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BACKGROUND
The construction of stadiums is one of the oldest of building arts, and they have been constructed by many methods: including cast in place concrete, brick and masonry, stone, precast concrete, cast iron, and steel. Of special interest is the stadium constructed for the Solano College, California, utilizing the teaching of Johnson U.S. Pat. No. 3,494,092, in which supportive elements were cast extending outward from the deck, and modules so formed were assembled to form alternate modules for the stadium, and then later modules with deck only were placed alternately to complete the structure. The method, at the date in 1971, proved to be the fastest and most economical in competitive bid. The method had the basic disadvantage of requiring transportation of the elements and being limited in the size that could be cast, which made it practical only for small stadiums. Other precast concrete methods have been relatively complex, and quite difficult to bring into proper alignment, to avoid warped and twisted elements, and to make water tight. In addition the structural suitability of the completed structure was difficult to attain.
The present invention bases itself on avoiding these problems and on the current experiences of the inventor in constructing various projects around the world with folding methods.
DESCRIPTION OF THE INVENTION
The basic concept begins with constructing a foundation slab for the entire stadium, and overlying this, constructing a series of modules, each module with an inner end positioned on the inner perimeter of the planned stadium, two sides extending perpendicular to this perimeter and an outer end located parallel to the inner end at the horizontal developed distance from the inner end; and girders are constructed along each of the edges of each module, and the inner ends of the girders are hingeably connected to the inner perimeter of the foundation, and supportive elements are fabricated between the girders, and hingeably connected to the outer portion of said girder lengths, and lifting the outer portion of the girders causes the supportive element to rotate downward to a position where the lower end of the rotated element is supported on the foundation, and it is secured to form a rigid structure. The present invention discloses methods of constructing the girders and the underlying supportive elements to produce the desired slopes for stadiums and the means of preassembling the required structural parts. There is disclosed a new and novel arrangement for constructing "wishbone" columns, and the method of constructing discontinuous decks for stepped stadiums. In addition, there is disclosed the arrangement for forming the modules to form segmentally curved stadiums.
Thus, an entire stadium may be precast in a preassembled position for a stadium of any shape, in which all the parts are prefit together, and lifting the modules one by one, brings them into alignment with the adjacent module, where adjacent decks may be secured together, and the vertical supportive elements secured to the foundation to complete a total structure. In addition, the method provides a great deal of freedom for the designer so that extremely handsome stadiums are possible and economical. It has been estimated that this method can save up to 25% of the structural cost for a comparable size stadium and save up to 30% in construction time. Other advantages will become apparent from the drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1, shows the foundation slab; the underlying girders and supportive elements; a completed module ready to lift; and two modules erected.
FIG. 2, and FIG. 3, show detail of a section of girder and pivot connection.
FIGS. 4, 5, and 6, show the arrangement for discontinuous deck in plan and section for a tiered stadium.
FIG. 7. shows the plan arrangement of modules around a curve.
FIG. 8. shows the detail for placing a gutter between adjacent modules.
DETAIL DESCRIPTION OF THE DRAWINGS
Referring to FIG. 1, the foundation slab 1, and an extension of a casting bed 2, is shown. The casting bed is required to provide for the developed length of the module in the flat. This casting bed may be developed as a walkway around the finished stadium if desired.
In module B, the side girders 3, are shown defining edges of the module, with supportive elements 4,5,6,7, cast between, and the supportive element 8 extending outward beyond the inner perimeter of the stadium foundation. Pivot connections 9, hingeably attach the girders to the supportive elements. The girders are divided by hinged joint 15 into an inner and outer portion.
Module C, is shown with a slab 11, cast over the underlying girders 3, and supportive element 4. In the preferred practice, this slab and the underlying girders would be cast monolithic. A series of planks 12 are cast overlying slab 11. Each of these planks is hingeably connected to slab 11, at the upper edge of the plank. A front wall 13, for the module, is shown in cast position with hinges at the inner edge. Hole 14 represents one of the possible design elements for the wall, which could be modeled or prefinished as desired while in the flat.
Modules D and E are shown erected with the girders elevated to a compound slope, and the supportive elements 4, and 5 rotated to the vertical and supportive position. Walls 6,7, and 8 have rotated down to form a rigid box element to provide lateral support for the deck 11, which is hingeably secured thereto. Seats 12, have been pivoted up to level position, and there secured. Wall 13, has been rotated up to a vertical position.
Module E is shown erected and connected to Module D, and the elements 4 of each module working together to provide structural support around the perimeter of the stadium. The horizontal decks that would be part of the completed stadium, have been omitted for clarity of the illustration. In addition, the thickness of the slab has been exaggerated for clarity. The shape of the element 4, at the top end is arbitrary and may be shaped to the designer's fancy. In addition, the lower configuration, which for element 4, is shown nested together in module B, may be modified as long as the structural integrity is maintained.
In FIG. 2, girders 3, are shown cast together with slab 11, and a pivot connection 9, providing the hinged connection to 5. Steps 12 are shown in elevation.
FIG. 3, shows the cross section and shows the division of the girder to provide the changing slope. It should be noted that this permits the approximation of the ideal curve for viewing angles for a stadium or amphitheater, which is here very easy to accomplish. The filler block 17, varies according to the steepness of the slope and is locked into position by the back edge of the next ahead tread. The actual seats would be applied later and would be of traditional type, wood, metal, plastic, or aluminum. If desired, heating pipes could pass thru void 18, or the voids could be used for passing warm air, which would give great comfort to a stadium theater. Hinges 16, secure the treads to the slab. In addition, a waterproof membrane, may be applied to the surface 19, and the embedded hinged element to provide a waterproof deck and protection from the weather.
FIG. 6 shows the plan arrangement of a discontinuous slab or girder arrangement. Side girders 20 are pivotally connected to the supportive element 21, by pivot 22. Pivot 22 may comprise a continuous tube thru which a post tensioned cable may be threaded to tie the entire stadium together. Item 23 shows a next supportive element with a pivot 24 connecting the supportive element to one portion of the girder, and a pivot 25, connecting the supportive element to the other portion of the side girder. The action of this arrangement is seen in FIG. 4, where the rotation of the supportive element serves to elevate a portion of the deck to a higher position, thus forming an upper tier. By selecting the length of 21, and 23, and 27, the specific slopes of the decks can be determined for the best viewing angle. In the preferred method of erecting the module, the inner end of the module would first be erected and walls 27,28,38 rotated to vertical, and secured to the foundation. The back portion of the stadium would then be elevated and ends 31, and 32, of the supportive elements brought into supportive position and secured to the foundation.
FIG. 8, shows one means of securing adjacent modules together with bolts threaded thru pivot tubes provided thru the girders 3. These tubes could be in position during the casting over a common core, so alignment is assured.
FIG. 8 also shows one form of gutter 45, which could be inserted between the sides of the girders. An expansive material 46, or a resilient material in the space, could complete the seal. Surface 48 would be covered with a waterproof membrane.
FIG. 7. shows two modules in the horizontal projected position, 36 and 37, with the gap 38, between them in this position. When the modules are elevated, the gap 38 would be eliminated and they could come together as 36A, and 37A. Since the sides of 38 are straight for each slope of the deck, and the width of the deck at the change of slope is mathematically determinable, there is no problem in forming a perfect fit.
IN CONCLUSION
From the above description, the invention has been disclosed to be a very simple method for achieving dramatic results in a new and novel way. In this disclosure, the use of concrete has been emphasized as the preferred material. However, the same general geometric configurations are attainable in steel and wood, and the invention should be considered applicable to the other materials, to the degree that they may comply with fire codes, earthquake codes and the like.
Details of specific hardware have been disclosed in other patents and patent applications of the present inventor, or are in his library as trade secrets.
In summary, it is believed that a new and novel method is disclosed for the construction of stadiums and the like, in a more efficient, economical, faster, better way, than any method known to the inventor. The fact that stadiums are currently being constructed by the old systems by the industry would make it seem that the subject material is not obvious to the practicioners of the art.
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The invention concerns the method of constructing and assembling the component structural elements for stadiums and the like structures, in which method the elements are assembled in overlying layers over the foundation for the structure, with hinged connections between the elements, and lifting certain of these elements, permits gravity to cause the other elements to rotate downward where the lower ends are placed on the supportive foundation, and they are secured to provide a rigid structure.
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This is a division of application Ser. No. 792,210, filed Apr. 29, 1977, now U.S. Pat. No. 4,189,524, which is also the parent of copending application Ser. No. 055,497 filed July 6, 1979 and assigned to the same assignee as the instant application.
BACKGROUND OF THE INVENTION
The present invention has for its object an improved structure of multilayer circuits essentially useful in the technology of electric components of the type called "miniaturized".
These multilayer circuits are normally constituted of a stack of "thin" layers, alternatively conductive and insulating, which are deposited in superposition, one atop the other, by any suitable means, such as well known chemical, aqueous, or vacuum deposition processes and all others, all such procedures coming within the realm of the invention which seeks to correct defects which occur regardless of the technology utilized for the deposition of the layers.
These thin layers may, as required, be conformed during and with respect to the production of the stack to obtain desired volumetric electric circuit configurations. The term "thin layer" is intended here in its presently accepted meaning:--layers of which the thicknesses are located from a few several hundreds of angstroms up to a small number of microns, less than 10.
A particular problem of multilayer circuits is that of short circuits which occur either during manufacture or in use. It is important since this effects not only the economics of manufacture but also the reliability of the products.
In a general way, it is desirable that the conductive layers be, in multi-layer circuits, relatively as thick as possible and the interposed insulating layers, relatively as thin as possible so that their electric efficiency is high. The short circuits appear more frequently as the insulating layers are made thinner. But it can also be stated that the frequency of short circuits increases with the thickness of the conductive layers which may require further explanation.
Whatever the technique used for deposition, the state of the surface of a conductive layer degrades as the thickness increases. The growth of crystalline nature and the mesh or size of the crystals increases rapidly with this thickness primarily under the effect of the macles or twins which are produced and the accumulation of defects in the microscopic range causing most often small crystalline growths. However, a very thin layer reproduces accurately the state of the surface of the substrate on which it is deposited. It follows that when a very thin insulating layer is formed on a relatively thick conductive layer whose surface condition is poor for the reasons above discussed, the very thin insulating layer will reproduce all of the defects of the surface of the conductive layer and will present variations of thickness leading readily to the existence of microporosities and the appearance of short circuits.
These risks of production of short circuits during manufacture therefore introduce a by no means negligible limitation on the ratios of the thicknesses of the conductive and insulating layers in multilayer circuits.
Further, multilayer circuits must often support during use of equipment in which they are incorporated large elevations of temperature which can for example reach 450° C. or thereabout. However, the conductive materials currently utilized in these circuits because they have a low resistivity, favorable to the flow of electric current, are, usually, the four metals of the group of copper, aluminum, silver and gold and their alloys. Each of these standard metals has a coefficient of its thermal expansion which is relatively large, that for copper, for example, being 14 10 -6 /°C., and crystallize easily when the temperature increases, with grains which enlarge quickly. The lattice of the crystalline structure is therefore under considerable stresses entailing or producing the formation of fissures. Thus, a metal-insulator-metal structure can develop a short circuit when submitted to an elevation of temperature which modifies the regular crystalline structure of the metal.
The object of the invention is to eliminate the above-described difficulties and particularly, to provide multilayer circuits with any desirable "high ratio" between the thicknesses of the conducting and insulating layers. The problem of the elevations of temperatures with respect to the insulating layers can be ignored since the materials usual for these insulating layers have high thermal stability at the temperatures to be considered for the efficiency of the circuits.
SUMMARY OF THE INVENTION
To these ends, the invention provides for multilayer circuits of the type above discussed a new structure essentially characterized in that it comprises between each thick layer of conductive material of low resistivity and relatively high coefficient of thermal expansion and at least the insulating layer which should separate it from the thick conductive layer following the stacking, a thin conductive layer of a conductive material having a relatively high resistivity with respect to the conductive material of low resistivity forming the conductors of the multilayer circuit, having a low thermal coefficient of expansion at least at the operating temperatures of the circuit and a crystalline lattice and size at least close to or similar to those of the conductive material of low resistivity.
The additional thin conductive layer having these properties could be deposited only on one side of the thick conductive layer, namely that side on which there will afterwards be formed a thin insulating layer in the course of deposition of the succeeding layers in the stack. It may be better for the final result to sandwich all thick conductive layers between two such additional thin layers in considering especially the point of view of heating during the use of the circuits.
The provision of these thin additional conductive layers assures that each very thin insulating layer of the stack will be deposited on a substrate of very good surface state and therefore at this level to prevent any appreciable microporosity in spite of its thickness ratio with respect to the conductive layer of low resistivity above which it is located higher than desirable for the object sought, that is the intensity of the electric current that the circuits should support during its use.
The choice of the material of the additional conductive layers assures at least and in fact reinforces the mechanical homogeneity of the multilayer because of the close crystallographic relationship between the conductive materials of the thick and thin layers. When further, the deposition process utilized requires heat, primarily in the case of evaporation under vacuum or under controlled atmosphere, the formation of an additional conductive layer thermally more stable on the crystalline plane assures to a certain degree a reduction of the macles or twins which may have occurred during the deposit of the underlying conductive layer of low resistivity. Actually, the additional material will be doped by the material of the underlying conductive layer to a certain predeterminable depth and during the dopage the superficial macles of the deposited layer will be destroyed, because their materials combine in doping with the crystals of the additional material over the said depth. Further, the interposition of the additional material has an additional advantage. Generally speaking, the conductive material of low resistivity will much more likely oxidize than the material of high resistivity forming the interposed layer. During the formation of the insulating layer, which in fact has an oxide base, in the process of deposition by evaporation under a controlled atmosphere, the oxygen utilized could and in fact does oxidize the surface of conductive layer of low resistivity. The additional layer will avoid this inconvenience.
The utilization of the sandwich form as discussed still further reduces the occurrences of the enumerated inconveniences as to the normal conductive layers of the multilayers.
When utilizing a multilayer circuit provided in accordance with the present invention subject to large heating up to, for example 450° C., the value which is taken as a limit in practice, this heating instead of being destructive of the electric insulation acts as a simple annealing reinforcing the doping and stabilizing the multi-layers with respect to short circuits and with respect to further heatings. The useful thickness of the layers of low resistivity for the normal intensities of the electric currents in use with the multilayers will be evaluated as a function of a known value in the art, knowing the facility of doping of the additional material by the less stable material from the thermal point of view, thus diffusing in the additional material.
It can therefore be provided, for example, that before any delivery for use, a multilayer of the present invention will be subjected to a systematic annealing at this maximum temperature and thereafter tested. When no short circuit is then revealed, the multilayers will have a very strong probability of reliability in use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary view, in vertical cross section, of a multi-layer structure of the type known in the prior art.
FIGS. 2 and 3 are fragmentary views, in vertical cross section, of multi-layer structures made in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a multilayer circuit of the type known in the prior art is made of alternatively depositioned layers one atop the other. After a thin film insulating layer 10 has been deposited over priorly formed layers (not shown), a conducting material layer 11, made of a material of relatively low resistivity and relatively high thermal expansion is deposited. Over this layer 11, which is thicker than the insulating film 10, there is deposited another thin film 12 of insulating material, and, thereafter, another conducting layer 13 of identical characteristics to layer 11. Over this further conducting layer 13, a further insulating film 14 is deposited; and so forth, the remaining layers of the stack not being shown. It must be understood that each insulating film is made of a refractory material such as, mainly, silica or ceramic.
The disadvantages of this conventional stack and defects resulting thereof have been hereinbefore described.
A multilayer stack made according to the teachings of the invention is shown in FIGS. 2 and 3.
In FIG. 2, between each of two insulating films 20, 22 and 22, 24, are inserted composite conducting layers, each comprises of a thicker low resistivity relatively high thermal expansion coefficient material, 21 and 25, respectively, and of a thinner layer, or film, 23 and 26, respectively, of a conducting material of relatively higher resistivity and relatively low thermal expansion coefficient. However, the materials of these two layers are so selected as to have close crystallographic characters, as it has been herein described.
In FIG. 3, between each of the two insulating films 20, 22 and 22, 24, are inserted composite conducting layers, each comprised of a pair of conducting films 30, 32, respectively, and 34-35, respectively, of a relatively high resistivity and high thermal strength. Between each pair of conducting films is a thicker conducting layer 31, 33 respectively, of a material of relatively low resistivity and relatively low thermal strength, however, the materials of the said layer and films are selected to present close crystallographic characters, as herein described.
In further explanation of the invention, an example can be considered in which the conductive material having low resistivity forming the thick conductive layers is copper, the material of the additional layers is chromium and the insulating material is silica. Silica is the most common binary compound of silicon and oxygen (S 1 O 2 ) and an insulating refractory material. Chromium and copper have somewhat similar crystallographic characteristics. Copper crystallizes in cubic form with centered faces and chrome crystallizes in cubic form with centered bodies, the dimensions of the lattice being close in these two materials. Chromium, as known, does not expand appreciably at a temperature not above approximately 450° C. It oxidizes only little beneath this limit of temperature when heated in an oxidizing atmosphere.
Two hundred (200) specimens of multilayer circuits were formed in two series. In the first only the usual structure was utilized, alternating regularly thick layers of copper on the order of one to four microns and thin insulating layers of silica on the order of 800A. In the second series, the present invention was utilized by separating each thick conductive layer from each thin insulating layer by a thin layer of chromium on the order of 200A in thickness.
With the multilayers of the first series, the range of loss after manufacture was on the order of 8% increasing to 96% at least when then followed by an annealing of the type described above. With the multilayers of the second series the range of losses was initially on the order of 2% and was raised to only about 15% after annealing.
The above example where the materials are copper and chromium is obviously only illustrative. There is a rather large choice from the crystallographic point of view and from the electric and thermal point of view involving a certain range of limitations of choice based on the one hand on the deposition process utilized and on the other hand whether or not magnetic materials can be employed in the stack.
From this last point of view all magnetic materials which would otherwise be useful--beta cobalt, nickel, for example, will be eliminated except to assure during manufacture a dopage such that the final form would be non-magnetic when required, by introduction of an additional doping element assuring such a transformation.
To manufacture multilayer circuits by application of evaporation in a controlled atmosphere, there will be eliminated bodies which evaporate badly; primarily the metalloids such as strontium, calcium, thallium, rhodium whose other characteristics of which would be compatible with the manufacture of the invention by other deposit procedures.
After the application of the elimination criteria set forth above, only simple crystalline bodies which crystallize similar to copper remain, such as, for example, chrome, titanium deposited in beta form and vanadium, and their alloys, or from that formed by Nickel and Beta Cobalt doped with the first material for a fabrication which relies on evaporation in a controlled atmosphere and where copper is the normal conductive material in the multilayers.
On the other hand, the use of aluminum for the material of low resistivity becomes easy since, when covered with thin additional layers of the invention, it does not oxidize during the deposit of silica, whereas previously oxidizing made its use difficult.
It should be noted that the use of bodies or alloys of similar crystallography, but not identical to that of the materials of low resistivity is made possible because, by evaporation under vacuum, at least, the well known phenomena of epitaxy comes into action in the deposit of thin layers, a phenomena which tends to cause the newly evaporated substance to "copy" the lattice of the substance which constitutes the substrate for it.
The thicknesses of the additional layers need not in practice of the invention be greater than 5000A, any more than the thicknesses of the insulating layers had, or still have, any need to be as much as a micron, since the thickness of the layers are not critical, it is obviously desirable to avoid the dissipation of the materials in industrial manufacture.
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To reduce the proportion of rejects resulting by reasons of short circuits in the manufacture and use of miniaturized multilayer circuits and to improve the electric efficiency, there is inserted between each conductive layer of low resistance and each insulating layer of high thermal stability, a very thin layer of a conductive material, preferably non-magnetic, of high resistivity and of crystallographic reference at least compatible with respect to the first conducting material and of low or negligible thermal expansion in the range of temperatures to which the circuits are submitted both during manufacture and use.
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FIELD OF THE INVENTION
The present invention relates to a sign that can be hung from a suspended ceiling, and more particularly, to an integral cantilevered and/or counterbalanced, locking bracket and sign that can be secured to the inverted "T" grid rail of a suspended tile ceiling.
BACKGROUND OF THE INVENTION
Hooks or clips that grip the inverted "T" grid rail of suspended ceilings are well known as devices for suspending signs and other weighted objects from suspended tile ceilings. Although these devices are useful for some purposes, there are a number of drawbacks to such means of attaching signs and other objects.
Suspended ceiling clips, such as the clip described in U.S. Pat. No. 4,073,458 ("the '458 patent"), utilize a "U" design attached to the lower edge of a grid rail. The '458 patent hanger clip is formed from a thin strip of metal with a U-bend portion formed in approximately the middle of the strip, that clips onto the horizontal ledge of the overhead beam, and lower end for attaching articles to. The '458 patent also uses a vertical portion extending from the upper end of the "U" clip which fits between the vertical leg of the overhead beam and a ceiling panel installed on that beam to hold the clip in position.
The device described in the '458 patent, although useful in some situations, may require the "U" clip conform to the dimensions of a specific grid rail. In the case of many present day suspended tile ceilings, "U" clips may be incapable of gripping grid rail ledges that can be 1/4 inch or less in width, and that may have rounded or beveled edges and surfaces for aesthetic as well as functional qualities, as such narrow, beveled or rounded rails permit ceiling tiles to fit tighter, resulting in superior sound and heat insulation performance. "U" clips are easily dislodged from such grid rails, if they can be affixed to such rails at all.
If the grid rail ledge is wide, or the weight suspended from it is heavy, the legs of the clip may be pulled apart by the weight suspended from the lower portion of the clip, so as to no longer permit the clip to grip the grid rail.
Another disadvantage of the use of such clips is that in order for the suspended item to be held horizontally stable, at least two clips must generally be used. As suspended tiles may be extremely lightweight, the use of such clips to suspend heavy items from "T" rails can cause grid rails to bend or deform in the case of a clip that fails to distribute the weight of suspended items along the greatest possible surface area of the grid rail ledge. Low-strength rails may also twist, causing the clip to become dislodged and the object suspended below to fall.
Further, as the object is suspended below such "U" clips via wire, chain, or other means, it is more likely that an object will catch on an upper edge of the sign or object, thereby dislodging the clips from the grid rail. Clips can become dislodged by horizontal stress if they inflexibly grip a particular location on a grid rail. Finally, clips can deform, scratch or otherwise deface exposed lower surface of the grid rail.
Similarly, U.S. Pat. No. 4,223,488 ("the '488 patent") teaches a ceiling hanger adapted to be removably installed on tile ceiling grid rails; the hanger includes a plate having a U-shaped end portion embracing one edge of the grid rail, a midportion underlying the grid rail, and a retaining clip embracing the opposite edge of the grid rail. Advertisements or objects are to be hung from hooks or fasteners below the clips. The device described in the '488 patent, has limitations similar to those found in other grid rail clips.
Clips may offer insufficient resistance to a variety of anticipated and unanticipated dynamic stress situations. Grid rail clips, hooks, and other fastening means may also provide no satisfactory means to suspend a sign or other object over the center of a ceiling tile, as clips must be fastened to opposing grid rails and wires strung between the clips. Should one of the clips becomes dislodged (particularly in the case of a metal sign), the object can swing into or fall on personnel or equipment. A danger that an object passing below becoming entangled in the suspended wires traversing the clips may also exist.
It would therefore be desirable to develop a locking, suspended ceiling grid rail sign and bracket that will overcome the shortcomings of other grid rail clips and hooks.
SUMMARY OF THE INVENTION
The present invention provides a cantilevered/counterbalanced grid rail sign that will conform to the ledge of a suspended ceiling grid despite the width or thickness of that grid rail.
The sign/bracket of the present invention remains fixed by a supporting ledge that runs the length of the upper exposed edge of the sign; further, the cantilevered and/or counterbalanced structure of the sign locks it firmly in place, and need not be tailored to a grid rail of a particular width and thickness. The sign is supported by and its weight is evenly distributed along the entire ledge in contact with the grid rail.
Embodiments of the present invention are also such that the sign can be suspended away from the grid rail, towards the center of the suspended ceiling tile it is adjacent to, via its cantilevered and/or counterbalanced properties.
Other details, objects and advantages of the cantilevered/counterbalanced sign will become more readily apparent from the following descriptions of the presently preferred embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, preferred embodiments of the invention are illustrated by way of example only, wherein:
FIG. 1 shows a perspective view of the cantilevered sign of the present invention;
FIG. 2. shows a perspective view of one embodiment of the counterbalanced sign of the present invention;
FIG. 3 shows a perspective view of a cantilevered and counterbalanced embodiment of the present invention;
FIG. 4 shows another embodiment of the present invention;
FIG. 5 shows another embodiment of the present invention;
FIG. 6 shows another embodiment of the present invention;
FIG. 7 shows another embodiment of the present invention; and
FIG. 8 shows another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a perspective view of cantilevered sign 1, attachable to inverted "T" grid rail 2 of a suspended tile ceiling. Horizontal flange 3 of sign 1 rests on ledge 4 of the inverted "T" grid rail; display surface 5 is suspended below the outer edge of horizontal flange 3. Vertical flange 6 of sign 1 rests against edge 7 of suspended ceiling tile 8. The weight of exposed, suspended display surface 5 of sign 1 is thereby cantilevered by the opposing force supplied by vertical flange 6 resting against end 7 of suspended ceiling tile 8; in this manner, the force of end 7 of ceiling tile provides opposing torque to the weight of display surface 5 suspended past the edge of ledge 4. This causes sign 1 to remain locked into position despite the anticipated or unanticipated static and dynamic forces that may act upon the suspended, exposed portion of sign 1. The weight of ceiling tile 8 on horizontal flange 4 provides additional stabilizing force on sign 1.
Sign 1 can easily be removed once vertical flange 6 is freed from its cantilevered resting position against edge 7 of suspended ceiling tile 8 by raising ceiling tile 8 above top edge 9 of vertical flange 6.
Another embodiment of sign 1 is detailed in FIG. 2, which shows a counterbalanced embodiment of sign 1, resting on inverted "T" grid rail 2 of a suspended tile ceiling. Horizontal flange 3 of sign 1 rests on ledge 4 of the inverted "T" grid rail; display surface 5 is suspended below the outer edge of horizontal flange 3. Vertical flange 6 rests between grid rail 2 and edge 7 of suspended ceiling tile 8. Counterbalancing member 10 is attached to upper edge 9 of vertical flange 6, thereby holding the weight of the exposed, suspended display surface 5 of sign 1 in equilibrium below suspended ceiling tile 8. In this manner, the gravitational force of counterbalancing member 10 provides opposing torque to the weight of display surface 5 suspended past the edge of ledge 4. This causes sign 1 to remain locked into position despite the anticipated or unanticipated static and dynamic forces that may act upon the suspended, exposed portion of sign 1. The weight of ceiling tile 8 on horizontal flange 4 provides additional stabilizing force on sign 1.
Sign 1 as shown in FIG. 2 thereby remains balanced in position until ceiling tile 8 is raised, and sign 1 is lifted from ledge 4. Sign 1 can easily be removed once vertical flange 6 is freed from its balanced resting position on ledge 4 by raising ceiling tile 8 above top edge 9 of vertical flange 6, and removing counterbalancing member 10 from its position over grid rail 2.
FIG. 3 shows a cantilevered and counterbalanced embodiment of the present sign and integral bracket, also attachable to inverted "T" grid rail 2 of a suspended tile ceiling. This embodiment provides the increased capacity and stability that may be needed to suspended signs or similar objects at increased distances from grid rail. Heavier display surfaces or objects may also be suspended further from grid rail 2 towards the center of ceiling tile S, without sacrificing stability or safety.
Horizontal flange 3 of sign 1 rests on ledge 4 of the inverted "T" grid rail as shown in FIG. 3; display surface 5 is suspended below the outer edge of horizontal flange 3. Vertical flange 6 of sign 1 rests against edge 7 of suspended ceiling tile 8. The weight of exposed, suspended display surface 5 of sign 1 is thereby cantilevered by the opposing force supplied by vertical flange 6 resting against end 7 of suspended ceiling tile 8; in this manner, the force of end 7 of ceiling tile 8 provides opposing torque to the weight of display surface 5 suspended past the edge of ledge 4.
Counterbalancing member 10 is attached to upper edge 9 of vertical flange 6, thereby holding the weight of the exposed, suspended display surface 5 of sign 1 in equilibrium below suspended ceiling tile 8. In this manner, the gravitational force of counterbalancing member 10 provides opposing torque to the weight of display surface 5 suspended past the edge of ledge 4.
The cantilevered and counterbalancing forces acting on sign 1 as shown in FIG. 3 cause sign 1 to remain locked and balanced in position on grid rail 2. Sign 1 remains balanced and locked in position until ceiling tile 8 is raised and sign 1 is removed.
Horizontal safety tab 11 as shown in FIG. 3 provides protection against allowing sign 1 to become dislodged as a result of accidental impacts, air currents, or other dynamic forces that may act on the exposed, suspended portion of sign 1. Horizontal safety tab 11 is attached to upper edge 9 of vertical flange 6. Horizontal safety tab 11 may be shorter that the length of vertical flange 6, and may be bendable so as to adapt to the upper surface of ceiling tile 8.
Horizontal safety tab 11 is not required to support sign 1 during static conditions, and does not grasp ceiling tile 8, which is normally a soft and otherwise easily damaged insulating material.
FIG. 3 also shows cantilevered and counterbalanced sign 1 additionally equipped with safety flange 19 extending from vertical flange 6 over the upper edge of grid rail 2. Safety flange 19 provides protection against allowing sign 1 to become dislodged as a result of accidental impacts, air currents, or other dynamic forces that may act on the exposed, suspended portion of sign 1.
Safety tab 19 may be shorter than the length of vertical flange 6, and may be bendable so as to adapt to the upper edge of grid rail 2. Safety flange 19 is not required to support sign 1 during static conditions.
The embodiment shown in FIG. 4 includes safety chain 12 attached at one end to vertical flange 6 of sign 1 as shown in FIG. 2. Safety chain 12 is attached at the other end to vertical flange 6 of sign 1 as fastened to grid rail support 13 via clasp 14 or similar means, so as to prevent sign 1 from falling should it be dislodged from grid rail 2. FIG. 4 also shows sign 1 equipped with hinge mechanism 15 near the upper edge of display surface 5 of sign 1. Hinge 15 permits the display surface 5 to swing freely if displaced by a force acting on it from below; display surface 5 may also be rotated into a horizontal, stored position when not in use.
FIG. 4 also shows retaining edge 18 which is slightly embedded into the soft insulating material that generally forms end 7 of ceiling tile 8. Retaining edge 18 provides a stabilizing means for vertical flange 6 to provide cantilevered support for display surface 5 of sign 1, and creates a tight fit for vertical flange 6 between grid rail 2 and end 7 of ceiling tile 8.
FIG. 5 shows cantilevered and counterbalanced sign 1 with an extended horizontal flange 3 and extended counterbalance member 10 so as to permit multidimensional display surfaces 15, 16 and 17 to be suspended near the center of ceiling tile 8. FIG. 6 also shows sign 1 with horizontal safety tab 11 connected to vertical flange 6, extending over the upper surface of ceiling tile 8, and safety flange 19 also extending along the upper edge of vertical flange 6, locking over and down grid rail 2. Safety flange 19 and may be bendable so as so grasp grid rail 2, and horizontal safety tab 11 may be bendable so as so to conform to the upper surface of ceiling tile 8.
FIG. 6 shows cantilevered and counterbalanced sign 1 with two extended counterbalance members 20 and 21 connected to the upper edges of vertical flanges 22 and 23. Vertical flanges 22 and 23 are connected at the bottom edge to short sides 24 and 25 of right triangle-shaped horizontal flange 26 so as to fit together on an intersecting 90° corner of adjacent grid rails 27 and 28. Vertical sign plane 29 is attached to long side 30 of horizontal flange 26 so as to be suspended at a 90° angle below horizontal flange 26.
FIG. 7 shows cantilevered and counterbalanced sign 1 with two extended counterbalance members 31 and 32 connected to the upper edges of vertical flanges 33 and 34. Vertical flanges 33 and 34 are connected at the bottom edge to grid rail edges 35 and 36 of four sided horizontal flange 37. The grid rail edges 35 and 36 of four sided horizontal flange 37 are at a 90° angle to each other, so as to permit four sided horizontal flange 37 to fit on intersecting 90° corner of adjacent grid rails 38 and 39. Vertical sign plane 40 is attached to long side 41, opposite short side 42 of four sided horizontal flange 37, so as to be suspended at a 90° angle below four sided horizontal flange 37.
The embodiment of FIG. 8 includes two cantilevered signs as shown in FIG. 1 in which vertical edge 42 of vertical display surface 43 is attached to vertical edge 44 of vertical display surface 45 is attached at a 90° angle so as to fit together on an intersecting 90° corner of adjacent grid rails 46 and 47.
While presently preferred embodiments of practicing the invention has been shown and described with particularity in connection with the accompanying drawings, the invention may be otherwise embodied within the scope of the following claims.
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The present invention relates to a sign that can be hung from a suspended ceiling. Specifically, the cantilevered and/or counterbalanced sign rests securely in the inverted "T" rail of a suspended ceiling tile grid, and can easily be inserted or removed without damaging or destroying the ceiling tile. At the same time, the cantilevered and counterbalanced structure of the present sign permits the sign to rest securely on grid rails with varying support ledge designs, shapes and dimensions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an axial piston machine with a rotating cylindrical drum, which has a multiplicity of cylindrical bores arranged concentrically to the axis of rotation with pistons capable of sliding longitudinally therein. The drum lies against a control surface adjacent the housing., in which case the pistons are in contact with a working surface that can be positioned diagonally to the axis of rotation and the cylindrical bores are provided with connecting openings to the control channels of the control surface, whereby the cylindrical drum is also supported in a longitudinally moveable manner. More particularly, the invention relates to such a machine wherein additional means is provided for controlling the pressing force of the cylindrical drum on the control surface, which is in working connection with the cylindrical drum.
2. Description of the Art
When such machines are used as pumps, especially as self-priming pumps, it is desirable that the pump have as high a suction rate as possible in order to minimize the filling losses caused by flow losses on the suction side and the resulting reduction in the delivery volume. The flow losses are a function of the flow velocity of the flow medium in the suction channel of the pump and the design of the latter. It is therefore necessary that the suction channel have as large a cross section as possible to keep the flow velocity and thus the pipe friction and flow losses low.
In the case of axial piston machines, there is a peculiarity that also leads to filling losses. This consists in the structurally induced gap between the housing control surface, which contains the orifices of the suction channel, designed as kidney-shaped control channels, and the rotating cylindrical drum lying against them. The gap is necessary so that a hydrostatic film of lubrication can form between the webs of the control surface and those of the cylindrical drum, which reduces the friction and facilitates disturbance-free and easy running of the machine. However, external leakage streams are caused by the gap, as well as inner leakage streams that flow directly from the high-pressure side to the low-pressure side of the control surface. The loss stream that results reduces the volumetric efficiency of the machine and thus the actual delivery volume. In order to achieve a satisfactory volumetric efficiency, the gap between the rotating cylindrical drum and the control surface must be kept as small as possible. This is achieved by a pressure spring which presses the cylindrical drum against the control surface and also by a connection which is produced between the cylindrical bores and the control channels through openings whose diameter is smaller than the diameter of the cylindrical bores. Through the latter measure, the cylindrical drum is pressed into the cylindrical bores against the control surface due to the fluid pressure, in which case the contact pressure is proportional to the loading of the machine. The leakage streams and/or filling losses of the axial piston machine are thus held at a low level.
The narrowed connection openings between the cylindrical bores and the control channels represent a constriction of the suction channel, which leads in the case of a certain desired delivery volume to a certain flow velocity in this region and thus to flow losses and, in accordance with the flow rate, to a restriction in the suction power of such a machine versus a machine lacking this structural means.
The geometric relationships on the suction side are thus essentially prescribed by the power and moment equilibrium between the hydrostatic release of the rotating cylindrical drum and limitation of the relief gap.
An axial piston machine of swash plate construction is disclosed in German patent DE-OS 22 50 510, in which an additional device situated around the outside diameter of the cylindrical drum induces an increase in the pressing force of the cylindrical drum on the control surface. A disadvantage in this device, however, is that it increases the structural volume of the axial piston machine substantially and leads to a complicated and expensive construction.
The present invention proposes to avoid those shortcomings and increase the suction ability of an axial piston machine in an economical manner.
SUMMARY OF THE INVENTION
According to the present invention, an axial piston machine with a cylindrical drum that lies against a control surface provided with control channels includes means for controlling the pressing force of the cylindrical drum on the control surface for increasing the suction ability. To increase the suction ability of the axial piston machine in an economical manner while retaining a small structural volume, the additional means is provided in a cavity between the inner surface of the cylindrical drum and the outer surface of the drive shaft. The additional means comprises at least one annular space that is formed by a hollow cylindrical inner surface of the cylindrical drum and two annular pistons capable of sliding longitudinally with respect to each other and arranged co-axially to the axis of rotation and is connected through connecting channels with the control channels and can be acted upon by high pressure, by which an additional pressing force can be exerted on the cylindrical drum.
The additional means can be thus obtained without the need for additional space and with simple means; it controls the pressing force of the cylindrical drum on the control surface, e.g., increasing it. An additional axial force is thus generated in the direction of the control surface. The additional contact pressure thus obtained can be used for an amplification of the kidney-shaped control channels in the control surface and the connection openings to the cylindrical bores, corresponding to the power and moment equilibrium. In some cases, the diameter of the connection openings can match the diameter of the cylindrical bores. A clear improvement in the suction capacity of the axial piston machine and an increase in the possible suction r.p.m. result in every case, which is advantageous, especially in machines that operate in an open cycle. An increase in the suction r.p.m. means that the machine can be capable of suction in an r.p.m. range that facilitates operation through a directly connected driving engine, so that reduction gearing, which was previously necessary, can be eliminated. This results in an increase in efficiency in such a unit.
The present invention can also be used for machines that operate in a closed cycle. The control channels can be enlarged and the webs between them can be broadened. The additional hydrostatic release of the cylindrical drum caused by a web broadening is then compensated by the axial force generated by the means.
It has proved advantageous if the additional means contains at least one piston surface that can be acted upon with operating pressure as a function of the delivery stream. The force of the cylindrical drum pressing on the control surface is controlled by the flow medium under the operating pressure that acts on the piston surface. The flow medium is drawn from the high-pressure control channels. The piston surface is thus loaded with flow medium under corresponding high pressure as a function of the load or the delivery stream of the machine.
The arrangement of the additional means can be used in machines whose cylindrical drum is supported in a longitudinally moveable manner on a drive shaft that passes through it centrally, as well as in machines that have no such central shaft.
In an advantageous embodiment of the invention, in which the additional means presses the cylindrical drum against the control surface and the cylindrical drum has a drive shaft passing through it centrally, the piston surface is formed between a hollow cylindrical inner surface of the cylindrical drum and two annular pistons that slide lengthwise with respect to each other and are arranged co-axially to the axis of rotation. The first annular piston has an axial support on the cylindrical drum and is capable of moving longitudinally with respect to the drive shaft and the second annular piston has an axial support on the drive shaft and is longitudinally moveable with respect to the cylindrical drum. The additional means can thus be constructed of only a few easily producable components and requires little space.
In another embodiment of the invention, the additional means has a direction of action away from the control surface. The cylinder block that is pressed by a pressure spring and, due to the pressure, into the cylindrical bores and the narrowings of the connection openings against the control surface thus undergoes a pressure-dependent release, which reduces the friction in the gap. Under certain conditions, i.e., if the axial force resulting from the relief pressure corresponds to the spring force, the force of the pressure spring is completely cancelled and the only force that still acts on the cylinder block is that resulting from the pressure in the cylindrical bores, and opposing it the hydrostatic release force in the gap. If the release pressure remains below a certain value, the full spring force acts on the cylindrical drum, by which higher r.p.m. are attainable, with no tipping of the cylindrical drum.
Hence, the additional means preferably comprises an annular piston arranged co-axially to the axis of rotation between a cylindrical outer surface of the drive shaft and a hollow cylindrical inner surface of the cylindrical drum. The piston is longitudinally moveable with respect to both the cylindrical drum and the drive shaft and with a cylindrical outer surface in connection with a hollow cylindrical inner surface of the cylindrical drum forms at least one annular space. In this case, the annular piston in the pressureless state of the axial piston machine has an initial end position, in which a pressure spring located between a hollow cylindrical inner surface of the annular piston and the cylindrical outer surface of the drive shaft has as large an axial extension as possible and the annular piston lies on a stop of the drive shaft. In the case of a given load of the axial piston machine, a second end position of the annular piston is provided, in which the pressure spring has as small an axial extension as possible and the annular piston lies on a stop of the cylindrical drum. When a certain pressure level is exceeded in the annular space, the annular piston moves into its second end position, so that the pressure spring no longer lies on the stop on the drive shaft and thus can no longer exert a pressing force on the cylindrical drum because the axial reaction force is no longer taken up by the drive shaft. Such a construction also has a low production cost. The pressure spring already present is supplemented only by an annular piston.
It is advantageous if at least one connecting channel located in the cylindrical drum is provided between the annular space and at least one of the control channels in the control surface. The connecting channel or channels can be readily introduced during production of the cylindrical drum. The drive shaft itself remains free of bore holes and grooves.
In axial piston machines with a device for adjusting the delivery volume and reversal of the direction of flow, e.g., a bilaterally pivotable axial piston pump of swash plate construction, according to another embodiment of the invention, at least one annular space and at least one connecting channel are assigned to each direction of flow. The additional means can be used in this case independently of the direction of flow, so that in each case the flow losses are reduced on both the suction and the pressure sides. It is desirable for this purpose if for the first direction of flow a multitude of connecting channels are spaced from each other concentrically to the axis of rotation on an initial graduated circle by an approximately identical angle, and for a second direction of flow a multitude of connecting channels are spaced by an approximately identical angle from each other concentrically to the axis of rotation on a second graduated circle. The annular space is thus loaded approximately uniformly with high pressure.
The invention will be understood and appreciated from a perusal of the specification taken with the following schematic representations showing one exemplary embodiment with several variants.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an axial section on line 1--1 of FIG. 2 showing an embodiment of an axial piston machine according to the invention;
FIG. 2 is a section on line 2--2 of FIG. 1 showing a control surface of the axial piston machine shown in FIG. 1;
FIG. 3 is an axial section on line 3--3 of FIG. 4 showing a second embodiment of an axial piston machine according to the invention;
FIG. 4 is a section on line 4--4 of FIG. 3 showing a control surface of the axial piston machine shown in FIG. 3;
FIG. 5 is an axial section on line 5--5 of FIG. 6 showing a third embodiment of an axial piston machine according to the invention;
FIG. 6 is a section on line 6--6 of FIG. 5 showing a control surface of the axial piston machine shown in FIG. 5;
FIG. 7 is an axial section on line 7--7 of FIG. 8 showing a fourth embodiment of an axial piston machine according to the invention; and
FIG. 8 is a section on line 8--8 of FIG. 7 showing a control surface of the axial piston machine shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The essential components of an axial piston machine according to the invention, in this example an axial piston machine of swash plate construction, are shown in the drawings wherein the housing and the working surface of the piston as well as some adjustment devices have not been shown.
A swash plate pump has a drive shaft 3 supported by bearings 1 and 2. The drive shaft 3 passes centrally through a cylindrical drum 4 and is connected with it in a rotationally contacting manner. The cylindrical drum 4 is longitudinally moveable within certain limits with respect to the drive shaft 3, which is achieved for example by a spline. The axial section shown in FIG. 1 is taken on section line 1--1 of FIG. 2. FIG. 2 in turn represents a section on line 2--2 of FIG. 1. The same drawing conventions apply for FIGS. 3-8.
An end of cylindrical drum 4 is located against control surface 5. The drum has a multitude of cylindrical bores 6 in which longitudinally moveable pistons 7 are located. The cylindrical bores 6 are arranged concentrically to the axis of rotation I of the drive shaft 3. The pistons 7 are connected with a working surface (not shown) that can be positioned obliquely to the axis of rotation. When the drive shaft 3 rotates, a piston stroke is induced in the conventional manner. The cylinder bores 6 are connected to control channels 9 and 10 of the control channel surface 5 by means of connecting openings 8 in certain rotational positions of the cylindrical drum 4. The connecting openings 8 are smaller in cross section than the cylindrical bores 6 so that the cylindrical drum 4 is pressed against the control surface 5 when a load-dependent pressure is present in the cylindrical bores 6. A hydrostatic relieving force, which acts in a known manner between the front face of the cylindrical drum 4 and the control surface 5, is directed against the axial force thus generated. In order to effect a certain pressing of the cylindrical drum 4 on the control surface 5 in the pressureless state of the swash plate pump and at a low pressure, a pressure spring 11 is provided, which is located in this embodiment inside the cylindrical drum 4 in an annular cavity 12 between a cylindrical outer surface 13 of the drive shaft 3 and a hollow cylindrical inner surface 14 of the cylindrical drum 4 co-axially to the axis of rotation I. The pressure spring 11 rests on the cylindrical drum 4 with its right end in the axial section via an annular piston 15 and a retaining ring 16. The annular piston 15 can also be made in several parts, as illustrated in the modification shown in the lower half of the axial section, namely of two parts 151 and 152, of which the latter forms a radial support flange 15a that projects inwardly toward the axis of rotation I. The annular piston 15 is moveable longitudinally with respect to both the inner wall 14 of the cylindrical drum 4 and the drive shaft 3, where the longitudinal movement with respect to the inner wall 14 of the cylindrical drum 4 is limited by the retaining ring 16 and makes contact with the hollow cylindrical inner surface 14 of the cylindrical drum 4 with its cylindrical outer surface. The annular cavity 12 in which the pressure spring 11 is located is situated between the cylindrical outer surface 13 of the drive shaft 3 and the inner surface of the annular piston 15.
The annular cavity 12 is closed off at one axial end by the support flange 15a and at the opposite axial end by a second annular piston 17, which forms an abutment for the pressure spring 11. The annular piston 17 is also axially moveable with respect to both the hollow cylindrical inner surface 14 of the cylindrical drum 4 and the drive shaft 3, in which case the axial movement relative to the drive shaft 3 is restricted by a collar 3a of the drive shaft 3. The pressure spring 11 is thus tensioned between the cylindrical drum 4 and the drive shaft 3.
The second annular piston 17 has a collar 17a oriented radially outwardly with respect to the axis of rotation I; its cylindrical outer surface lies on the hollow cylindrical inner surface 14 of the cylindrical drum 4. The first annular piston 15, together with the second annular piston 17 and the hollow cylindrical inner surface 14 of the cylindrical drum 4, form an annular space 18, which can be connected with at least one of the control channels 9 via a channel 19, which in this embodiment is essentially helical, and connection channels 20 in the cylindrical drum 4. The control channels 9 are under load-dependent high pressure when the pump is running. The connecting channels 20 are concentric to the axis of rotation I on a common graduated circle.
The number of connection channels 20 is basically arbitrary. However, the number and angular spacing are preferably chosen such that when the cylindrical drum 4 is rotating, at least one connecting channel 20 is always connected to a control channel 9. A connection to the control channel 10 of the control surface 5 is not provided in the embodiment shown in FIG. 1 because the swash plate pump is designed to have only one direction of throughflow.
The flow medium under high pressure passes from the control channels 9 through the connecting channels 20 and the channel 19 into the annular space 18, where it attempts to separate the annular pistons 15 and 17 from each other. A load-dependent additional pressing force is thus generated that presses the cylindrical drum 4 against the control surface 5. The additional means required for this consists, as described, only of the annular pistons 15 and 17, the channel 19 and the connecting channels 20.
The embodiment shown in FIGS. 3 and 4 differs from that shown in FIG. 1 in that the swash plate pump is designed for operation with different directions of flow, i.e., the swash plate can be swung from the zero position in two directions and back again. The additional means can thus operate bilaterally; two annular spaces 181 and 182 are provided to effect this mode of operation. The annular space 181 is connected to the connecting channels 20a and the annular space 182 to the connecting channels 20b. The connecting channels 20a are spaced by an approximately identical angular amount from each other on an initial inner graduated circle and are loaded with high pressure in an initial direction of flow. The connecting channels 20b are spaced by an approximately identical angular amount from each other on a second outer graduated circle. If the direction of flow changes, the connecting channels 20b are under high pressure. Independently of the direction of flow, one of the annular spaces 181 or 182 is thus always acted upon by high pressure in a load-dependent manner so that the additional means is active and presses the cylindrical drum 4 against the control surface 5.
"The embodiment shown in FIGS. 5 and 6 has a swash" plate pump with only one direction of flow. In this embodiment, only three connecting channels 20 arranged with a spacing of 120° on a graduated circle are required due to the configuration of the control channels 9 and 10 in the control surface 5 in order to achieve a uniform loading of the annular space 18 with high pressure.
A swash plate pump with two possible directions of flow is shown in FIGS. 7 and 8, in which the additional means relieves the cylindrical drum in operation. Instead of two annular pistons 15 and 17, a single stepped annular piston 251 is provided for this purpose; it works in conjunction with a stop 252. The annular piston 251 is moveable longitudinally with respect to both the cylindrical drum 4 and the drive shaft 3. In the rest position of the axial piston machine, the pressure spring 11 presses the annular piston 251 and the stop 252 apart into an initial end position, in which the annular piston 251 lies on the collar 3a of the drive shaft 3, the stop 252 lies on the retaining ring 16 on the cylindrical drum 4 and the pressure spring 11 has the greatest possible axial extension. The graduation of the annular piston 251 facilitates the development of two annular spaces 181 and 182, which can be loaded with high pressure depending on the direction of flow of the medium. Above a certain load or a certain pressure in one of the two annular spaces 181 or 182, the pressure spring 11 is compressed with the aid of the annular piston 251 and separated by the collar 3a until the annular piston 251 lies on the stop 252 in a second end position. The pressure spring 11 has its smallest possible axial extension in this position and cannot be further compressed. Although the pressure spring 11 is indeed tensioned, it still does not act on the cylindrical drum 4 to increase the pressing force on the control surface 5. The compressive force of the pressure spring Il is continuously reduced or increased between the two end positions by the load-dependent pressure rise in one of the two annular spaces 181 or 182.
Having described presently preferred embodiments of the invention, it is to be understood that the invention may be embodied within the scope of the appended claims.
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An axial piston machine having a longitudinally movable rotary cylindrical drum with cylindrical bores arranged concentrically to the axis of rotation of the drum. A longitudinally sliding piston located in each bore and lying against a control surface in contact with the drum. The pistons have an end in contact with a control surface that can be positioned diagonally to the axis of rotation of the drum and said cylindrical bores are provided with openings connecting to control channels in the control surface. Additional piston surfaces are provided in a cavity formed in the cylindrical drum for controlling the pressing force of the cylindrical drum on the control surface.
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TECHNICAL FIELD
[0001] Resonators that work with bulk acoustic waves, so-called FBAR (thin film bulk acoustic resonators) or also called BAW resonators (bulk acoustic wave resonators), are based on a piezoelectric base body that is embodied as a thin film and that is provided with an electrode on each of two main surfaces. Such resonators can be used to construct HF filters. A plurality of such resonators are wired in branched circuits in a component embodied as a filter.
BACKGROUND
[0002] Components based on BAW resonators play a role in particular as filters in end devices for mobile telecommunications.
[0003] Components with BAW resonators are generally constructed on a carrier substrate, e.g., a crystal wafer. Arranged between each resonator and the carrier substrate is either a recess that is filled with air, and that represents a high increase in impedance acting highly reflectively on the acoustic wave, or an acoustic mirror. In each case, this is how the acoustic wave is prevented from exiting the resonator in the direction of the carrier substrate TS.
[0004] An acoustic mirror comprises, e.g., an alternating sequence of layers with high and low acoustic impedance. The thickness of each of the mirror layers is approximately ¼ of the wavelength of the acoustic wave in the given material. A first acoustic mirror arranged under the resonator comprises an alternating sequence of layers with high and low acoustic impedance.
[0005] During production of a BAW resonator, as a rule the layers are produced on the component on top of one another, but each is produced separately from the other and when needed structured individually. The method for depositing and structuring the layers becomes more complex as the number of layers increases. For instance, errors in the deposition of the correct thickness for each layer can accumulate so that there is a significant scattering of the resonance frequencies of the resonators over the entire wafer and thus there is a significant scattering of the mid-frequency of filters.
[0006] In addition to the aforesaid BAW resonators, other components working with thin piezoelectric layers as functional layers are known, in particular thin film sensors and piezoelectric actuators. In the case of these components, as well, they are generally applied to carrier substrates and include a multilayer structure made of at least a first electrode, the piezoelectric functional layer, and a second electrode. Especially in the case of the piezoelectric actuators, multilayer structures are required in which the layer sequence of piezoelectric functional layer and electrode layer is repeated several times. In all components with a piezoelectric functional layer, the quality of the component is largely determined by the quality of the piezoelectric layer.
[0007] Realizing BAW resonators with low losses and a high piezoelectric coupling coefficient requires the strictly ordered orientation of the individual crystallites within the piezoelectric layer, which is only possible using a suitable deposition method, as a rule the PVD method, and on a suitable base. For BAW resonators, optimum electrical properties can be attained when the thin film grows such that within each crystallite of the thin film a preferred crystallographic direction is in a clear geometric relationship to a direction of the substrate. For instance, it is advantageous when the piezoelectric main axis is oriented strictly parallel to the normal on the substrate surface and the crystallites consequently grow strictly parallel to one another.
[0008] In addition to the deposition parameters, which are to be adjusted appropriately, this can in particular be attained using the selection of a suitable growth layer on which the crystallites of the piezoelectric layer can grow in an ordered manner. For this, in known components the piezoelectric layers are deposited on an electrode layer that also assumes the function of the growth layer. However, it is disadvantageous that the selection of suitable materials that offer both adequate electrode properties and also good conditions for ordered growth of the piezoelectric layer is very limited. The only materials that are available require compromises in terms of the electrode properties and the properties that support the growth of the piezoelectric layer.
SUMMARY
[0009] This application describes a component constructed on a substrate as a sequence of individual layers normally deposited as thin film and includes at least a first electrode layer, a structured growth layer that is thin relative to the first electrode layer, a piezoelectric (functional) layer, and a second electrode layer.
[0010] The application describes a component with a piezoelectric functional layer in which the piezoelectric functional layer is highly ordered and in which an electrode layer with optimum electrode properties can still be selected. This is accomplished by decoupling the electrode function and the growth-supporting function in the form of two separate layers. Thus, the growth layer and electrode layer can be optimized independent of one another, whereby a component with an improved electrode layer and a simultaneously improved piezoelectric layer is obtained, and thus improved electrical properties are obtained overall, which in the past has not been attainable simultaneously overall.
[0011] The component is constructed on a substrate that is the carrier for the successive layers of the component that are deposited upon one another. It is possible to provide between the substrate and first electrode layer one or a plurality of additional layers with a similar or different function. The substrate can be selected solely as a carrier layer with respect to adequate mechanical strength. It is also possible to use a semi-conductor substrate in order to facilitate the integration of electrical or electronic components into the substrate.
[0012] The first electrode layer can be a single uniform layer or can be realized as a multi-layer structure with at least two different layers. The electrode layer satisfies the electrode functionality and is therefore sufficiently conductive. Preferably the electrode layer, i.e., its surface, is embodied such that it is simple to apply electrical connecting elements. Bonding wires, bumps, or film electrodes can be provided as connecting elements. It is also advantageous when the electrode layer has a high power rating. Such a layer is advantageously attained with layers made of metals from the platinum group (Pt, Os, Ir, Pd, Ru, Rh), Ag, Au, and/or Cu or with multilayer structures that contain such individual layers. Aluminum and layer systems that contain aluminum are also advantageous, for instance AlCu, AlSiCu, AlMg, or Al alloys, or also ceramic electrode systems, e.g., titanium nitride. Layers or multilayer structures based on aluminum are also advantageous in particular when they are used in resonators that work with bulk acoustic waves because, due to how thin such layers or multilayer structures are, inhomogeneities in layer thickness as seen across the entire substrate lead only to moderate scattering in the resonance frequency of the resonators.
[0013] Applied over the electrode layer is a growth layer that is thin relative thereto and that facilitates the ordered, textured, and crystal-axis oriented growth of a piezoelectric layer. Materials and/or layers are already known; however, it has not been possible to use these in the past as optimum electrode materials due to disadvantages associated with them. It is the separation of electrode function and growth function that makes it possible to use optimized growth layers independent of the electrode layer.
[0014] Molybdenum and gold layers have proved themselves as growth layers, for instance. Further suitable are also metal layers made of tungsten or platinum, as well as a number of oxide or semi-conducting compounds, such as silicon which support crystal-axis oriented growth of piezoelectric layers. Growth layers can therefore also comprise, for instance, sapphire, spinel, barium titanate, zircon oxide, magnesium oxide, or titanium oxide.
[0015] The selection of the growth layer depends on the type of piezoelectric layer to be grown. Certain material combinations are particularly preferred. If for instance an aluminum nitride layer is used as the piezoelectric layer, molybdenum has proved to be a preferred material for the growth layer. Both gold and molybdenum are particularly suitable for a piezoelectric layer made of zinc oxide.
[0016] In addition to the material selection, modifying the growth layer can also be important. For instance with growth layers made of gold it was possible to observe results that were very different from one another during growth of the piezoelectric layer depending on the nature of the gold. For instance vapor-deposited gold is particularly preferred for the growth layer.
[0017] The piezoelectric layer is grown directly over the growth layer. It can include any desired piezoelectric material that permits crystal-axis oriented growth. The materials zinc oxide and aluminum nitride are also preferred since they have already proven themselves in components as piezoelectric functional layers.
[0018] A second electrode layer is provided over the piezoelectric layer. For producing a corresponding multilayer component, the second electrode layer can also be provided with a growth layer and thereover with another piezoelectric layer and finally with another electrode, whereby this structure can also be repeated several times. In addition, primer layers or adapting layers can also be provided between electrode layer and growth layer.
[0019] In one embodiment, the growth layer is structured such that it has a smaller surface area than the electrode region provided directly in the electrode layer. The structuring can be performed for instance using a lift-off method that makes it possible to avoid the use of complex plasma processes such as for instance dry etching and the associated (radiation) damages. These would require complex post-treatments using dry or wet methods that would complicate the method as additional process steps. Wet-etchable layers can be structured with no problem or risk after the growth layer has been deposited without this having a negative impact on the surfaces and the additional growth of layers thereunder.
[0020] The piezoelectric layer is preferably grown for the entire surface area, whereby it is ordered at least in the region over the growth layer and in particular grows in a manner oriented to the crystal-axis. Around the growth layer, the piezoelectric layer encloses with the electrode layer and/or its electrode region. Now it is also possible to structure the piezoelectric layer after deposition, whereby the structure limits are drawn such that the complete encapsulation of the growth layer between piezoelectric layer and electrode layer or between piezoelectric layer and electrode region is maintained. For the component, this has the additional advantage that there are no boundary surface problems or incompatibilities with the second electrode layer. Such incompatibilities, which on boundary surfaces of certain layer systems lead to material migration, would otherwise require additional barrier layers made of e.g. Ti or Pt in order to avoid direct contact between these electrode and growth layer materials that are incompatible with one another.
[0021] An additional advantage of the complete encapsulation of the growth layer is that now materials can be used that are actually not permitted as an exposed layer in further processing stages of components. In particular, when components are constructed on semi-conductor substrates and combined with CMOS processes, the use of various materials must be excluded for avoiding contamination. With the encapsulation of the growth layer, this is not necessary in terms of the growth layer and therefore it is possible to use materials that might otherwise not be considered because of this.
[0022] The embedding of the growth layer and/or the structuring of the growth layer and of the piezoelectric layer relative thereto also has the additional advantage that the structuring of the piezoelectric layer can occur selectively relative to the first electrode layer or selectively only to the uppermost layer of the multilayer structure used for the first electrode layer. Simultaneous structuring of a plurality of layers is therefore not necessary. Therefore, it is also possible to undertake wet-chemical structuring of the piezoelectric layer, which otherwise (when etching multilayer systems) could lead to under-etching. For this reason, as well, the otherwise damaging use of dry etching processes, which also involve greater costs, can be avoided.
[0023] For the selection of the growth layer, it is irrelevant whether the material used for this has adequate electrode properties and in particular current carrying capacity or whether the method used provides adequate edge covering. Electrical conductivity is not required at all, depending on the layer thickness used. Thus, poor electrical conductors can be used, as can deposition methods in which it is not possible or is very difficult to attain adequate edge covering.
[0024] Advantageously, metals or multilayer systems with a high power tolerance can be used for the second electrode layer or for an electrode multilayer system that is used as the second electrode layer. In this case, as well, layers or multilayer systems can be used that have individual layers made of metals from the platinum group, silver, gold, copper, titanium, molybdenum, and tungsten, as well as aluminum layer systems or layer system that include aluminum such as for instance AlCu, AlSiCu, AlMg. Just as suitable are ceramic electrode systems such as for instance titanium nitride.
[0025] Not only is a component with a piezoelectric layer with improved interior structure obtained, but the method for production is also improved such that a stable and capable process can be conducted (process capacity index (centered)>1.33). The method is suitable for integration in CMOS methods. Therefore the components with a piezoelectric (functional) layer and with electric and electronic components integrated in the substrate can be produced simultaneously in the process line.
[0026] Embodiments are described below in greater detail using the associated schematic figures, which are for explanatory purposes and are therefore not to scale.
DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic section of a layer structure.
[0028] FIG. 2 is a detailed depiction of the orientation of the crystallite in the piezoelectric layer.
[0029] FIG. 3 illustrates two possible embodiments for a BAW resonator.
[0030] FIG. 4 is a top view and two sections of a possible structuring of a BAW resonator;
[0031] FIG. 5 is a schematic section of a structured component; and,
[0032] FIG. 6 is a schematic section of a component embodied as a multilayer piezo-actuator.
DETAILED DESCRIPTION
[0033] FIG. 1 illustrates a layer structure with a substrate S, a first electrode layer E 1 , a growth layer W that is structured thin relative thereto, a piezoelectric layer P, and a second electrode layer E 2 thereover. The first and second electrode layers E 1 , E 2 can represent individual layers or a multilayer system. Diffusion-reducing and/or hard layers can be integrated into the multilayer system in order improve the power tolerance of the electrode layer. A primer or adapting layer, preferably a thin titanium layer, can be present between the first electrode layer E 1 and the substrate or between the substrate and the lower-most layer of a multilayer structure that realizes the electrode layer E 1 .
[0034] The growth layer W is relatively thin and has, for instance, a thickness of 100 nm or less. In comparison thereto, the first electrode layer E 1 has a total thickness of approx. 200 to 500 nm. The precise thickness depends on the component type, however. In a BAW resonator, the thickness of the electrode layer is involved in the dimensions of the total layer thickness required for the resonance frequency and therefore cannot be selected freely. In other components, the thickness of the electrode layer can be selected exclusively as a function of the desired current carrying capacity.
[0035] The piezoelectric layer P can comprise any desired piezoelectric materials that can be grown in an oriented manner. The layer thickness is determined as a function of the component type; for instance, that in a piezo-actuator is determined depending on the voltage applied, in a BAW resonator depending on the desired resonance frequency. In the latter case, the piezoelectric layer P has a thickness that is approximately equal to one-half wavelength of the acoustic wave that can be propagated in the BAW resonator.
[0036] The material selection for the second electrode layer E 2 is less critical than that for the first electrode layer E 1 , since no additional layers, and in particular no additional oriented layers, have to be deposited over this layer.
[0037] Using an enlarged detailed depiction, FIG. 2 illustrates a section of a layer structure. Illustrated purely schematically in the piezeoelectric layer P are individual crystals K that have grown parallel over the growth layer W. In this manner, the crystal axes KA are oriented parallel to one another and parallel to the normal over the growth layer W. If this crystal axis KA matches the piezoelectric axis, a maximum piezoelectric deflection can be attained with the component described herein. In such an orientation the piezoelectric coupling is also maximal.
[0038] FIG. 3 illustrates two different BAW resonators, known per se, that can be improved. FIG. 3 a illustrates a BAW resonator with membrane technology that in principle has the structure illustrated in FIG. 1 . In the active resonator region, which corresponds to the overlap of the electrodes E 1 and E 2 , an air gap L is provided between the substrate and first electrode layer E 1 , in contrast to FIG. 1 . What this leads to is that, based on the great difference in impedance between the electrode material of the first electrode layer E 1 and air, there is a high increase in impedance that leads to the reflection of the acoustic wave at the corresponding surface area of the first electrode layer E 1 . The air gap L can be produced prior to or after the construction of the layer system required for the component.
[0039] FIG. 3 b illustrates a BAW resonator with mirror technology in which an acoustic mirror AS is provided between substrate S and first electrode layer E 1 . It encompasses an alternating sequence of layers with alternating high and low impedance. In FIG. 3 b , four acoustic mirror layers R 1 , R 2 , R 3 , and R 4 are illustrated, whereby mirror layers with low impedance comprise for instance SiO 2 , layers with high impedance on the other hand comprise metal, in particular heavy metal such as Mo or W, or even non-metal layers such as e.g. aluminum nitride, silicon carbide, or diamond. The thickness of the mirror layers is adjusted to approximately one quarter of the wavelength for the resonance frequency of the BAW resonator. However, it is also possible to realize the component with a number of mirror layers that is different and even uneven, whereby the material selection can be made exclusively as a function of the impedance of the material.
[0040] FIG. 4A illustrates an exemplary structuring for the individual layers in BAW resonators. The first electrode layer E 1 is applied to the entire surface area and then structured such that an electrode region E 11 and a connection region E 12 occur. The growth layer W is applied with a surface area over the electrode region E 11 and then is structured, preferably wet-chemically, such that it has a smaller surface area than the electrode region E 11 . The edges of the growth layer W are distanced on all sides from the edges of the electrode region E 11 .
[0041] The piezoelectric layer P is applied with a surface area and then structured such that it completely covers the growth layer W, overlaps its edges on all sides, and encloses it directly with the electrode region E 11 . In addition, the piezoelectric layer can also overlap the edges of the electrode region. In the next step the second electrode layer E 2 is applied and structured such that a second electrode region E 21 and a second electrode connection surface E 22 are formed. The second electrode region E 21 is preferably covered with the surface of the growth layer W, is centered thereon, and even more advantageously has a smaller surface area than the growth layer.
[0042] FIG. 4C illustrates the layer structure using a schematic section along the sectional line X depicted in FIG. 4A . It is easy to see that the growth layer W is completely embedded in the piezoelectric layer W. The first connection region E 12 of the first electrode layer is exposed, as is a connection region E 22 of the second electrode layer.
[0043] FIG. 4B illustrates a section through the structure along the sectional line Y depicted in FIG. 4A . In this section, as well, it is easy to see the complete encapsulation of the growth layer W within the piezoelectric layer P. It can also be seen that the surface of the second electrode layer E 2 approximately matches that of the growth layer W.
[0044] FIG. 5 is a schematic section of a component constructed as a BAW resonator with mirror technology. Here it is easy to see that some of the mirror layers R 1 through R 4 are structured. In particular, the mirror layers are structured with high impedance since they usually comprise metal. The usually electrically insulating layers of low impedance, in this case layers R 1 and R 3 , are applied with the entire surface and remain unstructured, thereby encapsulating the mirror layers with high impedance R 2 and R 4 . The rest of the structure of the component corresponds to that illustrated in FIG. 4 .
[0045] In one embodiment of BAW resonator, a silicon wafer with <100> orientation acts as substrate S. On the surface, the latter is covered with an oxide layer O that is made of SiO 2 and that is approx. 530 nm thick. A high impedance layer made of tungsten, with a thickness of approx. 760 nm, acts as the lower-most mirror layer R 4 . Applied thereover is a mirror layer R 3 with low impedance, in this case an SiO 2 layer with a thickness of 675 nm. Thereover follows the mirror layer R 2 , which corresponds in terms of material and layer thickness to the mirror layer R 4 . The upper-most mirror layer is another SiO 2 layer R 1 that has a thickness of approx. 675 nm. An aluminum layer with a suitable thickness is used as first electrode layer E 1 . Sputtered thereover as growth layer W is a layer of molybdenum, for instance in a layer thickness of 80 nm. Applied thereover is the piezoelectric layer P, for instance an aluminum nitride layer in a thickness of approx. 2400 nm. Then a second electrode layer E 2 is applied (not shown in the figure), for instance made of an aluminum/copper alloy.
[0046] FIG. 6 is a schematic section of a component embodied as a multilayer piezo-actuator. In contrast to the general layer structure in accordance with FIG. 1 , in this component electrode layers E and piezoelectric layers P alternate, whereby a growth layer W 1 through W 4 is provided beneath each piezoelectric layer P 1 through P 4 . This actuator is also constructed with thin-layer technology, whereby the deposition conditions for the piezoelectric layer occur such that oriented growth occurs and thus a highly oriented crystalline piezoelectric layer is obtained. A multilayer piezo-actuator embodied in this manner in a thin-layer structure can include any desired number of piezoelectric layers including associated electrode layers. The limiting factor is always the quality of the growing layers.
[0047] The structuring of the individual layers of the piezo-actuator occurs such that the growth layer is encapsulated as usual by the piezoelectric layer P. The electrode layers E 1 , E 2 , and the additional electrode layers E 3 , E 4 , etc. located thereover are structured such that they can be connected alternatively to different external electrodes and thus to different potentials. This results in parallel circuitry of all individual actuators that each comprise two electrodes and a piezoelectric layer located therebetween.
[0048] Not explained in greater detail are components that have piezoelectric functional layers and that are embodied as sensors. These react to an external physical effect such as for instance pressure, temperature, acceleration, bending, or the effect of a chemical, whereby the piezoelectrically produced voltage can be measured as a variable. While given an increase in temperature or given the effect of a force the piezoelectric effect can be used directly on the piezoelectric layer, when a chemo-sensor is used this must generally be supported with an auxiliary layer that during the effect of a chemical changes its properties such that it acts on the piezoelectric effect. Such components are known per se, can have different embodiments, and therefore do not have to be explained in greater detail here. What is decisive is that in these components that have a piezoelectric (functional) layer and that are embodied as sensors, as well, the quality of the piezoelectric layer and thus the sensitivity of the sensor is increased by virtue of the features described herein.
[0049] Although the invention was explained using only a few exemplary embodiments, it is not limited to these. In addition to the explicitly illustrated designs, additional variations are conceivable, in particular with respect to the structuring of the individual layers, with respect to the selection of material, layer thicknesses, dimensioning, and with respect to the provision of additional layers.
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In an electrical component with thin-layer construction that has a piezoelectric functional layer, the layer quality of the functional layer is improved in that a growth layer is provided between the electrode layer and the piezoelectric layer. Thus the function of the electrode layer is separated from that of a growth-supporting layer, whereby the functions can be optimized using separate layers independent of one another. Inventive components can be embodied as BAW resonators, thin-layer piezo-actuators, or piezo-sensors.
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[0001] This application is related to U.S. patent application Ser. No. 09/698,009, filed Oct. 26, 2000, entitled “CUTTING AND LAMINATING APPARATUS FOR PRODUCING REINFORCED WEB,” and U.S. Patent Application Ser. No. 60/410,149, filed Sep. 12, 2002, entitled “FLAT-BOTTOMED RECLOSABLE PACKAGE WITH GUSSETS.”
BACKGROUND OF THE INVENTION
[0002] The present invention relates to reclosable packaging with interior support, and manufacturing processes for the same. More specifically, the present invention relates to packaging that may include properties of both a reclosable/resealable bag, but more specifically the characteristics of a structured canister that provides support and protection to the contents of the packaging. The packaging of the present invention may be used to contain foodstuffs in a structured and supported manner that has the outward look and feel of a flexible bag.
[0003] Various existing packaging designs provide a reclosable feature that allows the contents of the packaging to be accessed multiple times and closed after each time the packaging is opened. For instance, for the purposes of food packaging, flexible bags and rigid canisters both provide distinct benefits. Bag-like designs offer flexible, lightweight packaging, which can be resealed with a plastic wrapping film or adhesive. Canister-like designs offer a more supportive container, which can be reclosed with a lid that is snapped or screwed into the body of the canister. Other packaging exists that offers some of the advantages of these designs, such as pouch packaging, which is flexible like a bag but can stand upright like a canister.
[0004] These existing packaging designs satisfy the basic goal of providing a reclosable enclosure for foodstuffs. However, the designs fail to address certain needs of the modern consumer. For instance, the bag designs offer little if any protection for the contents they enclose. Further, bag packaging generally cannot maintain a predetermined shape or configuration, nor stand upright. While pouch packaging can usually maintain its upright position, it fails to offer strong protection for its contents. Pouch packaging typically requires more side seals than exist on standard bag packaging, thereby incurring additional time and expense for the manufacturing process of pouch packaging.
[0005] Canister designs typically provide more support and protection to their contents than bag designs, but available canisters have a limited number of shapes or configurations and are restricted in the types of reclosable lids they can use. Perhaps even more significant, canister designs require dense materials that are expensive to acquire, manufacture, and transport.
[0006] In order to provide a case effective flexible reclosable package that maintains a predetermined shape while offering strong protection for the contents, it is contemplated that improvements are needed before consumers are provided with a plastic bag that meets their needs. These improvements must relate to structured packaging of the present invention that minimizes the materials required for producing each bag and reduces the overall production expenses by decreasing the number of manufacturing steps. Additionally, the present invention provides a reclosable structured packaging that is not limited to the methods of enclosing rigid canisters.
SUMMARY OF THE INVENTION
[0007] In order to provide cost effective, bag-like rigid packaging and an efficient method for manufacturing the same, the present invention provides flexible packaging with an interior support that is able to contain products such as snacks, confections, pet foods, and liquids. The structured packaging of the present invention provides for a bag that has been appropriately sheared and reinforced. The bag has a supportive structure affixed inside the package that can supply support for the product and provide a method for keeping the package open for easy access or pouring. Additionally, the bag may have a reclosable top portion that encloses the contents of the bag.
[0008] The bag of the present invention is preferably formed from a primary web, wherein a reinforcing material is utilized to selectively reinforce portions of the bag. Reinforcing the bag material is particularly useful at sealing points, reclosing points, and other locations on the bag that require additional strength and durability. Because the overall exterior of the packaging is created from a bag sheared of various webs, the manufacturing of the packaging requires fewer steps than known packaging designs. For instance, pouch packages are typically manufactured from webs as well but require multiple side seals, which involve additional manufacturing. The packaging of the present invention can provide an upright bag that requires only a single side seal.
[0009] The supportive structure inside the bag may be formed from a variety of materials, such as a flexible film packaging, into a variety of shapes. The support structure is a rigid material that may be manipulated into predetermined shapes and configurations using both known methods and those disclosed herein for manufacturing packaging. For example, the support may be a heat-sealable structure that is manipulated using laser scoring. The support structure in its final state is a relatively rigid body that has been formed into a predetermined shape, such as a box or tube. Alternatively, the support structure may be individual components that, when incorporated into the package, will form the desired structure.
[0010] When the supportive structure is appropriately formed, it is affixed to the inside the primary web such that the bag and structure is formed, and the supportive structure is in the lower portion of the bag so that the bag encapsulates the support. The support is generally borne by the bag and fits snuggly therein such that the bag fits around the exterior of the support and substantially conforms to the shape and configuration of the support. The support may be heat sealed or sealed via other methods, i.e., pressure sensitive adhesive, spray adhesive, ultrasonic and the like, to the bag to ensure that the support is properly retained therein. The upper portion of the bag may extend beyond the height of the support such that the upper portion of the bag is flexible and has the general characteristics of a bag without such support.
[0011] The support structure can either conform to the bag's shape or take a shape distinct from that of the bag. For instance, the packaging may take on a “box-in-a-bag” structure, where the support has a square or rectangular shape and the bag has a round shape, or the bag conforms to the support's rectangular shape. Alternatively, both the support and the bag may have a round shape, where the support is a tube-like structure and the round bag fits around the support. A variety of different shapes is contemplated being used for both the bag and the support structure while keeping within the teaching of the present invention.
[0012] In addition to the supportive structure inside the bag, the upper portion of the bag material may constitute either a reclosable or non-reclosable opening. Where the bag is recloseable, the reclosable means may be achieved with a plastic wrapping film, a zipper lock, resealable adhesive strips, easy-snap technology or any number of bag-closing approaches. Any of the existing methods of enclosing bag packaging are applicable.
[0013] Accordingly, the present invention provides a cost effective rigid packaging that maintains the versatility and manufacturing benefits of a more flexible bag/package. The structured packaging of the present invention minimizes the materials required for producing each bag and reduces the overall production expenses by decreasing the number of manufacturing steps. Additionally, the present invention provides a reclosable structured packaging that is not limited to the methods of enclosing rigid canisters. Any of the existing methods of enclosing bag packaging are usable with the structured packaging of the present invention. This and other benefits of the dual nature of a structured bag are achieved by the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention will be more fully and completely understood from a reading of the Detailed Description of the Invention in conjunction with the drawings, in which:
[0015] FIGS. 1A and 1B are a top and side view, respectively, of one embodiment of a reclosable package according to the present invention;
[0016] FIG. 2 is a perspective view of another embodiment of a reclosable package with a supportive structure where the top portion of the package is in a closed position;
[0017] FIG. 3 is a top view of the reclosable package of FIG. 2 with a supportive structure where the top portion of the package is in an opened position; and
[0018] FIG. 4 is an interior view of a reclosable package with a supportive structure, showing the supportive structure in more detail.
