
Magnesium Stearate
1.75
1.75
0.55
Total Tablet Weight (Core)
320.00
320.00
100.00
[0058] The process used to prepare the tablet described above was as follows:
[0059] A Prescreen Alendronate Sodium Trihydrate, Lactose Anhydrous, Plasdone S630, and Croscarmellose Sodium NF through a #20 mesh and blend for 10 minutes.
[0060] B Prescreen Microcrystalline Cellulose PH 302 and Colloidal Silicone Dioxide through a #20 mesh. Prescreen Cholecalciferol Vitamin D through a #30 mesh and blend for 10 minutes.
[0061] C Prescreen Magnesium Stearate Non Bovine through a #60 mesh and blend for 3 minutes.
[0062] D Tablet at 15-18 Kp.
[0063] The dissolution times of resulting tablets were tested and compared to dissolution times for tablets of a commercially available alendronateNitamin D tablet (Fosamax D). Dissolution was tested in water using the procedure as set out in USP 23 third supplement.
[0064] The results depicted in FIG. 2 demonstrate that there was essentially no difference between the dissolution profiles of the tablets of the present invention and of the commercially available tablets. In the present study, the similarity factor, f 2 was calculated to be 62.3. Dissolution profiles are recognized to be similar if 50<f 2 <100.
[0065] All publications, patents and patent applications mentioned in this Specification are indicative of the level of skill of those skilled in the art to which this invention pertains and are herein incorporated by reference to the same extent as if each individual publication, patent, or patent applications was specifically and individually indicated to be incorporated by reference.
[0066] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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The present invention relates to pharmaceutical compositions containing a bisphosphonic acid in combination with a non-activated metabolite of vitamin D for oral administration. The compositions of the invention either do not contain or contain only low concentrations of a glidant. Also provided are methods for preparing such compositions and methods of use thereof, for preventing or treating abnormal bone resorption in mammals.
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BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to a method and an apparatus for controlling a moving web. More specifically, the present invention relates to a web guide apparatus having minimal mechanical backlash cooperating with a high speed control system which allows for precise control of a transverse location of the moving web. The present invention further includes a method of controlling the transverse location of the web.
[0002] Generally, there are two types of guide systems for controlling a transverse position of a moving web. A first type of guide system for controlling a transverse position of a moving web is a passive system.
[0003] An example of a passive system is a crowned roller, also called a convex roller, having a greater radius in the center than at the edges. Crowned rollers are effective at controlling webs that are relatively thick in relation to the width of the web such as sanding belts and conveyor belts.
[0004] Another passive type of guide system is a tapered roller with a flange. The taper on the roller directs the web towards the flange. The web edge contacts the flange and thereby controls the transverse position of the web. A tapered roller with a flange is commonly used to control the lateral position of a narrow web, such as a videotape.
[0005] However, a passive guide system cannot guide wide, thin webs because, depending on the type of passive guide system, either the edge of the web tends to buckle or the web tends to develop wrinkles. To effectively control a wide, thin web an active guide system is required.
[0006] A typical active guide system includes a sensing device for locating the position of the web, a mechanical positioning device, a control system for determining an error from a desired transverse location and an actuator that receives a signal from the control system and manipulates the mechanical positioning device. A typical control system used for actively guiding a thin, wide web is a closed loop feedback control system.
[0007] Typically, a web to be processed has been previously wound onto a spool. During the winding process, the web is not perfectly wound and typically has transverse positioning errors in the form of a zigzag or a weave. When the web is unwound, the zigzag or weave errors recur causing transverse web positioning problems.
[0008] In precision web applications such as webs used in optics and electronics, the transverse location of the web must be precisely controlled. Most commercially available active web guide systems are not capable of controlling the transverse location to the level of precision required for these web applications. Commercial web guides typically employ rod ends, belts, sheaves, slides and threaded nuts and bolts, each of which has some mechanical play. Often, in a commercially available guide, the total mechanical play is in range of 125-375 microns (0.005-0.015 inches). A control system cannot guide a web to within a range of the guide's backlash or mechanical play.
[0009] While the control system of a commercially available web guide has some error, often the error caused by the control system is insignificant when compared to the error caused by the mechanical backlash or play in the guide. The mechanical backlash, without accounting for any other error can preclude many commercially available web guides from being used for precisely locating a transverse location of a moving web.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention includes a method of controlling a moving web in relation to a selected transverse position comprising positioning a first positioning guide proximate a second positioning guide wherein the second positioning guide includes a mechanism for positioning the web having minimal backlash. The web is passed through the first positioning guide and the second positioning guide. A sensor detects the transverse position of the moving web at the second positioning guide. The sensor transmits the transverse location of the web at the second positioning guide to a controller. The controller manipulates a zero-backlash actuator where the zero-backlash actuator is coupled to the second positioning guide such that the transverse position of the web is controllable to within a preselected dimension of the selected transverse position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic view of the precision web guide assembly of the present invention.
[0012] FIG. 2 is a perspective view of a precision web guide of the present invention.
[0013] FIG. 3 is an additional perspective view of the precision web guide of the present invention.
[0014] FIG. 4 is an additional perspective view of the precision web guide of the present invention.
[0015] FIG. 5 is an additional perspective view of the precision web guide of the present invention.
DETAILED DESCRIPTION
[0016] The present invention generally relates to an assembly for controlling a transverse location of a moving web. The assembly includes a first web guide in series with a second web guide. The first web guide is manipulated by a first control system and the second web guide is manipulated by a second control system. The first and second control systems control the first and second web guides independent of each other to provide precision control of the transverse position of the moving web.
[0017] The assembly provides precise control of the transverse position of the moving web because of a number of design features including, but not limited to, positioning the first web guide, having a short exit span, and upstream and proximate the second web guide. The first web guide reduces the input angle error, the transverse position error, and the error rate of the moving web entering the second web guide.
[0018] With the input angle error, the transverse position error, and the error rate reduced by the first web guide, the second web guide precisely controls the transverse position of the moving web. The second web guide is designed to be lightweight and stiff while minimizing backlash caused by mechanical play. The lightweight, stiff second web guide with minimal backlash allows the second control system, having a fast, high resolution sensor communicating with a fast control system, to precisely control the transverse location of the moving web with a high bandwidth, zero backlash actuator connected to the second web guide with a zero backlash connection.
[0019] The second web guide also includes a relatively long guide span and a relatively short exit span. The long guide span reduces an angle needed to produce a correction to the transverse position of the moving web and reduces a twist angle of the moving web in the entrance and exit spans. The short exit span reduces the transverse position error caused by the input angle error.
[0020] As used herein, the terms “precision control” or “precise control” means controlling a transverse position of the web to within less than about 0.004 inches (0.0102 mm) of a desired location.
[0021] As used herein, the term “backlash” corresponds to the amount of mechanical play or lost motion found in the web guide. Backlash adversely affects the ability of a control system to precisely control the transverse position of the moving web.
[0022] As used herein, the term “zero-backlash” means tolerances or mechanical play of less than about 0.0001 inch (0.0025 mm).
[0023] As used herein, the term “exit span” means the distance between the last frame roller and the second base roller of the web guide that is preferably expressed in terms of a factor of a width of the web.
[0024] As used herein, the term “entrance span” means the distance between the first base roller and the first frame roller of the web guide that is preferably expressed in terms of a factor of a width of the web.
[0025] As used herein, the term “guide span” means the distance between the entrance span and the exit span. The guide span is preferably expressed in terms of a factor of a width of the web.
[0026] As used herein, the term “input angle error” is the error in the angular position of the web from the desired angle of the web as the web is detected by the sensor. Typically, the input angle error of the moving web is undetectable by a single web position sensor. Since a web position sensor detects the position of the web at only one point, the sensor detects the position of the web, but not the input angle of the web. Therefore, a single sensor may detect no positional error while there may be a significant amount of input angle error that is undetected. The input angle error, although undetected by a single position sensor, may result in a significant downstream position error.
[0027] The present invention generally includes an assembly 10 and method for precisely controlling a transverse position of a moving web 12 as illustrated in FIG. 1 . The moving web 12 is passed through a first web guide 14 followed by a second web guide 16 . While an exact distance between the first web guide 14 and second web guide 16 is not critical to practice the invention, it is preferred that first web guide 14 and second web guide 16 be disposed in close proximity with minimal or no intermediate processing of the web 12 . In an exemplary embodiment, an idler roller 18 is disposed within the path of the moving web 12 between the first web guide 14 and the second web guide 16 .
[0028] The first web guide 14 can include any conventional commercially available web guide. It is preferred that an exit span 20 between the last roller 21 and the second to the last roller 19 of the first web guide 14 be relatively short compared to an exit span of a conventional web guide. A short exit span 20 on the first web guide 14 significantly reduces the transverse angular error of the moving web 12 , reduces the input angle error, and minimizes output error. The exit span 20 of the first web guide 14 is preferably less than about one-half of the width of the moving web 12 . Upon reading this specification, one skilled in the art will appreciate that the shortest exit span possible is preferred that does not result in the wrinkling of the moving web 12 . An exemplary commercially available web guide that can be used as the first web guide is a DF Rotating Frame Guide “P-Model” manufactured by BST Pro Mark of Elmhurst, Ill.
[0029] Preferably, the first web guide 14 includes a first control system 22 that independently controls the first web guide 14 . The first control system 22 is preferably a closed loop feed back system, although a feed forward system, H infinity system, model based system, embedded model based system or any other control system which will effectively control the transverse position of the moving web 12 is also within the scope of the invention.
[0030] The first control system 22 includes a first web position sensor 24 that preferably detects a position of an edge of the moving web 12 . One skilled in the art will recognize that other position detecting sensors besides edge position sensors are within the scope of the invention. The first web position sensor 24 communicates with a first controller 26 . The first controller 26 detects the error of the transverse position of the edge of the moving web 12 from a selected setpoint. The first controller 26 preferably employs a proportional-integral controller (PI) control scheme.
[0031] The first controller 26 communicates the error to an actuator 28 . The actuator 28 adjusts the position of the first web guide 14 depending on the magnitude of error calculated by the first controller 26 .
[0032] Referring to FIG. 1 , after the moving web 12 exits the first web guide 14 , the moving web 12 preferably passes over the idler roller 18 prior to entering into the second web guide 16 . After passing through the first web guide 14 , the input error rate, the input angle error and the output transverse error of the moving web 12 have been significantly reduced as the moving web 12 enters the second web guide 16 . The second web guide 16 , as illustrated in FIGS. 2-5 , is also referred to as a precision web guide. The precision web guide 16 manipulates the transverse position of the moving web 12 to within less than about 0.004 inches (0.102 mm) of a desired transverse location.
[0033] The moving web 12 passes over a first base roller 32 disposed within a base 30 of the precision web guide 16 . The base 30 is fixed in a selected position, preferably with a plurality of bolts, however the base may be fixed into the selected position by a weld, a plurality of rivets or any other fastening means which fixedly retains the base in the selected position.
[0034] The base 30 also includes a second base roller 34 disposed therein. Preferably, an axis 35 of the first base roller 32 is substantially parallel to an axis 37 of the second base roller 34 . Both the first and second base rollers 32 , 34 , respectively, include laterally loaded or precision bearings. The laterally loaded or precision bearings are preferred to minimize or eliminate lateral backlash within the first and second base rollers 32 , 34 respectively. An exemplary laterally loaded bearing can be purchased along with an Ultralight Aluminum Idler manufactured by Webex, Inc. of Neenah, Wis.
[0035] After passing over the first base roller 32 , the moving web 12 contacts and passes over a first frame roller 38 that is disposed within a frame 36 . The frame 36 is connected to the base 30 but is also movable with respect to the base 30 . Preferably, the frame 36 is connected to the base 30 with a plurality of flexure plates 40 , 42 , 44 , 46 as viewed in FIGS. 1-5 . The plurality of flexure plates 40 , 42 , 44 , 46 allows the frame 36 to move relative to the base 30 without any mechanical backlash or mechanical play. Although a plurality of flexure plates 40 , 42 , 44 , 46 is preferred, one skilled in the art will recognize that other connecting mechanisms which allow the frame to move relative to the base with minimal or no mechanical backlash are within the scope of the invention. The alternative connecting mechanisms include, but are not limited to, linear ways, a precision pivot, and preloaded mechanical components.
[0036] Referring to FIGS. 2-5 , a length of each flexure plate 40 , 42 , 44 , 46 is significantly longer when compared to a width of each flexure plate 40 , 42 , 44 , 46 . The flexure plates 40 , 42 , 44 , 46 are designed to flex along the width of the flexure plate while maintaining stiffness along the length of the plate. In the exemplary embodiment, the frame is connected to the base with four flexure plates 40 , 42 , 44 , 46 .
[0037] The four flexure plates 40 , 42 , 44 , 46 connect the frame 36 to the base 30 such that the frame 36 rotates about a point 48 proximate the first frame roller 38 . Referring to FIGS. 2 and 3 , an optional pivot pin 49 is disposed between the frame 36 and the base 30 where the pivot pin 49 is fixed to the frame 36 but rotatable with respect to the base 30 . The pivot pin 49 is disposed within a bracket 51 attached to the base 30 to retain the pivot pin 49 in the selected position while allowing the pivot pin 49 to rotate therein.
[0038] Referring to FIGS. 2-5 , the first and second flexure plates 40 , 46 , respectively, attach the frame 36 to the base 30 proximate ends 39 of the first frame roller 38 . The first and second flexure plates 40 , 46 are positioned such that the lengths of the flexure plates 40 , 46 are substantially parallel to an axis of the first frame roller 38 .
[0039] The third and fourth flexure plates 42 , 44 connect the frame 36 to the base 30 between the first frame roller 38 and a second frame roller 50 . The third and fourth flexure plates 42 , 44 , respectively are positioned at angles which are mirror images of each other as referenced from a plane perpendicularly intersecting a midpoint of the first frame roller 38 . While the first and second flexure plates 40 , 46 , respectively, allow the frame 36 to move forward and backward relative to the path of the moving web 12 ; the third and fourth flexure plates 42 , 44 , respectively, allow the frame 36 to twist or rotate relative to the path of the moving web 12 . The four flexure plates 40 , 42 , 44 , 46 working in cooperation allow the frame 36 to pivot about the point 48 proximate the first frame roller 38 . An exemplary pivot point 48 is about at the midpoint of an entrance tangent line of the moving web 12 with the first frame roller 38 . In the context of this disclosure, what is meant by the entrance tangent line is the line defined by the first contact of the moving web with a roller.
[0040] After passing over the first frame roller 38 , the moving web 12 passes over the second frame roller 50 . The first and second frame rollers 38 , 50 , respectively, are also equipped with laterally loaded or precision bearings to minimize the amount of lateral backlash within the first and second frame rollers 38 , 50 . An exemplary laterally loaded bearing can be purchased along with an Ultralight Aluminum Idler manufactured by Webex, Inc. of Neenah, Wis.
[0041] One skilled in the art will recognize that one large roller may be substituted for the first and second frame rollers 38 , 50 , respectively. Additionally, one skilled in the art will recognize that the moving web 12 may pass over more than two rollers within the frame 36 while precisely controlling the transverse location of the moving web 12 .
[0042] An axis 51 of the second frame roller 50 is approximately parallel to an axis 41 of the first frame roller 38 . A distance from the first frame roller 38 to the second frame roller 50 defines a guide span 53 as best illustrated in FIG. 1 . The guide span 53 is relatively long as compared to the width of the moving web 12 .
[0043] One skilled in the art will recognize that a longer guide span reduces the amount of movement required by the flexure plates 40 , 42 , 44 , 46 to produce a desired transverse position correction. The ability to control the transverse position of the moving web 12 with a minimal amount of movement allows for a more accurate web guide control because twist angles in an entrance span 55 and an exit span 57 are minimized.
[0044] Additionally, minimizing the amount of movement while accurately controlling a transverse position of the moving web 12 allows use of the flexure plates 40 , 42 , 44 , 46 that have no mechanical backlash, but also have a limited range of motion. If significant motion were required, the movement may exceed the flexibility of the flexure plates 40 , 42 , 44 , 46 , thereby precluding the use of flexure plates in the present invention.
[0045] After passing over the last frame roller 50 , the moving web 12 passes over the second base roller 34 . In an exemplary embodiment, the path of the moving web 12 in the entrance and exit spans 55 , 57 , respectively is substantially perpendicular to a plane of rotation of the frame 36 . Applying the principles taught herein, one skilled in the art will appreciate that other web paths are within the scope of the invention, including but not limited to, the first base roller 32 being disposed above the first frame roller 38 and also at an angle not substantially perpendicular to the first frame roller 38 . Similarly, the second base roller 34 may be disposed in a position such that the path of the moving web 12 is not substantially perpendicular to the plane of rotation of the frame 36 .
[0046] Referring to FIG. 1 , a second control system 52 controls the precision web guide 16 . The second control system 52 is preferably a closed loop feed back system. However, a feed forward system, H infinity system, model based system, embedded model based system or any other control system which will effectively control the transverse position of the moving web 12 is also within the scope of the invention.
[0047] The second control system 52 includes a second web position sensor 54 that detects a position of the edge of the moving web 12 . One skilled in the art will recognize that other position detecting sensors besides edge position sensors are within the scope of the invention. The second positioning sensor 54 preferably includes a fast, high-resolution means of sensing a transverse position of the moving web 12 at an edge of the moving web 12 such as, at a minimum, a fifty-hertz sensor with at least twelve-micron resolution. A preferred second sensor 54 is a high speed, high precision digital micrometer Model No. LS-7030M manufactured by Keyence Corporation of America of Woodcliff Lake, N.J.
[0048] The second positioning sensor 54 preferable detects the transverse position of the moving web 12 at about or proximately below an exit tangent line 60 of the moving web 12 exiting the second frame roller 50 . In the context of this disclosure, what is meant by the exit tangent line is the line defined by the last contact of the moving web with a roller. By sensing the transverse position at about or proximately below the exit tangent line 60 of the second frame roller 50 , a transportation lag is minimized. What is meant by transportation lag is the transportation time from the last shifting roller, in this case the second frame roller 50 , to the second positioning sensor 54 .
[0049] However, the transverse position of the moving web 12 can be measured at numerous other locations including lower on the exit span or at about an exit tangent line of the moving web 12 exiting the second base roller 34 . At these alternative transverse position sensing locations, the transportation lag will need to be accounted for in the control system.
[0050] The detected transverse position of the moving web 12 by the second web position sensor 54 is transmitted to a second controller 56 . The second controller 56 compares the transverse position of the moving web 12 to a desired position or setpoint and calculates an error of the detected position from the desired position. The second controller 56 is typically a programmable logic controller using a proportional-integral (PI) controller with an update rate of at least about one millisecond. An exemplary controller is a TwinCAT PLC manufactured by Beckhoff Industrie Elektronik of Verl, Germany.
[0051] The second controller 56 communicates the error to a second actuator 58 . The second actuator 58 is mounted to the base 30 or another stationary structure. Referring to FIGS. 2-5 , the second actuator 58 is coupled to an extension 60 of the frame 36 that extends beyond the second frame roller 50 with a flexible bracket 62 . The flexible bracket 62 is preferred to provide a zero backlash coupling of the actuator 58 to the frame 36 . Further, the flexible bracket 62 allows the actuator 58 traveling in a linear motion to be coupled to the frame 36 that is traveling in an arcuate motion.
[0052] The plurality of flexure plates 40 , 42 , 44 , 46 are designed to allow the frame 36 to rotate in a plane about the point 48 proximate the first frame roller 38 at about a midpoint of the entrance tangent line. As the frame 36 pivots about the point 48 , an end 64 opposite the pivot point 48 moves in an arc. The flexible bracket 62 provides flexibility to allow the linear actuator 58 to cooperate with the frame 36 moving in an arcuate path.
[0053] The second actuator 58 has zero-backlash allowing for precise movement without mechanical play. The second actuator 58 is capable of control frequencies in excess of five hertz. An exemplary actuator is Model No. SR31-0605-XFM-XX1-238-PF-19413 manufactured by EXLAR (www.exlar.com). One skilled in the art will recognize that a direct linear or rotary motor may be used to practice the invention in place of the zero-backlash actuator.
[0054] The second actuator 58 does not require a significant amount of travel because the transverse position error is significantly reduced by the first web guide 14 and the first control system 22 . Referring to FIGS. 4 and 5 , a member 66 extending from the frame 36 towards the base 30 cooperates with first and second limit switches, 68 , 70 , respectively. If the member 66 contacts either of the limit switches 68 , 70 , the moving web 12 is stopped so that the web 12 can be manually realigned within the assembly 10 .
[0055] The frame 36 is designed to have excess material removed to decrease the mass of the frame 36 while maintaining the required stiffness. Removing the excess material results in the frame 36 having a high natural frequency. Further, the decrease in mass of the frame 36 allows for a high system gain on the precision guide 16 . The precision guide 16 of the present invention has a gain of greater than about thirty-three inverse seconds and a crossover frequency of greater than about five hertz.
[0056] Although the present invention has been described with reference to preferred embodiments, one having ordinary skill in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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A method of controlling a moving web in relation to a selected transverse position comprising positioning a first positioning guide proximate a second positioning guide wherein the second positioning guide has a mechanism for positioning the web having minimal backlash. The web is passed through the first positioning guide and the second positioning guide. A sensor detects the transverse position of the moving web at the second positioning guide. The sensor transmits the transverse location of the web at the second positioning guide to a controller. The controller manipulates a zero-backlash actuator wherein the zero-backlash actuator is coupled to the second positioning guide such that the transverse position of the web is controllable to within a preselected dimension of the selected transverse position.
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BACKGROUND OF THE INVENTION
This invention relates to an automatic weld flaw detector which scans a weld with a probe for flaw detection and records the presence and location of any such flaw detected, all in automatic operation.
Where a conventional ultrasonic flaw detector of the pulse type is used to detect any flaw in a weld and determine its location, as illustrated in FIG. 1, its angle-beam probe P is caused to travel in zigzag fashion on a surface along and parallel to the weld so as to scan the joint thoroughly. In locating a detected flaw F, as shown in FIG. 2, the time axis of the ultrasonic detector is calibrated in advance so that the distance X between the point of incidence of the beam of ultrasonic waves upon the metal surface and the flaw F being detected can be directly read out. Also, the distance Y between the centerline 1 of the weld W and the point of incidence is measured. Then, from the known angle of refraction 0, the distance Z in the direction of depth of the flaw and the distance y from the centerline 1 of the weld W are calculated.
Although the flaw F present in the weld W may be located in the manner described, the procedure when followed manually would necessitate complicated calculation or even in automatic operation would require too large a calculating arragement, such as an electronic computer, to be practical. For the reasons stated, it has been customary, in automatic flaw detection, to record only the presence of any flaw detected and leave the location of the defect unreported.
However, knowing the location of a flaw in the weld is very important because the information will tell the type of the defect and furnish a basis for further evaluation. In addition, it will provide utmost ease of correction of the weld, if necessary.
SUMMARY OF THE INVENTION
Accordingly the primary object of this invention is to provide an automatic weld flaw detector which automatically examines a weld for flaw detection, finds the exact location of any such detected flaw by calculation, and records the results, all by simplified means. To accomplish the object of the invention a preferred embodiment thereof is in the form of an ultrasonic flaw detector comprising a comparator for comparing the amplitude of an echo from a detected flaw upon movement of a probe over each unit distance with a maximum echo amplitude already known, a counting circuit adapted to work in response to the comparing action of the comparator so as to determine the distance the probe has covered, means adapted to be actuated by the output from the comparator thereby to memorize separately the maximum value of echo amplitude and the output at that moment from the counting circuit, and a recorder connector to said memorizing means.
The automatic flaw detector according to the present invention further comprises a storage arrangement composed of a memory and a latch memory so as to memorize separately a maximum value obtained by comparing the height of echo reflected back from a detected flaw upon movement of the probe over each unit distance with the maximum echo previously determined and the distance covered by the probe when such a maximum value was obtained, whereby the exact location of the flaw in the weld can be readily output from the recorder. These features enable the operator to have a general idea of the internal flaw for further evaluation without resorting to an expensive, large electronic computer or the like but employing much less costly means. The flaw detector of the invention also permits the operator to take the necessary step, such as correction of the weld, adequately and efficiently.
The above and other objects, advantages and features of the invention will become more apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a welded joint with a probe traveling for ultrasonic flaw detection of the weld;
FIG. 2 is a fragmentary side view of the welded joint of FIG. 1, illustrating the relationship between a flaw present in the weld and the probe;
FIG. 3 is a graph showing an echo reflected back from a flaw in a weld;
FIG. 4 is a graph showing a maximum echo from a flaw in a weld; and
FIG. 5 is a block diagram of an embodiment of the automatic weld flaw detector of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
When, as shown in FIG. 2, the distance Z in the direction of depth of a flaw F present in a weld W is to be determined using an ultrasonic flaw detector in accordance with the present invention, a probe P is caused to move zigzag from a starting point at a distance Yo from the centerline l of the weld so as to vary the distance Y between the probe P and the centerline l while scanning the weld across the centerline. The time axis is calibrated beforehand in order that the distance X between the flaw F and the incidence point of the ultrasonic wave beam be directly read out at any point of the scanning operation. Thus, the intensity lever, or amplitude or height h, of echoes f reflected back from the flaw F will be as graphically shown in FIG. 3. It will be appreciated that, given the distance Y between the originating point of ultrasonic scanning and the point where the height h of the echoes f reaches a peak, or the distance Ym, then the distance Z in the direction of depth of the flaw F would be readily determined by calculation on the basis of the known refraction angle θ of the ultrasonic beam. The refraction angle usually is large, in the neighborhood of 70°. Since the width ofthe weld W is limited, the distance Z may be considered directly proportional to the distance Y.
FIG. 5 is a block diagram of the arrangement embodying the invention for locating a defect F of a weld W and recording the location. In the figure, 1 is a synchronizing signal generator for the timing of the system operation, 2 is a high-voltage pulse oscillator, and 3 is a reception amplifier. These components are of known constructions and the detailed description is omitted. Numeral 4 designates a clock pulse oscillator for producing clock pulses of a frequency corresponding to the acoustic velocity, and 5 designates a preset counter for counting the clock pulses in response to the synchronizing signals. The counter 5 will continue counting until, as shown in FIG. 2, the beam of ultrasonic waves originated from the probe P in the position at a distance Yo from the weld centerline and reflected as echoes from the weld W returns to the probe P.
The count (preset number) of this preset counter 5 is established as follows.
It is possible to calculate the round trip or reciprocating time of reciprocation of the beam of ultrasonic waves between the probe P and the weld W by considering the distance of the probe P as a known value, the propagation speed, and the refraction angle θ of the ultrasonic beam. On the other hand, the frequency of the aforesaid clock pulse is already known. Accordingly, the round-trip or reciprocating time of the ultrasonic beam can be expressed in terms of the clock pulses.
Therefore, the preset counter 5 is manually preset and adjusted so that the number of clock pulses corresponding to the round-trip time of the beam may be calculated. A counter 6 is adapted to commence its action by an output when the preset counter 5 has counted clock pulses up to the aforesaid preset count and likewise to count the clock pulses. Thereupon, for example, when the probe P has moved a unit distance from a position Y o in FIG. 2 in the direction of Y, the round-trip time of the ultrasonic beam to its return to the probe P will naturally be longer than the round-trip time of the beam when the probe P is positioned at the distance of Y o . The aforesaid counter 6 is provided for the purpose of adding the increase in the round trip time of the beam upon movement of the probe P to the counted time of said preset counter 5.
This count is controlled by the counter circuit 11, described later, for measuring the amount of movement of the probe P. Moreover, when the probe moves in the direction reverse to Y direction of FIG. 2, said counter 6 deducts from the counter 5.
Numeral 7 indicates a gate circuit which is actuated upon receiving an output of the counter 6. The width of gate of the gate circuit 7 is preset so as to coincide with the round trip time of the ultrasonic beam in the weld W. Numeral 8 indicates an A-D converter which is adapted to quantize digitally a flaw detection signal input from the amplifier 3. The converter 8 is adapted to act for as long as the gate of said gate circuit is open. A comparator 9 compares a flaw echo amplitude at a time of an output from the A-D converter 8 with a maximum flaw echo amplitude memorized by the memory circuit 10, explained later, which was detected before the time of the output. Then, only when the flaw echo amplitude from said converter 8 exhibits a value larger than the maximum echo amplitude, the value of the former is applied to the memory circuit 10. Moreover, this comparator 9 is designed to commence its comparing action upon receiving a signal from an oscillator 13 which will be explained later on.
The memory circuit 10, is adapted to memorize a value before a point of time when a comparing signal value is applied from the comparator 9 in exchange for the comparing signal. Numeral 11 denotes the counting circuit, 12 a latch memory circuit, and 14 a recorder. The oscillator 13 produces one pulse per movement of the probe P for a unit distance and each ouput pulse is applied to the counting circuit 11. Accordingly, the content of the counting circuit 11 shows the position of the probe P and the content is applied to the counter 6 and the latch memory circuit 12.
The latch memory circuit can memorize the counting content of the counting circuit 11 only when an output signal has been issued from said comparator 9 and then the memorized content is transferred to said recorder 14.
Accordingly the content memorized by the memory circuit 10 indicates a flaw echo amplitude at the position of the probe P which is memorized by said latch memory circuit 12. In the flaw detecting apparatus of the present invention, when the probe P has moved a unit distance from the position Y.sub.θ and in the direction Y as shown in FIG. 2, the oscillator 13 produces a pulse corresponding to the amount of movement of the probe P, and this pulse is counted by said counting circuit 11.
Then the counting circuit 11 produces a signal of indication of position of the probe P to said counter 6 and the latch memory circuit 12 respectively.
On the other hand, the preset counter 5 counts the clock pulse from the clock pulse oscillator 4 and transfers an output signal to the counter 6 at the point of time of counting said clock pulse, whereby said counter 6 commences the counting of the clock pulse from said oscillator 4. At this instant, since the signal from said counting circuit 11 is input applied, the point of time of output signal from said counter 6 is sure to coincide with the point of time of reciprocation of the ultrasonic beam between the probe P, which has moved a unit distance, and the front edge of the weld W. Subsequently, the gate circuit 7 receives an output from said counter 6 and actuates A - D converter 8 for the aforesaid gate time. Out of the constituents of the signal input into the converter 8 from the amplifier 3, only the echo signal of ultrasonic wave beam having passed through the weld W can be extracted and quantized by the converter 8. Accordingly, the echo signal output from said converter 8 represents the echo F of the flaw F preset in the weld W and the amplitude of said echo F is applied to the comparator 9. And the amplitude h of the echo f input into said comparator 9 is compared with the contents already memorized by the memory circuit 10, namely, the amplitude hm of the echo which was detected when the probe P was positioned at the distance Y.
In this case, if h> hm, the height h of the echo is memorized by the memory circuit 10 as the maximum amplitude hm of flaw echo at the present instant.
Simultaneously, the output signal from the comparator 9 causes the latch memory circuit 12 to memorize the position of the probe P at the present time and the value thus memorized to be applied to the recorder 14. In addition, as the result of comparison at said comparator 9, if h<hm, there is no output from said comparator 9 and consequently there is no occasion for rewriting of memorized contents of the memory circuit either. Nor is there any output from the latch memory circuit 12.
In this way, by moving the probe P in turn for a unit distance, it is possible for the recorder automatically to record the maximum echo amplitude hm of flaw and the position of the probe at the time of movement of the probe P.
Due to the above, it is also possible automatically to detect and record the maximum echo amplitude hm of a flaw in the weld W and the distance Y m between the probe P and the central line of the weld W by dint of the probe's scanning for one time. Thus, on the basis of flaw detection data obtained by the recorder 14, it is possible to determine the position of said flaw F relative to the central line l and the depth Z.
The distance X can be obtained by dividing the time of ultrasonic wave beam moving from the probe P positioned at the distance Y m and reaching the flaw F by the speed of said ultrasonic wave beam. (Said time can easily known by wave-form observation with a cathode ray tube with the result that said position Y is obtained as Y=Y m -X sin θ and the depth Z as Z=X cos θ.
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An automatic weld flaw detector comprises a comparator for comparing the height of an echo from a detected flaw upon movement of a probe over each unit distance with a maximum echo height already known, a counting circuit adapted to work in response to the comparing action of the comparator so as to determine the distance the probe has covered, a device adapted to be actuated by the output from the comparator thereby to memorize separately the maximum value of echo height and the output at that moment from the counting circuit, and a recorder connected to the memorizing device.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to web processing systems, which may perform operations such as forming an image on a web (e.g. of paper) by printing, copying or other marking process, (hereinafter generally referred to as "printing") and/or handling arrangements such as folding or format adjustment. The present invention is particularly, but not exclusively, concerned with processing systems in which the paper or other material orginates as a continuous web on a roll.
2. Summary of the Prior Art
It is very well known to pass paper from a roll through a printing machine to form a series of images on it and then rewind, sheet or fold it into various formats. However, there are fundamental problems which provide a serious limitation to the efficiency of such machines. There is the problem of "down-time". Once the printing machine has been set up, and the paper put in motion, printing can occur very rapidly. However, with the known machines long delays can occur when any change is made to the method of delivery or to what is being printed. For example, if a different image is to be printed, or if the repeat length of the image is to be changed, or if a different colour is to be used, or the folded format is to be changed, then the print run has to be stopped. The design of the known printing machines is such that it is extremely difficult to make such changes, and hence it is common for the time such machines are not working (the down-time) to be much longer than the effective working time.
A further problem of existing arrangements is that printing machines are designed for a specific printing application, the machine being available as a single entity. What this means, in practice, is that if the owner of the machine wants to carry out more complex operations than are currently possible on his machine, he must undertake quite major engineering or buy a whole new machine.