[0019] FIG. 5 is a first view of an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] As shown in FIGS. 1A and 1B , a flexible package (bag 1 ) with a supportive structure 2 built into the package. The supportive structure 2 is appropriately formed and affixed to the lower portion 4 of bag 1 such that the bag encapsulates the support as shown. Preferably, the support for the supportive structure 2 is generally borne by the bag 1 , and the supportive structure 2 fits snuggly therein such that the bag 1 fits around the exterior of the supportive structure 2 and substantially conforms to the shape and configuration of the supportive structure 2 . The supportive structure 2 may be heat sealed, or the like, to bag 1 to ensure that supportive structure 2 is properly retained therein. The upper portion 6 of bag 1 may extend beyond the height of the support 2 such that the upper portion 6 of bag 1 is flexible and has the general characteristics of a bag without a support. For instance, the support may be 3½ inches in height, while the bag may extend upward beyond the top of the support an additional 4½ inches. The lower portion of bag 1 is shaped into a structured form that may give the packaging the ability to stand upright and protect its contents. The lower portion 4 of bag 1 may have any practical shape, such as square or rectangular, that provides stability and balance to the packaging. The upper portion 6 of bag 1 maintains bag-like characteristics and is not given the same structured form as lower portion 4 . This configuration offers more protection to the contents of the packaging than a regular unstructured bag.
[0021] The upper portion 6 of bag 1 may constitute either a reclosable or non-reclosable opening. Where the bag is recloseable, the reclosable means may be achieved with a plastic wrapping film, a zipper lock, resealable adhesive strips, or any number of bag-closing approaches. For example, as shown in FIG. 1A and 1B , easy-snap technology 8 is used as a reclosable feature. The easy-snap technology is disclosed in U.S. Pat. Nos. 6,350,057, 5,983,594, 5,944,425, 5,937,615, 5,928,749 and 4,679,693, all to Forman, and is incorporated herein by reference. As described herein, the reclosable portion of the bag may be created by selectively reinforcing parts of the main bag web with sheared reinforcing strips 18 that are laminated to the main bag web, as discussed in more detail below. See, FIG. 5 .
[0022] The supportive structure can either conform to the bag's shape or take a shape distinct from that of the bag. For example, the packaging may take on a “box-in-a-bag” structure, where the support has a square or rectangular shape and the bag has a round shape or conforms to the support's rectangular shape. See FIGS. 2-4 . As shown, bag 15 has a supportive structure 26 that has a square or rectangular shape, may be manufactured by scoring the supportive material at the fold locations. Various scoring methods will achieve the appropriate folds, including the laser scoring as previously described.
[0023] Alternatively, as shown in FIG. 5 , both the support 18 and bag 19 may have a round shape, where support 18 is a tube-like structure and rounded bag 19 fits around support 18 . A variety of different shapes are contemplated being used for both the bag and the support while keeping within the teaching of the present invention.
[0024] The supportive structure of the present invention inside the bag can be formed from a variety of materials, such as a flexible film packaging, into a variety of shapes. The support is a rigid material (relative to the primary web material) that can be manipulated into predetermined shapes and configurations by using both known methods and those disclosed herein for manufacturing packaging. For instance, the support may be a heat-sealable structure that is manipulated using laser scoring. The support, in its final state, is a relatively rigid body that has been formed into a desired shape such as a box, as shown in FIGS. 2-4 or tube.
[0025] Alternatively, the rigid body may be comprised of specific components that are configured to form the desired structure when incorporated into the bag. For instance, the rigid body may comprise two components that are fixedly attached to the bag: a first component that supports the left side of the bag and the portions of the front and back of the bag that are adjacent to the left side, and a second component that supports the right side of the bag and the portions of the front and back of the bag that are adjacent to the right side.
[0026] During assembly, the present invention as shown in FIGS. 1-5 , may be formed from a primary web, and support structure/reinforcing material is utilized to selectively reinforce portions of the bag. Reinforcing the bag material is particularly beneficial at sealing points, reclosing points, or any other locations on the bag that require additional strength and durability. One method of providing the desired support or structure includes using a primary web handling system and a secondary web handling system, a cross web shear, a strip handling system and a laminating device. The primary web handling system handles the main web of packaging material, or primary web, which will be reinforced, via the secondary web handling system for later operations.
[0027] In order to provide the supportive structure/reinforcement, strips may be produced from a secondary web and then laminated to the primary web. Specifically, the secondary supply web may be fed by the secondary web handling system and provides reinforcing material to the cross web shear, which cuts the secondary web into reinforcing strips of selectable predefined width. Subsequently, the laminating device is then utilized to attach the reinforcing strip to the primary web at appropriate locations. More detail on the laminating process may be found in related application U.S. Ser. No. 09/698,009, filed Oct. 26, 2000, entitled “CUTTING AND LAMINATING APPARATUS FOR PRODUCING REINFORCED WEB”, which is incorporated herein by reference.
[0028] It is contemplated, to appropriately reinforce the primary web, the reinforcing strip/support structure can be relatively narrow and small compared to the primary web, and precisely positioned relative to the primary web. Lamination of the reinforcing strip to the primary web in the desired location is then easily accomplished. While the use of the above-described system is one way of efficiently reinforcing or providing structure to a package, other methods are also possible. For example, a pre-dimensioned reinforcing tape, pressure sensitive adhesive, spray adhesive, or ultrasonic adhesive may be used. Alternatively, the primary web material may be overlapped to provide multiple layers at the desired location.
[0029] After the appropriate portions of the primary web have been reinforced, the web is sheared, if necessary, and then the bag is formed therefrom with, for example, a top seal, a bottom seal and a length-wise seal, as shown in FIGS. 1-5 . Referring to FIGS. 2-4 , the bottom of the bag 15 may be gusseted 20 to form a flat surface 22 that causes the package to stand up. The bottom seal 24 is made by first folding the sides 26 of bag 15 towards the center thereof. While the sides are being held in place, the end of the bag is sealed to form a flat, square shaped surface that causes the packaging to stand upright. Another seal 28 may be formed length-wise along one side of the package to form the sides of the pack, defining the interior volume of the bag. More detail on a flat-bottomed stand up package may be found in Provisional Application Ser. No. 60/410,149, filed Sep. 12, 2002, entitled “FLAT-BOTTOMED RECLOSABLE PACKAGE WITH GUSSETS”, which is incorporated herein by reference.
[0030] The top of the bag may be sealed in a manner consistent with existing vertical form fill and seal technology (VFFS) and horizontal form fill and seal technology (HFFS). For example, in an VFFS environment, a flat, full-length seal across the width of the top of the bag is made. Since there are no gussets in the top seal, the addition of a reclosable feature is possible where the bag material is reinforced. The reclosable feature of the present invention may be achieved with any conventional re-closing mechanism, such as a zipper, zipper-slider seal, easy-snap technology, or adhesive strips.
[0031] A mechanical module, laser module, or the like may be used for scoring or perforating the reinforcing strips and support structure. The module can also be used to cut, slit, or mark selected portions of the support or the primary web used to form the bag. The module can be easily integrated into a packaging machine used to manufacture the present invention. More detail on laser scoring and perforating may be found in related application Ser. No. 09/698,009, filed Oct. 26, 2000, entitled “CUTTING AND LAMINATING APPARATUS FOR PRODUCING REINFORCED WEB”, as stated above.
[0032] Those skilled in the art will further appreciate that the present invention may be embodied in other specific forms without departing from the spirit or central attributes thereof. In that the foregoing description of the present invention discloses only exemplary embodiments thereof, it is to be understood that other variations are contemplated as being within the scope of the present invention. Accordingly, the present invention is not limited in the particular embodiments which have been described in detail therein. Rather, reference should be made to the appended claims as indicative of the scope and content of the present invention.
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Disclosed herein is flexible packaging with a relative rigid structure portion, and an efficient method for manufacturing the same, that provides flexible packaging with an interior support that is able to contain products such as snacks, confections, pet foods, and liquids. The present invention provides for shearing and reinforcing portions of a primary web to form a bag. A supportive structure is also sheared and configured into a predetermined shape. The supportive structure is affixed inside the lower portion of the bag and provides form and support to the bag. The bag may also have a reclosable top portion that encloses the contents of the packaging.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an ornamental support pole for a luminaire or the like and more particularly to a non-tapered and fluted or a tapered and fluted support pole for a luminaire or the like wherein the flutes exhibit a color or finish which is different than the color or finish of the radiused surfaces therebetween.
2. Description of the Related Art
Support poles for luminaires or the like are normally comprised of a hollow metal pole formed from steel or aluminum. The base of the support pole is normally secured to a suitable foundation or directly embedded in the earth with the upper end of the pole supporting one or more luminaires or the like thereon. In many cases, the entire exterior surface of the pole, including the flutes and the radiused surfaces therebetween, are painted with a single color. In other cases, the pole is not painted at all. It has been found that a highly ornamental support pole is achieved when the flutes of the pole are painted or coated with a paint or coating which is colored or finished differently than the radiused surface therebetween.
SUMMARY OF THE INVENTION
An ornamental support pole for a luminaire or the like is described as well as the method of forming the same. In the first method of forming the pole, the pole, which is either tapered or non-tapered, is formed from a metal such as steel or aluminum. The pole is then sanded to remove the die marks therefrom if any are present. A plurality of spaced-apart, longitudinally extending flutes are formed in the pole which define radiused surfaces therebetween. The entire pole is then painted or coated with a liquid paint or coating. The painted pole is then subjected to a sanding operation wherein the paint or coating from the radiused surfaces between and around the flutes is removed and which leaves paint or coating in the flutes. In an optional step, the entire pole is then painted or coated with a transparent, clear translucent, or tinted coating. The end product is a highly ornamental pole wherein the flutes and radiused surfaces therebetween exhibit different colors or finish appearance.
It is therefore a principal object of the invention to provide an ornamental support pole for a luminaire or the like as well as the method of forming the same.
A further object of the invention is to provide an ornamental untapered and fluted or tapered and fluted support pole for a luminaire or the like wherein the flutes and the radiused surfaces therebetween exhibit different colors or finish appearance.
These and other objects will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the pole of this invention;
FIG. 2 is a sectional view of the pole as seen on lines 2 — 2 of FIG. 1;
FIG. 3 is a perspective view illustrating the pole being painted; and
FIG. 4 is an end view illustrating the pole being sanded to remove the paint from the radius terminations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The numeral 10 refers to a tapered and fluted support pole which has its base 11 conveniently supported upon a proper footing or the like. The pole may also extend downward and be directly embedded in the earth. The numeral 12 refers to a luminaire which is conventionally mounted on the upper end of the support pole 10 . Although the support pole 10 is preferably of the tapered configuration, non-tapered cylindrical support poles could also be utilized with this invention.
The tapered and fluted support pole of this invention is formed as follows. The pole 10 , either tapered or non-tapered, is formed from a metal such as steel or aluminum to define a hollow cylindrical cross-section, as seen in FIG. 2 . If the pole has been tapered, there normally will be die marks present on the exterior surface of the pole. If die marks are present, the exterior surface of the pole is preferably sanded to remove those die marks. The next step in forming the pole is to create spaced-apart, longitudinally extending flutes 14 in the pole in a conventional fashion, thereby defining radiused surfaces 16 between the flutes 14 . The precise shape of the radiused surfaces 16 may vary depending upon the particular style of fluting. Although FIGS. 2 and 4 illustrate that the interior surface of the pole 10 is cylindrical or smooth, the actual shape of the interior surface of the pole will usually mimic the outside fluted shape so as to provide a uniform wall thickness. The entire pole is then painted with a liquid paint or powder coated (FIG. 3 ). After the liquid paint or coating has been allowed to dry or is cured, the exterior surface of the pole is sanded with a conventional belt sander or cylindrical sander 18 to remove the paint or coating from the smooth radiused surfaces and which leaves paint or coating in the flutes 14 (FIG. 4 ). After the paint or coating has been sanded from the radiused surfaces, as described above, the entire pole, including radiused surfaces and flutes, may be painted or coated with a transparent, clear translucent, or tinted coating. The painting or coating of the entire pole tends to add color to the radiused surfaces. In other words, if a transparent or clear translucent paint or coating is applied over the flutes and the radiused surfaces, the radiused surfaces tend to take on or reflect some of the color from the flutes. The same is also true for a clear translucent or tinted coating.
Example A listed below sets forth the preferred steps of this invention while Example B sets forth a modified form of the method.
EXAMPLE A
Step 1. Form pole, either tapered or non-tapered, from metal such as steel or aluminum.
Step 2. Sand pole to remove die marks, if any.
Step 3. Create spaced-apart, longitudinally extending flutes in pole which define radiused surfaces therebetween.
Step 4. Paint or coat entire pole.*
Liquid paint, or liquid coating such as powder coating.
Step 5. Sand pole to remove paint or coating from radiused surfaces which leaves paint or coating in flutes.
Step 6. Paint or coat entire pole, radiused surfaces, and flutes with a transparent, clear translucent, or tinted coating.
EXAMPLE B
Step 1. Form pole, either tapered or non-tapered, from metal such as steel or aluminum.
Step 2. Create spaced-apart, longitudinally extending flutes in pole which define radiused surfaces therebetween.
Step 3. Paint or coat entire pole.*
Liquid paint, or liquid coating such as powder coating.
Step 4. Sand pole to remove paint or coating from radiused surfaces which leaves paint or coating in flutes.
It can therefore be seen that a highly ornamental support pole has been provided for a luminaire or the like.
Thus it can be seen that the invention accomplishes at least all of its stated objectives.
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An ornamental support pole for a luminaire is disclosed wherein the support pole is fluted to define longitudinally extending and spaced-apart flutes having radiused surfaces therebetween. The flutes are painted or coated so as to exhibit a color different than that of the radiused surfaces therebetween. The method of creating the pole structure is also described.
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BACKGROUND OF THE INVENTION
The present invention relates to oscillating hook type sewing machines, and more particularly to improvements in sewing machines wherein the shuttle hook oscillates in a substantially vertical plane.
Oscillating hook type sewing machines exhibit the advantage that the needle thread loop is not twisted during training around the hook and bobbin case and that the thread can readily pass between the hook and the shuttle driver finger, as a result of mere reversal in the direction of movement of the hook and driver finger, without any specially designed auxiliary equipment. As a rule, such types of hooks are not sensitive to changes in the tension of the thread and can assist in the making of eye-pleasing uniform stitches.
Friction between the limbs of the loop which is formed by needle thread often entails the making of slack stitches. This can take place in all kinds of sewing machines including those employing heretofore known oscillating type hooks. The magnitude of friction between the limbs of a loop depends on a plurality of parameters including the diameters and types of threads, the type of stitching, the length of loops, the width of stitches, the speed of the sewing machine and others. The just discussed friction can result in the making of non-uniform stitches.
For example, the loop which is formed by the needle thread in an oscillating hook type sewing machine must completely surround the hook, the bobbin case and the supply of bobbin thread in the case. The loop is cast off shortly or immediately before the hook changes the direction of its movement, and the thus released loop is lifted by the takeup lever so that its bight is moved against the underside of the work. As a rule, upward movement of the takeup lever entails an upward movement of the front limb of the needle thread loop, i.e., of that limb which extends through the eye of the needle. The rear limb is more or less passive. That portion of the bobbin thread which extends from the bobbin case to the underside of the work passes between the two limbs of the loop which is formed by the needle thread and normally does not interfere with a predictable reduction of the size of the needle thread loop. However, when the machine is set to make long and/or wide stitches, the needle penetrates behind that portion of the bobbin thread which extends from the bobbin case to the work during transition from a right downward stroke to a left downward stroke. Consequently, the needle thread is looped around the bobbin thread subsequent to castoff from the hook which entails the development of additional friction in the region of the front limb of the needle thread loop. This, in turn, entails a more rapid upward movement of the rear limb of the needle thread loop. The just described mode of operation does not appreciably affect the quality and/or appearance of the stitches when the sewing machine is operated at a medium speed or at an elevated speed because the making of stitches takes place at frequent intervals and the inertia of the rear limb is too pronounced so that it cannot react to the development of additional friction with the front limb. However, the situation is different when the sewing machine is operated at less than average speed or at a low speed. At such time, the upper and lower threads are in longer-lasting frictional engagement with each other because the speed at which the size of the needle thread loop is reduced is relatively low and the interval of frictional engagement between the two slowly moving threads is much longer. In other words, that component of static friction which causes the two threads to adhere to each other is more pronounced than the component of sliding friction. The upward movement of the rear limb of the needle thread loop is too rapid with the result that the entire needle thread is not drawn all the way into the work and the work is formed with so-called slack or loose stitches. Since the making of slack stitches takes place at random, they greatly affect the appearance of the product.
Attempts to avoid the making of slack stitches in other types of sewing machines include the utilization of retainers of the type disclosed in U.S. Pat. No. 4,095,539 which describes and shows a sewing machine with a rotary shuttle. This patent proposes to use a so-called work limb retainer which engages the loop during the normal loop taker cycle and discharges the thread after the thread has completed its passage around the loop taker. A somewhat similar proposal is described in German Utility Model No. 70 16 286.
The incorporation of features which lessen or eliminate the aforediscussed problems in rotary shuttle type sewing machines into an oscillating shuttle hook type sewing machine is impossible because of the entirely different nature and mode of operation of shuttles in such machines.
German Offenlegungsschrift No. 33 42 770 discloses an oscillating hook type sewing machine wherein the shuttle hook driver carries a device for braking the rear limb of the needle thread loop. A drawback of this proposal is that the braking device is complex, expensive and bulky. Moreover, the nature of the braking device which is disclosed in the Offenlegungsschrift is such that each of a short or long series of braking devices produces a different braking force so that the braking action must be individually adjusted in each and every sewing machine which employs the proposed braking device. This contributes significantly to the initial and maintenance cost of the sewing machine.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the invention is to provide a novel and improved needle thread braking device for use in sewing machines with hooks which are mounted for oscillatory movement in a substantially vertical plane.
Another object of the invention is to provide a braking device which can be assembled with and supported by hooks whose configuration need not appreciably depart from the configuration of presently used oscillating hooks.
A further object of the invention is to provide a sewing machine which embodies the above outlined braking device.
An additional object of the invention is to provide a simple, inexpensible and lightweight braking device which can stand long periods of use without any or with a minimum of maintenance.
Still another object of the invention is to prevent the making of slack stitches in an oscillating hook type sewing machine irrespective of whether the machine is operated at a normal or at a reduced speed.
A further object of the invention is to provide a novel and improved hook for use in conjunction with the above outlined braking device.
Another object of the invention is to provide novel and improved means for retarding the upward movement of one limb of each of a succession of loops which are formed by the needle thread in an oscillating hook type sewing machine.
An additional object of the invention is to provide a braking device which does not affect the appearance and/or other characteristics of stitches at any selected speed of the sewing machine.
Another object of the invention is to provide a braking device whose braking force remains at least substantially unchanged during the making of millions of stitches.
The invention is embodied in a sewing machine which comprises a substantially vertically reciprocable needle for the upper thread, a needle bar or analogous means for reciprocating the needle, a shuttle hook which is mounted for oscillatory movement in a substantially vertical plane about a predetermined axis, and means for oscillating the hook so that the hook and the needle cooperate in converting the upper thread into a series of loops each of which has several limbs. In accordance with a feature of the invention, the sewing machine of the above outlined type further comprises means for temporarily braking at least one limb of each loop. The braking means includes a loop-engaging member which is movable by successive loops with reference to the hook in a second plane that is at least substantially parallel to the vertical plane from a first or starting position to a second position in which the loop-engaging member casts off the loop as a result of upward movement of the engaged portion of the loop. The braking means further comprises means for yieldably biasing the loop-engaging member to its first position.
The hook includes a substantially disc-shaped or sector-shaped end portion which is disposed in the vertical plane, and the loop-engaging member is adjacent to such end portion of the hook. In accordance with a presently preferred embodiment of the invention, the biasing means is mounted on and shares the oscillatory movements of the hook.
The braking means can further comprise a loop catcher (e.g., in the form of a substantially tooth-shaped protuberance) which is movable with the loop-engaging member relative to the hook to transfer successive loops from the hook into the path of movement of the loop-engaging member while the latter moves from or while the latter still dwells in its first position. The loop-engaging member is or can constitute an elongated part which is integral with the loop catcher. For example, the loop-engaging member can include a substantially pallet- or tooth-shaped first end portion which engages successive loops during successive movements of the member from the first to the second position, at least during the last stage of each such movement, and a second end portion which is connected to (e.g., integral with) the biasing means. The loop catcher can be provided on such elongated loop-engaging member intermediate the two end portions.
The biasing means can comprise a torsion spring one end convolution of which is integral with a leg of the loop-engaging member. In such types of sewing machines, the loop-engaging member and the torsion spring can consist of a single piece of steel wire. Alternatively, the braking means can comprise means for securing a separately machined, extruded, molded or otherwise formed loop-engaging member to the torsion spring or other suitable biasing means. For example, the hook can comprise an integral or separately produced hollow mandrel and the spring can be anchored in the mandrel. To this end, the spring can be provided with a substantially U-shaped terminal portion which is remote from the loop-engaging member and is non-rotatably mounted in the mandrel. The hook can be provided with a post which extends substantially diametrically through the hollow mandrel, and the U-shaped portion of the spring can constitute an eyelet which is partially or completely convoluted around the post in the interior of the mandrel to thus ensure that the spring is compelled to share the oscillatory movements of the hook. Alternatively, the mandrel can be formed with two internal grooves which are at least substantially parallel to the axis of the hook, and the U-shaped or otherwise configurated terminal portion of the spring has parts which extend into such grooves to ensure that the spring oscillates with the mandrel and hence with the hook.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The improved sewing machine itself, however, both as to its construction and its mode of operation, together with additional features and advantages thereof, will be best understood upon perusal of the following detailed description of certain specific embodiments with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagrammatic perspective view of a piece of work which is provided with stitching including slack loops whose formation can be avoided in accordance with the present invention;
FIG. 2 is a perspective view of a shuttle hook and of a braking device which embodies one form of the present invention, a portion of the mandrel of the hook being broken away;
FIG. 3 is an enlarged view of a portion of the structure which is shown in FIG. 2;
FIG. 4 is a similar fragmentary perspective view of a slightly modified hook and a perspective view of a slightly modified braking device;
FIG. 5 is a fragmentary schematic elevational view of a portion of a sewing machine which embodies the structure of FIGS. 2 and 3, showing the loop-engaging member of the braking device in its starting position;
FIG. 6 shows the structure of FIG. 5 but with the loop-engaging member in an intermediate position;
FIG. 7 illustrates the structure of FIGS. 5 and 6, with the loop-engaging member shown in the second position at the time of castoff of the needle thread loop; and
FIG. 8 is an elevational view of the hook as seen from the left-hand side of FIG. 5, 6 or 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a piece of work 1 to be sewn and a row of stitches 7 which connect two superimposed panels of the work (e.g., a garment having two overlapping sheets of textile material). It will be seen that certain loops (denoted by the characters 9) of the upper or needle thread 53 are slack, i.e., the entire stitching is uneven which detracts from the appearance as well as from the reliability of the stitching. The slack of loops 9 is attributable to excessive length of the rear limbs 57 of these loops.
FIG. 2 shows a shuttle hook 11 which is mounted for oscillatory movement in a substantially vertical plane at a level below the support for the work so that it turns back and forth about a substantially horizontal axis A. The hook 11 comprises a coaxial hollow mandrel 13 which is surrounded by the case 15 (shown by phantom lines in FIG. 5) for a bobbin containing a supply of lower or bobbin thread. The axial bore or passage 17 of the mandrel 13 contains a portion of a novel and improved braking device 19 (see particularly FIG. 3) which includes a loop-engaging member 27 extending from the open end of the bore 17 and being located in a substantially vertical plane adjacent to the vertical plane of a substantially sector-shaped end portion or wall 37 of the hook 11. The braking device 19 further includes a torsion spring 25 which is confined in the bore 17, and more specifically in the interior of the hollow mandrel 13. The braking device 19 which is shown in FIGS. 2 and 3 consists of a single piece of metallic or other suitable wire, and the torsion spring 25 includes a substantially U-shaped terminal portion 21 which is convoluted around the intermediate portion of a post or stud 23. The latter extends diametrically of the mandrel 13 and ensures that the spring 25 is compelled to share the oscillatory movements of the hook 11 and its mandrel 13. The common axis of the convolutions of the spring 25 preferably coincides with the axis A of the hook 11. That convolution of the spring 25 which is remotest from the U-shaped terminal portion 21 is integral with one leg (35) of the loop-engaging member 27. The other leg (34) of the member 27 extends into the interior of the torsion spring 25.
The member 27 is elongated and one (59) of its end portions is bent slightly toward the free end of the mandrel and in a clockwise direction (as viewed in FIG. 3) out of the general plane of the member 27 and toward the inner (unexposed) side or surface of the end wall 37 of the hook 11. The other end portion of the member 27 includes the legs 34, 35, and an intermediate portion of the member 27 constitutes a tooth-shaped loop catcher 33 which also extends from the exposed side toward and beyond the inner side of the end wall 37 and is disposed radially inwardly of the end portion 59. The end portion 59 and the loop catcher 33 are movable relative to the end wall 37 of the hook 11 in a vertical plane which is parallel to the plane of the inner side of the end wall 37, and such movements of the parts 33, 59 take place under the action of the torsion spring 25 or under the action of a loop which is formed by the needle thread 53.
FIG. 3 shows that the entire torsion spring 25 is or can be confined in that portion of the bore 17 which extends into the mandrel 13. The U-shaped terminal portion 21 engages the intermediate portion of the post 23, and the rightmost convolution 26 of the spring 25 is integral with the aforementioned leg 35. The leg 35 extends from the bore 17 at the exposed side of the end wall 37 and has a 90-degree bend to extend substantially radially outwardly and to merge into the tooth-shaped loop catcher 33. The section 31 between the loop catcher 33 and the end portion 59 is or can be substantially straight and extends substantially radially of the hook 11. The section 29 between the end portion 59 and the leg 34 also extends substantially radially of the hook 11 and merges into the leg 34 which latter extends into the bore 17 and into the interior of the torsion spring 25. Those portions of the legs 34, 35 which are located in the bore 17 are or can be at least substantially parallel to the axis A. The end portion 59 is a loop which makes an angle of approximately 180 degrees so that the sections 29 and 31 of the loop-engaging member 27 are or can be substantially parallel to each other at the inner side of the end wall 37. The loop catcher 33 can be located substantially midway between the end portion 59 and the nearest portion of the bore 17 in the hook 11.
The loops of the needle thread 53 can move the end portion 59 (and hence the entire loop-engaging member 27) relative to the hook 11 in the aforementioned vertical plane (next to the inner side of the end wall 37) against the opposition of the torsion spring 25 from a first position which is shown in FIG. 5 toward and to a second position which is shown in FIG. 7. The loops of the needle thread 53 engage with the end portion 59 until the latter completes a predetermined angle relative to the hook 11 (e.g., an angle of approximately 105 degrees and in a clockwise direction, as viewed in FIG. 5) so that the loop is cast off the member 27 in response to upward movement of a takeup lever 45. The spring 25 stores energy during angular movement of the loop-engaging member 27 from the first position of FIG. 5 to the second position of FIG. 7 so that it can abruptly return the member 27 to the first position of FIG. 5 as soon as the loop is cast off, i.e., as soon as the end portion 59 is disengaged from the needle thread 53.
The loop catcher 33 preferably extends, at least in part, into the customary recess 12 of the hook 11.
FIG. 4 shows a portion of a somewhat modified shuttle hook 11' and a somewhat modified braking device 19'. This braking device includes a torsion spring 25' having an enlarged substantially U-shaped terminal portion 21'parts of which extend into two axially parallel grooves 39 which are machined into or otherwise formed in the internal surface of the mandrel 13' and extend all the way to the exposed side of the end wall 37'. The terminal portion 21' in the bore 17' cooperates with the mandrel 13' to ensure that at least the major portion of the spring 25' is compelled to share the oscillatory movements of the hook 11'. The configuration of the loop-engaging member 27' of the braking device 19' is or can be identical with that of the member 27 which is shown in FIGS. 2 and 3.
Other types of means for non-rotatably anchoring the torsion spring 25 or 25' in the mandrel 13 or 13' of the shuttle hook can be used with equal or similar advantage. Furthermore, the loop-engaging member 27 or 27' can be produced as a discrete part which is thereupon secured to the spring. This is shown schematically in FIG. 4 wherein the means for securing the member 27' to the front or outer end convolution 26' of the spring 25' comprises a butt weld 36 or a spot where the discrete part is bonded to the spring with a suitable adhesive (such as a cyanide glue). Still further, the member 27 or 27' can be replaced with a stamping of sheet metal or a suitably shaped piece of synthetic plastic material, as long as it can perform the loop-catching and loop-engaging or retaining functions of the parts 33 and 59 or 33' and 59'. The spring 25 or 25', or an analogous spring, serves to reliably ensure return movement of the loop-engaging member back to its first or starting position before the hook 11 or 11' is ready to be relieved of the next needle thread loop.
FIG. 5 to 7 illustrate certain additional components of the sewing machine which embodies the structure of FIGS. 2-3 or FIG. 4. The work 1 rests on and is movable relative to a support in the form of a horizontal platform 51 which is disposed at a level above the hook 11. The means for reciprocating the needle 43 comprises a needle bar 41, and the means for oscillating the hook 11, so that its end wall 37 turns back and forth in a substantially vertical plane, is shown schematically at 61 because its construction forms no part of the present invention. The work 1 is engaged by a conventional presser foot including a sole plate 47 and a shank 49. The upper or needle thread 53 is trained over the suitably configurated lower end portion of the takeup lever 45 and passes through the eye of the needle 43.
When the hook 11 completes the training of the needle thread 53 around the case 15 of the bobbin for the lower or bobbin thread (not shown), the thread 53 forms a loop which includes a front limb 55 and a rear limb 57. The limbs 55 and 57 of the needle thread loop contact the end wall 37. The reference character X denotes in FIG. 5 the location where the hook 11 releases the freshly formed needle thread loop including the limbs 55, 57 whereupon the takeup lever 45 begins to lift the loop in a well-known manner so that the loop ultimatesly lies flat against the underside of the work 1. Shortly prior to castoff of the loop, the limb 57 slides off the end wall 37 and over the loop catcher 33 on its way toward the end portion 59. The latter is bent in such a way (as shown in FIGS. 2, 4 and 8) that it can intercept the loop and can oppose a shortening of such loop under the action of the rising takeup lever 45. Thus, the end portion 59 engages with the loop between its limbs 55 and 57. The rising takeup lever 45 moves from the lower level of FIG. 5 to the higher level of FIG. 6 and thereby causes the member 27 to turn relative to the end wall 37 (in a clockwise direction, as viewed in FIG. 5) so that the spring 25 stores energy. Such deformation of the spring 25 causes the member 27 to maintain the limb 57 of the rising needle thread loop in tensioned condition.
The lever 45 continues to move upwardly and beyond the level of FIG. 6 to the level of FIG. 7 so that the extent of angular movement of the end portion 59 from the location X of FIG. 5 increases and the needle thread loop is ultimately cast off after the member 27 completes an angular movement of approximately 105 degrees with reference to the end wall 37 of the hook 11. At such time, the dimensions of the loop at a level below the support 51 and the work 1 thereon are reduced to a fraction of the dimensions of the loop which is shown in FIG. 5. The spring 25 is then free to abruptly dissipate energy and to return the member 27 to the position of FIG. 5 so that the member 27 is ready to engage its end portion 59 with the next needle thread loop.
The terminal portion 21 or 21' or a differently configurated terminal portion of the spring 25 or 25' can be anchored in a plastic pin which, in turn, is anchored against rotation in the deepmost portion of the bore 17 or 17' of the mandrel 13 or 13'.
An important advantage of the improved braking device is that it ensures the making of satisfactory stitches irrespective of the frequency of oscillatory movement of the hook. Moreover, the entire braking device is simple, inexpensive and can be readily installed in existing sewing machines which employ oscillatory shuttle hooks. The braking action of the improved device remains unchanged for extended intervals and, if necessary, the entire braking device can be removed from the hook in a simple and time-saving operation. The sewing machine can be furnished with two or more discrete braking devices each having a spring which can oppose the angular movements of the respective loop-engaging member with a different force. It has been found that the utilization of the improved braking device in a sewing machine with an oscillating hook greatly reduces the likelihood of making of slack stitches.
The loop catcher 33 constitutes an optional but desirable feature of the improved braking device because it ensures reliable engagement between successive loops of the needle thread and the end portion 59 or 59' of the selected loop-engaging member.
Tests with the improved braking device have shown that a torsion spring can stand several million angular movements of the respective loop-engaging member between its first and second positions prior to development of initial stages of fatigue of the material of the spring.
A braking device which is made of a single piece of wire exhibits the important advantage that its mass and inertia (and particularly the mass and inertia of the loop-engaging member) are negligible so that the spring can return the loop-engaging member to the starting position in good time for engagement with the next loop irrespective of the selected speed of the sewing machine.
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 and specific aspects of our contribution to the art and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the appended claims.
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One limb of each loop which is formed by the needle thread in an oscillating hook type sewing machine is temporarily in contact with the loop-engaging member of a braking device whose torsion spring is non-rotatably installed in the hollow mandrel of the hook. The loop-engaging member is turned by successive loops from a starting position, relative to the hook and against the opposition of the spring so that it tensions the loop while the latter is raised by the takeup lever. The spring thereupon rapidly returns the loop-engaging member to its starting position. The loop-engaging member is integral with a loop catcher which intercepts the loop when the latter is cast off the hook and which ensures that the loop comes in contact with the loop-engaging member.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to automated data collection systems that collect information from radio frequency identification (RFID) transponders, and more particularly, to an automated data collection system that uses the information encoded in the RFID transponder to control certain network applications.
[0003] 2. Description of Related Art
[0004] In the automatic data identification industry, the use of RFID transponders (also known as RFID tags) has grown in prominence as a way to track data regarding an object to which the RFID transponder is affixed. An RFID transponder generally includes a semiconductor memory in which digital information may be stored, such as an electrically erasable, programmable read-only memory (EEPROMs) or similar electronic memory device. Under a technique referred to as “backscatter modulation,” the RFID transponders transmit stored data by reflecting varying amounts of an electromagnetic field provided by an RFID interrogator by modulating their antenna matching impedances. The RFID transponders can therefore operate independently of the frequency of the energizing field, and as a result, the interrogator may operate at multiple frequencies so as to avoid radio frequency (RF) interference, such as utilizing frequency hopping spread spectrum modulation techniques. The RFID transponders may either extract their power from the electromagnetic field provided by the interrogator, or include their own power source.
[0005] Since RFID transponders do not include a radio transceiver, they can be manufactured in very small, lightweight and inexpensive units. RFID transponders that extract their power from the interrogating field are particularly cost effective since they lack a power source. In view of these advantages, RFID transponders can be used in many types of applications in which it is desirable to track information regarding a moving or inaccessible object. One such application is to affix RFID transponders to packages or parcels moving along a conveyor belt. The RFID transponders would contain stored information regarding the packages, such as the originating or destination address, shipping requirements, pick-up date, contents of the package, etc. An RFID interrogator disposed adjacent to the conveyor belt can recover the stored information of each RFID transponder as it passes no matter what the orientation of the package on the conveyor belt. The RFID interrogator may then communicate the collected information to a computer or computer network for further processing by a software application.
[0006] A drawback of conventional automated data collection systems is that the conveyance of information from the RFID interrogator to the software application operating on a computer or computer network is independent of the information content. The interrogator generally forwards the collected information to the software application irrespective of the content of the information, and the software application then determines what actions to take with respect to the information. There presently exist many known RFID transponder types having unique data formats and protocols, with each such format and protocol being generally incompatible with each other. More than one type of RFID transponder may be present within the operating environment of a single RFID interrogator, such as a first type of RFID transponder disposed on a truck and a second type of RFID transponder disposed on a pallet carried by the truck. Thus, separate software applications may be used to process the information from each of the RFID transponder types, and yet another software application may be used to distinguish between the collected information and route the information to the appropriate software application for subsequent processing. The use of a software application to provide the routing function necessarily limits the flexibility of the network applications that use the collected information.
[0007] It would therefore be desirable to provide an automated data collection system in which the RFID interrogator can convey collected information to different locations, computers and/or software applications based on the information content of the RFID transponder.
SUMMARY OF THE INVENTION
[0008] The present invention provides an RFID reader for use in a computer network in which the RFID reader can control networking applications on the basis of information collected from an RFID tag. The RFID tag is provided with certain designated fields that identify a destination computer system and/or application program for data recovered from the RFID tag. The RFID reader can then distribute the collected information in a format and to a destination that is determined by the RFID tag, thereby eliminating the need for intermediary software programs or human operators to make such decisions about the distribution of information. This capability permits RFID tag information to be automatically collected and distributed to network applications for ultimate data processing and collection.
[0009] In accordance with a first embodiment of the invention, an RFID reader detects data stored in certain predetermined fields of an RFID tag and conveys information collected from the RFID tag to external computer systems and/or application programs on the basis of the data from the predetermined fields. The RFID reader further comprises a radio module and a processor connected to the radio module. The radio module is responsive to commands provided by the processor to perform transmit and receive operations with at least one RFID tag. The RFID reader further comprises a memory coupled to the processor and having program instructions stored therein. The processor is operable to execute the program instructions, including detecting data loaded in the designated field of a memory of the RFID tag and communicating information to external systems connected to the RFID reader regarding the RFID tag responsive to the detected data.
[0010] Another embodiment of the invention comprises a computer network including a server having a plurality of application programs operating thereon, and at least one client computer connected to the server. An RFID reader is connected to the server and is adapted to communicate with RFID tags having a memory containing a designated field for storage of data. The RFID reader provides a message to the server regarding one of the RFID tags directed to a particular one of the plurality of application programs selected in accordance with data stored in the designated field of the RFID tag. The data stored in the designated field may include an address of a particular destination computer system connected to the network and/or a protocol used by the RFID tag. The RFID reader then communicates information to the server in accordance with the protocol. The plurality of application programs operative on the server may comprise an e-mail program, a website hosting program, a database program, and the like.
[0011] A more complete understanding of the networking applications for automated data collection will be afforded to those skilled in the art, as well as a realization of additional advantages and objects thereof, by a consideration of the following detailed description of the preferred embodiment. Reference will be made to the appended sheets of drawings that will first be described briefly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a block diagram illustrating a computer network having an RFID reader arranged to read data from a plurality of RFID transponders;
[0013] FIG. 2 is a block diagram of the RFID reader of FIG. 1 ;
[0014] FIG. 3 is a block diagram of an RFID transponder of FIG. 1 ;
[0015] FIG. 4 is a block diagram illustrating an operating system environment of a server of the computer network; and
[0016] FIG. 5 is a flow chart illustration operation of the RFID reader.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The present invention satisfies the need for an automated data collection system in which the RFID interrogator can convey collected information to different locations, computers and/or software applications using the information content of the RFID transponder. In the detailed description that follows, like element numerals are used to describe like elements illustrated in one or more of the figures.
[0018] Referring first to FIG. 1 , an automated data collection environment is illustrated that includes a computer system forming part of a local area network (LAN) or wide area network (WAN). The computer system includes a server computer 22 attached to the LAN/WAN 30 , and has plural client computers 24 connected to the server computer. The client computers 24 may each be a personal computer having a processor and non-volatile data storage device, such as a hard disk drive, optical disk drive, and the like. A user can enter commands and information into each client computer 24 through input devices such as a keyboard, mouse, microphone, joystick, game pad, scanner, etc. A monitor or other display device coupled to the each client computer 24 provides visual output to the user. Other output devices coupled to each client computer 24 may include printers, speakers, etc. The server computer 22 may comprise a high-speed microcomputer, minicomputer or mainframe computer that acts as a conduit for communication of data packets between the client computers 24 and the outside world. Although two client computers 24 are shown in FIG. 1 , it should be appreciated that a large number of client computers may be coupled to the server computer 22 . The server computer 22 may also provide various system applications for the client computers 24 , such as electronic mail (e-mail), central file management, database, etc. The computer system permits the server and client computers 22 , 24 to communicate with a remote computer such as personal computers 34 coupled to a remote server computer 32 .
[0019] The LAN/WAN 30 may further comprise the Internet or a corporate intranet. As known in the art, the Internet is made up of more than 100,000 interconnected computer networks spread across over one hundred countries, including commercial, academic and governmental networks. Businesses and other entities have adopted the Internet as a model for their internal networks, or so-called “intranets.” The server computers 22 , 32 may facilitate routing of messages over the LAN/WAN 30 between end users at the personal computers 24 , 34 . Messages transferred between computers within a network are typically broken up into plural data packets. Packet switching systems are used to route the data packets to their required destination and enable the efficient handling of messages of different lengths and priorities. Since each data packet includes a destination address, all packets making up a single message do not have to travel the same path. Instead, the data packets can be dynamically routed over the interconnected networks as circuits become available or unavailable. The destination computer receives the data packets and reassembles them back into their proper sequence to reconstruct the transmitted message. The client computers 24 , 34 may include a browser application that enables the user to view graphical information communicated across the computer network, including a portion of the Internet referred to as the World Wide Web.
[0020] Computer networks generally use the TCP/IP communications protocol, which is an acronym for Transmission Control Protocol/Internet Protocol. The TCP portion of the protocol provides the transport function by breaking a message into smaller packets, reassembling the packets at the other end of the communication network, and re-sending any packets that get lost along the way. The IP portion of the protocol provides the routing function by giving the data packets an address for the destination network and client at the destination address. Each data packet communicated using the TCP/IP protocol includes a header portion that contains the TCP and IP information.
[0021] The computer system further includes an RFID reader 40 coupled to the server computer 22 . The RFID reader 40 is adapted to read encoded data stored in RFID tags 14 a - 14 c . The RFID reader 40 may have a hard-wired link to the server computer 22 , or alternatively, may communicate over an RF or optical data link. The RFID reader 40 includes an antenna 42 that permits RF communication with the RFID tags 14 a - 14 c . As shown in FIG. 1 , the RFID tags 14 a - 14 c are affixed to packages 12 a - 12 c , respectively, that may be in motion with respect to the RFID reader 40 . For example, the RFID reader 40 may be mounted in a fixed location with respect to a conveyor belt on which a plurality of packages 12 a - 12 c is transported. Alternatively, the RFID reader 40 may be disposed adjacent to a doorway through which packages 12 a - 12 c are transported in a single direction or in both directions simultaneously. In either case, the RFID reader 40 reads the data stored in each RFID tag 14 a - 14 c as the tag passes thereby. While the RFID reader 40 is generally described herein as being mounted in a fixed position with respect to the RFID tags 14 a - 14 c , it should also be appreciated that aspects of the invention would be equally applicable to a hand-held reader that is manipulated by a user into proximity with the RFID tags.
[0022] Referring now to FIG. 2 , the RFID reader 40 is illustrated in greater detail. The RFID reader 40 comprises a processor 46 , a memory 48 and a radio module 44 . The processor 46 processes data signals received from the RFID tags 14 a - 14 c and communicates with the server computer 22 . The term “processor” as generally used herein refers to any logic processing unit, such as one or more central processing units (CPUs), digital signal processors (DSPs), application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), and the like. The memory 48 includes a random access memory (RAM) and a read-only memory (ROM) to provide storage for program instructions, parameters and data for the processor 46 . More particularly, the memory 48 contains stored instructions that are executed by the processor 46 to cause the processor to receive, write, and/or manipulate data recovered from the RFID tags 14 a , 14 c . The memory 48 may further comprise a flash memory or electronically erasable programmable read-only memory (EEPROM). The server computer 22 may communicate new, revised or additional instruction sets to the processor 46 for storage within the memory 48 in order to modify operation of the RFID reader 40 .
[0023] The radio module 44 provides for RF communications to/from the RFID tags 14 a - 14 c under the control of the processor 46 . The radio module 44 further comprises a transmitter portion 44 a , a receiver portion 44 b , and a hybrid 44 c . The antenna 42 is coupled to the hybrid 44 c . The hybrid 44 c may further comprise a circulator, directional coupler, or like component that permits bi-directional communication of signals with sufficient signal isolation. The transmitter portion 44 a includes a local oscillator that generates an RF carrier frequency. The transmitter portion 44 a sends a transmission signal modulated by the RF carrier frequency to the hybrid 44 c , which in turn passes the signal to the antenna 42 . The antenna 42 broadcasts the modulated signal and captures signals radiated by the RFID tags 14 a - 14 c . The antenna 42 then passes the captured signals back to the hybrid 44 c , which forwards the signals to the receiver portion 44 b . The receiver portion 44 b mixes the captured signals with the RF carrier frequency generated by the local oscillator to directly downconvert the captured signals to a baseband information signal. The baseband information signal may comprises two components in quadrature, referred to as the I (in phase with the transmitted carrier) and the Q (quadrature, 90 degrees out of phase with the carrier) signals. The hybrid 44 c connects the transmitter 44 a and receiver 44 b portions to the antenna 42 while isolating them from each other. In particular, the hybrid 44 c allows the antenna 42 to send out a strong signal from the transmitter portion 44 a while simultaneously receiving a weak backscattered signal reflected from the RFID tags 14 a - 14 c.
[0024] Referring now to FIG. 3 , an exemplary RFID tag 50 is illustrated in greater detail. The RFID tag 50 corresponds to the RFID tags 14 a - 14 c described above with respect to FIG. 1 . More particularly, the RFID tag 50 includes an RF interface 54 , control logic 56 and memory 58 . The RF interface 54 is coupled to an antenna 52 , and may include an RF receiver that recovers analog signals that are transmitted by the RFID reader 40 and an RF transmitter that sends data signals back to the RFID reader. The RF transmitter may further comprise a modulator adapted to backscatter modulate the impedance match with the antenna 52 in order to transmit data signals by reflecting a continuous wave (CW) signal provided by the RFID reader 40 . The control logic 56 controls the functions of the RFID tag 50 in response to commands provided by the RFID reader 40 that are embedded in the recovered RF signals. The control logic 56 accesses the memory 58 to read and/or write data therefrom. The control logic 56 also converts analog data signals recovered by the RF interface 54 into digital signals comprising the received commands, and converts digital data retrieved from the memory 58 into analog signals that are backscatter modulated by the RF interface 54 . The RFID tag 50 may be adapted to derive electrical power from the interrogating signal provided by the RFID reader 40 , or may include an internal power source (e.g., battery).
[0025] The memory 58 of the RFID tag 50 contains a space for data storage having plural fields that may be defined by an end user of the automated data collection system. In the present invention, at least two of the fields are predefined, including an IP Address field and a Port Number field. The IP Address field and Port Number field enable the RFID reader 40 to route data within the computer system in the same manner that these fields of a TCP/IP data packet permit routing within a computer network. In an embodiment of the invention, the IP Address field designates a destination computer system that should be provided with the data and the Port Number designates a protocol and associated software application that supports the protocol. Depending upon a particular protocol and associated software application that is designated by a particular Port Number, additional information contained in other fields of the memory 58 can be accessed.
[0026] Referring now to FIG. 4 in conjunction with FIG. 1 (described above), an operating system environment 60 of the server 22 is illustrated. The operating system environment 60 depicts the interconnection between received data packets and applications running on the operating system of the server. Particularly, the operating system environment 60 includes a routing process 62 and plural application programs 64 a - 64 c . The routing process 62 determines the routing of data packets into and out of the server 22 . The routing process 62 may include a table that defines the addresses and interconnection pathways between the server 22 , the client computers 24 , and the RFID reader 40 . The routing process 62 may further communicate with one or more network interfaces used to transfer data packets into and out of the server 22 . The application programs 64 a - 64 c each provide a specific function, and may include an e-mail program, a database program, a Website host, etc. Data packets generated either within the computer network, or external to the network, are directed first to the routing process 62 and are then forwarded to an appropriate one of the application programs 64 a - 64 c . The server 22 may have a designated IP Address, and each of the application programs 64 a - 64 c running on the server may have a designated Port Number. Similarly, the application programs 64 a - 64 c may send data packets through the routing process 62 for delivery to another location either within the computer network or external to the computer network.
[0027] For example, an e-mail message directed to a particular client computer 24 in the network from external to the LAN/WAN would be communicated in the form of one or more data packets that pass first through the operating system environment 60 of the server 22 . The routing process 62 would direct the data packets to one of the application programs, such as application 64 a , that provides an e-mail host program. A user at one of the client computers 24 can then access the message by communicating with the server 22 , which sends the message in the form of data packets back through the routing process 62 to the client computer 24 .
[0028] Referring now to FIG. 5 in conjunction with FIGS. 1 and 2 (described above), an exemplary process performed by the RFID reader 40 in communicating with the computer network is illustrated. The exemplary process would likely be encoded in the form of software instructions that are stored in the memory 48 of the RFID reader 40 and executed by the processor 46 . The process begins at step 100 and is followed by steps that form a continuous loop. In a first part of the loop, the RFID reader 40 attempts to communicate with RFID tags 14 that may be within a communication range. At step 102 , the RFID reader 40 transmits an interrogation field that may comprise a modulated RF signal and/or a continuous wave signal. If an RFID tag 14 is within the transmitting range of the RFID reader 40 , the RFID tag may communicate a response back to the RFID reader using backscatter modulation. At step 104 , the RFID reader 40 attempts to detect a response signal communicated by the RFID tag 14 . Then, at step 106 , the RFID reader 40 makes as determination as to whether a detected response was valid, i.e., whether a response signal originated from an RFID tag 14 or was an erroneous noise signal. If the response is determined to be not valid, the process returns to step 102 and the RFID reader 40 transmits another interrogation field. In this manner, the RFID reader 40 will attempt to communicate with an RFID tag on a periodic basis.
[0029] If at step 106 the detected response is determined to be valid indicating that an RFID tag 14 is present within the interrogating field, the RFID reader 40 communicates with the RFID tag and attempts to recover the data stored in the memory of the RFID tag. The recovered data is then transferred into memory of the RFID reader 40 for additional processing. At step 110 , the processor 46 reads the designated fields of the recovered data to identify an IP Address and Port Number. Then, at step 112 , the processor 46 determines whether the designated fields contain valid data. As described above, there are many different types of RFID tags that may be operative within a common field. It is therefore expected that certain types of RFID tags may be encoded with an IP Address and Port Number in designated fields, while other types of RFID tags may be programmed using an unknown protocol whereby the data in the designated fields would be unrecognizable and therefore not valid. If the IP Address and Port Number cannot be detected, indicating either an unknown tag protocol or a known protocol with the fields blank, the RFID reader 40 may simply forward the recovered tag data to a generic process in the server 22 for further processing. The generic process may comprise one of the application programs 64 a - 64 c illustrated in FIG. 4 . Alternatively, the RFID reader 40 may simply discard the recovered data if the IP Address and Port Number fields prove to be not valid. Thereafter, the process returns to step 102 to attempt communication with another RFID tag.
[0030] If a valid IP Address and Port Number is identified from the recovered RFID tag data at step 112 , the process enters a third portion of the continuous loop. Using the Port Number, the processor 46 will determine the protocol used by the RFID tag 14 and the associated software application that supports the protocol. At step 116 , the processor 46 determines a message format based on the protocol defined by the Port Number and generates a data packet containing the RFID tag data formatted in accordance with the defined protocol. The processor 46 may access a table that relates each Port Number to a particular protocol and message format. Then, at step 118 , the processor 46 forwards the message to the server 22 using the IP Address information as an ultimate destination for the data packet. Thereafter, the process returns to step 102 to attempt communication with another RFID tag.
[0031] In an exemplary application of the present invention, the RFID tags 14 may be used by a shipping company within labels affixed to packages. The RFID reader 40 may be located within a trans-shipment point that packages pass through on their way to a final destination. The Port Number may indicate that an e-mail application is designated, whereupon the processor 46 will prepare a data packet using data recovered from the RFID tag 14 to be transferred to the e-mail application in the server. The e-mail application would then forward an e-mail message to a destination computer system identified by the IP Address data, such as a client computer 24 directly connected to the computer network or the remote client computer 34 connected through the LAN/WAN. The destination computer system may belong to the customer, and the e-mail message may thereby notify the customer of the time and date in which the package reached the trans-shipment point. The e-mail message may contain additional information determined by the designated protocol, such as the temperature at the trans-shipment point that may be of interest in the shipment of perishable goods.
[0032] Alternatively, the Port Number may designate a Website host application program, whereupon the processor 46 will prepare a data packet using data recovered from the RFID tag 14 to be transferred to the Website host application. The recovered data may then be posted on a Website that may be accessed by the remote client computer 34 . The IP Address may be used to provide a security feature whereby only the destination computer system identified by the IP Address would be able to access the tag information posted on the Website. As in the preceding example, the Website may provide the customer with the time and date in which the package reached the trans-shipment point, as well as other information such as temperature. In a similar manner, the Port Number may designate a database application program on the server 22 and the IP Address may simply identify the server. Client computers 24 connected to the server 22 could then access the RFID tag data through the data base application program. It should be appreciated that numerous other types of application programs could make use of the RFID tag information, and specific protocols could be adopted to define message formats for the RFID tag information to interface properly with the application program.
[0033] Having thus described a preferred embodiment of networking applications for automated data collection, it should be apparent to those skilled in the art that certain advantages of the within system have been achieved. It should also be appreciated that various modifications, adaptations, and alternative embodiments thereof may be made within the scope and spirit of the present invention. The invention is further defined by the following claims.
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An RFID reader directly controls computer network applications on the basis of information collected from an RFID tag. The RFID tag includes certain designated fields that identify a destination computer system and/or application program for data recovered from the RFID tag. The RFID reader can then distribute the collected information in a format and to a destination that is determined by the RFID tag, thereby eliminating the need for intermediary software programs or human operators to make such decisions about the distribution of information. This capability permits RFID tag information to be automatically collected and distributed to network applications for ultimate data processing and collection.
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[0001] The present application is a continuation of and claims the benefit from U.S. patent application Ser. No. 11/538,154, filed Oct. 3, 2006, entitled “ARTICULATING SURGICAL STAPLING INSTRUMENT INCORPORATING A TWO-PIECE FIRING MECHANISM”, to Shelton, IV et al. which claims the benefit of the U.S. provisional patent application entitled “SURGICAL INSTRUMENT INCORPORATING AN ELECTRICALLY ACTUATED ARTICULATION MECHANISM”, to Shelton, Ser. No. 60/591,694, filed on 28 Jul. 2004 and which is a continuation-in-part patent application of the U.S. nonprovisional patent application entitled “SURGICAL STAPLING INSTRUMENT INCORPORATING AN E-BEAM FIRING MECHANISM” to Shelton et al., Ser. No. 10/443,617, filed on 20 May 2003, the disclosures of which are each hereby incorporated by reference in their respective entireties.
FIELD OF THE INVENTION
[0002] The present invention relates in general to surgical instruments that are suitable for endoscopically inserting an end effector that is actuated by a longitudinally driven firing member, and more particularly a surgical stapling and severing instrument that has an articulating shaft.
BACKGROUND OF THE INVENTION
[0003] Endoscopic surgical instruments are often preferred over traditional open surgical devices since a smaller incision tends to reduce the post-operative recovery time and complications. Consequently, significant development has gone into a range of endoscopic surgical instruments that are suitable for precise placement of a distal end effector at a desired surgical site through a cannula of a trocar. These distal end effectors engage the tissue in a number of ways to achieve a diagnostic or therapeutic effect (e.g., endocutter, grasper, cutter, staplers, clip applier, access device, drug/gene therapy delivery device, and energy device using ultrasound, RF, laser, etc.).
[0004] Positioning the end effector is constrained by the trocar. Generally these endoscopic surgical instruments include a long shaft between the end effector and a handle portion manipulated by the clinician. This long shaft enables insertion to a desired depth and rotation about the longitudinal axis of the shaft, thereby positioning the end effector to a degree. With judicious placement of the trocar and use of graspers, for instance, through another trocar, often this amount of positioning is sufficient. Surgical stapling and severing instruments, such as described in U.S. Pat. No. 5,465,895, are an example of an endoscopic surgical instrument that successfully positions an end effector by insertion and rotation.
[0005] More recently, U.S. patent Ser. No. 10/443,617, “SURGICAL STAPLING INSTRUMENT INCORPORATING AN E-BEAM FIRING MECHANISM” to Shelton et al., filed on 20 May 2003, which has been incorporated by reference in its entirety, describes an improved “E-beam” firing bar for severing tissue and actuating staples. Some of the additional advantages include affirmatively spacing the jaws of the end effector, or more specifically a staple applying assembly, even if slightly too much or too little tissue is clamped for optimal staple formation. Moreover, the E-beam firing bar engages the end effector and staple cartridge in a way that enables several beneficial lockouts to be incorporated.
[0006] Depending upon the nature of the operation, it may be desirable to further adjust the positioning of the end effector of an endoscopic surgical instrument. In particular, it is often desirable to orient the end effector at an axis transverse to the longitudinal axis of the shaft of the instrument. The transverse movement of the end effector relative to the instrument shaft is conventionally referred to as “articulation”. This is typically accomplished by a pivot (or articulation) joint being placed in the extended shaft just proximal to the staple applying assembly. This allows the surgeon to articulate the staple applying assembly remotely to either side for better surgical placement of the staple lines and easier tissue manipulation and orientation. This articulated positioning permits the clinician to more easily engage tissue in some instances, such as behind an organ. In addition, articulated positioning advantageously allows an endoscope to be positioned behind the end effector without being blocked by the instrument shaft.
[0007] Approaches to articulating a surgical stapling and severing instrument tend to be complicated by integrating control of the articulation along with the control of closing the end effector to clamp tissue and fire the end effector (i.e., stapling and severing) within the small diameter constraints of an endoscopic instrument. Generally, the three control motions are all transferred through the shaft as longitudinal translations. For instance, U.S. Pat. No. 5,673,840 discloses an accordion-like articulation mechanism (“flex-neck”) that is articulated by selectively drawing back one of two connecting rods through the implement shaft, each rod offset respectively on opposite sides of the shaft centerline. The connecting rods ratchet through a series of discrete positions.
[0008] Another example of longitudinal control of an articulation mechanism is U.S. Pat. No. 5,865,361 that includes an articulation link offset from a camming pivot such that pushing or pulling longitudinal translation of the articulation link effects articulation to a respective side. Similarly, U.S. Pat. No. 5,797,537 discloses a similar rod passing through the shaft to effect articulation.
[0009] In co-pending and commonly owned U.S. patent application Ser. No. 10/615,973, “SURGICAL INSTRUMENT INCORPORATING AN ARTICULATION MECHANISM HAVING ROTATION ABOUT THE LONGITUDINAL AXIS”, to Frederick E. Shelton IV et al, the disclosure of which is hereby incorporated by reference in its entirety, a rotational motion is used to transfer articulation motion as an alternative to a longitudinal motion.
[0010] In the application entitled “SURGICAL STAPLING INSTRUMENT INCORPORATING AN E-BEAM FIRING MECHANISM” to Shelton et al., Ser. No. 10/443,617, filed on 20 May 2003, the disclosure of which was previously incorporated by reference in its entirety, a surgical severing and stapling instrument, suitable for laparoscopic and endoscopic clinical procedures, clamps tissue within an end effector of an elongate channel pivotally opposed by an anvil. An E-beam firing bar moves distally through the clamped end effector to sever tissue and to drive staples on each side of the cut. The E-beam firing bar affirmatively spaces the anvil from the elongate channel to assure properly formed closed staples, especially when an amount of tissue is clamped that is inadequate to space the end effector. In particular, an upper pin of the firing bar longitudinally moves through an anvil slot and a channel slot is captured between a lower cap and a middle pin of the firing bar to assure a minimum spacing. While this E-beam firing bar has a number of advantages, additional features are desirable to enhance manufacturability and to minimize dimensional variations.
[0011] Consequently, a significant need exists for a surgical instrument with a firing bar that advantageously assures proper spacing between clamped jaws of an end effector and which facilitates articulation of its shaft.
BRIEF SUMMARY OF THE INVENTION
[0012] The invention overcomes the above-noted and other deficiencies of the prior art by providing a firing mechanism that affirmatively vertically spaces an end effector of a surgical stapling and severing instrument. Thus, the instrument structurally assures adequate spacing to achieve proper stapling, even in instances where too little tissue is clamped in the end effector. Integrally forming these features into an E-beam that includes a cutting edge realizes consistent spacing and performance as the E-beam fires through an end effector such as a severing and stapling assembly. Further, proximally attaching a separate, thinned firing bar to the E-beam enhances use in articulating surgical instruments wherein reduced cross sectional area and the ability to flex in a plane of articulation are desirable.
[0013] In one aspect of the invention, a surgical instrument includes a handle portion operable to produce a firing motion that actuates an implement portion. This implement portion has an elongate channel that receives a staple cartridge opposed by a pivotally attached anvil. A firing device includes a distally presented cutting edge longitudinally received between the elongate channel and the anvil, an upper member engageable to the anvil channel, a lower member engaging the channel slot, and a middle member operable to actuate the wedge sled, which is integral to the staple cartridge. The middle member advantageously opposes pinching of the end effector, assuring proper staple formation even when an otherwise too small amount of tissue has been clamped. These spacing and cutting features are advantageously formed into an E-beam while flexibility for articulation is provided by a thinned firing bar attached to the E-beam.
[0014] These and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and the description thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0015] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and, together with the general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the present invention.
[0016] FIG. 1 is a perspective view of an endoscopic surgical stapling instrument for surgical stapling and severing in an open, unarticulated state.
[0017] FIG. 2 is a left, front perspective view of an open staple applying assembly of the surgical stapling instrument of FIG. 1 with a right half portion of a replaceable staple cartridge included in a staple channel.
[0018] FIG. 3 is an exploded perspective view of the staple applying assembly of FIG. 2 with a complete replaceable staple cartridge and an alternative nonarticulating shaft configuration.
[0019] FIG. 4 is a perspective view of a two-piece knife and firing bar (“E-beam”) of the staple applying assembly of FIG. 2 .
[0020] FIG. 5 is a perspective view of a wedge sled of a staple cartridge of the staple applying assembly of FIG. 1 .
[0021] FIG. 6 is a left side view in elevation taken in longitudinal cross section along a centerline line 6 - 6 of the staple applying assembly of FIG. 2 .
[0022] FIG. 7 is a perspective view of the open staple applying assembly of FIG. 2 without the replaceable staple cartridge, a portion of the staple channel proximate to a middle pin of two-piece knife and firing bar, and without a distal portion of a staple channel.
[0023] FIG. 8 is a front view in elevation taken in cross section along line 8 - 8 of the staple applying assembly of FIG. 2 depicting internal staple drivers of the staple cartridge and portions of the two-piece knife and firing bar.
[0024] FIG. 9 is a left side view in elevation taken generally along the longitudinal axis of line 6 - 6 of a closed staple applying assembly of FIG. 2 to include center contact points between the two-piece knife and wedge sled but also laterally offset to show staples and staple drivers within the staple cartridge.
[0025] FIG. 10 is a left side detail view in elevation of the staple applying assembly of FIG. 9 with the two-piece knife retracted slightly more as typical for staple cartridge replacement.
[0026] FIG. 11 is a left side detail view in elevation of the staple applying assembly of FIG. 10 with the two-piece knife beginning to fire, corresponding to the configuration depicted in FIG. 9 .
[0027] FIG. 12 is a left side cross-sectional view in elevation of the closed staple applying assembly of FIG. 9 after the two-piece knife and firing bar has distally fired.
[0028] FIG. 13 is a left side cross-sectional view in elevation of the closed staple applying assembly of FIG. 12 after firing of the staple cartridge and retraction of the two-piece knife.
[0029] FIG. 14 is a left side cross-sectional detail view in elevation of the staple applying assembly of FIG. 13 with the two-piece knife allowed to drop into a lockout position.
[0030] FIG. 15 is a top view in section taken along lines 15 - 15 of an articulation joint (flex neck) of the surgical stapling instrument of FIG. 1 .
[0031] FIG. 16 is a front view in elevation taken in vertical cross section along lines 16 - 16 of the articulation joint of FIG. 15 , showing electroactive polymer (EAP) plate articulation actuators and EAP support plates for a firing bar.
[0032] FIG. 17 is a top view in section along lines 15 - 15 of the articulation joint of FIG. 16 after articulation.
[0033] FIG. 18 is a perspective view of the articulation joint of FIG. 15 .
DETAILED DESCRIPTION OF THE INVENTION
[0034] In FIGS. 1-3 , a surgical stapling instrument 10 has at its distal end an end effector, depicted as a staple applying assembly 12 , spaced apart from a handle 14 ( FIG. 2 ) by an elongate shaft 16 . The staple applying assembly 12 includes a staple channel 18 for receiving a replaceable staple cartridge 20 . Pivotally attached to the staple channel 18 is an anvil 22 that clamps tissue to the staple cartridge 20 and serves to deform staples 23 ( FIG. 3 ) driven up from staple holes 24 in the staple cartridge 20 against staple forming recesses 26 ( FIG. 6 ) in an anvil undersurface 28 into a closed shape. When the staple applying assembly 12 is closed, its cross sectional area, as well as the elongate shaft 16 are suitable for insertion through a small surgical opening, such as through a cannula of a trocar (not shown).
[0035] With particular reference to FIG. 1 , correct placement and orientation of the staple applying assembly 12 is facilitated by controls on the handle 14 . In particular, a rotation knob 30 causes rotation of the shaft 16 about its longitudinal axis, and hence rotation of the staple applying assembly 12 . Additional positioning is enabled at an articulation joint 32 in the shaft 16 that pivots the staple applying assembly 12 in an arc from the longitudinal axis of the shaft 16 , thereby allowing placement behind an organ or allowing other instruments such as an endoscope (not shown) to be oriented behind the staple applying assembly 12 . This articulation is advantageously effected by an articulation control switch 34 on the handle 14 that transmits an electrical signal to the articulation joint 32 to an Electroactive Polymer (EAP) actuator 36 , powered by an EAP controller and power supply 38 contained within the handle 14 .
[0036] Once positioned with tissue in the staple applying assembly 12 , a surgeon closes the anvil 22 by drawing a closure trigger 40 proximally toward a pistol grip 42 . Once clamped thus, the surgeon may grasp a more distally presented firing trigger 44 , drawing it back to effect firing of the staple applying assembly 12 , which in some applications is achieved in one single firing stroke and in other applications by multiple firing strokes. Firing accomplishes simultaneously stapling of at least two rows of staples while severing the tissue therebetween.
[0037] Retraction of the firing components may be automatically initiated upon full travel. Alternatively, a retraction lever 46 may be drawn aft to effect retraction. With the firing components retracted, the staple applying assembly 12 may be unclamped and opened by the surgeon slightly drawing the closure trigger 40 aft toward the pistol grip 42 and depressing a closure release button 48 and then releasing the closure trigger 40 , thereby releasing the two stapled ends of severed tissue from the staple applying assembly 12 .
[0038] Staple applying assembly.
[0039] While an articulation joint 32 is depicted in FIG. 1 , for clarity and as an alternative application, the surgical stapling instrument 10 of FIGS. 2-14 omit an articulation joint 32 . It should be appreciated, however, that aspects of the present invention have particular advantages for articulation as described below with regard to FIGS. 15-18 .
[0040] In FIGS. 1-3 , the staple applying assembly 12 accomplishes the functions of clamping onto tissue, driving staples and severing tissue by two distinct motions transferred longitudinally down the shaft 16 over a shaft frame 70 . This shaft frame 70 is proximally attached to the handle 14 and coupled for rotation with the rotation knob 30 . An illustrative multi-stroke handle 14 for the surgical stapling and severing instrument 10 of FIG. 1 is described in greater detail in the co-pending and co-owned U.S. patent application entitled “SURGICAL STAPLING INSTRUMENT INCORPORATING A MULTISTROKE FIRING POSITION INDICATOR AND RETRACTION MECHANISM” to Swayze and Shelton, Ser. No. 10/374,026, the disclosure of which is hereby incorporated by reference in its entirety, with additional features and variation as described herein. While a multi-stroke handle 14 advantageously supports applications with high firing forces over a long distance, applications consistent with the present invention may incorporate a single firing stroke, such as described in co-pending and commonly owned U.S. patent application “SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS” to Frederick E. Shelton IV, Michael E. Setser, and Brian J. Hemmelgarn, Ser. No. 10/441,632, the disclosure of which is hereby incorporated by reference in its entirety.
[0041] With particular reference to FIG. 3 , the distal end of the shaft frame 70 is attached to the staple channel 18 . The anvil 22 has a proximal pivoting end 72 that is pivotally received within a proximal end 74 of the staple channel 18 , just distal to its engagement to the shaft frame 70 . The pivoting end 72 of the anvil 22 includes a closure feature 76 proximate but distal to its pivotal attachment with the staple channel 18 . Thus, a closure tube 78 , whose distal end includes a horseshoe aperture 80 that engages this closure feature 76 , selectively imparts an opening motion to the anvil 22 during proximal longitudinal motion and a closing motion to the anvil 22 during distal longitudinal motion of the closure tube 78 sliding over the shaft frame 70 in response to the closure trigger 40 .
[0042] The shaft frame 70 encompasses and guides a firing motion from the handle 14 through a longitudinally reciprocating, two-piece knife and firing bar 90 . In particular, the shaft frame 70 includes a longitudinal firing bar slot 92 that receives a proximal portion of the two-piece knife and firing bar 90 , specifically a laminate tapered firing bar 94 . It should be appreciated that the laminated tapered firing bar 94 may be substituted with a solid firing bar or of other materials in applications not intended to pass through an articulation joint, such as depicted in FIGS. 2-14 .
[0043] An E-beam 102 is the distal portion of the two-piece knife and firing bar 90 , which facilitates separate closure and firing as well as spacing of the anvil 22 from the elongate staple channel 18 during firing. With particular reference to FIGS. 3-4 , in addition to any attachment treatment such as brazing or an adhesive, the knife and firing bar 90 are formed of a female vertical attachment aperture 104 proximally formed in the E-beam 102 that receives a corresponding male attachment member 106 distally presented by the laminated tapered firing bar 94 , allowing each portion to be formed of a selected material and process suitable for their disparate functions (e.g., strength, flexibility, friction). The E-beam 102 may be advantageously formed of a material having suitable material properties for forming a pair of top pins 110 , a pair of middle pins 112 and a bottom pin or foot 114 , as well as being able to acquire a sharp cutting edge 116 . In addition, integrally formed and proximally projecting top guide 118 and middle guide 120 bracketing each vertical end of the cutting edge 116 further define a tissue staging area 122 assisting in guiding tissue to the sharp cutting edge 116 prior to being severed. The middle guide 120 also serves to engage and fire the staple applying apparatus 12 by abutting a stepped central member 124 of a wedge sled 126 ( FIG. 5 ) that effects staple formation by the staple applying assembly 12 , as described in greater detail below.
[0044] Forming these features (e.g., top pins 110 , middle pins 112 , and bottom foot 114 ) integrally with the E-beam 102 facilitates manufacturing at tighter tolerances relative to one another as compared to being assembled from a plurality of parts, ensuring desired operation during firing and/or effective interaction with various lockout features of the staple applying assembly 12 .
[0045] In FIGS. 6-7 , the surgical stapling instrument 10 is shown open, with the E-beam 102 fully retracted. During assembly, the lower foot 114 of the E-beam 102 is dropped through a widened hole 130 in the staple channel 18 and the E-beam 102 is then advanced such that the E-beam 102 slides distally along a lower track 132 formed in the staple channel 18 . In particular, the lower track 132 includes a narrow slot 133 that opens up as a widened slot 134 on an undersurface of the staple channel 18 to form an inverted T-shape in lateral cross section, as depicted particularly in FIGS. 7 and 8 , which communicates with the widened hole 130 . Once assembled, the components proximally coupled to the laminate tapered firing bar 94 do not allow the lower foot 114 to proximally travel again to the widened hole 130 to permit disengagement.
[0046] In FIG. 9 , the laminate tapered firing bar 94 facilitates insertion of the staple applying assembly 12 through a trocar. In particular, a more distal, downward projection 136 raises the E-beam 102 when fully retracted. This is accomplished by placement of the downward projection 136 at a point where it cams upwardly on a proximal edge of the widened hole 130 in the staple channel 18 .
[0047] In FIG. 10 , the laminate tapered firing bar 94 also enhances operation of certain lockout features that may be incorporated into the staple channel 18 by including a more proximal upward projection 138 that is urged downwardly by the shaft frame 70 during an initial portion of the firing travel. In particular, a lateral bar 140 is defined between a pair of square apertures 142 in the shaft frame 70 ( FIG. 3 ). A clip spring 144 that encompasses the lateral bar 140 downwardly urges a portion of the laminate tapered firing bar 94 projecting distally out of the longitudinal firing bar slot 92 , which ensures certain advantageous lockout features are engaged when appropriate. This urging is more pronounced or confined solely to that portion of the firing travel when the upward projection 138 contacts the clip spring 144 .
[0048] In FIGS. 6-7 , the E-beam 102 is retracted with the top pins 110 thereof residing within an anvil pocket 150 near the pivoting proximal end of the anvil 22 . A downwardly open vertical anvil slot 152 ( FIG. 2 ) laterally widens in the anvil 22 into an anvil internal track 154 that captures the top pins 110 of the E-beam 102 as they distally advance during firing, as depicted in FIGS. 9-10 , affirmatively spacing the anvil 22 from the staple channel 18 . Thus, with the E-beam 102 retracted, the surgeon is able to repeatably open and close the staple applying assembly 12 until satisfied with the placement and orientation of tissue captured therein for stapling and severing, yet the E-beam 102 assists in proper positioning of tissue even for a staple applying assembly 12 of reduced diameter and correspondingly reduced rigidity.
[0049] In FIGS. 2-3 , 5 - 6 , 8 - 14 , the staple applying assembly 12 is shown with the replaceable staple cartridge 20 that includes the wedge sled 126 . Longitudinally aligned and parallel plurality of downwardly open wedge slots 202 ( FIG. 8 ) receive respective wedges 204 integral to the wedge sled 126 . In FIGS. 8-10 , the wedge sled 126 thus cams upwardly a plurality of staple drivers 206 that are vertically slidable within staple driver recesses 208 . In this illustrative version, each staple driver 206 includes two vertical prongs, each translating upwardly into a respective staple hole 210 to upwardly force out and deform a staple 23 resting thereupon against a staple forming surface 214 ( FIG. 10 ) of the anvil 22 . A central firing recess 216 ( FIG. 3 ) defined within the staple cartridge 20 proximate to the staple channel 18 allows the passage of the bottom, horizontal portion 218 ( FIG. 5 ) of the wedge sled 126 as well as the middle pins 112 of the E-beam 102 . Specifically, a staple cartridge tray 220 ( FIGS. 3 , 8 ) attaches to and underlies a polymer staple cartridge body 222 that has the staple driver recesses 208 , staple holes 210 , and central firing recess 216 formed therein. As staples 23 are thus formed to either side, the sharp cutting edge 116 enters a vertical through slot 230 passing through the longitudinal axis of the staple cartridge 20 , excepting only a most distal end thereof.
[0050] Firing the staple applying assembly 12 begins as depicted in FIG. 10 with the two-piece knife and firing bar 90 proximally drawn until the downward projection 136 cams the middle guide 120 on the E-beam 102 upward and aft, allowing a new staple cartridge 20 to be inserted into the staple channel 18 when the anvil 22 is open as depicted in FIGS. 2 , 6 .
[0051] In FIG. 11 , the two-piece knife and firing bar 90 has been distally advanced a small distance, allowing the downward projection 136 to drop into the widened hole 130 of the lower track 132 under the urging of the clip spring 144 against the upward projection 138 of the laminate tapered firing bar 94 . The middle guide 120 prevents further downward rotation by resting upon the stepped central member 124 of the wedge sled 126 , thus maintaining the middle pin 112 of the E-beam within the central firing recess 216 .
[0052] In FIG. 12 , the two-piece knife and firing bar 90 has been distally fired, advancing the wedge sled 126 to cause formation of staples 23 while severing tissue 242 clamped between the anvil 22 and staple cartridge 20 with the sharp cutting edge 116 . Thereafter, in FIG. 13 , the two-piece knife and firing bar 90 is retracted, leaving the wedge sled 126 distally positioned.
[0053] In FIG. 14 , the middle pin 112 is allowed to translate down into a lockout recess 240 formed in the staple channel 18 (also see FIGS. 7 , 10 ). Thus, the operator would receive a tactile indication as the middle pin 112 encounters the distal edge of the lockout recess 240 when the wedge sled 126 (not shown in FIG. 14 ) is not proximally positioned (i.e., missing staple cartridge 20 or spent staple cartridge 20 ).
[0054] In FIG. 1 , an articulation joint 32 is depicted that advantageously benefits from the flexible strength of the two-piece knife and firing bar 90 . In FIGS. 15-18 , the articulation joint 32 is depicted as a flex neck joint 300 formed by vertebral column body 302 having laterally symmetric pairs of arcing recesses 304 that allow articulation in an articulation plane. It is generally known to simultaneously compress and expand respective lateral sides 306 , 308 by selective movement of control rods (not shown) that longitudinally pass through the respective lateral sides 306 , 308 . Depicted, however, are EAP plate actuators 310 , 312 , each capable of powered deflection to one or both lateral directions.
[0055] A central passage 320 ( FIG. 16 ) defined longitudinally through the vertebral column body 302 receives a pair of support plates 322 , 324 that prevent buckling and binding of the laminate tapered firing bar 94 . In the illustrative version, each support plate 322 , 324 has a proximal fixed end 326 ( FIG. 15 ) and a sliding end 328 to accommodate changes in radial distance during articulation. Having a firing bar 94 of a thinner thickness is thus supported.
[0056] While the present invention has been illustrated by description of several embodiments and while the illustrative embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications may readily appear to those skilled in the art.
[0057] For example, while there are a number of advantages to having a wedge sled integral to a staple cartridge, in some applications consistent with aspects of the present invention, the wedge sled may be integral instead to an E-beam. For instance, an entire end effector may be replaceable rather than just the staple cartridge.
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A surgical severing and stapling instrument, suitable for laparoscopic and endoscopic clinical procedures, clamps tissue within an end effector of an elongate channel pivotally opposed by an anvil. An E-beam firing bar moves distally through the clamped end effector to sever tissue and to drive staples on each side of the cut. The E-beam firing bar affirmatively spaces the anvil from the elongate channel to assure properly formed closed staples, especially when an amount of tissue is clamped that is inadequate to space the end effector. In particular, an upper pin of the firing bar longitudinally moves through an anvil slot and a channel slot is captured between a lower cap and a middle pin of the firing bar to assure a minimum spacing. Forming the E-beam from a thickened distal portion and a thinned proximal strip enhances manufacturability and facilitates use in such articulating surgical instruments.
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BACKGROUND OF THE INVENTION
This invention relates to a monitoring method and device for monitoring operations of a mechanism, such as an injection device of an injection molding machine, driven by an actuator and, more particularly, to a monitoring data display method and device in which analog data variable in accordance with lapse of time is subjected to multipoint sampling and the data is displayed in or on a recorder or display tube.
With a conventional technique of recording of an analog data regarding a rapidly variable operation of a mechanism driven by an actuator, the analog data could be recorded only by the use of a fast acting recorder. However, in a conventional method of multipoint sampling and display of such data, when operation time and/or operation speed of the drive mechanism varies, a length of an axis of abscissa representing time (lapse of time) must be expanded or shortened at a time of monitoring the whole sampling numbers and the comparison of this data has to be made by changing the sampling mode, i.e. output frequency to a recorder or a display tube, every time the operation time and/or operation speed varies.
In another method for visually deciding the fact whether or not a profile of the detected data accords with a first displayed operation condition at a time of reproduction of a certain operation condition, there was not any convenient device suitable for comparing a reference profile with a sample profile and upper most and lowermost profiles of the reference with the sample profile by superposing the profiles. Moreover, in a case where the profile of the detected data exhibits operational characteristics different from the reference profile, it was difficult to clearly display a stage at which the difference of the characteristics occurred during the operation of the drive mechanism, i.e. first, intermediate, or final stage of the operation.
SUMMARY OF THE INVENTION
An object of this invention is to provide a monitoring data display method and device capable of visually superposing a reference data profile and a sample data profile, and moreover, allowable uppermost and lowermost limits of the reference data profile and a sample data profile at a time of reproduction of the operational characteristics.
Another object of this invention is to provide a monitoring data display method and device capable of visually discriminating the fact at which stage of the data detection the operational characteristic occurs by applying sectioning signals.
A further object of this invention is to provide a monitoring data display device including automatically operating means for operating sampling and display frequencies of the data for easily discriminating profiles regardless of the speed of operational condition to be monitored.
In one aspect, according to this invention, there is provided a method of displaying monitoring data of a continuously varying operation condition of a drive mechanism driven by an actuator in which data regarding the operation of the drive mechanism is detected as a variable of time and sampled at multipoints, the data is outputted with a frequency identical to or different from a sampled frequency, and the data is then displayed, and the method is characterized by the steps of storing detected data of one operation cycle of the drive mechanism as reference data, preliminarily displaying the reference data, and visually superposing detected data of an operation cycle of the drive mechanism succeeding to the one operation cycle on the reference data on a coordinate axis for monitoring deviation between the detected data and the reference data of one operation cycle of the drive mechanism.
In another aspect, according to this invention, there is provided a device for carrying out the method described above generally comprising detecting means for detecting data regarding an operation of the drive mechanism as a variable of time, monitoring means operatively connected to the detecting means for monitoring the detected data, and display means for displaying and comparing the detected data, and the device is characterized in that the monitoring means comprises a signal transmitting unit, a memory unit operatively connected to the detecting means and the signal transmitting unit for storing detected data of one operation cycle of the drive mechanism as reference data, and an operation unit operatively connected to the memory unit and the signal transmitting unit for discriminating and comparing conditions of the reference data and detected data of an operation cycle of the drive mechanism succeeding to the one operation cycle, and in that the display means includes a display unit in which the reference data is preliminarily displayed and the detected data of the operation cycle succeeding to the one operation cycle is visually superposed on the reference data on a coordinate axis.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a block diagram showing a monitoring data display device according to this invention;
FIG. 2 shows a graph displayed on a display unit of the device shown in FIG. 1, in which a reference data profile and a detected data profile are superposed;
FIG. 3 shows a graph displayed on the display unit shown in FIG. 2, in which an allowable data profile of the reference data and a detected data profile are superposed; and
FIG. 4 shows a deviation profile between the reference data and the detected data displayed on the display unit shown in FIG. 2, in which a bias data V is added to the zero level.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a monitoring unit of a monitoring data display device according to this invention is enclosed with dash and dot lines and designated by reference numeral 10. A detecting device 11 for detecting physical parameters such as temperature, pressure, and speed of a mechanism, for example, an injection system in an injection molding machine, driven by an actuator includes a plurality of detectors 11A, 11B, 11C, . . . for sensing the temperature, the pressure, and the speed, one of which is operatively selected, as occasion demands, by a sampling mode selector 15 contained in signal transmitting means 14 assembled in the monitoring device 10. A contact circuit 13 is operatively connected to the detecting device 11 and operates so as to select one of detectors 11A, 11B, 11C, . . . in accordance with a signal 13a generated from a signal control circuit 16, which is assembled in the signal transmitting means 14 and also operatively connected to the contact circuit 13 by depressing a key, not shown, attached to the sampling mode selector 15.
Memory means for memorizing the data detected by the detector 11 is contained in the monitoring device 10 and designated by reference numeral 17. The memory means 17 includes a detected (active) data memory 18 and a reference data memory 19. When an operator for operating the drive mechanism discriminates that the data memorized in the memory 18 itself is an aimed data for setting it as a reference data, the operator depresses a key, not shown, attached to a signal transmitter 20 contained in the signal transmitting means 14 to thereby generate a reference data setting signal EN from the control circuit 16, and then, the data from the memory 18 is transferred and set in the reference data memory 19 as a reference data Xo. After the reference data Xo has once been memorized in the memory 19, data detected thereafter by the detector 11 is monitored so as to accord with the reference data Xo during the operation of the drive mechanism.
The monitoring device 10 further includes discriminating and comparing means 21 in which the condition of the detected data X is discriminated in comparison with the reference data Xo set in the reference data memory 19, for example, for discriminating and comparing a fact whether or not the detected data X is within a predetermined allowable range of the reference data Xo.
The discrimination means 21 includes a ΔX setter 22 for setting a data representing an allowable variation range ΔX (allowance) of the reference data Xo and the allowance ΔX is inputted into the ΔX setter 22 by a signal SE generated from the control circuit 16 by depressing a key, not shown, located to the setter 23 in the signal transmitting means 14. The allowance data ΔX recorded in the ΔX setter 22 is then sent to an adder 24A or subtractor 24B for calculating an allowable maximum data (Xo+ΔX) or allowable minimum data (Xo-ΔX) for operating the drive mechanism.
The discrimination means 21 further includes a deviation calculator 25 for determining the difference (Xo-X) between the reference data Xo and the detected data X and a bias setter 26 into which a signal from the control circuit 16 is inputted by depressing a key, not shown, of the setter 23 of the signal transmitting means 14. The bias setter 26 operates to add a predetermined bias value V through the adder 27 so that the difference data (Xo-X) does not become negative. A sectioning signal transmitter 28 is operatively connected to the control circuit 16 and generates a sectioning signal S every predetermined lapse of time in the operation of the driving mechanismin accordance with a clock pulse CL generated from the control circuit 16. Reference numeral 29 designates a timer operator 29 which calculates an operating time of one operation cycle of the drive mechanism in use of a counter, for example, and operates a sampling period for the multipoint sampling operation and a period for outputting the sampling period for a recorder. The data obtained by the timer 29 is represented by F in FIG. 1.
A data switching unit 30 is further included in the discrimination means 21 for carrying out a data switching operation based on the inputted data, represented by A through G in FIG. 1, in accordance with a change-over signal CH generated by the signal transmitter 20 through the control circuit 16.
Display means 31 is operatively connected to the monitoring device 10 and includes a CRT (cathode ray tube) 32 and a recorder or display unit 33 for visually displaying varying compared and/or operated results obtained in the operation of the discriminating and comparing means 21. A display control circuit 34 controls the CRT 32 and the recorder 33 and is operated by a display signal P generated from the circuit 16 by depressing a key assembled in the signal transmitter 20. A hard copy 35 of the displayed material can be obtained as occasion demands.
The setter 23 is also provided with a member such as a key, not shown, for transmitting a clear signal CLR to cancel the set values inputted into the allowance setter 22 and/or the bias setter 26. Moreover, in the embodiment shown in FIG. 1, although the sampling mode selector 15, the signal transmitter 20, and the setter 23 are independently assembled in the signal transmitting means 14, they can be constructed as one unit.
As described above, the display device of this invention includes three keys assembled in association with the sampling mode selector 15, the signal transmitter 20 and the setter 23, respectively, for operating the same. These keys are once depressed respectively at a time of starting the monitoring operation and after the selection or settings of the operational conditions have been completed these keys are not depressed thereafter except when a change of operational conditions is required.
The monitoring data display device according to this invention and shown in FIG. 1 operates as follows.
When it is required to monitor operating condition of a drive mechanism, a clock pulse generating key located in the signal transmitter 20 is first depressed to generate a clock pulse CL from the signal control circuit 16 and start the counting of the operation cycle time for the drive mechanism. The signal STR is then generated to operate the contact circuit 13 and start the operation of the monitoring device 10. After the data recorded in the active data memory 18 has been transferred to the reference data memory 19 as a reference data Xo, the display of the operating condition of the drive mechanism on the display means 31 can be done by the display signal P generated from the control circuit 16 by depressing the key of the signal transmitter 20 thereby to take out the necessary data represented by A through G shown in FIG. 1.
FIG. 2 shows one example of a displayed graph having an axis of abscissa representing time and an axis of ordinate representing physical amount such as pressure, temperature, or speed and in which the curve A shows the detected (active) data and the curve B shows the reference data. FIG. 3 shows another example of a displayed graph in which the maximum and minimum data (curves C and D, respectively) of the allowable range of the reference data are displayed in comparison with the detected data (curve A).
FIG. 4 is a graph showing a case where data E (=(Xo-X)+V) inputted into the switching unit 30 from the adder 27 is taken out in connection with the sectioning time G from the timer 29, and in the graph, the deviation profile between the reference data and the detected data is shown and time values regarding G are displayed on the axis of abscissa as g 1 , g 2 , g 3 , g 4 , . . . In addition, operation change point Eo can be displayed on the display unit by stopping the output of the data now being detected for a short period or changing the output to an output level regardless of the detected data.
According to this invention, the operation condition of a drive mechanism can be visually and easily displayed on a recorder or display tube during the operation and/or after the operation.
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A technique is disclosed for displaying monitoring data of a continuously varying operation condition of a drive mechanism driven by an actuator, in which data of one operation cycle of the drive mechanism is detected preliminarily as reference data and data for another operation cycle succeeding to the one operation cycle is detected. The last-detected data is then superposed on the reference data and displayed on a coordinate axis on a monitor to show deviation between the reference data and the detected data of each operation cycle. Allowable uppermost and lowermost limit data of the reference data are also calculated and displayed on the same coordinate axis of the displaying surface of the monitor.
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RELATED APPLICATIONS
This Application is related to four U.S. patent applications entitled "Tester Systems" U.S. patent Application Ser. No. 09/033,364, "Parametric Test System And Method" U.S. patent application Ser. No. 09/032,968, "Microsequencer for Memory Test System", U.S. patent application Ser. No. 09/033,363, and "Programmable Pulse Generator", assigned to the assignee of the present invention, and filed on even date herewith.
FILED OF THE INVENTION
The invention relates generally to manufacturing verification systems for memory modules, and more particularly to test systems for verifying contact between pins of a memory tester and the I/O pins of a CMOS IC chip or module.
BACKGROUND OF THE INVENTION
Memory test systems typically test memory modules such as CMOS dynamic random access memories (DRAM) for shorted or open data lines and shorted or open address lines and shorted or open control lines. Before such tests may be conducted, however, a contact test is required to ensure that the test system is in contact with the pins of the DRAM, as well as whether the pins are shorted together or open. All known testers test with power applied to the memory I/O pins and a current of the order of 200 μamps to avoid damaging the memory module under test.
A recognized reference on contact tests is the text "Testing Semiconductor Memories, Theory and Practice", by A. J. van de Goor, John Wiley & Sons, copyrighted 1991, reprinted 1996. In the text, pages 295-297, van de Goor proposes a test circuit where all input and output pins of a memory chip are connected to the Vcc power line and the Vss ground line by way of protection diodes, which are said to ensure that the input and output pins cannot assume a voltage level on one diode voltage drop below Vss or one diode voltage drop above Vcc. A test algorithm for the contact test also is proposed which consists of the following steps:
1. Set all pins to 0 volts.
2. Force a forward biasing current through the diodes in the range of 100 μamps to 250 μamps.
3. Measure the voltage Vpin resulting from the forward biasing current, and
if |Vpin|<0.1 V, a short is assumed;
if 0.1V≦|Vpin|≦1.5 V, contact is assumed; and
if |Vpin|>1.5 V, an open is assumed.
In the above example, the tester cannot distinguish between a short to Vcc or ground, and a short to another pin.
U.S. Pat. No. 5,072,175 to Marek discloses a test method and system for identifying only pin contacts and opens. Pins shorts to a power supply terminal or to ground, and pin to pin shorts are not identified. Further, modification to the component under test is required to add diodes and a test terminal, whether component is a chip or a module.
SUMMARY OF THE INVENTION
An automated contact tester method and system is disclosed and claimed which detects the absence of contacts between I/O pins of the contact tester and I/O pins of a memory module under test, and identifies pins which are shorted to a power supply terminal or ground, pins which are shorted to other pins, and pins which are open.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention, and together with the general description given above and the detailed description of preferred embodiments given below serve to explain the principles of the invention.
FIG. 1 is an electronic schematic diagram of a contact test circuit; and
FIGS. 2a-2g together are a logic flow diagram of the steps taken by a programmed computer in conducting a contact test.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, a contact test system is comprised of an analog measurement section 10 and a functional test section 11, which are electrically connected to a memory module 12 through embedded program controlled switches 17 1a -17 na .
Sections 10 and 11 comprise a parametric measurement unit (PMU). More particularly, a 16-bit backplane bus 13 is in electrical communication with a digital-to-analog converter 14 by way of a 16-bit bus 15. The output of the converter 14 is applied to the input of a modified Howland voltage to current converter 16, the output of which is applied to the input of a single-pole-double-throw switch 17 1a , and to the input of a buffer amplifier 18.
The output of the buffer amplifier 18 is applied to the input of an analog-to-digital converter 19, the output of which is applied to the backplane 13 by way of a 16-bit bus 20.
The input of a second single-pole-single-throw switch 17 1b is electrically connected to the output of a digital buffer 21 1 , the input of which is held to a logic zero, and the output of which is held to an analog ground.
The pole of switch 17 1a is electrically connected to the pole of switch 17 1b , and to one of the diode protected I/O pins 22 1 of the memory module 12.
It is to be understood that there will be as many digital buffers such as buffer 21 1 , and as many pairs of switches such as switches 17 1a and 17 1b , as there are I/O pins such as 22 1 for a memory module under test. Thus, by the three dotted lines, and use of the letters 1-n, we indicate that there are n pins 22 1 -22 n as well n pairs of switches (17 1a , 17 1b -17 na , 17 nb ) and n digital buffers 21 1 -21 n .
Continuing with the description of FIG. 1, the input of a digital buffer 21 n is held at a logic zero, and the output of the digital buffer 21 n is held to an analog ground and applied to the input of switch 17 nb . The pole of switch 17 nb is electrically connected to the pole of switch 17 na and to a diode protected pin 22 n of the memory module 12. The input to switch 17 na is electrically connected to the output of converter 16, to the input of amplifier 18, and to the input of the switch 17 1a .
In operation, the V CC source for the memory module 12 is set to 0 volts, and the poles of grounding switches 17 1b -17 nb are closed to allow digital buffers 21 1 -21 n to force all pins 22 1 -22 n to ground. Thereafter, a voltage is applied by way of backplane 13 and converters 14 and 16, and grounding switch 17 1b is opened and measurement switch 17 1a is closed to cause a forward biasing current to flow through the pin 22 1 . If the voltage sensed at the output of converter 19 is within voltage tolerances, a normal contact between the pin under test and the PMU comprising sections 10 and 11 is presumed. If the voltage is above acceptable tolerance levels, however, an open at the pin 22 1 is identified.
If the voltage level sensed at the output of converter 19 is lower than acceptable tolerances, the pin 22 1 is presumed to have a short. However, because all other pins have been connected to ground by the closure of grounding switches 17 2b -17 nb , it is not determined whether the short detected at pin 22 1 is to ground or to another externally grounded pin. In this event, all grounding switches 17 1b -17 nb would be opened, measurement switch 17 1a would remain closed, and a second measurement would be conducted at pin 22 1 . Thereafter, if the voltage sensed at the output of converter 19 is lower than acceptable tolerances, the pin 22 1 is identified as shorted to ground. If, however, the voltage sensed is within acceptable tolerances, then it may be assumed that the previously sensed grounded condition was due to a short to another pin. A search is then conducted to find any pin shorted to pin 22 1 by sequentially connecting remaining pins 22 2 -22 n to ground using grounding switches 17 2 -17 n , respectively, while sensing the voltage measured at pin 22 1 . During this search sequence, when the voltage sensed at pin 22 1 indicates a grounded condition, it may be identified as shorted to the pin grounded by the grounding switch currently closed.
The above sequence may be repeated for each pin that is determined to be shorted. That is, the measurement switch in electrical communication with the functional test section 11 and associated with the shorted pin remains closed, and the grounding switch of the switch pair is opened while the grounding switches for the remaining pins to be tested are sequentially closed for voltage measurement and then opened, pin after pin, until another shorted pin is discovered.
In the preferred embodiment, the pin voltage measurements are taken and the associated switches are opened and closed under computer program control by a system processor (not shown). FIGS. 2a-2f comprise a logic flow diagram of the logic control process executed by the system processor.
In the description of the logic flow diagrams of FIGS. 2a-2g, the following tables are referenced:
TABLE I______________________________________ VOL-INDEX TAGE EXCLUDED SHORTED.sub.P-P SHORTED.sub.GND______________________________________0 FALSE FALSE FALSE1 FALSE FALSE FALSE2 FALSE FALSE FALSE. . . . .. . . . .. . . . .MAX.sub.-- PIN-1 FALSE FALSE FALSE______________________________________
TABLE II______________________________________INDEX FROM-PIN TO-PIN______________________________________2. . .. . .. . .MAX.sub.-- PIN-1______________________________________
The variables referred to in Tables I and II above are defined in the following Table III:
TABLE III______________________________________NAME DESCRIPTION______________________________________LOG.sub.-- INX Index into list of shorted pins. When scanning is complete, contains number of shorted pin-to-pin pairs.TEST.sub.-- INX Primary loop counter, index into per-pin array, and pin selector.MILLIVOLTS Holds value read from A/D converter in millivolts.SEARCH.sub.-- INX Secondary loop counter, index into per-pin array, and pin selector.______________________________________
The constant referred to in the description of the above Tables I and II is described in the following Table IV:
TABLE IV______________________________________NAME DESCRIPTION______________________________________MAX.sub.-- PIN Equal to the maximum number of pins testable.______________________________________
Referring to FIG. 2a, the logic control process begins at logic step 200, and thereafter moves to logic step 202 to initialize Tables I and II associated with the pin arrays of the memory module 12 by clearing all entries except the EXCLUDED entries, which are preset according to the memory module to be tested. Also, the logging index variable Log -- INX is reset to "0". The logic control process then proceeds to logic step 204 where the inputs of the digital buffers 21a-21n are set to logic zero. This is in preparation for using the outputs as a ground, and being able to switch a ground onto any one of the test pins.
Following logic step 204, the logic control process continues to logic step 206 where the test supply voltage V CC of the memory module 12 is set to 0.0 volts. The testing of pins now may occur with no voltage applied. The logic control process next proceeds from logic step 206 to logic step 208 where the digital-to-analog converter 14 and the voltage-to-current converter 16 are set to deliver a 200 μamp output to the pin of memory module 12 which is under test. Thereafter, at logic step 210 the loop counter variable TEST -- INX is set to "0" to signify the start of the first loop. From logic step 210 the logic control process continues to logic step 211 where a test is made to see if the pin under test is used by the memory module 12. That is, the memory test system typically has many more pins than the memory module. Thus, fewer than all pins of the memory test system will make contact with corresponding pins of the memory module. If the pin is to be excluded from testing, then the logic control process continues through node K to logic step 222 of FIG. 2b. If, however, the pin under test is to be included in testing, then the logic control process continues to step 212 where the functional test switch 17 1b is opened for the pin identified by the variable TEST -- INX.
Following logic step 212, the logic control process moves to logic step 214 where the analog measurement switch associated with the pin under test is closed. From logic step 214, the logic flow process continues to logic step 216 where the voltage output of converter 19 is read into the VOLTAGE column of Table I as indexed by the variable TEST -- INX. The voltage measurement is thereby associated with the pin under test. The logic control process then continues through node A to logic step 218 of FIG. 2b, where the analog measurement switch associated with the pin under test is opened.
The logic flow process next proceeds from logic step 218 to logic step 220 where the functional test switch associated with the pin under test is closed to effectively ground it. Following logic step 220, the logic control process continues to logic step 222 to increment the loop index variable TEST -- INX. The logic control process then proceeds to logic step 224, where a test is made to see if the variable TEST -- INX has reached the maximum pin count at the end of the test loop as identified by the constant MAX -- PIN. If not, the logic control process loops back by way of node B to the beginning of the loop at logic step 211 of FIG. 2a. In the event that the variable has reached the maximum pin count, the logic control process flows to logic step 226 where all functional test switches for all pins are opened. From logic step 226, the logic flow process continues to logic step 228 where all analog measurement switches for all pins are opened to completely float the unit under test with respect to ground.
Following logic step 228, the logic flow process proceeds to logic step 230 where the loop counter index variable TEST -- INX is again set to "0" in preparation for reuse. The logic control then proceeds through node C to logic step 232 of FIG. 2c where a test is made to see if the pin under test is used by the memory module 12. At logic step 232 the logic control process accesses the EXCLUDED column of Table I to determine whether the pin indexed by the variable TEST -- INX is to be excluded from testing because there is no corresponding memory module pin, or whether the pin under test has a corresponding memory module pin that should be in contact. If a true exists in the EXCLUDED column of Table I in the row of the pin to which the logic control process has been indexed, the pin under test is not to be tested. The logic control process thus branches by way of node E to the end of the test loop at logic step 278 of FIG. 2f, and all testing for the pin under test is stopped. In the event that the pin is to be tested, a false entry will appear in the EXCLUDED column and the row of the pin to which the variable TEST -- INX has pointed the logic control process. In that event, the logic control process continues to logic step 233 to determine whether a non-shorted condition exists for the pin under test. At logic step 233, the output of converter 20 in the VOLTAGE column of Table I, and at the row corresponding to the pin under test as indicated by the variable TEST -- INX, is accessed to determine whether the converter 20 voltage measurement is more negative than -125 millivolts. If true, then the pin under test is assumed to be non-shorted, and the logic control process branches through node E to logic step 278 of FIG. 2f, where the variable TEST -- INX is indexed to point to a new pin of the memory module 12. If false, the pin under test is presumed shorted to ground, and because the supply pin V CC is at 0.0 volts, to be shorted to V CC or to another pin, and the logic control process continues to logic step 234 to determine whether a pin-to-pin short exists for the pin under test by accessing Table I and reviewing the SHORTED P-P column in the INDEX row pointed to by the variable TEST -- INX.
If a true entry is found, the logic control process branches by way of node E to the end of the test loop at logic step 278 of FIG. 2f, and further testing on the pin under test is stopped. If the Table I entry is false, the logic control process continues to logic step 236 where the Table I column SHORTED GND at the row pointed to by the variable TEST -- INX is accessed to determine whether a true entry indicating a short to ground exists. If so, the logic control process branches through node E to logic step 278 of FIG. 2f, where the variable TEST -- INX is indexed to point to a new pin of the memory module 12. If the Table I entry is false, however, the logic control process proceeds from logic step 236 to logic step 240 where the analog measurement switch for the pin identified in the INDEX column of Table I by the variable TEST -- INX is closed.
From logic step 240, the logic control process continues to logic step 242 where the output of the converter 19 is measured and stored in a storage variable MILLIVOLTS. From logic step 242, the logic control process branches by way of node D to logic step 244, where the storage variable MILLIVOLTS is tested to determine whether it has a value less than -125 millivolts. If no, the pin under test is presumed to be shorted to ground because all other pins are floating at the time of the previous measurement. The logic control process thus branches by way of node H to logic step 274 of FIG. 2f. At logic step 274, a TRUE entry is stored in Table I under the column SHORTED GND at the location which is pointed to by the INDEX variable TEST -- INX. From logic step 274, the logic control process moves to logic step 276.
If the value stored in the variable MILLIVOLTS is found at logic step 244 to be less than -125 millivolts, the pin under test is not presumed to be shorted to ground, but to some other pin, and the logic control process proceeds to logic step 246 where a new search index SEARCH -- INX is initialized to a value equal to the TEST -- INX variable incremented by one. This allows an inner test loop to begin scanning pins from the point where the above described outer test loop branched to the end of the array of the memory modules pins. From logic step 246, the logic control process continues to logic step 248 where the column EXCLUDED of Table I is accessed under control of the SEARCH -- INX index variable to determine whether the pin under test is to be excluded from further testing. If a TRUE entry is found, the logic control process branches by way of node I to logic step 270 of FIG. 2f.
In the event that the pin under test is to be included in testing, the logic control process moves from logic step 248 to logic step 250 where the column SHORTED P-P of Table I is accessed at the entry specified by the index variable SEARCH -- INX. If a TRUE entry is found, the pin under test is presumed to be previously discovered to be shorted to another pin, and the logic control process branches by way of node I to logic step 270. In the event that a FALSE entry is found, the pin is not presumed to be shorted to another pin, and the logic control process continues from logic step 250 to logic step 252 to test for a short to ground. More particularly, the column SHORTED GND of Table I is accessed at the entry pointed to by the index variable SEARCH -- INX. If a TRUE entry is found which indicates that the pin under test is shorted to ground, the logic control process branches by way of node I to logic step 270. If a FALSE entry is found, however, the pin is not presumed to be shorted to ground, and the logic control process continues from logic step 252 to logic step 254. At logic step 254, the voltage value in the VOLTAGE column of Table I and at the location pointed to by the index variable SEARCH -- INX is tested to determine whether it is less than -125 millivolts. If yes, the pin is not shorted, and the logic control process branches by way of node I to logic step 270 of FIG. 2f. If greater than or equal to -125 millivolts, the logic control process continues from logic step 254 and through node G to logic step 256 of FIG. 2e. At logic step 256, the functional test switch for the pin under test, as identified by the index variable SEARCH -- INX for Table I, is closed.
From step 256, the logic control process flows to logic step 258 where the voltage value read measured at the output of converter 19 is written into the temporary storage variable MILLIVOLTS. Thereafter, the logic flow process transfers from logic step 258 to logic step 260 the voltage value stored in the variable MILLIVOLTS is compared with -125 millivolts. If the voltage value stored in variable MILLIVOLTS is less than or equal to -125 millivolts, the logic control process proceeds to logic step 268. However, if the voltage value is greater than -125 millivolts, the logic control process continues from logic step 260 to logic step 262, where the entry in the FROM-PIN column of Table II as indexed by the variable LOG -- INX is set equal to TEST -- INX. In other words the pin identified by the outer test loop at the time the inner test loop under the index variable SEARCH -- INX began is identified in the inner loop. Also, the pin identified by the SEARCH -- INX index variable is set in the index variable LOG -- INX to identify a particular location under the column TO-PIN of Table II. Lastly, the LOG -- INX index variable is indexed by one to point to the next succeeding pin.
Following logic step 262, the logic control process continues to logic step 264 where the location in the SHORTED P-P column of Table I that is identified by the TEST -- INX index variable is loaded with a TRUE entry to indicate a pin-to-pin short. Thereafter, the logic control process moves from logic step 264 to logic step 266 where the location in the SHORTED P-P column of Table I that is identified by the SEARCH -- INX index variable is set TRUE. This has the effect of marking the FROM-PIN and TO-PIN locations of Table II where the outer test loop ceased to test a pin under test, and where the inner test loop identified a new pin to test. The logic control process next proceeds to logic step 268 where the functional test switch for the pin identified by the index variable SEARCH -- INX is opened. The logic control process continues from logic step 268 and through node I to logic step 270 of FIG. 2f.
At logic step 270, the index variable SEARCH -- INX is incremented by one. Following logic step 270, the logic control process continues to logic step 272 to determine whether the index variable SEARCH -- INX has been incremented to a value equal to the maximum number of memory module pins that can be tested (MAX -- PIN). If not, the logic control process loops back through node J to logic step 248 of FIG. 2d at the beginning of the inner test loop. If the index variable SEARCH -- INX is determined at logic step 272 to have a value equal to MAX -- PIN, however, the logic flow process flows to logic step 276 where the analog measurement switch for the pin identified by the index variable TEST -- INX is opened. From logic step 276, the logic control process moves to the end of the outer test loop at logic step 278, where the index variable TEST -- INX is incremented by one.
From logic step 278, the logic control process proceeds to logic step 280 where the value stored in the variable TEST -- INX is compared with the maximum number of testable pins stored in MAX -- PIN. If the MAX -- PIN value has not been reached, the logic control process branches back by way of node C to logic step 232 of FIG. 2c at the beginning of the outer test loop. In the event that the variable TEST -- INX has reached the maximum constant stored in MAX -- PIN, the logic control process proceeds by way of node L to logic step 302 of FIG. 2g.
ALTERNATIVE EMBODIMENT
In the description of the logic flow diagram of FIG. 3, the following table is referenced:
TABLE V______________________________________INDEX OPEN______________________________________0 FALSE1 FALSE2 FALSE. .. .. .MAX.sub.-- PIN-1 FALSE______________________________________
At logic step 302, the logic control process initializes loop counter variable TEST -- INX to "0" to signify the start of the first loop. From logic step 302, the logic control process continues at logic step 304 where a test is made to see if the pin under test was used by the memory module 12. If the pin was excluded from testing, then the logic control process continues to logic step 310 where the pin under test may also be flagged as "open", that is, not electrically connected to the tester. If, however, the pin was included in testing, then the logic control process continues to logic step 306 to determine whether an open pin condition exists for the pin under test. At logic step 306, the output of converter 20 in the VOLTAGE column of Table I, and at the row corresponding to the pin under test as indicated by the variable TEST -- INX, is accessed to determine whether the converter 20 voltage measurement is more negative than -1500 millivolts. If false, then the pin under test is assumed to be either correctly connected or shorted, and the logic control process branches to logic step 308 where the location in the OPEN column of Table V that is identified by the TEST -- INX index variable is loaded with a FALSE entry to indicate a non-open pin. If true, the logic control process continues to logic step 310 where the location in the OPEN column of Table V that is identified by the TEST -- INX index variable is loaded with a TRUE entry to indicate an open pin. From either of logic steps 308 or 310, the logic control process continues at logic step 312 to increment the loop counter variable TEST -- INX. From logic step 312, the logic control process continues to logic step 314 where the value stored in the variable TEST -- INX is compared with the maximum number of testable pins stored in MAX -- PIN. If the MAX -- PIN value has not been reached, the logic control process branches back to logic step 304 at the beginning of the loop. In the event that the variable TEST -- INX has reached the maximum constant stored in MAX -- PIN, the logic control process exits the outer test loop at logic step 316 with "TRUE" entries in the OPEN column of Table V reflecting open pins of the memory module 12.
The invention has been described and shown with reference to particular embodiments, but variations within the spirit and scope of the general inventive concept will be apparent to those skilled in the art. Accordingly, it should be clearly understood that the form of the invention as described and depicted in the specification and drawings is illustrative only, and is not intended to limit the scope of the invention. All changes which come within the meaning and range of the equivalence of the claims are therefore intended to be embraced therein.
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A method and system for memory testers which detects the absence of contact between memory tester pins and memory module pins, and which identifies memory module pins which are shorted to a power supply terminal or to ground, pins which are shorted to other pins, and pins which are open.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a division of co-pending U.S. patent application Ser. No. 10/357,342.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to an elastic crawler for use in a crawler-type traveling apparatus adopted for traveling part of an agricultural machine such as a half-tractor or a combine, a construction machine such as a back-hoe, or an automobile, and is employed, for example, as a core-metalless elastic crawler (called also rubber crawler free of core metal) in which a core metal is not buried within a crawler main body of the crawler.
[0004] 2. Description of Related Art
[0005] A conventional crawler-type traveling apparatus adopted on a traveling part of agricultural or construction machine is structured, mainly, with an endless strip-formed crawler belt (covering belt) stretched over a driving wheel, an idler (follower wheel) and a plurality of rollers. By drivably rotating the driving wheel, the crawler belt is circulated along the circumferential direction, thereby enabling the machine to travel.
[0006] There exists, as the crawler belt, an elastic crawler having a crawler main body formed of a rubber-like elastic material into an endless belt and configured to convey drive power from the driving wheel through the driving projections provided in an inner surface of the crawler main body.
[0007] The elastic crawler has a core-metalless structure in which a core metal extending between the right and left ends of the crawler is not buried in the crawler main body.
[0008] Meanwhile, the crawler-type traveling apparatus adopting such a core-metalless elastic crawler employs outer-flanged type rollers rolling on right and left side regions in the inner surface of the crawler body. The crawler body is formed with right and left side regions having substantially uniform thickness (generally even thickness) entirely in the widthwise direction of the crawler.
[0009] As the size of the main body of the machine adopting the crawler-type traveling apparatus increases, the conventional elastic crawler also increases in its width in order to keep low ground contact pressure. This requires broadening the width of the roller, correspondingly. However, there is a limitation in broadening the width of the roller in view of increases in costs, weight, and so on.
[0010] In the case that the elastic crawler has such a broad width that its side regions largely extend out of the roller in the widthwise direction of the crawler, when the elastic crawler at the side region runs over a projection, a marginal stone or the like, as shown in FIG. 13 , the crawler body 20 at its side region 20 a is bent about a portion 23 of the crawler body 20 corresponding to the right and left ends of outer peripheral surface of the roller 21 . As a result, the bent portion is stretched on a ground-contacting surface side (stress concentration takes place in that portion) and, hence, crack might occur if the bent portion is in contact with a sharp obstacle.
[0011] Further, increases in lug height tend to trigger further local elongations due to a twist (entanglement) of the lug. Besides, during running over, clamping or swivel at a construction site with riprap or sharp matters, the crawler possibly encounters stretch and cut damage.
SUMMARY OF THE INVENTION
[0012] In view of the foregoing circumstance, it is an object of the present invention to prevent an elastic crawler having an elastically bendable side region from being cracked when the side region of the elastic crawler is bent.
[0013] The present invention has taken the following technical means in order to solve the technical problem.
[0014] Namely, an elastic crawler of the invention having a crawler body formed of a rubber elastic material into an endless belt so that rollers rotatively move on right and left side regions in an inner surface of the crawler body is characterized in that the crawler body is provided with a reinforcement rising in a thickness direction of the crawler body in an area on an outer peripheral surface of the crawler body corresponding to right and left ends of the roller.
[0015] Another technical means is an elastic crawler having a crawler body formed of a rubber elastic material into an endless belt so that rollers rotatively move on right and left side regions in an inner surface of the crawler body and characterized in that the crawler body is provided with a reinforcement rising in a thickness direction of the crawler body in an area on the inner surface of the crawler body corresponding to right and left ends of the roller.
[0016] Another technical means is an elastic crawler having a crawler body formed of a rubber elastic material into an endless belt so that rollers rotatively move on right and left side regions in an inner surface of the crawler body and characterized in that the crawler body is provided with a reinforcement having flexibility and being buried therein for reinforcing a region of the crawler body corresponding to right and left ends of the roller.
[0017] Another technical means is an elastic crawler having a crawler body formed of a rubber elastic material into an endless belt so that rollers rotatively move on right and left side regions in an inner surface of the crawler body and characterized in that the side regions each have a thickness gradually decreasing from a portion corresponding to right and left ends of the roller toward right and left ends of the crawler body.
[0018] Another technical means is an elastic crawler having a crawler body formed of a rubber elastic material into an endless belt so that rollers rotatively move on right and left side regions in an inner surface of the crawler body and characterized in that the side regions are each upwardly slanted from a portion corresponding to right and left ends of the roller toward right and left ends of the crawler body.
[0019] Another technical means is an elastic crawler having a crawler body formed of a rubber elastic material into an endless belt so that rollers rotatively move on right and left side regions in an inner surface of the crawler body and characterized in that the crawler body has on an outer peripheral surface thereof a lug having right and left ends arranged on positions outer than right and left ends of the roller, respectively, with respect to a lateral direction of the crawler body.
[0020] Another technical means is an elastic crawler having a crawler body formed of a rubber elastic material into an endless belt so that rollers rotatively move on right and left side regions in an inner surface of the crawler body and characterized in that the side regions each have a greater thickness in a region from a portion corresponding to right and left ends of the roller to right and left ends of the crawler body than in a central region of the crawler body with respect to a lateral direction of the crawler body.
[0021] Further objects, features and effects of the invention would be fully understood by the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a sectional view in a widthwise direction of an elastic crawler according to a first embodiment;
[0023] FIG. 2 is a view of the elastic crawler in the first embodiment as viewed on an outer periphery;
[0024] FIG. 3 is a side view of a crawler-type traveling apparatus;
[0025] FIG. 4 is a sectional view in a widthwise direction of an elastic crawler according to a second embodiment;
[0026] FIG. 5 is a view of the elastic crawler in the second embodiment as viewed on an outer periphery;
[0027] FIG. 6 is a sectional view in a widthwise direction of an elastic crawler according to a third embodiment;
[0028] FIG. 7 is a view of an elastic crawler according to a fourth embodiment as viewed on an outer periphery;
[0029] FIG. 8 shows a fifth embodiment wherein FIG. 8A is a view of an elastic crawler as viewed on an outer periphery and FIG. 8B is a sectional view in a widthwise direction of the elastic crawler;
[0030] FIG. 9 is a view of an elastic crawler according to a modification as viewed on an outer periphery;
[0031] FIG. 10 is a view of an elastic crawler according to a modification as viewed on an outer periphery;
[0032] FIG. 11 is a sectional view in a widthwise direction of an elastic crawler according to a modification;
[0033] FIG. 12 is a side view of a crawler-type traveling apparatus of another kind; and
[0034] FIG. 13 is a sectional view of a conventional crawler-type traveling apparatus.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Embodiments of the present invention will now be explained with reference to the drawings.
[0036] FIGS. 1 to 3 show a first embodiment. In FIG. 3 , the reference numeral 1 refers a crawler-type traveling device. The crawler-type traveling device 1 is basically structured with an elastic crawler 5 wrapped around a sprocket 2 (driving wheel), a pair of idlers 3 in the front and rear, and a plurality of rollers 4 and configured to travel by rotating the sprocket 2 so as to circulate (drive) the elastic crawler 5 in a circumferential direction A.
[0037] The elastic crawler 5 has a crawler body 6 formed of a rubber-like elastic material into an endless belt, as shown in FIGS. 1 and 2 . In the crawler body 6 , a tension member 7 and a plurality of layers of bias cords 8 are buried along the circumferential direction A of the crawler body 6 .
[0038] The elastic crawler 5 has driving projections 9 of a rubber-like elastic material that are provided in a central region with respect to the lateral direction B of the crawler body 6 (in a width direction of the crawler) at intervals over the entire periphery in the crawler circumferential direction A. The driving projections 9 are configured to convey drive force from the sprocket 2 therethrough. This elastic crawler 5 does not include a core metal extending between right and left ends of the crawler 5 to be buried within the crawler body 6 .
[0039] It should be noted that reinforcing members made of hard-resin or metal may be buried within the drive projections 9 .
[0040] The crawler body 6 is provided on its outer periphery (on a ground-contact side) with lugs 12 of a rubber-like elastic material at intervals in the crawler circumferential direction A.
[0041] The tension member 7 consists of tensile-resisting cords, such as steel cords, extended along the crawler circumferential direction A and juxtaposed in the lateral direction B. The bias cords 8 consists of tensile-resisting cords, such as steel cords, juxtaposed (arranged in parallel) to each other and inclined with respect to the crawler circumferential direction A. According to this embodiment, the bias cords 8 are provided in two layers on an outer side of the tension member 7 .
[0042] The sprocket 2 has a pair of disc-formed guides oppositely arranged in lateral direction B. Between the right and left guides, engaging teeth for engagement (meshing) with the driving projection 9 are arranged at intervals along a radially circumferencial direction of the sprocket, so that the right and left guides are connected through the engaging teeth.
[0043] Incidentally, respective outer peripheries of the guides are positioned on the right and left sides of the driving projection 9 so as to engage with the side surfaces of the driving projection 9 , thereby preventing the crawler body 6 from deviating sideways.
[0044] Meanwhile, corners 4 c of the roller 4 between the right and left side surfaces 4 a and the outer peripheral surface 4 b are rounded.
[0045] The elastic crawler 5 is provided with raised portions 10 (reinforcements) in the right and left side regions 6 a on the outer periphery of the crawler body 6 , which rise in a crawler thickness direction E.
[0046] The raised portion 10 is provided on the outer peripheral surface of the crawler body 6 in areas corresponding to the right and left ends 4 a of the roller 4 (hereinafter, merely referred to as roller ends 4 a ) (in areas beneath the roller ends 4 a and/or the vicinity thereof), thus providing the crawler body 6 with greater rigidity in the regions corresponding to the roller ends 4 a than that of the other region.
[0047] When the side region of the elastic crawler 5 runs over a projection or the like, it is bent at a laterally outward position of the raised portion 10 (at a position laterally outer than the region beneath the right and left ends 4 a of the roller 4 ). Thus, the stress caused by such bending on the elastic crawler 5 is dispersed (released from stress concentration) by means of the raised portion 10 to prevent crack occurrence in the elastic crawler 5 .
[0048] Namely, in the invention, when the elastic crawler 5 is bent at its side region, the raised portion 10 laterally outwardly deviates the elongation (stress) concentrated in the region corresponding to the roller end 4 a. Thus, the concentrated elongation is relaxed.
[0049] In this embodiment, the roller ends 4 a are each substantially positioned at a center of each of the raised portions 10 with respect to the lateral direction B.
[0050] The lugs 12 are arranged so that a lug 12 extending from an intermediate point close to one side region 6 a of the crawler body 6 to the end of the other side region 6 a, and a lug 12 extending from an intermediate point of the crawler body 6 close to the other side region 6 a to the end of the one side region 6 a are arranged alternately in a crawler circumferential direction A. Further, the lugs 12 are each arranged so that one end portion thereof with respect to the lateral direction B terminates within an area where one raised portion 10 is projected, while the other end portion thereof intersects with the area where the other raised portion 10 is projected.
[0051] Although the raised portions 10 , usually, are integrally formed with the crawler body 6 during forming the elastic crawler 5 , they may be formed separately from the crawler body 6 and fixed thereon by an adhesive or the like.
[0052] FIGS. 4 and 5 show a second embodiment. According to this embodiment, raised portions 10 (reinforcements) rising in the crawler thickness direction E are provided in the inner surface of the crawler body 6 in areas corresponding to the roller ends 4 a, and flexible reinforcing layers 13 (reinforcements) are buried within the crawler body 6 for reinforcing the regions of the crawler body 6 corresponding to the roller ends 4 a.
[0053] Each of the side region 6 a of the crawler body 6 has an outer peripheral surface inwardly slanted from a portion corresponding to the roller end 4 a toward the lateral end of the crawler body 6 , i.e., the side regions 6 a are each formed in a manner gradually reducing in thickness e toward the lateral end of the crawler body 6 with respect to the lateral direction B.
[0054] The other structures are substantially the same as the embodiment 1.
[0055] The reinforcing layer 13 is formed, for example, of tensile-strength cords such as steel cords, fibers, a rubber having a hardness higher than the rubber forming the crawler body 6 , or a rubber less stretchable than the rubber forming the crawler body 6 and, hence, has flexibility.
[0056] According to the second embodiment, the raised portions 10 , the reinforcing layers 13 , or the side region 6 a of the crawler body 6 having a thickness e gradually decreasing toward the lateral end of the crawler body 6 with respect to the lateral direction B provides the similar effect to the embodiment 1.
[0057] Accordingly, there is no need to provide all of the above structures on one elastic crawler 5 , that is, they may be separately provided.
[0058] FIG. 6 shows a third embodiment. According to this embodiment, the side regions 6 a of the crawler body 6 are each upwardly slanted from a portion corresponding to the roller end 4 a toward the lateral end of the crawler body 6 with respect to the lateral direction B. Further, the side region 6 a has a thickness e gradually decreasing from the portion corresponding to the roller end 4 a toward the lateral end of the crawler body 6 with respect to the lateral direction B.
[0059] The other structures are substantially the same as the embodiment 1.
[0060] This embodiment also provides the similar effect to the embodiment 1, owing to the above structure.
[0061] In this embodiment, the side regions 6 a of the crawler body 6 are each formed in a form upwardly slanted and having a thickness e gradually decreasing toward the lateral end of the crawler body 6 with respect to the lateral direction B. However, it is not necessary that both of the above features are provided in one elastic crawler 5 , that is, the side regions 6 a of the crawler body 6 may be formed to upwardly slanted toward the lateral ends of the crawler body 6 with respect to the lateral direction B or formed to have a thickness e gradually decreasing toward the lateral ends of the crawler body 6 with respect to the lateral direction B.
[0062] FIG. 7 shows a fourth embodiment. According to this embodiment, the lug 12 provided in the outer peripheral surface of the crawler body 6 has a summit (ground-contacting surface) having a lateral ends 12 a each arranged on a position which is intermediate of the side region 6 a and outer than the roller end 4 a with respect to the lateral direction B, that is, the width of the roller 4 b is smaller than the distance a between the lateral ends 12 a of the summits of the adjacent lugs 12 with respect to the lateral direction B. The other structures are substantially the same as the embodiment 1.
[0063] This embodiment also provides the similar effect to embodiment 1.
[0064] FIG. 8 shows a fifth embodiment.
[0065] In this embodiment, the crawler body 6 is formed with side regions 6 a each having a greater thickness d in a region from the portion corresponding to the roller end 4 a to the lateral end of the crawler body than a thickness c in a laterally central region of the crawler body 6 , thereby obtaining the similar effect to the foregoing embodiments. The other structures are substantially the same as the foregoing embodiments.
[0066] FIG. 9 shows a modification in which there are arranged, alternately in the crawler circumferential direction A, a lug 12 A having lateral opposite ends intermediately positioned in the side regions 6 a, respectively, with respect to the lateral direction B, and a pair of lugs 12 B each having lateral one end positioned on a lateral center of the crawler body 6 and the other lateral end positioned on the lateral end of the crawler body 6 (or a lug extending from one end to the other end of the crawler body 6 with respect to the lateral direction B). In this modification, the lateral ends of the lug 12 A are positioned in the projection areas of the reinforcements (raised portions 10 or reinforcing layers 13 ), respectively, while the lug 12 B is arranged to transverse the projection areas of the reinforcements (raised portions 10 or reinforcing layers 13 ). FIG. 10 shows a modification in which the reinforcements (raised portions 10 or reinforcing layers 13 ) are discontinuously provided with respect to the crawler circumferential direction A. The other structures are substantially the same as the foregoing embodiments.
[0067] The elastic crawler 5 or the crawler-type traveling device 1 is a mere showing of examples, and the invention is not limited to the structures of the embodiments.
[0068] For example, as shown in FIG. 11 , the elastic crawler 5 may have a core metal 14 which extends in the lateral direction so as not to reach the side regions 6 a of the crawler body 6 . This is to be adopted for an elastic crawler 5 having a crawler body 6 having elastically bendable side regions 6 a.
[0069] Meanwhile, the crawler-type traveling device 1 may have, for example, a structure as shown in FIG. 12 in which a crawler-type traveling device 1 is configured to convey a drive force by inserting the teeth of a sprocket 2 in the engagement holes formed in an elastic crawler 5 .
[0070] As can be seen in the detailed embodiments, according to the present invention, when the elastic crawler at its side region runs over a projections or the like, the side region of the elastic crawler is bent at a portion laterally outside of the portion corresponding to the right or left ends of the roller. Accordingly, the stress caused on the elastic crawler by the bending is dispersed (released from stress concentration) thereby preventing crack occurrence.
[0071] It should be noted that the present invention is not limited to the foregoing embodiments but can be appropriately modified within the scope of the claims.
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An elastic crawler having a crawler body formed of a rubber elastic material into an endless belt so that rollers rotatively move on right and left side regions on an inner surface of the crawler body is provided with a reinforcement provided extending outwardly in a thickness direction of the crawler body in an area of the crawler body extending at least partially under said right and left ends of each of the rollers. The prevents the elastically bendable side regions from being cracked when either of the side regions of the elastic crawler is bent about an axis that extends in a circumferential direction of the crawler.
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TECHNICAL FILED OF THE INVENTION
The present invention relates to a device for removing staples from on object, particular to an automatic staple remover.
BACKGROUND OF THE INVENTION
In the prior art, the staple remover is operated by hand, and no automatic staple removers have been disclosed. The staple remover in the art has many drawbacks such as inconvenient to use, not easy to collect pulled staples, and readily to have the object that the staple is enclosed broken down.
Therefore, it is needed to develop a new staple remover to solve the problems existing in the art.
SUMMARY OF THE INVENTION
Accordingly, the object of the invention is to provide an automatic staple remover that has a simple structure, is easily operate, and can collect removed staples.
The automatic staple remover according to the invention includes a frame, a motor fixed to the frame, a speed-reducing mechanism driven by the motor, a transmission mechanism connected to the speed-reducing mechanism, and a member having a jaw for removing a staple from an object connected to the transmission mechanism.
In one embodiment of the invention, the staple remover further comprises a transition member adjacent to the member for removing the staple mounted to the bottom of the frame.
In another embodiment of the invention, the staple remover further comprises comprising a magazine for containing the staple.
In another preferred embodiment of the invention, the staple remover comprises a switch mounted on the frame for triggering the motor via the shaft.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a staple remover of the invention.
FIG. 2 is a perspective view of the staple remover shown in FIG. 1 in another direction.
FIG. 3 is a partial perspective view of the staple remover shown in FIG. 1 .
FIG. 4 is a partially schematic view of the staple remover shown in FIG. 1 from the bottom.
FIG. 5 is a partial view of the staple remover of the invention showing that the switch contacts a project on the driving wheel.
FIG. 6 a shows pulling a staple using the staple remover of the invention.
FIG. 6 b shows the movement of the member for removing staples on the transition member according to the invention.
FIG. 7 a schematically shows the magazine at a close state.
FIG. 7 b schematically shows the magazine at an open state.
FIG. 8 is a cross-sectional view of a transition member and a magazine of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be further described in conjunction with the drawings.
Referring to FIGS. 1-4, a staple remover of the present invention includes a frame 1 . A motor 2 is arranged at the front portion of the frame 1 . A gear assembly including a plurality of gears with different diameters is connected to the motor. A first gear 3 with a small diameter is driven by the motor 2 . The first gear is engaged to a second gear 4 with a larger diameter than the first gear 3 . A third gear 5 with a smaller diameter than the second gear 4 is fixed to the axle of the second gear 4 at the other side of the frame 1 . The third gear 5 is engaged to a fourth gear 6 with a larger diameter than the third gear 5 . At the same side of the fourth gear 6 is disposed a fifth gear 61 that shares the same axle as the fourth gear 5 and has a smaller diameter than fourth gear 5 . The fifth gear 61 is engaged to a sixth gear 7 with a larger diameter than the fifth gear 61 .
A driving wheel 8 that has the same diameter as the sixth gear 7 is fixed to the axle of the sixth gear 7 . Two connecting rods 11 , 11 ′ are connected between the edge of the driving wheel 8 , the sixth gear 7 and a shaft 15 . A member 14 including a jaw 141 for removing a staple is mounted to the shaft 15 . At two sides of the frame 1 are provided two slide channels 16 . The shaft 15 is mounted in the channels 16 via two sleeves 21 such that the member 14 can move along the channels 16 .
Referring to FIG. 4 now, there is provided another shaft 20 at the front portion of the frame parallel to the shaft 15 . The shaft 20 is disposed within two inclined channels 22 parallel to the channels 16 .
Turning to FIGS. 3, 6 a , and 6 b , a transition member 13 is disposed at the bottom of the frame adjacent to the member for removing the staple, and has an inclined plane 131 providing a groove 18 that allows the jaw 141 of the member 14 to move along the inclined plane 131 .
Referring to FIG. 3, FIG. 7 a and FIG. 7 b , adjacent to the transition member 13 on the frame is disposed a magazine 12 for containing the removed staple 19 . The magazine 12 at the upper portion provides a bevel plane 26 extended from the inclined plane 131 of the transition member 13 . Onto the bevel plane 26 is provided a slide plate 24 to which a driving block 27 is mounted. A spring 25 is arranged at the plane 26 and is connected to the slide plate 24 .
As shown in FIGS. 1, 3 , 6 a , and 6 b , the member 14 may include a pair of blocks 23 at the two sides of the jaw to prevent the staple 19 from sliding off while operating.
Now turning to FIG. 5, a position-limit switch 9 is provided at the upper portion of the frame 1 . The position-limit switch 9 can contact a projection 17 disposed at the outer edge of the driving wheel 8 .
The operation of the staple remover according to the invention is now described.
When the jaw 141 of the member 14 is put under the staple 19 as shown in FIG. 6 a , a switch 10 disposed on the frame 1 is initiated to drive the motor 2 via the shaft 15 . The motor 2 drives the sixth gear 7 and the driving wheel 8 to rotate though the gear assembly. With the rotation of the gear 7 and the driving wheel 8 , the connecting rods 11 , 11 ′ are driven to direct the member 14 to move along the inclined channels 16 , 22 . At the same time, the removed staple with the jaw 141 moves along the groove 18 at the upper surface of the transition member 13 to reach the magazine 12 . The rear part of the member 14 pushes the driving block 27 on the slide plate 24 to move backwards so as to open the magazine. When the jaw moves above the magazine, the staple falls into the magazine by the weight. As shown in FIG. 8, the bottom 120 of the magazine 12 may be made from magnetic materials. At this time, the projection 17 contacts the switch 9 to stop the motor 2 to finish a cycle of removing the staple.
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The present invention provides an automatic staple remover including a frame, a motor fixed to the frame, a speed-reducing mechanism driven by the motor, a transmission mechanism connected to the speed-reducing mechanism, and a member having a jaw for removing a staple from an object connected to the transmission mechanism. The staple remover of the invention is convenient to use and to collect removed staples.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims priority to U.S. Provisional Patent Application No. 62/309,277 filed on Mar. 16, 2016, which is incorporated herein by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of linear motion. More particularly, the present invention relates to ball return mechanisms in ball screw assemblies.
BACKGROUND
[0003] A ball screw is a mechanical device that translates rotational motion into linear motion with minimal friction. Ball screws have high mechanical efficiency and are capable of being manufactured to very high tolerances, making them ideal for applications that require precision movements over a long lifetime.
[0004] Typical ball screws include a leadscrew portion that is threaded to include at least one raceway through which a series of ball bearings travel. Each raceway has a pitch, which is defined as the axial distance between threads and is typically measured in threads per inch or millimeter. Leadscrews may have one raceway, or may alternatively include multiple raceways that follow alongside each other. The ball bearings are captured inside a ball nut that includes its own raceways that correspond to the channels of the leadscrew. The ball bearings transfer the load between the ball nut and the leadscrew.
[0005] As the ball nut travels along the leadscrew, the ball bearings recirculate through the nut. As such, it is necessary to include a way for the balls to return from one end of the ball nut to the other. Typical ball return systems are either external, internal, or end cap. External ball return systems include a ball return tube outside the nut for each channel that carries the balls from one end of the channel to the other. Internal ball return systems operate very similarly to external ball return systems, except that the ball return component is located within the outer diameter of the nut. As the name suggests, end cap ball return systems include end caps, one on each end of the ball nut, that include channels to guide the balls into and out of a ball return tube formed in the ball nut.
[0006] All of the various ball return systems have their advantages and dis-advantages, but the simplest design is the end cap. In a ball nut fitted with end cap returns, the ball bearings enter one end of the nut as it travels down the screw and traverse the entire length of the nut before coming out the other end and getting picked-up by a plastic or metal cap placed on the end of the nut. After picking the ball bearings out of the ball raceway, the end cap redirects the balls into a return hole drilled longitudinally through the nut. The balls are then re-directed back into the screw raceway by a cap on the opposite end of the nut.
[0007] Current end cap designs typically employ a deflector, or “finger,” that extends into the raceway and lifts the balls out of the raceway before re-directing them into a return hole that is drilled through the nut. As the ball bearings roll through the passage leading to the finger, the finger lifts the balls out of their track in the screw and then re-directs the balls to the entrance of the return tube that is drilled through the nut. This finger is subjected to constant pounding as each ball crashes into it at high speed as it is lifted out of the ball track. Over time the finger will wear down until it eventually will not lift the balls from the ball track anymore and causes a total failure of the ball screw. Because of the need for high durability of the finger, it must be fabricated using expensive materials and processes.
[0008] As such, there is a need for an end cap design that is easy to manufacture in small quantities and is not subject to failure from repeated impacts to a finger.
SUMMARY
[0009] The present invention relates to a ball screw assembly. The assembly includes a ball nut and a leadscrew. A plurality of ball bearings are secured between the ball nut and the leadscrew and circulate within the ball nut as the leadscrew rotates. The ball screw assembly includes a leadscrew having at least one leadscrew raceway, and a ball nut. The ball nut has a main body surrounding the leadscrew and at least one internal raceway that aligns with the leadscrew raceway, and two ends. Two end cap returns are removably attached to the ends of the ball nut. Each end cap return includes a semi-round, helical protrusion extending therefrom and filling at least a portion of the leadscrew raceway. Near the helical protrusion, each end cap return further includes a depression that removes the ball bearings from the leadscrew raceway using tangential force. Each end cap also includes a ball track to direct the ball bearings from the depression to an entrance of a longitudinal tube that passes through the ball nut and into the ball track of the end cap at the other end of the ball nut.
[0010] It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can lead to certain other objectives. Other objects, features, benefits and advantages of the present invention will be apparent in this summary and descriptions of the disclosed embodiment, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above as taken in conjunction with the accompanying figures and all reasonable inferences to be drawn therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a ball screw having one embodiment of fingerless end caps in accordance with the invention;
[0012] FIG. 2 is a perspective view of a prior art end cap for a ball screw;
[0013] FIG. 3 is a perspective view of one embodiment of a fingerless end cap for a ball screw in accordance with the invention;
[0014] FIG. 4 is an exploded perspective view of the fingerless end cap of FIG. 3 showing an insert removed from the end cap body;
[0015] FIG. 5 is another perspective view of the fingerless end cap of FIG. 3 showing the insert inserted into the end cap body;
[0016] FIG. 6 is a section view of the fingerless end cap of FIG. 3 taken generally along the line 6 - 6 in FIG. 5 ;
[0017] FIG. 7 is another section view of the fingerless end cap of FIG. 3 taken generally along the line 7 - 7 in FIG. 6 ;
[0018] FIG. 8 is a top view of the ball screw of FIG. 1 ;
[0019] FIG. 9 is another perspective view of the ball screw of FIG. 1 with one end cap shown in section generally along the line 9 - 9 in FIG. 8 to show the path of the ball bearings through the end cap; and
[0020] FIG. 10 is another perspective view of the ball screw of FIG. 1 with one end cap attached in section generally along the line 10 - 10 in FIG. 8 to show the path of the ball bearings through the end cap.
DETAILED DESCRIPTION
[0021] This invention relates to an end cap for a ball screw assembly that, through the geometry of a ball passage in the end cap, uses the tangential force of the sidewall of the ball passage in the end cap to roll the ball sideways out of the raceway in the screw. As shown in FIG. 1 , ball screw assembly 10 includes a leadscrew 12 , a ball nut 14 , two end caps 16 , and ball bearings 18 that roll in precision raceways 20 in the leadscrew ( FIG. 9 ) and corresponding raceways in the ball nut. Rotating leadscrew 12 moves ball bearings 18 (the “balls”) along the raceways 20 , thereby causing ball nut 14 to move longitudinally along the screw.
[0022] The end caps 16 on each end of ball nut 14 remove the balls 18 from raceway 20 and re-direct them through a longitudinal tube 22 that passes longitudinally through the nut to return them to the beginning of their path. In the embodiment shown, end caps 16 in the present embodiment are identical, but the present invention may be practiced with non-identical end caps. For example, it may be advantageous for only one end cap to include additional features to allow the ball nut to attach to or interact with another component. FIG. 2 shows one embodiment of a prior art end cap 50 that includes a finger 52 that redirect the balls 18 from the raceway 20 and ultimately into the longitudinal tube 22 through ball nut 14 . The impact of the balls 18 on finger 52 causes the finger to wear down over time until it eventually will not lift the balls from the raceway 20 .
[0023] End cap 16 is particularly suited for use with custom made, low volume manufacturing where leadscrews and nuts employ any desired combination of screw diameter, lead and ball size. Typical end caps must be made of extremely tough and durable plastic and must be either injection molded or cast before being finish machined. These processes require significant quantities to be produced in order to be cost effective making them impractical for use in low-volume ball screw applications. In contrast, because end cap 16 does not include a protrusion that experiences repeated impact loads, it may be made of much less durable material such as Ultem 9085 (polyetherimide), nylon, or may even be made by additive manufacturing, otherwise known as 3D printing.
[0024] FIGS. 3-10 show one embodiment of a fingerless ball screw return end cap 16 in accordance with the invention. End cap 16 includes a main body 24 that surrounds the screw 12 and has a surface 13 that mates to the ball nut 14 . In the embodiment shown, end cap 16 is removably attached to ball nut 14 by screws, but any other suitable fastening means may alternatively be used without departing from the invention. End cap 16 further includes insert 34 that, in the embodiment shown, is made of a more durable material than the rest of the end cap. A ball track 32 directs balls 18 through end cap 16 and back into ball nut 14 .
[0025] Currently, the only known way to produce a substantially one piece end cap 16 is by additive manufacturing. The complex geometry of ball track 32 is blind and would be nearly impossible to machine and extremely difficult and cost ineffective to mold or cast. Additive manufacturing, on the other hand, easily creates ball track 32 and other complex geometry and is able to produce end caps for ball screws with endless combinations of screw diameter, lead and ball size without incurring any additional costs.
[0026] Ball track 32 includes a semi-round, helical protrusion 26 that extends from the end cap and fills the raceway 20 where the balls 18 are picked up or placed into the raceway. Adjacent helical protrusion 26 , a depression 30 forms half of the raceway 20 where the balls 18 enter the end cap 16 from the ball nut 14 . The depression 30 further eliminates sharp edges that would normally be subject to high wear and brittle fracture. Eliminating these sharp areas allows end cap 16 to be produced with using additive manufacturing and allows the end cap to be used in low-volume ball screw production.
[0027] As shown in FIGS. 4-5 , depression 30 may be included in an insert 34 , which may be made of a more durable material than the 3D printed portion of end cap 16 . In the embodiment shown, insert 34 is made of Nylatron GSM, but may be made of any suitable material without departing from the invention. Insert 34 is press-fit into end cap 16 and when the end cap is attached to ball nut 14 , it is captured between leadscrew 12 , the ball nut, and the end cap, making any additional fastening means unnecessary. Without the need to use additional fastening means, insert 34 may be easily and inexpensively replaced when it is worn.
[0028] As shown in FIGS. 9-10 , depression 30 removes the balls 18 from raceway 20 by permitting the balls to roll sideways out of the raceway. After passing through depression 30 , balls 18 pass through ball track 32 which re-directs the balls to the longitudinal tube 22 in ball nut 14 . The end cap 16 uses tangential force from the side walls of raceway 20 to roll the balls 18 sideways out of the raceway before reaching the portion of the end cap 16 that engages raceway 20 so minimal wear occurs to that part of the end cap. Even the part of the end cap 16 that directs the balls 18 into the end cap is not subjected to repeated impact forces, which increases the durability of the end cap when compared to existing end cap 50 that includes a finger 52 to remove balls 18 from raceway 20 . Once the balls 18 enter the end cap 16 , they are re-directed to the entrance of the longitudinal tube 22 through the ball nut 14 just as they are in a fingered design.
[0029] The end cap 16 opposite the direction of travel accepts the balls 18 from of the longitudinal tube 22 and directs them toward the direction of travel and provides a path for the balls back into raceway 20 . In the embodiment shown, end caps 16 on either side of ball nut 14 are identical and perform either of the above functions when the direction of travel reverses.
[0030] Although the invention has been herein described in what is perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description of the invention herein.
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This invention relates to an end cap return for a ball screw. The end cap uses tangential force from the sidewalls of the ball passage to roll the ball bearings sideways out of the leadscrew raceway rather than the typical protruding finger that picks the balls up directly. The end cap allows it to be advantageously fabricated with using additive manufacturing, making the end cap cost effective for use in custom ball screw assemblies. In some embodiments, the end cap may include an insert for certain portions of the end cap that can be easily and inexpensively replaced should the insert become worn.
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TECHNICAL FIELD
[0001] The invention relates to a system for detachable joining of beams with square or rectangular cross-sections in accordance with the preamble of claim 1 .
STATE OF THE ART
[0002] Steel beams with square or rectangular cross-sections are common construction elements in high performance static frameworks. In the automotive industry, such beams are used in the foundations of special machines for metal cutting. In the aerospace industry applications are found in jigs for assembling fuselage and wing sections of airplanes. In the processing industry such steel beams are used to support vessels and pipes in specific positions.
[0003] Advantageous for said kind of steel beams is:
1. high strength and stiffness relative to their weight 2. smooth surfaces facilitating cleaning. 3. availability on the market in a great number of sizes. 4. relatively low prices.
[0008] Disadvantageous for this kind of steel beams is that joints of the beams into frameworks have, until now, not been possible to make with strength values comparable to the capability of the beams, when used in applications where claims also are put on good possibilities of reconstruction and adjustment. It is then a requirement that the fixing devices comply with a combination of properties implying that:
1. they reach a strength comparable with the beams to be joined 2. they are detachable. 3. they are adjustable. 4. they are able to join beams of significantly different dimensions 5. they allow different perpendicular or parallel mounting positions 6. they are preferably available in the shape of cheap standard components in stock
[0015] At present, welded joints is the most common type of joints for tubular steel beams. They are of high strength and could be made at relatively low cost. However, they are not detachable and therefore they don't comply with the requirements for reconstruction. Bolt joints are also common and provide joints of high strength as well. The can be made with bolts through holes in the sides of the beams or through holes in flanges welded to the sides of the beams. The possibility of reconstruction will, however, be heavily restricted by that as a rule new holes have to be drilled for every new mounting position. Thus they don't comply with the requirements for reconstruction.
[0016] Friction joints, the field of the present invention, principally result in good possibilities of reconstruction and adjustment. Several successful construction kits for aluminium profiles utilizes friction joints to assemble the parts, which is illustrated in US2001/0025406A1.
[0017] In these profiles fixing devices in the shape of for instance anchoring nuts with fastening elements are engaging grooves extending in the longitudinal direction of the profile. The fixing devices can be displaced into optional positions leading to good possibility of reconstruction.
[0018] However, the types of friction joints having been developed for joining aluminium profiles cannot be used with steel profiles having square or rectangular cross-section. These profiles are missing the longitudinal grooves where fixing devices can engage. As an alternative for the steel profiles in question friction joints have sometimes been designed with encircling devices that apply force across the cross-section of the beams and thereby create the required friction forces.
[0019] Such wholly or partially encircling fixing devices are in some cases formed like yokes that keep steel beams pressed against each other by means of tightening bolts. They are also applied by means of common clamps pressing beams against each other and thereby keeping them interlocked by friction.
[0020] The problem with the aforementioned fixing devices is that in the present shape they have large dimensions relative their strength. Therefore in most cases one hasn't been able to provide them with strength values equal to the beams. It hasn't either been possible to give them a general shape to correspond to the demands for variation in applications where possibilities of reconstruction are required. The requirement of connecting a large number of beams of varying dimensions in different mounting positions with a reasonable number of different fixing devices has not been met. For the same reasons keeping prefabricated fixing for this purpose devices in stock hasn't been possible.
DESCRIPTION OF THE INVENTION
[0021] An object with the invention is to solve the problems existing in known solutions for detachable joining of steel beams. This is carried out by a system according to claim 1 .
[0022] The present invention relates to a modular fixing system for joining steel beams of square or rectangular cross-section for frameworks for supporting functions in machines and other industrial equipment.
[0023] Through a combination of locking by friction and locking by shape the fixing system provides a possibility to achieve the strength values corresponding to the requirements in demanding industrial applications. At the same time it gives possibility to detach the joints so that the frameworks can be reconstructed into new structures and also be adjusted to an increased accuracy. Beams of different dimensions and different perpendicular mounting positions can thanks to the modular design according to the thought of the invention be joined into extensive variations of structures for frameworks. By this modular design a reasonable number of different components required in the system can be achieved. In turn this results in that the parts of the fixing system can be manufactured as standard products, whereby the manufacturing cost will be reduced and storing facilitated. The parts can even be stored whereby access for use is achieved at short notice.
[0024] The invention is composed of a system of fixing devices for joining beams into frameworks of variable structures for industrial applications. The beams consist of square or rectangular profiles of steel with edge lengths being multiples of a certain module length.
[0025] The fixing devices comprises specifically designed fixing plates whose main dimensions constitutes multiples of half the module length. They are mounted in pairs on opposite sides of the beams and are tightened by bolts. The thrust in the bolts provides holding friction forces on the contacting surfaces between the fixing plates and the beams. The holding is further strengthened by stop screws or wedge devices extending from protruding edges or shoulders at the fixing plates and provide a shape determined locking of the beams. Joining locations for beams in frameworks are created by fixing plates at respective beam are put into contact with each other and locked in perpendicular or parallel positions by means of locking elements in the neutral plane between the contacting fixing plates. These locking elements are made of internal threaded sleeves fitting recesses in the fixing plates. At the same time the sleeves provide anchoring of the bolts that tightens the fixing plates to the respective beam.
[0026] The invention enables frameworks of high quality to be constructed in variable embodiments by means of a small number of fixing elements of different sizes. They will thereby be of low cost and quickly available for use.
SHORT DESCRIPTION OF THE FIGURES
[0027] FIG. 1 shows in a perspective view an embodiment of a fixing device in the system according to the invention
[0028] FIG. 2 shows the same fixing device in cross-section
[0029] FIG. 3 shows in a perspective view different embodiments of locking devices
[0030] FIG. 4 shows in a perspective view a first embodiment of a fixing plate
[0031] FIG. 5 shows in a perspective view fixing plates mounted opposite each other
[0032] FIG. 6 shows in a perspective view two beams joined with the system according to the invention
[0033] FIG. 7 shows in a perspective view three beams joined with the system according to the invention
[0034] FIG. 8 shows in a perspective view a framework according to the invention
[0035] FIG. 9 shows alternative embodiments of locking elements
[0036] FIG. 10 shows an alternative of a locking element
[0037] FIG. 11 shows in a perspective view a second embodiment of a fixing plate
[0038] FIG. 12 shows a second embodiment of locking the fixing plate to the beam
[0039] FIG. 13 shows in a top view the second embodiment
DESCRIPTION OF EMBODIMENTS
[0040] The design of the invention and further advantages are described more in detail below in connection with the FIGS. 1-13 .
[0041] FIG. 1 illustrates a recommended embodiment of a fixing device in the system according to the invention. Four fixing plates 1 of different kinds are in pairs holding two crossing beams 2 , fixed between them by means of tightening bolts 3 and 9 . From the sides of the fixing plate longitudinal strips 4 extend in the main directions of the beams.
[0042] FIG. 2 illustrates the same montage of the fixing device seen in cross-section. The thrust in the bolts 3 and 9 causes fastening friction forces in the contact surfaces 21 between the fixing plates and the beams. The resistance against side movements is strengthened by stop screws 5 , according to a recommended design, extends from de longitudinal strips 4 and provide a shape determined locking of the beams. The stop screws are also used to temporarily keep the fixing plates 1 in position during the mounting. The stop screws 5 are also used to adjust the side position of the fixing plates with respect to the beams.
[0043] FIG. 2 further shows how the fixing plates 1 , on each side of the beams, can be tightened according to two alternatives. The primary alternative is shown to the left in FIG. 2 . In this case the tightening bolts 3 engage the threaded sleeves 6 that are common to the two beams 2 and are located at the surfaces 30 opposite to each other of the two adjacent fixing plates. These sleeves 6 , shown enlarged in detail B of FIG. 2 , have internal threads 8 fitting with the bolts 3 . The sleeves 6 fits into recesses 10 in the fixing plates and cause that both the adjacent fixing plates 1 shape determined are kept fixed against side movements with respect to each other along the parting line 7 .
[0044] The secondary alternative for tightening the fixing plates towards each other is illustrated to the right in FIG. 2 . In this case longer tightening bolts 9 are used, which extends through the whole joint and tighten it. These bolts are anchored in threaded sleeves 12 , which are shown enlarged in Detail C in FIG. 2 and, which similar to the sleeves 6 , fit into the recesses 10 in the fixing plate. In the recesses 10 in the surfaces 30 opposite to each other in the adjacent fixing plates 1 sleeves 13 are used that similar to the sleeves 6 fits into the recesses 10 but have clearance holes 22 without any thread. These sleeves 13 thereby hold both fixing plates 1 shape determined fixed against side movements along the parting line 7 .
[0045] Through the secondary joining alternative mounting of beam joints on locations accessible from only one direction is enabled. It also enables that by means of further lengthened bolts joint corners with three or more joined beams can be constructed.
[0046] FIG. 3 illustrates, more in detail how the sleeves 6 , 12 and 13 according to the recommended alternative are designed. They have a cylindrical outer surface 11 and a longitudinal slot 17 to absorb the minor differences in positions and diameters that can exist between the sleeves and their connecting recesses in the fixing plates. The sleeves can of course be designed without a longitudinal slot, which then requires higher accuracy in manufacturing the parts but instead lead to improved stiffness and strength in the joint.
[0047] The length of the sleeves 6 and 13 are in the recommended design somewhat shorter than the added up depths of the recesses 10 , where they are located. A minor axial play 20 is thus created at the end surfaces 31 of the sleeves 6 and 13 with respect to the bottom surface 32 of the recesses 10 . The resisting force to the tightening force in the bolts 3 or 9 will thus in the recommended embodiment of the invention not pass through the sleeves 6 and 13 . Instead it passes over the outer surfaces 30 of the adjacent fixing plates and makes these surfaces contacting each other in the parting plane 7 . Thereby the position of the beams 2 with respect to their mutual distance is determined by the thickness of the fixing plates. Friction forces are created between the two outer surfaces 30 , which contribute to the strength of the joint.
[0048] The components of the fixing system are comprised in a superior modular system that increases the possibilities of combinations and reduces the number of varieties of components in the system. This modular system has a common module length m, which in practice can be an even dimension, for instance 50 mm. The width of the beams and a height should be multiples of the chosen module length m and can then be expressed as m*B respective m*H.
[0049] FIG. 4 shows the nominal dimensions for a fixing plate being designed in accordance with the rules of the modular system. The width of the plate is m*(B+1) and its length is likewise a multiple of L of the module length, i.e. it has the length m*L. It is evident that the holes for the joining bolts 3 or 9 lies with a distance that in breadth can be expressed with the formula m*(B+1)−2*G, where G is the distance from the centre of the holes to the edge of the plate. The distance between the holes in the longitudinal direction can in a corresponding way be expressed with m*L−2*G.