SUMMARY OF THE INVENTION
The present invention is therefore concerned with overcoming, or at least ameliorating, these problems to design a web processing system in which many changes can be made whilst the system is in operation (can be made "on the fly") and which may also have the advantage of being modular so that the system may be expanded in capability if required.
The web processing system with which the present invention is concerned may be divided into three parts. Firstly, there is the part of the system which takes the web from a roll or reel and feeds it to the rest of the system. Secondly, there is the part which forms an image on the web, and thirdly there is a handling arrangement for the printed web. The present invention has several aspects, each concerned with various parts of such a system.
The first aspect is concerned with the handling of rolls and the input of a web to a printing machine or other imaging apparatus. When webs are input into a printing machine, problems occur at the end of the web. If the machine is not to be stopped, then some splicing arrangement is necessary to attach the end of one web to the beginning of the next. There are two known systems for achieving this. Firstly, there is a system known as a "flying splice" in which joining is carried out with the surface of the new roll moving at the same speed as the running web. The second system is known as a "zero-speed splice" in which the join is effected while both the new roll and the running web are stationary but the press is kept running by means of a reservoir of web such as a festoon.
The first aspect of the present invention seeks to improve the efficiency of the roll handling and the splicing system. In its most general form, this aspect moves rolls of web material on suitable supports, e.g. mobile unwind stands relative to a splicer of a web processing apparatus. With one roll of web material being drawn into the web processing apparatus, another web may be brought up to the splicer, the two webs spliced together, and the web from the second roll drawn into the machine. Splicing may be achieved by flying or zero-speed splicing.
Thus according to this aspect, there may be provided a method of feeding web material to a web processing apparatus, the method comprising, moving, relative to a splicing position, a first reel of the web material from an initial position of that reel towards a final position for that reel; withdrawing web material from the first reel into the web processing apparatus; moving, relative to the splicing position, a second reel of the web material from an initial position of that second reel to a final position for that reel; splicing the web material of the first reel to the web material of the second reel at the splicing position, separating the splice from the web material remaining on the first reel, and then withdrawing web material from the second reel into the web processing apparatus; and completing the movement of the first reel to its final position.
Also there may be provided a mobile unwind stand for a reel of web material, having a movable base, means for supporting the reel such that it is rotatable about its longitudinal axis, and means for controlling the rate of that rotation, and a system for feeding web material to a web processing apparatus, having a plurality of such mobile reel stands, and a splicer adjacent an entrance to the web processing apparatus, the splicer being adapted to splice web material of a reel on one of the mobile unwind stands which is being fed to the entrance to the web processing apparatus to web material of a reel on another of the mobile unwind stands.
The mobile unwind stands provide: the transport systems between the paper store and the machine; the roll stand from which the web is unwound; and the means for returning part-used or reject rolls to the store. In use, successive reel stands may be positioned sequentially adjacent the splicing unit, and moved so that as the required amount of material has been unwound from one roll, the next can be in position. Thus, a replacement roll can be positioned, and the original roll removed, with the printing machine continuing its operation throughout. This reduces the amount of roll handling, facilitates the organisation of work at this part of the machine so as to fit in more flexibly with other machine operating tasks; and permits a machine layout with a better material flow, particularly in situations where part-used or reject rolls are to be removed from the machine.
The next three aspects of the invention are concerned with the imaging arrangement. These aspects are particularly, but not exclusively, concerned with web fed offset press. Such presses typically comprise, for each colour to be printed, and each repeat length: a pair of blanket cylinders between which the web passes (blanket-to-blanket formation); a pair of plate cylinders in contact with a corresponding blanket cylinder, and on which the image to be printed is mounted; and an inking and dampening system for each plate cylinder. Such a system is known as a "perfecting" press, as it prints on both sides of the web. It is also known to provide an impression cylinder, and a single blanket cylinder, plate cylinder, and inking and dampening system, if only one side of the web is to be printed.
The second aspect of the present invention proposes an imaging apparatus such as a web-fed offset perfecting press, comprising a plurality of cartridges in an array or stack, or even a plurality of stacks. A common unit for printing medium is then provided in common for several cartridges. Thus, this aspect may provide a web-fed printing apparatus comprising a plurality of cartridges in an array, for printing a web feedable through the array, and at least one unit containing printing medium, each cartridge having means for transferring the printing medium from the unit to the web; wherein the at least one unit is mounted relative to the array so that the at least one unit and the cartridges of the array are capable of relative movement, thereby to permit successive interaction of the at least one unit with at least two of the cartridges. The cartridges may form a web-fed offset printing press, in which case each cartridge may have a pair of blanket cylinders, and a corresponding pair of plate cylinders. The common unit may then be an inking and dampening unit displaceable relative to the cartridges to supply selectively the plate cylinders of at least some of those cartridges, or alternatively the cartridges themselves may be movable. Thus, it becomes possible to have a printing sequence that can be varied in detail in which the following features can be carried out: the inking and dampening unit is placed in an operative position for a first cartridge and a print run is carried out for that cartridge; then the blanket cylinders of the first cartridge are moved away from the web; the blanket cylinders of a second cartridge (which has different characteristics such as the nature of the image, the image pitch or colour) are moved into contact with the web when the inking and dampen-ing unit has moved to that cartridge. A new printing run can thus be started at the second cartridge with very little time delay. It then becomes possible to change, e.g., the image on a plate cylinder of the first cartridge, whilst the printing machine is running.
The apparatus may include a plurality of inking and dampening units for supplying respective different colours simultaneously to a plurality of selected cartridges (with, in general, at least an equal plurality of cartridges not the being supplied). There may be a plurality of arrays or stacks with driers interposed as required, or a system in which the cartridges can be exchanged for others stored elsewhere.
It is also possible to achieve the feature of interchangability between one printed image and another, by providing a web-fed printing apparatus comprising a plurality of cartridges in an array for printing a web feedable through the array, each cartridge having means for transferring printing medium from a unit for containing such printing medium to the web, the means including at least one printing cylinder which is adapted to contact the web, wherein the at least one printing cylinder of one of the cartridges has a different circumference from that of the at least one blanket cylinder of at least one other of the cartridges.
The printing cylinder may be a blanket cylinder of an offset press, there then being a plate cylinder between the unit for containing the printing medium and the blanket cylinder. For an offset perfecting press there will then be a blanket cylinder, and a corresponding plate cylinder on each side of the web. For other offest presses there is one blanket cylinder, with an impression cylinder on the other side of the web. For a gravure press, the printing cylinder is etched, and the printing medium is transferred from the unit directly to the printing cylinder. Similarly in a flexographic or letter press, printing medium is transferred directly to the cylinder, which in this case has a raised surface carrying the printing medium. For gravure, flexographic, and letter presses there is again an impression cylinder on the other side of the web to the printing cylinder.
The third aspect of the present invention concerns movement of the blanket cylinders of a printing apparatus into and out of contact with the web and their corresponding plate cylinders. In the known systems, the cylinders are constrained so that the blanket cylinders must be precisely mounted in order to achieve their required setting with respect to one another and their corresponding plate cylinders when printing commences. This aspect of the present invention, however, envisages means for moving one of the blanket cylinders towards and away from the plate cylinder and the other blanket cylinder, and hence away from the web, and biasing means for preventing that other blanket cylinder following completely the movement of the first blanket cylinder.
This aspect may therefore provide a web-fed printing apparatus having at least one cartridge, the or each cartridge having a pair of plate cylinders and a pair of blanket cylinders; wherein: the or each cartridge has means for controlling movement of a first one of the blanket cylinders between a first position and a second position; the first position corresponding to a printing position, in which the first blanket cylinder is in contact with a corresponding one of the plate cylinders, and also applies a force to the other blanket cylinder, which force holds the other blanket cylinder in a first position in contact with the other plate cylinder; the second position corresponding to a withdrawn position, in which the first blanket cylinder is withdrawn from contact with the corresponding plate cylinder, and also from the other blanket cylinder, the withdrawal of the first blanket cylinder from the other blanket cylinder permitting that other blanket cylinder to move from its first position to a second position in which it is withdrawn from contact with its corresponding plate cylinder.
Thus, the blanket cylinders move between inoperative positions, in which no printing occurs, and an operative position in which the web is held between the two blanket cylinders, and the two blanket cylinders bear against the plate cylinders so that an image can be transferred.
The fourth aspect of the invention concerns the relationship between the printing arrangement and the subsequent web handling. The printing industry has developed in two directions. One of them is concerned with the handling of elongate webs, such as described above, whilst the other is concerned with handling material in sheet form. In general, each type has its associated problems, and workers in the art tend to concentrate on their own field. It has been realised, however, that the problems of folding occurring in the field of elongate web handling can be effectively solved using techniques from the sheet handling field, which techniques have been evolved to handle the products of a sheet-fed printing machine. Therefore, the fourth aspect of the present invention proposes that the output of a web printing machine is cut into sheets and is fed to a sheet folding system.
Thus this aspect may provide a method of processing at least one web of material comprising printing on the at least one web, cutting in a time relationship with the printing the or each printed web into a plurality of separate sheets, and folding each sheet by a folder whose action is timed in dependence on the arrival of a sheet at the folder, wherein there is continuous movement of the material from prior to the printing to the commencement of the folding of the sheets.
This aspect may also provide a method of processing at least one web of material, comprising printing on the at least one web, forming a longitudinal fold in the or each printed web, cutting in a timed relationship with the printing the or each web into a plurality of separate sheets, and folding each sheet by a folder whose action is timed in dependence on the arrival of a sheet at the folder.
Furthermore, this aspect may provide a method of processing at least one web of material, comprising printing the at least one web, forming transverse perforations in the printed web, cutting in a timed relationship with the printing of the or each web into a plurality of separate sheets, and folding each sheet by a folder whose action is timed in dependence on the arrival of a sheet at the folder.
In a similar way, the present invention may provide a web processing system comprising an apparatus for printing continuously at least one web of material, means for transferring the printed web continuously to a means for cutting the web into a plurality of separate sheets, which means has an action having a timed relationship with the printing means, and means for transferring the sheets continuously to a means for folding the sheets, which folding means has and action which is timed in dependence on the arrival of a sheet at the folding means;
a web processing system comprising an apparatus for printing at least one web of material, means for forming a longitudinal fold in the or each web, means for cutting the web into a plurality of separate sheets, and means for folding the sheets;
a web processing system comprising an apparatus for printing at least one web of material, means for forming a transverse perforation in the or each web, means for cutting the web into a plurality of separate sheets, and means for folding the sheets.
Once the web has been cut, it can be fed to a buckle, knife, or combination folder which may perform various known folding operations on each sheet. This is particularly advantageous when handling lightweight stock, in that the known sheet systems cannot easily handle such stock, at least not unless they run at very reduced speeds. However, it is easy to make an initial fold in the web from the web printing machine, thereby stiffening the material. It also becomes possible to provide a perforation for the first fold made by the folding machine.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described in detail, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 shows a general view of a paper handling system with which the present invention is concerned;
FIG. 2 shows a schematic view of a paper web input system;
FIGS. 3a and 3b show the alignment arrangement for the system of FIG. 2 in plan and side view respectively;
FIG. 4 shows a first embodiment of a web-fed offset perfecting press embodying the second aspect of the invention;
FIG. 5 shows a plan view of the drive system for the press of FIG. 4;
FIG. 6 shows a side view of the drive system for the press of FIG. 4;
FIG. 7 shows a second embodiment of a web-fed offset perfecting press embodying the second aspect of the present invention;
FIGS. 8 and 9 show a third embodiment of a web-fed offset perfecting press embodying the second aspect of the present invention, FIG. 8 being a side view and FIG. 9 being a plan view;
FIG. 10 shows a detail of the cylinder movement system of the press of FIGS. 4 or 7, or 8 and 9, illustrating an embodiment of the third aspect of the present invention;
FIGS. 11 and 12 each show axial and radial views of a cylinder with adjustable diameter;
FIGS. 13 and 14 show alternative paper folding systems;
FIG. 15 shows one form of processing and folding paper from a web printing machine, embodying the fourth aspect of the present invention; and
FIG. 16 shows an alternative paper processing arrangement.
DETAILED DESCRIPTION
Referring first to FIG. 1, a web (in this example, paper) handling system with which the present invention is concerned involves three parts. A first part, generally indicated at 1, takes paper from one or more paper rolls in the form of a web 2 and transports it to a printing unit 3 and an optional drying unit 4. As illustrated in FIG. 1, a right-angled turn in the paper web 2 is achieved by passing the paper round an angled bar 5. After passing through the printing unit 3, and the drying unit 4, the paper web 2 is again turned for convenience through 90° via bar 6, and passed to a cutting and folding arrangement generally indicated at 7. Sheets of paper printed, cut and folded as appropriate then pass for e.g. stacking in the direction indicated by the arrow 8. Of course, any arrangement of paper web input unit 1, printing station 3, drying station 4, and cutting and folding arrangement 7 may be provided, the actual configuration depending on space and similar constraints.
As discussed above, the present invention is concerned with various developments of the components of this system.
FIG. 2 shows one embodiment of a transport and feeding arrangement 1 for material (e.g. paper) on rolls. It consists of a splicing unit generally indicated at 10 and a series of mobile reel stands in the form of roll transportation trolleys 11, 12 (although only two are shown, more may be provided). Each trolley consists of a base 13 with wheels or castors 14 which supports roll-lifting and carrying arms 15. The arms 15 of each trolley 11, 12 carry a roll 16 of paper with its axis generally horizontal so that the web of paper may be drawn from the roll and supplied to the splicing unit 10. Each trolley has means for controlling the unwinding of a roll in e.g. the arms 15 of the trolley 11, 12. The leading end of each trolley 11, 12 may be provided with means for interconnecting with the trailing edge of another trolley, or they may be queued without being connected. In this way, it becomes possible to push the trolleys 11, 12 sequentially under the splicing unit 10, so that as one roll is used up, another may be started. This idea of queued trolleys carrying paper rolls may be used with flying splicing arrangements, but zero-speed arrangements are preferred and the arrangement illustrated in FIG. 2 corresponds to the latter.
The trolleys serve for transport from the paper store to the machine and back, and as roll stands from which the paper is unwound. They can be queued so that they may be positioned sequentially adjacent the splicing unit, and moved so that as one roll finishes (on trolley 12) the next (on trolley 11) can be in position. The running web on the trolley 12 is therefore positioned to pass over a roller 17 at the splicing unit 10 at substantially the same angle, so that each subsequent splice is of a predetermined cut off length and is on the same side of the web. This reduces the amount of roll handling, enables the work at this part of the machine to be fitted in more flexibility with other machine operating tasks; and premits machine layout with a better material flow, particularly in situations where part used or reject rolls are to be removed from the machine.
As shown in FIG. 2, a paper web 18 from the leading trolley 12 passes via the roller 17 and a pressure plate 19 to a festoon system 20. The festoon system 20 has a roller 21 which is movable between the position shown in solid lines and the position shown in dotted lines. The roll 16 carrying the next web 22 of paper to be used is mounted on the second trolley 11, and its leading end mounted on a pivotable unit 23. The privotable unit 23 has a pressure system 24 into which the leading ends of the paper web 22 is fitted, preferably when the unit 23 is in its withdrawn position shown in dotted lines.
As the first web 18 is run, the roller 21 is moved to the position shown in solid lines so that there is a significant amount of paper running within the festoon unit 20. When the end of the web 18 being withdrawn from the trolley 12 approaches, or it is desired to replace one web with another, the input of the web 18 to the festoon unit 20 is stopped, but the output (in the direction of arrow 25) continues as the roller 21 moves towards its dotted position. With the part of the web 18 adjacent the pressure plate 19 stationary, the unit 23 is swung through the position shown in solid lines until the attachment unit 24 comes in contact with the pressure plate, thereby pressing the end of the web 22 (on which adhesive is provided) onto the web 18, causing a splice. The web 18 is then cut below the pressure plate 19 by a knife 26, unit 23 is then withdrawn, and the web 22 may then be drawn into the festoon unit 20 and the roller 21 moved back to its original position shown by a full line.
The accuracy of the feed of a web 18, 22 into the splicing unit 10 and hence through the festoon unit 20 to a printing machine depends on precise alignment of the axis of the rolls 16. If the axis of rolls 16 is not precisely positioned perpendicular to the direction of arrows 25 of the output from the festoon unit 20, there is the risk that the web 18, 22 may be creased or "track" (i.e. move sideways) in the printing machine. To prevent this, it is desirable that there is an arrangement for aligning the trolleys 11, 12, and hence the rolls 16, below the splicing unit. One such arrangement which may be used is shown in FIGS. 3a and 3b.
There are two different alignments needed: to ensure that the axis of the rolls is precisely transverse to the direction of movement of the web, and to ensure that the axis of the roll is at the correct distance from the splicer 10. FIG. 3a shows the first of these. As illustrated, one of the arms 15 of a trolley 11 has two guide balls 30 rotatably mounted on its outer surface, and the other arm 15 has a single guide ball 31, which is rotatably mounted, but also spring loaded, on its outer surface. When the trolley 11 is passed below the splicer 10 (in FIG. 2) the balls 30, 31 contact a pair of guide rails 32, one on each side of the trolley. The two balls 30 ensure that the corresponding arm 15, and hence the rest of the trolley 11, is precisely aligned with the guide rail 32, and the spring loaded ball 31 ensures adjustment due to slight variations in the width of the trolley. The three-point contact of the balls 30, 31 gives accurate alignment with the guide rails 32, which themselves may be accurately aligned with the direction of movement of the web.
As was mentioned with reference to FIG. 2, the trolleys are mounted on wheels or castors 14 and in theory, if the floor 33 was prefectly flat, and the wheels were precisely made, this would ensure accurate vertical positioning of the axis of a roll 16. In practice, however, such accurate positioning is not possible, and therefore the FIG. 3b shows one way of achieving vertical positioning. Each trolley 11 has a pair of support rollers 35 on each side thereof, and a ramp 36 is positioned on the floor 33 generally below the splicer 10. As the leading wheel 14 of the trolley 11 moves onto the ramp 36, the support rollers 35 engage a pair of guide rails 37, one on each side of the trolley 21. The guide rails 37 slope upwardly in the direction of trolley movement, so as the trolley 11 moves, the action of the support roller 35 and the rail 37 is to lift the rear wheel or castor 14 of the trolley 11 clear of the floor 33. Hence the vertical position of the trolley, and hence the roll 16, is determined primarily by the guide rail 37.
As the trolley moves forwards, the support roller 35 moves through positions A to J shown in FIG. 3b.
The system described above requires the arms 15 of the trolley 11 to be locked in position during the movement of the trolley 11 below the splicer 10. It is also thought possible to achieve accurate vertical positioning by moving the arms 15 to a position determined by a suitable stop, although such an arrangement is not preferred.
Thus, FIGS. 3a and 3b illustrate one embodiment of the first aspect of the present invention, embodiment as queuing trolleys for paper rolls.
As explained with reference to FIG. 1, the paper web then passes to a printing unit 3. FIG. 4 illustrates an embodiment of such a unit 3, being a web-fed offset perfecting press according to the second aspect of the present invention. As illustrated, the press has three cartridges 40, 41, 42, with each cartridge having a pair of blanket cylinders 43, 44 in blanket-to-blanket configuration, and a pair of plate cylinders 45, 46 the outer surface of each of which is formed by a printing plate in contact with a corresponding one of the blanket cylinders 43, 44: i.e. each cartridge contains a "printing couple". Normally the plate and blanket cylinders have the same diameter, but it is also known to have plate cylinders of half the circumference of the corresponding blanket cylinder. As illustrated, the cartridges 40, 41, 42 are immediately adjoining each other, as this gives the array of cartridges 40, 41, 42 a small size. It would be possible, however, for the cartridges 40, 41, 42 to be in a spaced-apart array. The web 2 passes round a roller 47 and between the pair of blanket cylinders 43, 44 of each cartridge 40, 41, 42. It is preferable if the cartridges 40, 41, and 42 are stacked substantially vertically but substantially horizontal arrangements are also possible including arrangements in which the cartridges are movable transverse to the web. The image to be printed on the web 2 is carried on the plate cylinders 45 and 46, and transferred via the blanket cylinders (hence "offset" printing) to the web. This, in itself, is known.
As shown in FIG. 4, a unit containing printing medium, e.g. an inking and dampening train 48, 49 is provided on each side of the web. The inking and dampening train 48, 49 are capable of moving vertically separately or together and each may contain throw-off mechanisms to facilitate that vertical movement (compare trains 48 and 49).
When printing is to occur, the inking and dampening trains 48, 49 are moved in the vertical direction to register with one of the cartridges 40, 41, 42. The inking and dampening rollers 50 are brought into contact with the plate cylinders 45, 46 by means of mechanisms which ensure correct operating geometries and pressures. As illustrated, the inking and dampening trains 48, 49 are provided on each side of the web 11, but are common to all three cartridges 40, 41, 42. If the cartridge 41 is to print, the trains 48, 49 are operated so that the inking and dampening rollers 50, move into contact with the two plate cylinders 45, 46 of that cartridge 41. A printing run then occurs. At the end of that printing run, the inking and dampening trains 48, 49 are moved to their thrown-off configurations (as shown for 48) and the trains 48, 49 are moved vertically until they are adjacent one of the other two cartridges 40, 42. By moving the inking and dampening rollers 50 into contact with the plate cylinders 45, 46 of another cartridge 40 or 42, a new print sequence can operate.
It is also possible for the cartridges to move vertically, with the trains remaining stationary, but this is mechanically more difficult to achieve. Note also that this arrangement permits "in machine" storage of the cartridges, which is more efficient than the known arrangements.
A suitable drive system for the press of FIG. 4 will now be described with reference to FIGS. 5 and 6. As shown in the plan view of FIG. 5, the inking and dampening trains 48, 49 are mounted on a support frame 51 movable relative to the main frame 52 of the press which supports the cylinders 43, 44, 45, 46 via end supports 52a. The mechanism for horizontal movement of the inking and dampening trains 48, 49 is not shown, but FIG. 4 shows that a stop 53 may be provided on the support frame 51 to limit this horizontal movement.
The vertical movement of the support frame 51, and hence of the inking and dampening trains 48, 49 is controlled by a hoist motor 54 mounted on the support frame 51. That motor 54 drives a shaft 55 extending across the support frame 51 and connected via bevel gears 56, 57 to two shafts 58, 59. Shaft 58 drives a pinion 60 engaging a toothed rack 61 on the main frame 52. Similarly, shaft 59 drives two pinions 62, 63 also attached to the main frame 52 which engage corresponding toothed racks 64, 65 on the opposite side of the main frame 52. Thus rotation of the motor 54 drives shafts 55, 58, 59 causing the pinions 60, 62, 63 to move either up or down on their corresponding racks 61, 62, 65, hence moving the support frame 51 relative to the main frame 52. In this arrangement, a three-point mounting is used, but it would also be possible to provide a four or more point mounting by providing pinions additional on the shafts 58, 59 with corresponding racks on the main frame 52. Accurate vertical positioning of the support frame may be achieved either by accurate control of the motor 54 or by providing a stop 66 (see FIG. 4) on the main frame 52. The stop 66 may be spring-loaded so that it moves out from the main frame 52 when the support frame 51 moves past it, and the support frame 51 then lowered onto the stop 66. Clearly the stop 66 has to be depressed to permit downward movement of the support frame 51, e.g. to operate cartridge 40 in FIG. 4.
The drive for the cylinders 43, 44, 45, 46 will now be described. In fact, the drive train for cylinders 43, 45 and the train for cylinders 44, 46 are the same and the following refers only to the cylinders 43, 45.
A shaft 67 extends up the main frame 52 and movably on it, but engaged for rotation with it is a gear 68 which meshes with a corresponding gear 69 connected to a shaft 70 which extends to a worm 71 which mates to a worm wheel 72. A shaft 73 is secured to the worm wheel 72 and is supported on the support frame 51 by a support 74. At the end of shaft 73 remote from the cylinders 43, 45 is an air cylinder 75 which is capable of moving the shaft 73 axially. At the other end of the shaft 73 is a clutch plate 76 which engages a corresponding clutch plate 77 on a stub shaft 78 extending from the plate cylinder 45. The clutch plates 76, 77 and their attached shafts 73, 78 pass through an aperture 79 in the main frame 52. At the end of the plate cylinder 45 are gears 80 which mesh with corresponding gears 81 on the blanket cylinder 43.
Thus, when the air cylinder 75 moves the shaft 73 so that the clutch plates 76, 77 are in engagement, drive from the shaft 67 is transmitted via gears 68, 69, shaft 70, worm 71, worm gear 72, shaft 73, clutch plates 76, 77, and the stub shaft 78 to the plate cylinder, and hence via gears 80, 81 to the blanket cylinder.
When the air cylinder 75 moves the shaft 73 to disengage the clutch plates 76, 77 no drive is transmitted. Furthermore, this movement of the shaft 73 is sufficient to move the clutch plate 76 clear of the aperture 79, permitting the whole assembly on the support frame to be moved relative to the main frame 52 to another cartridge. This arrangement has the advantage that cylinders of cartridges not in use cannot have any drive thereto, and therefore can be handled safely, e.g. for replacement of the printing plates of those cylinders. Since the cylinder drive mechanism moves with the inking and dampening trains, it is impossible accidentally to drive cylinders which are not to print at any particular time.
The clutch formed by clutch plates 76, 77 has another function. The clutch plates 76, 77 form a "single position" clutch preset to synchronise the position of the corresponding plate cylinder 45 to the drive. Thus, irrespective of the initial position of the plate cylinder 45, its rotation will be synchronised with the rotation of the shaft 67.
Sometimes, however, it is desired to vary the synchronisation of the shaft 67 and the plate cylinder 45, to advance or retard the printing image relative to the main drive. To do this, the worm 71 is moved along shaft 70 by a linear actuator 82, which normally holds the worm 71 fixed on the shaft 70. This rotates the worm wheel 72 which, via shaft 73, and clutch plates 76, 77 rotates the plate cylinder 45 relative to the position of the drive shaft 67. The movement of the worm 71 may also be achieved using a motor or hydraulic ram. Movement of the other plate cylinder 46 relative to the shaft 67 may be achieved in the same way either simultaneously with or separately from movement of the plate cylinder 45.
The drive to the inking and dampening cylinders 50 of the inking and dampening trains 48, 49 will now be described with reference to FIG. 6. Although FIG. 6 is an equivalent view to that of FIG. 4, the cartridges 40, 41, 42 have been omitted for the sake of clarity, as has the drive from hoist motor 54 to move the support frame 51 relative to the main frame 52.
As can be seen from FIG. 6, gears 83 extend from the shaft 70 from gear 69 to the worm 71. These gears 83 engage on an epicyclic gearing 84 on a further shaft 85. Each end of the shaft 85 carries gears 86 which engage gears 87 which connect to the drive system within the inking and dampening units in a conventional way. Thus the shaft 70 is connected to shaft 85 and the drive from shaft 69 which drives the cylinders 43, 44, 45, 46 as discussed with reference to FIG. 5 also drives the inking and dampening rollers 50.
However, this synchronisation depends on the diameter of the plate cylinders 45, 46, and if the press has two different sizes of cylindes, the drive system discussed above can only be in synchronisation for one size, and printing would be out of synchronisation when the inking and dampening units 48, 49 were moved to a cartridge having cylinders of a different size. The arrangement of FIG. 6 overcomes this by providing an auxiliary drive motor 88 connected via the epicyclic gearing 84 to the shaft 85. The speed of rotation of that auxiliary motor 88 is sensed, and the result fed to a comparator 89 which compares that speed with the speed of rotation of rollers 90 between which the paper web passes. These rollers 90 may also be associated with epicyclic gearing. If it is found that the drive is not synchronised, then the motor 88 is speeded up or slowed down until synchronisation is achieved. Thus the drive to the motor 88 modifies the drive transmitted by the gearing 83 to the shaft 85.
FIG. 6 illustrates a further feature of the system, namely that the shaft 67 which drives the plate and blanket cylinder is driven from a shaft 91 which extends beyond the printing station. Thus, additional printing stations may be connected to the shaft or, as illustrated in FIG. 6, may be connected to the perforating tool of a pre-folder 92, or the perforator and cutter of a cutting station. These will be described in detail later, but as can be seen the main shaft 91 has gears 93 drining a shaft 94 of the pre-folder 92 which rotates a perforating tool 95. Again, epicyclic gearing 96 may be provided, linked to the comparator 89.
As illustrated in FIG. 4, one pair of inking and dampening trains 48, 49 is provided in common for three cartridges. In general, therefore, the three cartridges may have different images on their plate cylinders, or even different sizes of cylinders, so that by changing from one cartridge to another, the pring length may be varied. Other arrangements are also possible, however. FIG. 7 illustrates an example of this having four cartridges 100, 101, 102, 103, each of which is similar to the cartridges 40, 41, 42 of the arrangement shown in FIG. 4. The web 2 of paper passes up the middle of the cartridge 100, 101, 102, 103. Four inking and dampening trains are provided, an upper pair 104, 105 serving the upper two cartridges 100, 101 and a lower pair 106, 107 serving the lower two cartridges 102, 103. In this way, for example, it is possible to print two different colours in like size print cylinders, and yet still maintain the possibility of change of image and/or repeat length. Also, as shown in FIG. 7, the cylinders of the cartridges may be different sizes, e.g. with the cylinders of cartridges 100, 102 being smaller than the cylinders of cartridges 101, 103. The press shown in FIG. 7, apart from having four cartridges, as discussed above, may be generally similar to the press of FIG. 4, and have a drive similar to that described with reference to FIGS. 5 and 6. Therefore, further detailed description of the arrangement of FIG. 7 will be omitted.
One feature of this system is that by adding additional cartridges, and possibly additional inking and dampening trains 48, 49, the number of different printing operations can be increased.
The embodiment described above with reference to FIGS. 4 to 7 have the inking and dampening units moving vertically relative to a vertically stacked array of cartridges. It is also possible to have a horizontal arrangement in which cartridges are in a fixed horizontal array and the inking and dampening units are movable relative to the cartridges on which printing is to commence. One or two inking and dampening units may be used. The drive to the plate cylinders and the inking and dampening units is as described in the vertical unit shown in FIG. 5. The difference lies in the fact that a horizontal power shaft running parallel to the main power shaft may be used to drive the plate cylinders. The drive from the main power shaft may be provided by a vertical shaft connecting the power shaft to the horizontal shaft through two pairs of bevel gears.
As described above, the array of cartridges is fixed and the inking and dampening units are movable. Since the present invention depends on relative movement, it is also possible to have the inking dampening units fixed and move the cartridges of the array. The cartridges may be moved by many ways, such as rollers, guide rails, or pneumatic jacks, and the drive to the plate cylinders of the cartridges may be achieved by single toothed clutches as described with reference to FIG. 6. The advantage of an arrangement using movable cartridges is that the inking and dampening units are fixed and hence the drive to the system may be fixed. However, it is currently considered to be more difficult to move the cartridges than to move the inking and dampening units.
A further embodiment involving fixed inking and dampening units and movable cartridges is shown in FIGS. 8 and 9. This embodiment has four cartridges 111, 112, 113, 114 such as to form a carousel 115. As illustrated in FIG. 8, each cartridge has a pair of plate cylinders 116 and a pair of blanket cylinders 117 in a manner generally similar to the plate and blanket cylinders of the cartridges 40, 41, 42 of the embodiment of FIG. 4. However, it can be seen from FIG. 8 that the plate and blanket cylinders 116, 117 of the cartridges 111, 113, are smaller than the blanket cylinders 116, 117 of the cartridges 112, 114. This enables the cartridges 111, 113, and the cartridges 112, 114 to give different point repeat lengths.
A web 2 of paper enters the printing machine via rollers 118, 119 to move along a horizontal path through two 114, 112 of the four cartridges 111, 112, 113, 114 of the carousel 115. The carousel is rotatably supported on a frame 120 and a second frame 121 supports one or two inking and dampening units 122 (one inking and dampening unit is shown more clearly in FIG. 9). Where one inking and dampening unit is provided it is preferably on the side of the carousel 115 into which the web is fed. Where two inking and dampening units are provided they are normally on opposite sides of the carousel 115 to permit the cartridges 111, 113 or the cartridges 112, 114 to be driven.
The printing machine shown in FIGS. 8 and 9 may operate in one of several ways. For example, it is possible to carry out a print run using only cartridge 114, and during that print run, cartridge 112 may be prepared for a different print run. When the print run through cartridge 114 is completed, the blanket cylinders 117 of cartridge 114, may be withdrawn from the web 2, and the drive to that cartridge removed and then the blanket cylinders 117 of cartridge 112 moved into contact with the web and a drive applied to cartridge 112. A print run may then be carried out using cartridge 112 and cartridge 114 prepared. If cartridges 112 and 114 have the same printing repeat length or printing diameter, it is possible to carry out two colour operation with cartridges 112 and 114 working in tandem.
To change printing to cartridges 111, 113, a motor 123 drives the carousel 115 and turns it on its frame 120, through 90° so that the cartridges 111, 113 are aligned with the web 2. Accurate positioning of the carousel may be achieved by steps (not shown). This rotation of the carousel 115 means that the web 2 must be broken in order to change from one pair of cartridges to the other, and hence this embodiment is less advantageous than the embodiment of FIG. 4. As shown by arrow 124, the carousel 115 may be rotated clockwise or anticlockwise, as desired.
The drive arrangement for the embodiment of FIGS. 8 and 9 will now be described. Referring particularly to FIG. 9, a shaft 125 (which may be connected to a drive system for an entire printing system as discussed with refernce to FIG. 6) drives via gears 126 a shaft 127, and hence via gears 128 to a drive arrangement 129 for the inking and dampening unit 122. The drive arrangement 129 may be similar to that described with reference to FIG. 6, i.e. the drive may pass via epicyclic gearing 130 which may be acted on by an auxiliary motor 131 enabling the synchronisation of the drive.