[0050] From FIG. 4 is also evident that the nominal material thickness of the plate is m*0.5 and that the distance between the two strips 4 is m*B+T. The distance T is a small play enabling that fixing plates can be mounted at the beams even when these have certain over-dimensions with respect to the nominal dimensions. The play T also enables certain minor sideward position displacements of the fixing plates by means of the stop screws 5 .
[0051] FIG. 5 shows how to combine two crossed beam sizes, the one with the width m*B and the other with the width m*B′. This is enabled by that the length of the first plate, which according to the module system can be written m*L, is chosen to fit with the width of the other plate, i.e. m*(B′+1). In the same way the length of the other plate is chosen, which can be written m*L′ to the width of the first plate m*B(B+1). The distance between the holes in the length direction for the first plate can then be expressed with the formula m*(B′+1)−2*G, which is the same formula that gives the distance between holes in breadth for the other plate. With the principle of the modular system the two contacting plates thus get coincident (coaxial) hole positions to enable fixing plates from the series of dimensions in the modular system to crate crossing points, where de tightening bolts 3 , 9 and accompanying guiding sleeves have a common hole pattern determined by the module. Thereby the number of variants of fixing elements is reduced compared to what had been required without module determined series of dimensions and without the described uniform rule for the hole pattern and the dimensions of the fixing plates.
[0052] FIG. 6 illustrates how the fixing plates according to the modular system can be located so that beams are held in parallel positions at a distance of one module and how fixing plates of larger sizes can be combined to join the beams in another main direction. Through these different ways of mounting the combinations can be extended without increasing the number of components in the modular fixing system.
[0053] FIG. 7 shows how more small beams according to the dimension series, when necessary can be put close to each other to provide increased stiffness and strength.
[0054] FIG. 8 shows in an overview further examples of how the fixing system can be used to combine beams of different sizes according to the rules of the modular system for frameworks according to specific needs.
[0055] FIG. 9 illustrates a variant of the modular fixing system where the sleeves in FIG. 3, 6 , 12 and 13 are provided with a somewhat conical outer surface 14 , 15 and 16 . This conical shape is of interest to simplify detachment of mounted joints. Connecting recesses 10 in the fixing plates should then be conical too.
[0056] FIG. 10 illustrates an alternative embodiment of the modular fixing system that is obtained when the sleeves 6 and 13 are designed to not only keep the fixing plates located opposite to each other fixed against mutual side movements along the parting line 7 , but also keep their positions fixed perpendicular to this parting line. An embodiment according to this alternative is shown to the left in FIG. 10 . The cylindrical sleeves 6 and 13 are here made so much longer that the axial play 20 is eliminated. At the same time the thickness of the material in the fixing plates is made smaller. A contact between end surfaces 31 at the sleeves 6 , 13 and the bottom surfaces 32 in the recesses 10 then arises. At the same time a play arises between surfaces 30 on the adjacent fixing plates at the parting line 7 . This design has advantages in those cases when for strength reasons a smaller material thickness of the plates can be accepted and at the same time, for cost reasons, the requirements of flatness of the outer surfaces 30 of the plates along the parting line 7 can be reduced.
[0057] Another design of the sleeves 6 and 13 that by the sleeves themselves gives a certain distance between the adjacent fixing plates is illustrated to the left in FIG. 10 . Here the sleeves are provided with a central brim 22 with oppositely directed shoulders 23 , which acts against machined land surfaces 24 on the fixing plates 1 . This embodiment could have advantages from the manufacturing point of view.
[0058] FIG. 11 shows a variant 25 of the fixing plate 1 , which instead of longitudinal strings 4 has corner projections 26 with a corresponding function. This embodiment enables each non square fixing plate according to the modular system to be used for two different beam sizes.
[0059] The number of different fixing plates for covering of the size alternatives in crossing points for beams will thereby be further reduced.
[0060] However, the space available for mounting stop screws for shape determined fixing at side forces of the kind described in connection with FIG. 2 would be smaller. Stop screws 5 , essentially for fixation during mounting of the joint can as well be placed as illustrated at the projections 26 in FIG. 11 .
[0061] FIGS. 12 and 13 illustrates an alternative to the stop screws 5 in the form of wedges 27 that are pressed down against chamfered surfaces 28 at the corner projections 26 or, in a similar manner at the strings 4 illustrated in FIG. 1 . These wedges can be knocked or pressed to a suitable depth by means of specific tools and can also be detached with specific tools. Within the scope of the invention there is a possibility to press down the wedges from other directions than the one illustrated in FIG. 12 , which in certain cases has advantages from the accessibility point of view.
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The invention constitutes of a system for detachable joining of beams with square and/or rectangular cross-section. The system comprises for respective beams, two or more fixing plates mounted in pairs on opposite sides of the beam and fixed along the beam by a friction joint maintained by tightening bolts. Respective fixing plate comprises a first surface the extension of which in at least one direction corresponds to a multiple of a beam width and a second surface turned away from the beam. The system is characterised in that two or more beams are arranged to be joined in perpendicular and/or parrallel directions by at least two opposite each other arranged fixing plates. These fixing plates are arranged to bear on each other along respective second surface. The mutual positions of the fixing plates are fixed by locking elements in through recesses in the each other facing second sides of the fixing plates. These locking elements also constitute anchoring of the tightening bolts.
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FIELD OF THE INVENTION
This invention relates to a system for determining the position of moving equipment within a bore such that, for example, an operator of a drilling system can determine the diameter, shape or orientation of the vertically moving equipment at specific locations within a well, especially at the wellhead and at the blow out preventer (BOP).
BACKGROUND TO THE INVENTION
When drilling in subsea applications, which can be at a water depth of as much as 10,000 feet (3,000 metres), it is important to know the location of the equipment with respect to the BOP, the wellhead, in the cased hole and in the bore of the drilled well. For example, it is important to know how equipment needs to be positioned in and along the bore for operations to be performed correctly.
The prime operations are: drilling the well, casing and cementing, well testing, completion and running any equipment inside the completion, a well workover and well intervention. In addition to the well operations, there are the system tests to check the integrity of individual systems and that they are performed as required. These may include the well, wellhead and BOP pressure tests and the BOP operating tests. A subsea well also creates additional complications in respect to a well kick operation or underbalance drilling (i.e. snubbing in or out of the hole) and the requirement to carry out an emergency disconnect and later the reestablishment of the well.
While carrying out all these operations from a floating vessel, it is important to know accurately, at any instant, the position of items of equipment within the system.
When drilling a subsea well, the prime pressure containing equipment that contains possible formation pressures includes the subsea wellhead, the casing which is hung from and cemented to the wellhead and the BOP on the wellhead.
A BOP assembly is a multi closure safety device which is connected to the top of a drilled, and often partially cased, hole. The accessible top end of the casing is terminated using a casing spool or wellhead housing to which the BOP assembly is connected and sealed.
The wellhead and BOP stack (the section in which rams are provided) must be able to contain fluids at a pressure rating in excess of any formation pressures that are anticipated when drilling or when having to pump into the well to suppress or circulate an uncontrolled pressurized influx of formation fluid. This influx of formation fluid is known as a “kick” and reestablishing control of the well by pumping to suppress the influx or to circulate the influx out under pressure is known as “killing the well”. An uncontrolled escape of fluid, whether liquid or gas, to the environment is termed a ‘blow out’. A blow out can result in major leak to the environment which can ignite or explode, jeopardizing personnel and equipment in the vicinity, and pollution.
Although normal drilling practices provide a liquid hydrostatic pressure barrier to a kick, a final second safety barrier is provided mechanically by the BOP assembly. The BOP assembly must close and seal on tubular equipment (i.e., pipe, casing or tubing) hung or operated through the BOP assembly and ultimately must be capable of shearing and sealing off the well. A general term for a tubular system run into the well is called a string. Wells are typically drilled using a tapered drill string having successively larger diameter of tubulars at the lower end. When running a completion or carrying out a workover, various diameter of tubulars, coiled tubing, cable and wireline and an assortment of tools are run. In addition, dual tubulars, or tubulars with pipes and cables as a bundle, must be considered.
A subsea conventional BOP assembly is attached to a wellhead and is provided with a number of rams either to seal around different set tubular diameters or to shear and seal the bore. These rams should be rated to perform at pressures in excess of any anticipated well pressures or kick control injection pressures which are approximately 10 to 15 kpsi (69-103 MPa). A minimum of one annular is provided above the rams to cater for any tubular diameter or for stripping in or out under pressure. An annular is a hydraulically energized elastometric toroidal unit that closes and seal on varying diameters of tubular member whether stationary or moving into or out of the well. Due to the nature of this pressure barrier element, a lower maximum rated working pressure of about 5 kpsi (34 MPa) is normally available.
Above the annulars, there are no further well pressure barrier elements with the riser only providing a hydrostatic head, liquid containment and guidance of equipment on a normal pressure controlled drilling operation. For a subsea riser system, the hydrostatic head of the different drilling liquids over the ambient sea water pressure means the low pressure zone above the subsea BOP assembly must still withstand hydrostatic pressures of, depending upon the depth of water, approximately 5 kpsi (34 MPa).
The conventional BOP assembly in effect provides a three zone pressure containment safety system. The three zones typically consists of the first high pressure lowermost section encompassing the rams, the medium pressure second zone having the annular or annulars and the low pressure third zone being the bore open to atmosphere and, on a subsea system, the riser bore to the surface vessel. Therefore it is critical that the correct rams are closed on the correct diameter and full pressure integrity is achieved. In an emergency disconnect it is important that, besides sealing on the pipe or tubular, the pipe is held and not dropped down the hole.
A BOP can be fitted with a ram or rams to suit various diameters of drill pipe, tubing or casing. Variable rams can be used, having carefully selected their range. A BOP is fitted with the rams mostly likely to be needed in a certain drilling/workover phase. If a stage is reached where an inadequate range of rams are in the BOP to handle the tools/equipment to be used in the next sequence, the BOP has to be pulled and appropriately redressed.
When drilling or carrying out well intervention on a subsea well where the wellhead is at the seabed, the subsea BOP attached to the subsea wellhead is connected to a buoyant floating drilling vessel by a riser. A floating drilling vessel should maintain its station vertically above the well to enable well operations to be performed.
Failure to do so caused by weather conditions, current forces, equipment malfunctions, drift off or drive off, fire or explosion, collision of other marine incidents means it is necessary if possible to make the well safe, isolate the well at the seabed and disconnect the riser system. In a severe emergency, shearing any tubulars or equipment in the BOP bore, sealing the well to full working pressure and disconnecting the riser system is required to be achieved in under 30 seconds.
At present, in order to know what components are run through the drill floor, a manual record of the relevant dimensions, such as the length and the diameter of components are logged. These records are typically made in a notebook before being totalled up. Mathematical errors can occur easily during the totaling or components can be left out of the tally entirely or additional equipment, over and above that scheduled to be run, run in through the rotary table can be ignored or forgotten. Therefore, on a number of occasions, the accuracy of the tally is questionable.
Furthermore, as there are a wide variety of components which can be run in the hole, often with minor variations in length for what otherwise appear to be identical components, it is important that each component is measured individually before it is attached to the string. It is easy for minor errors in measurement of each component to add up to a significant error over the length of the string.
A further problem is that even when the measurements are accurately taken at the rig, these measurements are passive, i.e. on unstressed dimensions of the component. Once the component has been run in on a string, it may have 5,000 metres of additional components hanging from its end and, although this would not produce a significant change in length of a single component, when the total change is added-up over all components of the drill string, the change can be significant.
Furthermore, as the riser extending between the wellhead and the drill rig may be 2000-3000 m in length, it is subject to subsea currents and may be caused to “snake” between the rig and the wellhead. In this case, the length of drill string run into the riser is not directly comparable to the straight distance between the rig and the wellhead.
Additional problems are encountered as the drilling rig heaves on the sea surface such that its position, which is dependent on the tide and the vessel draft, is constantly changing with respect to the sea bed. This can, in part, be compensated for by the use of telescopic joints and a travelling block, but these additional factors need also to be included in any calculation of the position of the string. As the rig can heave in a matter of seconds, it can, in rough conditions, be impossible to determine accurately the position of the string given that the calculations required at present are cumbersome and complex.
It is critical at certain instances to know the position of equipment in the hole and, on a floating vessel, this requires knowledge of the tally, water depth, the draft and any change of draft of the vessel, swell or tidal heave, position of the travelling block, the stroke of the compensator and the depth of hole drilled since the last summation was made. This does not take into account snaking of the riser due to currents or cross currents in deep water, or the extension of the tubular string due to tension and weight. It is therefore difficult to determine accurately what component is at any given depth in a quick and accurate manner.
An example outlining a subsea well operation is an emergency disconnect involving the drilling string.
The accurate position of the drill string is required in the event of an emergency shut in of the BOP by closure of, for example, the shear blind rams in the BOP stack. The shear blind rams are those which can cut the drill string or a pipe or tubing and then seal the BOP bore when there is a need to carry out an emergency disconnect of the riser system from the BOP stack. The shear blind rams are activated with only a set force and therefore, should the rams close on a section of equipment which is significantly larger than the shear capability of the rams, for example on a joint between adjacent pipe sections, the rams may not fully sever the drill string thereby not closing sufficiently to seal the well and allow an emergency disconnect to be carried out correctly. To prevent the drill string falling down the hole, and to enable the drill string to be available to kill and circulate the well on reconnection, it is very advisable to be able to hang the drill string off on a set of pipe rams. This is achieved by resting an up-set diameter of the string on a set of pipe rams below the blind shear rams.
For operations of this sort, it is necessary to know the position of a specific part of the drill string to approximately one metre over anything up to 3,000 metres:
Further examples in which it is important to know the precise position of equipment is in testing of the BOP, testing the wellhead, flow testing the well, kick control, well circulation and testing of spool trees between the wellhead and the BOP.
Accordingly, it is an aim of the present invention to provide a system which enables the above problems to be overcome and allows the operator of the drilling system to know the precise position of a string, which may be moving, relative to a section of the well, the BOP or the wellhead at any given moment.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a system for determining the real time position of equipment within a bore, the system comprising:
a data input means for inputting data concerning the physical characteristics of components which are run into the bore;
a sensing means located, in use, within the bore and including a sensor for determining data concerning at least one physical characteristic of the equipment at a given time;
a data storage means for recording the inputted data and the determined data; and
a comparison means for comparing the input data and the determined data to establish which part of the equipment is being sensed by the sensor.
Preferably, the information input to the data input means includes the length, shape and/or diameter(s) of components making up the equipment and run in or out of the bore. Many components may have multiple changes in diameter over their length and it is important that all such information is entered into the data input means.
Thus, the present invention provides a system by which the exact signature profile of the equipment is recorded as it is run into or out of the bore and a sensor, located at the relevant location in the bore, provides information relating to changes in a known physical characteristic of the equipment. By comparing the sensed data and the known data, it is possible to work out which part of the equipment is adjacent to the lower sensor and therefore the position of the equipment relative to the BOP and the wellhead.
Preferably, the information input to the data input means also includes the distance between the changes in diameter, either along a single component or between diameters on adjacent components. Preferably, the sensor determines the shape and/or diameter of the equipment at a given time.
The sensing means preferably includes a means for determining the distance between successive changes in diameter.
Preferably, the system further comprises a sensing means for determining the direction of travel of the equipment in the bore and this may be part of the downhole sensor or a vessel based sensor.
The system may be used on a subsea bore having a wellhead with a BOP connected to it, which, in turn has a riser connected to it which, in turn, is connected to a drilling rig having a telescopic joint, a derrick, a travelling block/compensator and draw works.
Preferably, a further sensor is located, in use, in the upper portion of the riser fixed to the vessel to determine the profile of the equipment as it is run into the riser system.
Furthermore, it is preferable that a travel sensor is located on the telescopic joint to measure the movement of the telescopic joint between the floating drilling vessel and the top end of the riser linked to the seabed or to compute the travel from a line travel sensor on a riser tensioner line.
Another variable is movement in the derrick between the connection to the equipment and the vessel caused by the compensator stroking and operations of the draw works. A location sensor on the lower part of the compensator relative to the derrick could be considered. A physical means would be to monitor the stroking of the compensator with a travel sensor and to register the position of the travelling block in respect to the derrick. A method is to monitor line travel of the drill line from the draw works to the travelling block taking account of the number of sheaved lines to obtain the true travel.
The data input means is preferably a further sensor of the type used in the bore and it can therefore measure accurately the diameters and the lengths of all equipment run or pulled through the drilling vessel's drill floor. This information can be enhanced by referencing detailed product specifications which could include internal diameters, type of connection, strength and identification number. This would then provide a cross reference between what is actually run and what was scheduled to be run.
With an accurate knowledge of the equipment's signature profile and additional information, the sensor in the bore actively monitors the motion of the equipment relative to the fixed position of the sensor and therefore relative to the wellhead. By combining these two sources of information with the well, wellhead, BOP configuration data, the position of any item of equipment can be related to any point in the well.
Using a microprocessor to collate this information/data, an active animated visual display may then be produced on a visual display device, such as a monitor, at a choice of scales most suited for the operation at the desired section of the well system.
This invention described in respect to a subsea drilling BOP can equally be applied to workover BOPs, wireline or coil tubing BOPs. Equally the system can cater for wire, cable or coil tubing operations by recording the length of cabling run past a line travel sensor.
A surface sensor, that is one on the drilling rig, may be provided to register the length of individually made up items of equipment. The reason for this is that in certain circumstances, a section of the equipment run into the bore may be made up of a plurality of tubulars which, when joined to each other, have a continuous outer diameter (ie external flush drill collars and liner pipes). The surface sensor can register their lengths as the joints are made up although a string sensor lower down the riser would not be able to detect any diameter or shape change.
Once the wellhead with the surface casing string, BOP and riser system is run, all subsequent casing strings and the drilling strings used to drill the next section of hole can also be recorded. This will allow an accurate elevation of casings within casings in the well at any depth to be formulated as casing strings are run and cemented inside the previous casing.
The ability of the bore sensors to monitor the shape and orientation means that when, carrying out certain down hole tasks, the number of rotations of the equipment can be registered at the BOP sensor, rather than having to rely on knowledge of the number turns made at the surface. The problem with relying solely on the information from the surface is that there may be some relative twist on the equipment run, such that, for example, ten turns at the surface only corresponds to five turns at the sensor.
By combining a knowledge of the time a string has been in its position and how much it has been rotated, likely wear characteristics in the riser or in the cased hole can be predicted and may then be reduced.
The down hole sensor(s) is (are) preferably located in a retrievable part of the LRP/riser system, such as the low pressure area of the BOP/riser, thereby allowing easier maintenance, service and repair. Additionally no disconnect and make-up interface is required compared with a BOP stack mounted sensor system.
BRIEF DESCRIPTION OF THE DRAWINGS
One example of the present invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a schematic longitudinal cross sectional view through a subsea well being drilled by a floating vessel showing the well, wellhead, subsea BOP, riser and drilling rig incorporating the present invention;
FIG. 2 is a schematic longitudinal cross sectional view of the drilling rig top side of FIG. 1 ;
FIG. 3 is a schematic longitudinal cross sectional view of a typical subsea BOP of FIG. 1 ;
FIG. 4 is a schematic longitudinal cross section through the BOP of FIG. 1 during normal drilling;
FIG. 5 is a schematic longitudinal cross section through the BOP of FIG. 1 at the start of an emergency disconnect;
FIGS. 6 and 7 are schematic longitudinal cross sections through the BOP of FIG. 1 during the emergency disconnect;
FIG. 8 is a schematic longitudinal cross sectional view through the BOP of FIG. 1 after the emergency disconnect;
FIG. 9 is a schematic longitudinal cross sectional view through part of the BOP after an emergency disconnect showing the status of the rams and the valves;
FIG. 10 is a vertical schematic cross section view through one example of a sensor which could be used as part of the present invention; and
FIG. 11 is a horizontal schematic cross-sectional view of the sensor of FIG. 10 .
DESCRIPTION OF PREFERRED EMBODIMENTS
A drilling rig 2 , a subsea BOP assembly 10 and wellhead assembly 11 is shown schematically in FIGS. 1 to 3 . A wellhead assembly 11 is formed at the upper end of a bore into the seabed 12 and is provided with a wellhead housing 13 . The BOP assembly 10 is, in this example, comprised of a BOP lower riser package (LRP) 15 and a BOP stack 16 . The LRP 15 and the BOP stack 16 are connected in such a way that there is a continuous bore 17 from the lower end of the BOP stack through to the upper end of the LRP. The lower end of the BOP stack 16 is connected to the upper end of the wellhead housing 13 and is sealed in place. The upper part of the LRP 15 consists of a flex joint 20 which is connected to a riser adaptor 28 , which is, in turn, connected to a riser pipe 19 . The riser pipe 19 connects the BOP assembly 10 to a surface rig 2 .
Within the bore 17 and the riser pipe 19 , a tubular string 21 is provided. Such a string is comprised of a number of different types of component including simple piping, joint members, bore guidance equipment, and may have attached at its lower end, a test tool, a drill bit or a simple device which allows the flow of desired fluids from the well. The wellhead housing 13 , as an example, is shown with one wear bushing 22 and a number of well casings 23 which have previously been set in the wellhead and which extend into the hole in the sea bed 12 .
The BOP stack is provided with a number of valve means for closing both the bore 17 and/or on the string 21 and these include lower pipe rams 30 , middle pipe rams 31 , upper pipe rams 32 and shear blind rams 33 . These four sets of rams comprise the high pressure zone in the BOP stack 16 and they can withstand the greatest pressure. The lower, middle and upper pipe rams are designed such that they can close around the string 21 . However, the rams are only designed to close around a specific diameter of the drill string, for example on a 5 inch (125 mm) pipe section, and it is therefore important to know, in the event of, for example, an emergency disconnect, whether or not the rams are opposite a suitable section of the drill string 21 to enable them to close correctly and provide a seal.
Of course, when the lower 30 , middle 31 and upper 32 pipe rams are closed, whilst the bore 17 is sealed, the bore of the drill string 21 itself is still open. Thus, the shear blind rams 33 are designed such that, when operated, they can cut through the drill string 21 and provide a single barrier between the upwardly pressurized drilling fluid and the surface.
Above the shear blind rams 33 , a lower annular 34 and an upper annular 35 are provided and these can also seal around the drill string 21 when closed and provide a medium pressure zone.
The lower pressure zone is located above the upper annular 35 and includes the flex joint 20 , the riser adaptor 28 and the riser 19 . The low pressure containing means of this zone is merely the hydrostatic pressure of the fluid which is retained in the bore open to the surface.
Extending from the surface rig 2 to the BOP assembly 10 are choke 40 and kill 41 lines for the supply of fluid to or from the BOP. The choke line 40 is, in this example, in fluid communication with the bore 17 , in this example, three locations, each location having an individual branch which is controlled by a pair of valves (see FIG. 3 ). The uppermost valves are inner 45 and outer 46 gas vents and the branch on which they are located extends to the bore 17 below the upper annular 35 . The choke line 40 extends, passing in and out of gas vents, through a choke test valve 47 and enters the bore 17 via upper, inner 48 and outer 49 choke valves above the middle pipe rams 31 and via lower, inner 50 and outer 51 choke valves below the lower pipe rams 30 .
On the opposite side of the BOP stack, the kill line 41 is equipped with a kill test valve 52 before the kill line 41 enters the bore 17 at two locations, again each of which is via a pair of valves; upper, inner 54 and outer 55 kill valves and lower, inner 56 and outer 57 kill valves respectively. The upper branch is between the upper pipe rams 32 and the shear blind rams 33 and lower branch is between the lower 30 and middle 31 pipe rams.
The drill rig 2 is connected to the riser 19 by means of a telescopic joint 60 (see FIG. 2 ). In this example, the upper end 61 of the telescopic joint 60 is spaced vertically from the lower surface of the drill floor 62 of the drill rig 2 and, as such, extending from the lower surface of the drill floor, there is provided a telescopic joint outer barrel 64 which extends into, and in sealing engagement 61 with, the telescopic joint outer barrel 64 of the telescopic joint 60 . As the drill floor moves vertically relative to the outer barrel 64 of the telescopic joint 60 , the inner barrel 63 can slide within a recess portion of the outer barrel 64 . The telescopic joint 60 is suspended from the drill floor 62 by means of riser tensioner cables 65 which are connected, via sheaves 84 , to motion compensating tensioners (not shown). The upper end of the inner barrel 63 is connected to a flexible joint 66 which, in turn, which forms the diverter assembly 67 extending below the lower surface of the drill floor 62 . The diverter assembly annular 68 is provided to seal the bore 17 if necessary. Drilling mud which passes up the riser 19 is directed through a mud outlet 69 through a flow nipple 70 . The choke and kill lines 40 , 41 are connected to respective flexible choke and flexible kill 71 , 72 lines which extend on to the main deck 73 of the rig 2 and connect to the manifold and a high pressure pumping system.
On the upper surface of the drill floor 62 , there is a derrick 74 which supports a set of sheaves 75 known as the crown block. The travelling block 76 is connected to a compensator and possibly a top drive assembly 77 which is, in turn, connected to the string 21 . The crown block 75 and the travelling block 76 are connected by a cable 79 which is connected into draw works 78 .
A number of sensors are included in the BOP 10 and the drilling rig 2 . These include a riser adaptor bore object sensor 80 which is located at the upper end of the LRP 15 and a telescopic joint bore object sensor 81 which is located at the upper end of inner barrel 63 . Each of these sensors can detect the diameter, shape and orientation of the string 21 which is within the sensor and they can transmit the information electronically to a centralized data collection means and a microprocessor (not shown). The sensors 80 and 81 thereby provide a series of measurements which can be used in determining the location of the string 21 at any given time. In particular, the telescopic joint bore object sensor 81 provides a sequence of measurements, especially the diameters, changes in diameter, shape and orientation of the string 21 , as it is run into the riser 19 and provides reference data for later comparison. The riser adapter bore object sensor 80 detects the diameters and changes in diameter the shape and orientation of the string 21 as it passes the sensor 80 near the BOP 10 . By comparing the sequence of diameters and diameter changes measured by the riser adaptor bore object sensor 80 with the reference data provided by the telescopic joint bore object sensor 81 , the processor on the rig can determine which section of the drill string which is within the BOP at any given time.
The BOP 10 may also be provided with ram travel sensors 90 located on each ram of the lower 30 , middle 31 , upper 32 pipe rams and on the shear blind rams 33 . Additionally, annular travel sensors 91 can be provided on the lower 34 and upper 35 annulars. In particular, the sensors can determine whether or not each of the rams or annulars has been activated, and if so, whether the ram or annular is in the correct position for sealing around the string 21 .
Further sensors can be provided to measure other movement, such as heave of the rig, which would affect the location of the string relative to the BOP.
For example, a heave sensor 86 is provided between the drill floor 62 and the telescopic joint outer barrel 61 to account for variations due to heave of the rig. Additionally a mechanical travel sensor is included on the compensator/top drive assembly 77 to take account of the movement the compensator. The position of the travelling block 76 is known by the use of a line travel sensor 85 in the draw works 78 .
An example description of the how the system can operate is shown in FIGS. 4 to 8 . The example taken is an emergency disconnect of the vessel from the well between the BOP stack and the LRP.
FIG. 4 shows a cross sectional view through the BOP when a drill string 21 is operating in a conventional drilling mode and is rotating. In this situation, the riser adaptor bore object sensor 80 can detect changes in diameter of the tool joint 92 , in this case, an increase in diameter, and this information would be relayed to the data storage means (not shown). In this example, the change in diameter at the tool joint 92 is effected by a section in which the diameter changes gradually from the smaller main pipe diameter to the larger diameter of the joint 92 . In this case, both sides of the tool joint are provided with the same profile but, if different profiles were used on each side of the tool joint 92 , it would be possible to determine in which direction the drill string 21 was moving as it passed the sensor 80 by detecting the shape of the profile of the diameter change. Alternatively, an additional sensor or an array of vertical sensors (not shown) could be provided to sense the direction and distance of travel of the string 21 . The ability to know the direction and distance of travel is of considerable importance in determining the section of string which is adjacent to the sensor 80 and therefore what profile is currently in the BOP.
FIGS. 5 to 8 show how, after determining the location of the string 21 within the BOP 10 , and therefore whether or not any tool joints 92 are present, an emergency disconnect can then be safely carried out. In this example, the rotating drill string 21 is monitored by the sensor 80 and the tool joint 92 is observed to be moving relative to the BOP. The location and operating status of the rams and annulars can be confirmed, by using the sensors 90 and 91 , to be in the fully retracted positions.
When a rapid controlled emergency disconnect is required, the drill string 21 is picked up until the tool joint 92 is above the lower pipe rams 30 and rotation is stopped. The drill string 21 is held in this position and confirmation is obtained that the tool joint is above those rams. The lower pipe rams 30 are then lightly closed and the sensors 90 connected to the lower pipe rams 30 can confirm the correct closure of the rams on the drill string 21 . The lower pipe rams 30 are closed only under a low operating pressure at this stage.
Then the drill string 21 is lowered such that the tool joint 92 rests on the upper surface of the lower pipe rams 31 which will now support the drill string ( FIG. 6 ). This can be detected by a loss of drill string weight recorded at the surface. At this stage, full ram close pressure is then applied to the lower pipe rams 30 . The sensors 90 can again confirm that the rams are fully closed around the drill string 21 . If present, ram locks (not shown) can be operated to prevent the lower pipe rams 30 from being forced apart.
A similar operation can then be carried out on the upper pipe rams if the diameter of drill string across the closure point of the upper pipe rams 32 is suitable (see FIG. 7 ).
Next, the shear blind rams 33 can be closed, cutting the string 21 , with the upper part being pulled up. Again this can be confirmed by the use of sensor 90 . The ram locks, if present, can also then be activated.
The lower riser package 15 can then be disconnected from the BOP stack 16 and pulled clear of the remaining subsea components ( FIG. 8 ).
The current method is to take the drill string position from the drillers tally and then account for heave, for vessel draft, for the position of the travelling block, note if the rig is off center, and then estimate the positions of the tool joints. Using the bore equipment detection system operating a drill floor monitor, and displaying a visual presentation, the driller can visually observe the situation at any given time.
FIG. 9 shows a typical exploded display that could be displayed on a drill floor monitor (not shown) and gives a view of the lower 30 , middle 31 and upper 32 pipe rams after an emergency disconnect has been carried out. In this example, the lower 30 and middle 31 variable pipe rams have been closed on the smaller diameter of the main drill string 21 and the ram lock would be in the closed position. Additionally, the shear blind rams 33 would also be closed and again the ram locks would be in the closed position. However, the middle pipe rams 31 have not been operated and therefore the ram locks would still be in the open position. This form of checking would be carried out at all stages within the emergency disconnect procedure to ensure that each ram and annular was in the appropriate position for that stage of the operation.
FIGS. 10 and 11 shows a close up view of one of the bore object sensors 80 or 81 . The sensor is an electronic/magnetic sensor that can determine electronically and accurately the diameter of a body within the bore 17 and its location within the bore, i.e. if the tubular string or strings is on one side of the bore, thereby indicating that the rig may not be vertically above the wellhead. A full string signature profile can be obtained by the surface bore object sensor 81 and this can be compared with the observed string profile which is determined by the riser adaptor bore object sensor 80 .
As the drill string 21 is run down through each of the sensors 80 , 81 , a profile is generated of the change in diameters and by comparing the data from the surface bore object sensor 81 with the measured data from the riser adaptor bore object sensor 80 , it is possible to determine which section of the drill string 21 is within the BOP. If necessary, additional bore object sensors could be located in other positions within the BOP or in the riser itself.
The bore object sensor is formed by using a non-metallic body 100 , possibly formed from an epoxy, within which are mounted a set of emitters 101 and receivers 102 . The emitters and receivers are connected to a microprocessor (not shown). Using an electrical pulse sent out by the emitters 101 , a uniform electric field would be monitored by the receivers 102 if no object were present in the field of the sensor. However, when an object, such as the drill string, enters this field, the field flux lines 103 are disturbed and each receiver 102 can monitor the change in the electric field. When requiring to sense non metallic objects, the frequency will have to be varied. This allows the microprocessor to compute the closeness and the shape of the object to each of the receivers and therefore determine its size, shape, orientation and position within the bore.
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It is important to know the precise position of equipment when testing of the BOP, testing the wellhead, flow testing the well, kick control, well circulation and testing of spool trees between the wellhead and the BOP. Accordingly, there is provided a system for determining the real time position of equipment within a bore, the system including a data input means for inputting data concerning the physical characteristics of components which are run into the bore; a sensing means located, in use, within the bore and including a sensor for determining data concerning at least one physical characteristic of the equipment at a given time; a data storage means for recording the inputted data and the determined data; and a comparison means for comparing the input data and the determined data to establish which part of the equipment is being sensed by the sensor.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rotor type open-end spinning frame and a yarn ending or piecing method therefor.
2. Description of the Related Art
Of spinning frames, open-end spinning frames which require no roving by a roving frame, can improve the productivity and reduce the cost involving equipment investment, and are therefore widely used. Of the open-end spinning frames, a rotor type is the oldest and has proved as reliable over the years.
In this rotor type open-end spinning frame, a supply sliver is opened by a combing roller to separate impurities. Then, the opened fibers are transported into the rotor by an air stream produced in the fiber transport channel based on the negative pressure in the rotor that is spinning at a high speed, and are collected at the fiber collecting section at the largest inside-diameter portion of the rotor. A bundle of fibers collected at the fiber collecting section is drawn, while being twisted, from the yarn drawing passage, provided on the open side of the rotor coaxial to the rotor, by the action of the drawing roller, and is wound around a bobbin as a package. More specifically, the fiber bundle separated from the fiber collecting section is drawn along the wall of the yarn drawing passage, and at this time, the fiber bundle is drawn while rotating along the inner wall of the yarn drawing passage by the friction to that wall in accordance with the rotation of the rotor, so that the fiber bundle is temporarily twisted, helping the twist propagation of actual twisting.
The fiber bundle collected at the fiber collecting section sticks on the inner wall of the fiber collecting section only by the centrifugal force created by the rotation of the rotor. When the fiber bundle drawn along the yarn drawing passage is twisted, therefore, this twist is propagated to the fiber bundle sticking at the fiber collecting section, causing the fiber bundle in the fiber collecting section to rotate. Therefore, sufficient tension cannot be obtained at the time of twisting so that fibers are twisted while being insufficiently stretched. As a result, the fibers are not twisted straight, resulting in lower strength of yarn, disadvantageously.
As a solution to this problem, Japanese Unexamined Patent Publication No. 51-64034 discloses an apparatus as shown in FIGS. 46 and 47. In this apparatus, a disk-shaped draft rotor (inner rotor) 93 is provided inside an outer rotor 92 having a fiber collecting section 91. The draft rotor 93 makes differential rotation with respect to the outer rotor 92. Formed in the center of the draft rotor 93 is a hole in which a yarn introducing pipe (yarn drawing pipe) 94 is loosely fitted. This hole is perpendicular to a yarn drawing hole 95 for drawing a fiber bundle F collected at the fiber collecting section 91. The draft rotor 93 is provided with a small disk 96 (see FIG. 47) which revolves and rotates while being pressed against the fiber bundle F.
In this apparatus, the draft rotor 93 rotates faster than the outer rotor 92, with a predetermined rotational difference with respect to the outer rotor 92, to draw the fiber bundle F, collected at the fiber collecting section 91, out of the yarn drawing hole 95. Accordingly, this apparatus spins out the fiber bundle F while drafting it. Due to the action of the small disk 96, this apparatus spins out the fiber bundle F while drafting it, with suppressed floating of the fiber bundle F.
As the entrance of the yarn passage to guide the fiber bundle (fleece), separated from the fiber collecting section, is narrow in this conventional apparatus, the standard thread inserted into the yarn passage from the yarn drawing hole 95 reaches the fiber collecting section with difficulty at the time of yarn ending. This results in poor success in yarn ending.
As used throughout this specification it should be understood that "yarn ending" is intended to be synonymous with "yarn piecing".
SUMMARY OF THE INVENTION
It is therefore a primary object of the present invention to provide a rotor type open-end spinning frame which can twist fibers, constituting a fiber bundle that is to be drawn while being twisted, into yarn while being stretched in a relatively straight fashion, thereby yielding yarn having high tensile strength, and a yarn ending method therefor.
It is another object of this invention to provide a rotor type open-end spinning frame which can permit the end of a standard thread to surely reach the fiber collecting section at the time of yarn ending, and a yarn ending method therefor.
To achieve the foregoing and other objects and in accordance with the purpose of the present invention, a rotor type open-end spinning frame of this invention comprises an outer rotor which rotates at a high speed and has a fiber collecting section on its inner wall, and a yarn drawing passage provided on the open side of the outer rotor, with its first end provided coaxial to the outer rotor. An inner rotor, which is actively driven independent of the outer rotor, is provided inside and coaxial to the outer rotor. The inner rotor is formed into such a shape that part of the inner rotor faces the first end of the yarn drawing passage. Formed on the inner rotor are a drawing yarn passage for guiding the fiber bundle, drawn from the fiber collecting section at the time of normal spinning, to the yarn drawing passage, and an introducing yarn passage which connects to the drawing yarn passage and serves to introduce a standard thread at the time of yarn ending. This spinning frame further has restriction means which engages with a fiber bundle, drawn from the fiber collecting section at the normal spin-out time, to restrict the fiber bundle to a predetermined position in the drawing yarn passage.
The inner rotor may be disposed at the opposite position to the opening end of the outer rotor with respect to an imaginary plane where the fiber collecting section lies. The restriction means may be provided with a twist preventing function and may be provided on the inner rotor. The inner rotor may have a guide surface for guiding a fiber bundle, drawn from a standard thread introduced in the introducing yarn passage, to the restriction means. In this case, the fiber bundle drawn from the fiber collecting section is drawn toward the restriction means from a separation point of the fiber collecting section, not directly toward the center of the outer rotor. Therefore, the force necessary to separate the fiber bundle from the fiber collecting section against the centrifugal force, created by the rotation of the outer rotor, becomes small.
The inner rotor may be provided with a recess which is open to the opening end of the outer rotor and where the restriction means is placed. The restriction means may be a pin perpendicular to a lengthwise direction of the inner rotor, with a gap between the pin and the side wall of the largest outside-diameter portion of the recess being set smaller than the diameter of the fiber bundle. In this case, twist prevention is accomplished by the gap between the pin and the wall of the recess.
The pin may be provided in such a way that the rotational center is eccentric to the center of the pin. In this case, even if the thickness of the fiber bundle varies slightly, the pin rotates accordingly, preventing excess force from acting on the fiber bundle. Further, it is unnecessary to adjust the gap between the pin and the wall of the recess in accordance with a change in thickness of the spun yarn which is caused by a change in spinning conditions.
The restriction means may comprise a support lever provided rotatable around a support shaft perpendicular to the lengthwise direction of the inner rotor, and a pin protrusively formed at the distal end of the support lever. The center of gravity of this support lever can be set closer to the pin than to the support shaft and the gap between the pin and the side wall of the largest outside-diameter portion of the recess can be set smaller than the diameter of the fiber bundle. In this case, it is easy to adjust the pressure that acts on the fiber bundle.
The restriction means may be provided at such a position that a distance from the center of the inner rotor becomes smaller than the radius of the fiber collecting section. In this case, the tension applied to the fiber bundle while it moves to the position corresponding to the restriction means becomes smaller than that in the case where the fiber bundle is drawn directly toward the center of the outer rotor from the fiber collecting section. The spinning at the time of fast rotation therefore becomes more stable. As the restriction means is located more inward than the fiber collecting section, the largest outside diameter of the inner rotor can be set about the same as the diameter of the fiber collecting section.
The inner rotor may be disposed at the opposite position to the opening end of the outer rotor with respect to an imaginary plane where the fiber collecting section lies, and the restriction means may be a navel whose distal end is movable between a position corresponding to the imaginary plane and a spin-out position at which the distal end can enter a recess formed in the inner rotor.
The inner rotor may be formed with an introduce passage which connects to the drawing yarn passage and is wider than at least the entrance of the drawing yarn passage. The restriction means may be provided at the entrance of the yarn passage. The restriction means may be a navel whose distal end is movable between a position corresponding to the imaginary plane and a spin-out position as in the above case.
A negative pressure generator may be provided closer to the yarn drawing side than the actual twist point in the yarn drawing passage. In this case, as a suction air stream directing toward the yarn passage is generated by the action of the negative pressure generator, the separation of the fiber bundle and the introduction of the fiber bundle into the yarn passage are carried out smoothly.
In a yarn ending method of the present invention, a passage in the inner rotor for a fiber bundle, drawn from the fiber collecting section and moving toward the yarn drawing passage at the time of normal spinning, is formed separate from a passage for introducing a standard thread at the time of yarn ending in a spinning frame having the aforementioned structure.
To specify a passage in the inner rotor, the aforementioned drawing yarn passage is provided in the inner rotor, and with the outer rotor and inner rotor both rotating, a standard thread is inserted into the introduce passage from the yarn drawing passage at the time of yarn ending. After the leading end of the standard thread reaches the fiber collecting section, the fiber bundle from the fiber collecting section is drawn, together with the standard thread, from the yarn drawing passage through the introduce passage. Thereafter, the fiber bundle may be transported to the drawing yarn passage from the introduce passage to continue the spinning.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly cross-sectional view of a spinning frame according to a first embodiment of the present invention;
FIG. 2 is a partly enlarged cross section of the spinning frame shown in FIG. 1;
FIG. 3 is a partly cross-sectional view showing the relationship between an outer rotor and an inner rotor and a support disk and a rotor shaft, with portions omitted, as viewed from the opening side of the outer rotor;
FIG. 4 is a schematic diagram of the inner rotor at the time of yarn ending as viewed from the entrance side of a yarn passage;
FIG. 5 is a schematic diagram of the inner rotor at the time of normal spinning as viewed from the entrance side of the yarn passage;
FIG. 6 is a partly cross-sectional view showing the normal spinning state of a spinning frame according to a second embodiment;
FIG. 7 is a reduced cross section taken along line 7--7 in FIG. 6;
FIG. 8 is a partly cross-sectional view showing the state of the spinning frame at the time of yarn ending;
FIG. 9 is a schematic diagram of an inner rotor at the time of yarn ending as viewed from the entrance side of a yarn passage;
FIG. 10 is a schematic diagram of the inner rotor at the time of normal spinning as viewed from the entrance side of the yarn passage;
FIG. 11 is a partly perspective view of an inner rotor according to a third embodiment as viewed from the opening side of an outer rotor;
FIG. 12 is a schematic diagram also showing the inner rotor, with a cover plate omitted, as viewed from the opening side of the outer rotor;
FIG. 13 is a schematic diagram showing the state of contact members at the spinning time, with the cover plate omitted;
FIG. 14 is a diagram of the inner rotor, with portions omitted, as viewed from the entrance side of a yarn passage;
FIG. 15A is a partly cross-sectional view showing the normal spinning state of a spinning frame according to a fourth embodiment;
FIG. 15B is an exemplary diagram showing the forces acting on a fiber bundle;
FIG. 16 is a schematic diagram of an inner rotor at the time of normal spinning as viewed from the entrance side of an outer rotor;
FIG. 17A is a schematic diagram showing the relationship between a fiber bundle and the inner rotor at the initial stage of yarn ending;
FIG. 17B is a schematic diagram showing a state immediately before the engagement of a fiber bundle with a pin;
FIG. 18 is a schematic diagram showing the fiber bundle engaged with the pin;
FIG. 19 is a schematic perspective view corresponding to FIG. 17A;
FIG. 20 is a schematic perspective view corresponding to FIG. 17B;
FIG. 21 is a schematic perspective view corresponding to FIG. 18;
FIG. 22 is a partly cross-sectional view showing the normal spinning state of a spinning frame according to a fifth embodiment;
FIG. 23 is a schematic diagram of an inner rotor at the time of normal spinning as viewed from the entrance side of an outer rotor;
FIG. 24 is a partly schematic perspective view showing the normal spinning state of a spinning frame according to a sixth embodiment;
FIG. 25 is a partly enlarged cross-sectional view;
FIG. 26 is a partly schematic perspective view showing the normal spinning state of a spinning frame according to a seventh embodiment;
FIG. 27 is a partly enlarged cross-sectional view at the non-spinning time;
FIG. 28 is a partly enlarged cross-sectional view at the time of normal spinning;
FIG. 29 is a partly cross-sectional view of a spinning frame according to an eighth embodiment at the non-spinning time;
FIG. 30 is a partly schematic cross-sectional view corresponding to FIG. 29;
FIG. 31A is an exemplary diagram showing the relationship between a support lever and a wall at the non-spinning time;
FIG. 31B is an exemplary diagram showing the relationship between the support lever and the wall at the spinning time;
FIG. 32 is a partly cross-sectional view at the time of normal spinning;
FIG. 33 is a partly schematic perspective view corresponding to FIG. 32;
FIG. 34 is a schematic diagram of an inner rotor at the time of normal spinning as viewed from the entrance side of an outer rotor;
FIG. 35 is a partly cross-sectional view of a spinning frame according to a ninth embodiment at the normal spinning state;
FIG. 36 is a partly cross-sectional view at the time of yarn ending;
FIG. 37 is a schematic perspective view at the time of yarn ending;
FIG. 38 is a schematic perspective view at the time of normal spinning;
FIG. 39A is a partly cross-sectional view of a spinning frame according to a tenth embodiment at the normal spinning state;
FIG. 39B is a partly cross-sectional view of a spinning frame according to a modification of the tenth embodiment;
FIG. 40A is a partly cross-sectional view of a spinning frame according to an eleventh embodiment at the normal spinning state;
FIG. 40B is a partly cross-sectional view of a spinning frame according to a modification of the eleventh embodiment;
FIG. 41 is a schematic diagram showing a modification of the inner rotor as viewed from the entrance side of a yarn passage;
FIG. 42 is a schematic diagram, with portions omitted, showing a modification of the inner rotor having contact members as viewed from the entrance side of the yarn passage;
FIG. 43 is a schematic perspective view of a modification of the pin;
FIG. 44 is a schematic perspective view of another modification of the pin;
FIG. 45 is a schematic perspective view of a modification of restriction means;
FIG. 46 is a cross section of a conventional apparatus; and
FIG. 47 is a front view showing the relationship between an outer rotor and a draft rotor of the conventional apparatus, with parts broken away, as viewed from the opening side of the outer rotor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
A first embodiment of the present invention will now be described referring to FIGS. 1 through 5. As shown in FIG. 1, a pair of drive shafts 2 (only one shown) is supported, in parallel to each other, via a bearing 3, on a base 1 secured to the frame (not shown) of this embodiment. Support disks 4 are fitted on both sides of each drive shaft 2 so as to be rotatable with that drive shaft 2. A pair of adjoining support disks 4 defines a wedged-shaped recess 5 (shown in FIG. 3). A hollow rotor shaft 7 with an outer rotor 6 securely fitted on the distal end thereof is supported in the recess 5 in such a way that the outer surface of the rotor shaft 7 contacts the individual support disks 4. A drive belt 8 common to a plurality of spindles is arranged between two pairs of support disks 4, in a direction perpendicular to the rotor shaft 7, with the rotor shaft 7 pressed against the support disks 4. As the drive belt 8 is driven by a drive motor (not shown), the rotor shaft 7 rotates with running of the drive belt 8. Bearings 9 are secured in large diameter portions 7a formed at both ends of the rotor shaft 7, and a shaft 10 penetrating through the rotor shaft 7 are rotatably supported coaxial to the rotor shaft via the bearings 9. The shaft 10 has a distal end on which an inner rotor 11 is securely fitted to be rotatable with the shaft 10, and a proximal end abutting on a thrust bearing 12. A drive belt 13 provided common to a plurality of spindles, like the drive belt 8, is pressed against the shaft 10 so as to run in a direction perpendicular to the shaft 10. As the drive belt 13 runs, the shaft 10 rotates. The thrust bearing 12 includes a case 14 retaining a lubricating oil "O", a ball 16 rotatably supported on an oil supplying member 15 made of felt, and an adjusting screw 15a which abuts on the ball 16 from the opposite side to the shaft 10. The support disks 4 are secured to the drive shafts 2 with slight inclination so that at the time the support disks rotate in accordance with the rotation of the rotor shaft 7, a thrust load directed toward the thrust bearing 12 acts on the rotor shaft 7. The thrust load acting on the rotor shaft 7 is transmitted via the bearings 9 to the shaft 10 and is received by the thrust bearing 12.
A housing 17 is disposed to face the open side of the outer rotor 6, and a boss 18 is formed on the housing 17 so as to protrude inside the outer rotor 6. Bored in the boss 18 is one end of a fiber transport channel 22 which guides fibers, supplied by the actions of a feed roller 19 and a presser 20 and opened by a combing roller 21, into the outer rotor 6. A casing 23, which covers the outer rotor 6, is disposed at the position facing the housing 17 in such a way as to abut via an O ring 24 on the end surface of the housing 17. The casing 23 is connected via a pipe 25 to a negative pressure source (not shown). The inner rotor 11 is secured to the shaft 10 in such a way as to make the gap between itself and the end face of the boss 18 as small as possible in order to provide good sealing between the boss 18 and the inner rotor 11.
A navel 27 in which one end of a yarn drawing passage 26 is bored is provided in the center of the boss 18. The navel 27 is disposed in such a manner that its distal end comes flush with a fiber collecting section 6a. An ejector 29 serving as a negative pressure generator is disposed in a midway of a yarn pipe 28 which constitutes the downstream portion of the yarn drawing passage 26. The yarn pipe 28 is so laid as to cross the center line of the navel 27, and its end portion 28a closer to the yarn drawing passage 26 is a yarn twist start point. The ejector 29 has a passage 30 provided in the center portion, a plurality of eject holes 31, provided outside the passage 30, for ejecting compressed air toward the outlet side (yarn drawing side) of the passage 30, and an annular chamber 32 provided outside the eject holes 31. The chamber 32 is connected to the individual eject holes 31 through holes 33, and has an opening to which a compressed air supply pipe 34 is connected. The compressed air supply pipe 34 is connected to a compressed air source (not shown), with a pressure regulator and a valve (neither shown) provided in a midway of the pipe 34. The ejector 29 is designed to generate negative pressure on the entrance side of the passage 30 as the compressed air with a given pressure, supplied via the compressed air supply pipe 34 from the compressed air source, is ejected through the eject holes 31.
The inner rotor 11 is so designed that part of its surface extends to the proximity of the fiber collecting section 6a of the outer rotor 6, and has a recess 35 formed in the center portion on that side which corresponds to the boss 18. The navel 27 is to be freely fitted in the recess 35. The radius of the largest outside-diameter portion of the inner rotor 11 is set larger than the radius of the inner wall of the opening of the outer rotor 6. A yarn passage 36 is formed at the largest outside-diameter portion of the inner rotor 11, extending in the radial direction thereof. The yarn passage 36 has a first end portion open in the vicinity of the fiber collecting section 6a of the outer rotor 6 and a second end portion open in the surface of the recess 35. A twist propagation preventing portion 37 is provided at the entrance of the yarn passage 36, at the corner on the side where the separation point of the fiber bundle F moves. The twist propagation preventing portion 37, constituted of a shaft having many rugged portions on the outer surface, is secured to the distal end of the inner rotor 11 with the shaft positioned perpendicular to the moving direction of the fiber bundle F. This shaft is secured by means of screw-in, adhesive, press fitting, etc. The rugged portions are so formed as to extend in the drawing direction of the fiber bundle F and to be smaller than the diameter of the fiber bundle F and larger than the diameter of fibers.
As shown in FIGS. 3 and 4, an introduce passage 38, which is connected to the yarn passage 36 on the opening side of the outer rotor 6, is formed at the largest outside-diameter portion of the inner rotor 11 in such a way as to extend in the radial direction of the inner rotor 11. The introduce passage 38, like the yarn passage 36, has a first end portion open in the vicinity of the fiber collecting section 6a of the outer rotor 6 and a second end portion open in the surface of the recess 35. As shown in FIG. 4, for example, the introduce passage 38 is so formed that its wall 38a on the side corresponding to the yarn passage 36 extends obliquely toward the link portion between the passages 36 and 38. A wall 36a of the yarn passage 36 on the side corresponding to the introduce passage 38 is formed to extend nearly vertically. This wall 36a constitutes restriction means to restrict the movement of the fiber bundle F toward the introduce passage 38. A cover plate 11a is securely attached to that portion of the inner rotor 11 where the yarn passage 36 and introduce passage 38 are formed.
The action of the thus structured spinning frame will be described below. In spinning mode, the drive belts 8 and 13 run in the same direction to rotate the outer rotor 6 and inner rotor 11 in the same direction via the rotor shaft 7 and shaft 10, so that the fiber bundle F is sequentially separated from the fiber collecting section 6a to enter the yarn passage 36. The rotational speed of the inner rotor 11 is slightly slower than the speed of separation of the fiber bundle F from the fiber collecting section 6a (slightly faster than the rotational speed of the outer rotor 6). Compressed air is supplied through the compressed air supply pipe 34 to the ejector 29 from the compressed air source, causing a suction action in the yarn drawing passage 26 upstream of the ejector 29 (outer rotor side) to provide negative pressure higher than that in the outer rotor 6. In this state, the fibers, which have been opened by the action of the combing roller 21 are fed into the outer rotor 6 via the fiber transport channel 22, slide along the inner wall of the outer rotor 6 to be collected at the fiber collecting section 6a which is the largest inside-diameter portion. The fiber bundle F collected at the fiber collecting section 6a is smoothly separated from the fiber collecting section 6a and guided into the yarn passage 36 by the suction air stream, generated based on the negative pressure in the yarn passage 36 and flowing toward the yarn passage 36.
The fiber bundle F is linked to yarn Y which is drawn through the yarn pipe 28 by a drawing roller (not shown). As the yarn Y is drawn, the fiber bundle F is drawn as the yarn Y, while being twisted by the rotation of the inner rotor 11. The twisting applied to the yarn Y and fiber bundle F is transmitted upstream from the end portion 28a of the yarn pipe 28 as the start point. The fiber bundle F is introduced into the yarn passage 36 while in contact with the twist propagation preventing portion 37 provided at the entrance of the yarn passage 36. Consequently, the rotation of the fiber bundle F is suppressed at that portion, so that the rotation of the yarn and fiber bundle which are drawn while being twisted, is suppressed from being propagated to the fiber bundle F upstream of the position corresponding to the twist propagation preventing portion 37. That is, twisting is stopped at the position corresponding to the twist propagation preventing portion 37. At the twisting time, therefore, the fiber bundle F is twisted while the fibers are stretched by the tension applied thereto, so that the fibers are twisted straight, thus increasing the strength of yarn and yielding tight yarn.
As the upstream propagation of the twisting of the fiber bundle F from the position corresponding to the twist propagation preventing portion 37 is prevented as described above, the fiber bundle F which has just been separated from the fiber collecting section 6a has a low strength. As the inner rotor 11 is actively driven at a predetermined speed independent of the outer rotor 6, however, the force acting on the fiber bundle F at the time of separation becomes stable, thus ensuring smooth separation of the fiber bundle F. As the suction air stream directed toward the yarn passage 36 is generated by the action of the ejector 29, thus ensuring smooth separation of the fiber bundle F and smooth introduction of the fiber bundle F into the yarn passage 36.
At the time of yarn ending, the rotational speed of the inner rotor 11 is set equal to the speed of separation of the fiber bundle F from the fiber collecting section 6a in order to reduce the yarn tension on the fiber bundle F. With the outer rotor 6 and inner rotor 11 rotating, the supply of the compressed air to the ejector 29 is stopped. As a result, the negative pressure in the outer rotor 6 acts on the yarn drawing passage 26, generating an air stream toward the entrances of the yarn passage 36 and introduce passage 38 from the yarn drawing passage 26 via the recess 35. As the introduce passage 38 has a cross-sectional area larger than the yarn passage 36, more air enters the introduce passage 38 than the yarn passage 36. When the standard thread is inserted into the yarn drawing passage 26 from the yarn pipe 28 in this condition, the standard thread is introduced to the introduce passage 38 where a larger amount of an air stream is running. Due to the action of the air stream and the centrifugal force, the distal end of the standard thread is smoothly led to the entrance and reaches the fiber collecting section 6a. When the drawing roller (not shown) is driven forward to draw the standard thread, the fiber bundle (fleece) F collected at the fiber collecting section 6a is wound around the end portion of the standard thread and is separated from the fiber collecting section 6a to be drawn. That is, the yarn Y is spun while being drawn out of the introduce passage 38 at the initial stage of the yarn ending as indicated by the chain line in FIG. 3 and the solid line in FIG. 4. The rotational speed of the outer and inner rotors 6, 11 can be reduced at the time of the above yarn ending, thus further improving the success rate of yarn ending.
Then, the rotational speed of the inner rotor 11 is set slower than the speed of separation of the fiber bundle F. This produces force which causes the yarn in the introduce passage 38 to move toward the yarn passage 36, so that the yarn Y moves along the wall 38a toward the yarn passage 36 and enters the passage 36. As the wall 36a of the yarn passage 36 on the side of the introduce passage 38 is formed perpendicular to the rotational surface of the inner rotor 11 and the yarn passage 36 is narrower, the yarn Y, once introduced into the yarn passage 36, does not escape the passage 36. Thereafter, the yarn Y is spun while being drawn from the yarn passage 36 as indicated by the solid line in FIG. 3.
Second Embodiment
A second embodiment of the present invention will now be described referring to FIGS. 6 through 10. This embodiment differs from the first embodiment in the shapes of the introduce passage 38, formed in the inner rotor 11, and the twist propagation preventing portion 37 and the structure of the navel 27. The yarn passage 36 is formed in the center portion of the largest outside-diameter portion of the inner rotor 11, and the twist propagation preventing portion 37 is provided at the entrance of the yarn passage 36 at that corner portion in which direction the separation point of the fiber bundle F moves. The introduce passage 38 is connected to the yarn passage 36 at that portion of the inner rotor 11 which is on the opening side of the outer rotor 6, and is integrally formed with the same width as the yarn passage 36. In other words, as the twist propagation preventing portion 37 is provided at the entrance of the yarn passage 36, the yarn passage 36 becomes narrower than the introduce passage 38 accordingly.
As shown in FIGS. 9 and 10, the twist propagation preventing portion 37 is formed into a column shape so that the end face corresponding to the introduce passage 38 extends obliquely in a direction away from the introduce passage 38.
The navel 27 is supported movable along the axis of the inner rotor 11 while its cylindrical section 27a inserted into the housing 17 and a cylindrical guide member 39 with a bottom, which is secured to the housing 17. The guide member 39 has a guide groove 39a formed therein. Formed in the middle portion of the cylindrical section 27a is an opening which is connected to the yarn pipe 28. An engaging section 27b is protrusively provided, penetrating the guide groove 39a, on the outer surface of the proximal end of the cylindrical section 27a in a direction perpendicular to the cylindrical section 27a. The guide groove 39a has such a shape as to move the navel 27 in the axial direction when the engaging section 27b is rotated by a rotary solenoid (not shown).
In the rotor type open-end spinning frame according to this embodiment, the navel 27 is disposed at the spin position at which its distal end comes flush with the fiber collecting section 6a at the time of normal spinning as shown in FIG. 6. In this state, the fiber bundle F separated from the fiber collecting section 6a travels through the yarn passage 36 while contacting the twist propagation preventing portion 37, and is drawn out of the yarn drawing passage 26. At the twisting time, therefore, the fiber bundle F is twisted while the fibers are stretched by the tension applied thereto, so that the fibers are twisted straight, thus increasing the strength of yarn and yielding tight yarn, as in the previous embodiment.
At the time of yarn ending, the distal end of the navel 27 comes closer to the opening side of the outer rotor 6 than the distal end of the twist propagation preventing portion 37, as shown in FIG. 8. With the outer rotor 6 and inner rotor 11 rotating, the supply of the compressed air to the ejector 29 is stopped, as in the previous embodiment. Under this condition, the standard thread is inserted into the yarn drawing passage 26 from the yarn pipe 28. The standard thread moves toward the inner wall of the outer rotor 6 by the air stream flowing into the recess 35, yarn passage 36 and introduce passage 38 from the yarn drawing passage 26 and the centrifugal force created by the rotation of the inner rotor 11. As the distal end of the navel 27 is positioned closer to the opening side of the outer rotor 6 than the distal end of the twist propagation preventing portion 37, the standard thread travels inside the introduce passage 38. After the distal end of the standard thread reaches the inner wall of the outer rotor 6 at the position closer to the opening side of the outer rotor 6 than the fiber collecting section 6a, it slides along that inner wall to reach the fiber collecting section 6a.
Then, the standard thread is drawn by the forward rotation of the drawing roller (not shown), and the fiber bundle F collected at the fiber collecting section 6a is wound around the end portion of the standard thread. Accordingly, the fiber bundle F is separated from the fiber collecting section 6a and is drawn together with the standard thread. That is, the yarn Y is spun while being drawn out of the introduce passage 38 at the initial stage of the yarn ending as shown in FIGS. 8 and 9.
Then, the navel 27 is moved in the axial direction and is disposed at the spin position at which its distal end comes flush with the fiber collecting section 6a as shown in FIG. 6. As shown in FIG. 10, the yarn Y in the introduce passage 38 moves toward the yarn passage 36 in accordance with the movement of the navel 27. By the time the movement of the navel 27 is complete, as shown in FIG. 6, the fiber bundle F separated from the fiber collecting section 6a has moved through the yarn passage 36 while contacting the twist propagation preventing portion 37, and is ready to be drawn out of the yarn drawing passage 26. In this embodiment, therefore, the navel 27 constitutes restriction means to restrict the movement of the fiber bundle F, introduced in the yarn passage 36, toward the introduce passage 38.
Third Embodiment
A third embodiment of the present invention will now be described referring to FIGS. 11 through 14. This embodiment differs from the above-described two embodiments in the structure of the twist propagation preventing portion 37. The introduce passage 38 in this embodiment has basically the same shape as the one in the first embodiment. Formed at the distal end of the inner rotor 11 and at the position corresponding to the entrance of the yarn passage 36 is a retaining recess 40 which is open toward the housing 17 and fiber collecting section 6a. That portion of the recess 40 on the side of the housing 17 is closed by the cover plate 11a. As shown in FIGS. 11 to 13, the recess 40 is so formed as to expand on both sides of the yarn passage 36, with a set of columnar contact members 41 and 42 disposed in the recess 40 to sandwich the yarn passage 36. Both contact members 41 and 42 constitute the twist propagation preventing portion 37. As shown in FIG. 14, the first contact member 41 is formed taller than the second contact member 42. The first contact member 41 is fixed unmovable to the inner rotor 11. The second contact member 42 has a pin 43 protruding from a position eccentric to the center O1. This pin 43 is rotatably supported in a support hole 44 formed in the inner rotor 11. The center O2 of the pin 43 is eccentric to the center O1 of the second contact member 42 by a distance "e". The position of the pin 43 is set in such a way that with the center O1 of the second contact member 42, the center O2 of the pin 43 and the rotational center of the inner rotor 11 being aligned on a straight line, the gap "X" between both contact members 41 and 42 is smaller than the thickness of the fiber bundle at the entrance.
The action of the spinning frame with the above-described structure will be explained. At the time of spinning, as in the above-described two embodiments, the fiber bundle F collected at the fiber collecting section 6a is smoothly separated therefrom, and is drawn as yarn Y in accordance with the drawing of the yarn Y, while being twisted by the rotation of the inner rotor 11. The fiber bundle F is introduced into the yarn passage 36 while in contact with both contact members 41 and 42 provided at the entrance of the yarn passage 36. In spinning mode in which the fiber bundle lies between the contact members 41 and 42, the second contact member 42 is not at the position where the center O1 of the second contact member 42, the center O2 of the pin 43 and the rotational center of the inner rotor 11 come on a straight line. As a result, the centrifugal force acting on the second contact member 42 according to the rotation of the inner rotor 11 urges the second contact member 42 to rotate in such a direction (clockwise in FIG. 13) that the center O1 of the second contact member 42, the center O2 of the pin 43 and the rotational center of the inner rotor 11 come on a straight line. In other words, the force which pushes the fiber bundle F toward the first contact member 41 always acts on the second contact member 42 during spinning.
Thus, both sides of the fiber bundle F moving in the yarn passage 36 are pressed against the contact members 41 and 42 at the position corresponding to those contact members 41 and 42. Consequently, the rotation of the fiber bundle F is suppressed at that portion, thus suppressing the propagation of the rotation of the yarn and fiber bundle, drawn while being twisted, to the fiber bundle F located upstream of the position corresponding to both contact members 41 and 42. That is, twisting is stopped at the position corresponding to both contact members 41 and 42. Because the second contact member 42 is rotatable around the pin 43, even if the thickness of the fiber bundle F varies slightly, the second contact member 42 rotates around the pin 43 accordingly, preventing excessive force from acting on the fiber bundle F.
At the time of yarn ending, first, the standard thread is introduced into the introduce passage 38 in the same condition as given in the first embodiment, and spinning is conducted with the yarn Y drawn from the introduce passage 38 as indicated by the chain line in FIG. 14. Then, the rotational speed of the inner rotor 11 is set slower than the moving speed of the separation point. This produces force to move the yarn Y in the introduce passage 38 toward the yarn passage 36, causing the yarn Y to move toward the yarn passage 36 along the wall 38a. As a plane, which passes the distal end of the navel 27 and fiber collecting section 6a, passes through nearly the lengthwise center of the first contact member 41, the yarn Y is introduced to the position in the yarn passage 36 where it is held between both contact members 41 and 42, as indicated by the solid line in FIG. 14. Thereafter, spinning is performed with the yarn Y drawn from the yarn passage 36 as indicated by the solid line in FIG. 14.
Fourth Embodiment
A fourth embodiment of the present invention will now be described referring to FIGS. 15 through 21. This embodiment differs considerably from the above-described embodiments in that in normal spinning mode, the position where the fiber bundle F (yarn Y) passes during the period in which the fiber bundle F is drawn from the fiber collecting section 6a and is guided to the navel 27, differs from an imaginary plane on which the fiber collecting section 6a lies. As shown in FIG. 15A, a retaining section 6b larger in diameter than the fiber collecting section 6a is formed in the outer rotor 6 on the opposite side to the opening side thereof with the fiber collecting section 6a therebetween. The inner rotor 11 has a shape of a disk whose both sides are cut out symmetrically, its largest outside-diameter portion larger than the diameter of the fiber collecting section 6a, and is securely fitted on the shaft 10 while being accommodated in the retaining section 6b.
Formed in the inner rotor 11 is a recess 45 which stretches to the recess 35 where the navel 27 is loosely fitted. The recess 45 stretches to the vicinity of the first end portion of the inner rotor 11. The recess 45 is formed on the rear side in the spinning rotational direction of the inner rotor 11 (the direction of the arrow in FIG. 16). The navel 27 is disposed at such a position that its distal end is located closer to the bottom side of the outer rotor 6 (opposite side to the opening side) than the imaginary plane containing the fiber collecting section 6a. The fiber collecting section 6a is indicated by the chain line in FIG. 16. The recess 45 serves as a yarn passage for introduction of the standard thread and a drawing yarn passage to guide the fiber bundle F, drawn from the fiber collecting section 6a, to the position facing the yarn drawing passage 26 at the time of normal spinning.
The radius of the largest inside-diameter portion of the recess 45 is set larger than that of the fiber collecting section 6a, while that portion of the recess 45 close to the largest outside-diameter portion of the inner rotor 11 has such a shape that the diameter of the bottom portion is larger than that of the opening edge portion, i.e., the recess 45 is scooped toward the first end portion of the inner rotor 11. A pin 46 serving as restriction means is protrusively formed in the recess 45 at a position close to the first end portion of the inner rotor 11, in such a way that it is perpendicular to the lengthwise direction of the inner rotor 11 and provides a gap between itself and the opening edge of the recess 45 on the first end portion side. A groove 46a for determining the drawing position of the fiber bundle F is formed close to the proximal end of the pin 46. That side of the distal end of the pin 46 which corresponds to the first end portion side of the recess 45 is obliquely cut away toward the proximal end side. A slanted guide surface 45a is formed on the first end portion side of the recess 45 at the position facing the pin 46.
The action of the spinning frame with the above-described structure will be explained. In spinning mode, the fiber bundle F collected at the fiber collecting section 6a is drawn therefrom toward the inner rotor 11 along the wall of the outer rotor 6 as shown in FIG. 15A. Then, the fiber bundle F is wound around the pin 46, changing its drawing direction toward the naval 27. The fiber bundle F is drawn as yarn Y while being twisted by the rotation of the inner rotor 11. Because the clearance between the pin 46 and the wall 45b of the recess 45 is small and the fiber bundle F is drawn while being wound around the pin 46, the rotation of the fiber bundle F is suppressed at the point where it is wound around the pin 46. That is, the rotation of the yarn Y and fiber bundle F, drawn while being twisted, is suppressed from propagating to the fiber bundle F located upstream of the position corresponding to the pin 46.
In the above-described embodiments, the fiber bundle F is drawn directly toward the center of the outer rotor 6 from the fiber collecting section 6a, and is guided to the entrance of the yarn passage 36 of the inner rotor 11. Therefore, the fiber bundle F is drawn with the centrifugal force, produced by the rotation of the outer rotor 6, acting against the force to draw the whole fiber bundle F. That is, large tension is applied to the fiber bundle F which has not been twisted. As the centrifugal force is proportional to the square of the angular velocity, with the outer rotor 6 rotating fast, it is difficult to draw the untwisted fiber bundle F directly toward the center of the outer rotor 6 from the fiber collecting section 6a against the centrifugal force.
According to this embodiment, however, the fiber bundle F collected at the fiber collecting section 6a is drawn toward the inner rotor 11 along the wall of the outer rotor 6, and is then drawn toward the center of the outer rotor 6 at the position of the pin 46. The fiber bundle F slides, untwisted, on the walls of the outer rotor 6 and inner rotor 11 up to the position corresponding to the pin 46. Therefore, the tension necessary to move the fiber bundle F has only to be large enough to overcome the component of the centrifugal force in the direction of the wall and the frictional resistance between the fiber bundle F and the wall.
Provided that the centrifugal force acting on the fiber bundle F is "f", the frictional coefficient between the fiber bundle F and the wall is μ and the angle defined by the direction perpendicular to the wall and the acting direction of the centrifugal force is Θ as shown in FIG. 15B, the force N1 acting on the fiber bundle F and the force N2 acting in parallel to the wall are expressed by the following equations:
N1=f×cos Θ, N2=f×sin Θ.
Thus, the tension T necessary to move the fiber bundle F is given by the following equation:
T=f×sin Θ+μ×f×cos Θ.
As the frictional coefficient μ is 10 -1 and cos Θ and sin Θ are smaller than one, the tension T becomes smaller than the centrifugal force "f", so that the fiber bundle F, although untwisted, smoothly moves to the position corresponding to the pin 46 from the fiber collecting section 6a. At the position where the drawing direction of the fiber bundle F is opposite to the direction of the centrifugal force and is toward the naval 27 from the pin 46, the fiber bundle F is twisted. Even with the outer rotor 6 rotating fast, the fiber bundle F can be drawn smoothly.
The action in yarn ending mode will be described next. At the time of yarn ending, the rotational speed of the inner rotor 11 is set equal to the speed of separation of the fiber bundle F from the fiber collecting section 6a and slightly faster than the rotational speed of the outer rotor 6. With the outer rotor 6 and inner rotor 11 rotating, the supply of the compressed air to the ejector 29 is stopped. As a result, the negative pressure in the outer rotor 6 acts on the yarn drawing passage 26, generating an air stream going into the outer rotor 6 from the yarn drawing passage 26. When the standard thread is inserted into the yarn drawing passage 26 from the yarn pipe 28 in this condition, the distal end of the standard thread reaches the fiber collecting section 6a due to the action of the air stream and the centrifugal force. When the drawing roller (not shown) is driven forward to draw the standard thread, the fiber bundle F collected at the fiber collecting section 6a is wound around the end portion of the standard thread and is separated from the fiber collecting section 6a to be drawn.
Then, spinning is conducted in such a way that the fiber bundle F is guided to the naval 27 via the recess 45 of the inner rotor 11 with the yarn Y not engaged with the pin 46 at the initial stage of the yarn ending, as shown in FIGS. 17A and 19. Then, the rotational speed of the inner rotor 11 is set slower than the speed of separation of the fiber bundle F. As a result, the position of the separation point P of the fiber bundle F relatively moves to the front side of the rotational direction of the inner rotor 11 from the position in FIG. 17A, and the fiber bundle F (yarn Y) also moves in the same direction. As the centrifugal force is acting on the fiber bundle F, the fiber bundle F which is being drawn along the walls of the outer rotor 6 and inner rotor 11 from the fiber collecting section 6a also moves while sliding on the walls when the fiber bundle F (yarn Y) moves. The fiber bundle F then comes between the pin 46 and the wall 45b of the recess 45 from the state shown in FIGS. 17B and 20, and engages with the groove 46a as shown in FIGS. 18 and 21. Thereafter, spinning is carried out with the fiber bundle F drawn while in engagement with the groove 46a of the pin 46 as shown in FIGS. 18 and 21. In FIGS. 17 and 18, the fiber collecting section 6a is indicated by the chain line.
The recess 45 serves as a yarn passage for introduction of the standard thread and a drawing yarn passage to guide the fiber bundle F, drawn from the fiber collecting section 6a, to the position facing the yarn drawing passage 26 at the time of normal spinning. As that portion of the recess 45 on the first end portion side of the inner rotor 11 is shaped in such a way that the diameter of the opening edge is larger than that of the bottom side, the centrifugal force helps guide the fiber bundle F to between the pin 46 and the wall 45b at the time the fiber bundle F moves to the normal spinning position in yarn ending mode.
Fifth Embodiment
A fifth embodiment of the present invention will now be described referring to FIGS. 22 and 23. This embodiment differs from the fourth embodiment in the structure of the restriction means, and the other structure is the same. In this embodiment, a wall 47 for partitioning part of the yarn drawing passage from the space on the outer rotor 6 side is so formed as to protrude from the frontward wall of the recess 45 in the rotational direction of the inner rotor 11 while covering part of the yarn drawing passage. A gap formed between the wall 45b and the first end portion of the wall 47 is slightly narrower than the diameter of yarn to be spun. A semi-columnar engaging section 47a as restriction means is formed at the first end portion of the wall 47, close to the first end portion of the inner rotor 11.
In the spinning frame of this embodiment, in normal spinning mode, the fiber bundle F collected at the fiber collecting section 6a is drawn therefrom toward the inner rotor 11 along the wall of the outer rotor 6. Then, the fiber bundle F passes between the wall 45b and the surface of the engaging section 47a and changes its drawing direction toward the naval 27 at the position of the engaging section 47a. The fiber bundle F is drawn as yarn Y while being twisted by the rotation of the inner rotor 11. Because the clearance between the engaging section 47a and the wall 45b is narrow, the rotation of the fiber bundle F is suppressed at that portion. That is, the rotation of the yarn Y and fiber bundle F, drawn while being twisted, is suppressed from propagating to the fiber bundle F located upstream of the position corresponding to the engaging section 47a.
This embodiment therefore has the same action and advantages as the fourth embodiment, and carries out yarn ending in the same procedures as the fourth embodiment.
Sixth Embodiment
A sixth embodiment of the present invention will now be described referring to FIGS. 24 and 25. This embodiment differs from the fourth embodiment in the structure of the restriction means, and the other structure is the same. More specifically, the difference lies in that instead of protrusively providing the pin 46 at a predetermined position, the pin is provided rotatable so that the center of the pin is eccentric to the rotational center of the pin. A pin 48 is formed to have its distal end side shaped into a truncated cone, with a shaft 49 projecting from the proximal end of the pin 48 at the position eccentric to the center thereof. The shaft 49 is supported rotatable on a bearing retained in a retaining hole (neither shown) formed in the wall of the recess 45. A groove 48a is formed in the pin 48 close to the proximal end.
The position of the shaft 49 is determined in such a way that with the pin 48 abutting on the wall 45b of the recess 45, the centrifugal force acting on the pin 48 when the inner rotor 11 rotates, urges the pin 48 in the direction opposite to the drawing direction of the fiber bundle F (i.e., in the counterclockwise direction in FIG. 25).
In this embodiment, in normal spinning mode, the fiber bundle F is drawn via the navel 27 while in engagement with the groove 48a of the pin 48 like the fourth embodiment. The center of the pin 48 is eccentric to the rotational center thereof or the center of the shaft 49, and the center of the shaft 49 is positioned closer to the opening side of the recess 45 than the center of the pin 48 at the spinning time as shown in FIG. 25. As a result, the centrifugal force acting on the pin 48 when the inner rotor 11 rotates, causes the pin 48 to rotate counterclockwise in FIG. 25 around the shaft 49. In other words, force to push the fiber bundle F against the wall 45b always acts on the pin 48 during spinning, so that twisting of the fiber bundle F is stopped at that position. As the pin 48 is rotatable around the shaft 49, even if the thickness of the fiber bundle F varies slightly, the pin 48 rotates around the shaft 49 accordingly, thus preventing excessive force from acting on the fiber bundle F. Unlike in the fourth embodiment, it is unnecessary to adjust the gap between the pin 48 and the wall 45b in accordance with a change in the thickness of spinning yarn caused by a change in spinning conditions.
Seventh Embodiment
A seventh embodiment of the present invention will now be described referring to FIGS. 26 through 28. This embodiment differs from the sixth embodiment in the structure of the restrictions means, and the other structure is the same. The restriction means is constituted of a support shaft 52 and a cylinder 53 which is loosely fitted on the support shaft 52, instead of the pin 48 provided rotatably. As shown in FIG. 26, the support shaft 52 is protrusively provided on the wall of the recess 45, with a cone-shaped guide section 52a formed at its distal end. A groove 53a is formed in the outer surface of the cylinder 53. As shown in FIG. 27, the cylinder 53 has its outer surface abuttable on the wall 45b with the inner surface engaged with the support shaft 52.
With the structure of this embodiment, if the fiber bundle F is not present between the cylinder 53 and the wall 45b with the inner rotor 11 rotating, the centrifugal force causes the outer surface of the cylinder 53 to abut on the wall 45b and causes the inner surface to abut on the support shaft 52. At the time of spinning, the fiber bundle F comes between the cylinder 53 and the wall 45b as shown in FIG. 28, and is pressed against the wall 45b by the cylinder 53 so that twisting is stopped there.
In this embodiment, the cylinder 53 is movable more freely than the pin 48 of the sixth embodiment, and can thus follow up a change in the thickness of the fiber bundle F more easily.
Eighth Embodiment
An eighth embodiment of the present invention will now be described referring to FIGS. 29 through 34. This embodiment differs from the sixth embodiment in the structure of the restriction means, and the other structure is the same. A support lever 54 is provided movable in the recess 45. A support shaft 55 is protrusively provided on the support lever 54, and is rotatably supported on a bearing provided on the wall of the recess 45. A pin 56 is provided projecting from the distal end of the support lever 54. As shown in FIG. 31A, the center of gravity G of the support lever 54 is closer to the pin 56 than its rotational center O3.
As shown in FIG. 31A, the position of the support shaft 55 is determined in such a way that with the support lever 54 positioned to set the center of gravity G and the rotational center O3 on a plane parallel to a plane containing the fiber collecting section 6a, there is a clearance Δt between the wall 45b and the pin 56. The clearance Δt is set smaller than the thickness of yarn to be spun. The pin 56 can come close to or away from the wall 45b in accordance with the rotation of the support lever 54.
As shown in FIGS. 32 and 33, at the spinning time, the support lever 54 is rotated in the drawing direction of the fiber bundle F by the force that draws the fiber bundle F, widening the clearance between the pin 56 and the wall 45b. During the rotation of the inner rotor 11, centrifugal force acts to set the support lever 54 to the position (reference position) in FIGS. 29 to 31, and this force causes the pin 56 to press the fiber bundle F against the wall 45b. With a constant rotational speed of the inner rotor 11, this pressure is a function of the rotational angle Θ1 from the reference position, the distance between the center of gravity G and the rotational center O3 and the distance between the rotational center O3 and the center of the pin 56 shown in FIG. 31B. The distance between the center of gravity G and the rotational center O3 and the distance between the rotational center O3 and the center of the pin 56 are determined by the shape of the support lever 54. By properly choosing the shape of the support lever 54, spinning is carried out with the desired pressure applied to the fiber bundle F.
With the clearance set to Δt ≈0, it is unnecessary to set the clearance Δt in accordance with the thickness of yarn to be spun. The structure of this embodiment ensures easier adjustment of the pressure acting on the fiber bundle F than the sixth and seventh embodiments.
Ninth Embodiment
A ninth embodiment of the present invention will now be described referring to FIGS. 35 through 38. This embodiment differs from the individual embodiments discussed in the foregoing description in that at the time of yarn ending, after the fiber bundle F is drawn toward the center of the outer rotor 6 directly from the fiber collecting section 6a outside the inner rotor 11, the fiber bundle F is allowed to pass inside the inner rotor 11.
As shown in FIGS. 37 and 38, like in the first to third embodiments, the inner rotor 11 is so formed that the first end portion is made narrower, and a yarn passage 57 stretching to the recess 35 is formed to be open to the opening side of the outer rotor 6. A retaining recess 58 is formed at the position corresponding to the first end portion of the yarn passage 57, stretching outward from both sides of the yarn passage 57, with a set of rollers 59 and 60 provided rotatable in the recess 58. The rollers 59 and 60 are arranged parallel to each other with a gap narrower than the thickness of spinning yarn, with their distal end sides slanted toward the inside of the inner rotor 11. The roller 59 located frontward in the rotational direction of the inner rotor 11 has such a length to protrude outside the recess 58. The roller 60 located rearward in the rotational direction of the inner rotor 11 has such a length not to protrude outside the recess 58 and has a cone-shaped distal end. Both rollers 59 and 60 constitute twist stopping means.
The navel 27 is designed movable in the axial direction of the inner rotor 11 by the activation of a rotary solenoid (not shown) as in the second embodiment. The navel 27 is positioned at the spinning position where its distal end comes inside the recess 35 in normal spinning mode as shown in FIGS. 35 and 38. In this state, the fiber bundle F collected at the fiber collecting section 6a is drawn therefrom toward the inner rotor 11 along the wall of the outer rotor 6 as in the fourth to eighth embodiments. Then, the fiber bundle F is wound around the roller 59, changing its drawing direction toward the navel 27, and is drawn as yarn Y while being twisted by the rotation of the inner rotor 11. Because the gap between both rollers 59 and 60 is narrower than the thickness of the spinning yarn, the rotation of the fiber bundle F is suppressed there. That is, the rotation of the yarn Y and fiber bundle F, drawn while being twisted, is suppressed from propagating to the fiber bundle F located upstream of the position corresponding to both rollers 59 and 60.
At the time of yarn ending, the navel 27 is disengaged from the recess 35 and comes to the position where its distal end lies on the same plane as the fiber collecting section 6a as shown in FIGS. 36 and 37. With the outer rotor 6 and inner rotor 11 rotating, the supply of the compressed air to the ejector 29 is stopped, as in the fourth to eighth embodiments. Under this condition, the standard thread is inserted into the yarn drawing passage 26 from the yarn pipe 28. The standard thread moves toward the inner wall of the outer rotor 6 by the air stream flowing inside the outer rotor 6 from the yarn drawing passage 26. After the distal end of the standard thread reaches the inner wall of the outer rotor 6 at the position closer to the opening side of the outer rotor 6 than the fiber collecting section 6a, it slides along that inner wall to reach the fiber collecting section 6a.
Then, the standard thread is drawn by the forward rotation of the drawing roller (not shown), and the fiber bundle F collected at the fiber collecting section 6a is wound around the end portion of the standard thread and is separated from the fiber collecting section 6a to be drawn together with the standard thread. Spinning is performed while the yarn Y is drawn from the navel 27 without going through the inner rotor 11 at the initial stage of the yarn ending as shown in FIGS. 36 and 37.
Then, the navel 27 is moved in the axial direction and is disposed at the spinning position at which its distal end is loosely fitted in the recess 35 and comes on the opposite side to the opening end of the outer rotor 6 from the plane where the fiber collecting section 6a lies, an shown in FIGS. 35 and 38. The yarn Y moves toward the yarn passage 57 in accordance with the movement of the navel 27. By the time the movement of the navel 27 is completed, as shown in FIGS. 35 and 38, the fiber bundle F separated from the fiber collecting section 6a has moved through the yarn passage 57 while contacting both rollers 59 and 60, to be ready to be drawn out of the yarn drawing passage 26. In this embodiment, therefore, the navel 27 constitutes restriction means to restrict the movement of the fiber bundle F, introduced in the yarn passage 57.
After the navel 27 is moved to the spinning position where it is loosely fitted in the recess 35, when the rotational speed of the inner rotor 11 is set lower than the speed of separation of the fiber bundle F, the separation point of the fiber bundle F relatively moves frontward in the rotational direction of the inner rotor 11. Even if the yarn Y is located off the yarn passage 57 when the navel 27 is moved to the spinning position, the above operation causes the yarn Y to shift to the position corresponding to the yarn passage 57. After engaging with the roller 59, the yarn Y is guided into the gap between the rollers 59 and 60.
Tenth Embodiment
A tenth embodiment of the present invention will now be described referring to FIG. 39. This embodiment differs from the fourth to eighth embodiments in that the wall 45b of the recess 45 formed in the inner rotor 11 is almost parallel to the axial direction of the inner rotor 11 and that the diameter up to the wall 45b is set nearly the same as the diameter of the fiber collecting section 6a. In the spinning frame as shown in FIG. 39A, the inclination of the wall of the outer rotor 6 extending toward the retaining section 6b from the fiber collecting section 6a is smaller than that in the individual embodiments described above, and the fiber bundle F, which is drawn from the fiber collecting section 6a and moves along the wall of the outer rotor 6 and the wall 45b of the inner rotor 11, is drawn nearly horizontally toward the pin 46.
In the spinning frame as shown in FIG. 39B, the wall of the outer rotor 6 extending toward the retaining section 6b from the fiber collecting section 6a is formed nearly parallel to the axial direction of the outer rotor 6. The wall 45b of the inner rotor 11 is likewise formed to lie on a line extending from the wall of the outer rotor 6.
In either case, the tension applied to the fiber bundle F when the fiber bundle F moves to the position corresponding to the pin 46, becomes smaller than that in the case where the fiber bundle F is drawn toward the center of the outer rotor 6 directly from the fiber collecting section 6a.
Eleventh Embodiment
An eleventh embodiment of the present invention will now be described referring to FIG. 40. This embodiment differs from the tenth embodiment in that the distance from the center of the inner rotor 11 up to the restriction means which is provided on the inner rotor 11 to stop twisting is smaller than the radius of the fiber collecting section 6a. In the spinning frame as shown in FIG. 40A, the wall of the outer rotor 6 extending toward the retaining section 6b from the fiber collecting section 6a is formed to extend inward. The wall 45b is formed to extend almost in parallel to the axial direction of the inner rotor 11 from the position corresponding to the opening edge of the retaining section 6b. In the spinning frame as shown in FIG. 40B, the wall of the outer rotor 6 extending toward the retaining section 6b from the fiber collecting section 6a is formed nearly parallel to the axial direction of the outer rotor 6. The wall 45b of the inner rotor 11 is formed to extend inward.
In this embodiment also, the tension applied to the fiber bundle F when the fiber bundle F moves to the position corresponding to the pin 46, becomes smaller than that in the case where the fiber bundle F is drawn toward the center of the outer rotor 6 directly from the fiber collecting section 6a. As the pin 46 is positioned inward of the fiber collecting section 6a in this embodiment, the largest outside diameter of the inner rotor 11 can be set about the same as the diameter of the fiber collecting section 6a. Therefore, the outside diameter of the outer rotor 6 can be set about the same as the one in the first to third embodiments in which the fiber bundle F is drawn toward the center of the outer rotor 6 directly from the fiber collecting section 6a.
The present invention is not limited to the above-described embodiments, but may be modified in various other forms without departing from the spirit or scope of the invention. For instance, the introduce passage 38 in the second embodiment may be formed in such a manner that its opposite side to the yarn passage 36 is open as shown in FIG. 41. In the third embodiment, the distal end of the first contact member 41 may be formed to have a rough surface, or the distal end of the second contact member 42 may be formed to have a cone shape as shown in FIG. 42. This structure allows the yarn Y, introduced to the yarn passage 36 from the introduce passage 38, to come between both contact members 41 and 42 more easily.
Further, the pin 46 in the fourth embodiment may be designed to have a number of stripes 46b formed on its outer surface in the circumferential direction as shown in FIG. 43. The pin 48 used in the sixth embodiment or the cylinder 53 used in the seventh embodiment may be modified to have no groove 48a or 53a on its surface as shown in FIG. 44 or 45. The restricting action and twist stopping function will work even without the groove 48a or 53a.
A curved leaf spring may be attached to the wall 47 in place of the engaging section 47a in the fifth embodiment. With the use of the leaf spring, when the thickness of spinning yarn varies, the leaf spring bends to prevent excessive pressure from acting on the fiber bundle F.
The twist propagation preventing portion may be omitted in the first to third embodiments. Further, other suction means than the ejector 29 may be connected as a negative pressure generator to the yarn pipe. Furthermore, the ejector 29 is not essential and may thus be omitted.
The inner rotor may be designed to have a disk shape as shown in FIG. 47. The shape of pin is not limited to be linear, but may be curved.
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A rotor type open-end spinning frame spins a yarn from a fiber bundle formed from unraveled fibers at a fiber collecting section while applying a twist to the fiber bundle during normal spinning, and which pieces the fiber bundle to a standard thread supplied to the fiber collecting section during yarn piecing. The spinning frame has a rotatable outer rotor which has an inner wall with a fiber collecting section. A conduit member is fixed opposite the open-end of the outer rotor and induct the fiber bundle and the standard thread therethrough. An inner rotor is disposed coaxially to and rotatable in the outer rotor. The inner rotor rotates independently of the outer rotor during both normal spinning and yarn piecing. A passage in the inner rotor communicates with the conduit member and guides the fiber bundle from the fiber collecting section to the conduit member during yarn spinning. Another passage in the inner rotor communicates with the conduit member and introduces the standard thread into the fiber collecting section from the conduit member during yarn piecing. A restriction device in the inner rotor retains the fiber bundle within the first passage by engaging with the fiber bundle during yarn spinning.
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RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/EP2005/011257, filed Oct. 19, 2005, published in English, and claims priority under 35 U.S.C. §119 or §365 to European Application No. 04024967.4, filed Oct. 20, 2004.
FIELD OF THE INVENTION
The invention relates to a series of substituted 3-arylamino pyridine derivatives that are useful in the treatment of hyperproliferative diseases, such as cancer and inflammation, in mammals. Also disclosed is the use of such compounds in the treatment of hyperproliferative diseases in mammals, especially humans, and pharmaceutical compositions containing such compounds.
SUMMARY OF THE RELATED ART
The Ras/Raf/MEK/ERK pathway is a central signal transduction pathway, which transmits signals from multiple cell surface receptors to transcription factors in the nucleus which regulate gene expression. This pathway is frequently referred to as the MAP kinase pathway as MAPK stands for mitogen-activated protein kinase indicating that this pathway can be stimulated by mitogens, cytokines and growth factors (Steelman et al., Leukemia 2004, 18, 189-218). Depending upon the stimulus and cell type, this pathway can transmit signals, which result in the prevention or induction of apoptosis or cell cycle progression. The Ras/Raf/MEK/ERK pathway has been shown to play important roles in cell proliferation and the prevention of apoptosis. Aberrant activation of this pathway is commonly observed in malignantly transformed cells. Amplification of ras proto-oncogenes and activating mutations that lead to the expression of constitutively active Ras proteins are observed in approximately 30% of all human cancers (Stirewalt et al., Blood 2001, 97, 3589-95). Mutated, oncogenic forms of Ras are found in 50% of colon and >90% pancreatic cancers as well as many other types of cancers (Kohl et al., Science 1993, 260, 1934-1937). The effects of Ras on proliferation and tumorigenesis have been documented in immortal cell lines (McCubrey et al., Int J Oncol 1995, 7,295-310). bRaf mutations have been identified in more than 60%. of malignant melanoma (Davies. H et al., Nature 2002, 417, 949-954). Given the high level of mutations that have been detected at Ras, this pathway has always been considered a key target for therapeutic intervention (Chang et al., Leukemia 2003, 77,1263-93),
The Ras/Raf/MEK/ERK signaling pathway can exert proliferative or antiproliferative effects through downstream transcription factor targets including NF-κB, CREB, Ets-1, AP-1 and c-Myc. ERKs can directly phosphorylate Ets-1, AP-1 and c-Myc, which lead to their activation. Alternatively, ERKs can phosphorylate and activate a downstream kinase target RSK, which then phosphorylates and activates transcription factors, such as CREB. These transcription factors induce the expression of genes important for cell cycle progression, for example, Cdks, cyclins, growth factors, and apoptosis prevention, for example, antiapoptotic Bcl-2 and cytokines. Overall, treatment of cells with growth factors leads to the activation of ERKs which results in proliferation and, in some cases, differentiation (Lewis et al., Adv. Cancer Res, 1998, 74, 49-139).
MEK proteins are the primary downstream targets of Raf. The MEK family of genes consists of five genes: MEK1, MEK2, MEK3, MEK4 and MEK5. This family of dual-specificity kinases has both serine/threonine and tyrosine kinase activity. The structure of MEK consists of an amino-terminal negative regulatory domain and a carboxy-terminal MAP kinase-binding domain, which is necessary for binding and activation of ERKs. Deletion of the regulatory MEK1 domain results in constitutive MEK1 and ERK activation (Steelman et al., Leukemia 2004, 18, 189-218).
MEK1 is a 393-amino-acid protein with a molecular weight of 44 kDa (Crews et al., Science 1992, 258, 478-80). MEK1 is modestly expressed in embryonic development and is elevated in adult tissue with the highest levels detected in brain tissue. MEK1 requires phosphorylation of S218 and S222 for activation, and substitution of these residues with D or glutamic acid (E) led to an increase in activity and foci formation in NIH3T3 cells (Huang et al., Mol Biol Cell, 1995, 6, 237-45). Constitutive activity of MEK1 in primary cell culture promotes senescence and induces p53 and p16 INK4a , and the opposite was observed in immortalized cells or cells lacking either p53 or p16 INK4a (Lin et al., Genes Dev, 1998, 12, 3008-3019). Constitutive activity of MEK1 inhibits NF-κB transcription by negatively regulating p38 MAPK activity (Carter et al., J Biol C hem 2000, 275, 27858-64). The main physiological substrates of MEK are the members of the ERK (extracellular signal-regulated kinase) or MAPK (mitogen activated protein kinase) family of genes. Aberrant expression of MEK1 has been detected in many different types of cancer, and mutated forms of MEK1 will transform fibroblast, hematopoietic and other cell types.
Constitutive activation of MEK1 results in cellular transformation. It therefore represents a likely target for pharmacological intervention in proliferative and inflammatory diseases (Lee et al., Nature 1994, 372, 739-746; Dudley et al., Proc. Natl. Acad. Sci. U.S.A. 1995, 92, 7686-7689).
Useful inhibitors of MEK have been developed that show potential therapeutic benefit in several studies. For example, small molecule MEK inhibitors have been shown to inhibit human tumor growth in nude mouse xenografts (Yeh, T. et al, Proceedings of the American Association of Cancer Research 2004, 45, Abs 3889 and Lee, P. et al., Proceedings of the American Association of Cancer Research 2004, 45, Abs 3890). MEK inhibitors also entered clinical trials, i.e. ARRY142886 (Wallace, E. et al, Proceedings of the American Association of Cancer Research 2004, 45, Abs 3891), PD-0325901 (Swanton C, Johnston S IDDB MEETING REPORT 2003, February 13-1) and PD-184352 (Waterhouse et al., Proceedings of the American Society for Clinical Oncology 2003, 22, Abs 816).
Compounds suitable as MEK inhibitors are also disclosed in U.S. Pat. No. 5,525,625; WO 98/43960; WO 99/01421; WO 99/01426; WO 00/41505; WO 00/42002; WO 00/42003; WO 00/41994; WO 00/42022; WO 00/42029; WO 00/68201; WO 01/68619; WO 02/06213; WO 03/077855; WO03/077914; WO2004/005284; WO2004/056789.
However, PD-184352 was lacking efficacy in clinical phase II trials. Tumors were much less responsive, as no partial responses and only a few patients with stable disease were observed. As a result, the clinical trials of this molecule were suspended (McInnes C IDDB MEETING REPORT 2003). PD-184352 was limited by poor solubility, high metabolic clearance and low bioavailability. This exemplifies the need for novel MEK inhibitors with superior pharmacological properties.
DESCRIPTION OF THE INVENTION
In view of the foregoing it is the object of the present invention to provide novel MEK inhibitors useful in the treatment of hyperproliferative diseases related to the hyperactivity of MEK as well as diseases modulated by the MEK cascade, such as cancer and inflammation, in mammals with superior pharmacological properties both with respect to their activities as well as their solubility, metabolic clearance and bioavailability characteristics.
As a result, this invention provides novel, substituted 3-arylamino pyridine derivatives and pharmaceutically acceptable salts, solvates or prodrugs thereof, that are MEK inhibitors and useful in the treatment of the above mentioned diseases.
The compounds are defined by Formula (I):
a pharmaceutically acceptable salt, solvate or prodrug thereof,
wherein:
R 1 , R 2 , R 9 , R 10 , R 11 R 12 , R 13 and R 14 are independently selected from hydrogen, halogen, cyano, nitro, azido, —OR 3 , —C(O)R 3 , —C(O)OR 3 , —NR 4 C(O)OR 6 , —OC(O)R 3 , —NR 4 S(O) j R 6 , —S(O) j NR 3 R 4 , —S(O) j NR 4 C(O)R 3 , —C(O)NR 4 S(O) j R 6 , S(O) j R 6 , —NR 4 C(O)R 3 , —C(O)NR 3 R 4 , —NR 5 C(O)NR 3 R 4 , —NR 5 C(NCN)NR 3 R 4 , —NR 3 R 4 and C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, —S(O) j (C 1 -C 6 alkyl), —S(O) j (CR 4 R 5 ) m -aryl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, heterocyclylalkyl, —O(CR 4 R 5 ) m -aryl, —NR 4 (CR 4 R 5 ) m -aryl, —O(CR 4 R 5 ) m -heteroaryl, —NR 4 (CR 4 R 5 ) m , heteroaryl, —O(CR 4 R 5 ) m -heterocyclyl, —NR 4 (CR 4 R 5 ) m -heterocyclyl, and —S(C 1 -C 2 alkyl) substituted with 1 to 5 F, where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl are substituted or unsubstituted; R 3 is selected from hydrogen, trifluoromethyl, C 1 -C 10 alkyl, C 2-10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl is substituted or unsubstituted; R 4 is selected from hydrogen or C 1 -C 6 alkyl whereby alkyl may be substituted or unsubstituted; or R 3 and R 4 can be taken together with the atom to which they are attached to form a 4 to 10 membered heteroaryl or heterocyclic ring, each of which is substituted or unsubstituted; R 5 is selected from hydrogen or C 1 -C 6 alkyl whereby alkyl may be substituted or unsubstituted; or R 4 and R 5 can be taken together with the atom to which they are attached to form a 4 to 10 membered carbocyclic, heteroaryl or heterocyclic ring, each of which is substituted or unsubstituted; R 6 is selected from trifluoromethyl; and C 1 -C 10 alkyl, C 3 -C 10 cycloalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, where each alkyl, cycloalkyl, aryl, heteroaryl and heterocyclyl substituted or unsubstituted; W is selected from heteroaryl containing 1-4 heteroatoms or heterocyclyl containing 1-4 heteroatoms each of which is unsubstituted or substituted by 1 to 5 substituents ZR 15 ; or W is —C(O)OR 15 , —C(O)NR 4 R 15 , —C(O)NR 4 OR 15 , —C(O)(C 3 -C 10 cycloalkyl), —C(O)(C 2 -C 10 alkyl), —C(O)(aryl), —C(O)(heteroaryl), —C(O)(heterocyclyl), S(O) j NR 4 R 15 , S(O) j NR 4 OR 15 , —S(O) j NR 4 C(O)R 15 , —C(O)NR 4 S(O) j R 6 , —C(O)NR 4 NR 4 R 15 , —C(O)C(O)R 15 , —C(O)CR′R″C(O)R 15 , —NR′R″, —NR′C(O)R′, —NR′S(O) j R′, —NRC(O)NR′R″, NR′S(O) j NR′R″, or —C(O)NR 4 NR 4 C(O)R 15 ; Z is a bond, NR 16 , O, NR 16 SO 2 or S; R 15 is independently selected from hydrogen, trifluoromethyl, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl is substituted or unsubstituted; R 16 is selected from hydrogen or C 1 -C 10 alkyl, or R 15 and R 16 form together a 4 to 10 membered cyclic ring with 1 or 2 N atoms and optionally an O atom, said ring being substituted or unsubstituted; X is N or N→O; m is 0, 1, 2, 3, 4 or 5; and j is 1 or 2.
Preferred are compounds of Formula (II),
a pharmaceutically acceptable salt, solvate or prodrug thereof,
wherein:
R 1 , R 2 , R 9 , R 10 , R 11 R 12 , R 13 and R 14 are independently selected from hydrogen, halogen, cyano, nitro, azido, —OR 3 , —NR 4 C(O)OR 6 , —OC(O)R 3 , —NR 4 S(O) j R 6 , —S(O) j NR 3 R 4 , —S(O) j NR 4 C(O)R 3 , —C(O)NR 4 S(O) j R 6 , S(O) j R 6 , —NR 4 C(O)R 3 , —C(O)NR 3 R 4 , —NR 5 C(O)NR 3 R 4 , —NR 5 C(NCN)NR 3 R 4 , —NR 3 R 4 and C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, —S(O) j (C 1 -C 6 alkyl), —S(O) j (CR 4 R 5 ) m -aryl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, heterocyclylalkyl, —O(CR 4 R 5 ) m -aryl, —NR 4 (CR 4 R 5 ) m -aryl, —O(CR 4 R 5 ) m -heteroaryl, —NR 4 (CR 4 R 5 ) m , heteroaryl, —O(CR 4 R 5 ) m -heterocyclyl, —NR 4 (CR 4 R 5 ) m -heterocyclyl, and —S(C 1 -C 2 alkyl) substituted with 1 to 5 F, where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl are substituted or unsubstituted; R 3 is selected from hydrogen, trifluoromethyl, C 1 -C 10 alkyl, C 2-10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, where each alkyl, alkenyl, alkynyl, cycloalkyl, heteroaryl and heterocyclyl is substituted or unsubstituted; or aryl which is unsubstituted or substituted with 1 to 5 groups independently selected from oxo, halogen, nitro, CF 3 , CHF 2 , CH 2 F, OCF 3 , OCHF 2 , OCH 2 F, azido, N′SO 2 R″″, SO 2 NR″, C(O)R′, C(O)OR′, OC(O)R′, NR′C(O)OR″″, NR′C(O)R″, C(O)NR′R″, SR″″, S(O)R″″, SO 2 R′, NR′R″, NR″C(O)NR″R′″, NR′C(NCN)NR″R′″, OR′, aryl, heteroaryl, arylalkyl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl; R 4 is selected from hydrogen or C 1 -C 6 alkyl whereby alkyl may be substituted or unsubstituted; or R 3 and R 4 can be taken together with the atom to which they are attached to form a 4 to 10 membered heteroaryl or heterocyclic ring, each of which is substituted or unsubstituted; R 5 is selected from hydrogen or C 1 -C 6 alkyl whereby alkyl may be substituted or unsubstituted; or R 4 and R 5 can be taken together with the atom to which they are attached to form a 4 to 10 membered carbocyclic, heteroaryl or heterocyclic ring, each of which is substituted or unsubstituted; R 6 is selected from trifluoromethyl; and C 1 -C 10 alkyl, C 3 -C 10 cycloalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, where each alkyl, cycloalkyl, aryl, heteroaryl and heterocyclyl substituted or unsubstituted; R′, R″ and R′″ are independently selected from hydrogen, C 1 -C 4 alkyl, C 2 -C 4 alkenyl, aryl and arylalkyl; R″″ is selected from C 1 -C 4 alkyl, C 1 -C 4 alkenyl, aryl and arylalkyl; W is selected from heteroaryl containing 1-4 heteroatoms or heterocyclyl containing 1-4 heteroatoms each of which is unsubstituted or substituted by 1 to 5 substituents ZR 15 ; or W is —C(O)OR 15 , —C(O)NR 4 R 15 , —C(O)NR 4 OR 15 , —C(O)(C 3 -C 10 cycloalkyl), —C(O)(heterocyclyl), S(O) j NR 4 R 15 , S(O) j NR 4 OR 15 , —S(O) j NR 4 C(O)R 15 , —C(O)NR 4 S(O) j R 6 , —C(O)NR 4 NR 4 R 15 , —C(O)C(O)R 15 , —C(O)CR′R″C(O)R 15 , —NR′R″, —NR′C(O)R′, —NR′S(O) j R′, —NRC(O)NR′R″, NR′S(O) j NR′R″, or —C(O)NR 4 NR 4 C(O)R 15 ; and when W is C(O)OH, then R 1 , R 2 , R 12 , R 13 and R 14 are independently selected from hydrogen, halogen, cyano, nitro, azido, —NR 4 C(O)OR 6 , —OC(O)R 3 , —S—C 1 -C 2 alkyl substituted with 1 to 5 F, —NR 4 S(O) j R 6 , —S(O) j NR 3 R 4 , —S(O) j NR 4 C(O)R 3 , —C(O)NR 4 S(O) j R 6 , S(O) j R 6 , —NR 4 C(O)R 3 , —NR 5 C(O)NR 3 R 4 , —NR 5 C(NCN)NR 3 R 4 and C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, —S(O) j (C 1 -C 6 alkyl), —S(O) j (CR 4 R 5 ) m -aryl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, heterocyclylalkyl, —O(CR 4 R 5 ) m -aryl, —NR 4 (CR 4 R 5 ) m -aryl, —O(CR 4 R 5 ) m -heteroaryl, —NR 4 (CR 4 R 5 ) m , heteroaryl, —O(CR 4 R 5 ) m -heterocyclyl and —NR 4 (CR 4 R 5 ) m -heterocyclyl, where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl are substituted or unsubstituted; —NR 33 R 44 , C(O)NR 3 R 44 , or OR 33 , whereby R 33 is selected from hydrogen, CF 3 , CHF 2 , CH 2 F, C 2 -C 10 alkyl, C 2-10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, where each alkyl, alkenyl, alkynyl, cycloalkyl, heteroaryl and heterocyclyl is substituted or unsubstituted, and R 44 is selected from hydrogen, CF 3 , CHF 2 , CH 2 F and C 2 -C 6 alkyl; Z is a bond, NR 16 , O, NR 16 SO 2 or S. R 15 is independently selected from hydrogen, trifluoromethyl, C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl is substituted or unsubstituted; R 16 is selected from hydrogen or C 1 -C 10 alkyl, or R 15 and R 16 form together a 4 to 10 membered cyclic ring with 1 or 2 N atoms and optionally an O atom, said ring being substituted or unsubstituted; X is N or N→O; m is 0, 1, 2, 3, 4 or 5; and j is 1 or 2
In one embodiment the compounds as defined by Formula (II) do not include the following compounds:
3-(4-Methoxy-phenylamino)-isonicotinic acid, that has been described as an intermediate in the synthesis of benzonaphthyridine derivatives as anti-malarial agents,
3-Phenylamino-isonicotinic acid methyl ester, that has been described as an anti-allergic agent (Sherlock et al., J. Med. Chem. 1988, 31, 2108-21);
2,3,6-Trifluoro-5-phenylamino-isonicotinic acid, whose synthesis has been described (Orlova et al., Izvestiya Sibirskogo Otdeleniya Akademii Nauk SSSR, Seriya Khimicheskikh Nauk 1994, 6, 93-7; and
3-Oxo-3-(3-phenylamino-pyridin-4-yl)-propionic acid ethyl ester, that has been described as in intermediate in the synthesis of phenyl dihydro-naphthydrine derivatives for the treatment of diabetes and diabetes-related disorders.
In preferred embodiments, the variants have the following meanings:
R 1 is as defined above, preferably hydrogen, halo, C 1 -C 4 alkyl, C 3 -C 4 cycloalkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, cyano, nitro, OR 3 or NR 3 R 4 ; more preferably hydrogen, halo or C 1 -C 4 alkyl, still more preferably hydrogen or halo, most preferably hydrogen or F. In one embodiment, R 1 is hydrogen.
R 2 is as defined above, preferably hydrogen, halo, C 1 -C 4 alkyl, C 3 -C 4 cycloalkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, cyano, nitro, OR 3 or NR 3 R 4 ; more preferably hydrogen, halo or C 1 -C 2 alkyl, still more preferably halo or methyl, most preferably Cl, F or methyl. In one embodiment, R 2 is methyl. In another embodiment, methyl is preferably further substituted by 1, 2 or 3 fluorines, preferably 3 fluorines. Most preferably, R 2 is F.
R 9 is as defined above, preferably hydrogen, halo, C 1 -C 4 alkyl, C 3 -C 4 cycloalkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, cyano, nitro, OR 3 or NR 3 R 4 ; more preferably hydrogen, halo or C 1 -C 4 alkyl, still more preferably hydrogen, methyl or halo, most preferably hydrogen, methyl, Cl or F. In one embodiment, R 9 is hydrogen.
R 10 is as defined above, preferably hydrogen, halo, C 1 -C 10 alkyl, C 3 -C 10 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, cyano, nitro, azido; NR 4 SO 2 R 6 ; SO 2 NR 3 R 4 ; SO 2 R 6 ; C(O)NR 3 R 4 ; C(O)OR 3 ; —S(O) j NR 4 C(O)R 3 , —C(O)NR 4 S(O) j R 6 , OR 3 or NR 3 R 4 , more preferably hydrogen, halo, nitro, C 1 -C 4 alkyl, O—C 1 -C 4 alkyl, SO 2 NR 3 R 4 or C(O)NR 3 R 4 , still more preferably hydrogen F, Cl, Br, nitro, methyl, O-methyl, SO 2 NR 3 R 4 or C(O)NR 3 R 4 , most preferably hydrogen, F, Cl, Br, methyl or O-methyl. In one embodiment R 10 is hydrogen. In another embodiment, R 10 is methyl. In yet another embodiment, methyl is preferably further substituted by 1, 2 or 3 fluorines, preferably 3 fluorines. In preferred embodiments of R 10 , R 3 and R 4 are independently C 1 -C 6 alkyl, more preferably C 1 -C 4 alkyl, optionally substituted by 1 or 2 alkyl amino, dialkyl amino, amino, O-alkyl, hydroxy, or R 3 and R 4 form together a cyclic ring with 1 or 2 N atoms and optionally an O atom, said ring being optionally substituted by 1 or 2 alkyl amino, amino, hydroxy or O-alkyl.
R 11 is as defined above, preferably hydrogen, halo, C 1 -C 4 alkyl, C 3 -C 4 cycloalkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, cyano, nitro, OR 3 or NR 3 R 4 ; more preferably hydrogen, halo or C 1 -C 4 alkyl or O—C 1 -C 4 alkyl, still more preferably hydrogen, methyl, O-methyl or halo, most preferably hydrogen, methyl, Cl, Br or F. In one embodiment, R 11 is hydrogen. In another embodiment, R 11 is methyl. In yet another embodiment, methyl is preferably further substituted by 1, 2 or 3 fluorines, preferably 3 fluorines.
R 12 is as defined above, preferably hydrogen, halo, C 1 -C 10 alkyl, C 3 -C 10 cycloalkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, cyano, nitro, azido; NR 4 SO 2 R 6 ; SO 2 NR 3 R 4 ; SO 2 R 6 ; C(O)NR 3 R 4 ; C(O)OR 3 ; OR 3 , NR 3 R 4 or —S(C 1 -C 2 alkyl) substituted with 1 to 5 F, more preferably hydrogen, halo, nitro, C 1 -C 4 alkyl, O—C 1 -C 4 alkyl, SCF 3 , SCHF 2 , SCH 2 F, SO 2 NR 3 R 4 or C(O)NR 3 R 4 , still more preferably hydrogen, F, Cl, Br, nitro, methyl, O-methyl, SCF 3 , SCHF 2 , SCH 2 F, SO 2 NR 3 R 4 or C(O)NR 3 R 4 , most preferably hydrogen I, Cl, Br, SCF 3 , SCHF 2 , SCH 2 F, methyl or O-methyl. In one embodiment R 12 is hydrogen. In another embodiment, R 12 is methyl, SCF 3 , SCHF 2 , SCH 2 F or O-methyl, wherein methyl or O-methyl is preferably unsubstituted or further substituted by 1, 2 or 3 fluorines, preferably 2 or 3 fluorines. In preferred embodiments of R 12 , R 3 and R 4 are independently C 1 -C 6 alkyl, more preferably C 1 -C 4 alkyl, optionally substituted by 1 or 2 alkyl amino, dialkyl amino, amino, O-alkyl, hydroxy, or R 3 and R 4 form together a cyclic ring with 1 or 2 N atoms and optionally an O atom, said ring being optionally substituted by 1 or 2 alkyl amino, amino, hydroxy or O-alkyl. Most preferably, R 12 is Br or I.
R 13 is as defined above, preferably hydrogen, halo, C 1 -C 4 alkyl, C 3 -C 4 cycloalkyl, C 2 -C 4 alkenyl or C 2 -C 4 alkynyl, more preferably hydrogen, F, Cl or methyl, most preferably hydrogen or F. in one embodiment, R 13 is hydrogen.
R 14 is as defined above, preferably hydrogen, halo, C 1 -C 4 alkyl, C 3 -C 4 cycloalkyl, C 2 -C 4 alkenyl or C 2 -C 4 alkynyl, more preferably hydrogen, F, Cl or methyl, most preferably hydrogen or F. In one embodiment, R 14 is hydrogen.
As set forth above, the variants of each of R 1 , R 2 and R 9 to R 14 may be substituted. In this case they can be substituted with 1 to 5, preferably 1 to 3, more preferably 1 or 2 groups independently selected from oxo, halogen, cyano, nitro, CF 3 , CHF 2 , CH 2 F, OCF 3 , OCHF 2 , OCH 2 F, SCF 3 , SCHF 2 , SCH 2 F, azido, NR 4 SO 2 R 6 , SO 2 NR 3 R 4 , C(O)R 3 , C(O)OR 3 , OC(O)R 3 , NR 4 C(O)OR 6 , NR 4 C(O)R 3 , C(O)NR 3 R 4 , NR 3 R 4 , NR 5 C(O)NR 3 R 4 , NR 5 C(NCN)NR 3 R 4 , OR 3 , aryl, heteroaryl, arylalkyl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, preferably oxo, halogen, cyano, nitro, CF 3 , CHF 2 , CH 2 F, OCF 3 , OCHF 2 , OCH 2 F, SCF 3 , SCHF 2 , SCH 2 F, azido, NR 4 SO 2 R 6 , SO 2 NR 3 R 4 , C(O)R 3 , C(O)OR 3 , OC(O)R 3 , OR 3 , more preferably oxo, halogen, cyano, nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy or azido, most preferably halogen, cyano, nitro, CF 3 , CHF 2 , CH 2 F, OCF 3 , OCHF 2 , OCH 2 F, SCF 3 , SCHF 2 , SCH 2 F, OH, O-methyl, NH 2 or N(methyl) 2 .
R 3 is as defined above, preferably hydrogen, trifluoromethyl, C 1 -C 4 alkyl, G 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 3 -C 6 cycloalkyl, C 3 -C 6 cycloalkylalkyl, more preferably hydrogen or C 1 -C 4 alkyl most preferably hydrogen, methyl or ethyl.
R 4 is as defined above, preferably hydrogen or C 1 -C 4 alkyl, more preferably hydrogen, methyl or ethyl.
In one preferred embodiment, R 3 and R 4 can be taken together with the atom to which they are attached to form a 4 to 7, preferably 5 or 6, membered heteroaryl or heterocyclic ring.
R 5 is as defined above, preferably hydrogen or C 1 -C 4 alkyl, more preferably hydrogen, methyl or ethyl.
In one embodiment, R 4 and R 5 can be taken together with the atom to which they are attached to form a 4 to 7, preferably 5 or 6, membered carbocyclic, heteroaryl or heterocyclic ring.
R 6 is as defined above, preferably trifluoromethyl, C 1 -C 4 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 3 -C 6 cycloalkyl, C 3 -C 6 cycloalkylalkyl, more preferably C 1 -C 4 alkyl, most preferably methyl or ethyl.
As set forth above, the variants of each of R 3 , R 4 , R 5 , R 6 or the rings formed by R 3 and R 4 and R 4 and R 5 may be substituted. In this case they can be substituted with 1 to 5, preferably 1 to 3, more preferably 1 or 2 groups independently selected from oxo, halogen, cyano, nitro, CF 3 , CHF 2 , CH 2 F, OCF 3 , OCHF 2 , OCH 2 F, azido, NR′SO 2 R″″, SO 2 NR″, C(O)R′, C(O)OR′, OC(O)R′, NR′C(O)OR″″, NR′C(O)R′, C(O)NR′R″, SR″″, S(O)R″″, SO 2 R′, NR′R″, NR′C(O)NR″R″′, NR′C(NCN)NR″R″′, OR′, aryl, heteroaryl, arylalkyl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, preferably coxo, halogen, cyano, nitro, CF 3 , CHF 2 , CH 2 F, OCF 3 , OCHF 2 , OCH 2 F, azido, NR′SO 2 R″″, SO 2 NR″, C(O)R′, C(O)OR′, OC(O)R′, NR′C(O)OR″″, NR′C(O)R″, C(O)NR′R″, SR″″, S(O)R″″, SO 2 R′, NR′R″, NR′C(O)NR″R′″, NR′C(NCN)NR″R′″ or OR′ preferably oxo, halogen, cyano, nitro, CF 3 , CHF 2 , CH 2 F, OCF 3 , OCHF 2 , OCH 2 F, azido, SR″″, S(O)R″″, SO 2 R′, NR′R″ or OR, most preferably In one embodiment, R 3 is preferably oxo, halogen, nitro, trifluoromethyl, OH, O-methyl, NH 2 or N(methyl) 2 .
R′ is selected from hydrogen, C 1 -C 4 alkyl, C 2 -C 4 alkenyl, aryl and arylalkyl, preferably hydrogen or C 1 -C 4 alkyl, more preferably hydrogen or methyl.
R″ is selected from hydrogen, C 1 -C 4 alkyl, C 2 -C 4 alkenyl, aryl and arylalkyl, preferably hydrogen or C 1 -C 4 alkyl, more preferably hydrogen or methyl.
R′″ is selected from hydrogen, C 1 -C 4 alkyl, C 2 -C 4 alkenyl, aryl and arylalkyl, preferably hydrogen or C 1 -C 4 alkyl, more preferably hydrogen or methyl.
R″″ is selected from C 1 -C 4 alkyl, C 1 -C 4 alkenyl, aryl and arylalkyl, preferably C 1 -C 4 alkyl, more preferably methyl.
Alternatively, any two of R′, R″, R′″ or R″″ can be taken together with the atom to which they are attached to form a 4 to 10 membered carbocyclic, heteroaryl or heterocyclic ring, each of which is optionally substituted with one to three groups independently selected from halogen, cyano; nitro, CF 3 , CHF 2 , CH 2 F, OCF 3 , OCHF 2 , OCH 2 F, azido, aryl, heteroaryl, arylalkyl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, preferably halogen, cyano; nitro, trifluoromethyl, difluoromethoxy, trifluoromethoxy and azido.
W is as defined above, preferably heteroaryl containing 1, 2 or 3 heteroatoms, or heterocyclyl containing 1, 2, or 3 heteroatoms, more preferably heteroaryl, each of which is unsubstituted or substituted by 1 to 5, preferably 1 to 3, more preferably 1, substituents ZR 15 , or W is —C(O)OR 15 , —C(O)NR 4 R 15 , —C(O)NR 4 OR 15 , —C(O)(C 3 -C 10 cycloalkyl), —C(O)(C 2 -C 10 alkyl), —S(O) j NR 4 C(O)R 15 , —C(O)NR 4 S(O) j R 6 , S(O) j NR 4 R 15 or S(O) j NR 4 OR 15 , more preferably W is heteroaryl containing 1, 2, or 3, specifically 2 or 3 N atoms, C(O)NR 4 OR 15 or S(O) 2 NR 4 OR 15 .
When W is heteroaryl, it is preferably
where Z and R 15 are as defined above, preferably Z is a bond, NR 16 , NR 16 SO 2 or O, more preferably NR 16 , wherein R 16 is as defined above, preferably hydrogen or C 1 -C 4 alkyl, more preferably hydrogen. R 15 is preferably selected from hydrogen, C 1 -C 4 alkyl, C 1 -C 4 alkenyl, C 4 -C 8 cycloalkylalkyl, each may contain 1 N atom optionally an O atom, where alkyl, alkenyl or cycloalkylalkyl may be further substituted by 1 or 2 of OH, O—C 1 -C 4 alkyl or NR′R″, where R′ and R″ are independently hydrogen or C 1 -C 4 alkyl where R′ and R″ form a 3 to 7 membered ring with 1 or 2 N atoms and optionally an O atom. Alternatively, R 16 and R 15 may form together a 4 to 10 membered cyclic ring with 1 or 2 N atoms and optionally an O atom, said ring being optionally substituted by 1 or 2 alkyl amino, amino, hydroxy or O-alkyl. More preferably R 15 is C 1 -C 4 alkyl or C 1 -C 4 alkenyl optionally substituted with 1 substitutent OH, O-Me, NH 2 , N(methyl) 2 or N(ethyl) 2 .
Y is O or NR′, preferably O.
Alternatively, W is preferably —C(O)OR 15 , —C(O)NR 4 R 15 , —C(O)NR 4 OR 15 , S(O) j NR 4 R 15 or S(O) j NR 4 OR 15 , more preferably —C(O)NR 4 OR 15 or S(O) 2 NR 4 OR 15 . In these cases R 15 is preferably as defined below.
According to Formula (II), when W is C(O)OH, then R 1 , R 2 , R 12 , R 13 and R 14 are independently selected from hydrogen, halogen, cyano, nitro, azido, —NR 4 C(O)OR 6 , —OC(O)R 3 , —NR 4 S(O) j R 6 , —S(O) j NR 3 R 4 , —S(O) j NR 4 C(O)R 3 , —C(O)NR 4 S(O) j R 6 , S(O) j R 6 , —NR 4 C(O)R 3 , —NR 5 C(O)NR 3 R 4 , —NR 5 C(NCN)NR 3 R 4 and C 1 -C 10 alkyl, C 2 -C 10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, —S(O) j (C 1 -C 6 alkyl), —S(O) j (CR 4 R 5 ) m -aryl, aryl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, heterocyclylalkyl, —O(CR 4 R 5 ) m -aryl, —NR 4 (CR 4 R 5 ) m -aryl, —O(CR 4 R 5 ) m -heteroaryl, —NR 4 (CR 4 R 5 ) m , heteroaryl, —O(CR 4 R 5 ) m -heterocyclyl, —NR 4 (CR 4 R 5 ) m -heterocyclyl and —S(C 1 -C 2 alkyl) substituted with 1 to 5 F, where each alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl and heterocyclyl are unsubstituted or substituted as set forth above; —NR 33 R 44 , C(O)NR 3 R 44 , or OR 33 , whereby R 33 is selected from hydrogen, CF 3 , CHF 2 , CH 2 F, C 2 -C 10 alkyl, C 2-10 alkenyl, C 2 -C 10 alkynyl, C 3 -C 10 cycloalkyl, C 3 -C 10 cycloalkylalkyl, arylalkyl, heteroaryl, heteroarylalkyl, heterocyclyl, and heterocyclylalkyl, where each alkyl, alkenyl, alkynyl, cycloalkyl, heteroaryl and heterocyclyl is unsubstituted or substituted, and R 44 is selected from hydrogen, CF 3 , CHF 2 , CH 2 F and C 2 -C 6 alkyl. In this case, preferred embodiments of R 1 , R 2 , R 12 , R 13 and R 14 are as described above, and R 33 is preferably selected from hydrogen, CF 3 , CHF 2 , CH 2 F, C 2 -C 4 alkyl and C 2-10 alkenyl, and R 44 is selected from hydrogen, CF 3 , CHF 2 , CH 2 F and C 2 -C 4 alkyl.
Z is as defined above, preferably a bond, NR 16 , NR 16 SO 2 or O, more preferably NR 16 .
R 15 is as defined above, preferably hydrogen, C 1 -C 4 alkyl, C 1 -C 4 alkenyl, C 4 -C 6 cycloalkylalkyl, more preferably C 1 -C 4 alkyl or C 1 -C 4 alkenyl, yet more preferably C 1 -C 4 alkyl. Alkyl or alkenyl may be further substituted with 1 to 5, preferably 1, 2 or 3, more preferably 1 or 2, substituents selected from OR 3 or NR′R″ wherein R 3 is selected from hydrogen, C 1 -C 4 alkyl or C 1 -C 4 alkenyl, C 4 -C 6 cycloalkylalkyl, more preferably hydrogen, methyl or ethyl, and where R′ and R″ are independently hydrogen or C 1 -C 4 alkyl, more preferably hydrogen, methyl or ethyl, still more preferably both R′ and R″ are methyl. Yet more preferably, R 15 may be substituted by 1 or 2 of OH, O—C 1 -C 4 alkyl or NR′R″.
Most preferably, R 15 is C 1 -C 4 alkyl or C 1 -C 4 alkenyl optionally substituted with 1 substitutent OH, O-Me, NH 2 , N(methyl) 2 or N(ethyl) 2 .
R 16 is as defined above, preferably hydrogen or C 1 -C 4 alkyl, more preferably hydrogen.
Alternatively, R 16 and R 15 may form together a 4 to 10, preferably 5 to 6, membered cyclic ring with 1 or 2 N atoms and optionally an O atom, said ring being optionally substituted by 1 or 2 alkyl amino, amino, hydroxy or O-alkyl.
X is as defined above. In one embodiment X is N, in another embodiment X is N→O.
m is as defined above, preferably 0, 1, 2 or 3, more preferably 0, 1 or 2, most preferably 1.
j is as defined above, preferably 2.
In the above, any of the preferred definitions for each variant can be combined with the preferred definition of the other variants.
The combinations as set forth in the claims are particularly preferred.
In the above and the following, the employed terms have independently the meaning as described below:
Aryl is an aromatic mono- or polycyclic moiety with preferably 6 to 20 carbon atoms which is preferably selected from phenyl, biphenyl, naphthyl, tetrahydronaphthyl, fluorenyl, indenyl or phenanthrenyl, more preferably phenyl or naphthyl.
Heteroaryl is an aromatic moiety having 6 to 20 carbon atoms with at least one ring containing a heteroatom selected from O, N and/or S, or heteroaryl is an aromatic ring containing at least one heteroatom selected from O, N and/or S and 1 to 6 carbon atoms. Preferably, heteroaryl contains 1 to 4, more preferably 1, 2 or 3 heteroatoms selected from O and/or N and is preferably selected from pyridinyl, imidazolyl, pyrimidinyl, pyrazolyl, triazolyl, pyrazinyl, tetrazolyl, furyl, thienyl, isoxazolyl, thiazolyl, oxazolyl, isothiazolyl, pyrrolyl, quinolinyl, isoquinolinyl, indolyl, benzimidazolyl, benzofuranyl, cinnolinyl, indazolyl, indolizinyl, phthalazinyl, pyridazinyl, triazinyl, isoindolyl, pteridinyl, purinyl, oxadiazolyl, triazolyl, thiadiazolyl, thiadiazolyl, furazanyl, benzofurazanyl, benzothiophenyl, benzothiazolyl, benzoxazolyl, quinazolinyl, quinoxalinyl, naphthyridinyl, and furopyridinyl. Spiro moieties are also included within the scope of this definition. Preferred heteroaryl include pyridinyl, imidazolyl, pyrimidinyl, pyrazolyl, triazolyl, pyrazinyl, tetrazolyl, isoxazolyl, oxazolyl, isothiazolyl, oxadiazolyl, triazolyl. Heteroaryl groups are optionally mono-, di-, or trisubstituted with, e.g., halogen, lower alkyl, lower alkoxy, haloalkyl, aryl, heteroaryl, and hydroxy.
Heterocyclyl is a saturated or unsaturated ring containing at least one heteroatom selected from O, N and/or S and 1 to 6 carbon atoms. Preferably, heterocyclyl contains 1 to 4, more preferably 1, 2 or 3 heteroatoms selected from O and/or N and is preferably selected from pyrrolidinyl, tetrahydrofuranyl, dihydrofuranyl, tetrahydrothienyl, tetrahydropyranyl, dihydropyranyl, tetrahydrothiopyranyl, piperidino, morpholino, thiomorpholino, thioxanyl, piperazinyl, homopiperazinyl, azetidinyl, oxetanyl, thietanyl, homopiperidinyl, oxepanyl, thiepanyl, oxazepinyl, diazepinyl, thiazepinyl, 1,2,3,6-tetrahydropyridinyl, 2-pyrrolinyl, 3-pyrrolinyl, indolinyl, 2H-pyranyl, 4H-pyranyl, dioxanyl, 1,3-dioxolanyl, pyrazolinyl, dithianyl, dithiolanyl, dihydropyranyl, dihydrothienyl, dihydrofuranyl, pyrazolidinylimidazolinyl, imidazolidinyl, azetidin-2-one-1-yl, pyrrolidin-2-one-1-yl, piperid-2-one-1-yl, azepan-2-one-1-yl, 3-azabicyco[3.1.0]hexanyl, 3-azabicyclo[4.1.0]heptanyl, azabicyclo[2.2.2]hexanyl, 3H-indolyl and quinolizinyl. Spiromoieties are also included within the scope of this definition.
Carbocyclyl is a monocyclic or polycyclic ring system of 3 to 20 carbon atoms which may be saturated, unsaturated or aromatic.
Alkyl is a saturated hydrocarbon moiety, namely straight chain or branched alkyl having 1 to 10, preferably 1 to 8 carbon atoms, more preferably 1 to 4 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, isopentyl, neopentyl, hexyl or heptyl.
Cycloalkyl is an alkyl ring having 3 to 10, preferably 3 to 8 carbon atoms, more preferably 3 to 6 carbon atoms, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl.
Alkenyl is an unsaturated hydrocarbon moiety with one or more double bonds, preferably one double bond, namely straight chain or branched alkenyl having 1 to 10, preferably 2 to 8 carbon atoms, more preferably 2 to 4 atoms, such as vinyl, allyl, methallyl, buten-2-yl, buten-3-yl, penten-2-yl, penten-3-yl, penten-4-yl, 3-methyl-but-3-enyl, 2-methyl-but-3-enyl, 1-methyl-but-3-enyl, hexenyl or heptenyl.
Alkynyl is an unsaturated hydrocarbon moiety with one or more triple bonds, preferably one triple bond, namely straight chain or branched alkynyl having 1 to 10, preferably 2 to 8 carbon atoms, more preferably 2 to 4 atoms, such as ethynyl, propynyl, butyn-2-yl, butyn-3-yl, pentyn-2-yl, pentyn-3-yl, pentyn-4-yl, 2-methyl-but-3-ynyl, 1-methyl-but-3-ynyl, hexynyl or heptynyl.
Halo or halogen is a halogen atom preferably selected from F, Cl, Br and I, preferably F, Cl and Br.
In the definitions cycloalkylalkyl, arylalkyl, heretoarylalkyl and heterocyclylalkyl it is contemplated that cycloalkyl, aryl, heretoaryl and heterocyclyl are bonded via an alkylene moiety. This alkylene moiety may be a straight chain or branched chain group. Said alkylene moiety preferably has 1 to 6 carbon atoms. Examples thereof include methylene, ethylene, n-propylene, n-butylene, n-pentylene, n-hexylene, iso-propylene, sec.-butylene, tert.-butylene, 1,1-dimethyl propylene, 1,2-dimethyl propylene, 2,2-dimethyl propylene, 1,1-dimethyl butylene, 1,2-dimethyl butylene, 1,3-dimethyl butylene, 2,2-dimethyl butylene, 2,3-dimethyl butylene, 3,3-dimethyl butylene, 1-ethyl butylene, 2-ethyl butylene, 3-ethyl butylene, 1-n-propyl propylene, 2-n-propyl propylene, 1-iso-propyl propylene, 2-iso-propyl propylene, 1-methyl pentylene, 2-methyl pentylene, 3-methyl pentylene and 4-methyl pentylene. More preferably, said alkylene moiety has 1 to 3 carbon atoms, such as methylene, ethylene, n-propylene and iso-propylene. Most preferred is methylene.
“Carboxy refers to the group —C(O)OR, where R includes hydrogen or “C 1 -C 6 -alkyl”.
“Acyl” refers to the group —C(O)R where R includes “C 1 -C 6 -alkyl”, “aryl”, “heteroaryl”, “C 3 -C 8 -cycloalkyl”, “C 3 -C 8 -heterocycloalkyl”, “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”. “Acyloxy” refers to the group —OC(O)R where R includes “C 1 -C 6 -alkyl”, “aryl”, “hetero-aryl”, “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”.
“Aryl acyl” refers to aryl groups having an acyl substituent, including 2-acetylphenyl and the like.
“Heteroaryl acyl” refers to heteroaryl groups having an acyl substituent, including 2-acetylpyridyl and the like.
“Alkoxy” refers to the group —O—R where R includes “C 1 -C 6 -alkyl”, “C 2 -C 6 -alkenyl”, “C 2 -C 6 -alkynyl”, “C 3 -C 8 -cycloalkyl”, “Heterocycloalkyl”, “heterocycloalkyl”, “aryl”, “heteroaryl”, “C 2 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”, “C 2 -C 6 -alkenyl aryl”, “C 2 -C 6 -alkenyl heteroaryl”, “C 2 -C 6 -alkynyl aryl”, “C 2 -C 6 -alkynylheteroaryl”, “C 1 -C 6 -alkyl cycloalkyl”, “C 1 -C 6 -alkyl heterocycloalkyl”. Preferred alkoxy groups include by way of example, methoxy, ethoxy, phenoxy and the like.
“Alkoxycarbonyl” refers to the group C(O)OR where R includes “C 1 -C 6 -alkyl” or “aryl” or “heteroaryl” or “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”.
“Alkoxycarbonylamino” refers to the group —NR′C(O)OR where R includes “C 1 -C 6 -alkyl” or “aryl” or “heteroaryl” or “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl” a and R′ includes hydrogen or “C 1 -C 6 -alkyl
“Aminocarbonyl” refers to the group C(O)NRR′ where each R, R′ includes independently hydrogen or C 1 -C 6 -alkyl or aryl or heteroaryl or “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl hetero-aryl”.
“Acylamino” refers to the group —NR(CO)R′ where each R. R′ is independently hydrogen or “C 1 -C 6 -alkyl” or “aryl” or “heteroaryl” or “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”.
“Sulfonyloxy” refers to a group —OSO 2 —R wherein R is selected from H, “C 1 -C 6 -alkyl”, “C 1 -C 6 -alkyl” substituted with halogens, e.g., an —OSO 2 —CF 3 group, “C 2 -C 6 -alkenyl”, “C 2 -C 6 -alkynyl”, “C 3 -C 8 -cycloalkyl”, “heterocycloalkyl”, “aryl”, “heteroaryl”, “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”, “C 2 -C 6 -alkenyl aryl”, “C 2 -C 6 -alkenyl heteroaryl”, “C 2 -C 6 -alkynyl aryl”, “C 2 -C 6 -alkynylheteroaryl”, “C 1 -C 6 -alkyl cycloalkyl”, “C 1 -C 6 -alkyl heterocycloalkyl”.
“Sulfonyl” refers to group “—SO 2 —R” wherein R is selected from H, “aryl”, “heteroaryl”, “C 1 -C 6 -alkyl”, “C 1 -C 6 -alkyl” substituted with halogens, e.g., an —SO 2 —CF 3 group, “C 2 -C 6 -alkenyl”, “C 2 -C 6 -alkynyl”, “C 3 -C 8 -cycloalkyl”, “heterocycloalkyl”, “aryl”, “heteroaryl”, “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”, “C 2 -C 6 -alkenyl aryl”, “C 2 -C 6 -alkenyl heteroaryl”, “C 2 -C 6 -alkynyl aryl”, “C 2 -C 6 -alkynylheteroaryl”, “C 1 -C 6 -alkyl cycloalkyl”, “C 1 -C 6 -alkyl heterocycloalkyl”.
“Sulfinyl” refers to a group “—(O)—R” wherein R is selected from H, “C 1 -C 6 -alkyl”, “C 1 -C 6 -alkyl” substituted with halogens, e.g., an —SO—CF 3 group, “C 2 -C 6 -alkenyl”, “C 2 -C 6 -alkynyl”, “C 3 -C 8 -cycloalkyl”, “Heterocycloalkyl”, “heterocycloalkyl” 3 , “aryl”, “heteroaryl”, “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”, “C 2 -C 6 -alkenyl aryl”, “C 2 -C 6 -alkenyl heteroaryl”, “C 2 -C 6 -alkynyl aryl”, “C 2 -C 6 -alkynylheteroaryl”, “C 1 -C 6 -alkyl cycloalkyl”, “C 1 -C 6 -alkyl heterocycloalkyl”.
“Sulfanyl” refers to groups —S—R where R includes H, “C 1 -C 6 -alkyl”, “C 1 -C 6 -alkyl” optionally substituted with halogens., e.g a —S—CF 3 group, “C 2 -C 6 -alkenyl”, “C 2 -C 6 -alkynyl”, “C 3 -C 8 -cycloalkyl”, “heterocycloalkyl”, “aryl”, “heteroaryl”, “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”, “C 2 -C 6 -alkenyl aryl”, “C 2 -C 6 -alkenyl heteroaryl”, “C 2 -C 6 -alkynyl aryl”, “C 2 -C 6 -alkynylheteroaryl”, “C 1 -C 6 -alkyl cycloalkyl”, “C 1 -C 6 -alkyl heterocycloalkyl”. Preferred sulfanyl groups include methylsulfanyl, ethylsulfanyl, and the like.
“Sulfonylamino” refers to a group —NRSO 2 —R′ where each R, R′ includes independently hydrogen, “C 1 -C 6 -alkyl”, “C 2 -C 6 -alkenyl”, “C 2 -C 6 -alkynyl”, “C 3 -C 8 -cycloalkyl”, “heterocycloalkyl”, “aryl”, “heteroaryl”, “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”, “C 2 -C 6 -alkenyl aryl”, “C 2 -C 6 -alkenyl heteroaryl”, “C 2 -C 6 -alkynyl aryl”, “C 2 -C 6 -alkynylheteroaryl”, “C 1 -C 6 -alkyl cycloalkyl”, “C 1 -C 6 -alkyl heterocycloalkyl”.
“Aminosulfonyl” refers to a group —SO 2 —NRR′ where each R, R′ includes independently hydrogen, “C 1 -C 6 -alkyl”, “C 2 -C 6 -alkenyl”, “C 2 -C 6 -alkynyl”, “C 3 -C 8 -cycloalkyl”, “heterocycloalkyl”, “aryl”, “heteroaryl”, “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”, “C 2 -C 6 -alkenyl aryl”, “C 2 -C 6 -alkenyl heteroaryl”, “C 2 -C 6 -alkynyl aryl”, “C 2 -C 6 -alkynylheteroaryl”, “C 1 -C 6 -alkyl cycloalkyl”, “C 1 -C 6 -alkyl heterocycloalkyl”.
“Amino” refers to the group —NRR′ where each R, R′ is independently hydrogen, “C 1 -C 6 -alkyl”, “C 2 -C 6 -alkenyl”, “C 2 -C 6 -alkynyl”, “C 3 -C 8 -cycloalkyl”, “Heterocycloalkyl”, “heterocycloalkyl”, “aryl”, “heteroaryl”, “C 1 -C 6 -alkyl aryl” or “C 1 -C 6 -alkyl heteroaryl”, “C 2 -C 6 -alkenyl aryl”, “C 2 -C 6 -alkenyl heteroaryl”, “C 2 -C 8 -alkynyl aryl”, “C 2 -C 6 -alkynylheteroaryl”, “C 1 -C 6 -alkyl cycloalkyl”, “C 1 -C 6 -alkyl heterocycloalkyl”, and where R and R′, together with the nitrogen atom to which they are attached, can optionally form a 3-8-membered hetero-cycloalkyl ring.
“Substituted or unsubstituted”: Unless otherwise constrained by the definition of the individual substituent, the above set out groups, like “alkyl”, “alkenyl”, “alkynyl”, “alkoxy”, “aryl” and “heteroaryl” etc. groups can optionally be independently substituted with from 1 to 5 substituents selected from the group consisting of “C 1 -C 6 -alkyl”, “C 1 -C 6 -alkyl aryl”, “C 1 -C 6 -alkyl heteroaryl”, “C 2 -C 6 -alkenyl”, “C 2 -C 6 -alkynyl”, primary, secondary or tertiary amino groups or quaternary ammonium moieties, “acyl”, “acyloxy”, “acylamino”, “aminocarbonyl”, “alkoxycarbonylamino”, “alkoxycarbonyl”, “aryl”, “aryloxy”, “heteroaryl”, “heteroaryloxy”, carboxyl, cyano, halogen, hydroxy, nitro, sulfanyl, sulphoxy, sulphonyl, sulfonamide, alkoxy, thioalkoxy, trihalomethyl and the like. Within the framework of this invention, said “substitution” is meant to also comprise situations where neighboring substituents undergo ring closure, in particular when vicinal functional substituents are involved, thus forming e.g. lactams, lactons, cyclic anhydrides, but also acetals, thioacetals, animals formed by ring closure for instance in an effort to obtain a protective group.
Compounds according to formula (I) include in particular those of the group consisting of:
Preferred embodiments of the compounds according to present invention are shown in scheme 1.
The compounds of the present invention can be in the form of a prodrug compound. “Prodrug compound” means a derivative that is converted into a compound according to the present invention by a reaction with an enzyme, gastric acid or the like under a physiological condition in the living body, e.g. by oxidation, reduction, hydrolysis or the like, each of which is carried out enzymatically. Examples of the prodrug are compounds, wherein the amino group in a compound of the present invention is acylated, alkylated or phosphorylated to form, e.g., eicosanoylamino, alanylamino, pivaloyloxymethylamino or wherein the hydroxyl group is acylated, alkylated, phosphorylated or converted into the borate, e.g. acetyloxy, palmitoyloxy, pivaloyloxy, succinyloxy, fumaryloxy, alanyloxy or wherein the carboxyl group is esterified or amidated. These compounds can be produced from compounds of the present invention according to well-known methods. Other examples of the prodrug are compounds, wherein the carboxylate in a compound of the present invention is for example converted into an alkyl-, aryl-, choline-, amino, acyloxymethylester, linolenoyl-ester.
Metabolites of compounds of the present invention are also within the scope of the present invention.
Where tautomerism, like e.g. keto-enol tautomerism, of compounds of the present invention or their prodrugs may occur, the individual forms, like e.g. the keto and enol form, are claimed separately and together as mixtures in any ratio. Same applies for stereoisomers, like e.g. enantiomers, cis/trans isomers, conformers and the like.
If desired, isomers can be separated by methods well known in the art, e.g. by liquid chromatography. Same applies for enantiomers by using e.g. chiral stationary phases. Additionally, enantiomers may be isolated by converting them into diastereomers, i.e. coupling with an enantiomerically pure auxiliary compound, subsequent separation of the resulting diastereomers and cleavage of the auxiliary residue. Alternatively, any enantiomer of a compound of the present invention may be obtained from stereoselective synthesis using optically pure starting materials.
The compounds of the present invention can be in the form of a pharmaceutically acceptable salt or a solvate. The term “pharmaceutically acceptable salts” refers to salts prepared from pharmaceutically acceptable non-toxic bases or acids, including inorganic bases or acids and organic bases or acids. In case the compounds of the present invention contain one or more acidic or basic groups, the invention also comprises their corresponding pharmaceutically or toxicologically acceptable salts, in particular their pharmaceutically utilizable salts. Thus, the compounds of the of the present invention which contain acidic groups can be present on these groups and can be used according to the invention, for example, as alkali metal salts, alkaline earth metal salts or as ammonium salts. More precise examples of such salts include sodium salts, potassium salts, calcium salts, magnesium salts or salts with ammonia or organic amines such as, for example, ethylamine, ethanolamine, triethanolamine or amino acids. Compounds of the present invention which contain one or more basic groups, i.e. groups which can be protonated, can be present and can be used according to the invention in the form of their addition salts with inorganic or organic acids. Examples for suitable acids include hydrogen chloride, hydrogen bromide, phosphoric acid, sulfuric acid, nitric acid, methanesulfonic acid, p-toluenesulfonic acid, naphthalenedisulfonic acids, oxalic acid, acetic acid, tartaric acid, lactic acid, salicylic acid, benzoic acid, formic acid, propionic acid, pivalic acid, diethylacetic acid, malonic acid, succinic acid, pimelic acid, fumaric acid, maleic acid, malic acid, sulfaminic acid, phenylpropionic acid, gluconic acid, ascorbic acid, isonicotinic acid, citric acid, adipic acid, and other acids known to the person skilled in the art. If the compounds of the present invention simultaneously contain acidic and basic groups in the molecule, the invention also includes, in addition to the salt forms mentioned, inner salts or betaines (zwitterions). The respective salts can be obtained by customary methods which are known to the person skilled in the art like, for example by contacting these with an organic or inorganic acid or base in a solvent or dispersant, or by anion exchange or cation exchange with other salts. The present invention also includes all salts of the compounds of the present invention which, owing to low physiological compatibility, are not directly suitable for use in pharmaceuticals but which can be used, for example, as intermediates for chemical reactions or for the preparation of pharmaceutically acceptable salts.
Furthermore, the present invention provides pharmaceutical compositions comprising a compound of the present invention, or a prodrug compound thereof, or a pharmaceutically acceptable salt or solvate thereof as active ingredient together with a pharmaceutically acceptable carrier.
“Pharmaceutical composition” means one or more active ingredients, and one or more inert ingredients that make up the carrier, as well as any product which results, directly or indirectly, from combination, complexation or aggregation of any two or more of the ingredients, or from dissociation of one or more of the ingredients, or from other types of reactions or interactions of one or more of the ingredients. Accordingly, the pharmaceutical compositions of the present invention encompass any composition made by admixing a compound of the present invention and a pharmaceutically acceptable carrier.
A pharmaceutical composition of the present invention may additionally comprise one or more other compounds as active ingredients like one or more additional compounds of the present invention, or a prodrug compound or other MEK inhibitors.
The compositions include compositions suitable for oral, rectal, topical, parenteral (including subcutaneous, intramuscular, and intravenous), ocular (ophthalmic), pulmonary (nasal or buccal inhalation), or nasal administration, although the most suitable route in any given case will depend on the nature and severity of the conditions being treated and on the nature of the active ingredient. They may be conveniently presented in unit dosage form and prepared by any of the methods well-known in the art of pharmacy.
In one embodiment, said compounds and pharmaceutical composition are for the treatment of cancer such as brain, lung, squamous cell, bladder, gastic, pancreatic, breast, head, neck, renal, kidney, ovarian, prostate, colorectal, oesohageal, testicular, gynecological or thyroid cancer. In another embodiment, said pharmaceutical composition is for the treatment of a noncancerous hyperproliferative disorder such as benign hyperplasia of the skin (e.g., psoriasis), restenosis, or prostate (e.g. benign prostatic hypertrophy (BPH)).
The invention also relates to the use of compounds according to formula (I) or formula (II) for the preparation of a medicament for the treatment of hyperproliferative diseases related to the hyperactivity of MEK as well as diseases modulated by the MEK cascade in mammals, or disorders mediated by aberrant proliferation, such as cancer.
The invention also relates to a compound or pharmaceutical composition for the treatment of pancreatitis or kidney disease (including proliferative glomerulonephritis and diabetes induced renal disease) or pain in a mammal which comprises a therapeutically effective amount of a compound of the present invention, or a pharmaceutically acceptable salt, prodrug or hydrate thereof, and a pharmaceutically acceptable carrier. The invention also relates to a compound or pharmaceutical composition for the prevention of blastocyte implantation in a mammal which comprises a therapeutically effective amount of a compound of the present invention, or a pharmaceutically acceptable salt, prodrug or hydrate thereof, and a pharmaceutically acceptable carrier. The invention also relates to a compound or pharmaceutical composition for treating a disease related to vasculogenesis or angiogenesis in a mammal which comprises a therapeutically effective amount of a compound of the present invention, or a pharmaceutically acceptable salt, prodrug or hydrate thereof, and a pharmaceutically acceptable carrier.
In one embodiment, said compound or pharmaceutical composition is for treating a disease selected from the group consisting of tumor angiogenesis, chronic inflammatory disease such as rheumatoid arthritis, inflammatory bowel disease, atherosclerosis, skin diseases such as psoriasis, excema, and sclerodema, diabetes, diabetic retinopathy, retinopathy of prematurity, age-related macular degeneration, hemangicma, glioma, melanoma, Kaposi's sarcoma and ovarian, breast, lung, pancreatic, prostate, colon and epidermoid cancer.
The invention also relates to of the use for treating a hyperproliferative disorder in a mammal that comprises administering to said mammal a therapeutically effective amount of a compound of the present invention, or a pharmaceutically acceptable salt, prodrug or hydrate thereof. In one embodiment, said use relates to the treatment of cancer such as brain, lung, squamous cell, bladder, gastic, pancreatic, breast, head, neck, renal, kidney, ovarian, prostate, colorectal, oesohageal, testicular, gynecological or thyroid cancer. In another embodiment, said use relates to the treatment of a non-cancerous hyperproliferative disorder such as benign hyperplasia of the skin (e.g., psoriasis), restenosis, or prostate (e.g., benign prostatic hypertrophy (BPH)).
The invention also relates to a use for the treatment of a hyperproliferative disorder in a mammal that comprises administering to said mammal a therapeutically effective amount of a compound of the present invention, or a pharmaceutically acceptable salt, prodrug or hydrate thereof, in combination with an anti-tumor agent selected from the group consisting of mitotic inhibitors, alkylating agents, antimetabolites, intercalating antibiotics, growth factor inhibitors, cell cycle inhibitors, enzyme inhibitors, topoisomerase inhibitors, biological response modifiers, antihormones, angiogenesis inhibitors, and anti-androgens.
The invention also relates to a use of treating pancreatitis or kidney disease or pain in a mammal that comprises administering to said mammal a therapeutically effective amount of a compound of the present invention, or a pharmaceutically acceptable salt, prodrug or hydrate thereof. The invention also relates to a use of preventing blastocyte implantation in a mammal that comprises administering to said mammal a therapeutically effective amount of a compound of the present invention, or a pharmaceutically acceptable salt, prodrug or hydrate thereof.
The invention also relates to a use of treating diseases related to vasculogenesis or angiogenesis in a mammal that comprises administering to said mammal a therapeutically effective amount of a compound of the present invention, or a pharmaceutically acceptable salt, prodrug or hydrate thereof. In one embodiment, said method is for treating a disease selected from the group consisting of tumor angiogenesis, chronic inflammatory disease such as rheumatoid arthritis, atherosclerosis, inflammatory bowel disease, skin diseases such as psoriasis, excema, and scleroderma, diabetes, diabetic retinopathy, retinopathy of prematurity, age-related macular degeneration, hemangioma, glioma, melanoma, Kaposi's sarcoma and ovarian, breast, lung, pancreatic, prostate, colon and epidermoid cancer. Patients that can be treated with compounds of the present invention, or pharmaceutically acceptable salts, prodrugs and hydrates of said compounds, according to the methods of this invention include, for example, patients that have been diagnosed as having psoriasis, restenosis, atherosclerosis, BPH, lung cancer, bone cancer, CMML, pancreatic cancer, skin cancer, cancer of the head and neck, cutaneous or intraocular melanoma, uterine cancer, ovarian cancer, rectal cancer, cancer of the anal region, stomach cancer, colon cancer, breast cancer, testicular, gynecologic tumors (e.g., uterine sarcomas, carcinoma of the fallopian tubes, carcinoma of the endometrium, carcinoma of the cervix, carcinoma of the vagina or carcinoma of the vulva), Hodgkin's disease, cancer of the esophagus, cancer of the small intestine, cancer of the endocrine system (e.g., cancer of the thyroid, parathyroid or adrenal glands), sarcomas of soft tissues, cancer of the urethra, cancer of the penis, prostate cancer, chronic or acute leukemia, solid tumors of childhood, lymphocytic lymphomas, cancer of the bladder, cancer of the kidney or ureter (e.g., renal cell carcinoma, carcinoma of the renal pelvis), or neoplasms of the central nervous system (e.g., primary CNS lymphona, spinal axis tumors, brain stem gliomas or pituitary adenomas).
This invention also relates to a compound or pharmaceutical composition for inhibiting abnormal cell growth in a mammal which comprises an amount of a compound of the present invention, or a pharmaceutically acceptable salt or solvate or prodrug thereof, in combination with an amount of a chemotherapeutic, wherein the amounts of the compound, salt, solvate, or prodrug, and of the chemotherapeutic are together effective in inhibiting abnormal cell growth. Many chemotherapeutics are presently known in the art. In one embodiment, the chemotherapeutic is selected from the group consisting of mitotic inhibitors, alkylating agents, anti-metabolites, intercalating antibiotics, growth factor inhibitors, cell cycle inhibitors, enzymes, topoisomerase inhibitors, biological response modifiers, anti-hormones, angiogenesis inhibitors, and anti-androgens. This invention further relates to a method for inhibiting abnormal cell growth in a mammal or treating a hyperproliferative disorder which method comprises administering to the mammal an amount of a compound of the present invention, or a pharmaceutically acceptable salt or solvate or prodrug thereof, in combination with radiation therapy, wherein the amounts of the compound, salt, solvate, or prodrug, is in combination with the radiation therapy effective in inhibiting abnormal cell growth or treating the hyperproliferative disorder in the mammal. Techniques for administering radiation therapy are known in the art, and these techniques can be used in the combination therapy described herein. The administration of the compound of the invention in this combination therapy can be determined as described herein. It is believed that the compounds of the present invention can render abnormal cells more sensitive to treatment with radiation for purposes of killing and/or inhibiting the growth of such cells. Accordingly, this invention further relates to a method for sensitizing abnormal cells in a mammal to treatment with radiation which comprises administering to the mammal an amount of a compound of the present invention or pharmaceutically acceptable salt or solvate or prodrug thereof, which amount is effective is sensitizing abnormal cells to treatment with radiation. The amount of the compound, salt, or solvate in this method can be determined according to the means for ascertaining effective amounts of such compounds described herein. The invention also relates to a method of and to a pharmaceutical composition of inhibiting abnormal cell growth in a mammal which comprises an amount of a compound of the present invention, or a pharmaceutically acceptable salt or solvate thereof, a prodrug thereof, or an isotopically-labeled derivative thereof, and an amount of one or more substances selected from anti-angiogenesis agents, signal transduction inhibitors, and antiproliferative agents.