The shaft 127 also has a further gear 132 which connects to a worm 133 acting on a worm wheel 134. The worm wheel turns a shaft 135, at one end of which is a linear actuator 136 and at the other end of which is a clutch 137. The clutch 137 connects to a shaft 138 which drives a plate cylinder 116 of one of the cartridges 111, 112, 113, 114. Thus the drive to the cartridge of this embodiment is generally similar to that described with reference to FIG. 5, and its operation will therefore be immediately apparent.
As shown schematically on the right hand side of FIG. 9, the shaft 127 may also extend to the opposite edge of the carousel 115, to drive another inking and dampening unit (not shown).
A further development of the arrangement shown in FIG. 4 (or FIGS. 7 or 8 and 9) is concerned with the mounting of the cylinders within the cartridges 40, 41, 42 (100, 101, 102, 103 or 111, 112, 113, 114). Clearly, if the cylinders were mounted in a conventional manner each time a cartridge is required to be changed, the printing positions would require precise and lengthy re-setting. Therefore, the third aspect of the present invention concerns an arrangement for moving the blanket cylinders easily into and out of their precise contact positions. When they are in contact, printing can occur. When they are moved out of contact they can then not hamper continuous printing, e.g. by a different cartridge. Furthermore, a cartridge may be removed from a press and replaced e.g. by a cartridge having cylinders of different size, and brought into precise running setting quickly and easily. In this way, many changes may be made to the machine with minimum downtime.
One embodiment of the system for moving the blanket cylinders 43, 44 into and out of contact with the web and their adjacent cylinders is shown in FIG. 10. The solid lines represent the position of the cylinders when they are printing, the dotted lines when they are not. One blanket cylinder 44 is pressed into contact with its associated plate cylinder 46, with the gears 79, 80 in FIG. 5 engaged, and also bears against the other blanket cylinder 43 (the web being then nipped between the blanket cylinders 43 and 44 to ensure good contact for printing). The blanket cylinder 43 then bears against its plate cylinder 45. Normally, a slight freedom is provided in the mounting of the blanket cylinders 43, 44, so that when blanket cylinder 44 is pressed into contact with its adjacent cylinders, both cylinders will automatically position themselves into their precise printing positions by the reactions of the contact pressures to their associated plate cylinders and their co-acting blanket cylinder.
To engage the blanket cylinders 43, 44 one of them (cylinder 44 in FIG. 10) is movable so that its axis moves between positions B and A. This may be achieved, e.g. by mounting the end so the support on which the cylinder rests in a slot, with one end of the slot corresponding to cylinder axis in position B and the other formed in such a way as to allow the cylinder axis to have freedom from the slot sides when in position A. The cylinder axis is pressed into position B by a loaded plunger 140 when printing is not taking place, so that blanket cylinder 44 is in the position shown in dotted lines, and is also out of contact with its corresponding plate cylinder 46 and the other blanket cylinder 43.
The other blanket cylinder 43 is carried on a pivoted support 141 which allows the cylinder axis to move along a restricted arc within an oversize hole (not shown). The boundary of this hole does not influence the axis position when the blanket cylinder 43 is in contact with plate cylinder 45 but does restrict the amount of movement away from that plate cylinder. This permits a gap to open between blanket cylinder 43 and plate cylinder 45 as blanket cylinder 44 moves to position B and also a gap between blanket cylinder 43 and 44 by cylinder 43 being able to follow cylinder 44 but not far enough to maintain contact with it. A similar effect can also be achieved by mounting the support of the blanket cylinder 43 in a slot arranged to allow contact with plate cylinder 45 but restrict movement away from it. If nothing holds the cylinder 43 in contact with plate cylinder 45 it moves away on its pivoted support 141 under a separating force which may be provided by gravity. It is required that the separating force should not exceed a threshold value. If the gravitational (or other) force on the roll 43 exceeds this value, the separating force is reduced by means of a spring 142 or other biasing means such as an air cylinder acting on the pivoted support 141.
As shown in FIG. 10, the blanket cylinder 44 is also mounted on a bracket 143 which is connected to a lever 144 pivoting at point 145. When lever 144 is moved, e.g. by a pneumatic system 146, to the position shown in solid lines, a force is applied to blanket cylinder 44 which moves its axis against the pressure of plunger 140 away from position B towards position A (i.e. the printing position). The blanket cylinder 44 abuts its plate cylinder 46, and also contacts the other blanket cylinder 43, moving it to contact the other plate cylinder 45. The precise positioning and pressure achieved is finally determined by the reactions of the blanket cylinders to their adjacent cylinders and the controlled forces moving them into position (and no longer by the influence of their mounting slots or holes).
Thus, by providing means for moving one of the cylinders into and out of a printing position, and means for the other cylinder to follow over a restricted distance controlled by force reactions, at the "on" position and slot or hole limits at the "off" position, printing may be disengaged and re-engaged quickly and simply, even after a different cartridge has been installed in the press. That is to say, the system provides force loading and self-setting. Ideally the cylinder should run on a continuous surface, and this is best achieved by cylinder bearers (to be discussed later).
The printing machines discussed with reference to FIGS. 4 to 10 thus generally permit printing to occur continously, but also permit changes of cartridges to be made with quick and easy establishment of the precise settings required. This is very important in minimising down-time. The arrangement shown in FIG. 4 is particularly applicable to single colour (including black) printing. It is also applicable to colour printing although then difficulties may occur in having common inking and dampening trains, and a large number of cartridges and inking and dampening trains may become necessary.
FIGS. 11 and 12 illustrate a design of cylinder which is particularly useful in the present invention. Each cylinder has a core 150 of a given size to which rim units of differing thicknesses may be fitted, as desired. FIG. 11 shows a cylinder with a relatively thick rim unit 151 and FIG. 12 shows a cylinder with a relatively thin rim unit 152. By interchanging the rim units the effective diameter of the cylinder can be changed, without removing the core 150 from the press. The rim units 151, 152 are anti-corrosive (acid gum in the damping fluid may otherwise cause corrosion) and removal of the rim units also allows easy maintenance.
As shown in FIGS. 11 and 12, the rim unit 151, 152 supports a printing plate 153, connected to it by clips 154, 155 which enable the printing plate 153 to be stretched around the cylinder. FIGS. 11 and 12 also show the end rings 156 and clamps 157 at the end of the cylinder for holding the rim unit 151, 152 onto the core 150. The rings 156 act as bearers to ensure smooth rotation of the cylinders, as has been mentioned previously. Note that the rings 156 are slightly thicker than the rim units 151, 152, so that their radially outer surface corresponds exactly with the outer surface of the printing plate 153.
Once the paper web has been printed, then another aspect of the invention comes into play. In most cases, the possibilities for folding of paper whilst in web form are limited (although one or more longitudinal folds may be made as will be described later), but few complicated folding combinations are practicable with the output from web printing machines. On the other hand, there are various techniques for folding paper sheets in e.g. gate folds, multiple transverse folds and longitudinal folds; two are ilustrated in FIGS. 13 and 14.
FIG. 13 shows an arrangement known as a knife folder in which the paper sheet 160 passes over a pair of contrarotating rollers 161, 162. With the sheet 160 stationary in that position, a knife 163 is lowered, forcing the sheet 160 into the "nip" 164, thereby providing a firm fold. The sheet 160 is then drawn down between the rollers 161, 162 for subsequent use. The knife 163 will normally be connected to a photocell or similar detector which detects the presence of sheet 160 below the knife. In this way the folding operation can by synchronised with the arrival of the paper sheet 160 at the folder, rather than synchronised with e.g. an earlier stage of the printing operation.
FIG. 14 shows an arrangement known as a buckle folder in which a sheet of paper 170 passes between a first pair of contra-rotating rollers 171, 172 and its leading edge strikes a ramp 173. The action of the rollers 171, 172 forces the paper sheet 170 up the ramp 173, until its leading edge strikes a stop 174, the position of which is determined by the desired position of fold. When paper strikes the stop 174, it can no longer move up the ramp, and so the action of rollers 171, 172 is force the paper sheet 170 into the nip defined between roller 172 and another roller 175. This forms a sharp fold in the paper, which then passes downwardly due to the action of rollers 172 and 175. It may then strike another ramp 176 and move downwardly to another stop 177. In this position the sheet 170 is then acted on by rollers 175 and 178, between which is another nip causing further folding. It is also possible to perforate the folded paper longitudinally by passing it through a perforating nip formed by rollers 179. Thus, the system in FIG. 14 permits successive transverse folding and perforating of the sheet, and by providing several such units with one or two ramps, any number of transverse folds may be provided. If the direction of movement of the sheet is changed between one buckle folder and the next, both longitudinal and transverse folds may be provided. However, the first fold is generally a transverse one, or extra equipment would be needed. Again the folding of the sheet 170 is in timed dependence on its arrival at the folder, not in dependence of the timing of the printing operation.
It is also possible to provide folders which are a combination of knife and buckle folders.
Referring now to FIGS. 15 and 16, a paper web 2 from a web printing machine (e.g. as in FIG. 4) is cut into sheets by a knife arrangement 180. FIG. 15 shows a perspective view of the arrangement, and the web 2 from the printing machine is first turned through 90° by a bar 6 as has already been described with reference to FIG. 1. Of course, this is not essential and the web path to the knife arrangement 180 may be straight as shown by dotted lines in FIG. 15. This knife unit 180 may be powered from a drive shaft common with the printing station, as described with reference to FIG. 6, i.e. the knife unit 180 shown in FIGS. 15 and 16 corresponding to the element 91 in FIG. 6. A drier unit may also be provided as discussed with reference to FIG. 1. Once the knife arrangement 180 has cut the web 2 into sheets, they may be passed to a folder 181 which may be e.g. a buckle folder such as shown in FIG. 14, although a knife folder as shown in FIG. 13 may also be used. One factor to bear in mind is that the speed of the web from the printing machine may be faster than can be handled by the known sheet folding systems, and it may be necessary to divide the sheet flow so that sub-streams follow two or more routes. In this example a divider 183 is provided so that some sheets pass straight on to the folder 181, and others are diverted to another folder 182. Further changes in direction may occur at units 184 and 185. Such two-route handling of paper sheets is known, and therefore it is unnecessary to discuss it in greater detail here. Clearly, it is possible to provide for any number of folds, depending on the use to which the paper is to be put.
Whereas, as explained above, the first fold is generally a transverse fold in sheet fed systems. FIG. 16 shows a simple way of providing a first, longitudinal, fold in the paper. This is particularly important with thin paper which cannot easily be handled by buckle folders such as shown in FIG. 14. The paper web 2 from the printer machine and (possibly) the drier passes to a former 190 which is triangularly shaped so that a longitudinal fold is placed in the paper as it moves downwardly from a roller 191 to a pair of guide rollers 192, between which a throat is formed. Thus, the paper fed to a buckle folder generally indicated at 193 has already been folded once, in the longitudinal direction, and is therefore less subject to malfunctioning in the folder. Again, however, a knife or similar cutter 194 has to be provided before the web enters the buckle folder 193.
As described above, the folds are made directly to the paper. However, to ease the transverse folding, a transverse perforating unit 195 may be provided upstream of the knife or other cutter 194. Furthermore, the use of a web printer permits longitudinal perforation to facilitate the longitudinal folding shown in FIG. 16, by means of the continuous perforating wheel 196 producing perforations 197. Furthermore, this wheel 196 may be powered from the main drive shaft to the printing station, as was described with reference to FIG. 6. Likewise, any other longitudinal fold can be produced on a continuous basis. Perforation also assists quality by permitting air to escape from within the fold.
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A printing apparatus has an array of cartridges for printing a web of e.g. paper passing through the array, and one or more units containing printing medium. The cartridges each are capable of transferring the printing medium from the unit(s) to the web. The unit(s) and the cartridges of the array are relatively movable, to allow the unit(s) to interact successively with at least two of the cartridges. In this way it is possible to change printing from one cartridge to another, allowing changes to be made to what is printed, without halting the movement of web significantly. The present invention also proposes that the cartridges may have printing cylinders of different sizes, and furthermore that a mobile unwind stand may be used to move web material to the printing apparatus, and the web output from the printing apparatus processed by sheet folding techniques.
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BACKGROUND OF THE INVENTION
The present invention relates to a supporting rail for lower ceilings, attachments and the like. More particularly, it relates to a supporting rail which has a rail central part with outwardly projecting rail edges for mounting clips which hold shaped panels or plates on the supporting rail.
Supporting rails of the above mentioned general type are known in the art and used in suspended constructions for lower ceilings to be suspended on a building ceiling. In the known suspending constructions only rectilinearly extending supporting rails are used. It is to be understood that this severely limits the use of such supporting rails.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a supporting rail which can be suitable for producing curved lower ceilings, attachments and the like.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a supporting rail which has a central rail part and at least one side rail edge, in which a plurality of formations are provided in the central rail part for allowing bending of the central rail part, and a plurality of through-going openings are provided between the formations for inserting additional elements.
The formations can be formed as cuts which not only allow bending of the central rail part but also allow insertion of a spreading tool for spreading the central rail part to provide a curved configuration. The formations can also be formed as corrugations which allow compression of the central rail part in a longitudinal direction. The elements insertable into through-going openings can be coupling elements, securing elements or suspending elements.
Supporting rails of the above type are produced from a thin metal sheet and obtain their stability by its profiling and formation a U-shaped rail or a T-shaped rail. The small wall thickness of the supporting rails does not allow bending of the rails in rolling process, for example as performed with metal pipes having greater wall thickness. Instead, for avoiding their cracking, the rails are provided for bending with cuts in expansion zones and/or with corrugations in compression zones for the rail shortening. By the exact selection of dimensions of the cuts and/or the corrugations, the use of the spreading tool or the use of the bending rollers can provide for a predetermined bending radii. The through-going openings in the supporting rail provide for a possibility of arranging securing rails other securing elements for maintaining under load the predetermined bending and preventing further deformation or return deformation.
The supporting rail formed in accordance with the present invention has the advantage that an individual desired curvature can be obtained in situ. The supporting rails can also be pre-fabricated to have a desired curvature and for example assembled of individual shorter and precurved portions or individually curvable portions. Each portion can be provided in the central rail part with a plug projection at its end, which is insertable into a respective plug opening at the end of the central rail part of the neighboring portion. The through-going openings are aligned with one another in the connecting region so as to allow insertion of coupling elements, in particular coupling pins.
The cuts which are formed in the supporting rails can each be composed of a plurality of individual cut portions which after spreading by means of a spreading tool, form a metal mesh-like deformation of the respective wall regions. By this deformation, simultaneously securing of the spreading position of the supporting rail is achieved. In the U-shaped supporting rails, an inclined position of the cuts in a base of the U-shaped profile guarantees that the supporting rail can pass through a bending roller device without excessive spreading of the rollers at the cut regions of the rail.
The self-bending of the supporting rails by a house worker can be facilitated by a special spreading tool which in accordance with the present invention has a tool shaft and at least one spreading end insertable into the cuts and having a predetermined width and/or predetermined angle relative to the tool shaft, to provide a desired spreading action over a predetermined spreading angle. Such a spreading tool can have the spreading ends at both sides of the tool shaft. The spreading ends can be formed with different widths and/or different angular arrangement. Also, a predetermined spreading angle can be achieved by a limiting of the engaging movement of such spreading tool by means of preferably movable or releasable abutment.
Anchoring of the curved supporting rail in accordance with the present invention on a building ceiling can be performed by means of suspending elements in a suspending construction with additional reinforcing action. In accordance with the present invention, the suspending elements can be formed as known suspending rails which, however, are provided with at least one wider coupling part at their end for abutting against the supporting rail. The coupling part can have at least one row of openings arranged along a circular arc. These suspending elements can be connected to a predetermined angular position with the supporting rail and/or other suspending elements. For example, at the coupling locations several or at least two coupling pins can be inserted into aligned openings of the suspending element and the supporting rail, to avoid pivotal coupling locations.
Securing elements or combined secured and coupling elements can be formed as U-shaped clamps with legs insertable into the openings of the supporting rail. An adjusted spreading position of a supporting rail can be secured by means of plug parts of a predetermined pitch insertable into the cuts.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective partial view of a curved lower ceiling and its supporting structure with a supporting rail in accordance with the present invention;
FIG. 2 is a view showing a section of a U-shaped supporting rail in accordance with the present invention, in a rectilinear position;
FIG. 3 is a view showing the portion of the supporting rail of FIG. 2 after bending to a curved position;
FIG. 4 is a view showing a portion of a T-shaped supporting rail in accordance with the present invention;
FIG. 5 is a view showing a portion of the U-shaped supporting rail in accordance with the present invention with differently formed cuts;
FIG. 6 is a plan view of the portion of the supporting rail of FIG. 5, after spreading, together with a special spreading tool;
FIG. 7 is a view showing a portion of the supporting rail of the invention with cuts of different shapes and with associated through-going openings, as well as with different securing elements insertable into the supporting rails;
FIG. 8 is a partial side view of a supporting rail in accordance with the present invention with a spreading tool placed thereon;
FIG. 9 is a side view of the spreading tool in accordance with another embodiment of the invention, associated with the supporting rail;
FIG. 10 is a view showing the spreading tool in accordance with still a further embodiment to be used with the supporting rail;
FIG. 11 is a partial view of the supporting rail of the present invention with a suspending element connected therewith;
FIG. 12 is a side view of a connecting point with the suspending element in direction of the arrow XII in FIG. 11;
FIG. 13 a partial view of two interconnected portions a curved supporting rail in accordance with the present invention;
FIG. 14 is a partial side view of a curved supporting rail assembled of several portions, in accordance with the present invention, in the region of its connected point with a suspending element;
FIG. 15 is a view showing the suspending element;
FIG. 16 is a perspective view of the suspending element of FIG. 15;
FIG. 17 is a partial view of a curved supporting rail in accordance with the present invention, together with a part of a suspending construction to hold the rail;
FIG. 18 is a view showing a portion of the supporting rail with arrow-shaped cuts; and
FIG. 19 is a view showing a bent portion of the supporting rail in accordance with the present invention, provided with a plurality of corrugations.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a curved lower ceiling 10 which is composed of a plurality of neighboring and interengaged shaped panels 11. A supporting structure for the ceiling includes a plurality of curved supporting rails 15 which are arranged at a distance from one another and anchored in a ceiling 16 and in side walls 17 via suspending elements 12, 13 and 14. The shaped panels 11 are mounted on the supporting rails 15 by means of clips 18 which are known per se and more clearly shown in FIG. 3.
FIGS. 2-7 show different embodiments of supporting rails which are provided with outwardly projecting rail edges 19 for mounting the clips 18.
FIG. 2 shows a portion of the U-shaped supporting rail 15 shown in FIG. 1. It is provided with bending cuts 20 which extend transverse to the longitudinal direction of the rail and are spaced from one another by uniform distances. The bending cuts 20 extend through a base 15.1 and through a part of both legs 15.2 of the U-shaped supporting rail 15. By means of the bending cuts 20, the supporting rail of FIG. 3 can be spread for obtaining a curved supporting rail. Through-going openings 21 and 22 are provided in the supporting rail 15 both in the base 15.1 and the legs 15.2 between the uniformly distributed bending cuts 20.
FIG. 4 shows a supporting rail 25 which is T-shaped and bent from a metal sheet strip. A web 25.1 which forms the central part of the supporting rail 25 is made of two abutting sheet portions. The bending cuts 20 are formed here in the web 25', and the through-going openings 22 are also provided between the individual bending cuts. In the immediate vicinity to the bending cuts, further through-going openings 23 are provided for inserting safety clamps which will be described later on in connection with FIG. 7.
FIG. 5 shows a U-shaped supporting rail 15 with differently formed bending cuts 20. At the left end of the supporting rail, a small bending cut 20 is formed which is similar to the bending cuts of FIGS. 2 and 3, and through-going openings 23 are provided in both legs 15.2. In the center of the supporting rail and at its right end, bending cuts 20.1 and 20.2 are provided and subdivided in the legs 15.2 of the supporting rail 15 into individual cut sections 24. These individual cut sections 24 produced during spreading of the cuts 20.1 and 20.2 a deformation between inwardly located wall regions, similarly to the production of metal mesh, and the wall deformation which takes place adds also for stabilizing the supporting rail 15 at the spreading locations for securing the performed spreading.
For obtaining an exactly determined spreading and thereby a desired predetermined curvature of the supporting rail 15, spreading tools shown in FIGS. 6, 8, 9 and 10 are utilized. FIG. 6 shows a spreading tool 26 which includes a web-like shaft 27 with perpendicularly bent ends and these bent ends form spreading ends 28 and 29 with an exactly predetermined width measurement. The spreading end 28 is relatively small. It can be inserted in an expanded central part 30 the bending cuts 20, 20.1 or 20.2. By turning of the shaft 27 of the spreading tool 26 by 90°, spreading is performed by a spreading angle which is exactly predetermined by the width of the spreading end 28. The spreading end 29 of the spreading tool 26 is wider. With this spreading end, during turning of the introduced spreading tool 26, a greater spreading angle is obtained as shown in FIG. 6 for the bending cut 20.2.
The spreading angles adjusted on the bending cuts 20 can be secured by elements shown in FIG. 7. These elements can be formed as wedges 31 and 32 which are made of sheet portions and have corresponding wedge angles, as clamps 33 and 34, as brackets 35 and 36 of different widths or lengths. The clamps 33 and 34 can be inserted in slot-shaped through-going openings 23.1 shown in FIG. 7. These openings are formed at both sides of a bending cut in the legs 15.2 of the U-shaped supporting rail. The brackets 35 and 36 can be inserted after spreading of the bending cuts 20 into slot-shaped recesses 37 which are formed in the base 15.1 of the supporting rail 15. FIG. 7 shows further possible embodiments for the bending cuts 20.
FIG. 8 shows a spreading tool 38 on the supporting rail 15. Both spreading ends 39 and 40 are arranged at different angles relative to a shaft 41 of the spreading tool 38, and upon pressing down of the shaft 41 relative to the base of the supporting rail 15 produce different spreading of the cuts 20. An abutment 42 is movably arranged on the shaft 41 and, depending upon its position of the shaft 41, more or less limits the lever path of the spreading tool 38 so as to produce different spreading angles at the locations of the bending cuts 20. Instead of the movable abutment 42, a spreading tool 38' can be provided at fixed locations of its shaft 41 with threaded openings 43 so that screw 44 can be screwed into the openings 43 to form the abutments for limiting more or less the lever path of the spreading tool 38.1. The spreading tool in accordance with this embodiment is shown in FIG. 9.
FIG. 10 shows a pliers-shaped spreading tool 45 with two pivotally connected levers 46 and 47. One end of the levers is formed as a spreading end 48. During opposite movement of two levers 46 and 47, spreading of the supporting 15 is performed by means of the spreading end 48 inserted in the bending slot 20. The desirable spreading angle can be adjusted by means of an adjusting screw 49.
FIGS. 11 and 12 show a suspending element 12 which is connected with the supporting rail 15 and has a U-shaped cross section. The supporting rail 15 is coupled with a suspending rail 13 via the suspending element 12 [a hanger]. The suspending element 12 and the suspending rail 13 are provided with a row of openings 52 and 53 in their legs. They can be brought in alignment with one another and a simple needle 54 can be inserted therethrough as a connecting element. The suspending element 12 is provided additionally with a row of openings 55 which are arranged in a crossing member at least at one end of the legs. The distances from the openings of the opening row 55 from an opening of the opening row 52 are determined upon the opposite distance from the through-going openings 22 of the supporting rail 15. Mounting of the supporting rail 15 on the suspending element 12 is performed by means of two needles 54.1. One of the needles is inserted through an opening of the opening row 52 of the suspending element 12 and through a through-going opening 22, while the other needle 54.1 is inserted in an opening or arcurately extending opening row 55 and a through-going opening 22 of the supporting rail 15. By means of the coupling with the aid of two needles 54.1, a predetermined angular position of the suspending element 12 relative to the supporting rail 15 can be adjusted, as can be seen from FIG. 17.
FIG. 13 shows a connecting point between two portions 55 of a supporting rail 56 which is assembled of a plurality of such curved portions 55. At one end of the portion 55 of the supporting rail, its central part is provided with a plug projection 57 which does not have laterally extending edge 19. The plug projection 57 engages in a plug opening which is formed at the other end of the portion 55. After insertion of the projection 57 into the not-shown matching plug opening of the neighboring portion 55, a U-shaped bridge member 58 is fitted onto the connecting location. The bridge member 58 is provided with through-going openings 59 which can be brought in alignment with the through-going openings 22 of the portion of the supporting rail, so that coupling pins 60 can be passed through. The bridge member 58 shown in FIG. 14 can also be provided with a cut 20.3 and arranged at the locations of the cuts 20 in the supporting rail 15 for reinforcing or bending securing of the latter. FIG. 14 also shows one suspending element 12 is connected with the supporting rail 56 in a desired angular position and secured by the coupling pin 54.1 in this position.
FIG. 15 shows another suspending element 61 in form of a connecting plate with an end provided with a row of openings 62 which are arranged over a circle around an opening 63 provided in a central point. The other end of the suspending element 61 is U-shaped in a known manner for embracing a suspending rail 13. The circularly arranged row of openings 62 in connection with the fixation described in FIGS. 11 and 14 provides a desired or required angular position of the suspending element 61 relative to the supporting rails 15, 25 or 56.
FIG. 16 shows a suspending element 12.1 which is formed similarly to the suspending element 12 of FIGS. 11 and 14. The legs of the suspending element 12.1 are rounded at one side of each end and provided at each end with the openings 55 extending over a circular arc about the associated openings 63 in the center point. Openings 65 are also provided in a base 64.
FIG. 17 shows a curved supporting rail 15 with suspending elements engaged thereon. One suspending element 12 is formed as a transverse reinforcing web between a suspending rail 13 and the curved supporting rail 15 and arranged in a transverse position. In this relative position it is secured to the supporting rail by means of two coupling pins 54.1. Instead of suspending elements 12 also the suspending elements 61 of FIG. 15 can be used here.
FIG. 18 shows a portion of a supporting rail 15 whose bending cuts 66 are arrow-shaped in the base 15.1 and therefore extend inclinedly relative to the longitudinal direction of the supporting rail. Supporting rail 15 can be worked preferably in a bending device provided with bending rollers, as well as a supporting rail 70 which is shown in FIG. 19. The supporting rail 70 does not have bending cuts. Instead, it is provided with a plurality of corrugations 67 in the rail edges 19 and a plurality of corrugations 68 in legs 70.2 of the rail. The individual crimps of the corrugations 68 extend from the rail edges 19 with a different length into the legs 70.2. The corrugations 67, 68 allow a compression of the supporting rail 70 and thereby an exact and continuous bending of the supporting rail 70.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a supporting rail for lower ceilings and attachments, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.
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A supporting rail for objects, particularly, lower ceilings, attachments and the like, comprises an elongated central rail part, and at least one elongated side rail edge extending along the central rail part and located at its one end for suspending shaped panels, boards and the like, the central rail part being provided for supporting curved objects with a plurality of formations spaced from one another in a longitudinal direction and allowing bending said central rail part, the central rail part being also provided with a plurality of through-going openings located between the formations for inserting additional elements.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is concerned with aqueous gluten-containing compositions useful for coating of paper stock, allowing the coated stock to be printed to obtain high quality, high gloss end products. More particularly, the invention is concerned with such compositions as well as methods of preparation and use thereof, where preferred compositions include reduced wheat gluten and wheat starch dispersions having relatively low viscosities up to about 2000 cP; these compositions are water soluble, so that the compositions and printing thereon may be easily removed from the paper stock by soaking in water, thereby facilitating repulping of the stock.
[0003] 2. Description of the Prior Art
[0004] The paper and board industries are constantly searching for better ways to make coated paper and board with improved quality at reduced cost. Thus, coatings are commonly applied to paper stock in an attempt to make the surfaces of the paper stock conducive to printing using high speed web fed printing equipment by improving the smoothness, gloss, ink printing sharpness, drum adhesion and pick resistance of the stock. Known paper coating formulations include latex or other synthetic resin materials. The generally lower viscosity and water binding capabilities of these coatings allows applications of high solids coating layers onto paper stock. While these formulations do improve the surface properties of the paper stock, but they are very expensive and difficult to use. Moreover, latex /synthetic resin coatings are hard to remove, making de-inking and de-waxing of the stock very difficult; this in turn prevents effective repulping of the stock at a reasonable cost.
[0005] Gelatinized, hydrolyzed, and other modified starches have also been used in prior art paper coating compositions. However, the viscosities of these starches are so high that the solids content of the formulations must be limited. This results in compositions which do not adequately coat the paper. Furthermore, the unpredictable behavior of starches such as corn starch, wheat starch, and potato starch typically leads to inconsistent coating properties, particularly at high coating speeds.
[0006] Producers of consumer packaging products or other paper stock items requiring high quality, high gloss printing have almost without exception been forced to use relatively expensive grades of paper stock. Kraft stock is readily available and is much less expensive than other types of paper. However, it has heretofore been virtually impossible to use Kraft where high quality printing is needed, owing to the tendency of printing inks to absorb into and smear on Kraft.
[0007] There is accordingly a real and heretofore unresolved need for improved compositions which can be used to form smooth, high quality coatings on paper products On the one hand a successful coating composition must permit sharp printing of ink images at high printing speeds using conventional printing equipment. On the other hand, such a coating must be relatively low cost and not present undue application problems. Finally, given the increasing concern about recycling of paper products, an improved coating must not interfere with, and preferably should enhance, the ability to repulp the coated paper products after use thereof.
SUMMARY OF THE INVENTION
[0008] The present invention overcomes the problems outlined above, and provides coating compositions which can be used to coat paper stock of virtually any kind (and particularly relatively inexpensive Kraft stock), so that the coated stock can be printed using conventional equipment to obtain a final printed product of high quality with heretofore unobtainable gloss values. Moreover, the preferred compositions are water soluble to facilitate repulping of the coated and printed stock.
[0009] In more detail, the coating compositions of the invention are in the form of aqueous dispersions including therein respective quantities of filler and wheat gluten. The filler is normally present in the dispersion at a level of from about 20-45 % by weight, and more preferably from about 25-35 % by weight, based upon the total weight of the dispersion taken as 100% by weight. The filler can comprise a mineral filler, a starch, or mixtures thereof. Preferred mineral fillers include clay (#1 and #2), calcium carbonate (ground or precipitated), talc, and mixtures thereof, while preferred starch fillers include wheat starch, corn starch, potato starch, rice starch, tapioca starch, modified versions of these starches (e.g., hydroxypropylated, acetylated, crosslinked, oxidized, cationized, acid-thinned starches), and mixtures thereof.
[0010] The wheat gluten should be present in the dispersion at a level of from about 6-18% by weight, and more preferably from about 6-12% by weight, based upon the total weight of the dispersion taken as 100% by weight. The gluten may be derived from commercially available wheat glutens of varying grades.
[0011] As used herein, “gluten” or “wheat gluten” refers to native and/or modified wheat glutens of various types. For example, wheat gluten may be modified by reducing agent(s) as hereafter described. However, other wheat gluten modifications, either in addition to or in lieu of reducing agent treatment can be used. Thus, wheat gluten may be oxidized, acylated, alkylated, deaminated or hydrolyzed (with a degree of protein hydrolysis usually less than 1%) or subjected to combined treatments.
[0012] As indicated, the preferred wheat gluten is initially modified with a reducing agent so as to cleave at least some of the disulfide bonds therein (preferably at least about 5%, and more preferably from about 10-100% of the disulfide bonds) and reduce the average molecular weight of the gluten. Thus, the gluten utilized preferably has a weight average molecular weight of less than about 1,000 kDa, more preferably less than about 500 kDa, and most preferably from about 20-60 kDa.
[0013] The gluten reducing agent is preferably added to the dispersion at a level of from about 0.05-2.0% by weight, and more preferably from about 0.1-1.0% by weight, based upon the total weight of the gluten taken as 100% by weight. Preferred reducing agents include alkali metal sulfites, alkali metal bisulfites, alkali metal metabisulfites, sulfur dioxide, mercaptan, and cysteine, with sodium metabisulfite being the most preferred reducing agent.
[0014] The compositions should have a Brookfield viscosity (determined on an RVT model equipped with a #2 spindle; 100 rpm; 73-74° F.) of less than about 2000 cP, preferably less than about 500 cP, and more preferably from about 60-150 cP. Furthermore, the solids content of the dispersion is preferably from about 25-57% by weight, and more preferably from about 30-50% by weight, based upon the total weight of the dispersion taken as 100% by weight. Finally, the finished compositions should have a pH of from about 9-12, and more preferably from about 9.5-11.
[0015] Preferably, the compositions have a weight ratio of filler:wheat gluten of from about 3:1 to about 5:1, and more preferably from about 3:1 to about 4:1. Normally, the preferred dispersions made up of wheat gluten and wheat starch are formulated using initially separate starch and gluten, i.e., they are not both derived from a single wheat flour or the like. In another embodiment, the preferred compositions consist essentially of aqueous dispersions including therein starch (and especially wheat starch), wheat gluten, a reducing agent, and a base (e.g., NaOH).
[0016] The compositions may be formed by preparing an aqueous dispersion of water and gluten, and may also include from about 0. 1-0.5% by weight of a defoamer (such as a silicone defoamer), based upon the total weight of all ingredients utilized taken as 100% by weight.
[0017] Thereupon, a base such as NaOH is mixed with the dispersion in sufficient amounts to yield a dispersion pH of from about 10-12, and more preferably from about 11.5-11.7. The base is typically mixed with the dispersion at a level of from about 1-3% by weight, and preferably from about 1.5-2.5 % by weight, based upon the total weight of the gluten utilized taken as 100% by weight. After base addition, the reducing agent is mixed with the dispersion so as to cleave disulfide bonds in the gluten.