In practical use, the compounds of the present invention can be combined as the active ingredient in intimate admixture with a pharmaceutical carrier according to conventional pharmaceutical compounding techniques. The carrier may take a wide variety of forms depending on the form of preparation desired for administration, e.g., oral or parenteral (including intravenous). In preparing the compositions for oral dosage form, any of the usual pharmaceutical media may be employed, such as, for example, water, glycols, oils, alcohols, flavoring agents, preservatives, coloring agents and the like in the case of oral liquid preparations, such as, for example, suspensions, elixirs and solutions; or carriers such as starches, sugars, microcrystalline cellulose, diluents, granulating agents, lubricants, binders, disintegrating agents and the like in the case of oral solid preparations such as, for example, powders, hard and soft capsules and tablets, with the solid oral preparations being preferred over the liquid preparations.
Because of their ease of administration, tablets and capsules represent the most advantageous oral dosage unit form in which case solid pharmaceutical carriers are obviously employed. If desired, tablets may be coated by standard aqueous or nonaqueous techniques. Such compositions and preparations should contain at least 0.1 percent of active compound. The percentage of active compound in these compositions may, of course, be varied and may conveniently be between about 2 percent to about 60 percent of the weight of the unit. The amount of active compound in such therapeutically useful compositions is such that an effective dosage will be obtained. The active compounds can also be administered intranasally as, for example, liquid drops or spray.
The tablets, pills, capsules, and the like may also contain a binder such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, lactose or saccharin. When a dosage unit form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier such as a fatty oil.
Various other materials may be present as coatings or to modify the physical form of the dosage unit. For instance, tablets may be coated with shellac, sugar or both. A syrup or elixir may contain, in addition to the active ingredient, sucrose as a sweetening agent, methyl and propylparabens as preservatives, a dye and a flavoring such as cherry or orange flavor.
Compounds of the present invention may also be administered parenterally. Solutions or suspensions of these active compounds can be prepared in water suitably mixed with a surfactant such as hydroxy-propylcellulose. Dispersions can also be prepared in glycerol, liquid polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (e.g., glycerol, propylene glycol and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oils.
Any suitable route of administration may be employed for providing a mammal, especially a human, with an effective dose of a compound of the present invention. For example, oral, rectal, topical, parenteral, ocular, pulmonary, nasal, and the like may be employed. Dosage forms include tablets, troches, dispersions, suspensions, solutions, capsules, creams, ointments, aerosols, and the like. Preferably compounds of the present invention are administered orally.
The effective dosage of active ingredient employed may vary depending on the particular compound employed, the mode of administration, the condition being treated and the severity of the condition being treated. Such dosage may be ascertained readily by a person skilled in the art.
When treating or preventing cancer, inflammation or other proliferative diseases for which compounds of the present invention are indicated, generally satisfactory results are obtained when the compounds of the present invention are administered at a daily dosage of from about 0.1 milligram to about 100 milligram per kilogram of animal body weight, preferably given as a single daily dose or in divided doses two to six times a day, or in sustained release form. For most large mammals, the total daily dosage is from about 1.0 milligrams to about 1000 milligrams, preferably from about 1 milligram to about 50 milligrams. In the case of a 70 kg adult human, the total daily dose will generally be from about 7 milligrams to about 350 milligrams. This dosage regimen may be adjusted to provide the optimal therapeutic response.
Some abbreviations that may appear in this application are as follows.
Abbreviations
Designation
b Broad peak
CDI N,N-Carbonyldiimidazole
d Doublet
DCM Dichloromethane
dd double doublet
DIPEA N-Ethyldiisopropylamine
DMF N,N-Dimethylformamide
EDC 1-(3-Dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride
HPLC High pressure liquid chromatography
LiHMDS. Lithium hexamethyldisilazide
MCPBA 3-Chloroperoxybenzoic acid
NMR Nuclear Magnetic Resonance
PG Protecting group
PyBOP Benzotriazole-1-yl-oxy-trispyrrolidinophosphonium hexafluorophosphate
q Quartett
rt Retention time
s Singlet
tert Tertiary-butyl
TFA Trifluoroacetic acid
THF Tetrahydrofurane
TLC Thin Layer Chromatography
The compounds of the present invention can be prepared according to the procedures of the following Schemes and Examples, using appropriate materials and are further exemplified by the following specific examples. Moreover, by utilizing the procedures described herein, in conjunction with ordinary skills in the art, additional compounds of the present invention claimed herein can be readily prepared. The compounds illustrated in the examples are not, however, to be construed as forming the only genus that is considered as the invention. The examples further illustrate details for the preparation of the compounds of the present invention. Those skilled in the art will readily understand that known variations of the conditions and processes of the following preparative procedures can be used to prepare these compounds. The instant compounds are generally isolated in the form of their pharmaceutically acceptable salts, such as those described above. The amine-free bases corresponding to the isolated salts can be generated by neutralization with a suitable base, such as aqueous sodium hydrogencarbonate, sodium carbonate, sodium hydroxide and potassium hydroxide, and extraction of the liberated amine-free base into an organic solvent, followed by evaporation. The amine-free base, isolated in this manner, can be further converted into another pharmaceutically acceptable salt by dissolution in an organic solvent, followed by addition of the appropriate acid and subsequent evaporation, precipitation or crystallization.
An illustration of the preparation of compounds of the present invention is shown in schemes 2 and 3. Unless otherwise indicated in the schemes, the variables have the same meaning as described above.
The examples presented below are intended to illustrate particular embodiments of the invention.
Scheme 2 illustrates the synthesis of compounds in the present invention. In step 1 the aniline 1 is reacted with 3-fluoro isonicotinic acid in an inert solvent, preferable THF, by addition af a base, preferably but not limited to LiHMDS. In step 2 the 3-anilino isonicotinic acid 2 is coupled with an O-alkyl hydroxalamine using an appropriate coupling reagent including but not limited to PyBOP; EDC or DCC in a suitable organic solvents like for example DMF, THF or DCM to yield hydroxamate 3. Compound 3 is then converted into the corresponding pyridine N-oxide 4 by using oxidation reagents as for example MCPBA or peracetic acid in a suitable solvent like for example THF or DCM.
Suitable anilines and isonicotinic acid derivatives are commercially available from Sigma-Aldrich Chemie GmbH, Munich, Germany or from Acros Organics, Belgium or from Fisher Scientific GmbH, 58239 Schwerte, Germany or can be routinely prepared by procedures described in “March's Advanced Organic Chemistry: Reactions, Mechanisms, and Structure”, 5th Edition; John Wiley & Sons. Scheme 3 illustrates the preparation of compounds of the present invention where W is heterocyclic. In step 1 the 3-anilino isonicotinic acid derivative 5 is reacted with pentafluorophenyl trifluoroacetate and a base, for example pyridine, to give the active ester 6 which is further converted in step 2 to hydrazide 7 by reacting it with hydrazine or hydrazine hydrate in an inert solvent such as DCM, DMF or THF. Reaction of 7 with CDI or any suitable carbonate equivalent in a preferred solvent such as DMF or DCM for example then gives Oxadiazolone 8, which forms N-substiutued hydrazinecarboxamides 9 when treated with a substituted amine in ethanol. Cyclization is achieved by addition of triphenylphosphine and a base such as triethylamine or DIPEA in an inert solvent like CCl 4 for example to give compound 10.
Compounds with other variants in the position of W can be prepared by derivatizing the COOH group appropriately as known to the person skilled in the art as described in Theophil Eicher, Siegfried Hauptmann “The Chemistry of Heterocycles; Structures, Reactions, Synthesis and Application”, 2 nd edition, Wiley-VCH 2003. The introduction of alternative heterocyclic or heteroaryl groups is exemplified e.g. in WO 03/077855 and WO 01/05391.
Unless otherwise noted, all non-aqueous reactions were carried out either under an argon or nitrogen atmosphere with commercial dry solvents. Compounds were purified using flash column chromatography using Merck silica gel 60 (230-400 mesh), or by reverse phase preparative HPLC using a Reprosil-Pur ODS3, 5 μm, 20×125 mm column with Shimadzu LC8A-Pump and SPD-10Avp UVN is diode array detector. The 1 H-NMR spectra were recorded on a Varian VXR-S (300 MHz for 1 H-NMR) using d 6 -dimethylsulfoxide or d 4 -methanol as solvent; chemical shifts are reported in ppm relative to tetramethylsilane. Analytical LC/MS was performed using Reprosil-Pur ODS3, 5 μM, 1×60 mm columns at a flow rate of 250 μl/min, sample loop 2.5 μl; retention times are given in minutes. Methods are: (I) runs on a LC10Advp-Pump (Shimadzu) with SPD-M10Avp UV/Vis diode array detector and QP2010 MS-detector in ESI+ modus with UV-detection at 214, 254 and 275 nm with a gradient of 15-95% acetonitrile (B) in water (A) (0.1% formic acid), 5 min. linear gradient; (II) idem but linear gradient 8 min 1-30% B; (III) idem but linear gradient 8 min 10-60% B; (IV) idem but linear gradient 8 min 15-99% B; (V) idem but linear gradient 5 min 10-90% B; (VI) idem but linear gradient 5 min 5-95% B.
EXAMPLES
The examples presented below are intended to illustrate particular embodiments of the invention, and are not intended to limit the scope of the specification or the claims in any way.
Example 1
3-[(2,4-Dichlorophenyl)amino]isonicotinic acid (2a)
2,4-Dichloraniline (162 mg, 1.00 mmol) and 3-fluoropyridine-4-carboxylic acid (141 mg, 1.00 mmol) were dissolved in dry THF (6.0 ml) under argon and the mixture was cooled to −78° C. A solution of LiHMDS (1.0M in THF, 3.5 ml) was added and the reaction mixture was allowed to warm to ambient temperature. After 18 h the reaction was quenched by adding a solution of HCl in dioxane (4.0M, 2.0 ml). The volatiles were removed in vacuo and the crude material was purified by flash chromatography using silica gel and a gradient of 0-10% methanol in DCM as eluent to give 204 mg (721 μmol; 72% yield) of pure desired product.
LC-MS (method I): rt=2.98 min; m/z [M+H] + 282.9; 1 H-NMR (300 MHz, DMSO-d 6 ): δ=7.72 (1H, dd, J=2.2 Hz, J=8.8 Hz); 7.48 (1H, d, J=8.8 Hz); 7.53 (1H, d, J=2.9 Hz); 7.71 (1H, d, J=4.4 Hz); 7.99 (1H, d, J=5.1 Hz); 8.46 (1H, s); 11.3 (1H, b).
Example 2
3-[(4-Bromo-2-methylphenyl)amino]isonicotinic acid (2b)
4-Bromo-2-methylaniline (186 mg, 1.00 mmol) and 3-fluoropyridine-4-carboxylic acid (141 mg, 1.00 mmol) were dissolved in dry THF (6.0 ml) under argon and the mixture was cooled to −78° C. A solution of LiHMDS (1.0M in THF, 3.5 ml) was added and the reaction mixture was allowed to warm to ambient temperature. After 24 h the reaction was quenched by adding a solution of HCl in dioxane (4.0M, 2.0 ml). The volatiles were removed in vacuo and the crude material was purified by flash chromatography using silica gel and a gradient of 0-10% methanol in DCM as eluent to give 215 mg (701 μmol; 70% yield) of pure desired product.
LC-MS (method I): rt 1.57 min; m/z [M+H] + 306.7; 1 H-NMR (300 MHz, DMSO-d 6 ): δ=2.23 (3H, s); 3.62 (1H, b); 7.27 (2H, s); 7.38 (1H, s); 7.65 (1H, d, J=4.1 Hz); 7.91 (1H, d, J=7.9 Hz); 8.45 (1H, s).
Example 3
3-[(4-Iodo-2-methylphenyl)amino]isonicotinic acid (2c)
4-Iodo-2-methylaniline (233 mg, 1.00 mmol) and 3-fluoropyridine-4-carboxylic acid (141 mg, 1.00 mmol) were dissolved in dry THF (6.0 ml) under argon and the mixture was cooled to −78° C. A solution of LiHMDS (1.0M in THF, 3.5 ml) was added and the reaction mixture was allowed to warm to ambient temperature. After 36 h the reaction was quenched by adding solid NH 4 Cl. After filtration the volatiles were removed in vacuo and the crude material was purified by flash chromatography using silica gel and a gradient of 0-10% methanol in DCM as eluent to give 208 mg (588 μmol; 59% yield) of pure desired product.
LC-MS (method I): rt 1.69 min; m/z [M+H] + 395.8; 1 H-NMR (300 MHz, DMSO-d 6 ): δ=2.20 (3H, s); 3.80 (1H, b); 7.15 (1H, d, J=8.8 Hz); 7.20 (1H, b); 7.48 (1H, dd, J=8.1 Hz, J=2.2 Hz); 7.61 (1H, d, J=1.5 Hz); 7.66 (1H, d, J=5.1 Hz); 7.97 (1H, d, J=4.4 Hz); 8.30 (1H, s).
Example 4
3-[(4-Bromo-2-methylphenyl)amino]-N-ethoxyisonicotinamide (3b)
3-[(4-Bromo-2-methylphenyl)amino]isonicotinic acid 2b (320 mg, 1.04 mmol) was dissolved in 15 ml dry DMF followed by the addition of DIPEA (2.08 mmol, 373 μl), ByBOP (1.25 mmol, 651 mg) and O-ethylhydroxylamine hydrochloride (2.08 mmol, 203 mg). The mixture was stirred for 2 h and the volatiles were removed in vacuo. The crude material was purified by flash chromatography using silica gel and a gradient of 0-5% methanol in DCM as eluent to give 280 mg (800 μmol; 77% yield) of pure desired product.
LC-MS (method I): rt 1.90 min; m/z [M+H] + 351.9; 1 H-NMR (300 MHz, DMSO-d 6 ): δ=1.20 (3H, t, J=6.6 Hz); 2.21 (3H, s); 3.91 (2H, q, J=6.6 Hz); 7.20 (1H, d, J=8.8 Hz); 7.34 (1H, dd, J=8.8 Hz, J=2.2 Hz); 7.42 (1H, d, J=5.1 Hz); 7.47 (1H, d, J=2.2 Hz); 8.08 (1H, d, J=5.1 Hz); 8.35 (1H, s); 8.70 (1H, b).
Example 5
N-Ethoxy-3-[(4-iodo-2-methylphenyl)amino]isonicotinamide (3c)
3-[(4-iodo-2-methylphenyl)amino]isonicotinic acid 2c (60 mg, 0.17 mmol) was dissolved in 6 ml dry DMF followed by the addition of DIPEA (0.20 mmol, 37 μl), ByBOP (0.20 mmol, 107 mg) and O-ethylhydroxylamine hydrochloride (0.34 mmol, 34 mg). The mixture was stirred for 4 h and the volatiles were removed in vacuo. The crude material was purified by preparative reversed phase HPLC to give 36 mg (91 μmol; 53% yield) of pure desired product.
LC-MS (method I): rt 2.14 min; m/z [M+H] + 397.9; 1 H-NMR (300 MHz, DMSO-d 6 ): δ=1.20 (3H, t, J=7.3 Hz); 2.19 (3H, s); 3.40 (b); 3.90 (2H, q, J=7.3 Hz); 7.07 (1H, d, J=8.8 Hz); 7.42 (1H, d, J=5.1 Hz); 7.48 (1H, 2, J=7.3 Hz); 8.08 (1H, d, J=4.4 Hz); 8.37 (1H, s); 8.71 (1H, b).
Example 6
3-[(4-Bromo-2-methylphenyl)amino]-N-ethoxyisonicotinamide 1-oxide (4b)
3-[(4-Bromo-2-methylphenyl)amino]-N-ethoxyisonicotinamide 3b (80.0 mg, 0.228 mmol) was dissolved in 4 ml dry DCM and 3-chloroperbenzoic acid (73% pure, 60 mg) was added at ambient temperature. After 2 h the solvent was removed in vacuo and the crude material was purified by flash chromatography using silica gel and a gradient of 0-10% methanol in DCM as eluent to give 37 mg (101 μmol; 44% yield) of pure desired product.
LC-MS (method II): rt 4.47 min; m/z [M+H] + 366.0; 1 H-NMR (300 MHz, DMSO-d 6 ): δ=1.22 (3H, t, J=7.3 Hz); 2.21 (3H, s); 3.94 (2H, q, J=7.3 Hz); 7.27 (1H, d, J=8.8 Hz); 7.41 (1H, dd, J=8.8 Hz, J=2.2 Hz); 7.51 (1H, d, J=6.6 Hz); 7.55 (1H, dd, J=10.3 Hz, J=2.2 Hz); 7.68 (1H, dd, J=6.6 Hz, J=2.2 Hz); 9.31 (1H, b).
General Method 1 starts with the reaction of various 3-halogenated isonicotonic acids with substituted anilines in the presence of base. The resulting acids were further derivatized by reaction with 1,1 carbonyldiimidazole in DMSO followed by addition of the desired nucleophile.
Intermediate 1
3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (R=fluoro)
A mixture of 2-fluoro-4-iodoaniline (20.0 g, 84.38 mmol) in dry THF (80 mL) was cooled to −67° C. (dry ice/IPA bath) under nitrogen, prior to slow addition of 1.0 M lithium bis(trimethylsilyl)amide (255 mL, 255 mmol) via addition funnel, at a rate that kept the internal temp below −59° C. (˜2 h). After final addition, the yellow-green slurry was stirred for 30 min and then treated with 2-fluoroisonicotinic acid (8.0 g, 56.69 mmol). The bath was not removed, but the contents were allowed to slowly warm to room temp. After 4 days, the dark slurry was poured into a biphasic mixture of aqueous 2.0 N sodium hydroxide (1000 mL) and ethyl acetate (150 mL). The aqueous layer was separated and the organics were again extracted with base (1000 mL). The pH of the two aqueous layers was adjusted to ˜2 with concentrated hydrochloric acid. A yellow solid precipitated, which was filtered. The resultant yellow cake was washed with water (2×400 mL) and dried under high vacuum at 40° C. (17-19 g). LC/MS [(5.2 min; 359 (M+1)].
Intermediate 2
3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (R=chloro): synthesized as intermediate 1 by reacting 15.7 mmol of 2-chloro-4-iodoaniline with 23.55 mmol 2-fluoroisonicotinic acid. LC/MS [(5.9 min; 376 (M+1)].
Intermediate 3
3-[(2-methyl-4-iodophenyl)amino]isonicotinic acid (R=methyl): synthesized as intermediate 1 by reacting 4.7 mmol of 2-methyl-4-iodoaniline with 7.0 mmol 2-fluoroisonicotinic acid. LC/MS [(5.3 min; 355 (M+1)]. See detailed procedure in Example 3.
Synthesis of MEK Inhibitors; General Procedure for Carboxylic Acid Derivatization of 3-phenylamino-isonicotinic acids
The carboxylic acid (see intermediates 1-3) (0.2-8 mmol) and CDI (1,1 carbonyldiimidazole) (1.3 eq) in dry DMSO (10-20 volumes) was stirred at room temp (13-18 h). The dark-yellow solution was then treated with a substituted amine, substituted hydrazine or O-substituted hydroxylamine (1-2 eq). The contents were stirred at room temp for 4-18 h and the resultant dark-yellow solution was poured into ethyl acetate, washed with brine and concentrated.
Method for the synthesis of 3-phenylamino-1-oxy-isonicotinic acid derivatives
1-oxy derivatives were synthesized in a similar manner. First step in this synthesis was the N-oxidation of 3-fluoroisonicotinic acid. The subsequent steps were performed as previously described under General Method 1. Procedural details for this synthesis are as following:
3-fluoroisonicotinic acid 1-oxide
To a solution of 3-fluoroisonicotinic acid (5.0 g, 35.33 mmol) in acetic acid (25 ml) was added hydrogen peroxide (6 ml). The reaction mixture was stirred at 70-80° C. overnight. The solvent was removed to obtain 5.5 g of 3-fluoroisonicotinic acid 1-oxide in quantitative yield.
3-(2-Fluoro-4-iodo-phenylamino)-1-oxy-isonicotinic acid
Lithium 1,1,1,3,3,3-hexamethyldisilazan-2-ide (62 ml, 62.0 mmol) was added to a solution of 2-fluoro-4-iodoaniline (7.24 g, 30.55 mmol) in THF at −78° C. The mixture was stirred for 90 min at −78° C., then another 1.2 equiv. of lithium 1,1,1,3,3,3-hexamethyldisilazan-2-ide (3r1 ml 31.0 mmol) was added, following by 3-fluoroisonicotinic acid 1-oxide (4.0 g, 25.46 mmol). The reaction mixture was warmed to room temperature and stirred overnight. The solvent was evaporated, and water was added (50 ml). The pH of the aqueous layer was adjusted to <3, and washed with ether (20 ml×2). The product precipitated as a yellow solid. It was filtered, and dried to get 3.50 g of material. (36%) of 3-(2-Fluoro-4-iodo-phenylamino)-1-oxy-isonicotinic acid. LC/MS: [7.32 min; 374 (M+1)]
3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide 1-oxide
3-(2-Fluoro-4-iodo-phenylamino)-1-oxy-isonicotinamide was synthesized according to the general procedure of Method 1 as, outlined above, starting with 110 mg (0.29 mmol) of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid 1-oxide and 56 mg (0.74 mmol) of ammonium acetate LC/MS: [7.32 min; 375 (M+1)]
Method for the Synthesis of 2-Bromo-3-Phenylamino-Isonicotinic Acid Derivatives
2-Bromo-3-phenylamino-isonicotinic acid derivatives were synthesized in a similar manner. A typical procedure for the synthesis of such analogs follows below:
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-isonicotinic acid
Lithium 1,1,1,3,3,3-hexamethyldisilazan-2-ide (11.9 ml, 1.00 M, 11.82 mmol) was added to a solution of 2-fluoro-4-iodoaniline (1.40 g, 5.91 mmol) at −78° C. The pale green colored solution was stirred for 1½ h at −78° C. Then, lithium 1,1,1,3,3,3-hexamethyldisilazan-2-ide (5.45 ml, 1.00 M, 5.45 mmol) was added followed by 2-bromo-5-fluoroisonicotinic acid (1.00 g, 4.55 mmol) in THF (5 ml). The dark colored homogeneous mixture was warmed to room temperature and stirred overnight. The crude was diluted with EtOAc (300 ml). Then, it washed with dilute HCl solution (20 ml), H 2 O (20 ml), dried and purified on Flashmaster II using a 100 g cartridge to obtain 1.18 g (59%) of 2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-isonicotinic acid.
LC/MS: 7.43 min, 438 (M+1)
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-isonicotinamide
To a solution of 2-bromo-5-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid
(145.0 mg, 0.33 mmol) in N,N-dimethylformamide (1.50 ml). 1,1′-carbonylbis(1H-imidazole) (60 mg 0.36 mmol) was added, and the mixture was stirred at room temperature for 7 hours to obtain a homogeneous solution. Ammonium acetate (65 mg 0.83 mmol) was added, and stirred for 2 h. Water (10 ml) was added, and the precipitated solid was filtered, washed with hot methanol to obtain 2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-isonicotinamide as an yellow solid (85 mg, 58%) LC/MS: [9.59 min; 436, 438]
Method for the Synthesis of 2-Alkyl-3-Phenylamino-Isonicotinic Acid Derivatives
A typical procedure for the synthesis of 2-alkyl-3-phenylamino-isonicotinic acid derivatives:
Methyl 2-bromo-5-fluoroisonicotinate
To a solution of 2-bromo-5-fluoroisonicotinic acid (1.5 g, 6.82 mmol) in methanol (75 ml), thionyl dichloride (2.5 ml, 34.09 mmol) was added drop-wise. The reaction mixture was stirred overnight. The solvent was removed under high vacuum. The residual solid was distilled at 90° C. under vacuum to get 1.3 g (81%) of pure methyl 2-bromo-5-fluoroisonicotinate:
Methyl 5-fluoro-2-methylisonicotinate
To a solution of methyl 2-bromo-5-fluoroisonicotinate (1.0 g, 4.27 mmol) in tetrahydrofuran (25 ml) tetrakis(triphenylphosphine)palladium (495.0 mg, 0.43 mmol) was added. The mixture was stirred for 10 min, and then trimethylaluminum (5.13 ml, 1.00 M in heptane, 5.13 mmol) was added. The mixture was refluxed for 4 h, and the reaction was monitored by TLC (10% EtOAc-Hexane). Then, the reaction was diluted with EtOAc (75 ml) and a few drops of saturated. ammonium chloride were added. The mixture was filtered through a small silica gel pad, followed by removal of the solvent. The crude product was re-dissolved in 5N NaOH solution in water and stirred at room temperature for 2 hours. The crude product was purified on Flashmaster II to afford 250 mg of 5-fluoro-2-methylisonicotinic acid.
5-[(2-fluoro-4-iodophenyl)amino]-2-methylisonicotinic acid
5-[(2-fluoro-4-iodophenyl)amino]-2-methylisonicotinic acid was synthesized according to the general procedure of Method 1 as, outlined above, starting with 200 mg (1.29 mmol) of 5-fluoro-2-methylisonicotinic acid, 370 mg (1.55 mmol) of 2-fluoro-4-iodoaniline and two portions of lithium bis(trimethylsilyl)amide (3.35 ml, 3.35 mmol), and (1.55 ml, 1.55 mmol). Yield: 30 mg, 6%, LC/MS [5.5 min; 473 (M+1)]
Method for the Synthesis of 2-Aryl-3-Phenylamino-Isonicotinic Acid Derivatives
A typical procedure for the synthesis of 2-alkyl-3-phenylamino-isonicotinic acid derivatives:
5-fluoro-2-phenylpyridine
To a solution of 2-bromo-5-fluoropyridine (10.0 g, 56.82 mmol, Aldrich) in tetrahydrofuran (100 ml) was added tetrakis (triphenylphosphine)Pd complex and stirred for 10 min. Then, phenylmagnesium bromide (68.2 ml, 1.00 M in THF, 68.19 mmol) was added drop-wise at 0° C. The mixture was stirred overnight. Then the reaction was diluted with EtOAc (600 ml), and filtered. The filtrate was concentrated and purified by flash chromatography by eluting with 2% EtOAc-Hexane to obtain 6.8 g (69%) of 5-fluoro-2-phenylpyridine.
5-fluoro-2-phenylisonicotinic acid
To a solution of 5-fluoro-2-phenylpyridine (760.0 mg, 4.39 mmol) in tetrahydrofuran (15.0 ml) was added n-butyllithium (2.11 ml, 2.50 M in THF, 5.27 mmol) at −45° C. The mixture was stirred for 1 h at −45° C., then poured into THF containing dry ice Stirred for 1 h, then MeOH (2 ml) was added. The solution was concentrated, and purified on Flashmaster II to get 560 mg (58%) of 5-fluoro-2-phenylisonicotinic acid.
5-[(2-fluoro-4-iodophenyl)amino]-2-phenyl isonicotinic acid
Lithium bis(trimethylsilyl)amide (2.8 ml, 1.0 M in THF, 2.76 mmol) was added to a suspension of 5-fluoro-2-phenylisonicotinic acid (500 mg, 2.30 mmol) in THF (10 ml) at −78° C. The dark colored suspension was stirred for 30 min. In another flask, 2-fluoro-4-iodoaniline (709.30 mg, 2.99 mmol, 1.30 eq) was dissolved in (15 ml) THF and cooled to −78° C. To this solution lithium bis(trimethylsilyl)amide (5 ml, 1.00 M, 5.06 mmol, 2.20 eq) was added and the mixture was stirred for 1 h. The reaction mixture became very viscous. To this, the homogeneous solution of acid-LiHMDS mixture was added via syringe. The mixture was warmed to room temperature and stirred overnight. Diluted with EtOAc (300 ml), washed with dilute HCl (20 ml), water (20 ml), and then dried and concentrated. Purified on Flashmaster using 100 g cartridge to obtain 565 mg of 5-[(2-fluoro-4-iodophenyl)amino]-2-phenylisonicotinic acid. LC/MS: [8.59 min; 435 (M+1)]
Example 7
N-{[(2R)-2,3-dihydroxypropyl]oxy}-3-[(2-fluoro-4-iodophenyl)-amino]isonicotin-amide
A suspension of N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide (synthesis described below) (3.0 g, 6.16 mmol) in dichloromethane (20 mL) was treated with trifluoroacetic acid (20 mL) and the clear-yellow solution was stirred at room temp. After stirring for 8 h, the contents were concentrated to a yellow oil, which was dissolved in ethyl acetate (100 mL) and poured into water (150 mL). The pH of the biphasic mixture was adjusted between 6 and 7 with 2.0 N aqueous sodium hydroxide and the layers were separated. The organics were dried over sodium sulfate, concentrated to a yellow oil and placed under high vacuum at 40° C. The resultant yellow, solid foam weighed 2.39 g (5.34 mmol, 87%) after drying for 18 h. LC/MS [5.22 min; 448 (M+1)]
N-{[(2R)-2,3-dihydroxypropyl]oxy}-3-[(2-fluoro-4-iodophenyl)-amino]isonicotin-amide hydrochloride
The diol from the previous entry (2.09 g, 4.67 mmol) was suspended in water (20 mL) and treated with aqueous 1.0 N HCl (4.7 mL). Complete dissolution occurred and the solution was placed on the lyophilizer. After 18 h, the yellow solid weighed 2.23 g (4.61 mmol, 99%). LC/MS [5.22 min; 448 (M+1)]
Example 7a
N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide
A mixture of the carboxylic acid Intermediate 1 (3.00 g, 8.38 mmol) and CDI (1.70 g, 10.48 mmol) was suspended in dry DMSO (40 mL) and the contents were stirred at room temp for 15 h. At that time, the dark-yellow solution was treated with the amine (2.05 g, 13.93 mmol) and the contents were stirred at room temp for 5 h and then poured into brine (250 mL) and extracted with ethyl acetate (250 mL). The organics were washed with brine (2×250 mL), dried over sodium sulfate and concentrated to a solid (3.06 g, 75%) LC/MS [6.03 min; 488 (M+1)]
3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid
To suspension of 3-fluoroisonicotinic acid (2.00 g, 14.17 mmol, in tetrahydrofuran (50 ml) at −78° C. was added lithium bis(trimethylsilyl)amide (14.3 ml, 17.01 mmol). The dark colored suspension was stirred for 15 min. In another flask, to a solution of 2-chloro-4-iodoaniline (4.7 g, 18.43 mmol) in THF (50 ml) was added lithium bis(trimethylsilyl)amide (24.9 ml, 29.77 mmol) at −78° C. under N 2 . The resulting green colored solution was stirred for 15 min. To this green colored solution the lithiated acid solution was added. The cold bath was removed, allowed to warm to room temperature, and stirred overnight. The mixture was filtered, and the crude was diluted with EtOAc (400 ml). It was then washed with dilute HCl (25 ml), H 2 O (25 ml), and dried. During concentration of the solvent, 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid was separated out as an yellow solid. (1.3 g, 24%)
Example 7b
3-[(2-chloro-4-iodophenyl)amino]-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}isonicotinamide
From the previous reaction 3-[(2-chloro-4-iodophenyl)amino]isonicotinic (120.00 mg, 0.32 mmol) acid was suspended in dichloromethane (5 ml). Pyridine (50.68 mg, 0.64 mmol) and N,N-Diisopropylethylamine (82.81 mg, 0.64 mmol) (DIEA helps to obtain a homogeneous solution) were added. To this mixture was added oxalyl chloride (121.99 mg, 0.96 mmol) and stirred for 1 h at room temperature. The mixture was concentrated, and the residue was dried under vacuum. The crude acid chloride was dissolved in DCM (5 ml) and DIEA was added (83 mg, 0.64 mmol,) followed by O-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methyl}hydroxylamine (142 mg, 0.96 mmol,). The reaction mixture was stirred for 3 h, it concentrated, and purified on Flashmaster II to get 125 mg of 3-[(2-chloro-4-iodophenyl)amino]-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}isonicotinamide in 770% yield.
Example 8
3-[(2-chloro-4-iodophenyl)amino]-N-{[(2R)-2,3-dihydroxypropyl]oxy}-isonicotinamide
3-[(2-chloro-4-iodophenyl)amino]-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}isonicotinamide (100.00 mg, 0.198 mmol.) from the reaction described above was dissolved in acetic acid (1 ml) was heated at 90° C. for 2 h. The reaction was monitored by HPLC. After completion, acetic acid was removed and the crude was purified on Flashmaster II to obtain 40 mg (43%) of 3-[(2-chloro-4-iodophenyl)amino]-N-{[(2R)-2,3-dihydroxypropyl]oxy}isonicotinamide. LC/MS: [7.97 min; 464, 466 (M+1)]
Example 9
3-[(2-methyl-4-iodophenyl)amino]-N-{[(2R)-2,3-dihydroxypropyl]oxy}-isonicotinamide
3-[(2-methyl-4-iodophenyl)amino]-N-{[(2R)-2,3-dihydroxypropyl]oxy}isonicotinamide was synthesized as 3-[(2-chloro-4-iodophenyl)amino]-N-{[(2R)-2,3-dihydroxypropyl]oxy}isonicotinamide using Intermediate 3 instead of intermediate 2. LC/MS: [7.36 min; 464, 445 (M+1)]
Example 10
Methyl 3-[(2-chloro-4-iodophenyl)amino]isonicotinate
Carboxylic acid Intermediate 2 (0.200 g, 0.534 mmol) and CDI (0.095 g, 0.586 mmol) in dry DMSO (5 mL) was stirred at room temp for 18 h. The clear-yellow solution was then treated with dry methanol (0.5 mL) and 1,8-diazabicyclo[5.4.0]undec-7-ene (0.090 g. 0.591 mmol) and the contents were warmed to 50° C. After 2 days, the dark-yellow solution was poured into water and ethyl acetate. The layers were separated and the organics were washed with brine dried and concentrated to a yellow solid (0.207 g, 100%). LC/MS [8.20 min; 389 (M+1)]
Example 11
3-[(2-chloro-4-iodophenyl)amino]isonicotinamide
3-[(2-chloro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 6 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 12 mmol of. ammonium acetate. LC/MS [8.29 min; 374 (M+1)]
3-[(2-chloro-4-iodophenyl)amino]isonicotinamide hydrochloride
The amide form the previous entry (4.5 mmol) was suspended in water (10 mL) and treated with aqueous 1.0 N HCl (9 mL). The contents were stirred for 15 min, cooled to 3° C. and filtered. The yellow-green solid was dried under high vacuum at 40° C. LC/MS [8.29 min; 374 (free base, M+1)]
Example 12
3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 8 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 16 mmol of. ammonium acetate. LC/MS [7.27 min; 358 (M+1)].
3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide hydrochloride
The amide form the previous entry (4 mmol) was suspended in water (12 mL) and treated with aqueous 1.0 N HCl (8 mL). The contents were stirred for 15 min, cooled to 3° C. and filtered. The yellow-green solid was dried under high vacuum at 40° C. LC/MS [7.26 min; 358 (free base, M+1)]
Example 13
3-(2-Fluoro-4-iodo-phenylamino)-N-(2-morpholin-4-yl-ethyl)-isonicotinamide
3-(2-Fluoro-4-iodo-phenylamino)-N-(2-morpholin-4-yl-ethyl)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.35 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.50 mmol of. 2-morpholin-4-yl-ethylamine LC/MS [1.74 min; 471 (M+1)].
Example 14
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-hydroxypropyl)-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-hydroxypropyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.45 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.62 mmol of 2-amino-isopropanol. LC/MS [5.11 min; 416 (M+1)]
Example 15
3-(2-Fluoro-4-iodo-phenylamino)-N-(2-hydroxy-ethyl)-isonicotinamide
3-(2-Fluoro-4-iodo-phenylamino)-N-(2-hydroxy-ethyl)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.39 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.50 mmol of ethanolamine. LC/MS [3.42 min; 402 (M+1)]
Example 16
3-(2-Fluoro-4-iodo-phenylamino)-N-(2-methoxy-ethyl)-isonicotinamide
3-(2-Fluoro-4-iodo-phenylamino)-N-(2-hydroxy-ethyl)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.45 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.60 mmol of 2-methoxy-ethylamine. LC/MS [3.42 min; 402 (M+1)]
Example 17
[3-(2-Fluoro-4-iodo-phenylamino)-pyridin-4-yl]-morpholin-4-yl-methanone
3-(2-Fluoro-4-iodo-phenylamino)-pyridin-4-yl]-morpholin-4-yl-methanone was synthesized according to the procedure for General Method 1, outlined above, starting with 0.36 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.47 mmol of morpholine. LC/MS [7.67 min; 428 (M+1)].
Example 18
N-ethyl-3-[(2-fluoro-4-iodophenyl)amino] isonicotinamide
N-ethyl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.34 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.48 mmol of monoethylamine. LC/MS [5.96 min; 386 (M+1)]
Example 19
3-[(2-fluoro-4-iodophenyl)amino]-N-piperidin-1-ylisonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-piperidin-1-ylisonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.30 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.47 mmol of piperidin-1-ylamine LC/MS [8.81 min; 441 (M+1)]
Example 20
3-[(2-fluoro-4-iodophenyl)amino]-N-[3-(1H-imidazol-1-yl)propyl]-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-[3-(1H-imidazol-1-yl)propyl]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.40 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.60 mmol of 3-imidazol-1-yl-propylamine. LC/MS [4.82 min; 466 (M+1)]
Example 21
N-benzyl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide
N-benzyl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.3 mmol 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.45 mmol of benzylamine. LC/MS [7.55 min; 448 (M+1)]
Example 22
3-[(2-chloro-4-iodophenyl)amino]-N-methylisonicotinamide
3-[(2-chloro-4-iodophenyl)amino]-N-methylisonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.32 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.43 mmol of monomethylamine LC/MS [9.23 min; 389 (M+1)]
Example 23
3-[(2-chloro-4-iodophenyl)amino]-N-dimethylisonicotinamide
3-[(2-chloro-4-iodophenyl)amino]-N-dimethylisonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.30 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.40 mmol of dimethylamine LC/MS [8.38 min; 402.7 (M+1)]
Example 24
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-methoxyethyl)-N-methyl-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-methoxyethyl)-N-methylisonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.42 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.57 mmol of (2-methoxy-ethyl)-dimethyl-amine LC/MS [7.84 min; 430 (M+1)]
Example 25
3-[(2-fluoro-4-iodophenyl)amino]-N-morpholin-4-ylisonicotin-amide
3-[(2-fluoro-4-iodophenyl)amino]-N-morpholin-4-ylisonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.5 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.81 mmol of morpholin-4-ylamine LC/MS [8.25 min; 443 (M+1)]
Example 26
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-phenoxyethyl)-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-phenoxyethyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.32 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.45 mmol of 2-phenoxyethylamine. LC/MS [10.10 min; 478 (M+1)]
Example 27
3-[(2-fluoro-4-iodophenyl)amino]-N-[2-(2-methoxyphenyl)-ethyl]isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-[2-(2-methoxyphenyl)ethyl]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.54 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.81 mmol of 2-(2-methoxy-phenyl)-ethylamine. LC/MS [10.19 min; 492 (M+1)]
Example 28
N′-{3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}-1H-indazole-3-carbohydrazide
N′-{3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}-1H-indazole-3-carbohydrazide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.32 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.47 mmol of 1H-indazole-3-carboxylic acid hydrazide. LC/MS [9.14 min; 517 (M+1)]
Example 29
N-[2-(3-chlorophenyl)ethyl]-3-[(2-fluoro-4-iodophenyl)-amino]isonicotinamide
N-[2-(3-chlorophenyl)ethyl]-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.5 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.75 mmol of 2-(3-chlorophenyl)ethylamine. LC/MS [10.47 min; 496 (M+1)]
Example 30
3-[(2-fluoro-4-iodophenyl)amino]-N-[3-(2-oxopyrrolidin-1-yl)propyl]isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-[3-(2-oxopyrrolidin-1-yl)propyl]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.6 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.85 mmol of 1-(3-amino-propyl)-pyrrolidin-2-one LC/MS [8.70 min; 483 (M+1)]
Example 31
2-Chloro-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide
2-Chloro-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.2 mmol of 2-Chloro-3-(2-fluoro-4-iodo-phenylamino)-isonicotinic acid and 0.5 mmol of ammonium acetate. LC/MS [8.61 min; 392 (M+1)].
Example 32
3-[(2-fluoro-4-iodophenyl)amino]-N′-phenylisonicotinohydrazide
3-[(2-fluoro-4-iodophenyl)amino]-N′-phenylisonicotinohydrazide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.45 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.7 mmol of phenylhydrazine. LC/MS [9.52 min; 449 (M+1)]
Example 33
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-piperidin-1-ylethyl)-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-piperidin-1-ylethyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 2.5 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 4.0 mmol of 2-piperidin-1-ylethylamine. LC/MS [5.40 min; 469 (M+1)]
Example 34
tert-butyl(1-{3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}-piperidin-4-yl)carbamate
tert-butyl(1-{3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}piperidin-4-yl)carbamate was synthesized according to the procedure for General Method 1, outlined above, starting with 2.4 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 4.0 mmol of piperidin-4-yl-carbamic acid tert-butyl ester. LC/MS [9.47 min; 541 (M+1)]
Example 35
3-[(2-fluoro-4-iodophenyl)amino]-N-(3-morpholin-4-ylpropyl)-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(3-morpholin-4-ylpropyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 1.0 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 1.6 mmol of 3-morpholin-4-yl-propylamine. LC/MS [4.66 min; 485 (M+1)]
Example 36
3-(2-Chloro-4-iodo-phenylamino)-N-(5-hydroxy-pentyl)-isonicotinamide
3-(2-Chloro-4-iodo-phenylamino)-N-(5-hydroxy-pentyl)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.30 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.40 mmol of 5-amino-pentan-1-ol. LC/MS [9.33 min; 461 (M+1)]
Example 37
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-hydroxyethylmethyl-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-hydroxyethylmethylisonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.4 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.6 mmol of 2-methylamino-ethanol. LC/MS [6.47 min; 416 (M+1)]
Example 38
2-Chloro-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide
2-Chloro-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.2 mmol of 2-chloro-3-(2-fluoro-4-iodo-phenylamino)-isonicotinic acid and 0.3 mmol of O-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methyl}-hydroxylamine LC/MS [9.19 min; 522 (M+1)].
Example 39
3-[(2-fluoro-4-iodophenyl)amino]-N-(4-hydroxybutyl)-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(4-hydroxybutyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.5 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.63 mmol of 4-hydroxy-butylamine. LC/MS [8.42 min; 430 (M+1)]
Example 40
3-[(2-fluoro-4-iodophenyl)amino]-N-(pyridin-2-ylmethyl)-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(pyridin-2-ylmethyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.46 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.78 mmol of pyridine-2-methylamine. LC/MS [8.33 min; 449 (M+1)]
Example 41
3-[(2-fluoro-4-iodophenyl)amino]-N-[(2S)-2-hydroxypropyl]-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-[(2S)-2-hydroxypropyl]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.3 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.4 mmol of 2-(R)-hydroxypropylamine. LC/MS [8.40 min; 416 (M+1)]
Example 42
N-azepan-1-yl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide
N-azepan-1-yl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.45 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 6.2 mmol of azepan-1-ylamine. LC/MS [8.99 min; 455 (M+1)]
Example 43
2-Chloro-N-[(2R)-2,3-dihydroxy-propoxy]-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide
Deprotection of 2-Chloro-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide with 50:50 mixture of TFA/dichloromethane at room temperature for 30 minutes afforded the desired product. Purification by reverse phase LC/MS [7.94 min; 482 (M+1)].
Example 44
4-[(4-aminopiperidin-1-yl)carbonyl]-N-(2-fluoro-4-iodophenyl)pyridin-3-amine hydrochloride
4-[(4-aminopiperidin-1-yl)carbonyl]-N-(2-fluoro-4-iodophenyl)pyridin-3-amine was synthesized from tert-butyl(1-{3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}piperidin-4-yl)carbamate (described below) by deprotection of the Boc group with TFA/DCM: 0.33 mmol of tert-butyl(1-{3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}piperidin-4-yl)carbamate was dissolved in 4 ml of 50:50 mixture of TFA/dichloromethane. After 2 hours of stirring at room temperature the volatiles were stripped and the residue was re-dissolved in 2 ml of methanol. 1.0N HCl in diethylether was added and the product precipitated. LC/MS [2.01 min; 441 (free base, M+1)]
Example 45
tert-butyl 2-{3-[(2-fluoro-4-iodophenyl)amino]-isonicotinoyl}hydrazine-carboxylate
tert-butyl 2-{3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}hydrazine-carboxylate was synthesized according to the procedure for General Method 1, outlined above, starting with 3 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 5 mmol of hydrazinecarboxylic acid tert-butylester. LC/MS [9.37 min; 473 (M+1)]
Example 46
4-[({3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}-amino)methyl]benzoic acid
4-[({3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}-amino)methyl]benzoic acid was synthesized according to the procedure for General Method 1, outlined above, starting with 0.3 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.45 mmol of 4-aminomethylbenzoic acid. LC/MS [9.25 min; 492 (M+1)]
Example 47
N-cyclopropyl-3-[(2-fluoro-4-iodophenyl)amino] isonicotinamide
N-cyclopropyl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.2 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.23 mmol of cyclopropylamine. LC/MS [8.78 min; 398 (M+1)]
Example 48
3-[(2-fluoro-4-iodophenyl)amino]-N-[(2R)-2-hydroxypropyl]-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-[(2R)-2-hydroxypropyl]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 2 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 3 mmol of 2-(R)-hydroxypropylamineLC/MS [8.33 min; 416 (M+1)]
Example 49
3-[(2-fluoro-4-iodophenyl)amino]-N′-pyridin-2-ylisonicotino-hydrazide
3-[(2-fluoro-4-iodophenyl)amino]-N′-pyridin-2-yl isonicotinohydrazide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.5 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.8 mmol of pyridin-2-yl-hydrazine. LC/MS [6.90 min; 450 (M+1)]
Example 50
3-[(2-fluoro-4-iodophenyl)amino]-N′-[4-(trifluoromethyl)pyrimidin-2-yl] isonicotinohydrazide
3-[(2-fluoro-4-iodophenyl)amino]-N′-[4-(trifluoro methyl)pyrimidin-2-yl]isonicotinohydrazide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.4 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.6 mmol of 4-trifluoromethyl-pyrimidin-2-yl)-hydrazine. LC/MS [9.38 min; 519 (M+1)]
Example 51
3-[(2-fluoro-4-iodophenyl)amino]isonicotinohydrazide
3-[(2-fluoro-4-iodophenyl)amino]isonicotinohydrazide hydrochloride was synthesized from tert-butyl 2-{3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}hydrazine-carboxylate (described earlier) by deprotection of the Boc group under acidic conditions (50:50 TFA/DCM). LC/MS [7.11 min; 373 (free base, M+1)]
Example 52
5-[(2-fluoro-4-iodophenyl)amino]-2-(4-methoxyphenyl)isonicotinic acid
5-[(2-fluoro-4-iodophenyl)amino]-2-(4-methoxyphenyl)isonicotinic acid was synthesized according to the General method 5, outlined above. First 5-Fluoro-2-(4-methoxyphenyl)pyridine was synthesized starting with 1.0 g (5.68 mmol) of 2-bromo-5-fluoropyridine and p-methoxy phenylmagnesium bromide (13.7 ml, 0.5 M in THF, 6.82 mmol) in the presence of 0.66 g (0.57 mmol) of tetrakis (triphenyl phosphine)Pd complex. Yield: 766 mg, 66%. Then 5-fluoro-2-(4-methoxyphenyl)isonicotinic acid was synthesized from 765 mg (3.76 mmol) of 5-fluoro-2-(4-methoxyphenyl)pyridine, butyllithium (1.8 ml, 2.50 M in THF, 4.52 mmol) and dry ice. Yield: 450 mg, 48%. 5-[(2-fluoro-4-iodophenyl)amino]-2-(4-methoxyphenyl)isonicotinic acid was then synthesized with 2.37 mmol of 2-fluoro-4-iodoaniline and by 1.82 mmol of 5-fluoro-2-(4-methoxyphenyl)isonicotinic acid as described in General Method 5. LC/MS [9.52 min, 465 (M+1)]
Example 53
N-(cyclopropylmethyl)-3-[(2-fluoro-4-iodophenyl)amino]-isonicotinamide
N-(cyclopropylmethyl)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.2 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.23 mmol of cyclopropylmethylamine. LC/MS [9.79 min; 412 (M+1)]
Example 54
3-(2-Chloro-4-ethynyl-phenylamino)-N-(2,3-dihydroxy-propoxy)-isonicotinamide
0.43 mmol of 3-[(2-chloro-4-iodophenyl)amino]-N-{[(2R)-2,3-dihydroxypropyl]oxy}isonicotinamide (synthesis described above), 0.02 mmol of dichlorobis(triphenylphosphine)palladium(II), and 0.03 mmol of copper (I) iodide were dissolved and DMF and TEA. 0.93 mmol of trimethylsilylacetylene was added to the stirring solution and the resultant orange mixture was vigorously stirred for 18 h at ambient temperature. The solvent was then removed under reduced pressure and the residue was diluted with EtOAc, washed with water (2×) and saturated brine (2×). The organics were dried over Na 2 SO 4 , filtered, and then concentrated under reduced pressure to give a brown solid, which was then dissolved in methanol. 3.10 mmol of CsF was added and the mixture was stirred at ambient temperature. After stirring for 16 h, the solution was concentrated, taken up in EtOAc, and then the organic phase was washed with water, brine, dried over Na 2 SO 4 , filtered, and concentrated under reduced pressure. The residue was subjected to column chromatography (Flashmaster) on silica gel using EtOAc/MeOH (0-100%) to afford the desired product LC/MS [5.29 min; 362 (M+1)]
Example 55
3-[(2-fluoro-4-iodophenyl)amino]-N′-(3-methoxybenzoyl)-isonicotinohydrazide
3-[(2-fluoro-4-iodophenyl)amino]-N′-(3-methoxybenzoyl)isonicotinohydrazide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.4 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.55 mmol of 3-methoxy-benzohydrazide. LC/MS [9.23 min; 507 (M+1)]
Example 56
N′-(7-chloroquinolin-4-yl)-3-[(2-fluoro-4-iodophenyl)amino]-isonicotino-hydrazide
N′-(7-chloroquinolin-4-yl)-3-[(2-fluoro-4-iodophenyl)amino]isonicotino-hydrazide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.33 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.50 mmol of 7-chloroquinolin-4-yl-hydrazine.LC/MS [7.69 min; 534 (M+1)]
Example 57
2-[4-(dimethylamino)phenyl]-5-[(2-fluoro-4-iodophenyl)amino]-isonicotinic acid
2-[4-(dimethylamino)phenyl]-5-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid was synthesized according to the General Method 5, outlined above. First 4-(5-fluoropyridin-2-yl)-N,N-dimethylaniline was synthesized starting with 5.68 mmol of 2-bromo-5-fluoropyridine and 4-(N,N-dimethyl)anilinemagnesium bromide (6.82 mmol) in the presence of 0.66 g (0.57 mmol) of tetrakis (triphenylphosphine)Pd complex. Yield: 650 mg, 59%. Then 2-[4-(dimethylamino)phenyl]-5-fluoroisonicotinic acid was synthesized from 2.66 mmol of 4-(5-fluoropyridin-2-yl)-N,N-dimethylaniline, butyllithium (17.3 mmol) and dry ice. Yield: 460 mg, 66%. 5-[(2-fluoro-4-iodophenyl)amino]-2-(4-methoxyphenyl)isonicotinic acid was then synthesized with 1.25 mmol of 2-fluoro-4-iodoaniline and by 0.96 mmol of 2-[4-(dimethylamino)phenyl]-5-fluoroisonicotinic acid as described in General Method 5. LC/MS: [8.86 min, 478 (M+1)]
Example 58
N-cyclobutyl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide
N-(cyclobutyl)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.34 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.42 mmol of cyclobutylamine.LC/MS [9.86 min; 412 (M+1)]
Example 59
N-(2,3-dihydro-1H-inden-1-yl)-3-[(2-fluoro-4-iodophenyl)amino]-isonicotinamide
N-(2,3-dihydro-1H-inden-1-yl)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.43 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.57 mmol of indanylamine. LC/MS [10.69 min; 474 (M+1)]
Example 60
N-cyclopentyl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide
N-cyclopentyl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.45 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.57 mmol of cyclopentylamine. LC/MS [9.55 min; 426 (M+1)]
Example 61
N-cyclohexyl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide
N-cyclohexyl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.33 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.42 mmol of cyclohexylamine. LC/MS [10.52 min; 440 (M+1)]
Example 62
N-(1,2-dimethylpropyl)-3-[(2-fluoro-4-iodophenyl)amino]-isonicotinamide
N-(1,2-dimethylpropyl)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.4 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.6 mmol of 2,3,dimethyl butylamine LC/MS [10.32 min; 428 (M+1)]
Example 63
N-{[(4S)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-3-[(2-fluoro-4-iodophenyl)amino] isonicotinamide
N-{[(4S)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-3-[(2-fluoro-4-iodophenyl)amino] isonicotinamide was synthesized as its isomer N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamideLC/MS. [8.94 min; 488 (M+1)]
Example 64
N-(2-Acetylamino-ethyl)-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide
N-(2-Acetylamino-ethyl)-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.32 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.44 mmol N-(2-amino-ethyl)-acetamideLC/MS [8.38 min; 4.59 (M+1)]
Example 65
3-(2-Chloro-4-iodo-phenylamino)-pyridine-4-carbonyl]-carbamic acid tert-butyl ester
3-(2-Chloro-4-iodo-phenylamino)-pyridine-4-carbonyl]-carbamic acid tert-butyl ester was synthesized according to the procedure for General Method 1, outlined above, starting with 0.6 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.8 mmol of carbamic acid tert-butyl ester. LC/MS [9.69 min; 445.8 (M+1)]
Example 66
3-[(2-fluoro-4-iodophenyl)amino]-N-hydroxyisonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-hydroxyisonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.31 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.6 mmol of hydroxylamine. LC/MS [7.37 min; 374 (M+1)]
Example 67
3-(4-iodo-phenylamino)-isonicotinamide
3-(4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.2 mmol of 3-(4-iodophenyl)amino-isonicotinic acid and 0.4 mmol of ammonium acetate. LC/MS [5.03 min; 340 (M+1)]
Example 68
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-isonicotinamide
The synthesis of 2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-isonicotinamide was described under General Method 3.
Example 69
2-bromo-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-5-[(2-fluoro-4-iodophenyl)amino]isonicotinamide
2-bromo-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-5-[(2-fluoro-4-iodophenyl)-amino]isonicotinamide was synthesized as described in General Method 3: to a solution of 2-bromo-5-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (145.0 mg, 0.33 mmol) in DMF (1.5 ml) was added 1,1′-carbonylbis(1H-imidazole) (60 mg, 0.36 mmol). The reaction mixture was stirred at room temperature under argon for 6 hrs. Then, O-[(2,2-dimethyl-1,3-dioxolan-4-yl)methyl]hydroxylamine (125 mg 0.83 mmol) was added, and stirred overnight. The reaction mixture was poured into water (10 ml). Extracted with EtOAc(3×15 ml), the combined organic layer was washed with brine (2×15 ml), and dried over MgSO 4 . The solvent was evaporated, and the residue was purified on silica gel column (Hex:EtOAc=3:1) to obtain 104 mg (55%) of 2-bromo-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-5-[(2-fluoro-4-iodophenyl)-amino] isonicotinamide.LC/MS:10.43 min, 566, 568.
Example 70
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(3-hydroxy-propyl)-isonicotinamide
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(3-hydroxy-propyl)-isonicotinamide was synthesized according to General method 3, starting with 145 mg (0.33 mmol) of 2-bromo-5-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid and 62 mg (0.82 mmol) of 3-Amino-propan-1-ol. LC/MS: [9.15 min, 494, 496]
Example 71
2-Bromo-N-(2,4-dihydroxy-butoxy)-5-(2-fluoro-4-iodo-phenylamino)-isonicotinamide
2-Bromo-N-(2,4-dihydroxy-butoxy)-5-(2-fluoro-4-iodo-phenylamino)-isonicotinamide was synthesized as described in General method 3: To a solution of 2-bromo-N-{[(4R)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-5-[(2-fluoro-4-iodophenyl)amino]-isonicotinamide (100.0 mg 0.18 mmol) in dichloromethane (1 ml) was added trifluoroacetic acid (1 ml) at RT. The reaction mixture was stirred at RT for 30 min, and monitored by TLC (Hex:EtOAc=1:1 and contain TEA). Upon completion, the volatiles were evaporated, and the residue was dissolved in dichloromethane, washed with 5% aq. NaHCO 3 to get a precipitate. The residue was filtered, washed with water, and dried to get 53 mg (56%) of 2-Bromo-N-(2,4-dihydroxy-butoxy)-5-(2-fluoro-4-iodo-phenylamino)-isonicotinamide. LC/MS: [8.76 min, 541 (M+1)]
Example 72
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(3-imidazol-1-yl-propyl)-isonicotinamide
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(3-imidazol-1-yl-propyl)-isonicotinamide was synthesized according to the General Method 3, starting with 145 mg (0.33 mmol) of 2-bromo-5-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid and 103 mg (0.83 mmol) of 3-Imidazol-1-yl-propylamine. Yield: 55 mg, 30%, LC/MS: [7.31 min, 545 (M+1)]
Example 73
3-(4-iodo-phenylamino)-isonicotinic acid
3-(4-iodo-phenylamino)-isonicotinic acid was synthesized according to the procedure for General Method 1 and as Intermediate 1 by reacting 1.4 mmol of 4-iodoaniline with 2.8 mmol of 2-fluoro-isonicotinic acid LC/MS [6.29 min; 341(M+1)].
Example 74
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(2-hydroxy-ethyl)-isonicotinamide
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(2-hydroxy-ethyl)-isonicotinamide was synthesized according to General Method 3, starting with 145 mg (0.33 mmol) of 2-bromo-5-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid 51 mg (0.83 mmol) of 2-amino-ethanol. LC/MS: [8.98 min, 480, 482]
Example 75
N-{[(2S)-2,3-dihydroxypropyl]oxy}-3-[(2-fluoro-4-iodophenyl)-amino]isonicotin-amide
N-{[(4S)-2,2-dimethyl-1,3-dioxolan-4-yl]methoxy}-3-[(2-fluoro-4-iodophenyl)-amino]isonicotinamide (0.162 g, 0.332 mmol) was suspended in dichloromethane (4 mL) and then treated with trifluoroacetic acid (4 mL). The dark-yellow solution was stirred at room temp for 24 h, concentrated, re-dissolved in methanol (10 mL) and concentrated again. The residue was then placed in ethyl acetate (15 mL) and brine (20 mL) and the pH was adjusted between 6 and 7 with aqueous 2 N NaOH. The layers were separated and the organics were washed with brine (25 mL), concentrated to a yellow oil and placed under high vacuum for 3 h to afford the diol as a yellow semi-solid (0.118 g, 80%). LC/MS [7.11 min; 448 (M+1)]
Example 76
N-ethoxy-3-(4-iodo-phenylamino)-isonicotinamide
N-ethoxy-3-(4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.30 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.40 mmol of O-ethyl-hydroxylamine LC/MS [9.14 min; 418 (M+1)]
Example 77
N-allyloxy-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide
N-allyloxy-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.20 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.36 mmol of O-allyl-hydroxylamine. LC/MS [9.30 min; 430 (M+1)]
Example 78
N-isopropoxy-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide
N-isopropoxy-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.30 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.42 mmol of O-Isobutyl-hydroxylamine. LC/MS [10.06 min; 446 (M+1)]
Example 79
N-(3-chloropropyl)-3-[(2-fluoro-4-iodophenyl)-amino]isonicotinamide
N-(3-chloropropyl)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 1 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 1.3 mmol of 3-chloropropylamine. LC/MS [9.24 min; 434 (M+1)]
Example 80
N-methoxy-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide
N-methoxy-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.30 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.42 mmol of O-methyl-hydroxylamine. LC/MS [8.75 min; 404 (M+1)]
Example 81
N-Benzyloxy-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide
N-Benzyloxy-3-(2-chloro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.25 mmol of 3-[(2-chloro-4-iodophenyl)amino]isonicotinic acid (intermediate 2) and 0.36 mmol of O-methyl-hydroxylamine. LC/MS [10.0]min; 480 (M+1)]
Example 82
N-bicyclo[2.2.1]hept-2-yl-3-[(2-fluoro-4-iodophenyl)amino]-isonicotinamide
N-bicyclo[2.2.1]hept-2-yl-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.31 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.45 mmol of bicyclo[2.2.1]hept-2-ylamine. LC/MS [10.01 min; 452 (M+1)]
Example 83
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-hydroxyphenoxypropyl)-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(2-hydroxyphenoxypropyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.34 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.45 mmol of 2-hydroxyphenoxypropylamine. LC/MS [9.53 min; 508 (M+1)]
Example 84
3-[(2-fluoro-4-iodophenyl)amino]-N-(tetrahydro-2H-pyran-2-yloxy)-isonicotin-amide
3-[(2-fluoro-4-iodophenyl)amino]-N-(tetrahydro-2H-pyran-2-yloxy)isonicotin-amide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.4 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.52 mmol of O-(tetrahydro-pyran-2-yl)-hydroxylamine. LC/MS [9.07 min; 458 (M+1)]
Example 85
3-[(2-fluoro-4-iodophenyl)amino]-N-[2-(4-methylphenyl)-ethyl]isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-[2-(4-methylphenyl)ethyl]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.54 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.62 mmol of 2-(4-methylphenyl)ethylamine. LC/MS [10.25 min; 476 (M+1)]
Example 86
N-(1-{3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}piperidin-4-yl)-2-(4-methylphenyl)acetamide
A mixture of p-tolyl acetic acid (0.027 g, 0.180 mmol) and CDI (0.036 g, 0.222 mmol) in dry DMSO (2 mL) was heated to 50° C. for 2 h prior to addition of 4-[(4-aminopiperidin-1-yl)carbonyl]-N-(2-fluoro-4-iodophenyl)pyridin-3-amine hydrochloride (described above) (0.052 g, 0.109 mmol). The contents were then stirred at room temp. After 6 h, HPLC indicated near-complete reaction. The contents were poured into water (30 mL) and extracted with ethyl acetate (30 mL). The organics were washed with brine (2×30 mL), dried over sodium sulfate and concentrated to a yellow oil. The oil was further dried under high vacuum for 2 h at 40° C. to provide the desired product as a yellow semi-solid (0.068 g, 0.119 mmol, 66%). LC/MS [8.92 min; 573 (M+1)]
Example 87
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(2-methoxy-ethyl)-isonicotinamide
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(2-methoxy-ethyl)-isonicotinamide was synthesized according to the General method 3, starting with 145 mg (0.33 mmol) of 2-bromo-5-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid and 51 mg (0.83 mmol) of 2-amino-ethanol. Yield: 88 mg, 55%, LC/MS: [9.55 min; m/z: 495 (M+1)]
Example 88
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(2-morpholin-4-yl-ethyl)-isonicotinamide
2-Bromo-5-(2-fluoro-4-iodo-phenylamino)-N-(2-morpholin-4-yl-ethyl)-isonicotinamide was synthesized according to the General Method 3 starting with 145 mg (0.33 mmol) of 2-bromo-5-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid and 108 mg (0.83 mmol) of 2-morpholin-4-yl-ethylamine. Yield: 95 mg, 52%. LC/MS: [7.08 min, 550, 552 (M+1)]
Example 89
N-(2,2-Dimethyl-[1,3]dioxolan-4-ylmethoxy)-3-(2-fluoro-4-iodo-phenylamino)-1-oxy-isonicotinamide
N-(2,2-Dimethyl-[1,3]dioxolan-4-ylmethoxy)-3-(2-fluoro-4-iodo-phenylamino)-1-oxy-isonicotinamide was synthesized as described in General Method 2: to a solution of 3-(2-Fluoro-4-iodo-phenylamino)-1-oxy-isonicotinic acid (110 mg, 0.29 mmol) in DMF (1.2 ml) was added 1,1′-carbonylbis(1H-imidazole) (52.45 mg, 0.32 mmol). The reaction mixture was stirred at RT under argon for 6 hrs. Then, O-[(2,2-dimethyl-1,3-dioxolan-4-yl)methyl]hydroxylamine (109 mg 0.74 mmol) was added, and the mixture stirred overnight. Then, it was poured into water (10 ml), extracted with EtOAc (3×15 ml), and the combined organic layers were washed with brine (2×15 ml), and dried over MgSO 4 . The solvent was evaporated, and the residue was purified on silica gel column to obtain 75 mg (51%) of N-(2,2-Dimethyl-[1,3]dioxolan-4-ylmethoxy)-3-(2-fluoro-4-iodo-phenylamino)-1-oxy-isonicotinamide. LC/MS: [8.54 min, 504 (M+1)]
Example 90
3-[(2-fluoro-4-iodophenyl)amino]-N′-(3-methylphenyl)isonicotino-hydrazide
3-[(2-fluoro-4-iodophenyl)amino]-N′-(3-methylphenyl)isonicotinohydrazide: was synthesized according to the procedure for General Method 1, outlined above, starting with 0.44 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.63 mmol of 3-methyl-phenylhydrazine. LC/MS [6.05 min; 463 (M+1)]
Example 91
N-(benzyloxy)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide
N-(benzyloxy)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.5 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.72 mmol of O-benzyl-hydroxylamine. LC/MS [9.50 min; 464 (M+1)]
Example 92
[({3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}amino)oxy]acetic acid
[({3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}amino)oxy]acetic acid was synthesized according to the procedure for General Method 1, outlined above, starting with 0.3 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.51 mmol of aminoxy-acetic acid. LC/MS [5.21 min; 432 (M+1)]
Example 93
N-(2,4-difluorobenzyl)-3-[(2-fluoro-4-iodophenyl)amino]-isonicotinamide
N-(2,4-difluorobenzyl)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.33 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.49 mmol of 2,4-difluorobenzylamine. LC/MS [6.28 min; 484 (M+1)]
Example 94
3-[(2-fluoro-4-iodophenyl)amino]-N-(3-iodobenzyl)isonicotin-amide
3-[(2-fluoro-4-iodophenyl)amino]-N-(3-iodobenzyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.23 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.43 mmol of 3-iodobenzylamine. LC/MS [6.37 min; 574 (M+1)]
Example 95
3-(2-Fluoro-4-iodo-phenylamino)-2-methyl-isonicotinic acid
3-(2-Fluoro-4-iodo-phenylamino)-2-methyl-isonicotinic acid was synthesized according to the procedure for General Method 1 and as Intermediate 1 by reacting 2 mmol of 2-fluoro-4-iodoaniline with 3.4 mmol of 2-fluoro-3-methyl-isonicotinic acid LC/MS [4.63 min; 373 (M+1)].
Example 96
N-{[(2R)-2,3-dihydroxypropyl]oxy}-3-(4-iodophenylamino)-isonicotinamide
N-{[(2R)-2,3-dihydroxypropyl]oxy}-3-(4-iodophenylamino)-isonicotinamide 3-(4-iodo-phenylamino)-isonicotinamide was synthesized in the same manner as N-{[(2R)-2,3-dihydroxypropyl]oxy}-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide (described above). LC/MS [7.17 min; 430 (M+1)]
Example 97
3-(2-Fluoro-4-iodo-phenylamino)-1-oxy-isonicotinamide
The synthesis of 3-(2-Fluoro-4-iodo-phenylamino)-1-oxy-isonicotinamide was described under General Method 2.
Example 98
N-(2,2-diethoxyethyl)-3-[(2-fluoro-4-iodophenyl)amino]-isonicotinamide
N-(2,2-diethoxyethyl)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.33 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.5 mmol of 2,2-diethoxy-ethylamine. LC/MS [5.51 min; 474 (M+1)]
Example 99
3-[(2-fluoro-4-iodophenyl)amino]-N′-(4-methylphenyl)isonicotino-hydrazide
3-[(2-fluoro-4-iodophenyl)amino]-N′-(4-methylphenyl)isonicotinohydrazide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.4 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.6 mmol of 4-methyl-phenylhydrazine. LC/MS [5.07 min; 463 (M+1)]
Example 100
3-(2-Fluoro-4-iodo-phenylamino)-2-methyl-isonicotinamide
3-(2-Fluoro-4-iodo-phenylamino)-2-methyl-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.2 mmol of 3-[(2-fluoro-4-iodophenyl)amino]-2-methyl-isonicotinic acid and 0.4 mmol of ammonium acetate. LC/MS [1.85 min; 372 (M+1)].
Example 101
N′-[3,5-bis(trifluoromethyl)phenyl]-3-[(2-fluoroiodophenyl)amino]-isonicotino-hydrazide
N′-[3,5-bis(trifluoromethyl)phenyl]-3-[(2-fluoroiodophenyl)amino]isonicotino-hydrazide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.37 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.53 mmol of 3,5-ditrifluoromethylbenzylhydrazine. LC/MS [6.47 min; 585 (M+1)]
Example 102
4-[2-({3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}-amino)ethyl]benzoic acid
4-[2-({3-[(2-fluoro-4-iodophenyl)amino]isonicotinoyl}amino)ethyl]benzoic acid was synthesized according to the procedure for General Method 1, outlined above, starting with 0.66 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.83 mmol of 4(2-ethylamine)benzoic acid. LC/MS [6.10 min; 506 (M+1)]
Example 103
3-[(2-fluoro-4-iodophenyl)amino]-N-[(pentafluorobenzyl)oxy]-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-[(pentafluorobenzyl)oxy]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.32 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.43 mmol of O-pentafluorophenylmethyl-hydroxylamine. LC/MS [6.50 min; 554 (M+1)]
Example 104
3-[(2-fluoro-4-iodophenyl)amino]-N-(3-methoxyphenyl)-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(3-methoxyphenyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.31 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.46 mmol of 3-methoxyaniline. LC/MS [6.40 min; 464 (M+1)]
Example 105
3-[(2-fluoro-4-iodophenyl)amino]-N-[3-fluoro-5-(trifluoromethyl)-benzyl]isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-[3-fluoro-5-(trifluoromethyl)benzyl]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.25 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.37 mmol of 3-fluoro-5-trifluoromethyl-benzylamine. LC/MS [6.51 min; 534 (M+1)]
Example 106
3-[(2-fluoro-4-iodophenyl)amino]-N-(3-hydroxybenzyl)-isonicotinamide
3-[(2-fluoro-4-iodophenyl)amino]-N-(3-hydroxybenzyl)isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.22 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.35 mmol of 3-hydroxybenzylamine. LC/MS [6.01 min; 464 (M+1)]
Example 107
N-(4,4-diethoxybutyl)-3-[(2-fluoro-4-iodophenyl)amino]-isonicotinamide
N-(2,2-diethoxybutyl)-3-[(2-fluoro-4-iodophenyl)amino]isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.30 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.45 mmol of 2,2-dibutyloxy-ethylamine. LC/MS [6.33 min; 502 (M+1)]
Example 108
N-(4-Fluoro-benzyl)-3-(2-fluoro-4-iodo-phenylamino)-iso-nicotinamide
N-(4-Fluoro-benzyl)-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.25 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.33 mmol of 4-fluoro-benzylamine. LC/MS [6.99 min; 466 (M+1)]
Example 109
3-(2-Fluoro-4-iodo-phenylamino)-N-(2,2,2-trifluoro-ethyl)-isonicotinamide
3-(2-Fluoro-4-iodo-phenylamino)-N-(2,2,2-trifluoro-ethyl)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.30 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.45 mmol of 2,2,2-trifluoro-ethylamine. LC/MS [6.73 min; 440 (M+1)]
Example 110
3-(2-Fluoro-4-iodo-phenylamino)-N-(1-hydroxymethyl-cyclo-pentyl)-isonicotinamide
3-(2-Fluoro-4-iodo-phenylamino)-N-(1-hydroxymethyl-cyclopentyl)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.25 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.42 mmol of 1-amino-cyclopentyl)-methanol. LC/MS [6.04 min; 456 (M+1)].
Example 111
5-[(2-fluoro-4-iodophenyl)amino]-2-methylisonicotinic acid
The synthesis of 5-[(2-fluoro-4-iodophenyl)amino]-2-methylisonicotinic acid is described under General Method 4.
Example 112
N-(1-(S)-Carbamoyl-2-hydroxy-ethyl)-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide
N-(1-(S)-Carbamoyl-2-hydroxy-ethyl)-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.30 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.45 mmol of L-serinamide. LC/MS [5.09 min; 445 (M+1)]
Example 113
3-(2-Fluoro-4-iodo-phenylamino)-N-(trans-2-hydroxy-cyclohexyl)-isonicotinamide
3-(2-Fluoro-4-iodo-phenylamino)-N-(trans-2-hydroxy-cyclohexyl)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.27 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.40 mmol of trans-2-aminocyclohexanol. LC/MS [6.40 (10 min) min; 640 (M+1)]
Example 114
N-(1,1-Bis-hydroxymethyl-propyl)-3-(2-fluoro-4-iodo-phenyl-amino)-isonicotin-amide
N-(1,1-Bis-hydroxymethyl-propyl)-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.33 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.47 mmol of 2-amino-2-ethyl-propane-1,3-diol. LC/MS [5.93 min; 460 (M+1)]
Example 115
N-(2,3-dihydroxy-propyl)-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide
N-(2,3-dihydroxy-propyl)-3-(2-fluoro-4-iodo-phenylamino)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.56 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.84 mmol of 2-amino-2-ethyl-propane-1,3-diol. LC/MS [5.41 min; 432 (M+1)]
Example 116
3-(2-Fluoro-4-iodo-phenylamino)-N-(3-piperazin-1-yl-propyl)-isonicotinamide
3-(2-Fluoro-4-iodo-phenylamino)-N-(3-piperazin-1-yl-propyl)-isonicotinamide was synthesized according to the procedure for General Method 1, outlined above, starting with 0.32 mmol of 3-[(2-fluoro-4-iodophenyl)amino]isonicotinic acid (intermediate 1) and 0.47 mmol of. 2-piperazin-1-yl-ethylamine. LC/MS [5.02 min; 484 (M+1)].
Example 117
2-Chloro-3-(2-fluoro-4-iodo-phenylamino)-isonicotinic acid
2-Chloro-3-(2-fluoro-4-iodo-phenylamino)-isonicotinic acid was synthesized as outlined in General Method 1 and according to the procedure for the synthesis of intermediate 1 by reacting 4 mmol of 2-methyl-4-iodoaniline with 6 mmol 2-fluoro-3-chloro-isonicotinic acid. LC/MS [10.25 min; 390.9 (M−1)-ESI-].
Example 118
3-(4-Methoxy-phenylamino)-isonicotinic acid
3-Fluoro-isonicotinic acid (50 mg, 0.354 mmol) and p-anisidine (44 mg, 0.354 mmol) was added to 2 ml dry THF and the mixture was cooled to −78° C. LiHMDS (1M in THF, 1.24 ml) was added and the mixture was allowed to warm to room temperature over night. Hydrochloric acid (1M in methanol, 5 ml) was added and the volatiles were removed in vacuo. The crude material was purified by preparative RP chromatography to give 11 mg (45 μmol; 13% yield) of pure desired product. LC-MS (method V): rt=1.82 min; m/z [M+H] + 245.
Example 119
3-(4-Trifluoromethylsulfanyl-phenylamino)-isonicotinic acid
3-Fluoro-isonicotinic acid (50 mg, 0.354 mmol) and 4-(trifluoromethylthio)aniline (68.5 mg, 0.354 mmol) was added to 2 ml dry THF and the mixture was cooled to −78° C. LiHMDS (1M in THF, 1.24 ml) was added and the mixture was allowed to warm to room temperature over night. Hydrochloric acid (1M in methanol, 5 ml) was added and the volatiles were removed in vacuo. The crude material was purified by preparative HPLC to give 11.4 mg (45 μmol; 10% yield) of pure desired product. LC-MS (method V): rt=3.09 min; m/z [M+H] + 315.
Example 120
3-(4-Trifluorornethoxy-phenylamino)-isonicotinic acid
3-Fluoro-isonicotinic acid (50 mg, 0.354 mmol) and 4-(trifluoromethoxy)aniline (62.8 mg, 0.354 mmol) was added to 2 ml dry THF and the mixture was cooled to −78° C. LiHMDS (1M in THF, 1.24 ml) was added and the mixture was allowed to warm to room temperature over night. Hydrochloric acid (1M in methanol, 5 ml) was added and the volatiles were removed in vacuo. The crude material was purified by preparative HPLC to give 9.5 mg (32 μmol; 9% yield) of pure desired product. LC-MS (method V): rt=2.69 min; m/z [M+H] + 299.
Example 121
3-[(4-Bromo-2-fluorophenyl)amino]-N-ethoxyisonicotinamide
Step 1: Synthesis of 3-[(4-Bromo-2-fluoro)amino]isonicotinic acid.
3-Fluoro-isonicotinic acid (1 g, 7.09 mmol) and 4-bromo-2-fluoroaniline (1.35 g, 7.09 mmol) was added to 10 ml of dry THF and the mixture was cooled to −78° C. LiHMDS (1M in THF, 24.8 ml) was added and the mixture was allowed to warm to room temperature over night. Solid ammonium hydrochloride (2 g) was added and after 1 h the mixture was filtered and the volatiles were removed in vacuo. The crude material was purified by flash-chromatography using C2-modified silica and a gradient of 0-12% methanol in DCM as eluent to give 1.21 g (3.89 mmol; 55% yield) of pure desired carboxylic acid product.
Step 2: 3-[(4-Bromo-2-fluoro)amino]isonicotinic acid from step 1 (300 mg, 0.964 mmol) was dissolved in 6 ml dry DMF followed by the addition of DIPEA (1.16 mmol, 208 μl), PyBOP (1.16 mmol, 602 mg) and O-ethylhydroxylamine hydrochloride (1.93 mmol, 188 mg). The mixture was stirred at ambient temperature over night and the volatiles were removed in vacuo. The crude material was purified by flash chromatography using silica gel and a gradient of 0-5% methanol in DCM as eluent to give 822 mg of a mixture of the desired product and PyBop-derived phosphoramide byproduct. A 215 mg sample thereof was further purified by preparative RP-HPLC to give 23.3 mg (65.5 mmol) of the pure title compound. LC-MS (method III): rt=6.46 min; m/z [M+H] + 354/356
Example 122
3-[(4-Iodo-2-fluorophenyl)amino]-N-ethoxyisonicotinamide
Step 1: Synthesis of 3-[(4-iodo-2-fluoro)amino]isonicotinic acid.
3-Fluoro-isonicotinic acid (1 g, 7.09 mmol) and 4-iodo-2-fluoroaniline (1.68 g, 7.09 mmol) was added to 10 ml of dry THF and the mixture was cooled to −78° C. LiHMDS (1M in THF, 24.8 ml) was added and the mixture was allowed to warm to room temperature over night. Solid ammonium hydrochloride (2 g) was added and after 1 h the mixture was filtered and the volatiles were removed in vacuo. The crude material was purified by flash-chromatography using C2-modified silica and a gradient of 0-12% methanol in DCM as eluent to give 932 mg (2.32 mmol; 33% yield) of pure desired carboxylic acid product.
Step 2: 3-[(4-Iodo-2-fluoro)amino]isonicotinic acid from step 1 (200 mg, 0.559 mmol) was dissolved in 4 ml dry DMF followed by the addition of DIPEA (0.671 mmol, 121 μl), PyBOP (0.371 mmol, 350 mg) and O-ethylhydroxylamine hydrochloride (1.12 mmol, 110 mg). The mixture was stirred at ambient temperature over night and the volatiles were removed in vacuo. The crude material was purified by preparative RP-HPLC to give 113 mg (282 mmol; 50% yield) of the pure title compound. LC-MS (method III): rt=7.03 min; m/z [M+H] + 402.
Example 123
N-[3-(4-Iodo-2-methyl-phenylamino)-pyridine-4-carbonyl]-methanesulfonamide
3-[(4-Iodo-2-methylphenyl)amino]isonicotinic acid (example 3) (50 mg, 0.141 mmol) was dissolved in 4 ml dry THF followed by the addition of 1,1′-carbonyldiimidazole (CDI) (0.311 mmol, 50 mg), methanesulfonamide (0.169 mmol, 16.1 mg) and DBU (0.169 mmol, 26 mg). The mixture was stirred for 16 h at 40° C. and the volatiles were removed in vacuo. The crude material was purified by preparative HPLC to give 20.3 mg (47 μmol; 33% yield) of pure desired product. LC-MS (method III): rt=2.74 min; m/z [M+H] + 432.
Example 124
N-((S)-2,3-Dihydroxy-propoxy)-3-(4-iodo-2-methyl-phenylamino)-isonicotinamide
The title compound was synthesized by the procedure as described for Example 119 using O—((S)-2,2-dimethyl-[1,3]dioxolan-4-ylmethyl)-hydroxylamine as a building block. LC-MS (method III): rt=3.22 min; m/z [M+H]+ 444.
Example 125
3-(4-Bromo-2-fluoro-phenylamino)-2-chloro-isonicotinic acid
2-Chloro-3-fluoro-isonicotinic acid (200 mg, 1.14 mmol) and 4-bromo-2-fluoroaniline (217 mg, 1.14 mmol) were added to 5 ml of dry THF and the mixture was cooled to −78° C. LiHMDS (1M in THF, 4.0 ml) was added and the mixture was allowed to warm to room temperature over night. Solid ammonium hydrochloride (1 g) was added and after 1 h the mixture was filtered and the volatiles were removed in vacuo. The crude material was purified by flash-chromatography using a gradient of 0-12% methanol (containing 0.5% formic acid) in DCM as eluent to give 213 mg (0.617 mmol; 54% yield) of pure desired carboxylic acid product. LC-MS (method III): rt=4.42 min; m/z [M+H]+ 386/388.
Example 126
5-[3-(4-Bromo-2-fluoro-phenylamino)-pyridin-4-yl]-3H-[1,3,4]oxadiazol-2-one
Step 1: Synthesis of 3-(4-Bromo-2-fluoro-phenylamino)-isonicotinic acid hydrazide.
3-(4-Bromo-2-fluoro-phenylamino)-isonicotinic acid (synthesis: see example 121 step 1) (1.5 g, 4.82 mmol) was dissolved in dry DMF (30 ml), N-t-butoxycarbonylhydrazide (1.27 g, 9.64 mmol), ByBOP (3.26 g, 6.27 mmol) and DIPEA (2.52 ml, 14.5 mmol) were added and the mixture was stirred at 60° C. for 14 h. The volatiles were evaporated, the residue was redissolved in ethyl acetate and washed consecutively with saturated NaHCO 3 , water and brine and dried over sodium sulfate. The volatiles were evaporated and the crude material was purified by flash-chromatography using a gradient of 0-10% methanol in DCM as eluent. The Boc-protected hydrazide was treated with 4N HCl in dioxane (40 ml) at ambient temperature for 14 h and the volatiles were removed under reduced pressure to give 1.59 g (4.66 mmol) of the crude hydrazide.
Step 2: The material derived from step 1 was dissolved in DMF, DIPEA (1.14 ml,
6.52 mmol) and 1,1′-carbonyldiimidazole (CDI, 945 mg, 5.83 mmol) were added and the mixture was stirred at room temperature for 14 h. The volatiles were evaporated and the crude material was purified by flash-chromatography using a gradient of 30-80% ethyl acetate in cyclohexane to give 888 mg (2.53 mmol, 52% yield, 2 steps) of the title compound. LC-MS (method V): rt=3.27 min; m/z [M+H]+ 351/353.
Example 127
2-{5-[3-(4-Bromo-2-fluoro-phenylamino)-pyridin-4-yl]-[1,3,4]oxadiazol-2-ylamino}-ethanol
Step 1: 5-[3-(4-Bromo-2-fluoro-phenylamino)-pyridin-4-yl]-3H-[1,3,4]oxadiazol-2-one (example 19, 100 mg, 0.277 mmol) was dissolved in ethanol (4 ml), ethanolamine (85 mg, 1.38 mmol) was added and the mixture was stirred for 20 min at 160° C. in a microwave oven. The volatiles were removed to give the crude compound, which was used in the next step.
Step 2: Dry dichloromethane (10 ml) was added to the product derived from step 1, triphenylphosphine (113 mg, 0.429 mmol), triethylamine (58 μl, 0.416 mmol) and carbon tetrachloride (107 μl, 1.11 mmol) were added. The mixture was heated at 100° C. for 10 min in a microwave oven, the volatiles were removed and the crude material was purified by preparative HPLC to give 43 mg (40% yield) of the title compound. LC-MS (method III): rt=4.92 min; m/z [M+H]+ 394/396.
Example 128
N-{5-[3-(4-Bromo-2-fluoro-phenylamino)-pyridin-4-yl]-[1,3,4]oxadiazol-2-yl}-N′-methyl-ethane-1,2-diamine
Step 1: 5-[3-(4-Bromo-2-fluoro-phenylamino)-pyridin-4-yl]-3H-[1,3,4]oxadiazol-2-one (example 19, 100 mg, 0.277 mmol) was dissolved in ethanol (3 ml), N-(2-aminoethyl)-N-methylcarbamic acid t-butylester (96 mg, 0.554 mmol) was added and the mixture was stirred for 20 min at 150° C. in a microwave oven. The volatiles were removed to give the crude compound, which was used in the next step.
Step 2: Dry dichloromethane (5 ml) was added to the product derived from step 1 followed by triphenylphosphine (113 mg, 0.429 mmol), triethylamine (58 μl, 0.416 mmol) and carbon tetrachloride (107 μl, 1.11 mmol). The mixture was heated at 1° C. for 20 min in a microwave oven, the volatiles were removed and the crude material was purified by preparative HPLC to give 87 mg (62% yield) of the Boc-protected title compound. The material was treated with 4N HCl in dioxane (4 ml) for 1 h at ambient temperature and the volatiles were removed to give the pure title compound. LC-MS (method V): rt=1.94 min; m/z [M+H]+ 407/409.
Example 129
[4-(5-Allylamino-[1,3,4]oxadiazol-2-yl)-pyridin-3-yl]-(4-bromo-2-methyl-phenyl)-amine
Step 1: 3-(4-Bromo-2-methyl-phenylamino)-isonicotinic acid hydrazide was prepared from 3-[(4-bromo-2-methylphenyl)amino]isonicotinic acid (example 2) by the procedure as described for example 126 step 1.
Step 2: 3-(4-Bromo-2-methyl-phenylamino)-isonicotinic acid hydrazide (0.426 mmol) was dissolved in 5 ml THF and treated with allylisocyanate (110 mg, 0.852 mmol) followed by DIPEA (110 mg, 0.852 mmol) and the mixture was stirred for 2 h at ambient temperature. The volatiles were removed to give the crude compound, which was used for the next step.
Step 3: The product derived from step 2 was cyclized by the procedure described for example 127 step 2. LC-MS (method III): rt=6.99 min; m/z [M+H]+ 386/388.
Assay 1: MEK-1 Enzyme Assay (LANCE-HTRF)
The activity of the compounds of the present invitation may be determined by the following procedure: Inhibition of human MEK1 kinase activity was monitored with a homogenous, fluorescence based assay. The assay uses time resolved fluorescence resonance energy transfer to probe for phosphorylation of ERK1 by MEK1. The assay is carried out in low volume 96 well microtiterplates. In a total volume of 15 μl, compounds are incubated with 100 nM MEK1, 15 μM ATP, 300 nM ERK2 employing a buffer containing 20 mM TRIS/HCl, 10 mM MgCl2 , 100 μM NaVO4, 1 mM DTT, and 0.005% Tween 20 (pH 7.4). After two hours, 5 nM Europium-anti-PY20 (Perkin Elmer) and 50 nM Anti-GST-Allophycocyanin (CisBio) in buffer containing 50 mM EDTA and 0.05% BSA are added and the reaction incubated for one hour in the dark. Time-resolved fluorescence is measured using a LJL-Analyst (Molecular Devices) with an excitation wavelength of 340 nm and an emission wavelength of 665 nm. The final concentration of DMSO is 2%. To assess the inhibitory potential of the compounds, IC50-values were determined.
In this assay compounds of the invention exhibited IC50s within certain ranges. The following compounds exemplify such activity with “+” meaning 1 μM<IC50≦10 μM and “++” IC50≦1 μM. All results are shown in Table 1.
Assay 2: Tumor Cell Proliferation Assays (ATP Lite)
Murine colon C26, human melanoma A375 and MeI5 or human pancreatic MiaPaCa-2 cells were plated in 96 well Corning white plates (1500 cells/well for C26, and 2000 cells/well for A375, and MiaPaCa-2) and cultured overnight at 37° C. in 5% CO2. Inhibitors were serially diluted in 100% DMSO and subsequently added to cells to reach a final concentration of 0.25% DMSO. The cells were incubated for 4 days in the presence of test compounds in cell growth media (DMEM with 10% fetal bovine serum, 2 mM glutamine for C26, and MiaPaCa-2, and RPMI with 10% fetal bovine serum, 2 mM glutamine for A375). Cell proliferation was quantitated using the ATP lite cell proliferation kit (Packard). Inhibition of cell proliferation is shown in Table 1. Columns 4-6 show the concentration of compounds required to induce 50% cell death (IC50 in μM) of human end ometriotic cells. With “+” meaning 3 μM<IC50≦10 μM and “++” IC50≦3 μM and “n.d.” means not determined. Few compounds were also tested on human melanoma cell MeI5. Compound of Example #124 showed an IC50 of “++”, the compound of Example 4 showed an IC50 of “+” and the compound of Example 5 showed an IC50 of “++”.
Assay 3: Microsomal Stability Assay
Compounds were tested on their stability in human, rat and mouse liver microsomal preparations (HLM, RLM and MLM respectively). At a final concentration of 3 μM, compounds were incubated at 37° C. with 0.5 mg/ml human, rat or mouse liver microsomes in a buffer containing 50 mM phosphate, pH 7.4 and 2 mM NADPH. Pooled human liver microsomes or pooled male rat liver microsomes (Sprague Dawley) were obtained from NatuTec (Frankfurt, Germany). Incubations without NADPH served as negative controls. Reactions were stopped after 0, 15, 30, 45 or 60 min by the addition of acetonitrile and microsomes were pelleted by centrifugation (10 min at 6200×g). Supernatants were analyzed by HPLC regarding the concentration of mother compound Finally, the half life of compounds in the regarding microsomal preparation was calculated. Results are shown in Table 2 Wherein “+” means t 1/2 of 1-30 min, “++” means t 1/2 of 31-120 min and “+++” means t 1/2 of >120 min.
Assay 4: Caco-2 Permeability Assay
Caco-2 cells obtained from the ATCC at passage number 27 are used. Cells (passage number 40-60) were seeded on to Millipore Multiscreen Caco-2 plates or Falcon HTS inserts at 1×105 cells/cm2. Cells were cultured for 20 days in DMEM and media was changed every two or three days. On day 20 the permeability study was performed.
Permeability was studied by applying compound to the apical surface of cell monolayers and measuring compound permeation into the basolateral compartment. The experiment was also performed in the reverse direction (B-A) to investigate active transport. Hanks Balanced Salt Solution (HBSS) pH 7.4 buffer with 25 mM HEPES and 10 mM glucose at 37° C. was used as the medium in permeability studies. Incubations were carried out in an atmosphere of 5% CO 2 with a relative humidity of 95%.
The monolayers were prepared by rinsing both basolateral and apical surfaces twice with HBSS at 37° C. Cells were then incubated with HBSS in both apical and basolateral compartments for 40 minutes to stabilize physiological parameters.
HBSS was then removed from the apical compartment and replaced with test compound dosing solutions. The solutions were made by diluting 10 mM DMSO concentrates with HBSS to give a final test compound concentration of 10 μM (final DMSO concentration adjusted to 1%). The fluorescent integrity marker lucifer yellow was also included in the dosing solution. Analytical standards were made from dosing solutions. Test compound permeability was assessed in duplicate. On each plate compounds of known permeability characteristics were run as controls.
The apical compartment inserts were then placed into ‘companion’ plates containing fresh HBSS. For basolateral to apical (B-A) experiments the experiment was initiated by replacing buffer in the inserts then placing them in companion plates containing dosing solutions. At 120 minutes the companion plate was removed and apical and basolateral samples diluted for analysis by LC-MS/MS (the donor compartment was also sampled to permit determination of starting concentration after non-specific binding has occurred).
Analysis
The integrity of the monolayers throughout the experiment is checked by monitoring lucifer yellow permeation using fluorimetric analysis. Lucifer yellow permeation was low if monolayers have not been damaged. Test and control compounds were quantified by LC-MS/MS cassette analysis using a 5-point calibration with appropriate dilution of the samples. Should lucifer yellow Papps were above QC limits in more than one well per test compound, the compound was re-tested.
The permeability coefficient for each compound (P app ) was calculated from the following equation:
P app =[dQ/dt]/[C 0 ×A]
Whereby dQ/dt is the rate of permeation of the drug across the cells, C 0 is the donor compartment concentration at time zero and A is the area of the cell monolayer. C 0 is obtained from analysis of the donor compartment at the end of the incubation period.
Test compounds were grouped into low, medium or high absorption potential based on comparison with control compounds, which have known human absorption.
In addition, permeation was studied in both directions across the cells, and an asymmetry index was reported from mean A-B and B-A data. This was derived from:
P app(B-A) /P app(A-B)
Results are shown in Table 2. Wherein “+” means a caco A-B and caco B-A value of 1-10 and “++” means a caco A-B and caco B-A value of 11-100.
TABLE 1
Results of MEK enzyme assay and tumor cell proliferation assay
MEK
IC50 [μM]
IC50 [μM]
IC50 [μM]
Example #
inhibition
C26
A375
Miapaca
1
++
2
++
3
++
4
++
++
n.d.
5
++
+
++
n.d.
6
+
7
++
++
++
++
8
++
++
++
++
9
++
+
++
n.d.
10
++
+
++
++
11
++
++
++
++
12
++
++
++
++
13
++
++
++
++
14
++
++
++
++
15
++
++
++
++
16
++
++
++
++
17
++
++
++
++
18
++
++
++
++
19
++
+
++
++
20
++
++
++
++
21
++
+
++
+
22
++
++
++
++
23
++
++
++
++
24
++
++
++
++
25
++
++
++
++
26
++
+
++
+
27
++
+
+
+
28
++
+
++
+
29
++
+
++
+
30
++
++
++
++
31
++
++
++
++
32
++
++
++
++
33
++
++
++
++
34
++
+
++
+
35
++
++
++
++
36
++
++
++
++
37
++
n.d.
n.d.
n.d.
38
+
n.d.
n.d.
n.d.
39
++
++
++
++
40
++
+
++
+
41
++
++
++
++
42
++
+
++
+
43
++
+
++
+
44
++
+
++
+
45
++
+
++
+
46
++
+
++
+
47
++
++
++
++
48
++
++
++
++
49
++
++
++
++
50
++
+
++
+
51
++
+
++
++
52
+
n.d.
n.d.
n.d.
53
++
++
++
++
54
+
+
55
++
+
++
+
56
+
+
++
+
57
+
n.d.
n.d.
n.d.
58
++
++
++
++
59
+
n.d.
n.d.
n.d.
60
++
++
++
++
61
++
+
62
++
+
++
63
++
++
64
++
+
++
+
65
++
+
++
+
66
++
++
67
++
++
++
++
68
++
++
++
++
69
++
+
++
70
++
++
++
++
71
++
+
++
+
72
++
+
++
+
73
++
74
++
+
++
+
75
++
++
++
++
76
++
+
++
+
77
++
+
++
+
78
++
+
++
79
++
++
++
++
80
++
++
+
81
++
+
++
+
82
++
+
++
+
83
++
++
++
++
84
++
+
++
85
++
+
++
+
86
++
+
++
+
87
++
++
+
88
++
+
+
+
89
+
n.d.
n.d.
n.d.
90
++
++
++
++
91
++
+
++
+
92
++
+
++
+
93
++
+
++
+
94
++
+
95
++
96
++
++
++
++
97
++
++
++
++
98
++
+
++
+
99
++
+
++
+
100
++
+
++
+
101
++
+
++
+
102
++
+
++
+
103
++
n.d.
nd.
n.d.
104
++
n.d.
n.d.
nd.
105
++
n.d.
n.d.
n.d.
106
++
n.d.
n.d.
n.d.
107
++
n.d.
n.d.
n.d.
108
++
n.d.
n.d.
n.d.
109
++
n.d.
n.d.
n.d.
110
++
n.d.
n.d.
n.d.
111
++
n.d.
nd.
n.d.
112
++
n.d.
n.d.
n.d.
113
++
n.d.
nd.
n.d.
114
++
n.d.
n.d.
nd.
115
++
n.d.
n.d.
n.d.
116
++
n.d.
n.d.
n.d.
117
n.d.
n.d.
n.d.
n.d.
118
+
n.d.
n.d.
n.d.
119
+
n.d.
n.d.
n.d.
120
n.d.
n.d.
n.d.
121
++
n.d.
n.d.
n.d.
122
n.d.
n.d.
n.d.
123
++
n.d.
n.d.
n.d.
124
++
+
n.d.
n.d.
125
++
n.d.
n.d.
n.d.
126
+
n.d.
n.d.
n.d.
127
n.d.
n.d.
n.d.
128
++
n.d.
n.d.
n.d.
129
++
nd.
n.d.
n.d.
TABLE 2
Results of caco-2 permeability assay and microsomal stability assay
HLM t 1/2
RLM t 1/2
MLM t 1/2
Example #
[min]
[min]
[min]
Caco A-B
Caco B-A
4
++
++
n.d.
n.d.
n.d.
9
+++
+++
+++
+
++
123
++
+
n.d.
n.d.
n.d.
127
+++
+++
+
++
++
128
+++
++
n.d.
++
++
129
+++
++
+++
++
++
|
The invention provides novel, substituted 3-arylamino pyridine compounds (I) pharmaceutically acceptable salts, solvates and prodrug compounds thereof, wherein W, R1, R2, R9, R10, R11, R12, R13, R14 are as defined in the specification. Such compounds are MEK inhibitors and useful in the treatment of hyperproliferative diseases, such as cancer, restenosis and inflammation. Also disclosed is the use of such compounds in the treatment of hyperproliferative diseases in mammals, especially humans, and pharmaceutical compositions containing such compounds.
| 2
|
FIELD OF THE INVENTION
[0001] The invention relates to the technical field of drilling, and particularly, to a drilling auxiliary system.
BACKGROUND OF THE INVENTION
[0002] Logging While Drilling (LWD) in oil and gas exploration refers to the technologies to constantly measure geophysical information around borehole in the process of drilling, and to real-time transmit the logging data back to the surface. One of the key technologies of LWD is the real-time signal transmission. Currently, mud-pulse telemetry system is widely applied, in which the signals are sent to the surface with the help of pulses transmitted through the drilling mud. The mud-pulse telemetry system is used in a wide range of drilling wells, but with a fairly low data transmission rate, usually less than 8 bit per second. Electromagnetic (EM) telemetry technology was developed to improve the transmission rate, which sends signals from the down hole to the surface through EM waves. A short insulation section is installed between the non-magnetic drill collar and the upper drill pipe, and a low frequency alternative current is applied on both ends of the insulation section to generate the EM field. This EM filed contains the logging information, and will be achieved by measuring the voltage between the surface pipe and an electrode, which is set on a remote ground surface. FIG. 1 shows a typical EM telemetry system of a prior art. An insulating ring 2 is set on the drill pipe 5 (on the top of the drill bit 4 ) to divide the drill pipe into two mutually insulated segments. Power source 3 loads a low-frequency current to both ends of the insulating ring. As the arrows in the figure indicate, the formation (refers to the formation from the vicinity of both ends of the insulating ring 2 to infinity) and the power source form a current loop. In the FIG. 1 , the arrowed lines indicate the current distribution in the formation at a certain moment. Wherein, thick lines indicate strong current intensity, thin lines imply weak current intensity, and dotted lines stands for very small current intensity. The currents in the different part of formation change both value and direction with respect to time, but the ratios among the current intensity are substantially constant. As shown in FIG. 1 , there is relatively larger current intensity in the sub-loop near the insulating ring 2 , and much weaker current intensity in the sub-loop far from the insulating ring 2 . And when the well is deep (such as a well 2000 meters long), the current in the sub-loop through the vicinity of surface will be very weak. The LWD data is loaded on the power source, and will be transmitted to the surface through the electromagnetic field generated by the currents. A signal receiver 10 is connected between the terminal A (surface part of casing 1 of the drilling well) and a far ground terminal B. Thus, the downhole data can be acquired by measuring the voltage between terminal A and B using the signal receiver 10 . However, because the EM signal strength near the ground surface is very small, the signal receiver 10 is required of an extremely high sensitivity, and the data transmission rate is also quite limited.
[0003] As one of wild applied technologies of LWD, Case ranging is the process to locate the downhole casings of the nearby existing wells during the drilling process. There are two relatively mature techniques in case ranging. One is to put a transmission line (or a transmitter) into the wells to be located, and place a receiver on the pipe of the drilling well. The transmission line (or transmitter) generates an EM field (or static magnetic field) in the formation, which is measured by the receiver, and is used to determine the location of the already existing well. This method has a long detection distance, but it requires complicated operations and is expensive. The other technique is to place the transmitter and the receiver both on the pipe of the drilling well. The transmitter excites an EM field in the formation, which will generates an induced current in the casing of the already existing wells. The induced current produces a secondary EM field in the formation, which is detected by the receiving device. The secondary EM filed will be used to determine the locations of the already existing wells. This method is relatively simple, but its detection range is greatly reduced.
SUMMARY OF THE INVENTION
[0004] An object of the invention is to overcome the shortcomings of the prior art and provides a solution for efficient downhole EM data transmission.
[0005] Another object of the present invention is to overcome the shortcomings of the prior art and provides a solution for downhole casing ranging.
[0006] In order to achieve the above objects, the present invention provides a drilling auxiliary system, which establishes one or more links among multiple wells or among different branches of the same well.
[0007] Wherein said drilling auxiliary system establishes one or more electrical connections among multiple wells.
[0008] Wherein said electrical connections are conductive wire and/or circuit connection.
[0009] Wherein said drilling auxiliary system establishes a link between a drilling well and an existing well for high-efficiency data transmission.
[0010] Wherein by establishing a link between a currently drilling well and an existing well, said drilling auxiliary system implements casing detection of the existing well.
[0011] Wherein said casing detection of the other well is to detect one of the casing's distance, orientation and trend, or any two of them, or all of them.
[0012] Wherein by establishing a link between a currently drilling well and an existing well, said drilling auxiliary system implements data transmission and casing detection of existing well.
[0013] Wherein by establishing a link between different branches of the same well, said drilling auxiliary system improves the efficiency of the data transmission from downhole to ground surface or drilling platform.
[0014] Wherein by establishing a link between different branches of the same well, said drilling auxiliary system helps the currently drilling branch to implement casing detection of existing branches.
[0015] Wherein said casing detection of existing branch is to detect one of the branch casing's distance, orientation and trend, or any two of them, or all of them.
[0016] Wherein by establishing a link between different branches of the same well, said drilling auxiliary system improves the efficiency of the data transmission from downhole to ground surface or drilling platform, and simultaneously helps a currently drilling branch to implement casing detection of existing branch.
[0017] Wherein said casing detection of existing branch is to detect one of the casing's distance, orientation and trend, or any two of them, or all of them.
[0018] Wherein said electrical connection is a circuit connection, the circuit for the electrical connection comprises one or more power supplies to enhance the current or voltage.
[0019] Wherein said power source is a current power source or voltage power source.
[0020] Wherein the frequency of said power source is any frequency from DC to low frequency then to high frequency.
[0021] Wherein said electrical connection is a circuit connection, the circuit for the electrical connection comprises a current amplifier or voltage amplifier to enhance the current or voltage.
[0022] Wherein said drilling auxiliary system further comprises a signal receiver for receiving the signal of the loop formed between the currently drilling well and the existing well.
[0023] Wherein said signal receiver is placed on ground surface or drilling platform, or is connected into the circuit between wells; or is inserted into the loop formed by the currently drilling well and the existing well, or is placed at any position connected or close to the loop, or any position around of the wells.
[0024] Wherein said signal receiver is connected into the existing circuit in series or parallel, or placed near the existing circuit.
[0025] Wherein the signal detected by said signal receiver is current, voltage, electric field, magnetic field or other electrical signals.
[0026] Wherein said drilling auxiliary system further comprises a transmitting device, wherein the downhole measurement signal is loaded into voltage, current, electric field or magnetic field generated by said transmitting device, and transmitted to said signal receiver by the loop formed between the currently drilling well and the existing well.
[0027] Wherein said transmitting device is a power source.
[0028] Wherein said power source is a power source from low frequency to high frequency or a DC power source.
[0029] Wherein said power source is located in the loop which is formed between the currently drilling well and the existing wells or between different branches of the same well.
[0030] Wherein said power source is located in the downhole.
[0031] Wherein said well is an oil-based mud well, wherein said transmitting device is located on the ground surface or drilling platform or is connected into the circuit between the drilling wells, with a signal loading device in the downhole.
[0032] Wherein when there are multiple existing wells around the currently drilling well, separately or simultaneously establishing the links between the currently drilling well and those existing wells.
[0033] Wherein said drilling auxiliary system further comprises a casing detection device mounted in the downhole.
[0034] Wherein said casing detection device implements the casing ranging according to the signal of the loop constituted of the currently drilling well, the existing well, and the formation.
[0035] Wherein the signal detected by said casing detection device includes current, voltage, electric field, magnetic field or other electrical signals.
[0036] Wherein said casing detection device is mounted on an insulation ring or a drill pipe above or below a downhole transmitting device.
[0037] Wherein said transmitting device is a power source.
[0038] Wherein said power source is a DC power source or a power source from low frequency to high frequency.
[0039] Wherein said power source is connected into the loop between the currently drilling well and the existing wells or between different branches of the same well.
[0040] Wherein said power source is located in the downhole.
[0041] Wherein said well is an oil-based mud well, and said transmitting device is located on the surface or drilling platform, or is connected into the circuit between the drilling wells.
[0042] The present invention further provides a detection method basing on said drilling auxiliary system, wherein when there are multiple existing wells around the currently drilling well, establishing a link separately between the currently drilling well and each of those existing wells;
[0043] For any existing well thereof, basing on the link established between the currently drilling well and the existing well, using said casing detection device to detect the casing of the existing well.
[0044] The present invention further provides another detection method basing on the drilling auxiliary system, wherein when there are multiple existing wells around the currently drilling well, first selecting an existing well and establishing a link between the selected existing well and the currently drilling well, and using said casing detecting device to detect the casing of the selected existing well; Then each time selecting an existing well from the wells outside the group of the wells have been linked, and establishing a new link between the selected well and the wells have been linked; then based on the signals of the group of linked wells, deriving the azimuth, distance, and trend of the new selected well; and repeatedly performing such steps till the casings of all of the existing wells around the currently drilling well are detected.
[0045] Compared with the prior art, the invention has the following technical effects:
[0046] 1. When the present invention is applied to the EM data transmission, it can significantly reduce unwanted electric energy consumption in the formation, thus effectively improve data transmission efficiency.
[0047] 2. When the present invention is applied to the casing detection, it can achieve a large detection range and greatly simplify the complexity of the operation, thereby saving costs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIG. 1 shows a typical prior art of a downhole EM telemetry system.
[0049] FIG. 2 shows a downhole EM data transmission system.
[0050] FIG. 3 shows another downhole EM data transmission system.
[0051] FIG. 4 shows a downhole EM data transmission system of still another embodiment of the present invention.
[0052] FIG. 5 shows a casing detection system of an embodiment of the present invention.
[0053] FIG. 6 shows a solution for casing detection of another embodiment.
[0054] FIG. 7 shows a drilling auxiliary system which simultaneously implements downhole EM data transmission and casing detection in an embodiment of the present invention.
[0055] FIG. 8 shows a system which simultaneously implements downhole EM data transmission and casing detection in another embodiment of the present invention.
[0056] FIG. 9 shows a still another embodiment of a system which simultaneously implements downhole EM data transmission and casing detection in the present invention.
[0057] FIG. 10 shows the electric current distribution of the present invention. In this figure, for simplicity, the circuit connection between the drilling well and the existing well is a simple wire connection.
[0058] FIG. 11 shows an embodiment of downhole EM data transmission system applied to oil-based mud drilling in the present invention.
[0059] FIG. 12 shows another embodiment of downhole EM data transmission system applied to oil-based mud drilling in the present invention.
[0060] FIG. 13 shows an embodiment of the drilling auxiliary system for oil-based mud drilling, which simultaneously implements downhole EM data transmission and casing detection in the present invention.
[0061] FIG. 14 shows an embodiment of the present invention applied to downhole data transmission in the wells with multiple downhole branches.
[0062] FIG. 15 shows an embodiment of the present invention applied to downhole casing detection in the wells with multiple downhole branches.
[0063] FIG. 16 shows an embodiment of the present invention applied to the wells with multiple downhole branches which simultaneously implements data transmission and casing detection.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0064] The invention will be further described by description of embodiments with reference to the accompanying drawings.
[0065] According to an embodiment of the present invention, FIG. 2 shows a downhole EM data transmission system, which improves the efficiency of data transmission from downhole to surface (or drilling platform) by establishing a link between the wells being drilled and the already existing wells. In the currently drilling well 1 , insulating ring 2 is set on the drill pipe 5 .
[0066] The electrical power source 3 is connected to the pipe 5 on the parts to both ends of the insulating ring 2 . Well head terminal A of the casing 7 of the currently drilling well 1 is connected with the terminal B of the casing 8 of the already existing well 6 by a wire, and a signal receiver 10 is serially connected to the wire between two wells. Thus the electrical power source 3 , the drilling pipe 5 , the casing 7 (usually a conductor) of drilling well 1 , the wire between the two wells, the casing 8 of existing well 6 , and the formation around the two wells forms a large circuit loop, of which the formation energy dissipation is reduced. It can be used to improve the data transmission efficiency. In the FIG. 2 , a signal receiver 10 is serially connected into the loop, so the data can be received by detecting the current in the wire. As an embodiment of the present invention, FIG. 3 shows another downhole EM data transmission system. The embodiment of FIG. 3 is similar to that of FIG. 2 , and therefore the same reference numerals identify the same elements. The difference between the embodiments of FIG. 3 and FIG. 2 is that: one terminal of signal receiver 10 of FIG. 3 is connected with point A (not limited to point A) in the loop and the other terminal is placed at a point 9 far way, and then the data transmission will be achieved by measuring the voltage between the point A and the far point 9 .
[0067] FIG. 4 shows a downhole EM data transmission system of still another embodiment of the present invention. The embodiment of FIG. 4 is similar to that of FIG. 2 , and therefore the same reference numerals identify the same elements. The difference is that: signal receiver 10 is placed in the vicinity of a large loop formed by two wells and then the data transmission is conducted by measuring the EM field.
[0068] FIG. 5 shows a casing detection system of an embodiment of the present invention, which detects the position, orientation and trend of the existing well 6 from the drilling well 1 by establishing a link between two wells. In this embodiment, in the drilling well 1 , the insulating ring 2 is set on the drilling pipe 5 and connects with power source 3 . The casing 7 of currently drilling well 1 and the casing 8 of already existing well 6 are connected by a wire. Thus, the power source 3 , the pipe 5 and the casing 7 of the drilling well, the wire connecting the two wells, the casing 8 of the existing well and the formation around the two wells forms a large loop, which can be used to detect the casings of existing wells.
[0069] Casing detection device 11 in FIG. 5 is placed on the drilling pipe above the transmission power source 3 , and is used to detect the location of the casing 8 of the already existing well by measuring the magnetic field. Better to give an explanation, the casing detection device 11 of the present invention is not limited to the detection of the magnetic field, which is well understood by a person skilled in the art.
[0070] FIG. 6 shows a solution for detecting the nearby existing wells of another embodiment. The embodiment of FIG. 6 is similar to that of FIG. 5 , and therefore the same reference numerals identify the same elements. The difference between the embodiments of the FIG. 6 and the FIG. 5 is that: the casing detection device 11 is placed on the drilling pipe under the power source 3 in the FIG. 6 , and the casing direction of the already existing wells may be conducted by measuring the electric field direction. Of course, the casing detection device 11 of the present invention is not limited to the detection of the electric field, which is well understood by a person skilled in the art.
[0071] FIG. 7 shows an embodiment of a comprehensive logging system which simultaneously implements the downhole EM data transmission and the casing detection in an embodiment of the present invention. The embodiment simultaneously implements the data transmission and the casing detection by establishing a link between currently drilling well 1 and already existing well 6 . In this embodiment, currently drilling well 1 and already existing well 6 are connected with each other by a wire, but in other embodiments, a complex circuitry or other connection methods may be used. Signal receiver 10 and casing detection device 11 are both placed in one set of system, and they simultaneously completes the tasks of the data transmission and the casing detection. The positions of signal receiver 10 and casing detection device 11 are not limited to the positions shown in FIG. 7 , and the positions may be other positions of the logging system, such as the positions shown in FIGS. 3, 4, and 6 .
[0072] FIG. 8 shows another embodiment of a system which simultaneously implements the downhole EM data transmission and the casing detection of the present invention. The embodiment of FIG. 8 is similar to that of FIG. 7 , therefore the same reference numerals identify the same elements, and will not be repeatedly described herein. The difference between FIG. 8 and FIG. 7 is that: the system of FIG. 8 adds an auxiliary power source 12 . This auxiliary power source can help the system to achieve better data transmission as well as better casing detection. The auxiliary power source may also be separately added to the embodiments in FIG. 2, 3, 4, 5, 6, 7 .
[0073] FIG. 9 shows a still another embodiment of a system, which simultaneously implements the downhole EM data transmission and the casing detection of the present invention. The embodiment of FIG. 9 is to establish a link between two offshore platforms through a circuit. The connection circuit for the link may be placed on the seabed, and the signal receiver 10 may be placed on the offshore platforms above the sea or placed on the seabed 14 as shown in FIG. 9 .
[0074] FIG. 10 shows an electric current distribution diagram of an example of the present invention. In the figure, for simplicity, the circuit between the currently drilling well and the already existing well is a simple wire. In fact, it may be a complex circuit to enhance the frequency of the downhole transmission power source, and/or increase the current intensity in the formation of the loop, thereby obtaining better signal transmission and measurement effects. If there are multiple wells surrounding the currently drilling well, they may be connected together simultaneously or by time-sharing to obtain better results. The power source shown in the figure may be a DC power source or an AC power source from low frequency to high frequency. In fact, the electric current in the FIG. 9 may be treated as two separate loops. The first loop is formed by the current out flowing from the upper terminal of the transmission power source, then passing through the drilling pipe, the surface wire, the casing of the existing wells, the formation and the drilling pipe below the insulated ring, and finally returning to the transmission power source; the second loop is formed by the current out flowing from the upper terminal of the transmission power source, then passing through the drilling pipe, the formation and the drilling pipe below the insulated ring, and finally returning to the transmission power source. Since the power of the first loop is mainly consumed in the formation between the downhole casing of the existing well and the drill pipe (and drill bit) below the insulated ring. When the distance is not far between the existing well and the currently drilling well, the current in this loop is quite strong. Since most of this current flows through the connection wire between the currently drilling well and the existing well, so MWD data loaded on downhole transmission power source may be received by measuring current, voltage or EM field on the surface, so as to achieve signal transmission effect. Similarly, since the first loop current is relatively strong, it is possible to apply a relatively high frequency, thereby increasing the transmission efficiency. Compared with the traditional solution, its efficiency can be increased dozens of times.
[0075] As shown in FIG. 10 , the electric current in the vicinity of the surface, which flows from the drilling well through formation to the existing well, is very weak, so it is represented by grey arrows. On the contrary, the current flowing through the connection wire to the existing well is much stronger, and it is represented by dark bold arrows. When the current flows to the existing well, the current will flow downwards along the casing of the existing well, then pass through the formation to the drill pipe below the insulated ring of the currently drilling well, and finally return back to the power source. Obviously, quite a part of current flows through the casing of existing well, which generates secondary EM field, Receiving device on the drill pipe can detect the EM field generated by the casing current, so as to determine the distance and azimuth of the existing wells.
[0076] FIG. 11 shows an embodiment of downhole EM data transmission system suited for oil-based mud drilling. Because of the large resistivity of oil-based mud, most of the current flows through the casing 7 of the drilling well, the connection wire, the casing 8 of the existing well, the formation, the drill bit 4 of the drilling well, and finally goes back to the bottom side of source through the pipe 5 , so as to form a large loop. As shown in FIG. 11 , the source 3 may be placed on the surface. Thus a faster downhole data transmission rate can be achieved by increasing the current and voltage. Downhole data can be loaded by a signal loading device 15 mounted on the drill pipe 5 , and the data is received on the surface by the signal receiver 10 . The signal loading device 15 may be a current or a voltage controller.
[0077] FIG. 12 shows another embodiment of downhole EM data transmission system suited for oil-based mud drilling. Because of the large oil-based mud resistivity, most of the current flows through the casing 7 of currently drilling well, drill pipe 5 and drill bit 4 , the formation, the casing 8 of existing well, then flows upwards along the casing 8 of the existing well to the surface, so as to form a large loop. This source 3 can be placed on/near the surface. As Shown in FIG. 12 , casing detection device 11 is mounted on drill pipe 5 . A more effective distance of casing detection can be achieved by increasing the current (or voltage) of power source 3 .
[0078] FIG. 13 shows an embodiment of a comprehensive logging system which suits for oil-based mud drilling and simultaneously implements the downhole EM data transmission and the casing detection. The embodiment of FIG. 13 is similar to that of FIG. 11 , therefore the same reference numerals identify the same elements, and will not be repeatedly described herein. The difference between FIG. 13 and FIG. 11 is that: a casing detection device 11 is further mounted on drill pipe 5 in FIG. 13 . The power source 3 can be placed near the surface in the system of FIG. 13 , thus by increasing the current (or voltage) of the source, a faster data transmission rate and a farther effective distance of casing detection can both be achieved.
[0079] FIG. 14 shows an embodiment suited for downhole data transmission in the well with downhole branches. The system establishes a link between different branches of one well, thereby effectively improving the downhole data transmission efficiency. Regarding a currently drilling branch of a well as a special currently drilling well, and an already existing branch of the same well as a special already existing well, the principle of establishing a link between different branches of one well is the same with that of establishing a link between different wells. As shown in the FIG. 14 , signal receiver 10 of the system is placed on the surface, wherein one terminal of the signal receiver 10 is connected with the connection (such as wires) between different branches by a wire, and the other terminal of the signal receiver 10 is connected to the far ground terminal 9 . Signal receiver 10 may receive data by detecting the voltage from the connection between different branches (such as wires) to the infinitely far ground terminal 9 . Thus a large loop is formed by the transmission power source 3 , the drill pipe 5 of the currently drilling branch 16 , the casing 17 (usually conductor) of the currently drilling branch 16 , the wire between the two downhole branches, the branch casing 19 of the already existing downhole branch 18 and the formation around the two downhole branches, wherein the energy dissipation of the loop in the formation is relatively small. By connecting signal receiver 10 to the wire between the two downhole branches, the data from downhole drilling branch can be efficiently received.
[0080] FIG. 15 shows an embodiment of the present invention suited for downhole casing detection in a well with multiple downhole branches. The casing detection system establishes a link between different branches of one well, thereby effectively simplifying the complexity of casing detection. The embodiment of FIG. 15 is similar to that of FIG. 14 , therefore the same reference numerals identify the same elements, and will not be repeatedly described herein. The difference is merely that: FIG. 15 does not contain the receiving device on the surface for downhole data transmission, but adds a detecting device on the currently drilling branch to detect already existing branches.
[0081] FIG. 16 shows an embodiment of the present invention suited for comprehensive system with downhole branches which simultaneously implements the downhole data transmission and the casing detection. The system establishes a link between different branches of one well, and thereby simultaneously achieving the effects of downhole data transmission and casing detection for the existing branches. The embodiment of FIG. 16 is similar to that of FIG. 14 , therefore the same reference numerals identify the same elements, and will not be repeatedly described herein. The difference is merely that: a casing detection device is mounted on the drill pipe of the currently drilling branch to detect the existing branch.
[0082] Finally, it should be noted that the above embodiments are merely to describe the technical solutions of the invention, not to limit the technical methods. This invention in application can be extended to other modifications, variations, uses and embodiments, and therefore it is believed that all this modifications, variations, uses and embodiments are within the scope of the spirit and teachings of the invention.
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The present invention provides a drilling auxiliary system, which establishes one or more links among multiple wells or among different branches of the same well. When the present invention is applied to the EM data transmission, it can significantly reduce unwanted electric energy consumption in the formation, thus effectively improve data transmission efficiency. When the present invention is applied to the casing detection, it can achieve a large detection range and greatly simplify the complexity of the operation, thereby saving costs.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to managing and manipulating computer archive files, and more particularly to a system and method for managing and manipulating zip files through a computer program integrated into Microsoft Windows Explorer.
[0002] Compression of computer files has been around for years. Compressing files can save tremendous amounts of disk space, and transfer time when downloading files from the Internet or transferring files through email. These days, almost any file one downloads from the Internet is compressed in some way. A standard compressed file or folder as it is sometimes called contains one or more files that were compressed into a single file or folder. A lot of different compression formats have been developed over the years. The zip format, created by the assignee of the present invention, is the most common compressed file format for the personal computer, but there are many others in use today. Any file with a “.zip” extension is most likely a compressed file in the zip format. Zipping a file means compressing the file into the zip format archive so that it occupies less disk space, and unzipping a file means uncompressing a compressed file in the zip format. A zip file is a file which has been compressed with PKZIP®, from PKWare, Inc., or another compatible archiver. Zip files are indicated by a “.zip” filename extension.
[0003] A computer file is compressed through the use of one or more compression algorithms. A compression algorithm is essentially a mathematical formula that scans the data in the file for compressible information. For example, compressible information may be any repeating pattern or string that can be represented once. The compression algorithm will then represent the repeated patterns in a coded manner to save space. For standard compression, most of the compression algorithms work basically the same way. Some are just more efficient or faster than others.
[0004] Generally, the contents of a compressed file cannot be accessed unless the archive is uncompressed. In order to uncompress a file, a user needs to either use the same program used to compress the file, or use another program that is compatible with the particular compression format. That meant that users were required to use standalone programs to compress and uncompress their files. The same problem occurs when trying to work with and manipulate compressed archived files. For example, a user wanting to open an existing compressed file, modify the file, or extract data from the file and transfer it to another file would have to command a standalone program to uncompress the original file and command the standalone program to compress the modified file. This process is often burdensome and inconvenient to the user. Therefore, it would be beneficial to create a product that would eliminate the need for separate standalone compression programs, and eliminate the need to separately command a file to be uncompressed or compressed each time the file is opened, modified, or saved.
[0005] Such products have been developed by many companies, including products used in a Microsoft Windows Explorer environment. Microsoft Windows Explorer is a browser program in Windows for exploring directories, files, and folders in a computer system. In connection with Windows Explorer, Microsoft provides a shell name space extension application program interface (API) for software developers to use to integrate other software utility programs into Windows Explorer. Several companies have developed compression file manipulation programs using the Microsoft Windows Explorer interface. Some of these products include: ArjFolder by Raphael Mounier; Cab Viewer by Microsoft Corporation; CleverZip by Cleverness, Inc.; Zip Explorer Pro by Aeco Systems; Internet Neighborhood by KnoWare, Inc.; Net Explore; ZipMagic by Mijenix Corporation; and Netzip Classic by Netzip Inc. The Internet Neighbrohood and Net Explore products are file transfer protocol (FTP) products which integrate FTP sites into Windows Explorer. ZipMagic and Netzip Classic are device driver products.
[0006] ZipMagic, patented under U.S. Pat. No. 5,907,703, is directed to a device driver for accessing computer files. The ZipMagic patent utilizes a device driver implemented in the operating system of Windows Explorer that makes all zip files appear to be folders.
[0007] However, all of the above products are implemented differently from the present invention, and do not include many of the features of the present invention. Many of the above programs have increased performance overhead in processing (compressing/uncompressing) files continuously in and out, and it is often difficult for a user to determine if he is in a zip file or rather in a folder.
[0008] Accordingly, there is a need for a system and method for easy management and manipulation of archive files. The program of the present invention is intended for use on Microsoft Windows 9x, Me (Millennium Edition), NT 4.0, and 2000 systems. Windows 95 and NT 4.0 systems require Microsoft Internet Explorer 4.0 or greater.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention provides a software utility program that is seamlessly integrated into Microsoft Windows Explorer. The program allows users to manage and manipulate their zip archive files without leaving the Explorer environment. Users may open, archive, compress, extract, create, modify and add to their zip archive files using Windows Explorer's context and pull-down menus, toolbars, copy and paste operators, and drag and drop operators. A mail compressor attachment module integrates into Microsoft Outlook to automatically archive files sent via email. An Internet plug-in module works with Internet Explorer 4.0+ or Netscape Communicator 4.0+ to facilitate the handling of downloaded zip files from the Internet. The Internet module allows a user to view and manipulate zip archive files downloaded from the Internet.
[0010] An archive manager provides quick access to a user's zip files stored on the computer. The archive manager can create a hierarchical tree representation of a zip file which allows quick and easy management and manipulation of complex zip archives. Shortcuts may also be optionally created and/or deleted by the archive manager. Double-clicking a shortcut will open a zip file under the archive manager. File shortcuts may be created using copy and paste operators, dragging a file into the archive manager, or via the scan and add function. File shortcuts are deleted by highlighting the shortcut and selecting delete on the keyboard or Windows Explorer menu. Shortcuts may be created that branch to a zip file's contents under a specified working directory as an alternative to working within the archive manager. Archive files may be extensively modified before the actual changes are saved. As a result, system overhead is minimized, as the resources required for such operations are only needed when the archive is actually saved. An edit mode of the archive manager during archive modification illustrates graphic instruction cue icons (indicating Add and Delete states) in the far left column of the Explorer Window.
[0011] In addition to easily opening, extracting, creating and modifying archive files, the present invention also includes several miscellaneous features or functions selectable by the user. These functions include edit-before-saving, digital certificate based file authentication and encryption, selecting compression methods by file type and spanning/splitting of archive files.
[0012] In one aspect of the invention, an edit-before-saving function that is useful during creating, opening, modifying or extracting an archive file. The edit-before-saving function provides graphic instruction cue icons (indicating Add and Delete states) next to archives that have been modified. Archives may be extensively modified before the actual changes are saved. As a result, system overhead is minimized, as the resources required for compressing and uncompressing are used only when the archives are actually saved.
[0013] In another aspect of the invention, a Public Key Infrastructure (PKI) based digital signature, file authentication and encryption function adds a layer of authenticity to the zip archive files. The invention includes a X.509 based authentication and encryption function which allows a user to digitally sign and encrypt individual files archived in a zip file and subsequently authenticate and decrypt those files upon extraction. Digitally signing a zip file allows one to detect whether the integrity of a zip file has been compromised. Encrypting a file denies access to the file's contents by unauthorized users. The ability to store a PKI based digital signature using standard X.509 based certificate (e.g., VeriSign Digital ID) information is a significant enhancement to the zip archive file format. This function allows users to digitally sign an archive file and its contents using a standard X.509 based digital certificate.
[0014] This function also allows a user to digitally sign the central directory of the zip file and to encrypt file names and supplemental information such as, but not limited to, file system security descriptor information.
[0015] In a further aspect of the invention, a user may select a compression method based on the type of file being saved. The compression methods include Store, Deflate, and DCL Implode. By default, the present invention compresses all files using the Deflate algorithm. A user may choose to compress all files using the Deflate algorithm, or may optionally modify the default method of compression, as well as the method to be used on a specified file type. In addition, a user may specify to use the 64k dictionary version of the Deflate algorithm for improved compression.
[0016] The spanning function of the invention allows a user to span large zip archives over multiple removable media diskettes. The splitting function of the invention allows a user to divide an archive file into specified file segment sizes.
[0017] Various other features, objects, and advantages of the invention will be made apparent to those skilled in the art from the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0018] FIG. 1 is a diagram illustrating the software components underlying the system of the present invention;
[0019] FIGS. 2 a - 2 e are diagrams illustrating the different compression and extraction chains used in the present invention;
[0020] FIG. 3 displays a right-click context menu of the present invention;
[0021] FIG. 4 displays a progress dialog screen of the present invention;
[0022] FIG. 5 displays a save as dialog screen of the present invention;
[0023] FIG. 6 a displays a table of toolbar buttons used in the present invention;
[0024] FIG. 6 b displays a table of menu items used in the present invention;
[0025] FIG. 7 displays an extract dialog screen of the present invention;
[0026] FIG. 8 displays an add dialog screen of the present invention;
[0027] FIG. 9 displays a log dialog screen of the present invention;
[0028] FIG. 10A displays a “General” screen of a series of selection properties dialog screens of the present invention;
[0029] FIG. 10B displays a “Comment” screen of a series of selection properties dialog screens of the present invention;
[0030] FIG. 10C displays a “Digital Signature” screen of a series of selection properties dialog screens of the present invention;
[0031] FIG. 11A displays a “General” screen of a series of authenticity/certificate dialog screens of the present invention;
[0032] FIG. 11B displays a “Comment” screen of a series of authenticity/certificate dialog screens of the present invention; and
[0033] FIG. 11C displays a “Digital Signature” screen of a series of authenticity/certificate dialog screens of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] FIG. 1 is a diagram illustrating the software components underlying the system 10 of the present invention. There are three basic components of the underlying software. These components are the user interface (UI) 20 , the file management (FM) component 30 , and the compression/extraction engine (CE) 40 .
[0035] The lowest level component is the compression/extraction engine 40 . The compression/extraction component 40 consists of the actual compression, extraction, and crc-32 algorithms. These are written as a set of portable C language routines, with higher level C++ routines interfacing with the higher level file management component 30 . The file management component 30 consists of the central directory 32 which holds a cached tree-like structure of the archive independent of the actual archive type. Actual archive implementation is used by the central directory 22 to read/write data to the archives 34 and the user interface 20 . The central directory 32 consists of folder objects and file objects 36 . A services object 38 is also part of the file management component 30 . The services object 38 acts as a helper interface between the user interface component 20 and the file management component 30 . The user interface 20 consists of a shell 22 , a graphical user interface (GUI) 24 , and a call level interface (CLI) 26 .
[0036] The data object 36 supports one or more standard file formats (Explorer or File Manager drag and drop), and one or more custom formats (zip compressed non-encrypted and zip compressed). When files are dropped from Explorer to the archive, the archive requests available standard data formats to compress the data. When files are dropped from archive to Explorer, Explorer requests available standard data formats. In this instance, the data object will need to uncompress the data. When files are dropped from one zip archive to another zip archive, the target archive will be able to detect the native data and copy it without modification. When files are dropped from an ARJ archive to a zip archive, the zip archive will be able to recognize only standard formats, as a result, the ARJ data object will uncompress the data and the zip archive will compress the data. So it is possible to convert data between different archives.
[0037] FIGS. 2 a - 2 e illustrate the different compression and extraction used by the present invention. In FIG. 2 a , regular compression and extraction chains are shown. In FIG. 2 b , compression data chains are shown, including the use of a generic converter involving no compression. In FIG. 2 c , data here compression chains are shown. In FIG. 2 d , GetData extraction chains are shown. In FIG. 2 e , GetDataHere extraction chains are shown.
[0038] The compression/extraction engine 40 and the file management component 30 form the data compression library that is used to build applications, such as the present invention, needing zip compatible compression and file management.
[0039] The present invention provides a software utility program that is integrated into Microsoft Windows Explorer for managing and manipulating archive files without leaving the Explorer environment. The invention includes an archive manager which allows a user to open, view, modify (add/delete), and extract data from an existing archive, or create a new archive using modified Windows Explorer right-click context menus, pull-down menus, toolbars, copy and paste operators, or drag and drop operators.
[0040] FIG. 3 displays a right-click context menu 50 of the present invention which may be used to open, modify and extract files from an exiting zip file, or create a new zip file. In opening a zip file, a user may simply double-click the file to view the contents of the file. Alternatively, the following is an example of the steps one might follow to open and view the contents of a zip file. First, the zip archive to be opened is located by using Windows Explorer. Then, the user right-clicks on the zip file he wants to open. A context menu appears. PKZIP/Explore is selected. The contents of the zip file will be displayed in the right pane under the archive manager. As another alternative, a user may select PKZIP/Explore PKZIP Folder to create a folder shortcut under the current folder, and display the contents of the zip file via this folder.
[0041] To extract individual files and/or folders archived in a zip file, a user opens the zip file in Explorer as discussed above and invokes the extract dialog, by selecting the Extract menu item in the right-click context menu. The Extract dialog appears, FIG. 7 , allowing the user to manually specify a destination directory. Alternatively, a user may select PKZIP/Extract Here to extract the contents of the archive into the directory where the zip archive resides. To create a directory (e.g., “Test”) under the directory where the zip archive resides, and extract all files in that directory, the user selects the “Extract-to” menu item. Alternatively, files may be extracted using a drag and drop operation. The user highlights the files and/or folders he wishes to extract, drags the files to a destination, and drops the files in the enabled destination. The files and/or folders will be automatically extracted into the drop destination. As the extraction process proceeds, the progress is displayed in a progress dialog, as shown in FIG. 4 . If there is an error encountered during the extraction process, the error is indicated in the progress dialog and a log dialog, shown in FIG. 9 .
[0042] The present invention also allows a user to create a new zip file. The following is an example of the steps one might follow to create a new zip file. First, the user highlights the files and/or folders he wishes to archive. The user then clicks his right mouse button to bring up the context menu. PKZIP/Compress is then selected. The “Save as” dialog appears, FIG. 5 . A name and destination are specified for the zip file, and the save button is clicked to proceed. The progress dialog appears to monitor completion and to indicate errors in the process. The new zip file should now reside in the specified destination directory. A user may alternatively create a new zip file by other means as well. A user may create a new folder in an archive by selecting the New Folder menu toolbar item and specifying a folder name as desired.
[0043] Adding or deleting files in a zip file works somewhat differently than these same operations do in Explorer. For example, in Explorer, when a user highlights a file and clicks the delete key, that file is immediately deleted. The present invention includes an edit-before-saving function, so that when a user highlights a file and clicks the delete key, a graphic instruction cue icon is displayed directly to the left of the file icon, indicating that this file is to be deleted. Similarly, when a file is added to an archive, the program will display an add icon directly to the left of the file icon indicating that this file is to be added. In other words, a zip file is not actually modified until the user specifically instructs the program to save the zip file.
[0044] The following is an example of the steps one might follow to modify an existing zip file. A user first locates and opens the zip file he wishes to modify. Next, the files and/or folders to add to the archive are specified by clicking the add toolbar button, thereby invoking the add dialog, or by dragging the files and/or folders from their source and dropping them at a destination. A user may alternately use the copy and past operation to specify files and/or folders to add to the archive. The program will display an add icon (such as plus symbol) indicating that these files and/or folders are to be added when the archive is saved.
[0045] In a similar manner, a user may specify files and/or folders to delete in the archive by highlighting the files the user wishes to delete, and clicking the delete key, or by selecting the Delete menu item. The program will display a Delete icon (such as a circle with a slash through it) indicating that these files and/or folders are to be deleted when the archive is saved.
[0046] After the user is finished modifying the zip file, the file may be saved by selecting the Save menu item available under the File menu, or by use of the right-click context menu. A user may also click the Save button on the toolbar. To save the modifications to another zip file, select the Save As or Save Copy As menu items.
[0047] FIGS. 6 a and 6 b display modifications and additions to the Explorer toolbar buttons and menu items used in the present invention.
[0048] The present invention may also include many options which may be configured in the options tab dialog accessible via the menu/tool bar or via the right-click context menu. One option is the compression method. Under this option, a user may specify a compression algorithm other than the default algorithm. The compression algorithms to choose from may include Store, DCL Implode, and Deflate. By default, all files are compressed using the Deflate algorithm. As one example, a user may wish to use the Store feature for all JPEG files, since the compression ratios on files of this type are typically negligible. A user may specify a default method or extension specific method under the extension column. Depending on the compression method specified, a user may wish to configure one or more of the storage parameters, as described below.
[0049] There are no available settings for the store method. The program simply archives the specified files without compression. Since the program does not expend time compressing files, this is the fastest method of archival.
[0050] Under the DCL Implode method of compression, the dictionary byte size (i.e., 1024, 2048, 4096) a user wishes to use when compressing files is configurable along with the data type. The binary setting should be selected to optimize compression of program files or other non-text files. The ASCII setting should be selected to optimize compression of text files.
[0051] Most zip utilities use the Deflate algorithm to compress files. Under this algorithm, the compression level may be set using a slide bar to specify the level of compression you wish to apply when archiving files. Moving the slide bar all the way left instructs the program to use the fastest method of compression. Moving the slide bar right increases the time the program expends compressing the file which, as a result, improves compression. Moving the slide bar all the way right instructs the program to apply maximum compression to files. This is the slowest method of file archival because the program must expend time maximizing compression on the files. Typically, applying maximum compression results in the smallest zip file.
[0052] In addition, the dictionary kilobyte size may be selected when using the Deflate algorithm. The dictionary size is selectable between a 32K dictionary and a 64K dictionary. The 64K dictionary provides slightly better compression ratios, but may not be compatible with all zip utilities.
[0053] The present invention also allows the user to digitally sign and encrypt the individual files archived in a zip file as well as the central end directory, and subsequently to authenticate and decrypt those files upon extraction. The signing and encrypting functionality is based on PKCS No. 7, and related public key encryption standards and is therefore compatible with security functionality in other applications such as Microsoft's Internet Explorer. Signing a zip file allows one to detect whether a zip file's integrity has been compromised. Encrypting a file denies access to the file's contents by unauthorized users.
[0054] Before a user can sign or encrypt files, he must first have a digital certificate with which to sign or encrypt. A digital certificate may be obtained from VeriSign or Thawte or from another certificate authority.
[0055] The present invention also provides a software utility program that integrates the compression/extraction engine into Microsoft Outlook to compress, encrypt and authenticate email attachments without leaving the Outlook environment. The invention includes a toolbar button and a tooltray menu that allows turning the compression of email attachments on or off. The compression of email attachments reduces the storage and transfer time of email messages and can reduce the spread of common email attachment viruses.
[0056] The system of the present invention may further include a more generally applicable mail attachment compressor module. Most email programs support sending file attachments along with the main body of the email message. Most users can choose to send the attached file as it originally exists, or compress it prior to attachment to the mail message so it is smaller and more efficient to send and store. Currently, the file to be attached must be manually compressed outside the email program and then attached using the attachment features of the email program. The mail attachment compressor module of the present invention integrates compression into the standard Microsoft Outlook mail message edit form so compressing attachments can be done automatically as the message is sent. The mail attachment compressor module also provides the ability to digitally sign attachments as they are sent for greater security.
[0057] After installing the program of the present invention, the mail form of Microsoft Outlook will have two additional buttons in its “standard” toolbar. These buttons include a Toggle Compression button and an Options button. If the Toggle Compression button is not depressed (the default state), all mail attachments will be compressed automatically when the standard “send” button is used to send the message. Attachments already compressed when attached will be left as is, while attachments that are not compressed will be compressed into a single ZIP file that will replace the original uncompressed attachments. When the Toggle Compression button is depressed, the compression will not be done and the files will be sent as attached. The Options button will display the Options configuration dialogs from the compression/extraction engine so that the compression actions can be configured. The primary use of this button is to configure digital certificates, but any configurable parameters supported by the compression/extraction engine can be set. These parameters include digital certificates, passwords and compression method options.
[0058] Operation of the mail attachment compressor program is initiated by installing the mail attachment compressor module software onto the users system, and initiating Microsoft Outlook. If the mail attachment compression feature is enabled through the toggle button, the attachments will automatically be compressed when the message is sent using the send button. If the mail attachment compression feature is not enabled, then the attachments will be sent unaltered.
[0059] The components of the mail attachment compressor module provide the functionality to be implemented within Microsoft Outlook and provide integration between this module and the underlying compression/extraction engine. When compressing an attachment, the files to be compressed will be passed off to the compression/extraction engine of the underlying software program. After compression, the compressed file will be reattached to the original message, the original copies of the attachments that are now compressed will be removed from the message, and any temporary files created during compression will be deleted.
[0060] The mail attachments module uses the compression/extraction engine to hook directly into Microsoft Outlook to allow users to compress email attachments into zip files. This module provides an automation hook so that email attachments appended to Outlook mail messages can be automatically compressed when the message is sent.
[0061] The Scan and Add dialog of the archive manager is invoked via the Scan and Add toolbar button or the Explorer File/right-click menu. Once the user is finished specifying files to add to the archive manager list, the user clicks OK to add the selected file shortcuts to his list and return to Explorer, or he clicks Apply to add the selected files and remain in the Scan and Add dialog. The options available via this dialog include Files and Folders, multiple selection scan, and Scan and Add form. The archive manager allows the user to add unopened archives to the archive manager list, and to add multiple files using the multiple selection scan option under the archive manager.
[0062] While the invention has been described with reference to preferred embodiments, those skilled in the art will appreciate that certain substitutions, alterations and omissions may be made without departing from the spirit of the invention. Accordingly, the foregoing description is meant to be exemplary only, and should not limit the scope of the invention set forth in the following claims.
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A computer program for managing and manipulating archive zip files of a computer. The program includes a system and method for opening, creating, and modifying, and extracting zip archive files. The program is fully integrated into Microsoft Windows Explorer and is accessed via Explorer menus, toolbars, and/or drag and drop operations. An important feature of the program is the archive manager which may be used to open a zip file, create a new zip file, extract zip files, modify zip files, etc. The program is integrated into Microsoft Windows Explorer using the shell name space extension application program interface developed by Microsoft.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to high pressure sodium vapor lamps. More particularly, the invention relates to a mercury-free high pressure sodium vapor lamp, which is dosed with sodium, xenon and elemental zinc to prevent an undesirable low-voltage operating mode at end-of-life.
2. Discussion of the Art
Traditional arc-discharge high pressure sodium (“HPS”) vapor lamps are described in U.S. Pat. No. 3,248,590 to Schmidt, entitled “High Pressure Sodium Vapor Lamp.” These lamps utilize a slender, tubular envelope of light-transmissive refractory oxide material resistant to sodium at high temperatures, suitably high-density polycrystalline alumina or synthetic sapphire. The filling has traditionally comprised sodium along with a rare gas such as xenon to facilitate starting and mercury for improved efficiency. The ends of the alumina tube are sealed by suitable closure members affording connection to thermionic electrodes which may comprise a refractory metal structure activated by electron emissive material. The ceramic arc tube is generally supported within an outer vitreous envelope or jacket provided at one end with the usual screw base. The electrodes of the arc tube are connected to the terminals of the base, that is to shell and center contact, and the interenvelope space is usually evacuated in order to conserve heat.
New environmental standards have necessitated that mercury be eliminated from the traditional arc-discharge HPS lamp design. These new designs are dosed only with sodium and xenon. Accordingly, as sodium is “lost” by chemical reactions or diffusion, the voltage decreases markedly. The resultant low voltage mode is characteristic of a xenon discharge. Low voltage operation at end-of-life is very undesirable, resulting in an overheated ballast, which gives rise to reduced ballast life.
SUMMARY OF THE INVENTION
There is a particular need for a mercury-free high pressure sodium lamp, which maintains lamp voltage within established operating limits thereby ensuring that the lamp does not cycle (from high voltage) and the ballast is not overheated (from low voltage) at the end-of-life.
Briefly, in accordance with one embodiment of the present invention, a new and improved mercury-free high pressure sodium lamp is provided. The lamp is designed to prevent an undesirable low-voltage operating mode of the sodium-xenon discharge, which otherwise occurs when sodium is no longer available to participate in the arc discharge. The end-of-life operating voltage designed into the mercury-free HPS lamp is configured to be within a range acceptable to the ballast in accordance with established ANSI/IEC standards.
A principal advantage of the present invention is that an undesirable low-voltage operating mode of a sodium-xenon discharge associated with a mercury-free HPS lamp is prevented.
Another advantage of the present invention is that the end-of-life operating voltage for a mercury-free HPS lamp falls within a range acceptable to established ANSI/IEC standards.
Still another advantage of the present invention is that mercury-free HPS lamps can be produced in a normal product line without significant equipment changes or increase in lamp variable cost.
Still a further advantage of the present invention is that the mercury-free HPS lamps are direct replacements to standard HPS lamps, saving time and money in retrofit applications.
Still another advantage of the present invention is that mercury, a toxic substance according to the United States EPA's TCLP guidelines, is eliminated from the HPS lamp.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view in section of a mercury-free high pressure sodium discharge lamp of the present invention.
FIG. 2 is a graph illustrating the visible spectra of the Na—Xe and Na—Zn—Xe lamps constructed and tested in accordance with Examples 1 and 4.
FIG. 3 is a graph illustrating the visible spectra of FIG. 2 magnified 8 times in the blue-green region between 450 and 500 nanometers.
FIG. 4 is a graph illustrating the orange spectral region between 580 and 600 nanometers for the Na—Xe and Na—Zn—Xe lamps constructed and tested in accordance with Examples 1-4.
FIG. 5 is a graph illustrating a plot of luminous efficacy versus arc electric field for various Na—Xe and Na—Zn—Xe lamps having a 4.0 mm bore.
FIG. 6 is a graph illustrating a plot of luminous efficacy versus arc electric field for various Na—Xe and Na—Zn—Xe lamps having a 4.5 mm bore.
FIG. 7 is a graph illustrating the visible spectrum of a zinc-xenon lamp constructed and tested in accordance with Example 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, which illustrate a preferred embodiment of the invention only and are not intended to limit same, FIG. 1 shows a mercury-free high pressure sodium lamp 1 , which includes a high pressure alumina discharge vapor arc chamber or arc tube 2 disposed within a transparent outer vitreous envelope 3 . Arc tube 2 contains under pressure the arc-producing medium comprising sodium, elemental zinc, and preferably xenon as a starting gas. The xenon fill gas has a cold fill pressure from about 10 to 500 torr, preferably about 200 torr. During operation, the xenon pressure increases to about 8 times the cold fill pressure. The partial pressure of the sodium ranges from 30 to 1000 torr during operation, preferably about 70 to 150 torr for high efficacy. Electrical niobium lead wires 4 and 5 allow coupling of electrical energy to tungsten electrodes 6 , containing electron emissive material, and disposed within the discharge chamber 2 so as to enable excitation of the fill 7 contained therein. Sealing frit bonds the lead wires 4 and 5 to the alumina of the arc chamber 2 at either end. Sealing is first done at lead wire 4 . Sealing at lead wire 5 is accomplished using an alumina bushing feedthrough assembly. Lead wires 4 and 5 are electrically connected to the threaded screw base 8 by means of support members 15 and 16 , and inlead wires 9 and 10 , which extend through stem 17 .
Initiation of an arc discharge between electrodes 6 requires a starting voltage pulse of 2 to 4 kilo volts. This ionizes the starting gas, initiating current flow which raises the temperature in arc tube 2 and vaporizes the sodium and zinc contained therein. Arc discharge is then sustained by the ionized vapor and the operating voltage stabilizes.
The lamp 1 also includes a niobium foil heat-reflective band 18 , which maintains a higher operation of temperature at the end of arc chamber 2 toward the lamp base as compared to the opposite end. As a result, the unvaporized amounts of metallic dose components, i.e., sodium and zinc, reside at the colder end of arc chamber 2 during operation. The lamp 1 is designed to prohibit contact of liquid sodium with the sealing frit to avoid life-limiting reactions and the possibility of rectification (high ballast current) during startup.
In the present invention, fill 7 contained within the outer envelope 3 consists of sodium and a starting gas, preferably xenon. The metallic dose (at the monolithic alumina corner) is introduced in conjunction with the xenon starting gas. Other acceptable starting gases would include any non-reactive ionizable gas such as a noble gas sufficient to cause the establishment of a gaseous arc discharge.
Traditionally, mercury has been used in the fill to increase the voltage of the lamp 1 , thereby reducing lamp current. But, in view of established EPA TCLP guidelines limiting mercury content in solid waste and disposal costs for HPS lamps which contain mercury, the fill 7 is mercury-free, necessarily resulting in low-voltage operation at end-of-life. In accordance with the present invention, the use of an additional dosing element or additive in the sodium-xenon discharge eliminates the unwanted low-voltage effect at end-of-life. The additive element is selected based upon certain design criteria: it must have a lower excitation potential than the starting gas (the excitation potential of xenon being 8.4 electron volts); and a higher excitation potential than sodium (the excitation potential of sodium being 2.1 electron volts). Also, it must have sufficient vapor pressure during lamp operation so that when the sodium is lost, the additive becomes the primary radiator and maintains the end-of-life voltage of the HPS lamp within certain predetermined limits. For example, limits established by ANSI/IEC trapezoidal diagrams range from about 85% to about 150% of the rated nominal lamp voltage. By the terminology “rated nominal lamp voltage” it is meant a rating for the voltage of the lamp published by a recognized standardization body, e.g., International Electrotechnical Commission (IEC), American National Standards Institute (ANSI), and Japanese Industrial Standards (JIS).
The additive is preferably elemental zinc. Zinc's excitation potential of 4.0 electron volts lies between those of sodium (2.1 eV) and xenon (8.4 eV), so that when sodium is present, the spectrum is dominated by sodium radiation, with high luminous efficacy. Zinc is also chemically compatible with the typical materials of the arc tube (e.g., niobium, tungsten, alumina, sealing frit, and emission materials).
If the amount by weight of the elemental zinc additive is set below a certain value, then the zinc vapor pressure is said to be unsaturated. When the zinc vapor pressure is unsaturated, the zinc pressure during operation depends primarily on geometrical parameters which determine the volume of the arc tube and the quantity of zinc. For zinc doses above this critical value, the zinc vapor pressure is substantially independent of the arc tube volume or the dosed quantity of zinc, and accordingly, the zinc vapor pressure depends primarily on the temperature of the arc tube coldest spot. In a preferred embodiment, both zinc and sodium are dosed in a sufficient quantity to produce saturated vapor during operation, because performance is then dependent upon fewer manufacturing variables.
The design objective is to build arc tubes with at least a minimum amount of dosed zinc to maintain the saturated vapor mode (i.e., both a liquid phase and a vapor phase) during operation. This saturated vapor mode ensures that the zinc vapor pressure is independent of the quantity of zinc dosed and the arc tube volume.
To estimate dosing requirements for zinc in a just-saturated vapor condition, TABLE I below was prepared using the following data, calculations and assumptions:
Use of values for the arc tube inner diameter (or bore, B) and arc gap, G, as known by those skilled in the art.
An increase to about 727° C. (1000 Kelvin) of the cold spot temperature (about 700° C. when sodium is present) when the sodium is gone, due to higher arc temperature of the Metal—Xe discharge.
Vapor pressures at 727° C. (1000 Kelvin) from tables set out in “Vapor Pressure of the Chemical Elements”, by A N Nesmeyanov (1963).
Calculation of average gas temperature between the electrode using formula (2*To+Tw)/3, where To is the core temperature of the M-Xe discharge, and Tw is the wall temperature. This relationship is easily shown if a parabolic radial temperature profile is assumed.
Assumption that To=5500 Kelvin, characteristic of a mercury arc, according to “Light Sources” by W. Elenbaas (1972) (approximately 1200 Kelvin higher than the axis temperature of an Na—Xe discharge).
Assumption that Tw=1623 Kelvin (approximately 200 Kelvin higher than the typical mercury-free wall temperature when Na is present (based on previous known measurements with pure Hg in HPS arc tubes)).
Ignore effect of axial variation of the average gas temperature between electrode tips, since the aspect ratio G/B>15 for mercury-free designs.
Estimation of electrode backspace to be 1 cm at each end. Ignore effect of electrode volume. Estimation of average gas temperature in the backspace regions to be 925° C.
Using the ideal gas law, moles of metal, i.e., zinc, in the backspace regions and between the electrode tips for each product were calculated and are set out in the results in Table I as N 1 and N 2 , respectively. Total vapor phase Zn atoms were converted to micrograms, for each wattage. As shown in Table I, the quantity of Zn in the electrode backspace region is about one-third to one half of the total dosed.
Table I shows that required micrograms of zinc vary from about 18 micrograms for the 50 W lamp to about 81 micrograms for the 400 W lamp, for the just-saturated vapor condition. The minimum amount of dosed zinc, then, was determined to be about 10 to 100 micrograms per arc tube, depending upon the wattage of the lamp. Any additional zinc content within the arc tube will not affect the arc voltage or spectrum.
Similar calculations known to those skilled in the art for the just-saturated vapor condition for sodium showed that at least about 10 to 100 micrograms of sodium per arc tube, depending upon the wattage, are required for high efficacy.