[0018] Next, a starch such as Midsol 50 wheat starch (available from Midwest Grain Products, Atchison, Kans.) is added to the gluten dispersion in the ratio of 3:1 to about 5:1 as a filler. Final pH of dispersion at this stage is in a range of9.0-12.0, but preferable from 10.0 to 10.8.
[0019] In alternate forms, a dry mixture of wheat gluten, starch and a reducing agent (e.g., sodium metabisulfite) can be provided. As needed, this dry mixture may be processed by the addition of water in a vacuum dissolver so as to simultaneously reduce the gluten and provide the necessary mixing to create the use dispersion. The latter may be used directly by application to paper stock, or can be stored for future use. In such an embodiment, the starch: gluten ratio should be from about 3:1 to 5:1. The gluten is normally present at a level of from about 16-25% by weight of the dry composition, the starch is present at a level of from about 75-85% by weight of the dry composition, and the reducing agent is present at a level of from about 0.05-1% by weight of the wheat gluten. In the mixing procedure, an appropriate amount of the dry composition is added to water to achieve the above-described amounts of ingredients in a flowable coating composition.
[0020] The compositions hereof can be applied to paper stock (as used herein, paper stock is intended to include all forms, types and weights of paper such as Kraft stock). Conventional coating equipment can be employed for this purpose. Normally, in order to achieve the best quality coated stock, the compositions are applied as separate coatings or “bumps”, with intermediate partial or complete drying and curing of the compositions. The final coated stock can be printed using normal web-fed printing equipment and conventional inks. A particular feature of the coated stock of the invention is that the final printing can achieve very high gloss values on the order of from about 50-65 units. Furthermore, the coated stock will give a passing result when subjected to Testing Association for the Pulp and Paper Industry (TAPPI) Useful Method 557 as described herein (also known as the “3M” test).
[0021] Another feature of the invention is that the coated stock may be readily repulped. That is, the compositions of the invention are preferably water soluble, so that when the coated/printed stock is placed in water the coating and ink layers come off as a skimmable layer, leaving the stock ready for conventional repulping. Thus, previously hard to repulp products such as polyether wax treated poultry boxes can be easily repulped if the paper stock is first coated with compositions in accordance with the invention prior to application of wax and printing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a schematic illustration of the preferred equipment for coating paper with the inventive coating composition;
[0023] [0023]FIG. 2 is an end view of the coating storage and circulation systems depicted in FIG. 1; and
[0024] [0024]FIG. 3 is a schematic illustration of a modified coating apparatus making use of a doctor blade.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Turning now to the drawing, a coating assembly 10 is depicted in FIG. 1. Assembly 10 includes first and second coating stations 12 , 14 , a web handling assembly 16 and drying station 18 . The stations 12 , 14 share a coating composition circulating assembly 20 .
[0026] In more detail, the first coating station 12 includes an upper rubber coated cylinder 22 and an adjacent, lower engraved coating cylinder 24 ; as shown, the cylinders 22 , 24 cooperatively present a coating nip 26 . The overall station further includes an elongated, triangular in cross-section trough or pan 28 for holding a recirculating supply of coating composition 30 . The cylinder 24 is situated within pan 28 below the normal level of composition 30 therein. The roll 24 is preferably provided with a helical surface groove ( 250 coils per inch of cylinder length and approximately 40 μm deep).
[0027] As illustrated in FIG. 2, the pan 28 includes three spaced apart lower composition outlets 32 a , 32 b , 32 c and four spaced apart upper inlets 34 a , 34 b , 34 c , 34 d . Valve-controlled inlet lines 36 a , 36 b , 36 c , 36 d are operatively connected to the respective inlets and to a supply 38 of the coating composition 30 via line 37 . A return line 40 extends from the outlets 32 a - 32 c to supply 38 .
[0028] The coating station 14 is very similar to station 12 , and includes rubber coated upper cylinder 42 , engraved lower cylinder 44 , and pan 46 adapted to hold the composition 30 . The cylinders 42 , 44 cooperatively define a coating nip 47 as shown. These components are identical with their counterparts in station 12 , and thus need not be further described. However, the station 14 includes a 10 mm diameter smooth coating rod 48 adjacent upper rubber cylinder 42 and defining therewith another nip 49 . It will also be seen that a return line 50 extends from supply 38 and is operatively coupled with the three lower outlets provided with pan 46 , and that a supply line 51 extends from the supply 38 to the pan inlets. Thus, the circulation assembly 20 is made up of the supply 38 and the respective supply and return lines leading to the pans 28 , 46 . Although not shown, it will be appreciated that appropriate pump(s) are interposed within the supply lines for delivery of composition 30 to the individual pans.
[0029] The web handling assembly 16 is designed to guide and transfer a continuous web 52 into and through the coating stations 12 , 14 , and ultimately through drying station 18 for downstream processing. The assembly 16 includes, adjacent station 12 , spaced apart guide rollers 54 , 56 serving to guide the web 52 into and through nip 26 . Downstream of the station 12 , the assembly 16 includes a large heated roll 58 and spaced conveyor rollers 60 , 62 . At the region of station 14 , the assembly 16 includes guide rolls 64 , 66 serving to direct the web 52 through the coating nip 47 . Finally, the assembly 16 includes one or more downstream conveyor rolls 68 serving to guide the web 52 through secondary nip 49 and drying station 18 .
[0030] The drying station 18 includes one or more fans 70 as well as downstream dryer drums (not shown) preferably heated to a temperature of from about 240-300° F. Of course other types of drying apparatus can be used in lieu of that illustrated, so long as the composition 30 applied to the web 52 is sufficiently dried and cured.
[0031] Referring to FIG. 3, a preferred alternate coating embodiment is illustrated, making use of a doctor blade 72 in contact with coating cylinder 24 . In some instances, use of such a blade 72 provides improved coating performance. A doctor blade could be used in either or both of the coating stations 12 , 14 . Moreover, the blade 72 may be placed in a leading relationship as shown in FIG. 3, or in a trailing relationship where the blade is oppositely oriented against the cylinder 24 .
[0032] In use, a web 52 of paper stock is trained through the assembly 10 as illustrated in FIG. 1. Thus, the web passes in serial order through the coating nips 26 and 47 , and through secondary nip 49 during processing. As will be appreciated, the stations 12 , 14 are operated during passage of the web 52 therethrough, with the cylinders 22 , 24 and 42 , 44 being continuously rotated. The helical grooves formed in the surfaces of the cylinders 24 and 44 “catch” portions of the coating composition 30 within the pans 28 and 46 and transfer such composition onto the surface of web 52 . Between the stations 12 and 14 , the composition 30 on the web 52 is at least partially cured and dried by passage around heated roller 58 .
[0033] It will also be appreciated that the composition 30 is continuously circulated through the stations 12 and 14 by circulating assembly 20 . It is preferred that the composition 30 is flowing or moving at all times. Moreover, the flow of composition 30 is adjusted so that the amount entering each pan 28 , 46 through the inlets 34 a - 34 d is slightly larger than the quantity of the composition which exists through the outlets 32 a - 32 c . Thus, there is an excess amount of composition 30 entering each pan, as compared to the amount exiting the pan, with that excess amount being approximately equal to the amount of composition 30 which is applied to the web 52 in the respective coating stations. It has also been found preferable that the outlets 32 a - 32 c and inlets 34 a - 34 d be substantially uniformly spaced along the length of the coating cylinders 24 and 44 , so as to provide a substantially even distribution of the composition 30 on the cylinders.
[0034] A first “bump” of coating composition 30 is applied to the web 52 in the station 12 , and this “bump” is at least partially dried during passage around roller 58 . A second “bump” of composition 30 is applied in station 14 with the latter being smoothed during passage through nip 49 by coating rod 48 .
[0035] The fully coated and cured web 52 can be immediately printed using standard web-fed printing equipment and conventional inks. This can be done in-line, i.e., the coated web 52 is fed directly to the printing apparatus. Alternately, the web 52 can be rolled up for storage and later use.
EXAMPLES
[0036] The following examples set forth preferred methods in accordance with the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
Example 1
Preparation of a Coating Composition
[0037] First, 740 parts by weight of H 2 O (ambient temperature and a pH of 8.3) and 0.1% by weight of a silicone defoamer (based upon the total weight of all ingredients used taken as 100% by weight; sold under the name PI-135 and obtained from INX International Ink Company) were placed in a Cowles dissolver having a peripheral speed of around 600 rpm. Mixing was commenced, and 100 parts by weight of FP3000 (a wheat gluten product containing approximately 90% protein and available from Midwest Grain Products, Inc., Atchison, Kans.) was gently and incrementally added to the mixer, verifying that all of the protein was wet with the water/defoamer solution. Mixing was carried out for about 5 minutes. The pH of the mixture at this point was about 5.
[0038] Next, 17 parts NaOH (10% solution) was slowly added to the mixture while mixing to give a pH of about 11.6 Mixing was continued for 5 minutes.
[0039] The mixture was quite thin at this stage. It was allowed to degas for about 30 minutes. Then, sodium metabisulfite (0.6% by weight, based upon the total weight of the FP3000 taken as 100% by weight) was added dry to the mixture under low rpm mixing for about 30 minutes. After mixing, 375 parts by weight of Midsol 50 (a wheat starch available from Midwest Grain Products) was added slowly over the course of about 7-8 minutes.
[0040] The final coating composition had a viscosity of 80 cP on a #2 spindle at 100 rpm and 73-74° F. The composition was bright tan in color, had a pH of 10.3, and a solids content of about 35% by weight.
Example 2
Properties of Coating
[0041] The composition prepared in Example 1 was applied to the finished side of 42 Kraft liner following the process illustrated in FIGS. 1 and 2 and described above. Coated samples were printed upon with black, red, blue, green and yellow ink according to conventional printing methods. The glosses of the samples were then determined using an Horiba IG-320 gloss checker with a 60° optical path. The gloss values ranged from 50 (for blacks) to as high as 60 and 65 (for reds and yellows, respectively).
[0042] Testing Association for the Pulp and Paper Industry (TAPPI) Useful Method 557, (also known as the 3M test) was used to determine the quality of the coating. In this test, solutions from various “kits” (see Table 1) were applied to the coating and allowed to remain theron for 13-14 seconds as described in Useful Method 557. The penetration of the solution into the coating and paper was observed. If no penetration occurred for kits 1-5, then the coating is considered to have passed. Each of the samples coated with the inventive coating passed this test.
TABLE 1 Kit # Castor Oil (mL) Toluene (mL) Heptane (mL) 1 200 0 0 2 180 10 10 3 160 20 20 4 140 30 30 5 a 120 40 40 6 100 50 50 7 80 60 60 8 60 70 70 9 20 80 80 10 20 90 90 11 0 100 100 12 0 90 110
Example 3
[0043] One hundred parts of FP 3000 (a wheat gluten supplied by Midwest Grain Products, Inc. Atchison, Kans.), 375 parts Midsol 50 (a granular wheat starch supplied by Midwest Grain Products, Inc., Atchison, Kans.) and 0.5 parts sodium metabisulfite are mixed together in a batch mixer. The mixture is transferred to a Vacuum dispersion unit (VacuShear manufactured by Admix) equipped with a Rotosolver mixing head and additional mixing blades under 20 in″ Hg vacuum. The VacuShear unit contains 700 parts water and 0.1% by weight of a silicone defoamer (based upon the total weight of all ingredients used taken as 100% by weight; sold under the name PI-135 and obtained from INX International Ink Company). The mixing speed is set at 1750 rpm. The transferring process takes about 3 minutes. The vacuum is allowed to increase to near full vacuum and about 17 parts of 10% NaOH solution is introduced quickly through a tube immersed under the dispersion media at a mixing speed of 2500 rpm. The dispersion goes through a gel phase and breaks loose to form a flowable dispersion. The whole process takes about 8-10 minutes. The temperature of the dispersion is around 76° F. The dispersion has a Brookfield viscosity of 180 cp (#2 spindle at 100 rpm) at a solids content of about 37% and a pH of 10.4. The dispersion is ready for use after release of the vacuum.
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Improved compositions for coating paper stock, methods of forming such compositions, and methods of coating paper stock with those compositions are provided. The compositions comprise an aqueous dispersion including therein from about 20-45% by weight filler (e.g., a starch such as wheat starch) and from about 6-18% by weight wheat gluten. Preferably, the gluten is initially modified with a reducing agent so that the average molecular weight of the gluten is less than about 1,000 kDa. The compositions have a viscosity of up to about 2000 cP and a solids content of from about 25-57% by weight, thus making them suitable for high speed coating of paper stock. The finished, coated stock may be conventionally printed to achieve high gloss end products. The compositions are preferably water soluble, thereby greatly facilitating repulping of the coated stock.
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BACKGROUND OF THE INVENTION
A transfer joint of this type is known e.g. from East German Pat.DL-PS No. 55,868. This proposes a dish-shaped or ball-shaped transfer joint of material which can be cast or moulded and which should advantageously be non-metallic. Bushes with internal threads or thread bolts are inserted in the joint to enable it to receive appropriate bars. The joint is made by placing the connecting pieces such as bushes or thread bolts in a and mould then filling the mould with casting material or by moulding in the connecting pieces as inserts in a mouldable material with the aid of the mould.
The disadvantage of such a joint is that although the grouting materials in question have good resistance to pressure they have only relatively slight tensile strength. This means that such joints can only be used when one is sure that the bars connected by them have only to absorb weak tensile forces.
Another drawback of such joint is that it requires special connecting pieces and appropriate shaping of the ends of the bars, usually in the form of thread bolts. This involves a corresponding outlay on production and also makes assembly more difficult, since it can only be carried out in accordance with a suitably detailed plan if bars threaded at both ends are used.
SUMMARY OF THE INVENTION
The object of the invention is to provide a transfer joint which is suitable both for bars which are heavily loaded in compression and bars which are heavily loaded in tension, and where no special connecting pieces are required.
According to the invention this is achieved in that the joint member comprises a metal casing which forms the casting mould for the grout and which contains holes for insertion of the bars before the grout has set, and that casing has a rigid connection with the hardened grout, which enables forces to be transferred through the transfer joint.
The rigid connection between the grout and the metal casing is achieved by loading the grout in compression even when the bars are loaded in tension. A pressure cone forms in the part of the grout surrounding the tensioned bar and rests against the interior of the casing, causing the casing to absorb the tensile forces. However, compressive loads on the grout can also be increased since the casing prevents any migration of the grout in a plane perpendicular to the direction of the force.
Another advantage of the joint according to the invention is that the bars can be rapidly and securely linked with the joint members on the building site and that no complicated assembly plan is required to construct a rigid frame since, as e.g. in the case of a welded construction, it is immaterial which end of the bar is inserted in the corresponding joint. It is an advantage to provide the ends of the bars with recesses and/or projections in order to achieve a positive connection between the bars and the grout. In such cases and in the case of bars of a noncircular cross-section or even of a cross-section which increases towards the end, it is helpful to provide circular holes in the casing and to insert centering discs, preferably of divided construction, in these holes. Divided centering discs may be mounted in a radial direction on the bar already inserted in the casing and then pressed or screwed into the hole.
Centering discs provide a suitable guide for the bars and prevent the grout from flowing out, particularly in the case of non-circular bars.
If relatively large joint members are required and particularly if grouting materials of low tensile strength are used, it is advisable to fit reinforcements, which are preferably joined to the casing, during the manufacture of the joint member. Strength can be increased in this way. The internal surface of the hollow member may also be provided with elements appropriate to transfer forces, so that a clamping effect can be obtained between the grout and the hollow member as in a "composite construction".
The grout may consist of plastics, particularly fibreglass-reinforced plastics, high grade concrete or plastic mortars, possibly reinforced with asbestos fibers or with granulated metal, solder metals, glass and similar materials added to them. The grouts may be cast in by the action of gravity or injected under pressure.
For example, for joints which are entered predominantly by pressure bars -- in addition to bars loaded moderately in tension, inserted to considerable depth and with their ends shaped to allow a positive connection to the grout -- as in the case with single-shell bar grating cupolas and single-shell bar grating domes, it is possible to use conventional concrete mortar with a compressive strength from 600 to 800 kp/cm 2 after 28 days'hardening. The composition of such a mortar might comprise e.g. 1 part by weight high grade Portland cement (preferably Austrian Standard PZ 475), 2.5to 4 parts by weight of sand within grain limits 0.06 to 2 mm, which may be stirred with about 0.6 part by weight of water. In order to increase resistance to shearing, part of the coarse-grained parts of the sand, of grain size 1 to 2 mm, may be replaced by equal proportions (by volume) of granulated steel. Depending on requirements, optimum mixing ratios and screen lines may be planned for each specific case by testing samples for suitability.
The concrete mortars can preferably be injected into the casing at fairly high pressures instead of being poured in, in order to obtain a casting which is (a) as far as possible free from shrinkage because of the low water content and (b) as far as possible free of air pores.
For joints with bars which are highly loaded in tension specially shrink-proof mortar mixtures must be used if a suitably strong bond is to be obtained between the grout and the casing. For ecample, a cememt mixture in accordance with Austrian Pat. No. 298,321 may be used for such a purpose, although other shrink-proof concrete cement mixes on the market are also suitable.
A plastics mortar, preferably based on epoxy resin, may be used instead of concrete mortar. A plastics mortar of this type comprises e.g. a bonding agent making up 15 to 20% of the volume. The bonding agent is blended with and binds quartz sand, the grain distribution of the sand being graduated in accordance with control screen lines and part or all of the sand being replaced by granulated steel, depending on the modulus of elasticity desired. The quartz sand and/or granulated steel fillers preferably have a grain size up to about 3 mm, their function being to improve the modulus of elasticity, creep behaviour, temperature resistance and the favourable effect on reaction shrinkage. Granulated steel
The epoxy resin "Araldit GY 254", manufactured and marketed by Messrs. Ciba-Geigy AG of Basle, may be used e.g. as the bonding agent together with hardeners "YB 2606" or "YB 2625".
With the transfer joints according to the invention a plurality of load-bearing members may be joined at different angles enabling tensile and compressive forces as well as bending moments to be transferred. The joints may be used inter alia for multiple-chord skeleton girders, skeleton plates, rigid three dimensional frames, rigid grating frames, skeleton barrels, folded skeleton structures, single and multiple-layer skeleton cupolas and rigid frame cupolas, bar grating bearing structures and plane bearing structures.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further explained with reference to the accompanying drawings, wherein:
FIG. 1 is a section through the casing of a joint member according to the invention,
FIG. 2 is a section through a transfer joint according to the invention
FIGS. 3, 4, 5, 8, 9 and 10 illustrate embodiments of the end portions of the bars according to the invention, and
FIGS. 6 and 7 are examples of the construction of centering discs according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The casing 1 of a joint member according to the invention is shown in section in FIG. 1. Attachments 3 and 4 to improve the clamping of the casing to the grout are shown in the upper half of the Figure, and an example of the insertion of a reinforcement 5 is shown in the lower half. Attachment 3 has a free end which is divided, and the attachment is welded to the inside of the casing 1. The attachments for clamping the grout to the casing 1 may be shaped differently, e.g. like the attachment 4 in FIG. 1 where the shank also has a spiral 4' wound around it, thus providing a very good clamping action.
The reinforcement 5 comprises concentric rings connected by bridges. In order to obtain particularly high strength, reinforcement 5 is joined to the casing 1 by struts 6. The reinforcement 5 is inserted and/or joined to the casing 1 during the manufacture of the casing, which may have any shape. Reinforcements are appropriate particularly when the transfer joints are heavily loaded and when the grouts used do indeed have good resistance to compression but only poor tensile strength as in the case of conrete mortar.
The bars 8 are inserted in the joint member through holes 2, one hole being left free and acting as a pouring aperture 7. It is of course also possible for highly stressed bars to be guided through the joint member.
When the bars, which may be of any cross-sectional shape, have been inserted in the joint member, the joint member is filled by pouring grout into it or injecting it under pressure. It is an advantage to use grouts which will not shrink during hardening but which will rather expand. Where hot-cast materials are used it is an advantage to make the casing of a material which will expand more, at the casting temperatures used for the grout, than the grout will shrink during setting, so that the casing 1 will always be loaded in tension. The use of grouts which increase in size relative to the casing 1 also produces high adhesive stress at the bars 8 and consequently high resistance to extraction, so that the transfer joint can be appropriately loaded in tension. In the case of pure pressure or bending connections on the other hand, the bars are supported by having their ends or side surfaces seated on the cast member.
If the joint is exposed to high tensile forces it is an advantage to have not only a non-positive but also a positive connection between the bars and the grout. Examples of how the ends of the bars may be shaped in order to provide a positive connection between the bar 8 and the grout are shown in FIGS. 3, 4, 5, 8, 9 and 10. In the FIG. 3 example the end of the bar 8 is provided with a head which has raised portions 10 and recessed or lowered portions 11, the height of the raised portions 10 decreasing from the end towards the centre of the bar. A centering disc 9 is provided to centre the bar 8 in the hole in the casing 1. The disc 9 is either of divided construction or consists of one piece which is pushed onto the head of the bar before it is forged together.
If the bars 8 are tubular they must be sealed before the joint member is cast. This can be done, e.g. as shown in FIG. 4, by using an end piece 12 which is inserted in the tube and joined to it. The free end of the piece 12 is provided with corrugations 21 in order to achieve a positive connection.
Instead of fastening a tubular bar to the outside of the casing 1 of the joint member, it is also possible for the ends of the tube to be pressed flat and bent over. It is then advantageous to use centering discs. These may either be in the form of divided discs which are placed on the ready-deformed bar in a radial direction and pressed or screwed into the hole in the casing, or they may be discs in one piece which are pushed onto the bar before the ends are deformed and which are inserted in the hole when the bar has been placed in the joint member.
With bars 8 of non-circular cross-section the use of centering sleeves 9 is again very advantageous since it avoids the necessity of the provision in the casing of apertures adapted to the cross-section of the bars. Such specially shaped apertures are very costly to produce and therefore expensive, whereas apertures for the bars 8, particularly with divided centering discs where the components can be held together by spring rings 24 as illustrated e.g. in FIGS. 6 and 7, are far easier and cheaper to obtain. In order to achieve a positive connection between the grout and a bar 8 of non-circular cross-section, it is advisable to deform the end 13 of such a bar, e.g. as shown in FIG. 5 with reference to a bar having an L-shaped profile, to slit the end portion and to spread open the profiled sections.
Other possible shapes for the ends of the bars 8 are illustrated in FIGS. 8 to 10. Thus, as shown in FIG. 8, the end of the bar 8, which is tubular, may be incised in an axial direction, the slit 25 opened out and/or the divided ends 14 bent apart. A spreading plug 19 is provided to seal the tube and maintain the spreading action. In order to obtain a local increase in the strength of the grout the bar 8 is provided with a double spiral reinforcement 20. The ends 22 of the reinforcement are looped around the spread-out ends 14 of the bar 8 and the other ends 23 of the reinforcement are anchored in the centering sleeve 9, which has corrugations 18' but which is seated in a smooth hole in the casing 1. Before it is mounted the spiral reinforcement 20 has an external diamter which is smaller than the diameter of the hole 2. When the bar 8 has been placed in the joint member, the spacing disc 9, which is seated loosely on the bar 8 and joined to the ends 23 of the reinforcement 20 fixed to the splayed-out ends 14 of the bar, is turned in the direction of the pitch of reinforcement 20. This causes the diameter of the reinforcement 20 to increase and the reinforcement to take on a pear-like shape. In this way the favourable formation of a pressure cone within the grout is achieved when tensile forces act on the bar 8.
A positive connection between the bars 8 and the grout may be obtained by mounting components on the ends of the bars instead of by deforming the bars. As shown in FIG. 9, for example, a cage 15 made of square material may be fixed to the end of the bar. This can advantageously be done in an axial direction by means of welded seams. Such seams cause virtually no reduction in the cross-section of the bar 8 and, if they are of suitable length, tensions in the seams can be kept to a minimum.
Another way of fitting components which will provide a positive connection in the end portions of the bars 8 is illustrated in FIG. 10. The bar 8 is provided with grooves to receive split rings, e.g. Seeger rings 16, and possibly with grooves 17 to improve the tension gradient in the bar 8. The use of a centering disc 9 which is provided with thread 18 and screwed into the casing 1 makes it possible for forces to be diverted into the casing 1 by way of the centering sleeve, which is positively connected to the grout and to the casing 1.
It is not always necessary for the bars 8 to be anchored in the grout with a positive connection, but it is an advantage to use bars with a relatively rough surface at least at the ends in order to obtain a good adhesive connection.
The joint members may be either open members or closed members provided with a pouring aperture, which are filled with the grout once the bars 8 have been inserted.
Transfer joints which are very rigid and resistant to bending are obtained with the joints according to the invention. This has great advantages, particularly in view of the problems of stability with single-layer bar gratings and single-layer bar cupolas, since with single loads which may cause the joints to move into the other state of stability the elbow lever action can be avoided by joints which are resistant to bending. In addition, the bar-connecting point is no longer eccentric relative to the centre of the joint in the transfer joints according to the invention. In contrast with most known transfer joints therefore, those according to the invention are not in danger of tipping, since they have no hinge points or hinge-like points outside the centre of the joint. Another advantage of the transfer joint according to the invention is that it avoids any reduction in the cross-section of the bars at the critical or connecting points.
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The invention relates to a transfer joint for rigid frames comprising a solid joint member, the interior of which is made of hardened grout and has three or more bars joined to it with a non-positive and/or positive connection.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to French Patent Application Number 0702615 filed Apr. 10, 2007, the entirely of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to the field of communications, and more particularly, to communications between an individual and electronic devices in a vehicle.
BACKGROUND
[0003] Conventionally, for communicating with an electronic device, such as a CD player, a user handles the player control members, such as buttons, or a knurled wheel or a cursor, in order to start playing a CD or to change a track.
[0004] However, the multiplication of electronic devices in conveying vehicles, and more particularly in automobiles, requires limiting the number of control members on the dashboard. Indeed, the surface of the dashboard being restricted, it is not possible to arrange thereon control members of each of such devices.
[0005] For communicating with a large number of electronic devices despite a restricted number of control members, it is necessary to achieve a software interface between the members and functional cores of the devices which are arranged in a platform. For making things clear and explaining what a core means, the functional core of a CD player could comprise, for example, a playing lens, a laser head and a mechanism for rotating the CD. Through the software interface, control members could be used for controlling several functional cores.
[0006] Achieving a software interface is a long and demanding process comprising a large number of steps.
[0007] Conventionally, such a process comprises a theoretical “prototyping” step involving schematizing on a tracing paper, using various and colored forms (discs, rectangles, etc.), the control members required for controlling the functional cores of the devices. By way of an example, for an auto-radio comprising a radio receiver, a rectangle, representing a display area, and a colored disc, representing a button, are defined on tracing paper.
[0008] The prototyping step is accompanied by a step involving drafting specifications allowing for the relationships to be defined between the control members and the device functional cores. Thus, referring back to the previous example, it is provided, in the specifications, that when the button is activated, the radio receiver is activated and transmits the name of the captured station as well as the title of the song to the display area. Such specifications make it possible to define the requirements of the software Interface.
[0009] In a coding step, specifications are translated into a language to be interpreted by the various device functional cores.
[0010] Generally speaking, electronic devices are able to interpret a so-called “low-level” language enhancing the performing rate and the error checking, such a coding type being conventionally used in any on-board systems. Such a language is contrasted with the so-called “high-level” language used for achieving prototypes enhancing the graphics.
[0011] The coding step is based on the specification document and is specifically implemented for each of the functional cores. This is why, still referring to the previous example, it is required to carry out an individualized coding for an auto-radio having a Hertz radio receiver and an auto-radio having a satellite radio receiver. The generated code is transmitted to a management module located in the vehicle, the management module autonomously administrating the communication between the control members and the functional cores.
[0012] Creating the software interface is completed with a practical simulation step where communication between the control members and the functional cores is tested by a user handling said members.
[0013] Such a conventional process for creating an interface Involves a large number of disadvantages.
[0014] During the coding step, it may happen that the specification document is not strictly respected for technical reasons, so that functions or representation modes are then unable to be coded.
[0015] In addition, it is common that the graphics of tracing papers being previously approved when specifications were drafted is not longer suitable. It is then necessary to redefine a prototype, to modify the specifications and to code again the software interface. Repeating previous designing steps results in an extension of the designing cycle.
[0016] Additionally, material modifications of functional cores could occur while the interface is being designed. Thus, some functions are removed or added although specifications have been approved, creating the software interface having then to be reinitiated.
[0017] Creating a software interface, so-called Human Machine interface (HMI), is a fastidious and long process. Its lack of flexibility requires repeating designing steps without, however, any guarantee for a successful communication between the control members and the functional cores.
SUMMARY OF THE INVENTION
[0018] The invention of the present application aims at overcoming such disadvantages. To this end, it relates to a system for an automated creation of a software interface between an operator and electronic device functional cores being arranged in a target platform. Such a system can comprise:
[0019] a designing module comprising a designing window, wherein interface visual elements corresponding to control members of the platform, and a state machine wherein the interface visual, elements are functionally connected;
a validation module for testing whether data issued from the designing module match the properties of the functional cores; and a simulation module of the target platform comprising a translation unit converting data coming from the validation module and transmitting them to a management member of the platform in order to simulate said functional cores by means of the control members.
[0022] The system advantageously allows for the creation cycle of an interface to be shortened while providing for some designing flexibility. The creation system is of the multi-purpose type and could be adapted to any type of devices.
[0023] Preferably, the system comprises a simulation module for a software device platform arranged for simulating data from the validation module without being connected to functional cores of the electronic devices.
[0024] Thus, the interface is able to be tested without depending on physical devices, thereby avoiding slowing down of the interface, creation when such devices are unavailable.
[0025] Still preferably, the interface is simulated by means of a computer connected to the simulation module of a software device platform.
[0026] Still preferably, data from electronic device functional cores are displayed on a computer monitor.
[0027] Preferably, the interface visual elements have attributes corresponding to the properties of electronic device functional, cores.
[0028] This advantageously allows for the application to be Implemented on the target platform without fearing any incompatibilities between the visual elements and the functional cores.
[0029] Still preferably, the state machine comprises blocks representing the different interface possible states, the blocks being connected by links representing transition means between the various states.
[0030] Yet still preferably, the translation unit of the target simulation module can be parameterized depending on the electronic device functional cores.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] This invention will be better understood with the following description and the appended drawing on which:
[0032] FIG. 1 represents a diagram of the interface creation system according to the present invention;
[0033] FIG. 2 represents a diagram of the designing window according to the present invention;
[0034] FIG. 3 represents a state diagram according to the present invention; and
[0035] FIG. 4 represents another embodiment of the system of this invention with a simulation module of a software device platform.
DETAILED DESCRIPTION
[0036] An automobile can comprise several leisure electronic devices (CD/DVD player, radio receiver) and/or electronic devices used for a purpose directly related to driving (GPS receiver, radar detector). In the case of an automobile only comprising a radio receiver, control members of the radio receiver could be used for controlling the receiver, the control members, comprising push or rotary buttons as well as movable cursors.
[0037] When a vehicle comprises several of such devices, it is then not possible to arrange on the dashboard of the automobile the control members for all devices.
[0038] The various devices with the respective control members thereof are then replaced by a leisure platform gathering the functional cores of the various devices, the functional core of a CD player for example comprising a playing lens, a laser head and a mechanism for driving the CD into rotation. For communicating with a large number of electronic devices despite the limited number of control members, it is necessary to implement a software interface between the members and the device functional cores.
[0039] Before explaining the automated creating system of such a software interface, the various constituent modules will be detailed referring, by way of an example, to a multimedia leisure platform 300 for an automobile, comprising the functional cores of a radio receiver 331 , a CD player 332 and a GPS unit 333 .
[0040] The target platform 300 further comprises control members 310 such as push buttons, rotary buttons as well as a liquid crystal display screen (LCD) (not shown). The platform 300 also comprises a management member 320 that could he an on-board calculator, in order to process the various controls received by a user 401 via the control members 310 , the control members being transferred to the cores 331 , 332 , 333 by the member 320 .
[0041] The interlace creation system comprises a designing module 200 , explained herein, allowing for the control members 310 to be theoretically put in communication with the functional cores 331 , 332 , 333 . The designing module 200 is connected with a validation module 210 arranged for checking whether the data supplied to the designing module 200 are consistent with the properties of the functional cores 331 , 332 , 333 . For example, the validation module 210 makes it possible to check whether the screen size shows dimensions compatible with a video output of the GPS unit 333 .
[0042] The data as issued from the validation module 210 are then transferred to a simulation module for the target platform 230 comprising a translation unit 231 converting data into a language able to be interpreted by the management member 320 . The software interface of the platform 300 could then be autonomously simulated via the control members 310 . In such an exemplary embodiment, the modules 200 , 210 , 230 are gathered in a computer(not shown) or the like.
[0043] Referring to FIG. 2 , the designing module 200 comprises a designing window 1 . In such a window 1 are represented graphical forms such as colored discs—representing push buttons 21 , 22 , 23 and a rotary button 24 —and a rectangle representing a liquid crystal screen (LCD) 10 for displaying various graphical characters, such as text, pictures or videos. Such graphical forms are referred to as interface visual elements 10 , 21 , 22 , 23 , 24 .
[0044] Such interface visual elements 10 , 21 , 22 , 23 , 24 possess functional attributes corresponding to the functional properties of the cores of the units to be interfaced. By way of an example, the rectangle 10 here has, as an attribute, the screen resolution, the number of colors able to be displayed and the updating frequency. Similarly, the attributes for a rotary button are the number of pitches in rotation and the degree of the no-return force. Thus, for two leisure platforms of the same range, the first one having a LCD (Liquid Crystal Display) type display screen and the second a TFT (Thin-Film Transistor) type display screen, the same designing window 1 could be used with the same interface visual elements, only the attributes thereof being different.
[0045] Referring to FIG. 3 , the designing module 200 further comprises a diagram or state machine 100 , making it possible to define logical, sequential and functional behaviors of interface visual elements 10 , 21 , 22 , 23 , 24 arranged in the designing window 1 . The machine 100 represents the state of the various interface visual elements 10 , 21 , 22 , 23 , 24 upon their actuation.
[0046] The interface visual elements 21 , 22 , 23 respectively activate the core of the radio receiver 331 , the core of the audio CD player 332 and the core of the GPS unit 333 , the rotary button 24 allowing for switching between the various functional cores.
[0047] The state machine 100 has the form of a set of blocks 51 , 52 , 53 representing the various interface states, the blocks 51 , 52 , 53 being connected with each other by links corresponding to transitions between states.
[0048] The initial state, upon the interface activation, is indicated on the state machine 100 and is marked by the INI abbreviation in the state block 51 .
[0049] The state blocks 51 , 52 and 53 here respectively correspond to the active state of the cores of the radio receiver 331 , the audio CD player 332 and the GPS unit 333 .
[0050] In the initial state, radio is activated. If some action is exerted on the element 22 , corresponding to the CD player, the radio is inactivated while the audio CD player is activated. the system being then in the state as represented by the block 52 . Similarly, the procedure proceeds to the state as represented by the block 53 while activating the button 23 , the GPS unit being then activated. Thus, the buttons 21 , 22 and 23 advantageously allow for switching between the various functions of the platform 300 .
[0051] Similarly, when the state of the system is represented by the block 51 (radio state), activating the button 21 (radio button) does not result in any state modification.
[0052] The rotary button 24 is used for switching between the different functions of the platform 300 . When the state of the system is represented by the block 5 . 1 , it is sufficient to drive the button 24 into rotation to the left for switching to the GPS function (state 53 ) and to the right for switching to the CD function (state 52 ). The dashed arrows on FIG. 3 represent the transitions between the various states upon a rotation of the rotary button 24 .
[0053] All those actions result In modifications of the display screen 10 , such as the display of the name of the radio station, of the artist and of the song, as well as for the receiving frequency.
[0054] When an interface visual element 10 , 21 , 22 , 23 , 24 is arranged in the designing window 1 , such an element could be arranged simultaneously in the state diagram 100 , thereby allowing for all attributes of the elements to be accessed rapidly,
[0055] Data being added in the designing module 200 , both in the designing window 1 and in the state diagram 100 , are transmitted to the validation module 210 for checking,
[0056] The validation module 210 makes it possible to ensure that the logical sequence of events as defined in the state machine 100 , as well as the visual elements 22 , 23 , 24 as defined in the designing window 1 , are entered with a suitable format and are consistent with the properties of the functional cores of the units 331 , 332 , 333 .
[0057] Such an automated validation step could occur at any time during the interface designing. For example, it is possible to validate the interface after the insertion of each button 21 , 22 and 23 into the designing window 1 . Such a partial validation allows for any error risk to be prevented and thereby for the interface quality to be enhanced. It thus results from this a time saving on the whole creation process of the interface.
[0058] Once the data from the designing module 200 are validated by the module 210 , the data are transmitted to a simulation module of the target platform 230 , so-called target simulation module, for simulating the interface by means of the control members 310 .
[0059] The software language used in the designing module 200 is different from that used in the managing member 320 of the platform 300 . Thus, for performing a real simulation, a translation unit 231 for the target simulation module 230 allows for designing data to be converted into a so-called “target” low-level language able to be interpreted by the management member 320 of the platform 300 . Such a translation is automatically performed, resulting in some time saving.
[0060] Moreover, the translation unit 231 could be parameterized as a function of the functional cores 331 , 332 , 333 it comprises. Thus, for a leisure platform range for an automobile, it is sufficient to modify parameterizing the translation unit 231 in order to adapt the code being generated to the various platforms of the range.
[0061] During the real test, a user 401 could actuate control members 310 , observe the behavior of functional cores and detect defects typical of the implementation on the target platform 300 .
[0062] In another embodiment of this invention, it could happen that the platform 300 or the functional cores 331 , 332 , 333 are unavailable or that it is desired to perform tests with any dependence neither on the physical platform 300 nor on the control members 310 . In such an hypothesis, referring to FIG. 4 , data from the designing module 200 are transmitted to a simulation module for a software device platform 220 , the so-called software simulation module 220 220 , simulating the interface created by means of a computer 250 or the like connected with the module 220 .
[0063] An operator 402 , in principle the same operator 401 , tests the interface using the software simulation module 220 by clicking with a computer mouse on the button 22 for activating the audio CD player, thereby triggering the display of the “CD” text in the rectangle 10 of the designing window 100 displayed on the computer 250 monitor.
[0064] Thus, the operator, who could be a designer or a customer, can appreciate the quality of the interface without, however, depending on the platform 300 . This is why, even if the cores of the platform 300 are missing, it is always possible to develop the interface. Moreover, such a “theoretical” interface has been validated by the validation module 220 ensuring the future compatibility of the interface with the platform 300 and the unavailable cores.
[0065] As used herein, the terms buttons, knurled wheels, cursors or other handles, also encompass all means for actuating device functions such as sound (for example, vocal) commands, visual commands (detection of the user's movements), touch commands (touch screens), as wed as all the so-called “wireless” commands (infrared, bluetooth, WiFi, radio wave, etc).
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A system of automated creation of a software interface between an operator and electronic device functional cores arranged in a target platform. The system includes a designing module comprising a designing window, wherein there are arranged interface visual elements corresponding to control members of the platform and a state machine wherein elements are functionally connected; a validation module for testing whether data issued from the designing module match the properties of the functional cores; and a simulation module of the target platform comprising a translation unit converting data issued from the validation module and transmitting them to a managing member of the target platform in order to simulate said functional cores by means of the control members.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of U.S. patent application Ser. No. 11/063,532 filed Feb. 24, 2005 and claims priority to and the benefit of Korean Patent Application No. 10-2004-0012191, filed on Feb. 24, 2004, which is hereby incorporated by reference for all purposes as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0002] (a) Field of the Invention
[0003] The present invention relates to a UV nanoimprint lithography process and its apparatus, and more specifically, to a UV nanoimprint lithography process and its apparatus capable of repeatedly fabricating nanostructures on a substrate (e.g. wafer, glass, quartz, etc.) with a stamp having the nanostructures engraved thereon.
[0004] (b) Description of Related Art
[0005] The UV nanoimprint lithography technology is an economical and effective method of fabricating nanostructures. It is multidisciplinary, so that it should be supported by various technologies from such fields as nano-scale materials science, stamp fabrication, anti-adhesion layer, etching and measurements. The nano-scale precision control technology is regarded as a basis.
[0006] The UV nanoimprint lithography technology is applicable to ultra high-speed metal-oxide-semiconductor field-effect transistors (MOSFETs), metal-semiconductor field-effect transistors (MESFETs), high-density magnetic storage devices, high-density compact disks (CD), nano-scale metal-semiconductor-metal photodetectors (MSM PDs), and high-speed single-electron transistor memory, etc.
[0007] In the nanoimprint process, developed by Prof. Chou et al. at Princeton Univ. in 1996, a stamp having embossed structures fabricated by the electron beam lithography process is pressed at high temperature on the wafer coated with a polymethylmethacrylate (PMMA) resist, and is released when the resist is cooled. Thus, the resist is imprinted with the negative patterns of nanostructures of the stamp, and an anisotropic etching process is followed to open the etch window of the wafer. In 2001, a laser-assisted direct imprint (LADI) method, that uses a single 20-ns Excimer laser with a wavelength of 308-nm to instantaneously melt the surface of a silicon wafer or the resist coated on a silicon wafer. Similarly, in a nanosecond laser-assisted nanoimprint lithography (LA-NIL) applied to polymer, nanostructures with a line width of 100 nm and a depth of 90 nm are imprinted to polymer-based resist.
[0008] The aforementioned nanoimprint technologies are performed at high temperature. This makes them inapplicable to the implementation of semiconductor devices, a multi-layer process, because thermal deformation occurring in these technologies will hinder multi-layer alignment. Furthermore, high pressure (about 30 atmospheric pressures) required to imprint high-viscosity resist can break or damage previously fabricated nanostructures. Opaque stamps used in these processes are also an obstacle to the multi-layer alignment.
[0009] To address these problems, the step & flash imprint lithography (SFIL) process is suggested by Prof. Sreenivasan at the University of Texas at Austin in 1999. This process uses a UV-curable material to fabricate a nanostructure at low pressure and room temperature is characterized by the fact that UV-transparent materials such as quartz and Pyrex® glass are used for the stamp. In the SFIL process, a transfer layer is first spin-coated on a silicon wafer, and a low-viscosity UV-curable resin is filled into the nanostructures while maintaining a certain interval between the UV-transparent stamp and the transfer layer.
[0010] Subsequently, at the time of completion of the filling, the stamp is in contact with the transfer layer and the resin is cured by illuminating with UV light. Thereafter, the stamp is separated and the nanostructure is transferred on the wafer by the etching and the lift-off processes.
[0011] However, the gap distribution between the stamp and the wafer for use in the UV nanoimprint lithography process is not constant (e.g., Si wafer: 20˜30 μm), so that the resist may be insufficiently pressed by the stamp during imprinting. In the SFIL process using a small-area stamp, the distance between the stamp and the wafer is measured with distance sensors attached at the sides of the stamp before pressing the stamp is used, and, based on the measurements, the stamp is finely rotated to the stamp as parallel as possible to the wafer. In other words, in SFIL, imprinting is performed in such a way that the stamp with nanostructures is manipulated according to the waveness of the wafer surface.
[0012] The SFIL process is also characterized by the fact that the entire wafer is imprinted not at one time but repeatedly in several times because it uses a small-area stamp, smaller than the wafer in size. This is a sort of the step-and-repeat type imprinting. Since it uses a small-area stamp and the alignment and imprinting should be repeated, it will take a long time to finish imprinting of a large-area wafer.
[0013] Further, to imprint a large-area wafer in a short time, a large-area stamp on which nanostructures are fabricated can be used to press the resist deposited on the wafer. However, the larger the stamp and the wafer become, the more serious the error of flatness becomes. This means that some of the resist may be insufficiently pressed and some of the nano structures may be incompletely filled. In addition, the non-uniform residual layer thickness, which occurs because of the error of flatness, can make the etching process difficult or unsuccessful.
SUMMARY OF THE INVENTION
[0014] The present invention provides a UV nanoimprint lithography process and its apparatus capable of efficiently forming high-precision, high-quality nanostructures irrespective of the error of flatness thereof.
[0015] The present invention also provides a UV nanoimprint lithography process and its apparatus capable of yielding a large-area stamp at low cost.
[0016] According to an exemplary embodiment of the present invention, there is provided a method of performing a UV (ultraviolet) nanoimprint lithography process for forming nanostructures on a substrate. The method may include preparing a stamp having more than two element stamps. The nanostructures may be formed on the surface of each element stamp. Resist may be applied to the surface of a substrate or on the element stamps. The stamp and the substrate may be mounted on a stamp chuck and a substrate chuck, respectively. In some embodiments the substrate chuck or the stamp chuck may be moved to press the resist on the surface of a substrate or on the element stamps. Pressurized gas may be applyed to some selected regions of the substrate to help complete some incompletely filled element stamps. Pressed resists may be cured by illuminating the resists with UV light to cure the resist. The stamp may be separated from the substrate. A relative position between the substrate and the stamp may be changed to continue imprinting another predetermined region of the substrate. By repeating the above steps, nanostructures may be formed all over the surface of substrate.
[0017] Here, a wafer or stamp materials (UV-transparent materials) may be used for the substrate.
[0018] In addition, applying the resist may be performed by one of the following methods: including but not limited to a spin coating method which applies the resist to all over the surface of the substrate, a droplet dispensing method which directly deposits resist droplets to the surface of each element stamp, and a spraying method which arranges a mask having an opening corresponding to the positions of the respective element stamp and sprays the resist thereon, thereby applying the resist to some portion of region over the substrate.
[0019] For the droplet dispensing method or the spraying method, after separating the stamp from the substrate, the resist may be applied to the surface of the element stamp for the second process,
[0020] when the resist is imprinted on the predetermined region of the substrate, nanostructures may be transferred to the substrate by etching the upper surface of the substrate having the deposited resist.
[0021] According to another exemplary embodiment of the present invention, a UV nanoimprint lithography apparatus for forming nanostructures on a substrate may be included. The UV nanoimprint lighography may include a substrate chuck for mounting a substrate; a stamp made of a transparent material transmitting UV light and having more than two element stamps, wherein nanostructures are formed on a surface of each element stamp; a stamp chuck for mounting the stamp; a UV lamp unit for providing UV light to cure resist applied between the element stamps and the substrate; a moving unit for moving the substrate chuck or the stamp chuck to press the resist on the surface of substrate or on the element stamps; and a pressure supply unit for applying pressurized gas to some selected regions of the substrate to help complete some incompletely filled element stamps.
[0022] In addition, the substrate chuck may be arranged to move in the horizontal direction along the guide block and to move in the vertical direction by the moving unit.
[0023] In some embodiments, the substrate chuck may be guided by a plurality of guide rods while moving in the vertical direction using the moving unit.
[0024] The moving unit may be arranged to move the pressure supply unit in the vertical direction may include a hydraulic cylinder or a motor-driven actuator.
[0025] In an embodiment, the pressure supply unit may include: a closure type of housing having a hollow cavity. In addition, a plurality of gas supply holes may be provided in the housing and connected to the hollow cavity. Some embodiments may also include a gas supplier for supplying pressurized gas to the hollow cavity and through holes connected to the plurality of gas supply holes and provided in the substrate chuck.
[0026] Furthermore, a sealing member (e.g. an O-ring) may be mounted on the upper surface of the housing to prevent leakage of the pressurized gas supplied to the through-holes via the plurality of gas supply holes.
[0027] In addition, the apparatus may further include a gas supply nozzle for spraying gas between the stamp and the substrate to separate the stamp from the substrate when the imprinting is finished.
[0028] Furthermore, the stamp may be an element wise patterned stamp. The element-wise patterned stamp may include at least two element stamps on which nanostructures are engraved. In addition, the element-wise patterned stamp may include a plurality of channels being deeper than the nanostructures between adjacent element stamps, or a well-known planar-type stamp.
[0029] According to an embodiment, a resist insufficiently pressed due to the error of flatness between a stamp and a substrate during imprinting can be further pressed by applying pressurized gas. Therefore, the insufficient filling of the resist, which may be generated when the nanostructures are fabricated on a large-area substrate (e.g. 8 inch wafer) in a single-step or step-and-repeat imprinting by using a large-area stamp (e.g. 5 in.×5 in. stamp), can be prevented. Accordingly, it is possible to economically and efficiently form high-precision and high-quality nanostructures in a short time.
[0030] Moreover, it is also possible to fabricate the stamp having the same working area with a substrate by using the afore-mentioned apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings.
[0032] FIG. 1 is a schematic perspective view showing a a UV nanoimprint lithography apparatus according to an embodiment of the present invention;
[0033] FIG. 2 is a side view for the UV nanoimprint lithography apparatus of FIG. 1 ;
[0034] FIG. 3 is a plan view of an element-wise patterned stamp according to an embodiment of the present invention;
[0035] FIG. 4 is a cross sectional view taken along a line A-A′ of FIG. 3 ;
[0036] FIGS. 5A to 5D are diagrams showing a sequence of the UV nanoimprint lithography process according to an embodiment of the present invention; and
[0037] FIG. 6 is a cross sectional view of a planar stamp according to another embodiment of the present invention.
DETAILED DESCRIPTION
[0038] Now, embodiments of the present invention will be described with reference to the attached drawings.
[0039] FIG. 1 is a schematic perspective view showing a UV nanoimprint lithography apparatus according to an embodiment of the present invention, and FIG. 2 is a side view for the UV nanoimprint lithography apparatus of FIG. 1 .
[0040] FIG. 1 depicts the apparatus including a base 10 having upper and lower frames 10 a and 10 b and left and right frames 10 c and 10 d . The base 10 is supported by four supporting corners 12 arranged on the lower plate 10 b.
[0041] As shown in FIG. 2 , a stamp chuck 16 mounting an element-wise patterned stamp 14 is fixedly arranged on the upper frame 10 a . The stamp chuck 16 is made of a UV-transparent material and includes a back plate 16 a for vacuum absorption of the element-wise patterned stamp 14 and the main body 16 b mounting the back plate 16 a , as shown in FIG. 2 .
[0042] Although not shown in detail, the back plate 16 a includes a vacuum line 16 ′ a for vacuum absorption of the element-wise patterned stamp 14 . The vacuum line 16 ′ a is connected to a vacuum generator (not shown).
[0043] In addition, UV lamp unit 18 transmitting the element-wise patterned stamp 14 mounted on the stamp chuck 16 and illuminating the resist with UV light is arranged over the upper frame 10 a at a certain height through two supporting bodies 18 ′. The resist may be pressed by a substrate.
[0044] In addition, FIG. 1 shows a guide block 22 guiding horizontal movement of a substrate chuck 20 (e.g., the wafer or the stamp board) arranged on the lower frame 10 b . A slide block 24 ′ of the chuck mounting plate 24 is coupled to a guide rail 22 ′ of the guide block 22 . A plurality of guide rods 26 guiding vertical movement of the substrate chuck 20 as well as supporting the substrate chuck 20 are arranged on the chuck mounting plate 24 .
[0045] As illustrated in FIG. 2 , a pressure supply unit 30 supplying pressurized gas to a substrate 28 mounted on the substrate chuck 20 may be positioned below the substrate chuck 20 . The pressure supply unit 30 includes a closure type of housing 30 b having a hollow cavity 30 a , a plurality of gas supply holes 30 c provided in the housing 30 b and connected to the hollow cavity 30 a , a gas supplier (not shown) for supplying gas to the hollow cavity 30 a through a gas supply tube 30 d , and a plurality of through holes 30 e connected to the plurality of gas supply holes 30 c and provided in the substrate chuck 20 . In addition, a plurality of O-rings 30 f are arranged on the housing 32 b closely contacted to the lower surface of the substrate chuck 20 to prevent leakage of the gas discharged from the gas holes 30 c.
[0046] The pressure supply unit 30 with the afore-mentioned construction may be arranged such that the housing 30 b can move upward and downward by a moving unit 32 . The moving unit 32 provides a force to move the substrate chuck 20 upward toward the element-wise patterned stamp 14 . The moving unit 32 may include a hydraulic cylinder or a motor-driven actuator.
[0047] Further, a stamp mounting jig 34 mounting the element-wise patterned stamp 14 on the stamp chuck 16 is arranged on the left frame 10 c . The stamp mounting jig 34 is interposed between the stamp chuck 16 and the substrate chuck 20 . In addition, a gas spray nozzle (not shown) for intermittently spraying gas (e.g., air or nitrogen) between the substrate 28 and the element-wise patterned stamp 14 may be included to facilitate separation between the substrate 28 and the element-wise patterned stamp 14 .
[0048] FIG. 3 is a plan view of an element-wise patterned stamp according to an embodiment of the present invention, and FIG. 4 is a cross sectional view taken along a line A-A′ of FIG. 3 .
[0049] As shown in FIGS. 3 and 4 , the element-wise patterned stamp 14 has a plurality of element stamps 14 a arranged like a matrix according to an embodiment of the present invention. A plurality of channels 14 b are provided between the adjacent element stamps. In addition, a plurality of nanoimprints 14 ′ a imprinted by a nanofabrication process such as electron-beam lithography are formed on the respective element stamps 14 a.
[0050] Here, the depth h G of the channel 14 b may be in a range from about 2 times to 1000 times as large as the depth h s of the nanostructure 14 ′ a . When the depth h G of the channel 14 b is formed less than twice of the depth h s of the nanostructures 14 ′ a , the resist flowed into the channel 14 b cannot be sufficiently accepted due to the little difference between the depth h G of the channel 14 b and the depth h S of the nanostructures 14 ′ a . Otherwise, when the depth h G of the channel 14 b is 1000 times as large as the depth h s of the nanostructures 14 ′ a , the strength of the stamp 14 is reduced, so that the stamp 13 may be damaged during the nanoimprint process.
[0051] Now, a method of performing a UV nanoimprint lithography process using the afore-mentioned apparatus will be described with reference to FIGS. 1 , 4 , 5 A through 5 D.
[0052] First, to fabricate the nanostructures on the substrate 28 (e.g., the wafer) resist droplets 36 are applied on the surface of the nanostructures 14 ′ a formed in the element stamps of the element-wise patterned stamp 14 . Here, instead of applying the resist droplet on the surface of the nanostructures 14 ′ a of the element stamps 14 a , a spin-coating or spraying method may be used to apply the resist droplets to some or all regions of the wafer. In addition, it is desirable that the resist be made of a UV curing polymer.
[0053] Like this, the element-wise patterned stamp 14 having the deposited resist droplets 36 is mounted on the stamp chuck 16 by using the stamp mounting jig 34 . The wafer is mounted on the substrate chuck 20 . Here, the element-wise patterned stamp 14 is fixedly mounted on the stamp chuck 16 by using a vacuum pressure generated by the vacuum generator.
[0054] Next, the moving unit 32 (e.g., the hydraulic cylinder or the motor-driven actuator) operates to move the housing 30 b of the pressure supply unit 30 vertically upward. When the housing 30 b is moved upward, the O-rings 30 f arranged on the surface of the housing 30 b are closely adhered to the lower surface of the substrate chuck 20 .
[0055] During this state, when the moving unit 32 keeps operating, the substrate chuck 20 moves upward along with the housing 30 b . The moving unit 32 may move until the surface of the wafer mounted on the substrate chuck 20 presses the resist droplets 36 deposited on the surface of the nanostructures 14 ′ a of the element-wise patterned stamp 14 .
[0056] If the surface of the wafer presses the resist droplet by driving the moving unit 32 , then the gas supplier of the pressure supply unit 30 will be driven. In addition, the gas supplied from the gas supplier passes through the gas supply tube 30 d the hollow cavity 30 a , the gas supply holes 30 c , and the through holes 30 e one after another and is selectively supplied to some region of the bottom surface of the wafer. Therefore, some regions of the wafer, preferably, regions facing the element stamps 14 a , are pressed toward the respective element stamps 14 a due to the gas pressure, so that the insufficient filling of the resist into the channels of the nanostructures due to the error of flatness between the element-wise patterned stamps and the wafer can be prevented.
[0057] During the gas supply process, the O-rings 30 f prevent gas leakage.
[0058] Next, the resist 36 is cured by illuminating resist 36 with UV light from the UV lamp unit 18 .
[0059] When the resist 36 is cured, the element-wise patterned stamp 14 is separated from the wafer. Due to the channels 14 b of the element-wise patterned stamp 14 , the separation between the element-wise patterned stamp 14 and the remaining cured resist over the wafer surface can be easily made. The gas between the element-wise patterned stamp 14 and the wafer may be intermittently sprayed by using the gas spray nozzle (not shown) to make the separation more effectively.
[0060] Next, the resist droplet is applied again to the separated surface of the nanostructures 14 ′ a of the element-wise patterned stamp 14 , and the substrate chuck 20 is moved to perform the second process. Here, the substrate chuck 20 is moved along the guide block 22 . The stamp chuck 16 and the pressure supply unit 30 remain fixed when the substrate chuck 20 is moved. In addition, after the substrate chuck 20 is moved, the resist may be formed in a predetermined region of the wafer by repeating the afore-mentioned process. For example, when the nanostructures are formed in an 8 inch wafer by using the 5×5 inch element-wise patterned stamp, the resist may be formed by repeating the afore-mentioned process four times. Next, the upper surface of the wafer having the deposited resist 36 is etched. When the resist left in the upper surface of the wafer is removed, the nanostructures are formed on the wafer.
[0061] Further, when the stamp board rather than the wafer is used for the substrate, the large-area element-wise patterned stamp can be fabricated at low cost by performing the afore-mentioned process.
[0062] While the nanostructures fabricated by using the element-wise patterned stamp in the step and repeat method has been described above, the apparatus and process of the present invention can also be achieved by using a planar-type stamp 14 ′ that does not include the channels 14 b of FIG. 4 , as shown in FIG. 6 . However, in this case, to remove defects such as air entrapment, the apparatus according to the embodiment of the present invention should be arranged inside the vacuum chamber and performed under the vacuum ambient.
[0063] In addition, when the large-area stamp (planar-type stamp or element-wise patterned stamp) having the same working area with the wafer is fabricated by the stamp board as the substrate 28 , the process can be completed at one time by using the afore-mentioned large-area stamp.
[0064] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. Therefore, the scope of the invention is defined not by the detailed description of the invention but by the appended claims, and all differences within the scope will be construed as being included in the present invention.
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A UV nanoimprint lithography process and its apparatus that are able to repeatedly fabricates nanostructures on a substrate (wafer, UV-transparent plate) by using a stamp that is as large as or smaller than the substrate in size are provided. The apparatus includes a substrate chuck for mounting the substrate; a stamp made of UV-transparent materials and having more than two element stamps, wherein nanostructures are formed on the surface of each element stamp; a stamp chuck for mounting the stamp; a UV lamp unit for providing UV light to cure resist applied between the element stamps and the substrate; a moving unit for moving the substrate chuck or the stamp chuck to press the resist with the element stamps and substrate; and a pressure supply unit for applying pressurized gas to some selected regions of the substrate to help complete some incompletely filled element stamps.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of prior U.S. application Ser. No. 13/335,898, filed Dec. 22, 2011, which claims the benefit of U.S. Appl. No. 61/540,821, filed Sep. 29, 2011, all incorporated by reference herein.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to methods and apparatus for operating well bore tubing and, more particulary, to advancing the bottom assembly of a drilling string and/or freeing the drilling string including but not limited to a coiled tubing string in a borehole.
Description of the Prior Related Art
It is well known to those of skill in the art that there are limits to the ability of a surface rig to push a tubular string into a bore hole. After a certain depth is reached, the flexibility of the tubular string does not permit the transmission of force through the length of the string to move the bottom hole assembly. An analogy often made is that of attempting to push a string through a long or sticky tube.
The problem occurs in the drilling of oil and gas wells due to the length of the tubular strings and the drag and potential sticking of the drill string against the well bore wall. This results in increased resistance to movement of the pipe.
This effect is often more evident in a coiled tubing applications. Coiled tubing is typically even more flexible than drill pipes. Coiled tubing strings cannot be rotated in the well bore like drill strings. Coiled tubing also to some extent retains the spiral effect of the diameter of the reel on which the coiled tubing is stored. Therefore, coil tubing may have additional points of drag and sticking of the coiled tubing in the well bore as compared with standard drilling pipe even though the effect is also present with standard drilling pipe.
In wells with high angles and/or horizontal sections, this problem becomes greatly exaggerated, often essentially prohibiting advancement of the drill string.
Many attempts and methods have been employed in the past by those of skill in the art to solve this problem. Prior art attempts to solve problems have included downhole tractors, jars, centralizers, and even wheels and skids. Other attempts utilize pulsation inducing devices, which lengthens the pipe momentarily by a small amount by restricting flow through the drill pipe. However, this technique results in increased fatigue of the drill string. As well, the on and off fluid pulses may not operate downhole motors effectively.
In some cases, the pipe string becomes stuck in the well bore so the string can neither be moved up or down. Perhaps even more devices and methods have been provided to simply loosen and retrieve the stuck string rather than attempting to go deeper in the well. Accordingly, these devices are not designed for advancing the drill string further into the well but rather attempt to retrieve the stuck drill pipe or at least a portion thereof.
The following patents discuss various attempts related to the above discussed problems.
U.S. Pat. No. 3,152,642, issued Oct. 13, 1964, to A. G. Bodine discloses a method of loosening an elastic column (drill string), which is stuck in a well at a distance down from the upper end and which is acoustically free there above that includes applying a torsional bias to the column, acoustically coupling the vibratory output member of a freely operating torsional elastic wave generator to the acoustically free portion of the column above the stuck point and in a manner to apply an alternating torque to the column, and operating the generator at a torsional resonant frequency of the column, and at a power output level developing a cyclic force at the stuck point which exceeds and opposes the force holding the column at the stuck point.
U.S. Pat. No. 3,155,163, issued Nov. 3, 1964, to A. G. Bodine discloses an apparatus for loosening a fish (drill string) at a point below its upper end in a bore hole, includes a grappling tool adapted to rigidly engage the upper end of the fish, a drill collar coupled to the grappling tool, an acoustic vibration located adjacent the upper end of the drill collar comprising a mass element rotatable on and linearly reciprocal along the vertical axis of the drill collar, a non-rotatable member adapted for corresponding reciprocation along the axis, cam means between the mass element and the non-rotatable member for converting rotation of said mass element into axial vibration of the mass element the non-rotatable members, the non-rotatable reciprocal member being coupled to the drill collar for transmission of reciprocating force to the upper end thereof to set up in the collar and fish an acoustic standing wave, an inertia collar adapted to be lowered into the bore hole on a rotatable drill pipe string, suspended from a rotary table at the ground surface, and a torque transmitting spring connecting said inertial collar and the rotatable mass element of the wave generator, the spring being yieldable in a vertical direction too isolate the inertia collar from vibration transmitted upwards from the wave generator.
U.S. Pat. No. 3,500,908, issued Mar. 17, 1970, to D. S. Barler discloses a device for freeing a tubular member stuck within an oil well comprising upper and lower frames mounted on the surface, horizontal plates, a plurality of cylindrical shells, a plurality of pistons mounted in the shells, a plurality of helical springs, means for adjustably supporting the frame at a desired elevation above the well, a pair of heavy eccentrically loaded, power driven bodies that are transversely spaced a fixed distance in a horizontal plane and rotate in opposite directions, with the eccentric loading, and rigid frame members to support the power driven bodies.
U.S. Pat. No. 3,168,140, to A. G. Bodine, issued Feb. 2, 1965, discloses a method of moving a column system embodying a portion held fast in the earth and a portion extending therefrom which is acoustically free and in a condition to sustain a vibration wave pattern that comprises acoustically coupling a fluid-drive vibrator to the acoustically free portion of the column system at a point spaced from and the held portion, and fluid driving the vibration at a frequency which produces resonance of the column system and which establishes a vibration patter with cyclic impulse force in the column system with the region of the held portion, where in the resonant frequency and the vibration patter are established independently of minor irregularities in fluid drive effort by reason of inherent fluid drive flexibility.
U.S. Pat. No. 4,429,743, to Bodine, issued Feb. 7, 1984, discloses a well servicing system in which sonic energy is transmitted down a pipe string to a down hole work area a substantial distance below the surface. The sonic energy is generated by an orbiting mass oscillator and coupled therefrom to a central stem to which the piston of a cylinder-piston assembly is connected. The cylinder is suspended from a suitable suspension means such as a derrick, with the pipe string being suspended from the cylinder in an in-line relationship therewith. The fluid in the cylinder affords compliant loading for the piston while the fluid provides sufficiently high pressure to handle the load of the pipe string and any pulling force thereon. The sonic energy is coupled to the pipe string in a longitudinal vibration mode which tends to maintain this energy along the string.
U.S. Pat. No. 4,667,742, to Bodine, issued May 26, 1987, discloses a method wherein the location of a section of drill pipe which has become stuck in a well some distance from the surface is first determined. The drill string above this location is unfastened from the drill string and removed from the well. A mechanical oscillator is connected to the bottom of the re-installed drill string through a sonic isolator section of drill pipe designed to minimize transfer of sonic energy to the sections of drill string above the oscillator. The oscillator is connected to the down hole stuck drill pipe section for transferring sonic energy thereto. A mud turbine is connected to the oscillator, this turbine being rotatably driven by a mud stream fed from the surface. The turbine rotates the oscillator to generate sonic energy typically in a torsional or quadrature mode of oscillation, this sonic energy being transferred to the stuck section of drill pipe to effect its freeing from the walls of the well.
The above discussed prior art does not address solutions provided by the present invention, which teaches a system that is useful for both advancing the bottom hole assembly further into the well and/or for loosening the pipe to prevent or to free the pipe from becoming stuck in the well bore. The prior art also does not show a tool which has the ability to be reversed causing the drill string to be moved back up the hole.
Consequently, those skilled in the art will appreciate the present invention that addresses the above described and other problems.
SUMMARY OF THE INVENTION
One possible object of the present invention is an improved tool to impart propulsion in a bottom hole assembly.
Another possible object of the present invention is to reduce sticking of tubing including coiled tubing.
Another possible object of the present invention is to apply a sonic vibration into the drilling motor and bit (and bottom hole assembly) resulting in a true sonic and/or vibration drill application.
Accordingly, the present invention may comprises a downhole tool, which in one possible embodiment may comprise an outer tubular housing and a fluid flow path through the housing. In this embodiment, at least one fly wheel may comprise gears or teeth mounted on the fly wheel positioned to encounter fluid flow through the flow path whereby the fly wheel is rotated. The fly wheel could be mounted to provide a center of mass for the fly wheel that is at an offset from the center of rotation, which results in vibrations being created during rotation. The fly wheel may sized and rotated at a speed to produce a gyroscopic effect. In one possible embodiment, a timing wheel may be utilized comprising teeth which engage the flowpath. This engagement could be utilized to delay, control, average, or other affect the flow of the exiting drilling fluid.
In another possible embodiment, a propulsion generator for use in a downhole tool is provided to urge movement of a string of pipe within a well bore, which may comprise elements such as, for example only, an outer tubular housing mountable to the bottom end portion of the string of pipe. The outer tubular defines a fluid flow path through the outer tubular housing to permit fluid flow through the downhole tool. At least one fly wheel is positioned within the outer tubular housing. The fly wheel comprises a center of mass.
A plurality of fins may be operatively connected to the fly wheel and positioned within the fluid path to receive energy from fluid flow through the flow path whereby the at least one fly wheel is rotated. The plurality of fins may rotate as the fly wheel rotates.
A mounting for the fly wheel controls a center of rotation of the fly wheel. In one embodiment, the center of mass of the fly wheel is offset from the center of rotation, which results in vibrations being created during rotation of the fly wheel.
The propulsion generator might comprise a first fly wheel housing in which the mounting is provided for a first fly wheel. A second fly wheel may be mounted within a second fly wheel housing whereby a second center of mass of the second fly wheel is offset from a center of rotation of the second fly wheel. The first fly wheel housing and the second fly wheel housing define at least a portion of the fluid flow path through the outer tubular housing.
In one possible embodiment, the propulsion generator may comprise that the second fly wheel housing is substantially identical to the first fly wheel housing. The propulsion generator may further comprise connectors to mount the first fly wheel housing to the second fly wheel housing. In one embodiment, the connectors are operable for mounting the first fly wheel housing and the second fly wheel housing at different orientations with respect to each other whereby the at least one fly wheel is selectively oriented the same or differently from the at least one second fly wheel housing.
In one embodiment, the plurality of fins are positioned with respect to the fluid flow path such that during operation as a fly wheel rotates that the amount of variation of instantaneous fluid flow through any particular cross-section of the fluid flow path does not vary by more than 30% than an average fluid flow through the cross-section of the fluid flow path.
A propulsion generator may further comprise a plurality of bearing members for mounting the fly wheel. The plurality of bearings may comprise an outer bearing with an outer bearing circumference. The plurality of bearings may be constructed asymetrically to produce a center of rotation of the fly wheel, which is offset from a center of the average circumference of the fly wheel and/or otherwise whereby the center of mass is offset from the center of rotation of the fly wheel.
In one possible embodiment, a propulsion generator may comprise a shaft for the fly wheel centrally positioned with respect to the average circumference of the fly wheel. The bearings may comprise an inner bearing and an outer bearing, the outer bearing may comprise a circular outer circumference, and the inner bearing may support the shaft such that a center of the shaft is offset from a center of the circular circumference.
In another embodiment, a propulsion generator may comprise a shaft for a fly wheel, which comprises a cylindrical shaft with centrally positioned axis. In this embodiment, the shaft axis may be positioned offset from a center of an average radius and/or average circumference of the fly wheel and/or center of mass of the fly wheel.
A propulsion generator may comprise a timing wheel which is mounted within the outer tubular housing whereby a center of mass of the timing wheel and a center of rotation of the timing wheel are coincident.
In another embodiment of the invention, a method for making a propulsion generator may comprise steps such as, but not limited to, providing an outer tubular housing for the downhole tool, providing that the outer tubular housing defines a fluid flow path through the tubular housing to permit fluid flow there through, providing at least one fly wheel within the outer tubular housing with a center of mass.
Other steps may comprise providing that the fly wheel receives energy for rotation in response to fluid flow through the fluid flow path and providing that the mounting for the at least one fly wheel controls a center of rotation of the fly wheel. The center of mass of the fly wheel is offset from the center of rotation, which results in vibrations being created during rotation of the at least one fly wheel.
The method may further comprise providing a first fly wheel housing for a first fly wheel, providing a second fly wheel housing for mounting a second fly wheel, and/or providing that a center of mass for the second fly wheel is different from a center of mass of the second fly wheel. Other steps may comprise providing that the second fly wheel receives energy for rotation in response to fluid flow through the fluid flow path.
The method may further comprise utilizing connectors operable for mounting the first fly wheel housing and the second fly wheel housing at different orientations with respect to each other whereby the at least one fly wheel is selectively oriented the same or differently from the at least one second fly wheel housing.
The method may further comprise providing bearings to produce a center of rotation of the at least one fly wheel which is offset from a center of an average circumference of the at least one fly wheel.
The method may further comprise utilizing a shaft for the one fly wheel which is centrally positioned within or at the center of mass of the fly wheel and/or with respect to an average circumference of the fly wheel, and further utilizing an inner bearing and an outer bearing wherein the outer bearing comprises a circular circumference. In this embodiment, the inner bearing supports the shaft such that a center of the shaft is offset from a center of the circular circumference.
Another method may comprise utilizing a shaft for a fly wheel which is positioned at a position offset from a center of the fly wheel with respect to an average outer circumference and/or center of mass of the fly wheel.
In another embodiment, a method may comprise utilizing a second wheel which may comprise a plurality of fins that are positioned to engage fluid flow through the fluid flow path, and providing that a center of mass of the second wheel coincides with a center of rotation of the second wheel thus controlling, timing, averaging, smoothing, delaying, or other affecting the fluid flow through the propulsion generator.
In one possible embodiment, a method may comprise that the propulsion generator is constructed so that that the amount of variation of instantaneous fluid flow through any cross-section of a fluid flow path leading to or away from the fly wheel does not vary by more than 30% than an average fluid flow through the same cross-section of the fluid flow path.
In yet another embodiment, a propulsion generator may comprise one or more elements such as, but no limited to, a first fly wheel housing mounted to the string of pipe, a second fly wheel housing mounted to the string of pipe, a first fly wheel mounted in the first fly wheel housing, a second fly wheel mounted in the second fly wheel housing.
A first mounting for the first fly wheel may be utilized that controls or constrains or supports a center of rotation of first fly wheel, whereby the center of mass of the first fly wheel is offset from the center of rotation, which results in vibrations being created during rotation of the first fly wheel.
A second mounting for the second fly wheel may be utilized that controls a center of rotation of the second fly wheel, whereby the center of mass of the second fly wheel is offset from the center of rotation, which results in vibrations being created during rotation of the first second fly wheel.
In one embodiment, the first fly wheel housing and the second fly wheel housing define a fluid flow path through the the first fly wheel housing and the second fly wheel housing.
The propulsion generator may further comprise a third housing mounted to the string of pipe, a third wheel within the third wheel housing, a third wheel mounting for the third wheel which controls a center of rotation of the third wheel, whereby the center of mass of the third wheel coincides with the center of rotation of the third wheel, which may be a timing wheel as discussed herein and/or another fly wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention and many of the attendant advantages thereto will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts and wherein:
FIG. 1 is a side elevational view, partially in section, which discloses a multiple section propulsion tool in accord with one possible embodiment of the invention;
FIG. 2A is an enlarged front elevational view, partially in section, of a single fly wheel section from the propulsion tool of FIG. 1 , in accord with one possible embodiment of the invention;
FIG. 2B is an enlarged side elevational view, partially in section, taken along lines B-B of FIG. 2A , in accord with one possible embodiment of the invention;
FIG. 3A is a schematic showing a coiled tubing unit having a pipe string and bottom hole assembly within a angled wellbore in accord with one possible embodiment of the present invention;
FIG. 3B is a sectional view, showing drill pipe or coiled tubing spiraled, coiled, or otherwise compressed within a well bore and/or casing;
FIG. 4 is a side elevational view of a fly wheel in accord with one possible embodiment of the present invention;
FIG. 5 is another perspective view of the fly wheel of FIG. 4 in accord with one possible embodiment of the invention;
FIG. 6 is a front elevational view of the fly wheel of FIG. 4 in accord with one possible embodiment of the present invention;
FIG. 7 is an enlarged side elevational view of a timing wheel section from FIG. 1 in accord with one possible embodiment of the present invention;
FIG. 8 is a side elevational view of a timing wheel in accord with one possible embodiment of the present invention; and
FIG. 9 is a perspective view of the timing wheel of FIG. 8 in accord with one possible embodiment of the present invention.
FIG. 10 is a front elevational view of a timing wheel section from FIG. 8 in accord with one possible embodiment of the present invention;
FIG. 11 is a solid bearing inner race with offset for use with a fly wheel in accord with one embodiment of the invention; and
FIG. 12 shows a sine wave of vibrational motion amplitude versus time in accord with one possible embodiment of the present invention.
FIG. 13 shows the path of movement of a fly wheel in accord with one possible embodiment of the invention.
FIG. 14 shows jet flow path in free surroundings.
FIG. 15 shows jet flow path attached to an adjacent surface.
FIG. 16 shows jet flow path attached to a curved surface.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly to FIG. 3A , there is shown drilling system 100 , which in this embodiment comprises coiled tubing unit 102 . However, the present invention may be utilized with other types of drilling systems and/or workover systems including rotary drilling systems and the like. The present invention is especially useful for providing propulsion to coil tubing units because the coil tubing cannot be rotated.
In this embodiment, tubular string 104 goes into wellbore 106 and includes bottom hole assembly 108 . As discussed earlier, due to the high angle wellbore portion as indicated at 116 , or horizontal wellbore portion as indicated at 118 , and/or other factors, bottom hole assembly 108 may no longer be readily movable outwardly to a greater depth. It will be noted that depth as used herein may include not only vertical depth but also distance of a more extended range, either vertical or horizontal or therebetween of length of pipe within the borehole. If tubular string 104 is being used for drilling, and includes a drill bit 110 , then drilling may have effectively stopped due to the inability to move bottom hole assembly 108 deeper or more laterally. It will also be appreciated by one of skill that the tubular string is more susceptible to becoming stuck in the wellbore due to these conditions for many reasons including but not limited to differential sticking, tight portions of the bore hole, expanding formations in contact with drilling fluids, and the like. Propulsion tool 10 of the present invention may be incorporated or connected into bottom assembly 108 , which is at a lower end of pipe 104 , as shown in FIG. 3A to provide propulsion or movement of greater depth to drill string 104 and drill bit 110 and/or for removing or partially withdrawing drill string 104 from borehole 106 .
FIG. 3B shows tubular string 104 spiraled, coiled, and/or compressed within wellbore 106 . The added friction of increased contact between the tubular string and the wellbore wall increases the likelihood of sticking or difficulty in moving the bottom hole assembly downward.
Tubing drilling or workover system 100 may also comprise riser pipe or lubricator 112 and well head valve 114 , which would allow bottom hole assembly 108 to be pulled into lubricator 112 , and valve 114 closed, so that if wellbore 106 is under pressure or potentially under pressure, then the entire assembly could be removed under pressure, if desired. Another advantage of propulsion tool 10 of the present invention is a relatively short length so that bottom hole assembly 108 , propulsion tool 10 and bit 110 may fit within the limitations of the length of lubricator 112 . It will be understood that there are often significant practical limitations to the length of lubricator or riser pipe 112 .
Bottom hole assembly 108 may comprise a mud motor for rotating drill bit 110 and/or other components. In a preferred embodiment of the present invention, propulsion tool 10 is mounted in bottom hole assembly 108 and can be operated by drilling mud, mud co-mingled with nitrogen, any suitable combination of gas or air or drilling mud or fluids, and the like used for drilling, which are referred to herein collectively as drilling fluid. If desired, the drilling fluids can even be changed during drilling, e.g., changing from air and/or other gasses to water and/or other liquids as the drilling fluid. Typically, as discussed hereinafter, the drilling fluid flows through the bottom hole assembly and is recirculated back up wellbore 106 outside of tubing string 104 . Accordingly, tool 10 may, if desired, be continuously powered by continuously flowing recirculated drilling fluid flow.
As another feature, fluid flow through the tool is never completely shut off. Thus, fly wheels 36 and/or timing wheel 70 are positioned such that if these wheels freeze up or otherwise fail, then circulation through tool 10 is not lost. Moreover, during operation fluid flow through tool 10 remains substantially constant.
This feature of the tool provides significant advantages. For example, if the drill string is still advancing, then drilling might continue. This feature causes less problems for drilling motors and turbines in bottom hole assembly 108 . As well, because circulation can be maintained, the drilling string may be removed more easily and/or the mud can be changed for pressure control, and the like. Circulation is normally an important factor for keeping a well bore from being damaged and the present propulsion tool, in a presently preferred embodiment, is designed so that the tool does not shut off fluid flow through the drill string at any time. Moreover, circulation fluid flow through tool is substantially constant.
In other words, instantaneous velocity of fluid and/or instantaneous amount of fluid flowing as compared to average velocity and/or instantaneous amount of fluid flow through any particular cross-section of the fluid flow path entering or leaving fly wheel 36 or timing wheel 70 during normal operation does not vary by more than 50%, and may vary less than 40%, or less than 30%, or less than 20%, or less than 10%. More specifically, the variation in instantaneous velocity of fluid and/or instantaneous amount of fluid flow as compared to average velocity or amount of fluid through reduced diameter passageways, such as passageway 28 entering fly wheel 28 or passageway 76 directly prior to entering timing wheel 70 is relatively small, such as less than a variation of 30%, or less than 20%, or less than 10%, or less than 5%. Timing wheel 70 may be utilized to provide a delay or accumulator effect so that the fluid flow through tool 10 is relatively continuous so as to provide even less disruption to mud motors or turbines within bottom hole assembly 108 .
Referring now to FIG. 1 , there is shown multiple section propulsion tool 10 , in accord with one possible embodiment of the present invention. In this embodiment, tool 10 comprises three gyro harmonic oscillation wheel sections 12 , 14 , and 16 . It will be noted that the frequencies of operation may or may not include selected harmonic frequencies although the effects of tool operation can be more pronounced at those frequencies and/or resonance frequencies, as discussed hereinafter.
Propulsion tool 10 may also comprise at least one timing wheel section 18 . Gyro harmonic oscillation wheel sections 12 , 14 , 16 , and timing wheel section 18 are mounted within tubular housing 20 . Sections 12 , 14 , 16 , and 18 are bolted together and can be rotationally oriented with respect to each other at different selectable angles with respect to each other although in this embodiment each section is angularly oriented the same. Top sub 21 and bottom sub 23 secure the sections within tubular housing 20 , connect with the coiled tubing, drill pipe, or the like, and direct drilling fluid flow through sections 12 , 14 , 16 and 18 . The housings for each section 12 , 14 , 16 , and 18 may be substantially the same for advantageously reducing manufacturing costs, providing redundancy for quick repair, and so forth.
Drilling fluid is pumped or recirculated through the tubing or coiled tubing to the bottom hole assembly, as discussed hereinbefore. Drilling fluid enters tool 10 as indicated by arrow 22 and exits tool 10 as indicated by arrow 24 . The fluid path components comprise chambers interconnected with tubulars, which are shaped to provide a laminar style flow through tool 10 entering the fly wheels 36 and/or timing wheel 70 , which reduces turbulence for smoother operation. Chamber 26 may comprise a dome structure 27 and/or inverted dome structure 29 (See FIG. 2B ) that imparts a swirl to the drilling fluid whereby the drilling fluid enters tubular 28 , which leads to gyro harmonic oscillation wheel 36 , which may also be referred to as fly wheel 36 herein. Fluting or the like (not shown) within the dome structures might also be utilized to direct and/or swirl the fluid.
After passing by fly wheel 36 , the fluid output flow out of gyro harmonic wheel section 12 may preferably go through expansion chamber 30 , which provides reduced back pressure for more efficient fluid flow past fly wheel 36 and then swirling or laminar flow through reduced diameter tubular 32 shown in FIG. 1 , which focuses the drilling fluid onto the next gyro harmonic wheel to increase energy transfer to fly wheels 36 from the fluid flow while maintaining a relatively constant fluid flow through tool 10 to protect drilling motors and/or turbines in bottom hole assembly 108 as discussed hereinbefore. This type of fluid flow passageway profile may be repeated for each section 12 , 14 , 16 and, if desired, also timing section 18 . There may be more or fewer sections as desired, as discussed in more detail hereinafter.
Referring to FIG. 2A and FIG. 2B , there is shown gyro harmonic wheel section 12 , which may be representative of sections 12 , 14 and 16 . While the present drawings are not intended to manufacturing level drawings, and there may be differences with the manufactured versions of propulsion tool 10 , in one embodiment, the gyro harmonic wheel sections may advantageously be identical to each other for reasons such as those discussed hereinbefore. Any desired number of gyro harmonic wheel sections may be utilized in tool 10 . The gyro harmonic wheel sections are conveniently mounted to each other with any number of fasteners, guides, or connectors such as connectors 34 . Because the fluid flow lines will match up regardless of orientation, sections 12 , 14 , 16 and 18 can be rotated to a desired orientation with respect to each other. For example, a fly wheel in one section may be parallel to, at right angles with, upside down, or otherwise oriented with respect to a fly wheel or timing wheel in another section. Other mounting and orientation means, such as screws, clamps, or the like, may be provided as desired for angularly orienting the sections with respect to each other to increase the number of possible orientations.
Referring to FIG. 2A , fly wheel 36 oscillates or moves, as discussed in detail hereinafter, in response to rotation as indicated by solid and dashed lines representing fly wheel 36 , which solid and dashed lines may be exaggerated in the drawing for effect.
Fly wheel 36 (which may sometimes also be referred to herein as a gyro wheel) is representative of the other fly wheels used in the gyro harmonic wheel sections 12 , 14 , and 16 , and/or other harmonic wheel sections. However, different sized or mounted fly wheels may be utilized, if desired. In one embodiment, fly wheel 36 is preferably mounted off the center line of tool 10 and is preferably decentralized within fly wheel chamber 38 . In a presently preferred embodiment, the center of mass of the fly wheel may be offset from the center of rotation of the fly wheel by various means some of which are discussed herein so that the fly wheel produces vibration. However, the various means for producing vibration are not limited to those discussed herein. Fly wheel chamber 38 is preferably cylindrical as shown in FIG. 7 , which shows fly wheel 36 removed wherein one possible outer roller bearing assembly 58 is disclosed. In this embodiment, bearing assembly 58 comprises one or more circular outer bearing members or races 59 , which comprise a circular circumference that mounts within an interior and/or end portions of cylindrical fly wheel chamber 38 .
Fly wheel 36 has an outermost diameter that may, in one embodiment, be about 80-90 percent of the circumference of cylindrical fly wheel chamber 38 . The fly wheel chamber may typically have a diameter 40-75% or typically 55-65% of the tool diameter. Fly wheel 36 has a thickness of 10% to 30% of tool 10 . The invention is not limited to this particular arrangement but is presently preferred. Furthermore in this embodiment, fly wheel 36 is preferably offset within wheel chamber 38 . The size/mass of fly wheel 36 , typically comprised of steel, produces a gyroscopic effect during rotational operation of fly wheel 36 , which may enhance propulsion produced by tool 10 .
As discussed herein, the fly wheel may be mounted so that the center of mass is offset from the center of rotation by various means including an offset mounted shaft and/or offset bearing mountings and/or offset mounted weights. In FIG. 2B , outermost surface or outermost circumference 40 of fly wheel 36 is positioned more closely to wall 42 of fly wheel chamber 38 adjacent fluid inlet 28 . Outer surface or circumference 40 of fly wheel 36 may have a greater offset from wall 42 of fly wheel chamber 38 adjacent outlet 30 for maximizing the fluid flow force through the housing and minimizing back pressure.
Referring to FIG. 2A , FIG. 2B , FIG. 4 , and/or FIG. 11 , in one possible embodiment, the offset mounting of flywheel 36 , as discussed herein, will cause the clearance between wall 42 and outermost circumference 40 of flywheel 36 to change repetitively during rotation of flywheel 36 . In this embodiment, the change in clearance will change the fluid flow velocity and energy received by flywheel 36 . Accordingly, in this embodiment, flywheel 36 can be made to vary and/or repetitively change and/or continuously change in rotational speed and/or acceleration, speeding up and slowing down. The speed and/or the acceleration change due to this effect may be substantially repetitive and/or variable and/or continuous during each rotation of flywheel 36 . The change in fluid velocity and energy received by flywheel 36 may be quite large depending on the change in clearance with respect to wall 42 . For example, for a small minimum clearance, the change from minimum to maximum clearance might easily be, for example only, a factor of 100 to 1000. The mass of a flywheel, the amount of change in clearance with respect to wall 42 , the types of fins, the type of drilling fluid, and other factors such as these can be utilized to create a desired amount of continuously and/or repetitively varying speed and/or varying acceleration of rotational speed of one or more flywheels 36 in propulsion tool 10 .
The mounting of fly wheel 36 may also be offset from the centerline of tool 10 , which is the axis of tubular housing 20 . The offsets may be in the range of 0.005 to 0.5. For example, for a particular coiled tubing size, the offset might be 70 thousandth of an inch. However, this offset can be changed as desired. In one embodiment, this offset may be changed by simply changing the bearings. Offsets may be changed in increments of one thousandths, two-thousandths, five-thousands, ten-thousandths or the like as desired. The offset for a particular design may be in a range of plus or minus one thousandths, two-thousandths, five-thousands, ten-thousandths, or the like as desired.
In accord with various embodiments of the present invention, offsets may be created in different ways. In one embodiment, perhaps best shown in FIG. 4 , it will be seen that shaft 54 , which is cylindrical, is offset with respect to the average outer circumference or average radius of fly wheel 36 , whereby the actual center point of mass and/or center of the average circumference of fly wheel 36 is shown at 70 . However, the center point of cylindrical shaft 54 is at 72 . The center of mass of cylindrical shaft 54 , in this example is also at 72 and assumes a uniform shaft. In this embodiment, the center of shaft 54 is offset from the center point and also the center of gravity or mass of fly wheel 36 . In other words, shaft 54 is mounted by the bearings 58 (shown in FIG. 7 ) to fly wheel 36 at a position offset from the center 70 of mass and/or center of average radius or average circumference of fly wheel 36 . In this embodiment, but not in other embodiments discussed hereinafter, the center point of the bearings will be at or along the center point of the housings and tool 10 axial line, as shown in FIG. 7 at center point 80 (shown in FIG. 7 ) which coincides with tool 20 center line 82 . In one embodiment, centerpoint 72 may or may not coincide with centerpoint 80 , depending on the selectably desired positioning of flywheel 36 within chamber 38 , which was also discussed hereinbefore.
However, offsets that may be utilized to create vibrations during rotation of flywheel 36 , in accord with other embodiment of the present invention, may be created in other ways. As one example, an offset may be created using the bearing mountings rather than an offset flywheel shaft 54 . For example, in FIG. 11 , inner race 98 may be utilized with a solid bearing for mounting shaft 54 of fly wheel 36 . In this example, cylindrical shaft 54 may be centralized on fly wheel 36 so that the center of mass of fly wheel 36 and shaft 54 coincide with the physical center of shaft 54 at 92 . Outer circumference (race) 96 of inner bearing 90 engages the outer bearing race which may be of various types (see for example roller/ball/frictionless bearings 58 in FIG. 7 ).
Referring again to FIG. 11 , it will be seen that round circumference (race) 98 within inner bearing 90 (which contains cylindrical shaft 54 ) is not mounted concentrically with respect to outer circumference (race) 96 of inner bearing 90 . Instead, the center of inner bearing 90 is at 94 . (These distances may be shown exaggerated in FIG. 11 for illustration purposes). Accordingly, outer bearing 58 (which may or may not be solid, roller, ball, frictionless or the like), and the circumference (race) 59 of outer bearing may or may not be centered or concentric around the center point 80 of the housing and/or as shown in FIG. 7 . However, regardless, shaft 54 and fly wheel 36 will be offset due to the offset location of circumference (race) 98 within inner bearing with respect to the center of mass being offset from the center of rotation of fly wheel 36 . Conceivably, the offset could also be formed in the outer bearing instead of the inner bearing and/or in both the inner and outer bearings. Suitable cylindrical support is insertable and/or machined within housing 56 for the bearing configuration of choice.
Other means of providing offsets of mass with respect to the center of mass of fly wheel 36 could also be utilized whereby the center of mass of the fly wheel is offset from the center of rotation to produce vibration as the fly wheel rotates. Moreover, by simply changing inner and/or outer bearing members, the position of circumference 98 (race) (which contains shaft 54 ) within inner bearing 90 , the offset may be changed making it possible to relatively easily vary the desired offset as desired, without any significant machining. It will also be noted that shaft 54 and the interior of inner bearing (race) 96 need not be cylindrical but could be shaped otherwise to mate with and secure shaft 54 within inner bearing (race) 96 .
In yet another possible embodiment, it will be appreciated that weights 44 (See FIGS. 4 and 5 ) and/or additional weights, and/or the absence of weights, and/or other offset features will change the center of mass of fly wheel 36 whereby fly wheel 36 may be mounted centered or not, while still producing vibrations due to a center of mass offset from a center of rotation. For example, all bearings could be centralized, the shaft centralized, so that without the weight, then center of mass would coincide with the center of rotation. However, with weights 44 added (or material removed), then the mass will be offset from the center of rotation to create vibration. Weights may also be added to an already offset mass configuration. Accordingly, it will be appreciated that offset weights 44 (see e.g. FIG. 4 ), if used, may be utilized to create and/or augment vibrations. Thus, bearings may be changed, weights may be changed, physical elements of the fly wheel may be changed, and/or other changes made to offset the center of mass with respect to the center of rotation of fly wheel 36 in accord with one possible embodiment of the present invention.
In the above-described embodiment, weights 44 are offset by a distance of 30% to 70% of the radius of fly wheel 36 from fly wheel center of mass 70 . The mass and radial position may be utilized to increase or decrease vibrational motion amplitude. In this embodiment, it will be seen that two weights 44 are provided, whose effective mass center is in line with the offset of shaft 54 , as indicated by line 74 . Accordingly, the vibrational force of weights 44 (if used) will be synchronized with the vibrational force due to the offset shaft 54 . Accordingly, various types of center of mass/center of rotation offsets may be utilized to create the desired vibrations of the present invention by moving the center of mass with respect to the center of rotation.
This construction creates vibration or oscillation in each gyro harmonic wheel section as each fly wheel 36 rotates. The vibration or oscillation movement in tool 10 versus time can, in one possible embodiment, be described as a sine wave, such as the sine wave of FIG. 12 , wherein at least one of amplitude, frequency, and wavelength can be varied by changing the wheel center mounting offset from the axis of tool 10 and/or offset in the individual housing and/or the number of teeth in fly wheel 36 and/or changing the weights 44 and/or by changing the relative position of fly wheel 36 within fly wheel chamber 30 and/or changing the fluid flow rate and/or mud weight and viscosity and/or by adjusting the timing wheel 70 , as discussed hereinafter. Weights 44 may be made heavier are lighter or removed, if desired. During operation, the frequency may also be changed by altering the drilling fluid flow rate, which is controlled from the surface.
In another embodiment, if desired, the frequency may be adjusted so as to be resonant or harmonic with respect to the drill pipe coiled tubing. The resonant frequency may be chosen based on the size and/or type of drilling pipe. A system as a whole may have a harmonic frequency at which it would oscillate if energy were applied. At the resonant frequency the drill pipe (or some portion of the drill pipe) may be induced to vibrate considerably more strongly than would occur if the frequency were off the resonant frequency. However, the tool is operable over a wide range of frequencies and harmonic and/or resonant frequency operation is not required for tool operation but may be selectively utilized as yet another means for increasing/decreasing propulsion effects of tool 10 .
When a semi-elastic body is subjected to axial strain, as in the stretching of a length of pipe, the diameter of the pipe will contract. When the pipe is under compression, the diameter will expand. Since a length of pipe is subjected to vibration, it will also experience alternate tensile and compressive waves along the longitudinal axis of the pipe. This can result in the pipe momentarily being free during the undulations of the pipe. The surrounding bonded area at the point of contact with the pipe is also subjected to the undulating waves, thereby momentarily reducing the differential sticking pressure of the formation to the pipe. Another factor in reducing stuck tubular situations is acceleration of the pipe. A vibration stroke of only one inch will greatly enhance the reduction of friction along the entire tubular length of the drill pipe. Moreover, in conjunction with tension applied by reel 102 , rotational force of bit 110 , variation in pump flow, and operation of tool 10 , heavy weight sections where used in the pipe, overall pipe weight, jars, and/or other means, the pipe may be moved either downwardly or upwardly as desired.
One possible embodiment of fly wheel 36 is shown enlarged in various views in FIG. 4 , FIG. 5 , and FIG. 6 . Fly wheel 36 is rotated in response to drilling fluid flow as discussed above and produces a gyroscopic effect due to the rotation. The gyroscopic effect and vibration created by fly wheel operation have been found to not only resist sticking but also provide propulsion of the bit even in high angle holes. While the center of mass of fly wheel 36 is moved away from the center line of tool 20 , fly wheel 36 is preferably symmetrical so that the gyroscopic effect is more focused. It is believed that these factors, along with the inherent weight of the bottom hole assembly (assuming at least some angle of the bore hole), and/or other factors discussed herein, can be especially significant in moving the drilling bit downward, upward, forward, laterally, and/or the like.
To maximize the gyroscopic effect, the fly wheel dimensions may be matched to the coiled tubing size so that the fly wheel may have a diameter of 40% to 80% of the internal diameter (ID) of the tubing and may preferably be in a range of 60% to 70% of the pipe ID. The width may be in the range of 5% to 40% and may be preferably 10% to 20%, while keeping the shaft sized for reliable mounting. Shaft 54 diameter may be in the range of 20% to 40% of the fly wheel diameter and may have a length of 70% to 120% of the fly wheel diameter. Fly wheel 36 may comprise steel or may comprise heavier materials or components or weights, if desired.
It will also be noted that the fly wheels in different sections may be the same or may be different, such as by the number of teeth 46 , the outer diameter, the offset, or dimensions or features discussed hereinbefore.
Referring to the possible embodiments shown in FIG. 2B and/or FIG. 4 , teeth 46 have a contour of the outer radius, which largely coincides with the radius of the circumference of the circle that defines the outer boundaries of fly wheel 36 . Each tooth has a width, which may act to trap fluid and transfer fluid energy to fly wheel 36 as the wheel rotates. A pocket 48 is formed between teeth that is designed and oriented to catch and momentarily trap the drilling fluid and the force of drilling fluid flow. Accordingly, wall 58 is sloping more gradually, and in this embodiment is longer that wall 52 with respect to the minimum radius of the fly wheel at the bottom of pocket 48 so that when fly wheel 36 is oriented so that the force of fluid is applied to wall 52 , then more energy is received from the fluid that would be the case if fly wheel 36 were otherwise oriented. In one embodiment, the depth of pocket 48 may be about 10% to 30% of the radius of fly wheel 36 . The depth of pocket 48 also affects the amount of energy recovered from the flow of drilling fluid whereby a deeper pocket tends to absorb a greater amount of energy.
While this embodiment has teeth extending outwardly along the periphery of fly wheel 36 other embodiments may locate fins or teeth on the sides of the wheels positioned within the periphery, with a change in the flow path to engage the teeth or fins. The size and shape of fins will affect the speed of rotation. There could be radial flow paths formed within the fly wheel that are fed from a position interior to the fly wheel. In yet another possible embodiment, fly wheel 37 might have no teeth and operate on friction between the liquid and the fly wheel. Accordingly, the fly wheel may be powered by the drilling fluid in many different ways.
As discussed previously, the fly wheels may be positioned so as to rotate at different angles with respect to each other, thereby providing a gyroscopic effect in different directions. In other words the fly wheels have an axis of rotation that would extend radially with respect to the tubular housing and each fly wheel axis would be angled differently. The fly wheels may be mounted perpendicular and/or at any desired orientation.
Another advantage of the gyroscopic effect is to reduce wandering or other undesired movement of the bottom hole assembly. The gyroscopic effect may reduce the reverse torsional oscillations of the drill string as well, and be effective to reduce slip stick thereby resulting in drill bits that last longer and/or faster drilling rates and/or a smoother borehole, which allows casing to be run more easily. The type of gyroscopic movement will affect the vibration and may limit the vibration in selected directions, if desired. However, in one preferred embodiment sinusoid vibrations are produced in both axial and radial directions with respect to the axis of tubular housing 20 .
Accordingly, fly wheel 36 is mounted or formed on shaft 54 , which is then mounted within sockets and/or bearings of chamber 26 gyro harmonic wheel sections 12 , 14 , and 16 . The bearings may be of different types.
FIG. 7 shows a representative housing 56 that may be utilized for mounting fly wheel 36 and/or a timing wheel, as discussed hereinafter. Within the chamber of housing 56 , in this embodiment, are sealed frictionless roller bearings 58 (which may also be ball bearings/solid bearings/or other types of bearings) that may be utilized to support fly wheel 36 and/or a timing wheel. It will be noted that a different sized chamber can be used in the timing wheel section 18 , which is shown in FIG. 1 . The fluid flow path is indicated by arrows 60 , 62 , and 64 . As discussed, hereinbefore, the flow path is designed to maintain a laminar flow leading to fly wheel 36 , that reduces turbulent flow, increases energy transfer, and the like as discussed previously. Within the chamber, the wheels tend to push the fluid radially outwardly to act as radial flow turbines.
Another embodiment of tool 10 may or may not also utilize one or more timing sections, such as timing section 18 , shown in FIG. 1 . Timing wheel section 18 comprises timing wheel 70 , also shown enlarged in FIGS. 8, 10, and 11 . Unlike the fly wheels discussed hereinbefore, timing wheel 70 is preferably centralized within cylindrical chamber 72 (See FIG. 1 ) and has a maximum radius that is slightly smaller than the radius of cylindrical chamber 72 . Accordingly, shaft 73 is centered on timing wheel 70 so that the center of mass of timing wheel 70 preferably coincides with the center of rotation. However, the timing wheel could be offset from the tool centerline and/or have an offset mounting or the like as discussed above with respect to fly wheel 36 .
Timing wheel 70 creates pressure or timing pulses within the tubing of coiled tubing due to drilling fluid flow therethrough. In this embodiment, the radius of timing wheel 70 is about 50% to 70% as large as that of the fly wheels but may be larger or smaller as desired. For that matter, as discussed above, the fly wheels may have different sizes and/or offsets, if desired.
In one presently preferred embodiment, the timing wheel does not completely shut off drilling fluid flow. Completely starting and stopping fluid flow may cause problems in the mud motor for rotating the bit and/or other problems. Instead, in a presently preferred embodiment, as discussed previously, the fluid flow pulses but does not shut off completely. If desired, the tolerances of the timing wheel can be increased or decreased to increase or decrease the pulse amplitude (maximum fluid flow rate or maximum drilling fluid pressure) relative to the minimum flow rate or minimum pressure. The tolerances between timing wheel outer circumference 71 and the housing inner circumference may be decreased to increase the minimum flow rates and reduce the pulse amplitudes.
Accordingly, timing wheel 70 restricts or times the fluid flow by some amount and may have resistance to further increase the pulse amplitude. The number of teeth or cogs 74 and/or the width of each cog, may be altered to change the frequency range of the timing section 18 .
Timing wheel 70 also effects the fly wheels because the fluid pulses produced by timing wheel 70 , the pulse width, and the frequency will limit or control the vibrations created by the fly wheels. During the time that the width of each cog 74 is in the flow path inlet 76 , the build up of vibrational speed in the fly wheels is reduced. Accordingly, timing wheel 70 can also be used to further control the period or wavelength of the vibrations and/or the frequency based on the fluid flow allowed.
As well, as discussed hereinbefore, timing wheel 70 may be utilized to smooth the flow of fluid through tool 10 thereby providing better operation of the drilling motor or turbine for rotating bit 110 , as discussed hereinbefore.
As discussed previously with respect to the fly wheels, the flow rate of the drilling fluid, which can be varied from the surface, and the number of teeth 74 , as well as resistances, weights, the depth of each socket 75 , and the like affect the rotational speed and pulse rate of timing wheel 70 . Timing 70 may be mounted in a way that resistance to rotation is provided or may be mounted for freely rotating.
Accordingly, in operation, tool 10 is mounted to the bottom hole assembly 108 as shown in FIG. 3 . While drilling may be the purpose of introducing tubing into the well, the tool 10 may also be used in downhole assemblies for cleaning scale out of tubulars, work over operations, milling, and/or for other purposes besides drilling through open hole. While preferably mounted in the bottom hole assembly, tool 10 could actually be mounted elsewhere in the drill string if desired. Multiple tools such as tool 10 may be utilized.
During operation, oscillatory harmonic timed tool 10 produces a longitudinal wave action, which is believed to produce an inch worm type of movement that results in an observed downward movement of the drilling string in response to operation of tool 10 either downwardly with the weight of the drilling string or upwardly with upward tension applied to the drill string. This movement may be created with or without use of the timer wheel. This movement may normally be directed downhole due to the weight of the string inching downwardly. Other factors some of which are discussed below has resulted in movement upwardly as upward tension is applied.
In one possible embodiment, the present invention may utilize what is sometimes called the Coanda effect to change direction of our longitudinal movement of our tool. The Coanda effect occurs when jet flow attaches itself to a nearby surface and remains attached even when the surface curves away from the initial jet direction. In some cases, these principles may also involve a Tesla effect involving water surface tension and/or friction.
As shown in FIG. 14 , during free jet flow, in free surroundings, a jet of fluid entrains and mixes with its surroundings as it flows away from a nozzle.
In FIG. 15 , an example is shown of jet attachment to adjacent surface. In When a surface is brought close to the jet, this restricts the entrainment in that region. As flow accelerates to try to balance the momentum transfer, a pressure difference across the jet results and the jet is deflected closer to the surface—eventually attaching to it.
In FIG. 16 , the jet attaches to and turns with curved surface even if the surface is curved away from the initial direction, the jet tends to remain attached. This effect can be used to change the jet direction. In doing so, the rate at which the jet mixes is often significantly increased compared with that of a equivalent jet.
The above principles may be used in various embodiments to amplify and reverse the direction and amplitude of the resultant oscillations used in our tool design. There are many variations of the exact Coanda and/or Tesla effects being utilized in our tool. Accordingly, flow and/or weighted Gyro wheels, and/or borehole conditions may be utilized for the purpose of advancing and/or reversing and generally easier movement of the drilling string.
FIG. 13 shows the paths of motion 102 of various parts of one embodiment of one or more gyro or fly wheels 36 . This motion can produce multiple (e.g., four) vibrations during each revolution. In one embodiment, the desired vibrations may be produced in the range of from 100 HZ to 500 HZ, however other ranges of vibrations may also be produced. The vibrations may be longitudinal waves, oscillation, and/or harmonic motion.
Tool 10 is very short (less than 10 feet in a longer version, less than about 5 feet in the embodiment of FIG. 1 assuming about 4 inch pipe, and in a very short embodiment may be less than one or two feet) and therefore convenient for use in operations which have a lubricator or pressure control tubular 112 , as discussed above, at the surface with valves at the bottom to close in the well after the tool is removed from the well bore, whereupon any pressure in the lubricator may be bled off and the tool safely removed from a pressurized well bore.
Assuming tool 10 is utilized in the bottom hole assembly, drilling fluid is pumped into tool 10 as indicated by arrow 22 . The fluid is then focused through opening 28 onto fly wheel 36 . Opening 28 may have a width or circumference about the same said as the width of fly wheel 36 shown in FIG. 6 , and may be oval, elliptical, or the like. Because fly wheel 36 may be mounted with an offset center of mass, as discussed before, vibrations are created. A gyroscopic effect is also created by the spinning fly wheels. The fly wheels may be oriented differently with respect to each other so that the gyroscopic effect is provided in different planes. In other words, rotation in one plane may provide a different gyroscopic effect that rotation in two different planes. The timing wheel 70 will also be rotated, which will affect the amplitude, wavelength, and/or frequency of the vibrations created by the fly wheels. Tool 10 applies a sonic vibration into the drilling motor and bit resulting in a true sonic and/or vibration drill application.
Because the tool is preferably made all metal, including bearings, the temperature rating of the tool is above 500 degrees Fahrenheit. Therefore the tool may be utilized in geothermal operations, which are normally higher than 350 degrees Fahrenheit.
Various changes may be made within the concepts of the invention. For example, while fly wheel 36 is shown to be substantially circular or have an average circular radius, fly wheel 36 may be asymmetrically shaped, cam shaped, or otherwise shaped as desired. The fins may be utilized to operate other gears, which drive the fly wheel. In another embodiment, a mud motor may be utilized to supply electrical power to operate an electric motor for operation of fly wheel 36 and/or timing wheel 70 .
Accordingly, it will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention.
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A propulsion generator which employs one or more unbalanced rotors, such as fly wheels or other unbalance rotating members, which can be connected at a lower portion of a downhole coiled tubing string or other downhole tubular string for inducing propulsion of the coiled tubing. The unbalanced rotors may be oriented at different positions with respect to each other. The instantaneous fluid flow through the propulsion generator is substantially equivalent to the average fluid flow rate through the tool to provide relatively consistent fluid flow to downhole motors below the propulsion generator for operating the drill bit and/or cutters.
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BACKGROUND
[0001] The present invention relates to a nozzle for fastening a material layer to a sub-structure, comprising a plate and a hollow shaft integrally formed thereon for receiving a fastening screw, a stepped hole being provided in the hollow shaft, the stepped hole comprising at least two steps between at least three regions, the hollow shaft being formed so as to taper conically at least in part on an outer surface, the hollow shaft being provided with radially expandable elements and the expandable elements being formed as axial grooves on the outside in the conically tapering part of the hollow shaft.
[0002] The present invention also relates to a fastening element for fastening a material layer to a sub-structure, wherein the fastening element is in two parts and comprises the nozzle according to the invention and a fastening screw.
[0003] One problem, which is often encountered in conjunction with building insulation, consists in fixing a material layer, for example insulating material and roofing membranes, to a sub-structure. In order to make it as easy as possible to mount an insulating material and a roofing membrane and to prevent any damage to the insulating material and/or the roofing membrane during mounting, fastening elements are usually used which comprise a nozzle and a screw which is adapted to the nozzle. Fastening elements and nozzles of this type are known from DE 296 18 959 U1, EP 0 600 284 A1 and EP 1 117 882 B1, for example.
[0004] E 35 00 084 A1 describes a fastening element comprising a plate and a short, integrally formed shaft. The shaft, which is designed to receive a fastening screw, comprises a stepped hole comprising a shoulder, which acts as a stop for the fastening screw in the mounted stated, and lips comprising sloping upper surfaces. In this way, a stepped holed having two steps is produced. Furthermore, longitudinal slots in the lower region of the shaft are also described, by means of which movable lips are provided on the lower shaft end which can be spread apart in a resilient manner when the fastening screw penetrates the shaft.
[0005] DE 10 2010 048 537 A1 describes a nozzle comprising a plate and a hollow shaft integrally formed thereon for receiving a fastening screw, a stepped hole being arranged in the hollow shaft, which hole has a total of four different radii. Furthermore, a length compensation element in the region of the shaft is described.
[0006] US 2012/0017529 A1 describes a nozzle comprising a plate and a hollow shaft integrally formed thereon, in which a fastening screw is received during mounting. Lips which can flexibly bend outwards and are separated from one another by grooves are arranged on the lower end of the shaft. Furthermore, projecting ribs are arranged inside the hollow shaft, which allow the nozzle to be used reliably together with fastening screws of different thicknesses.
[0007] DE 36 06 321 A1 describes an insulating-board dowel comprising a plate and a hollow shaft integrally formed thereon, which comprises radially projecting ribs on the inside and outside thereof, by means of which drilled-hole tolerances are compensated.
[0008] A drawback of some of the known fastening elements is in particular the need to use different screws which are adapted to the present sub-structure or to the weight of the insulating materials used. Therefore, a large number of different nozzles which are adapted to the screws and the insulating materials also have to be provided. Overall, a large number of different nozzles and fastening elements thus have to be produced and supplied in order for a sufficiently secure fastening to always be possible.
SUMMARY
[0009] The present invention makes it possible to simplify the production and supply of the nozzles and the fastening elements.
[0010] The problem addressed by the present invention is that of improving the stability of the universal nozzle independently of the fastening screw.
[0011] This problem is solved by one or more of the features of the invention.
[0012] Advantageous embodiments are provided below and in the claims.
[0013] The invention builds on the generic nozzle in that the grooves are each provided on the bottom thereof at least in part with a thin base which can be stretched or broken by the expansion. In particular when using a fastening screw which does not expand the narrowing portion, providing the base on the bottom of the grooves increases the stability of the universal nozzle at the end thereof which faces away from the plate, which end normally has to penetrate the material layer to be fastened, for example insulating material and roofing membranes. At the same time, despite the thin base on the bottom of the grooves, the deformation of the narrowing portion during expansion can be predetermined. The base on the bottom of the grooves is thin compared with the radial thickness of the adjoining, adjacent expandable elements. The base on the bottom of the grooves may for example be considered to be thin when the thickness thereof is less than a fifth of the thickness of the adjacent expandable elements. The thin base may furthermore have a thickness which remains constant over the groove width between two adjacent, adjoining expandable elements. When expanding the nozzle by means of the fastening screw, the base is either pulled apart, so that the thickness thereof decreases because the volume thereof remains the same, or is broken by the tensile forces applied because the resilience thereof is insufficient. The nozzle may, if required, that is to say depending on the material layer, for example insulating material or roofing membrane, or on the available sub-structure, be used together with different screws which are in particular of different sizes, that is to say of different diameters and/or different screw-head sizes. A single, universal nozzle can thus be used, and therefore there is no longer the need to produce and supply a large number of different nozzles. Each of the at least two regions may thus represent a centering/guidance for a fastening screw which can be used together with the nozzle and of which the diameter is equal to or greater than the diameter of the region. Irrespective thereof, each of the at least two steps may represent an axial stop for a screw head of a corresponding size.
[0014] It is provided that the hollow shaft is formed so as to taper conically at least in part on an outer surface. In this way, the nozzle can be caused to penetrate the material layer to be fastened in a particularly simple manner.
[0015] Furthermore, it is also provided that the hollow shaft is provided with radially expandable elements. The expandable elements promote the use of fastening screws of different sizes/thicknesses, that is to say fastening screws having a different diameter, in that controlled deformation of the universal nozzle is ensured when using a fastening screw having a diameter which is greater than the smallest diameter of the at least two regions.
[0016] It is also provided that the expandable elements are formed as axial grooves on the outside in the conically tapering part of the hollow shaft. By means of the axial grooves, the deformation of the universal nozzle can be particularly easily predetermined when using a fastening screw which expands the narrowing portion.
[0017] It may be provided that at least one of the at least three regions has a constant diameter. Owing to the diameter which remains constant over the region, improved guidance in the nozzle can be produced for fastening screws comprising corresponding threaded shafts of different thicknesses. In this case, a region could be conical; however, it could also have the at least three regions having different diameters which each remain constant.
[0018] Advantageously, it may be provided that the different diameters of the at least three regions which remain constant over the respective regions decrease starting from an end of the hollow shaft facing the plate. Owing to the diameter which decreases from region to region, different axial stops may be provided for different screws, which differ in particular in the size of the screw head which can be received, for a single universal nozzle. This makes it possible for the screws used to project out of the available sub-structure in a manner which is adapted in particular to the weight of the insulating material. Furthermore, guidance which is adapted to different diameters of the fastening screw may also be provided.
[0019] It may also be provided that at least one of the at least two steps is designed as an axial stop for the fastening screw. In this way, different defined end positions can be determined for different fastening screws which can be used together with the nozzle.
[0020] Furthermore, it may be provided that the material of which the nozzle is made has a lower strength than the fastening screw, and therefore the stepped hole can be expanded by the second fastening screw. In this way, it can be ensured that the fastening screw used is not damaged on the nozzle. Furthermore, the strength of the nozzle, which is lower than the fastening screw, can ensure the alternative use of fastening screws of different sizes together with the universal nozzle, since the hollow shaft can be prevented from breaking in the region of the stepped hole owing to the expandability.
[0021] Furthermore, it may be provided that the grooves are each open at the end thereof opposite the plate. This first makes it possible for the narrowing portion to deform during expansion and moreover makes it possible for the nozzle to be inserted into the insulating material, since, instead of a continuous ring, a plurality of small, that is to say “more pointed”, circular arc segments perforate the insulating material used independently of one another when inserted.
[0022] Usefully, it may be provided that the hollow shaft is provided, at the end thereof opposite the plate, at least with two diametrically opposed axial grooves as expandable elements. This is the simplest symmetrical arrangement of at least two grooves by means of which the expansion of the narrowing portion can be predetermined. Alternatively, it is of course also possible to provide additional grooves, which may be arranged on the end of the nozzle facing away from the plate so as to be substantially evenly spaced. For example, instead of two, there may also be three, four, five or six grooves which are evenly arranged around the end of the nozzle facing away from the plate. The various grooves may be of different axial lengths, which for example may be adapted to the positioning of the at least two regions. For example, different axial grooves may end at the axial height of different axial steps.
[0023] The fastening element according to the invention comprises a nozzle according to the invention and a fastening screw which is or can be received thereby and can be anchored in the sub-structure.
[0024] Advantageously, it may be provided that the screw has a thread-free shaft portion directly below the head.
[0025] Furthermore, it may be provided that the thread-free shaft portion of the fastening screw can be received in one of the at least three regions without radial play.
[0026] Usefully, it may be provided that the fastening screw which has been inserted into the nozzle is held without play in the pre-mounted state by at least one of the at least three regions and/or axially abuts one of the at least two steps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention is explained by way of example on the basis of preferred embodiments, with reference to the accompanying drawings, in which:
[0028] FIG. 1 is a sectional view through an embodiment of a nozzle;
[0029] FIG. 2 a is a three-dimensional external view of a hollow shaft;
[0030] FIG. 2 b is a three-dimensional external view of a further hollow shaft;
[0031] FIG. 3 is a sectional view of a hollow shaft comprising a pre-mounted fastening screw;
[0032] FIG. 4 is a detailed view of the sectional view from FIG. 3 ;
[0033] FIG. 5 is a further sectional view of a hollow shaft comprising a pre-mounted fastening screw;
[0034] FIG. 6 is a detailed view of the sectional view from FIG. 5 ;
[0035] FIG. 7 is a sectional view of a first embodiment of a hollow shaft;
[0036] FIG. 8 is a sectional view of a second embodiment of a hollow shaft;
[0037] FIG. 9 is a sectional view of a third embodiment of a hollow shaft;
[0038] FIG. 10 is a sectional view of a fourth embodiment of a hollow shaft;
[0039] FIG. 11 is a sectional view of a fifth embodiment of a hollow shaft; and
[0040] FIG. 12 is a sectional view of a sixth embodiment of a hollow shaft.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] In the drawings, identical reference numerals denote identical or similar parts.
[0042] FIG. 1 is a sectional view through an embodiment of a nozzle. The nozzle 10 shown in FIG. 1 comprises a hollow shaft 14 and a plate 12 which is integrally formed on the hollow shaft 14 . The hollow shaft 14 is open at the end thereof facing the plate 12 , so that, from this end of the hollow shaft 14 , a fastening screw can be inserted through the plate 12 into the hollow shaft 14 as far as a step 28 of a stepped hole 16 which is arranged at the other end of the hollow shaft 14 . The stepped hole 16 comprises a first region 18 and a second region 20 , the first region 18 having a smaller diameter than the second region 20 . The step 28 is arranged between the first region 18 and the second region 20 , which step is formed as an axial stop for a head of a screw to be inserted. A narrowing portion 30 may also optionally be attached to the first region 18 , which portion may represent an additional region. The narrowing portion 30 is for example attached to the first region 18 at the end of the hollow shaft 14 which faces away from the plate 12 . Grooves 40 may be arranged at the level of the narrowing portion 30 which allow the narrowing portion 30 to be expanded in a controlled manner. The grooves 40 may optionally also extend over additional regions and thus optionally also allow the nozzle 10 to be expanded in a controlled manner. The entire nozzle 10 may in particular be made of plastics material, in order for example to ensure the desired thermal insulation of the fastening screws and to produce a strength that is lower than that of the fastening screws and a greater deformability. The first region 18 thus provides screw centring, which in the optional narrowing portion 30 can be “reduced” again. The second region 20 may allow the head of an adapted fastening screw to freely rotate.
[0043] FIG. 2 a is a three-dimensional external view of a hollow shaft. The hollow shaft 14 shown in FIG. 2 a shows in particular grooves 40 on the conically tapering end of the hollow shaft 14 , which is arranged on the end of the hollow shaft 14 facing away from the plate 12 .
[0044] FIG. 2 b is a three-dimensional external view of an additional hollow shaft. The hollow shaft 14 shown in FIG. 2 b differs from the hollow shaft 14 shown in FIG. 2 a in particular by thin bases 42 which are arranged in the grooves 40 and can be stretched or broken during expansion of the narrowing portion.
[0045] FIG. 3 is a sectional view of a hollow shaft comprising a pre-mounted fastening screw. A first fastening screw 24 shown in FIG. 3 comprises a head 26 which abuts the step 28 between the first region 18 and the second region 20 in the axial direction. The first fastening screw 24 also comprises a first threaded shaft 22 and an optional, thread-free shaft portion 44 between the first threaded shaft 22 and the head 26 . The cooperation between the first fastening screw 24 and the hollow shaft 14 is shown in FIG. 4 .
[0046] FIG. 4 is a detailed view of the sectional view from FIG. 3 . As can be seen from FIG. 4 , the diameter of the thread-free shaft portion 44 corresponds to the diameter of the narrowing portion 30 , so that the first fastening screw 24 is guided by the optional narrowing portion 30 in a form-fitting manner. The portion of the first region 18 which does not belong to the narrowing portion 30 accordingly has a greater diameter than the optional, thread-free shaft portion 44 , so there is play here. As can be seen from FIG. 3 and to some extent from FIG. 4 , the first threaded shaft 22 of the first fastening screw 24 may have a greater diameter than the first optional, thread-free shaft portion 44 , so that the first fastening screw 24 can be retained so as not to be lost in the position shown in FIG. 3 which is relative to the hollow shaft 14 . This is also possible without the optional, first, thread-free shaft portion 44 . The first threaded shaft 22 may, when the first fastening screw 24 is pre-mounted on the nozzle 10 , for example resiliently deform the narrowing portion 30 in order to ensure that the first fastening screw 24 is fastened so as not to be lost.
[0047] FIG. 5 is a further sectional view of a hollow shaft comprising a pre-mounted fastening screw. The hollow shaft 14 shown in FIG. 5 substantially corresponds to the hollow shaft 14 which is already known from FIG. 3 . Instead of the first fastening screw 24 , however, a second fastening screw 34 is pre-mounted which in particular has a greater diameter than the first fastening screw 24 . The second fastening screw 34 comprises, similarly to the first fastening screw 24 , a head 48 and a second threaded shaft 32 , and an optional, thread-free shaft portion 46 arranged between the head 48 and a second threaded shaft 32 . The region between the hollow shaft 14 and the second fastening screw 34 is enlarged in FIG. 6 .
[0048] FIG. 6 is a detailed view of the sectional view from FIG. 5 . As can be seen from FIG. 6 , the second threaded shaft 32 also has a greater diameter than the thread-free shaft portion 46 . Accordingly, the second fastening screw 34 is also, similarly to the first fastening screw 24 , retained in the hollow shaft 14 on the optional, thread-free shaft portion 46 so as not to be lost. This is also possible without the optional, thread-free shaft portion 46 . Owing to the greater diameter of the second fastening screw 34 , the narrowing portion 30 is, however, permanently expanded by the second fastening screw 34 during pre-mounting, so that the second fastening screw 34 is retained in the narrowing portion 30 in a frictionally connected manner. Furthermore, there is also no play between the thread-free shaft portion 46 and the remainder of the first region 18 . There may be form-fitting guidance without play in this case.
[0049] FIG. 7 is a sectional view of a first embodiment of a hollow shaft. FIG. 7 shows in particular the end of the hollow shaft 14 facing away from the plate 12 , on which end the grooves 40 having the bases 42 are arranged in the narrowing region 30 . The step 28 arranged between the first region 18 and the second region 20 can also be clearly seen, and is designed as an axial stop for heads of the fastening screws in the first embodiment shown in FIG. 7 and forms a continuous transition between the first region 18 and the second region 20 . The sectional plane in FIG. 7 is rotated by 90° about the longitudinal axis compared with the view of the hollow shaft 14 which is already known from FIG. 1 .
[0050] FIG. 8 is a sectional view of a second embodiment of a hollow shaft. The second embodiment shown in FIG. 8 differs from the first embodiment which is already known from FIG. 7 in particular by a third region 36 which is attached to the second region 20 on the side of the second region 20 which faces away from the first region 18 . An additional step 38 is provided between the second region 20 and the third region 36 . The third region 36 has a greater diameter than the second region 20 . The additional step 38 may, just like the step 28 , be designed as an axial stop. In this way, different screw heads, that is to say screw heads having different diameters, can be used together with the universal nozzle. Owing to the different axial positioning of the step 28 and the additional step 38 , the fastening screws can be screwed into the nozzle to different extents, so that ends of the fastening screws used which project out of the sub-structure penetrate the fastened material layer, for example insulating material or roofing membrane, to different extents. In this way, an adaptation to the weight of the fastened material layer can take place. If necessary, additional regions having different diameters can be provided in the hollow shaft 14 . For example, on the side of the third region 36 which faces away from the second region 20 , an additional region 52 can be provided which may have a diameter which is yet larger than the third region 36 . Between the third region 36 and the additional region 52 , an additional step 50 may be provided which may also be formed as an axial stop. In addition to the groove 40 , an additional groove 58 , rotated by 90°, can be seen in the sectional view. The additional groove 58 extends in the axial direction beyond the narrowing portion 30 and the first region 18 as far as the second region 20 , in order to allow the nozzle to be expanded in a controlled manner when using a “thick” screw, that is to say a fastening screw having a shaft diameter that is greater than the first region 18 .
[0051] FIG. 9 is a sectional view of a third embodiment of a hollow shaft. The third embodiment of the hollow shaft 14 shown in FIG. 9 differs from the hollow shaft 14 known from FIG. 7 in particular by the conical tapering of the first region 18 , which may also have, outside the narrowing portion 30 , a diameter which decreases starting from the second region 20 and the step 28 .
[0052] FIG. 10 is a sectional view of a fourth embodiment of a hollow shaft. The fourth embodiment shown in FIG. 10 differs from the third embodiment known from FIG. 9 by a particular configuration of the grooves 40 in the region of the narrowing portion 30 . In the fourth embodiment shown in FIG. 10 , the grooves 40 are raised further towards the plate 12 on the outside of the hollow shaft 14 , so that a particularly controlled expansion of the tip of the hollow shaft 14 is possible when a correspondingly dimensioned fastening screw is pre-mounted.
[0053] FIG. 11 is a sectional view of a fifth embodiment of a hollow shaft. The fifth embodiment shown in FIG. 11 comprises an indentation 54 in the region of the narrowing portion 30 , which indentation can serve to additionally fix a pre-mounted screw in a frictionally connected manner. In the fifth embodiment shown in FIG. 11 , the grooves 40 are extended beyond the narrowing region 30 into the rest of the first region 18 , so that the expansion of the hollow cylinder by a correspondingly dimensioned fastening screw is particularly easy.
[0054] FIG. 12 is a sectional view of a sixth embodiment of a hollow shaft 14 . In the sixth embodiment shown in FIG. 12 , too, the end of the hollow shaft 14 facing away from the plate 12 is designed in a particular manner. Similarly to the fifth embodiment which is already known from FIG. 11 , in the sixth embodiment too, the transition between the narrowing portion 30 and the non-narrowed portion of the first region 18 is arranged below the grooves 40 . Furthermore, on the outside of the hollow shaft 14 in the region of the narrowing portion 30 , an edge 56 is additionally provided which makes it possible to expand the tip of the hollow shaft 14 in a particularly defined manner when a correspondingly dimensioned fastening screw is pre-mounted.
[0055] The features of the invention which are disclosed in the above description, in the drawings and in the claims may be essential to carrying out the invention both in isolation and in any combination thereof.
LIST OF REFERENCE NUMERALS
[0000]
10 nozzle
12 plate
14 hollow shaft
16 stepped hole
18 first region
20 second region
22 first threaded shaft
24 first fastening screw
26 head
28 step
30 narrowing portion
32 second threaded shaft
34 second fastening screw
36 third region
38 additional step
40 groove
42 base
44 thread-free shaft portion
46 thread-free shaft portion
48 head
50 additional step
52 additional region
54 indentation
56 edge
58 additional groove
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The invention relates to a nozzle ( 10 ) for fastening a material layer to a substructure, comprising a plate ( 12 ) and a hollow shank ( 14 ), integrally formed thereon, for taking a fastening screw ( 24; 34 ), wherein a stepped bore ( 16 ) is provided in the hollow shank, wherein the stepped bore ( 16 ) comprises at least two steps ( 28; 38; 50 ) between at least three regions ( 18; 30; 36; 2 ), wherein the hollow shank ( 14 ) is formed so as to taper at least partially in a conical manner on an external surface, wherein the hollow shank ( 14 ) is provided with radially expandable elements, and wherein the expandable elements are formed as axial grooves ( 40 ) externally in that part of the hollow shank ( 14 ) that is formed in a conically tapering manner. The invention proposes that the grooves ( 10 ) are each provided at the groove base at least partially with a thin bottom ( 42 ) that is stretchable or breakable by the expansion. The present invention also relates to a fastening element comprising a nozzle ( 10 ) according to the invention and a fastening screw ( 24; 34 ).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to a handling device and, more particularly, to an electrically powered rotary collator which collates sheets.
Rotary collators use a rotating drum with radially extending partitions which divide the drum into radially extending bins. Each successive bin may be loaded with a plurality of sheets of successive pages of a booklet to be collated. Some of the bins may be empty. As the drum rotates, the pile of sheets in each loaded bin is held against its bin by a sheet clamp except at a sheet ejecting position or a region thereof when the stack of sheets must be released or unclamped so that the top sheet can be withdrawn from the bin. A sheet from each of the loaded bins is withdrawn and the sheets are assembled together in sequence so that they may be stapled or otherwise bound together.
After each bin passes the sheet ejecting position, the sheet clamp is operated to clamping position by an activating device that uses a toggle structure. In known machines, the sheet clamp held against each bin is released when the bin reaches its ejecting position and is clamped again soon after the bin moves beyond its ejecting position. In these previous systems, the clamping/unclamping procedure takes place on each bin irrespective of whether sheets are loaded in the particular bin in question.
The clamping springs used are strong enough to hold thick stacks of sheets against the partition side. Consequently, the cumulative effect of the noise generated by released sheet clamps slamming shut against empty bins is significant in these previous system. In addition, individual elements of the mechanism are subject to wear, despite the fact that their functions are not always required.
2. Description of the Prior Art
U.S. Pat. No. 2,936,168 teaches the use of a rotating drum with radially extending partitions. No provision is made therein for programmably disabling sheet clamps which are not required during the collating operation. U.S. Pat. No. 3,970,297 shows and describes apparatus for withdrawing a single top sheet from each bin as the bin reaches the ejecting position in the collator cycle. The sheet withdrawing invention described in the above patent can be used in conjunction with the present invention, as hereinafter disclosed.
U.S. Pat. No. 3,796,422 teaches the use of a sheet clamp release activating device which uses a toggle structure. The activating device of that invention is actuated each time a bin approaches its ejecting position, regardless of whether the bin contains sheets. The resulting objectionable noise and wear of parts are significant in that system.
Accordingly, the present invention now reduces the noise associated with sheet clamping operations of a rotary collator. Only those sheet clamps which must be released, or opened, during the eject cycle of their corresponding bins are specified in advance. Certain bins which are either empty or loaded with unwanted sheets now remain intact in a closed position at all times during the collating cycle. The life expectancy of mechanical elements is extended by reducing wear on those clamp mechanisms associated with empty or unused bins. The total amount of energy expended for a normal collating project is also reduced by the present invention by activating less than all mechanisms during each sheet ejecting cycle.
SUMMARY OF THE INVENTION
Briefly, the sheet clamp actuator of the present invention is for use in a rotary collator in which sheets are stacked in collator bins. The present invention includes an electromechanical solenoid connected to a suitable power supply. An extension bar is pivotably connected to the solenoid at one end, and pivotably connected to an interposer link at the other end. The interposer link has a protuberance which fits into the detent of a switching cam. The switching cam is capable of movement into the path of sheet clamps as the collator drum rotates, thus causing the individual sheet clamps to release during a specified portion of the collating cycle. Once the sheet clamps are in a release position, sheets may be removed from their collator bins. Upon passing the point in the collator cycle at which the sheet clamp actuator interacts with the sheet clamp, the clamp returns to its normally closed position, thus retaining the stacks of sheets in their bins for the major portion of the collating cycle.
From the foregoing discussion it is clear that an object of the present invention is to provide an improvement of a rotary collator.
Another object of the present invention is to provide a sheet clamp actuator to release only specified sheet clamps during the collating cycle.
A further object of the present invention is to reduce the general operating noise associated with a rotary collator.
Yet another object of the present invention is to reduce energy consumption of a rotary collator when operating with less than all bins containing sheets.
Still another object of the present invention is to extend the life expectancy of sheet clamps by not actuating them when not in use.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features which are characteristic of the present invention are set forth with particularity in the claims, but the invention will be understood more clearly and fully from the following detailed description of a preferred embodiment thereof, as set forth in connection with the accompanying drawings in which:
FIG. 1 is a diagrammatic view of a rotary collator.
FIG. 2 is a partial view of the collator drum and sheet clamps in relation to the sheet clamp opening path.
FIG. 3 is a detailed view of a sheet clamp and the sheet clamp actuator.
FIG. 4 is a simplified electrical circuit for energizing solenoid.
FIG. 5 is a partial view of the collator drum and sheet clamps in relation to the sheet clamp closing means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein a preferred embodiment of the invention is illustrated, FIG. 1 discloses a rotary collator apparatus. The rotary collator includes a drum 10 having spaced side plates 12 which drum is mounted for rotation on an axle or shaft 14 carried by a suitable frame 16. The drum 10 is divided into a plurality of bins 18 by a plurality of spaced radially or substantially radially extending partitions 20 which are suitably secured to the spaced side plates 12. Each partition 20 forms a bin 18 for a stack of sheets, not shown. Suitable ejecting means, not shown, ejects the top sheet from the stack of sheets and delivers it to a receiving or transfer table 22 which establishes the ejecting position for each bin 18. In the rotary collator, each stack of sheets is disposed in generally horizontal position, resting on its partition 20 as it passes through the sheet ejecting position. As the drum 10 turns, the partitions 20 become disposed vertically with respect to the ground at the top and at the bottom of the drum 10. Clamping means, described in more detail hereinafter, are provided to retain each stack of sheets against its associated partition 20 through all or the major portion of the rotation of the drum 10 except for the sheet ejecting position and preferably shortly thereafter as will be further described hereinafter.
Referring now to FIGS. 2 and 3, reference numeral 24 denotes a toggle extension. A cam follower 26 is suitably mounted on the toggle extension 24. The toggle extension 24 is rotatably mounted at a support pivot 28 to the revolving drum 10 by a supporting member 30. A shaft 32 inserted in a compression spring 34 connects the toggle extension 24 at a connection pivot 36 to a pivotable link 38 at a lower connecting pivot 40. The compression spring 34 is a spring with flat ends abutting their respective surface. The pivotable link 38 is connected to a clamp 42 by a clamp plate 44, which is connected to the pivotable link at an upper fixed pivot 46. The upper fixed pivot 46 is attached to the revolving drum 10. The clamp 42 normally rests on a partition 20 or on a stack of sheets loaded on said partition. The partition 20 is itself mounted on and part of the revolving drum 10.
The compression spring 34 has a length such that its pressure on the toggle extension 24 ceases or is light when the toggle is fully open. When the clamp 42 is closed on a stack of sheets or against the partition 20, the toggle extension 24 is in locked position with the connection pivot 36 past (above) a line between the centers of the pivots 28 and 40.
When a thick stack of sheets rests on a partition 20, the compression spring 34 is at its maximum compression. Since usually the stack is half or less of capacity, this means that most of the time this compression spring 34 is operating in its area of less or minimum compression. The compression spring 34 is strong enough to hold the stack of sheets against its partition 20 without slippage in all positions of the latter. The compression spring 34 also accommodates for the varying thickness of the stack of sheets.
Cam means for maintaining an open clamp position, when required, is located adjacent to the top of the drum 10 and is carried by frame members 16. A cam mounting plate 48, forming a part of the frame 16, is secured to the frame by bolts 50. An opening cam 52 is attached to the cam mounting plate 48 by bolts 54. This opening cam 52 has a rising surface 56 part of which may be arcuate and which is engaged by selected cam followers 26 as the drum 10 rotates and opens the toggle extension 24. This rising surface 56 comes to a peak 58 after which the surface of the opening cam 52 drops away in angular portion 60. The contoured angle portion 60 of the opening cam 52 is provided to guide the cam follower 26 past the cam if the drum 10 is reverse rotated.
A restraining cam 62 is provided adjacent to the opening cam 52. A sharply angled clamp closing portion 64 is provided as a first part of the surface of the restraining cam 62 so that if a clamp 42 is open for any reason, the cam follower 26 engages this portion and closes the clamp. The restraining cam 62 then has a restraining portion 66 parallel to and spaced from the opening cam 52 by the diameter of the cam follower 26 to the peak 58 after which the surface of the restraining cam surface continues gradually outwardly to restrain any rapid opening of the clamp 42. Finally the restraining cam 62 levels out as the clamp 42 approaches full open position with the compression of the compression spring 34 largely or perhaps entirely dissipated. The clamp 42 is in full open position at least as the partition 20 nears sheet ejecting position.
Referring now again to FIG. 3, reference numeral 68 denotes generally an activating mechanism for switching the toggle extension 24 from one position (hereinafter the open position) to another position (hereinafter the closed position) constructed in accordance with the invention. A solenoid 70 is mounted on the non-revolving collator frame 16 shown in FIG. 1. The plunger 72 of the solenoid 70 is pivotably connected by means of a pin 74 to an extension bar 76 which is pivotably connected by means of a pin 78 to an interposer link 80. The interposer link 80 is pivotably mounted on the fixed collator frame 16 by means of a pin 82 located below the pivot pin 78.
One end of a tension spring 84 is connected to the interposer link 80 and the other end is attached to a point 86 on the fixed collator frame 16. The interposer link 80 has a protuberance 88 which fits and locks into a detent 90 of a switching cam 92. From the point 86 at which the first tension spring 84 is connected to the interposer link 80, another tension spring 94 is connected to the switching cam 92. The switching cam 92 is pivotably mounted by pin 96 to the fixed collator frame 16.
Referring now to FIG. 4, a schematic electrical circuit is shown generally at 98 and is constructed in accordance with the invention. The solenoid 70 is in electrical series with an electrical switch 100 and a power source 102.
Referring now to FIG. 5, reference numeral 104 denotes a closing cam. This closing cam 104 has a contoured rising surface 106 which is engaged by selected cam followers 26 as the drum 10 rotates and closes the toggle extension 24. This rising surface 106 comes to a peak 108 after which the surface of the closing cam 104 drops away in angular portion 110. The angular portion 110 of the closing cam 104 is provided to guide the cam follower 26 past the cam if the drum 10 is reverse rotated.
In operation, the electrical switch 100 is enabled during the sheet ejecting portion of the collating cycle and completes the electrical circuit 98, energizing the solenoid 70. When the solenoid 70 is energized, its plunger 72 holds the extension bar 76 back. The interposer link 80 remains in a clockwise orientation on its pin 82, overcoming the tension spring 84 attached to it. The protuberance 88 of the interposer link 80 is seated in the detent 92 of the switching cam 90. In this position, the switching cam 90 is restrained by the tension spring 94 attached to it, and is not brought into contact with the cam follower 26 mounted on the toggle extension 24 as the follower moves in its trajectory past the cam. The cam follower 26 moves along the lower path of the opening cam 52. Consequently, none of the members connected to the toggle extension 24--including the shaft 32 and compression spring 34, the pivotable link 38, the clamp plate 44, and the clamp 42--is moved from its normal position. The clamp 42 is pressed against its partition 20 during all portions of the collating cycle including the sheet ejecting portion, when power is applied to the solenoid 70.
Means are provided for synchronizing completion of the electrical circuit 98 with the revolving collator drum 10, such that at a specified time in the sheet ejecting cycle, power is applied to the activating mechanism 68, causing the clamp 42 to remain closed. Details of this synchronizing means are not required to understand the operation of the activating mechanism 68.
If sheets are to be removed from a specific bin 18 during the sheet ejecting portion of the collating cycle, the electrical switch 100 is disabled, breaking the electrical circuit 98, deenergizing the solenoid 70. When power is removed from the solenoid 70, its plunger 72 is extended, driving the extension bar 74 forward. The interposer link 80 is forced to move in a counter-clockwise direction on its pin 82, aided by the tensile force of the tension spring 84 attached to it. The protuberance 88 of the interposer link 80 moves down and out of the detent 92 in the switching cam 90. In this position, when the interposer link 80 presses into the lower portion of the switching cam 90, the cam is forced to move around its pivot 96 in a clockwise direction. The lower portion of the switching cam 90 moves into the trajectory of the cam follower 26, forcing the toggle extension 24 up. The upper portion of the toggle extension 24 is driven in a counter-clockwise direction around its support pivot 28. The cam follower 26 is guided along the upper path 56 of the opening cam 52, which forces the toggle extension 24 even further into a counter-clockwise position. When the cam follower 26 reaches the peak 58 of the opening cam 52, the toggle extension 24 has been broken from locked position so that the compression spring 34 takes over to continue the opening of the toggle extension 24 until the spring has reached an expansion of reduced compression to open the clamp 42.
The lower portion of the toggle extension 24 moves counter-clockwise about its support pivot 28, increasing the distance between pivots 28 and 40. A tensile force is generated along the compression spring 34, tending to pull the pivotable link 38 in a counter-clockwise direction about its upper fixed pivot 46. The upper fixed pivot 46 is fixed to the clamp plate 44, so a counter-clockwise movement of the pivotable link 38 causes the clamp plate 44 and the clamp 42 attached to it to swing up off the partition 20 also in a counter-clockwise direction, generally towards the center of the collator drum 10. In this released position, a sheet can be withdrawn from a stack of sheets, if present, which rests on the partition 20.
After the partition 20 has passed sheet ejecting position and a sheet has been ejected and withdrawn from the bin 18, the closing cam 104 is engaged by the cam follower 26 to close the clamp 42. Preferably the clamp 42 is closed a short distance after passing ejecting position so that if the second sheet has been partially projected outwardly it can be pushed back before the clamp is fully closed.
The closing cam 104 is located approximately on a horizontal line through the center of the drum 10. The closing cam 104 begins with a surface 106 generally rising inwardly until the clamp 42 is practically closed. At this point a spring pressed cam 112 moves the toggle extension 24 to locked position. The spring pressed cam 112 is pivoted on a pin 114 and has a curved surface 115 extending inwardly to engage the cam followers 26 and complete the closing of the toggle extension 24 to locked position. The spring pressed cam 112 is propelled radially inwardly by a spring 116, one end of which is fixed to a pin 118 on the closing cam 104. The spring pressed cam 112 provides assurance that the toggle extension 24 is closed. The clamp 42 remains in this closed position until the collating drum 10 is again rotated to a position where the cam follower 26 is brought into contact with the switching cam 92.
Should the clamp 42 be jammed for any reason, the compression spring 34 yields and if the toggle extension 24 should jam, the spring pressed cam 112 yields and in this manner protects the clamp 42 and the associated mechanism from being damaged. The angular portion 110 of the closing cam 104 continues radially outwardly so that it engages the cam follower 26 in the event that the drum 10 is reverse rotated.
Preferably the clamp 42 is opened about six bins 18 before sheet ejecting position so the bins can be loaded with sheets in this quadrant of drum 10 rotation when the clamps 42 are open. A sheet backstop, not shown, provided in the bins 18 retains the sheets undisturbed in their bin and on their partition 20.
The synchronizing means, now shown, coordinates disabling of the electrical switch 100 with the drum 10 rotation. The solenoid 70 is re-energized and all elements of the activating mechanism 68 return to their initial closed positions.
This invention is presented to fill a need for improvement in a rotary collator with sheet clamp actuator. It is understood that various modifications in structure, as well as changes in mode of operation, assembly and manner of use, may and often do occur to those skilled in the art, especially after benefitting from the teachings of an invention. This disclosure illustrates the preferred means of embodying the invention in useful form.
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A rotary collator having a rotatable drum with a plurality of radially extending partitions or bins in which sheets to be collated are held by a sheet clamp mounted in each bin. The sheet clamp for each bin has a solenoid-based activating device which releases the sheet clamp during the sheet ejecting portion of the collating cycle. The sheet clamp is released a short time before the rotatable drum brings the associated bin into a sheet ejecting position. A toggle structure and a relatively high compression spring are used to hold the sheets in the bin when in clamping position. The sheet clamp of any empty bin is programmed not to release, thereby greatly reducing noise and extending the life of the mechanism.
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BACKGROUND OF THE INVENTION
The present invention relates to a rotary compressor for compressing desired gaseous fluid such as refrigerant and, more particularly, to an improvement in a rotary compressor of the type having a plurality of vanes mounted on a rotor.
A rotary compressor of the type described generally has a housing made up of a cylinder and a pair of side blocks mounted on axially opposite ends of the cylinder. A rotor is rotatably disposed in the housing and provided with vanes which are slidably received in substantially radially extending slots of the rotor. The nearby vanes define a fluid chamber in cooperation with the housing and rotor. During operation of the compressor, the rotor is rotated to cause the radially outermost ends of the vanes into sliding movement on the inner surface of the cylinder, thereby repeatedly increasing and decreasing the volume of the fluid chamber to compress incoming gas. The primary requisite in compressing gas in the manner described is that the outermost ends of the vanes be constantly held in sealing contact with the inner surface of the cylinder to fluidly isolate nearby fluid chambers. Such has been implemented by defining a back-pressure chamber by the radially innermost end of each vane and its associated slot and communicating a high fluid pressure to the back-pressure chamber. In operation, the pressure in the back-pressure chamber cooperates with centrifugal force developed in the vane in forcing the vane radially outwardly into sealing contact with the cylinder.
It has heretofore been customary to control the pressure P in the back-pressure chamber to a constant value as expressed by
P=1/2 (Pd+Ps)
where Pd is a delivery pressure and Ps, a suction pressure.
The problem encountered with the above prior art implementation is that during a compression stroke the pressure P becomes short to allow the vane to retract into the associated slot beyond the periphery of the rotor and, upon the subsequent suction stroke, suddently project from the slot hitting against the inner surface of the cylinder. This results in the generation of noise generally referred to as vane chattering.
To eliminate vane chattering, there has been proposed a rotary compressor of the type which makes the back-pressure chamber fluidly independent in the course of a compression stoke, as disclosed in Japanese Patent Laid-Open Publication No. 57-26293/1982, for example. Specifically, the back-pressure chamber in a compression stroke becomes an independent space so that the pressure therein may be raised against retraction of the associated vane into the slot. This type of configuration is not fully acceptable, however, since where the proportion of oil or like pressurized liquid in the back pressure chamber is substantial the vane compresses that liquid to raise the previously mentioned pressure P to an excessive level, resulting in an increase in the sliding friction between the vane and the cylinder and, therefore, a poor coefficient of performance.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a rotary compressor which is capable of eliminating vane chattering without raising the pressure in a back-pressure chamber to an unusual level during a compression stroke.
It is another object of the present invention to provide a generally improved rotary compressor.
A rotary compressor of the present invention is of the type including a cylindrical housing, and a rotor rotatably disposed in the housing and provided with a plurality of vanes slidably mounted respectively in substantially radial slots which are formed in the rotor, each of the vanes defining a back-pressure chamber at an radially innermost end thereof in cooperation with the rotor and axially opposite ends of the housing. A passageway communicates a fluid pressure from a source of fluid pressure supply to the back-pressure chamber while the chamber is in a suction stroke range. The back-pressure chamber is fluidly isolated from the source of fluid pressure supply while the chamber is in a compression stroke range. A damper damps the fluid pressure in the back-pressure chamber in the compression stroke range.
In a preferred embodiment the damper comprises a blind hole formed in that surface of an end wall of the housing which faces the rotor, the back-pressure chamber aligning with the blind hole in the compression stroke range.
Preferably the passageway includes an arcuate recess formed in the surface of the end wall of the housing such that the back-pressure chamber aligns therewith in the suction stroke range.
The above and other objects, features and advantages of the present invention will become apparent from the following detailed description taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical section of a rotary compressor embodying the present invention;
FIG. 2 is a section taken along line A--A of FIG. 1;
FIG. 3 is a front view of a side block included in the rotary compressor of FIG. 1; and
FIG. 4 is a graph showing the advantage of the present invention over the prior art with respect to pressure variation in a back-pressure chamber.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While the rotary compressor of the present invention is susceptible of numerous physical embodiments, depending upon the environment and requirements of use, a substantial number of the herein shown and described embodiment have been made, tested and used, and all have performed in an eminently satisfactory manner.
Referring to FIGS. 1-3 of the drawings, a rotary compressor embodying the present invention comprises a housing which is generally designated by the reference numeral 10. The housing 10 includes a cylinder 12 which is formed with a bore 14 having an elliptical cross-section. The left and right ends (as viewed in FIG. 1) of the cylinder 12 are closed by side blocks 16 and 18, respectively.
A cylindrical rotor, generally 20, is disposed in the housing 10 and rigidly mounted on a drive shaft 22. The drive shaft 22 extends throghout the rotor 20 at the center of the latter and is rotatably received in bearing holes 24 and 26, which are formed through the side blocks 16 and 18, respectively. The rotor 20 contacts the inner surface of the cylinder 12 at opposite ends of the shorter axis of the ellipse each with a slight clearance. Also, the opposite ends of the rotor 20 contact the side blocks 16 and 18 each with a slight clearance. The rotor 20 is formed with substantially radially extending slots 28 at equally spaced locations along the circumference, e.g. five locations as in the illustrative embodiment. Vanes 30 are slidably mounted in the slots 28, respectively, and engage with the inner wall (not designated) of the bore 14.
The housing 10 is surrounded by a head 32 which is sealingly mounted on one of the side blocks, 16, and a shell 34 sealingly connected with the head 32. An inlet or suction passageway 36 and an outlet or delivery passageway 38 are formed through one end of of the shell 34 remote from the head 32. The inlet passageway 36 is communicated to a low pressure chamber 40, and the outlet passageway 38 to a high pressure chamber 42. A cover 44 is mounted on the side block 18 to fluidly isolate the low pressure chamber 40 from the high pressure chamber 42. Passageways 46 extend throughout the cylinder 12 and side blocks 16 and 18 to provide communication between the low pressure chamber 40 and the interior of the head 32, the latter thus constituting part of the low pressure chamber 40 and being designated by the same reference numeral 40. In the low pressure chamber 40 inside the head 32, a partition 46 extends from the head 32 to define a seal chamber 48. A sealing device 50 is disposed in the seal chamber 48 and interposed between the head 32 and the drive shaft 22 which protrudes from the side block 16, thereby maintaining the low pressure chamber 40 fluid-tight from the ambience.
The high pressure chamber 42 is defined by the housing 10 and the shell 34. An oil separator 50 is positioned in the chamber 42, while an oil reservoir or sump 52 is defined in a lower portion of the chamber 42.
The low pressure chamber 40 is communicated to the bore 14 of the housing 10 by inlet openings 54 formed through the side blocks 16 and 18, and the high pressure chamber 42 by outlet openings 56 formed through the circumferential wall of the cylinder 12. In each of the side blocks 16 and 18, two inlet openings 54 are located at an angular spacing of substantially 180 degrees for each other. The outlet openings 56 are located in positions where the cylinder 12 is engaged by the rotor 20, and each is closed by a reed type delivery valve 58. As shown in FIG. 2, the vanes 30 in conjunction with the rotor 20 and the inner wall of the bore 14 define fluid chambers 60. The outlet passageways 56 are controlled by the check valves 58 into alternate communication with the fluid chambers 60. While the rotor 5 is in rotation, the vanes 30 are pressed against the inner wall of the bore 14 by centrifugal force developed therein and back pressure communicated to back-pressure chambers 62, thereby sealing the nearby fluid chambers 60 from each other.
Each back-pressure chamber 62 is defined in the innermost end of the slot 28 by the rotor 20, vane 30 and side blocks 16 and 18. The pressure developing in the chamber 62 is adjusted by a back-pressure adjusting arrangement which will be described.
The back-pressure adjusting arrangement is associated with each of the side blocks 16 and 18. For the construction of the adjusting arrangement, as shown in FIG. 2, the locus along which each end of the back-pressure chamber 62 moves on the side block 16 or 18 (circular locus in the illustrative embodiment) is divided into alternating high pressure sections α and normal pressure sections β in the circumferential direction. Each high pressure section α, briefly stated, covers an angular range in which any of the vanes 30 is positioned at and in the vicinity of the outlet opening 56. Specifically, the high pressure section α extends from the position where the rear end of the back-pressure chamber 62 with respect to the direction of rotation of the rotor 20 is located when an imaginary extension of a leading side 28a of the slot 28 with respect to the same direction assumes a position just before the port of the outlet opening 56, to the position where the front end of the chamber 62 is located when a trailing side 28b of the slot 28 assumes a position just after the point of contact between the cylinder 12 and the rotor 20. The normal pressure sections β cover the rest of the locus.
Arcuate grooves 64 and 66, for example, extend from one end to the other end of the respective normal pressure sections β in that surface of each of the side blocks 16 and 18 which faces the rotor 20. The grooves 64 and 66 in each side block 16 or 18 communicate to the bearing hole 24 or 26 via an annular recess 68 which is located radially inwardly of the grooves. A passageway 70 extends through the side block 16, and a passageway 72 through the side block 18. Each of these passageways 70 and 72 provides communication between the associated bearing hole 24 or 26 and the oil sump 52. In this construction, fluid, which is oil in this particular embodiment, is communicated from the sump 52 to the grooves 64 and 66 of each side block 16 or 18 by way of the passageway 70 or 72 while being restricted by the clearance between the drive shaft 22 and the bearing hole 24 or 26. Further, the side blocks 16 and 18 are each provided with blind holes 74 and 76 on their surfaces adjacent to the rotor 20 and in positions which lie in the previously mentioned high pressure sections α where compression strokes are effected.
In each normal pressure section β, therefore, the back-pressure chamber 62 will face any of the grooves 64 and 66 at opposite ends thereof and over its whole sectional area so that the pressure of the oil in the grooves is directly admitted into the chamber 62. Meanwhile, in the high pressure section α, the chamber 62 will be fluidly isolated from the grooves 64 or 66 by that part of each side block which intervenes between the grooves 64 and 66 and brought into alignment with the blind holes 74 or 76 instead, so that the pressure in the chamber 62 is released, or damped, into the blind holes while being confined in the chamber and the blind holes.
In the illustrative embodiment, the blind holes 74 and 76 are each positioned substantially at the center between the two grooves 64 and 66 and provied with a circular shape. In practice, however, their position, shape and size will be suitably determined depending upon the specific pressure variation characteristic in the back-pressure chambers 62.
The rotary compressor having the above-described construction will be operated as follows.
When the drive shaft 22 is rotated, it causes the rotor 20 to rotate together with the vanes 30. As any of the fluid chambers 60 defined by nearby vanes 30 increases in volume, it sucks gas thereinto via the inlet passageways 54. Then, while decreasing in volume, the fluid chamber 60 compresses the gas and delivers it to the high pressure chamber 42 via the delivery opening 56 forcing the delivery valve 58 to open. Such suction and compression strokes are repeated to compress the incoming gas. The compressed gas is temporarily retained in the high pressure chamber 42 to raise the pressure therein. As a result, the oil in the oil sump 52 is pumped into the bearing holes 24 and 26 via the passageways 70 and 72, respectively. The oil in the bearing holes 24 and 26 are communicated to the grooves 64 and 66 except for part thereof which is admitted into the seal chamber 48, while being restricted by the clearance between the drive shaft 22 and the bearing holes 24 and 26.
While the back-pressure chamber 60 is in the normal pressure section β, its opposite ends are held in communication with the grooves 64 or 66 so that the oil in those grooves and, therefore, its pressure is admitted into the chamber 62. Also, the chamber 62 is held in communication with the chamber 60 via the clearance between the vane 30, rotor 20 and the like. Hence, as shown in FIG. 4, the pressure P 1 in the chamber 62 is controlled substantially to 1/2 (Pd+Ps) where Pd and Ps designate respectively a delivery pressure a suction pressure, as previously stated.
Thereafter, as the front end of the back-pressure chamber 62 with respect to the direction of rotation begins to enter the high pressure section α, the area of the chamber 62 overlapping with the grooves 64 or 66 gradually decreases. When the rear end of the chamber 62 has entered the high pressure section α, the chamber 62 becomes completely isolated from the grooves 64 or 66 and, at the same time, the vane 30 is gradually forced to retract into the slot 28 due to the configuration of the bore 14. Therefore, the volume of the chamber 62 is reduced tending to sharply raise the pressure in the chamber 62. However, since the chamber 62 has then been aligned with the blind holes 74 or 76 to release the pressure therefrom into the latter, the pressure in the chamber 62 does not rise in the manner indicated by a dash-and-dots line in FIG. 4 and, instead, remains at a predetermined level P 2 as indicated by a solid line.
In summary, it will be seen that the present invention provices a rotary compressor which prevents the pressure in back-pressure chambers in compression strokes from being raised to an unusual level and, thereby, confines the sliding friction of the outermost ends of vanes in an allowable range to attain a desirable result coefficient. In addition, the back-pressure chambers can be depressurized in a rapid and accurate manner.
Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof.
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A rotary compressor has a plurality of vanes which are slidably disposed in radial slots of a rotor to define fluid chambers in cooperation with a cylindrical housing. The radially innermost end of each vane, rotor and opposite ends of the housing define a back-pressure chamber which is supplied with a pressure during a suction stroke for maintaining the associated vane in sealing contact with the inner wall of the housing. Each of opposite ends of the housing has a unique configuration which damps the pressure in the back-pressure chamber when the chamber is fluidly isolated from a source of the pressure supply during a compression stroke, thereby eliminating excessive friction between the vane and the housing.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional application of application Ser. No. 10/894,972, filed on Jul. 20, 2004, now U.S. Pat. No. 7,168,887.
BACKGROUND OF INVENTION
This invention relates to a method for repairing a crack, particularly in a recreational court or surface.
A variety of methods exist for repairing cracks in surfaces, such as roadways, pavements and other concrete or asphalt surfaces, and particularly for recreational courts or surfaces, such as tennis courts, outdoor basketball courts, volleyball courts, running tracks and multi-sport play courts. Such cracks are a significant problem, especially in those areas of the country where there are significant variations in temperature throughout the year. The conventional process for repairing cracks in recreational courts or surfaces requires cleaning debris out of the cracks and filling the cracks with a crack filler material which solidifies to a hardened state. Prior to hardening, this crack filling material is leveled to the level of the recreational court or surface.
Unfortunately, crack repairs made using this conventional process are only a temporary fix. Continued maintenance of the recreational court is necessary because of the formation of new cracks or the further deterioration of the earlier crack caused by changes in temperature and moisture in the environment as well as ground movement or settling and problems with the construction of the court or surface. Cracks repaired using this conventional process often tear open again as the asphalt or concrete pavement expands or contracts caused by temperature changes, moisture level increases, ground movement or settling, or the freeze and thaw of the surrounding ground.
A more complex process for repairing cracks in recreational courts or surfaces, particularly tennis courts, requires covering the filled crack with a slip-sheet, i.e. a non-adhering material which isolates the crack from the surrounding environment. This process requires the crack to be cleaned and filled with a hardened crack filler to the level of the surrounding pavement or recreational court. A slip-sheet is then secured, usually by an adhesive, to the surface of the recreational court, completely covering the filled crack. The top surface of this slip-sheet, which is applied over the crack, is required not to adhere to other materials which cover the slip-sheet. Another layer or layers of material, such as one or more fiberglass sheets, are then placed over the non-adhering surface of the slip-sheet and are secured at least at their peripheral edges to the pavement or recreational court. By this method, the top surface of the slip-sheet is isolated from the remaining materials, enabling the slip-sheet to expand and contract with the court or surface without putting stress on the crack repair. Early slip-sheet methods are disclosed in U.S. Pat. Nos. 3,663,350 and 3,932,051.
Another method of crack repair using a slip-sheet utilizes a tape material with a shiny outer surface, prepared from polyethylene, Mylar, Teflon or other such materials, as disclosed in U.S. Pat. No. 6,450,729. An adhesive tape, such as duct tape, which has a non-adhering polyethylene top surface, is one example of a slip-sheet of this invention.
In an alternative method, which is disclosed in U.S. Pat. No. 5,464,304, a liquid waterproofing material is applied directly over the filled crack. This liquid waterproofing material dries with a non-adhering top surface that isolates the crack from additional materials placed over the non-adhering surface. Over this non-adhering surface are secured several fabric layers by use of acrylic binders. The key step in this process, however, is the crack isolation step produced by the application of the liquid waterproofing material to the recreational court.
The process of U.S. Pat. No. 5,464,304 is similar to that of U.S. Pat. No. 6,450,729 in that both rely on the application of a non-adhering material to the recreational court or surface over which other materials are placed. Many different types of materials and adhesives may be applied over the slip-sheet or other non-adhering surface to complete the crack repair.
While these processes for filling cracks in recreational courts or surfaces have shown utility, they can be difficult to apply, require an extensive amount of time to cure and still result in problems caused by the recurrence of the cracks.
Accordingly, it is an object of the invention to disclose a method for repairing a crack in a court or surface, particularly a recreational court or surface, which addresses the problems of the prior art. These and other objects can be obtained by the process for repairing a crack in a recreational court or surface that is disclosed in the present invention.
SUMMARY OF THE INVENTION
The present invention is a process for repairing a crack in a recreational court or surface comprising
cleaning the crack to remove loose material, filling the crack with a crack filling material, which adheres to and seals the inside edges of the crack, applying a laminate to the recreational surface and to the exposed sealant material to cover the crack completely, wherein the laminate comprises an adhesive secured to one side of a flexible fabric material, wherein the adhesive is secured to the recreational surface and the exposed sealant material, and securing a fabric, preferably a flexible polyester fabric, to at least the edges of the flexible fabric material of the laminate using an adhesive material.
In a further preferred embodiment one or more layers of paint, preferably an acrylic paint, are then applied to the fabric material, exposed laminate and recreational court or surface to complete the repair of the crack in the recreational court or surface.
DETAILED DESCRIPTION
The invention is a method for repairing a crack in a recreational court or surface. The court or surface to be repaired can be formed of any conventional material, such as concrete or asphalt and can be formed into a roadway, driveway, or sidewalk, but preferably is formed as an outdoor recreational court or surface, such as a tennis court, basketball court, volleyball court, running track, multi-sport or play court. In composition conventional recreational courts or surfaces have a certain thickness and are generally placed over a stone base or the ground. Cracks form in these recreational courts as a result of changes in the environmental conditions, such as occur when there are significant changes in the outdoor moisture or temperature, as well as ground movement or settlement and problems with the construction of the court or surface. Cracks formed in the recreational court or surface may have different shapes, widths and lengths and can extend a significant distance or only a small distance into the recreational court.
The first step in the repair of the crack in the recreational court is to clean the crack to remove all loose material and debris. This can be effectively done by brushing, hand removal, high pressure steam and/or the use of air under pressure.
After the crack has been completely cleared of loose debris, a crack filling material is introduced into the crack. In prior art processes this crack filling material was a material which formed a hardened fill material, such as an epoxy binder. In an alternative process, silica, sand, and Portland Cement were mixed together with a liquid to form a wet mortar to fill the crack. This mixture was then allowed to dry to a hardened consistency. These processes, which utilize hardened crack filling agents, may not provide flexibility for the fill material and sometimes permit water to reenter the crack.
While these crack filling materials are still useful for many types of courts, it has been surprisingly discovered that an improved crack filling material is one that can expand and contract with changes in the weather conditions, yet still forms a waterproof bond around the inside edges of the crack to prevent water from entering the crack and causing further deterioration of the existing crack. Any material which can fill the crack completely and securely, yet remain flexible to accommodate expansion and contraction when exposed to changes in temperature and moisture and which also is waterproof, is within the scope of the invention. In one preferred embodiment a flexible polyurethane foam product, such as “Great Stuff” manufactured by Dow Chemical Company, is introduced into the cleaned crack as the flexible sealant material. Sufficient flexible sealant material should be utilized to fill the crack completely up to the level of the surrounding recreational court. After application, the surface of the recreational court should be leveled prior to the complete drying and curing of the sealant material.
After the crack is filled and the crack filling material has been allowed to dry and cure, a laminate is applied to cover completely the crack and the surrounding recreational court or surface. Regardless of whether a flexible sealant is used, it is important that the laminate be flexible to expand and contract with the expansion and contraction of the court. If the crack filling material is a sealant material which is flexible and thus can expand or contract depending on the temperature, it is especially important that this laminate also be flexible to permit expansion and contraction with changes in weather conditions, especially temperature.
The laminate is preferably formed from an adhesive material, preferably waterproof, applied to a flexible fabric material. The adhesive material is preferably a waterproof adhesive which will tightly secure the laminate to the recreational court and to the exposed crack filling material. In one preferred embodiment the adhesive material comprises a waterproof, rubberized asphaltic adhesive.
Secured to the adhesive material is the flexible fabric material. The flexible fabric material can be any material which expands and contracts in coordination with the expansion and contraction of the recreational court. In one preferred embodiment this material may also be waterproof. In addition, this flexible material is preferably elastic. The adhesive portion of the laminate is secured tightly, preferably permanently bonded during production, to one side of this flexible material. In one preferred embodiment the adhesive portion is applied in liquid form to the flexible fabric and when cured, is or becomes bonded, preferably permanently bonded, to the flexible material. Prior to application of the laminate to the surface, the adhesive material is preferably covered by a paper release backing to assist in the storing, utilization and application of the laminate. One preferred laminate material is supplied by Protecto Wrap Company and comprises a construction waterproofing, flexible, adhesive anti-fracture membrane.
Following the filling and curing of the sealant material in the crack, the paper release backing is removed from the adhesive portion of the laminate and the adhesive is applied to and secured firmly to the recreational court and to the exposed sealant material.
In the next step of the inventive process, a flexible fabric is secured to at least the edges of the flexible fabric material of the laminate by an adhesive. This portion of the process differs dramatically from those processes which use a “non-adhering” surface. In the prior art processes the fabrics which cover the “non-adhering” surface are not secured to the “non-adhering” surface. In contrast in the process of the invention, the laminate is secured by adhesive to those fabrics which cover the laminate. In a preferred embodiment the flexible fabric of the invention comprises a flexible polyester fabric, sufficiently sized to cover at least the edges of the laminate. It is secured to at least the edges of the laminate and the surrounding recreational court by use of an adhesive material, preferably a waterproof acrylic or latex adhesive, which is applied to the polyester fabric, prior to or during application. The adhesive is also preferably applied to the edges of the flexible fabric layer, where the edges contact the recreational court or surface. In a preferred embodiment this flexible fabric is secured to portions of recreational court or surface which extends beyond the outer edges of the laminate. In a preferred embodiment the polyester fabric is Bamilex XP403 produced by St. Gobain Technical Fabrics.
After the adhesive on the polyester fabric has dried and cured, the court or surface that has been repaired may be coated with paint, preferably an acrylic paint, with its color coordinated with the color of the non-repaired section of the recreational court or surface that surrounds the repaired crack. Other recreational court or surface materials, such as sand, may be added to the acrylic paint to enhance the coating process.
In operation, the crack in the recreational court or surface is first cleaned and swept clear of debris. The crack is then filled with a crack filling material, preferably a flexible sealant material, and more preferably a polyurethane foam sealant material. A sufficient amount and type of the crack filling material is utilized to adhere completely to the edges of the crack and prevent or limit exposure of the crack to water. After the crack filling material has dried, paper release backing is removed from the adhesive side of the laminate. The adhesive side of the laminate is then applied to the recreational court, completely covering the crack. This adhesive side of the laminate is then pressed firmly in place against the recreational court or surface and the exposed crack filling material. Applied to at least to the edges of the top of the laminate by means of an adhesive material, such as an acrylic adhesive, is the flexible polyester fabric. Finally, the repaired surface is painted to coordinate its color with that of the surrounding recreational surface.
It will be apparent from the foregoing that while particular forms of the invention have been illustrated, various modifications can be made without departing from the scope of the invention.
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A process for repairing a crack in a recreational court or surface comprising cleaning the crack to remove loose material, filling the crack with a crack filling material, such as a flexible sealant material which adheres to the edges of the crack and securely seals the crack, applying a laminate to the recreational surface and to the exposed sealant material to completely cover the crack, wherein the laminate comprises a waterproof adhesive applied to a flexible material, and securing a polyester flexible fabric to at least the edges of the laminate using an adhesive material.
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