TABLE I
Zn
Zn
Zn
torr
N1
N2
Zn
Zn
Bore (B)
Gap (G)
Psat @
Moles
Moles
Moles
Atomic
Lamp
(cm)
(cm)
727° C.
in Gap
in ends
Total
Weight
Zn (grams)
Zn (micrograms)
50 W
0.32
5
76
1.16E−07
1.64E−07
2.8E−07
65.4
1.83E−05
18.3
70 W
0.33
5.6
76
1.39E−07
1.74E−07
3.13E−07
65.4
2.04E−05
20.4
100 W
0.33
6.3
76
1.56E−07
1.74E−07
3.3E−07
65.4
2.16E−05
21.6
150 W
0.37
7
76
2.18E−07
2.19E−07
4.36E−07
65.4
2.85−05
28.5
250 W
0.45
8.5
76
3.91E−07
3.23E−07
7.15E−07
65.4
4.67E−05
46.7
400 W
0.55
11
76
7.56E−07
4.83E−07
1.24E−06
65.4
8.1E−05
81.0
The invention will now be described in detail in the following examples.
EXAMPLE 1
A mercury-free HPS lamp was constructed for a 150 W reference ballast, having 4.0 mm bore, 7.9 cm arc gap, and charged with 1.9 milligrams of sodium and a xenon cold fill pressure of 275 millibar (209 torr). The lamp was burned for 100 hours to stabilize the electrical and photometric properties. Volts, efficiency (lumens/watt) and color rendering index (Ra) for the lamp were determined using methods well-known to those skilled in the art and are recorded in Table II.
EXAMPLE 2
Example 1 was repeated in an identical manner. Volts, efficiency (lumens/watt) and color rendering index (Ra) for the lamp are recorded in Table II.
EXAMPLE 3
Example 1 was repeated in an identical manner with the exception that the lamp was also charged with a 1 milligram dose of zinc. Volts, efficiency (lumens/watt) and color rendering index (Ra) for the lamp are recorded in Table II.
EXAMPLE 4
Example 3 was repeated in an identical manner. Volts, efficiency (lumens/watt) and color rendering index (Ra) for the lamp are recorded in Table II.
EXAMPLE 5
A mercury-free HPS lamp was constructed for a 150 W reference ballast having a 4.0 mm bore, 7.9 cm arc gap, and charged with 1 mg zinc and a xenon cold fill pressure of 275 millibar (209 torr). The lamp was burned for 100 hours to stabilize the electrical and photometric properties. The average operating voltage was measured as 112 volts.
EXAMPLE 6
Mercury-free HPS lamps were constructed for a 150 W reference ballast having a 4.5 mm bore, 7.0 cm arc gap, and charged with either 5 mg or 1 mg zinc, and a xenon cold fill pressure of 350 mbar (266 torr). After 100 hours stabilization, the average operating voltage of the lamps was measured as 88 volts.
EXAMPLE 7
A mercury-free HPS lamp was constructed for a 150 W reference ballast having a 4.0 mm bore, 7.9 cm arc gap, and charged with a xenon cold fill pressure of 275 millibar (209 torr). The lamp was burned for 100 hours to stabilize the electrical and photometric properties. The average operating voltage was measured as 64 volts.
EXAMPLE 8
A mercury-free HPS lamp was constructed for a 150 W reference ballast having a 4.5 mm bore, 7.0 cm arc gap, and charged with a xenon cold fill pressure of 350 mbar (266 torr). After 100 hours stabilization, the average operating voltage was determined to be 52.5 volts.
EXAMPLE 9
A mercury-free HPS lamp was constructed for a 150 W reference ballast having 4.0 mm bore, 7.9 cm arc gap, and charged with 1 milligram zinc and xenon cold fill pressure of 275 millibar (209 torr). The lamp was burned for 100 hours to stabilize the electrical and photometric properties.
EXAMPLE 10
Example 8 was repeated in an identical manner with the exception that the lamp was also charged with a 1 milligram dose of zinc. Efficiency (lumens/watt) was determined to be 5.7.
TABLE II
Color Rendering Index
Lamp
Volts
Lumens/Watt
(Ra)
Example 1
109
108.1
30.2
Example 2
108
108.5
29.2
Example 3
116
109.7
29.1
Example 4
121
108.2
31.1
FIG. 2 illustrates the visible spectra of selected Na—Xe and Na—Zn—Xe lamps from Examples 1 and 4, respectively, the visible spectrum generally being defined as the wavelength range between 380-760 nm. As illustrated in FIG. 2, the visible spectra of the selected lamps appear to overlap completely. Visible radiation is primarily from the sodium.
At the higher magnification demonstrated in FIG. 3, a very small contribution from blue 472 and 481 nm zinc lines can be seen. When sodium is present, zinc hardly radiates because of the large difference in excitation potentials, i.e., 4.03 eV for zinc versus 2.1 eV for sodium.
The self-reversal width of the sodium D-lines at 589 nm is a well-known measure of the sodium partial pressure during operation. This spectral region was essentially the same width for each of the lamps tested in Examples 1-4 and is illustrated in FIG. 4 . The Color Rendering Index, Ra, another common measure of the sodium pressure, was also virtually the same for the four lamps set out in Examples 1-4.
Despite “spectral equivalence”, the Na—Zn—Xe lamps were 10.5 volts higher than the Na—Xe lamps, on average, as shown in Table II. Zinc therefore appears to behave as a buffer gas, contributing to the lamp voltage—but not the light output—analogous to mercury in standard Na—Hg—Xe HPS lamps. From Table II, it can be determined that zinc's contribution to the arc electric field is approximately 11%.
To estimate the value of the electric field where efficacy is optimum (E 0 ), the luminous efficacy versus the arc electric field for several Na—Xe and Na—Zn—Xe lamps subjected to the same testing as the Na—Xe and Na—Zn—Xe lamps shown in Examples 1 through 4 were plotted in FIGS. 5 and 6 for lamps having a 4.0 mm bore and a 4.5 mm bore. The formula used to calculate the electric field was E=(V-12)/G, where V is the lamp voltage, G is the arc gap, and an electrode end fall of 12 volts was assumed. Data series of lamps in FIGS. 4 and 5 are labeled by “test number, _arc gap in cm and reference ballast wattage”, and also according to whether the Na—Xe lamp also contained zinc. From that information, one skilled in the art can readily see the design features corresponding to each lamp tested. In line with Examples 1-4, the zinc dosed was 1 milligram, where applicable. The charge for each lamp tested in FIGS. 5 and 6 also included from two to five milligrams of sodium, an amount well in excess of the critical amount needed to obtain for saturated vapor, and xenon at 275 millibar average pressure.
The graphs of FIGS. 5 and 6 illustrate that higher efficacy is achieved at a higher power per unit arc gap, and that an optimum value of E for luminous efficacy exists with a numerical value which depends upon the bore size. These effects are well known in HPS technology. From FIGS. 5 and 6 it may be concluded that the same efficacy is achievable if zinc is added to the sodium-zenon mix. The Na—Zn—Xe data are just shifted to the right by about 11% as a result of the buffer gas effect.
Table III sets out, in part, the E 0 value estimated from FIGS. 5 and 6 for a Na—Xe lamp. E 0 for an Na—Xe lamp having a 4.0 mm bore was determined from FIG. 5 to be 11 V/cm by estimating the peak of the parabola shown therein. For a 4.5 mm bore Na—Xe lamp, E o was determined by estimating the peak of the parabola plotted in FIG. 6 .
The E o value for the corresponding Na—Zn—Xe lamps was estimated from Table II to be 11% greater than the value shown for the Na—Xe lamps in Column 1, of Table III. Thus, the E o values for the Na—Zn—Xe lamps in Table III are estimated to be 11% greater than those for the Na—Xe lamps.
TABLE III
Eo_Na—Zn—
Eo_Na—Xe
Xe
E_Zn—Xe
E_Xe
Bore
V/cm
V/cm
V/cm
V/cm
4.0 mm
11
12.2
12.6
6.6
4.5 mm
9.5
10.6
10.9
5.8
The E values in Table III for the Zn—Xe dosed lamps were calculated from the voltage values measured in Examples 5 and 6. The E values for the xenon-dosed lamps were calculated from the voltage values measured in Examples 7 and 8.
Using the experimental values of E 0 and E set out in Table III, it is possible to illustrate zinc's success at eliminating an undesirable end-of-life failure mode for a mercury-free HPS arc tube.
EXAMPLE 11
For a 150 W MF lamp to be designed in 4.0 mm bore, with an IEC prescribed arc length of 7 cm, and design center voltage of 100 volts, the optimum efficacy in the Na—Xe design space occurs at (11*7+12)=89 volts. But in order to center the design at 100 volts, the Na coldspot temperature must be further increased so that E>E 0 . The operating point moves to the right of optimum with perhaps 1-2penalty in efficacy. With Na—Zn—Xe dosing, optimum efficacy occurs essentially at the design center voltage or (12.2*7+12)=98 volts. Further, at end-of-life, when the sodium is lost, the lamp voltage is (12.6 * 7+12)=100 volts. Lamp voltage for the Na—Zn—Xe dosing is remarkably constant over life. On the other hand, without zinc, lamp voltage could drop to that for Xenon—that is, (6.6*7+12)=58 volts—well below the IEC minimum of 85 volts. Such a drop results in ballast overheating.
EXAMPLE 12
For a 250W lamp to be designed in 4.5 mm bore, with an IEC prescribed arc length of 8.5 cm, and design center voltage of 100 volts, the optimum efficacy in the Na—Xe design space occurs at (9.5*8.5+12)=93 volts. But in order to center the design at 100 volts, the Na coldspot temperature must be further increased so that E>E 0 . The operating point moves to the right of optimum, again with perhaps 1-2% lumen penalty. With Na—Zn—Xe dosing, optimum efficacy occurs very near the design center voltage or (10.6*8.5+12)=102 volts. Further, at end-of-life, when the sodium is lost, the lamp voltage is (10.9*8.5+12)=105 volts, again, remarkably constant and well within specification. On the other hand, without zinc, lamp voltage could drop to that for xenon—that is, (5.8*8.5+12)=61 volts, well below the IEC minimum of 85 volts. Such a drop results in ballast overheating.
Aside from the prevention of the undesirable low voltage operating mode corresponding to the sodium-xeon discharge, another advantage of using zinc is that the resultant zinc-xenon discharge has a distinctly different color when compared to the initial sodium-zinc-xenon dosed lamp. For example, compare FIG. 7, showing only several prominent blue lines and several weaker red lines in the visible spectrum, of a zinc-xenon discharge, with the initial sodium spectrum of FIG. 2 . Further, as is best demonstrated using the results of Example 10, an efficacy of the zinc-xenon discharge of 5.7 lumens/watt was measured—about 5% of the original value measured in Examples 3 and 4. In this regard, the change from golden-white to a typical reddish-blue color and lower luminous efficacy can become the primary indication, at the end-of-life phase of the lamp, that the lamp must be replaced.
The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon the reading and understanding of this specification. For example, other dosing elements, aside from those referenced herein, may be utilized in the discharge as long as certain design parameters are met. The invention is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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A mercury-free high pressure sodium vapor lamp is dosed with sodium, xenon and zinc as an elemental metal additive. The addition of the metal additive prevents an undesirable low-voltage operating mode of the sodium-xenon discharge associated with a mercury-free HPS lamp, which otherwise occurs when sodium is no longer available to participate in the arc discharge.
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The present invention relates to the field of wheels for sports or leisure equipment such as skateboards, inlines and the like, and more specifically to wheels having a radial surface comprising at least two different materials having different mechanical properties.
BACKGROUND AND PRIOR ART
The wheels of a skateboard are typically made of polyurethane and come in many different sizes and shapes adapted to different types of skating.
It is also well known that the properties of the surface material affect the behavior of the skateboard. Polyurethane, which can be found with different friction coefficients, rolling resistance, and rebound depending on the mechanical properties of the material, such as its hardness. Hardness is usually measured on a Shore durometer scale in the range of Shore A 75 to Shore A 100 or harder. For example, hard wheels can slide more easily while softer wheels are can maintain higher speeds without sliding. Skateboard wheels have a wide surface engaging the ground, ranging from approximately 1 cm to over 5 cm. Traditionally, skateboarders have had to make compromises between control and a smooth ride on one hand and high speed on the other. Thinner wheels are generally made of relatively hard urethane, facilitating slides, grinds and other tricks. Thicker wheels are typically made with softer urethane for more control, making them suitable for, for example, downhill racing.
U.S. Pat. No. 6,953,225 discloses a skateboard wheel as initially defined. This wheel has a radial surface comprising outer portions and an inner portion between the outer portions, with a substantially linear border between them. Each of the three portions extends completely around the circumference of the wheel. The outer portions are made from a harder material than the inner portion, giving the outer portions a lower friction and thereby properties suitable for making tricks, especially involving sliding, while the inner portion has a higher friction thereby providing a higher degree of control, according to U.S. Pat. No. 6,953,225. The wheel has an axle passage through the centre with a bearing surface facing a hub for mounting the wheel on a skateboard. Hence, a designer of skateboard wheels can vary the properties of the wheels through selection of the hardness and friction coefficient of the materials used on the surface, and the width of the outer and inner portions of the wheels Similar considerations apply to other types of wheels, for example for roller skates or inline roller skates.
U.S. Pat. No. 4,699,432 discloses a safety wheel for use with, for example, roller skates or skateboards. The wheel is designed to provide improved traction and performance and comprises portions of a first material having a relatively low friction coefficient and a second material, softer than the first material and having a higher friction coefficient.
SUMMARY OF THE INVENTION
The invention relates to a wheel for sports equipment, such as a skateboard, a scooter, a snakeboard, a roller skate or an inline roller skate. The wheel has a radial surface arranged to provide contact with the ground comprising areas of at least a first material and areas of at least one additional material, said additional material or materials having mechanical properties differing from that of the first material. The first and additional second materials are arranged in such a way that they form a pattern on the radial surface which varies around the circumference of the wheel. The first and additional materials are chosen in such a way that they will form molecular bonding between them. Typically both materials will be polyurethane.
Said mechanical properties include but are not limited to hardness, rebound, abrasion, rate, coefficient of friction. Typically, a harder polyurethane material is used as the first material and a softer polyurethane is used as the second material. It would also be possible to use materials that have essentially the same mechanical properties but different colours. This would achieve a pattern in the wheel that would not be worn off in the same way as printed patterns on the surface.
By using polyurethane for both materials a molecular bonding can be achieved between the different areas. In contrast, when different types of materials are used, some sort of mechanical bonding must be used to keep the areas of different materials together. In practice, a wheel comprising two or more different types of polyurethane material can be made to function as one integral piece where the different areas cannot be separated from each other. As a consequence, there is no space between the different areas and no risk of rifts or crevices forming between the different areas. Such imperfections in the surface of the wheel serve to reduce the performance of the wheel so avoiding them is a major advantage. Further, the manufacturing process can be made more cost-efficient, since less effort will be needed to bond the areas of different materials together.
Varying the pattern of the two materials over the radial surface enables the wheel designer to modify the performance of the wheel beyond limitations in urethane materials. A design having different urethanes in alternating contact with the riding surface would give the rider the individual benefits of each material. The wheel can be adapted according to the intended use of the wheel, skills of the intended user, the surface on which the user will ride, or any other parameter.
Further, the visible differentiation a mix of materials in a pattern conveys a marketing benefit, since the patterns may be designed to look cool. Patterns may even be designed to reflect, for example, the logotype of a company or any other attractive image. This enables the differentiation of wheels from a particular manufacturer, or wheels having a particular set of properties just by looking at them.
In a preferred embodiment the surface is arranged so that only one of the first and additional second materials is in constant contact with the riding surface. The other material or materials form isolated areas, or islands, on parts of the radial surface. With alternating contact, the hard material gives stability and controls deformation and rolling resistance, the softer material gives better grip and higher rebound. By alternating materials we can engineer and optimize the wheel beyond previous limitations.
It would be possible to use a combination of more than two different materials as well.
In a preferred embodiment, the blended center surface is the principal weight supporting surface which interacts with the riding surface, because of its mix of materials in alternating contact enables the ability to manage the mechanical properties, tribology, and performance of the wheel.
In an alternative preferred embodiment, the blended center surface is combined with one or two outer portions of a similar type as in the prior art. In this case, the friction of the outer portions will be minimized, to facilitate tricks, while the friction of the center portion can be adapted as desired.
At any given moment more than one of the materials will normally be in contact with the riding surface, but the distribution between the materials will vary. By varying the design, size and pattern of the different materials we can affect the ride in the same way that alternating patterns on studded tires affect grip in snow. One material is engineered to give stability, while a second material gives grip and rebound. The degree of which any one material or a combination of two materials that is in alternating contact with the riding surface will vary depending upon the properties optimal for each type of skateboard wheel which is manufactured according to the patent technology.
In one embodiment the pattern of two different materials extends to at least one side of the wheel. This is particularly useful for applications in which the wheel may be tilted, for example for inline rollerskates.
The physics of wheels are the same for skateboarding, roller skating, inline skating, and scooters. All of these products utilize polyurethane wheels and therefore benefit from the ability to engineer the wheels properties through design.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following embodiments of the invention will be described in detail, with reference to the appended drawings, in which
FIGS. 1A-1C show different views of skateboard wheel according to a first embodiment of the invention.
FIGS. 2A and 2B show examples of what a section through the wheel of FIGS. 1A to 1C might look like.
FIG. 3A is a view of part of the circumference of a skateboard according to an embodiment of the invention.
FIG. 3B is a section through the skateboard wheel of FIG. 2A .
FIG. 4A shows a third embodiment of a wheel according to the invention.
FIG. 4B is a section view of the wheel of FIG. 4A .
FIG. 5 shows a fourth embodiment of a wheel according to the invention.
FIG. 6 shows a section trough a wheel according to an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1A is a perspective view of an embodiment of a wheel 1 according to the invention. The wheel has a hub 3 , which exhibits an axle passage 5 for mounting on a skateboard, a rollerskate or the like. A bearing (not shown) is typically provided around the axle passage for smooth rotation of the wheel. The wheel has a tapered edge 7 and an outer surface 9 which forms the interface towards the ground. The tapered edge 7 and the outer surface 9 are primarily made from a first material 11 having a first set of mechanical properties, including a first hardness, shown in white in the Figure. Around the circumference of the wheel, a second material 13 having a second set of mechanical properties, including a second hardness, is applied in such a way that the outer surface 9 and/or the tapered edge 7 comprises areas of the first material 11 and areas of the second material 13 . In this particular embodiment, the exterior surface around the circumference of the wheel comprises a central narrow line of the first material 11 surrounded by a feather-like pattern in which areas of the second material 13 extend from the central line to the edge outer surface around the whole circumference, interrupted by curved lines of the first material 11 . In this embodiment, the edges 7 of the wheel are beveled, so that the first material surfaces at the edges and sides of the wheel.
The wheel may be made entirely from the first material, with only the areas of the second material applied as shown, or one or more other materials or compositions may be used for the interior or portions of the interior of the wheel. Alternatively, the wheel may have hollow portions inside, such as the chambers shown in FIG. 1 .
FIG. 1B is a view of the wheel of FIG. 1 a , seen from the side, including the hub 3 , the axel passage 5 and the tapered edge 7 . The pattern around the circumference is seen in the narrow outer circle as wider areas of the second material 13 interrupted by narrow areas of the first material 11 .
FIG. 1C is a view of the wheel of FIGS. 1 a and 1 b , as seen towards the circumference of the wheel. The outer surface 9 is seen having a narrow central line of the first material 11 around its circumference and a feather-like pattern of the second material 13 extending from the narrow central line across the outer surface 9 towards the tapered edges 7 .
FIG. 2A shows a section through the wheel of FIGS. 1A-1C according to a first embodiment. As can be seen, a core 15 made from the material forming the hub 3 extends radially from the axel passage 5 to form the major part of the wheel. This core 15 is covered, around the areas that are adapted to connect to the ground, by a layer of the first material 11 constituting the main part of the wheel. The areas of the second material 13 extend a relatively short distance into the first material as can be seen in the Figure.
FIG. 2B shows a section through the wheel of FIGS. 1A-1C according to an alternative embodiment. As can be seen, the hub 3 in the middle is surrounded by an area of the first material 11 constituting the main part of the wheel. The areas of the second material 13 extend a longer distance into the first material as can be seen in the Figure. Of course, the areas of the second material 13 could extend longer or shorter into the first material. For example, it could extend halfway, or more than halfway in, or approximately as shown in FIG. 2A . FIG. 6 below shows yet another possible implementation.
Although the Figures show wheels suitable for a skateboard, using two or more different materials having different mechanical properties in the outer surface of the wheel can be utilized in wheels for a number of different applications, including rollerskates, inlines, snakeboards and scooters. How to make such wheels is well known in the art, including dimensions, shapes, how to arrange the hub, the use of bearing, etc. The only change that is made according to the invention lies in how the surface material is applied to the wheel.
FIG. 3A shows a second embodiment of the wheel, seen towards the circumference of the wheel. The side view would be essentially as shown in FIG. 1A . In this embodiment, the second material is applied in three areas: a first and a second band 13 ′ around the edges of the wheel and a band 13 ″ in the middle. The borders between the first and second bands 13 ′ and the areas 11 ′ of the first material have a serrated shape. Of course, the borders could have any shape that was not entirely linear, since a variation should be provided around the circumference of the wheel.
FIG. 3B shows a section through the line A-A of FIG. 3B . As in FIG. 2B , the second material forms the main part of the wheel, extending from the hub 3 all the way to the circumference. In the example shown, areas of the second material extend a short way into the first material around the circumference. Of course, the wheel of FIG. 3A could also be implemented in the different ways discussed in connection with FIGS. 2A and 3A .
FIG. 4A shows a third embodiment of the wheel. As in FIG. 1A , a hub 103 is surrounded by a first material 111 making up the main part of the wheel. Areas of a second material 113 are placed in the beveled portions of the wheel, only. FIG. 2B shows a section through the wheel of FIG. 2A , in which areas of the second material 113 extend a short distance into the first material at the beveled side portions of the wheel.
FIG. 4B shows a section through the wheel of FIG. 4A . In this example, the second material 113 extends only a short distance into the first material 111 . Of course, the wheel of FIG. 4A could also be implemented in the different ways discussed in connection with FIGS. 2A and 3A .
FIG. 5A shows a fourth embodiment of a wheel to illustrate that the first 211 and second 213 materials may be arranged in any pattern on the circumference of the wheel. In this particular example, the areas of the second material are heart shaped. The section through the wheel could be as any of the embodiments discussed above, or as discussed in connection with FIG. 6 .
FIG. 6 shows an alternative section through a wheel having a hub 303 around an axel passage 305 . In this embodiment the second material is arranged to form a band 313 around the hub. The first material 311 is arranged around the band 313 and extends to the circumference. The band has arms 313 ′ extending radially through the first material towards the circumference of the wheel, to form areas of the second material in the first material on the surface. The cross-section of the arms 313 ′ may have any shape, typically corresponding to the pattern that should be made around the circumference of the wheel. For example in the wheel of FIG. 5 the cross-section could be heart-shaped.
The wheel according to the invention may be produced in a number of different ways, as will be clear to the person skilled in the art. For example, the core of the wheel is made of the first material and extends from the hub 3 of the wheel all the way to the outer surface. The core is then place in a mold shaped like the outer shape of the wheel. The second material is poured into the mold and forms the outer surface of the wheel fused with the first material of the core. Alternatively, it would be possible to make the wheel of the second material and apply the first material only around the outer surface.
Alternatively a patterned insert ring with an outer diameter matching the outer surface of the wheel is molded. This ring is then placed in a mold and the second material is poured into the mold and forms the outer surface of the wheel fused with the first material of the ring. An optimal thickness of the ring would be in the range from 2 mm to 10 mm.
A third option would be to make a wheel of the first material with cavities in the first material and fill in the cavities using the second material. The cavities can be made as deep as desired, from extending about 1 millimeter into the wheel to 25 millimeters into the wheel, or extending all the way to the hub. A preferred thickness would be 6 mm to 7 mm.
The diameter of the wheel varies depending on the type of wheel, as the skilled person will be aware. For skateboard wheels, the diameter is typically within the range from 45 mm to 60 mm for a street wheel, between 55 mm and 70 mm for a park/vert/transition wheel. A longboard speed wheel typically has a diameter between 60 mm and 120 mm.
The shape of a wheel and the width of the wheel contacting the riding surface also depends on the type of wheel. An inline, snakeboard or scooter wheel has an elliptical form and the portion contacting the riding surface is very narrow, from 2 mm to 15 mm.
A skateboard wheel the width of the portion contacting the riding surface starts at 15 mm for a 360 freestyle wheel. For a street skateboard wheel it is typically between 20 mm and 30 mm, and for a park/vert/transition wheel it is typically between 25 mm and 40 mm. The contacting portion of a longboard wheel is typically 35 mm to 80 mm.
As the skilled person will understand, the dimensions given above are merely intended as examples and are not limiting in any way. Further, the wheel according to invention is not limited to the uses mentioned. The wheel can be made in the conventional way for the intended use, apart from the combination of two or more surface materials as discussed in this document.
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A wheel for a skateboard, roller skate or the like has a radial surface arranged to provide contact with the ground, said radial surface comprising areas of at least a first material and areas of a second material, said second material having at least one mechanical property differing from that of the first material. The first and second materials are arranged in such a way that they form a pattern on the radial surface which varies around the circumference of the wheel. This enables the adaptation of the behavior of the wheel in a very flexible way.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to doors and, more particularly, is directed towards entrance doors having interconnected extruded sections.
2. Description of the Prior Art
Entrance doors of various configurations have been fabricated from a plurality of precut extruded sections that are welded together to form a rigid structure. In a conventional manner, a door frame which corresponds generally to the entrance door configuration is secured in place. Then, the entrance door is hung on the door frame. At times, for various reasons, the entrance door does not properly mate with the door frame. In such cases, due to the rigid construction of the entrance door, shims are used to adjust the door frame opening so that it will correspond to the entrance door configuration. A need has arisen for an entrance door that can be adjusted to compensate for variations between the door and door frame.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an entrance door that is adjustable for proper mating with a door frame. The adjustable entrance door is characterized by a plurality of extruded sections that are interconnected to form an opened rectangular frame in which a rectangular glass panel is mounted. The extruded sections include a lead edge stile, a hinge stile, a top rail and a bottom rail. Tie rods, which extend through each rail and into each stile, are provided for interconnecting the extruded sections. An inner face of each extruded section is configured to captively hold a pair of interlocking glazing beads, the glass panel being secured between the beads with the edges of the panel askew with respect to the inner edges of the rectangular frame. The top rail is provided with a block that engages the top edge of the glass panel for relative vertical movement of the lead edge stile and hinge stile. The bottom rail is fitted with an adjustable member that extends the width of the door and is vertically movable for mating alignment with a threshold.
It is another object of the present invention to provide an adjustable entrance door in which the lead edge stile is formed with an integral lip that overlaps a doorjamb for security and weather protection.
Other objects of the present invention will in part be obvious and will in part appear hereinafter.
The invention accordingly comprises the devices, together with their parts, elements and interrelationships, that are exemplified in the following disclosure, the scope of which will be indicated in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
A fuller understanding of the nature and objects of the present invention will become apparent upon consideration of the following detailed description taken in connection with the accompanying drawings, wherein:
FIG. 1 is a front elevation of an entrance door embodying the invention;
FIG. 2 is an exploded view in perspective of the entrance door of FIG. 1;
FIG. 3 is a sectional view of the lead edge stile taken along the lines 3--3 of FIG. 2;
FIG. 4 is a sectional view of the hinge stile taken along the lines 4--4 of FIG. 2;
FIG. 5 is a sectional view of the top rail taken along the lines 5--5 of FIG. 2;
FIG. 6 is a sectional view of the bottom rail taken along the lines 6--6 of FIG. 2;
FIG. 7 is a sectional view of the bracket taken along the lines 7--7 of FIG. 2;
FIG. 8 is a sectional view of one section of the glazing bead taken along the lines 8--8 of FIG. 2;
FIG. 9 is a sectional view of the other section of the glazing bead taken along the lines 9--9 of FIG. 2;
FIG. 10 is a sectional view of the adjustable expander taken along the lines 10--10 of FIG. 2;
FIG. 11 is a front elevation of the entrance door of FIG. 1 with certain parts removed to show the lead edge stile and hinge stile adjustment;
FIG. 12 is a front elevation of an alternative embodiment of the invention;
FIG. 13 is a sectional view of the lead edge stile taken along the lines 13--13 of FIG. 11;
FIG. 14 is a front elevation of another embodiment of the invention; and
FIG. 15 is a front elevation of yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, particularly FIG. 1, there is shown an outwardly opening entrance door 10 which is hung on a door frame 12 by means of hinges 14, for example butt hinges. Door 10 comprises a plurality of extruded sections including a lead edge stile 16, a hinge stile 18, a top rail 20 and a bottom rail 22 which are interconnected to form a substantially rectangular frame in which a panel 24, for example a glass panel, is captively held. Door frame 12 comprises a plurality of extruded sections including side jambs 26, 28, a header 30 and a threshold 32 which are interconnected to form a substantially rectangular open frame. In the following description, the sides of each extruded section of door 10 are denoted as inner, outer, interior and exterior. The inner sides of the extruded sections face one another, glass panel 24 being in juxtaposition with the inner sides. The outer sides are opposite the inner sides. The exterior sides of the extruded section are on the outside of the door and the interior sides are on the inside of the door opposite the exterior sides. The extruded sections of door 10 and frame 12 are composed of an aluminum alloy having a hard, highly resistant thermoset coating. Preferably, the extruded sections are composed of an aluminum alloy consisting essentially of approximately 0.4 percent silicon, 0.7 percent magnesium and 98.9 percent aluminum and having an aluminum Associated alloy designation 6063-T5 as specified in the Aluminium Association Standardized System of Alloy Designation adopted Oct., 1954. The nominal thickness of the extruded sections is approximately 3.2 mm (0.125 inches). The thermoset coating is an acrylic resin with amide side chains copolymerized from styrene and ethyl acrylate.
In the embodiment of FIG. 1, hinges 14 are mounted to hinge stile 18 and side jamb 28 in such a way that door 10 swings outwardly. A pull handle 34 is fastened to the exterior side of lead edge stile 16. A push bar 36 is mounted between lead edge stile 16 and hinge stile 18 on the interior face thereof. A lock mechanism 37 is mounted to lead edge stile 16. The detail construction of entrance door 10 is shown in FIG. 2. The cross sectional profiles of lead edge stile 16, hinge stile 18, top rail 20 and bottom rail 22 are shown in FIGS. 3, 4, 5 and 6, respectively.
Referring now to FIGS. 2 and 3, it will be seen that lead edge stile 16 comprises an inner side 38, an outer side 40, an interior side 42, an exterior side 44 and an extending flange 46. Inner side 38, outer side 40, interior side 42 and exterior side 44 have a generally trapezoidal profile in right cross section. Interior side 42 and exterior side 44 are in spaced parallel relationship to one another, the exterior side being wider than the interior side. Inner side 38 is in perpendicular relationship to interior side 42 and exterior side 44. Outer side 40 diverges inwardly towards inner side 38 from exterior side 44 to interior side 42. One edge of outer side 40 is flush with one edge of interior side 42. The other edge of outer side 40 extends beyond one edge of exterior side 44 and terminates in flange 46 which includes a shoulder 47 and an arm 49. Shoulder 47 is parallel to inner side 38 and arm 49 is parallel to exterior side 44. A mortise 51, which is formed at a medial portion of arm 49 at the interior side thereof, is configured to receive a weather strip (not shown). Flange 46, which overlaps side jamb 26 when door 10 is closed, provides security and weather protection. The other edges of interior side 42 and exterior side 44 extend beyond the edges of inner side 38 to form a mortise 48. As shown at 53, the inner faces of exterior side 44 and interior side 42 are thickened for support at the union of inner side 38 and exterior side 44, at the union of inner side 38 and interior side 42, and at the union of outer side 40 and exterior side 44.
Referring now to FIG. 4, it will be seen that hinge stile 18 has a substantially trapezoidal profile in right cross section and includes an inner side 50, an outer side 52, an interior side 54 and an exterior side 56. Interior and exterior sides 54 and 56 are parallel to one another and are perpendicular to inner side 50. One edge of interior side 54 extends beyond one edge of inner side 50 and one edge of exterior side 56 extends beyond the other edge of inner side 50 to form a mortise 58. The other edges of interior side 54 and exterior side 56 are flush with opposite edges of outer side 52. The width of exterior side 56 is greater than the width of interior side 54, inner side 52 lying in a plane that diverges inwardly from exterior side 56 towards interior side 54. The inner faces of exterior side 56 and interior side 54 are thickened at 57 for support at the union of exterior side 56, inner side 50 and outer side 52, and at the union of interior side 54 and inner side 50.
As shown in FIG. 5, top rail 20 has a substantially double I beam profile in right cross section and includes an inner side 58, an outer side 60, an interior side 62 and an exterior side 64. Inner side 58 and outer side 60 are parallel to one another and perpendicular to interior side 62 and exterior side 64. One edge of interior side 62 and one edge of exterior side 64 extend beyond the edges of outer side 60 to form a shallow, substantially U-shaped channel 66. The other edge of interior side 62 and the other edge of exterior side 64 extend beyond the edges of inner side 58 to form a mortise 68. As shown at 67, the inside corners formed at the union of outer side 60, interior side 62, and exterior side 64 are thickened for support. In addition, as shown at 69, the inner faces of interior side 62 and exterior side 64 are thickened for support at the union of inner side 58, interior side 62 and exterior side 64.
Referring now to FIG. 6, it will be seen that bottom rail 22 has a substantially A-shaped profile in right cross section and includes an inner side 70, an outer side 72, an interior side 74 and an exterior side 76. Inner side 70 and outer side 72 are parallel to one another and perpendicular to interior side 74 and exterior side 76. One edge of interior side 74 and one edge of exterior side 76 extend beyond the edges of outer side 72 to form a deep, substantially U-shaped channel 78. The other edge of interior side 74 and the other edge of exterior side 76 extend beyond the edges of inner side 70 to form a mortise 80. The inner faces of outer side 72 are thickened for support at 82, the union of outer side 72, interior side 74 and exterior side 76. Also, the inner faces of interior side 74 and exterior side 76 are thickened for support at 84, the union of inner side 70, interior side 74 and exterior side 76.
As previously indicated, lead edge stile 16, hinge stile 18, top rail 20 and bottom rail 22 are interconnected to form a rectangular frame by means of tie rods 86 and 88. The upper margin and the lower margin of inner side 48 of lead edge stile 48 are formed with holes 90 and 92, respectively. The upper margin and the lower margin of inner side 50 of hinge stile 18 are formed with holes 94 and 96, respectively. Holes 90 and 92 are in registration with holes 94 and 96, respectively. Registered holes 90 and 94 are configured to receive tie rod 86, for example a threaded rod and registered holes 92 and 96 are configured to receive tie rod 88, for example a threaded rod. Top rail 20 rests on a pair of brackets 98 and 100 which are fastened to the upper margins of lead edge stile 18 and hinge stile 20. Bracket 98 is formed with a through hole 102 which is in registration with hole 90 and bracket 100 is formed with a through hole 104 which is in registration with hole 94. Bracket 98 is positioned within mortise 48 and the edges of mortise 48 are crimped to secure bracket 98 thereto. In a similar manner, bracket 100 is crimped within mortise 58, hole 104 being in registration with hole 94. Bottom rail 22 rests on a pair of brackets 106 and 108 which are fastened to the lower margins of lead edge stile 18 and hinge stile 20. Bracket 106 is formed with a through hole 110 which is in registration with hole 92 and bracket 100 is formed with a through hole 112 which is in registration with hole 94. Brackets 106 and 108 are crimped within mortises 48 and 58 in the manner hereinbefore described in connection with bracket 98.
As shown in FIG. 7, bracket 108 is an extruded section having a C-shaped profile in right cross section and includes a base 114 and a pair of parallel legs 116,118 that extend outwardly from one side of base 114 in perpendicular relationship thereto. The free ends of legs 116 and 118 are beveled inwardly. The other side of base 114 is provided with a pair of ribs 120 and 122 that define a flaring tenon 124 which is adapted to be snugly received within mortise 58. Brackets 108, 104 and 106 are identical in construction to bracket 98.
After the tenons of brackets 106 and 108 are inserted into their respective mortises to form a dovetail joint and are crimped therein, tie rod 88 is passed through bottom rail 22. Next, one end of tie rod 88 is passed through holes 112 and 96 into the interior of hinge stile 18. Next, bottom rail 22 is pressed into bracket 108 with legs 116 and 118 contacting the inner faces of interior and exterior sides 74 and 76 to prevent rotational movement of the bottom rail, the beveled ends of the legs facilitating reception of the bottom rail. Next, a rectangular washer 126, composed of steel for example, formed with a central hole 128 is placed on tie rod 88. Finally, a lock nut 130 is threaded onto tie rod 88. In a like fashion, the other end of bottom rail 18 is secured to lead edge stile 16. Top rail 20 is mounted to hinge stile 18 and lead edge stile 16 in a similar manner.
As shown in FIG. 2, the bottom margins of lead edge stile 16 and hinge stile 18 are formed with substantially rectangular openings 132 and 134, respectively, which dimensionally correspond to and are in registration with channel 78. An adjustable leaf 136 is snugly received within channel 78 and openings 132, 134. Referring to FIG. 8, adjustable leaf 136 has a substantially U-shaped profile in right cross section and includes a base 138 which is formed with a mortise 140 and a pair of upright legs 142, 144. Mortise 140 is configured to receive a weather strip (not shown). Legs 142 and 144 press against the inner faces of interior side 74 and exterior side 76 of bottom rail 22 in such a manner that leaf 136 is constrained against free movement within channel 78 and is constrained for forced movement within channel 78.
Glass panel 24 is captively held to door 10 by means of a pair of interlocking glazing beads 146, 148 that are snap-fitted into mortises 48, 58, 68 and 80. The details of glazing beads 146 and 148 are shown in FIGS. 9 and 10, respectively. Glazing bead 146 includes a body 150 having a substantially rectangular profile in right cross section and an extension member 152 which terminates in a tab 154. The lower portion of body 150 at the right hand side thereof as viewed in FIG. 9 is provided with a lock 156. Tab 154 and lock 156 are operative to hold glazing bead 146 to mortises 48, 58, 68 and 80. The left hand side of body 150 is formed with a mortise 158. Extension member 152 includes a strip 160 which constitutes a lock for glazing bead 148. As shown in FIG. 10, glazing bead 148 has a substantially rectangular profile in right cross section and includes a pair of upright members 162, 164, a connecting cross piece 166 and a tab 168. Upright member 164 is formed with a mortise 169 at an edge adjacent cross piece 166. Tab 168 extends from the lower edge of upright 162 towards the lower edge of upright 164 in parallel relationship to cross piece 166. Glazing bead 148 is captively held to glazing bead 146 by inserting tab 168 into an opening 170 formed between strip 160 and tab 154, the inner faces of uprights 162, 164 being in contact with the outer edges of strip 160.
In fabrication of entrance door 10, after lead edge stile 16, hinge stile 18, top rail 20 and bottom rail 22 are interconnected to form a rigid frame, glazing bead 146 sections are snapped into mortises 48, 58, 68 and 80, body 150 being on the exterior side of the door. Suitable packing (not shown) is placed in mortise 158. Glass panel 24 is inserted in a channel 172 formed in extension 152 between body 150 and strip 160. As viewed in FIG. 11, rubber shims 174, 176 and rubber shims 178, 180 are positioned adjacent the edges of glass panel 24 at the upper right hand corner and lower left hand corner of door 10, respectively. That is, shims 174 and 176 are positioned at the corner formed by top rail 20 and lead edge stile 16, shim 174 being closer to the corner than shim 176. Shims 178 and 180 are positioned at the corner formed by bottom rail 22 and hinge stile 18, shim 178 being closer to the corner than shim 180. The arrangement of shims is such that glass panel 24 is mounted obliquely with respect to the assemblage of lead edge stile 16, hinge stile 18, top rail 20 and bottom rail 22, the assemblage and panel being disposed in a common plane. The face of glass panel 24 is parallel to the faces of exterior sides 44, 56, 64 and 76, and is oblique with respect to the faces of inner sides 38, 50, 58 and 70. As viewed in FIG. 11, from the exterior side of door 10, glass panel 24 is tilted counterclockwise within the rectangular opening defined by the interconnected extruded sections of door 10, the edges of glass panel within channel 172. An adjusting lever or block 182, composed of a plastic such as a polyamide resin, rests on the upper edge of glass panel 24 adjacent shim 174. Adjusting block 182 has a step profile in right cross section and includes treads 184,186 and riser 188,190. Riser 190 projects through an opening 192 formed in inner side 58 of top rail 20 into contact with the upper edge of glass panel 24. A mover 194, for example a screw, is threaded into a hole 196 formed in outer side 60 of top rail 20, screw 194 being in contact with tread 184. As screw 194 is turned into hole 196, riser 190 presses against the edge of glass panel 24 and pulls lead edge stile 16 upwardly with respect to hinge stile 18. After glass panel 24 is in position, glazing beam 148 is snapped into glazing bead 146, tab 168 being received in opening 170 and the inner edge of upright 164 pressing against the edge of strip 160 nearest body 150. A suitable packing (not shown) is positioned in mortise 169.
As best shown in FIG. 2, outer side 52 of hinge stile 18 is formed with a pair of substantially rectangular openings 182 and 184, each of which is configured to snugly receive one leaf of hinges 14, the exposed face of the hinges being flush with the exposed face of inner side 52. Each hinge 14 is mounted to a back plate 186 by means of screws and the back plates, which are larger than openings 182 and 184, are fastened to outer side 52 by means of screws. After door 10 is hung on frame 12, screw 194 is turned to compensate for any misalignment between the top edge of door 10 and frame 12. Strip 160 is adjusted to compensate for any misalignment between the bottom edge of door 10 and frame 12.
An alternative embodiment of door 10 is shown in FIG. 12 at 188. The construction of door 188 is similar to door 10 and has like parts with the exception of flange 46. Door 188 includes an extruded lead edge stile 190 having a rectangular configuration as shown in FIG. 13. Lead edge stile 190 has an inner side 192, an outer side 194, an interior side 196 and an exterior side 198. Outer side 194 is bowed outwardly and is formed with a mortise 200 at a medial portion thereof for a weather strip (not shown). Interior side 196 and exterior side 198 are parallel to one another and perpendicular to inner side 192. A mortise 202, which corresponds to mortise 48, is provided on the inner face of inner side 192. The inner faces of interior side 196 and exterior side 198 are thickened for support at 204, adjacent the union of inner side 192, interior side 196 and exterior side 198. In one embodiment, door 188 is provided with butt hinges 206 and swings either inwardly or outwardly. In an alternative embodiment, door 188 is hung on pivot pins of the type shown in FIG. 15 and swings both inwardly and outwardly.
In the embodiment of FIG. 14, there is shown a double door configuration 208 which swings outwardly and comprises a right hand door 210 and a left hand door 212. Right hand door 210 is similar to door 10 and left hand door is similar to door 188. Right hand door 210 includes a flange 214 which corresponds to flange 46 and overlaps the lead edge stile of door 212 for security and weather protection.
FIG. 15 shows another embodiment in the form of a double door configuration 216 which swings inwardly and outwardly and comprises a right hand door 218 and a left hand door 220, each door being hung on a pair of pins 222 and 224. Pin 222 is fixed to a door frame 226 and pin 224 is spring loaded to door frame 226.
Since certain changes may be made in the foregoing disclosure without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description and depicted in the accompanying drawings be construed in an illustrative and not in a limiting sense.
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An adjustable entrance door with a plurality of extruded sections that are interconnected with tie rods to form a rectangular frame in which a glass panel is mounted. The extruded sections include a lead edge stile, a hinge stile, a top rail and a bottom rail, the tie rods extending through the rails and into the stiles. The top rail is provided with a block that engages the top edge of the panel for relative vertical movement of the lead edge stile and hinge stile. The bottom rail is fitted with an adjustable member that extends the width of the door and is vertically movable for alignment with a threshold.
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[0001] The present application is a continuation-in-part of Ser. No. 08/940,936, filed Sep. 30, 1997, now allowed.
[0002] The present invention relates to a deicing fluid composition. More particularly the present invention relates to a deicing fluid composition which is environmentally benign. Most particularly the present invention relates to an environmentally benign deicing fluid composition which is obtained from various industrial waste streams or from the pure components.
BACKGROUND OF THE INVENTION
[0003] Freezing point lowering compositions are in widespread use for a variety of purposes, especially to reduce the freezing point of an aqueous system so that ice cannot be formed or to melt formed ice. Generally, freezing point lowering compositions depend for their effectiveness upon the molar freezing point lowering effect, the number of ionic species which are made available and the degree to which the composition can be dispersed in the liquid phase in which the formation of ice is to be precluded and/or ice is to be melted.
[0004] The most pervasive of the commonly used products for deicing are common salt, calcium chloride and urea, with common salt (sodium chloride) being the least expensive and most commonly used. Common salt is widely used to melt ice on road surfaces and the like. In this manner the salt forms a solution with the available liquid in contact with the ice and thereby forms a solution with a lower freezing point than the ice itself so that the ice is melted. Chloride salts however suffer from relatively severe drawbacks, such as the harmful effects on surrounding vegetation by preventing water absorption in the root systems, and its corrosive effects on animal skin such as the feet of animals, clothing, roadways and motor vehicles.
[0005] Other inorganic salts are also known to be useful as freezing point lowering agents such as magnesium chloride, potassium phosphates, sodium phosphates, ammonium phosphates, ammonium nitrates, alkaline earth nitrates, magnesium nitrate, ammonium sulfate, alkali sulfates.
[0006] Typical of solutions of low freezing points include brines, ethylene glycol and propylene glycol solutions. Brines are used to transfer heat at temperatures below the normal freezing point of water, and the ethylene glycol solutions are well known for use as coolants for automobiles and the like in regions in which the temperature may fall below the normal freezing point of water. Ethylene and propylene glycols are used in relatively large quantities at major airports in northern climates in order to keep air traffic flowing during inclement weather. The fluids are generally applied to the wings, fuselage and tail of aircraft as well as the runways to remove ice. However, these glycol compounds likewise have environmental drawbacks and can be detrimental to sewage treatment processes.
[0007] Other prior art deicing fluids such as alcohols have toxic effects and high volatility particularly in the low molecular weight range and may be the cause of offensive smell and fire danger. Furthermore, mono- and polyhydric alcohols oxidize in the presence of atmospheric oxygen to form acids, which can increase corrosion of materials.
[0008] Due to the problems associated with deicing agents as described above there have been attempts to prepare even more deicing agents. For, example, Kaes, U.S. Pat. No. 4,448,702 discloses the use of a freezing-point lowering composition and method which calls for the addition of a water soluble salt of at least one dicarboxylic acid having at least three carbon atoms, such as a sodium, potassium, ammonium or organoamine salt of adipic, glutaric, succinic or malonic acid.
[0009] Peel, U.S. Pat. No. 4,746,449 teaches the preparation of a deicing agent comprising 12-75% acetate salts, trace-36% carbonate salts, 1-24% formate salts and 1-32% pseudolactate salts which is prepared from a pulp mill black liquor by fractionating the black liquor into a molecular weight fraction and concentrating the collected low molecular weight fraction to produce the deicing agent.
[0010] U.S. Pat. No. 4,960,531, teaches that small amounts of methyl glucosides, i.e. less than 10%, can be employed as a trigger to conventional salt deicers.
[0011] However, all of these disclosures still require the presence of salts. Accordingly there still exists in the art a need for a deicing and/or anti-icing agent which is environmentally benign and relatively inexpensive to obtain.
SUMMARY OF THE INVENTION
[0012] Accordingly the present invention comprises a deicing and/or anti-icing agent which is environmentally benign and can be produced from relatively inexpensive feedstocks. In one embodiment of the present invention the deicing agent comprises a water soluble solution of hydroxycarboxylic acid based esters which are preferably prepared from waste process streams such as from the admixture of components of a pulp mill black liquor with distiller grain solubles and/or whey; the acid treatment of pre-distilled wood, agricultural and/or milk fermentation; the alcoholysis of distiller grain solubles or any combination thereof.
[0013] The compositions of the present invention can be applied to a wide variety of surfaces, particularly metallic and non-metallic surfaces of aircraft, which prevents icing, removes frozen water from the surface and prevents its reformation. The invention provides for a deicing composition which can be used on airplanes, runways, bridges, streets and the like. Further, the compositions can be used in heat transfer applications and to applications in which it is vital to maintain a liquid in the unfrozen state, e.g., as in a fire extinguisher. Additionally, the present invention provides for an anti-icing composition which can be applied to a surface, such as bridges, prior to the onset of icing conditions in order to prevent icing from occurring.
[0014] The present invention further provides deicing and/or anti-icing agents which are prepared from the pure components, hydroxycarboxylic acid esters, hydrocarbyl aldosides, and or combinations thereof. In one further embodiment of the present invention there is provided a method for deicing and/or anti-icing a surface, the method comprising applying to the surface a composition comprising (a) a deicing and/or anti-icing agent comprising at least about 15 weight percent of a hydrocarbyl aldoside and (b) water. In another further embodiment, there is provided a deicing and/or anti-icing agent composition comprising (a) a hydroxycarboxylic acid salt, (b) a hydrocarbyl aldoside and (c) water.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
[0015] The present invention provides a novel composition useful as a deicing agent and/or an anti-icing agent and a novel method of preparing the deicing and/or anti-icing agents.
[0016] The deicing agents of the present invention comprise a hydroxycarboxylic acid ester, a hydrocarbyl-aldoside, or both.
[0017] Hydroxycarboxylic acid esters are well known to those of ordinary skill in the art and typically comprise hydroxyformate, hydroxyacetate, hydroxypropionate, hydroxybutyrate, hydroxylaurate, hydroxypalmitate, hydroxyoleate, hydroxybenzoate as well as others. Preferred for use in the practice of the present invention are deicing agents comprising a-hydroxypropionate type esters such as alkyl lactates.
[0018] Hydrocarbyl aldosides are well known to those of ordinary skill in the art. Preferably the hydrocarbyl aldosides comprise alkyl aldosides and/or sorbitols.
[0019] The alkyl aldosides can be prepared by a continuous alcoholysis process for making mixed aldoside from polysaccharides, and more particularly, for making mixed alkyl glycosides directly from starch, as described in U.S. Pat. No. 4,223,129. A further process of producing aldosides for use in the practice of the present invention is described in U.S. Pat. No. 4,329,449.
[0020] Typical of the alkyl aldosides useful in the practice of the present invention are alpha-methyl glucoside, beta-methyl glucoside, methyl furanosides, methyl maltosides, methyl maltotriosides, mixtures thereof and the like.
[0021] In addition to the hydroxycarboxylic acid esters and/or hydrocarbyl aldosides, a wide variety of other components may be included in the deicing and/or anti-icing compositions of the present invention. Along with the free hydroxycarboxylic acid, preferably these include water soluble anionic hydroxycarboxylic acid salts. Generally these components may be added to the deicing and/or anti-icing compositions of the present invention or they are present in or are derived from the process waste streams from which the compositions of the present invention may be obtained.
[0022] Also, it is contemplated herein that anionic hydroxycarboxylic acid salts alone or with amino acids and/or water soluble salts of dicarboxylic acids having at least three carbon atoms, preferably selected from adipic, succinic, glutaric and malonic acids may also be included but are not necessary to the practice of the present invention. These can be added separately such as through the addition of pulp mill black liquors or via alkali additions to hydroxycarboxylic acid containing compositions.
[0023] The deicing agents may be prepared from the pure chemical ingredients. For instance, a solution of 25% H 2 O/10% sodium lactate/65% ethyl lactate was found to have no crystal formation at a temperature of −50° C.
[0024] However, it is contemplated by the present invention to obtain the deicing agents of the present invention from any of a number of industrial waste streams which comprise a water soluble solution of hydroxycarboxylic acid, since lactic acid as it occurs in dilute fermentation liquors is inexpensive. The purification of this material is difficult due to its similarity in solubility characteristics to water as the presence of impurities such as dextrins, proteins and unfermented sugars. For instance, the present invention contemplates the use of waste stream selected from the group consisting of a grain stillage, a wood stillage, agricultural or milk fermentation and mixtures of any of the foregoing. Generally, the components of the present invention are present in or are derived by alcoholysis of the process waste streams. Typically these waste streams include components such as lactic acid fractions and low molecular weight sugars such as sorbitols, maltoses and glucoses.
[0025] By subjecting the waste streams to alcoholysis (with an alkyl alcohol) under conditions such as reacting with an alkyl alcohol in the presence of a cation exchange material or other acid, or the addition of an alkyl alcohol to a heated fermentation liquor as taught in Ind. Eng. Chem., 38, pg. 228, 1946 by E. M. Filachione and C. H. Fisher, at least some of the hydroxycarboxylic acids present are converted to the hydroxycarboxylic acid based esters and at least some of the sugars are converted to glucosides, thereby improving the overall acidity of the material. For instance, ethanol treatment of a typical agricultural fermentation waste stream comprising lactic acid and glucose would be partially converted to ethyl lactate and ethyl glucoside. The use of the alcoholysis process aids in increasing the concentration of the glycosides and hydroxycarboxylates, thereby providing an improved product.
[0026] For example, components of the present invention can include, but are not limited to: ethyl lactate, glycerol, glycol lactate, ethyl glycinate, ethyllevulinate, ethylenecarbonate, glycerin carbonate, pipecolic acid, tetrahydrofurfuryl acetate, tetrahydrofurfuryl tetrahydrofuroate, sorbitol, glucose glutamate, methylglucosides, acetals and ketals of glycerol such as 2,2-dimethyl-1,3-dioxolane-4-methanol and salts thereof and the like.
[0027] As discussed above, although not critical for the present invention, the compositions of the present invention may further comprise high solubility salts in combination with the hydroxycarboxylates and glucosides. For example, useful salts could include, but are not limited to: hydroxycarboxylic acid salts (including cesium, sodium, potassium, calcium and magnesium salts) such as sodium lactate; acetate salts such as cesium acetate, sodium acetate, potassium acetate; formate salts such as sodium formate; citrate salts such as sodium citrate; amino acids and their salts such as lysine glutamate, sodium pyrrolidone carboxylate and sodium glucoheptonate; dicarboxylic acids salts such as sodium and potassium salts of adipic, glutaric, succinic and malonic acids; lignin components such as lignin sulfonate; boric acid and its salts, glycerin and the like.
[0028] Glycols such as propylene glycol, ethylene glycol may also be employed with the compositions of the present invention where desired.
[0029] The amount of the acid components, i.e. the hydroxycarboxylic acid esters, hydroxycarboxylic acid salts, lignins and glucosides, which are present in the compositions of the present invention may vary widely and still provide the improved freezing point lowering effect. Preferably, however, the compositions of the present invention comprise a total weight of acid components ranging from about 10 to about 75 weight percent, more preferably from about 20 to about 75 weight percent and most preferably from about 30 to about 75 weight percent, based on the weight of acid and water combined.
[0030] The compositions of the present invention are considered non-toxic and readily breakdown, even at low temperatures, in the natural environment without any significant adverse effects. Moreover, the compositions of the present invention are considered to have lower Biological Oxygen Demand (BOD) requirements than comparable de-icers, and a lesser amount of the composition of the present invention (higher water concentration) is required to prevent ice formation at a particular ambient air temperature or quantity of ice. Since the concentration of an anti-icer that is applied should be sufficient to prevent significant ice formation under reasonable conditions much smaller material usage for the composition of the present invention at particular outside air temperatures and precipitate rates results.
[0031] In the methods of the present invention, the deicing and/or anti-icing compositions of the present invention are combined with water and applied, such as by spraying, onto the surface desired to be treated. In the case of deicing, the surface already has ice formed thereon, and the deicing compositions of the present invention melt the ice already formed and are further effective in preventing additional ice formation. In the case of anti-icing, upon learning of a weather forecast which predicts possible dangerous icing conditions, the roads and bridges or other surfaces can be pretreated with the anti-icing compositions of the present invention in order to prevent ice formation on the surfaces.
[0032] In one embodiment of a method of the present invention where the deicing and/or anti-icing agent includes a hydrocarbyl aldoside without a hydroxycarboxylic acid ester component, the amount of hydrocarbyl aldoside employed to obtain the benefits of the present invention is at least about 15 weight percent based on the weight of the deicing and/or anti-icing agent (not including water) and can comprise up to 100 weight percent. Typically, however the amount of hydrocarbyl aldoside is from about 15 to about 90 weight percent, such as from about 30 to about 90 weight percent, and more particularly from about 50 to about 75 weight percent.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The following examples are provided for illustrative purposes and are not to be construed to limit the scope of the claims in any manner whatsoever. Unless otherwise indicated, melting points were determined using a Differential Scanning Calorimeter (DSC). Scans were conducted from −160° C. up to 30° C. at 10° C. per minute on a 1 mg sample taken from a 20 g mixture. The complete melt point was utilized.
Example 1
[0034] A mixture of 25% by weight water, 65% by weight ethyl lactate and 10% by weight sodium lactate was prepared. No crystal formation was observed at a temperature of −50° C.
Example 2
[0035] A mixture of 50% by weight water and 50% by weight ethyl lactate was prepared. The mixture had a melting point of −18° C.
Example 3
[0036] A mixture of 70% by weight water, 24% by weight ethyl lactate and 6% by weight sodium lactate was prepared. The mixture had a melting point of −25° C. as determined by DSC and a pH of 6.0. For comparison, a 70% by weight water/30% by weight ethylene glycol solution has a melting 15 point of −18° C.
Example 4
[0037] The addition of 50% by weight of a 50% mixture of ethyl lactate in water to a concentrated, filtered corn steep liquor (containing 50% water and 50% solids comprising mostly lactic acid and sugars) caused a reduction in freezing point from −11° C. to −16° C. The addition of 2% by weight sodium lactate further reduced the freezing point to −20° C.
Example 5
[0038] A mixture of 60% by weight water, 20% by weight sodium lactate, 2% by weight proline (an amino acid), 8% by weight sorbitol and 10% by weight sodium pyrrolidone carboxylate (sodium PCA) was prepared. No crystal formation at −35° C. was observed. The pH was 6.57. For comparison a 50% by weight solution propylene glycol has a freezing point of −36° C.
Example 6
[0039] A mixture of 12% by weight methyl lactate, 44% by weight methyl glucoside and 44% by weight water was prepared. A melting point of −18° C. was observed. The mixture had a pH of 5.
Example 7
[0040] A mixture containing 35% by weight methyl lactate, 35% by weight methyl glucoside and 30% by weight water has a melting point of −21° C. as determined by DSC.
Example 8
[0041] A filtered concentrated liquid residue of a 50% mixture of corn stillage and steepwater containing 50% by weight water with a freezing point of −12° C. is heated to 90° C. and treated with 5% ethanol for 8 hours. The resulting mixture has a freezing point of −17° C. The addition of 2% sodium lactate further reduces the freezing point to −21° C.
[0042] The above-referenced patents and publications are hereby incorporated by reference.
[0043] Many variations of the present invention will suggest themselves to those skilled in the art in light of the above-detailed description. For example, any process stream which contains components from which hydroxycarboxylates can be prepared may be used to prepare the compositions of the present invention. Additionally, a wide variety of lignins, sugars and glucosides may be present in the compositions of the present invention. All such obvious modifications are within the full intended scope of the appended claims.
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The present invention provides deicing compositions which are environmentally benign, a process for producing the composition from certain waste process streams, and methods of deicing and/or anti-icing.
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BACKGROUND OF THE INVENTION
The invention relates to techniques for lessening wafer slip and scratching in semiconductor processing chambers.
In many semiconductor device manufacturing processes, the required high levels of device performance, yield and process repeatability can only be achieved if the substrate (e.g., a semiconductor wafer) is not subject to large stresses during processing.
For example, consider rapid thermal processing (RTP), which is used for several different fabrication processes, including rapid thermal annealing (RTA), rapid thermal cleaning (RTC), rapid thermal chemical vapor deposition (RTCVD), rapid thermal oxidation (RTO), and rapid thermal nitridation (RTN).
There is a trend in these processes to increase substrate size so as to increase the number of devices which can be fabricated simultaneously. One type of large substrate for which processing techniques are currently being developed is a 300 millimeter (mm) diameter circular silicon (Si) wafer. The next generations of such wafers may be even larger, having diameters of 350 mm, 400 mm or even more. Of course, rectangular wafers are also used in some systems. If substrate thickness is constant, the mass of the substrate is proportional to the square of its radius or edge length. In susceptor systems, the substrate is supported by being placed on a susceptor support. Thus, the amount of support is proportional to the surface area of the substrate.
In susceptorless systems, the substrate is usually only mechanically supported around its perimeter. The amount of support in this type of system is only proportional to the diameter of the substrate (the edge length for a rectangular substrate), not the area as in a susceptor system. In these systems, as substrates get larger, they tend to sag where they are not supported, i.e., in areas away from the perimeter support.
In particular, gravity causes stress in the substrate. This gravitational stress results in a strain which is evidenced by sagging. Strain can damage the substrate by causing wafer slip in the silicon crystal. This wafer slip will usually destroy devices through which they pass.
Another potential cause of stress are radial temperature gradients. These occur when the center of the substrate is at a different temperature than the edge. Such radial temperature gradients typically occur when the substrate is heated or cooled rapidly, as the rate of heat loss is usually different at the center than at the edge. Thus, radial temperature gradients occur most frequently in rapid thermal processes.
Both causes of stress, gravity and radial temperature gradients, affect the maximum temperature to which a substrate may be brought without wafer slippage. For example, consider a large wafer that is perfectly conductive and thus has no radial temperature gradients. If this wafer is only supported around its perimeter, and is thus subject to substantial gravitational stress, the wafer's maximum processing temperature is lower than if no gravitational stress is present. Similarly, if a small wafer, otherwise not subject to large gravitational stresses, is caused to have a large temperature gradient, the wafer's maximum processing temperature is lower than if no temperature gradients were present.
Substrates in rapid thermal processing chambers may be required to withstand maximum processing temperatures of, for example, 1250° C. If stress is present, this maximum processing temperature is lowered. Thus, to maintain high maximum processing temperatures, it is important to minimize the causes of stress.
It has been modeled that the gravitationally induced stress is equivalent to a center-to-edge radial temperature difference of approximately 3° C. for a 300 mm wafer. However, the impact of the stress on the maximum processing temperature is generally more significant, on the order of fifty to a hundred degrees Celsius.
It is an object of the invention to provide a susceptorless method of supporting substrates that produces less stress in the substrate. It is a further object to provide a substrate support method that causes less wafer slip and less scratching to be produced in the substrate than prior methods.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the claims.
SUMMARY OF INVENTION
In one embodiment, the invention is directed to a method of reducing stress on a substrate in a thermal processing chamber. The method includes the steps of supporting a first portion of a substrate by means of contacting the same such that a second portion of the substrate is not contacted, part of the second portion forming one wall of a cavity, and flowing a gas into the cavity such that the pressure of the gas exerts a force on the second portion to at least partially support the second portion.
Implementations of the invention include the following. The supporting step is performed by an annular support, such that the first portion of the substrate is contacted by the annular support. The second portion can be the backside of the substrate except for the first portion. The annular support can be an annular edge ring. The thermal processing chamber can be a chemical vapor deposition apparatus. Another step is heating the gas. The gas flow can be controlled by a closed-loop or open-loop feedback system. The force exerted by the gas can be about one-third to two-thirds of the weight of the substrate. The flowing gas can enter the cavity through a nozzle or an air plenum at a rate of between about three to five liters per minute. The pressure differential between the cavity and the remainder of the chamber in a range of between about 50 millitorr and about 200 millitorr, for example about 100 millitorr. Another step can be setting a predetermined support force for the substrate, such that the predetermined support force for the substrate is approximately equal to a pressure differential between the cavity and the remainder of the chamber times the area of the part of the second portion.
In another embodiment, the invention is directed to a method of reducing backside scratching and damage to a substrate in a thermal processing chamber. The method includes the steps of supporting a first portion of a substrate by means of contacting the same such that a second portion of the substrate is not contacted, part of the second portion forming one wall of a cavity, and flowing a gas into the cavity such that the pressure of the gas exerts a force on the second portion to at least partially support the second portion.
In another embodiment, the invention is directed to a method of reducing stress on a substrate in a thermal processing chamber. The method includes the steps of supporting a first portion of a substrate by means of contacting the same such that a second portion of the substrate is not contacted, part of the second portion forming one wall of a cavity, and flowing a gas into the cavity such that the force of the gas on the second portion at least partially supports the second portion.
Implementations of the invention include the following. The gas impacts the substrate at or near the center of the substrate. Another step can be heating the gas before the step of flowing the gas into the cavity.
Among the advantages of the invention are the following. It is an advantage of the invention that substrates in thermal processing chambers suffer fewer dislocations than in previous methods because the substrates are more evenly supported. Substrates can be brought to high temperatures without the onset of dislocations and slippage. Substrates are more robust and have a higher tolerance with respect to high temperatures and high temperature gradients than in previous support methods. It is yet a further advantage that the overall weight of the substrate on the edge ring is lessened, reducing the probability of the edge ring damaging the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, schematically illustrate the invention and, together with the general description given above and the detailed description given below, serve to explain the principles of the invention.
FIG. 1 is a diagrammatic cross-sectional side view of an RTP system using a gaseous substrate support.
FIG. 2 is a diagrammatic cross-sectional side view of another embodiment of an RTP system using a gaseous substrate support where the gas is provided through an air plenum.
FIG. 3 is a more detailed cross-sectional side view of another embodiment of an RTP system according to the invention using a gaseous substrate support.
FIG. 4 is a graph showing the allowable temperature gradient as a function of processing temperature.
FIG. 5 is a diagrammatic cross-sectional side view of another embodiment of an RTP system using a gaseous substrate support where the gas is provided through a nozzle.
DETAILED DESCRIPTION
In the following description, we refer to a "substrate". This is intended to broadly cover any object that is being processed in a thermal processing chamber. The term "substrate" includes, for example, semiconductor wafers, flat panel displays, glass plates or disks, and plastic workpieces. In this description, reference is made to a 300 mm wafer. However, the invention is also applicable to wafers having either larger or smaller diameters, and is particularly applicable to wafers having a size sufficient to induce gravitational sagging.
A simple diagram of an embodiment of an RTP system incorporating the invention is shown in FIG. 1. In FIG. 1, an RTP chamber 14 is shown having a base 28. Base 28 is underneath a substrate 10. Substrate 10 has a top side 22 and a bottom side 26. Substrate 10 is supported by an edge ring 36 mounted on a rotating support 12. Specifically, edge ring 36 mechanically supports the substrate by contacting an annular first portion 32 of substrate 10, while a second portion 33 of substrate 10, in this embodiment the remainder of the substrate, is left uncontacted. Internal cavity 31 is formed by the bottom side 26 of substrate 10, a cylindrical wall portion 56 of support 12, and base 28. While an annular edge ring is shown, the invention may also be used with other types of susceptorless supports.
Reaction gases 18 enter the chamber from a reaction gas supply 16 through an air plenum 20. Air plenum 20 may, for example, have a number of ports or nozzles through which reaction gases 18 emerge. These reaction gases provide reactants which may be used to thermally treat substrate 10. The thermal treatments envisioned include, among others, annealing, deposition, diffusion, oxidation, and reduction. These gases or the gases from the reaction products are removed through exhaust port 24.
According to an embodiment of the present invention, a support gas supply 30 may be provided which supplies a gas 39 to internal cavity 31 through input port 34. Chamber 14 is thus divided into two sections: internal cavity 31 and a reaction zone or processing volume 35. Most of the latter volume is located generally above substrate 10. Input port 34 is shown in FIG. 1 as a small input passageway. Input port 34 may also have a cross-flow injection design (not illustrated), also referred to as a horizontal showerhead, so that gas 39 emerges in a direction parallel to the substrate so as not to result in local cooling effects.
Input port 34 may alternatively include a perforated disk or air plenum mounted to base 28. Alternatively, a valve (not illustrated) may be employed in port 34 to supply gas to cavity 31. A gas plenum system is shown in FIG. 2, where multiple ports 37 supply gases 32.
By providing gases to internal cavity 31, gas pressure is built-up and is used to at least partially support substrate 10 at second portion 33.
The system of the invention will now be described in more detail.
A more detailed RTP system according to another embodiment of the invention is shown in FIG. 3. This system is more fully described in U.S. Pat. No. 5,660,472 entitled "Method and Apparatus for Measuring Substrate Temperatures", assigned to the assignee of the present application, and herein incorporated by reference.
The RTP system includes a processing chamber 114 for processing a substrate 110 such as a disk-shaped, 300 mm diameter silicon wafer. The substrate 110 is mounted inside the chamber on a substrate support structure 112 and more particularly by an edge ring 135 mounted on support 112. The substrate is heated by a heating element 100 located directly above the substrate. The heating element 100 generates radiation which enters the processing chamber 114 through a water-cooled quartz window assembly 107 which may be approximately one inch (2.5 cm) above the substrate.
Reaction gases 118 enter processing volume 182 through port 64, react with substrate 110, and are exhausted by exhaust system 166. It is noted that reaction gases 118 may, however, enter from any suitable port on the body of the chamber.
Beneath substrate 110 is a reflector 104 which is mounted on a water-cooled, stainless steel base 106. Reflector 104 may be made of aluminum and has a highly reflective surface coating 108. The bottom side 126 of substrate 110, the top of reflector 104, and the walls of support structure 112 form a reflecting cavity 150 for enhancing the effective emissivity of the substrate.
The separation between the substrate and reflector may be approximately 0.3 inch (7.6 mm), thus forming cavity 150 which has a width-to-height ratio of about 27. In processing systems that are designed for 300 mm silicon wafers, the distance between the substrate 110 and reflector 104 may be between about 5 mm and 30 mm, and preferably between 5 mm and 25 mm.
The temperatures at localized regions of substrate 110 are measured by a plurality of pyrometers 153 (only two of which are shown in FIG. 3). These pyrometers 153 include sapphire light pipes that pass through a conduit 154. Conduit 154 extends from the backside of base 106 through the top of reflector 104 through windows 152.
During thermal processing, support structure 108 is rotated at about 90 RPM. The support structure which rotates the substrate includes, as noted, edge ring 135. The edge ring contacts the substrate around a first portion including the substrate's outer perimeter, thereby leaving a second portion of the underside of the substrate exposed except for a small annular region about the outer perimeter. Edge ring 135 includes a depressed pocket portion for contacting and supporting the substrate. The pocket portion may constitute a ledge with a width of approximately 4 mm. To minimize the thermal discontinuities that occur at the edge of substrate 110 during processing, edge ring 135 is made of the same, or similar, material as the substrate, e.g. silicon or silicon carbide.
As noted, edge ring 135 is supported by support structure 112. More particularly, edge ring 135 rest on a rotatable quartz cylinder 156 of support structure 112. The cylinder 156 is coated with a material such as silicon to render it opaque in the frequency range of the pyrometers. Other opaque materials may also be used. The bottom of the quartz cylinder is held by an annular upper bearing race 158 which rests on a plurality of ball bearings 160 that are, in turn, held within a stationary, annular, lower bearing race 162. The ball bearings 160 may be made of steel and coated with silicon nitride to reduce particulate formation during operation. Upper bearing race 158 is magnetically-coupled to an actuator (not shown) which rotates cylinder 156, edge ring 135 and substrate 110 during thermal processing.
A purge ring 172 that is fitted into the chamber body surrounds the quartz cylinder 156. Purge ring 172 has an internal annular cavity 180 which opens up to a region above upper bearing race 158. Internal annular cavity 180 is connected to a purge gas supply 174 through a passageway 178. During processing, a purge gas may be flowed into the chamber through purge ring 172, as the process requires. For example, such purge gases may be used to flush the chamber or to prevent reaction gases from entering areas in which they are undesired. Such gases may be exhausted by, for example, exhaust system 166.
As the edge ring only contacts substrate 110 around its perimeter, the remainder of substrate 110 is uncontacted. If substrate 110 is a large wafer, say 300 mm in diameter, the effects of gravity may cause the uncontacted sections of substrate 110 to sag a substantial amount. For example, sags of 150 microns have been noted for a 300 mm wafer at room temperature. As discussed above, this results in a lower maximum processing temperature as well as a lessened robustness with respect to temperature gradients.
FIG. 4 demonstrates this behavior. In particular, the allowable temperature gradient ΔT Allowable °C.! (above which wafer slippage occurs) is plotted on the y-axis and the processing temperature °C.! is plotted on the x-axis. The dotted lines indicate the behavior for a three-point support. The solid lines indicate the behavior for an annular edge ring, the annular support structure described above. For each of these two sets of curves, the curve on the left indicates the allowable temperature gradient for a substrate whose crystal lattice includes 8 parts per million (ppm) precipitated oxygen. The curve on the right shows the behavior for a substrate having 2 ppm precipitated oxygen.
The negative slope of the curves shows that the allowable temperature gradient ΔT °C.! decreases as the processing temperature °C.! of the substrate rises. At a gradient of about 3° C., the temperature to which the substrate may be safely heated without slippage drops dramatically. The reason for this precipitous drop is gravity and the effects of sagging.
It is also evident from the graph that the allowable temperature gradient drops as the amount of precipitated oxygen rises. Furthermore, for a three-point support, as indicated by the dotted lines, the substrate cannot even achieve a common processing temperature of 1025° C. without slippage.
The present invention inhibits dislocations such as wafer slip by supporting the mechanically uncontacted second portion of the substrate with gas pressure. Support gas 132 is supplied to cavity 150 through gas line 168 from a support gas supply 130 in a controlled manner through input port 134, which may generally be any of the types of gas distribution systems noted above in connection with input port 34. By controlling the gas supply to cavity 150, the pressure within this cavity can be controlled. A pressure differential range (from cavity 150 to processing volume 182) which may be advantageously used is 0.05 torr to 0.2 torr and especially 0.1 torr, but generally depends on factors such as the weight of the substrate. As mentioned above, for 300 mm substrates, a pressure differential which may be used is about 0.1 torr, i.e., the pressure within cavity 150 may be 0.1 torr higher than the pressure in a processing volume 182 which constitutes the remainder of chamber 114, which is generally that portion of the chamber above substrate 110 and support structure 112. If the pressure in chamber 114 is ambient or atmospheric, its pressure measures about 760 torr. In this case, a suitable pressure within cavity 150 may be about 760.1 torr.
It should be noted that the gas pressure built-up within cavity 150 is accomplished without special seals, although such seals may be used if fine pressure control is required. The gas generally exits cavity 150 through the bearing 160 and race 162 system of cylinder 156. In the system described, this gas conductance path is circuitous and allows a pressure differential to be built-up.
Of course, a very wide range of pressures may be used within cavity 150, and these are in part dependent on the pressure in processing volume 182. Other factors influencing the pressure chosen for cavity 150 include the type of material constituting the substrate, the desired support for the substrate, the weight of the substrate, and the extent to which dislocations are undesirable. For example, depending on the purposes to which the substrate is to be put, it may be desirable to lift one-third to two-thirds of the weight of the substrate off of the edge ring using the support gas pressure. The pressure gradient range (from cavity 150 to processing volume 182) which may be used generally depends on the gas conductance.
The present invention may require a high flow rate for the support gas so that the same can support the substrate. Values of gas flow which may be used have been found to be on the order of 3-5 liters per minute. These rates are useful in the bearing system described above. However, greater or lesser flow rates may be used depending on the requirements of the process, the hardware design details, and the conductance of the gas exit path. In processes which may additionally employ a backside purge so as to eliminate backside deposition, a backside purge being described in U.S. patent application Ser. No. 08/687,166, for a "Method and Apparatus for Purging the Back Side of a Substrate During Chemical Vapor Processing", filed Jul. 24, 1996 by J. V. Tietz, B. Bierman, and D. S. Ballance, assigned to the assignee of the present invention, and herein incorporated by reference, the requirements of the backside purge and those of the support gas may generally be reconciled to achieve a gas pressure appropriate for both. Such processes employing a backside purge include chemical vapor deposition, oxidation and nitrogen implant anneals.
The gas within cavity 150 provides a support force to substrate 110 with a force equal to the gas pressure times the area of the part of substrate 110 which it contacts, in this case, the circular bottom side of the substrate except for that part supported by the annular edge ring. The gaseous support for substrate 110 may be chosen so as to inhibit wafer slip.
In this embodiment, it should be noted that the position of input port 134 is immaterial. While FIGS. 1-3 and 5 (discussed below) show the input port roughly in a position in-line with the center of the substrate, the input port can be located anywhere in base 106. In certain applications, however, it may be desired to place the port away from the perimeter of the wafer.
It is often important to ensure that the gaseous support for the wafer is not so great that the wafer slides or skips on the edge ring during rotation. One way of ensuring this is to rotationally accelerate the wafer in an appropriate nonlinear fashion. For example, if the wafer backside contacts the edge ring with a low value of friction, it may be necessary to use a low radial acceleration in bringing the wafer up to operating speed. In any case, the upper limit for the gaseous support for the wafer is often dictated by the sliding of the wafer on the edge ring.
In the above embodiment, either open or closed-loop control may be used to control the pressure in cavity 150.
In open-loop control, for example, empirical data can be used to determine how much gas flow is required to support the substrate a desired amount. This gas flow rate, usually on the order of liters per minute but measured in standard cubic centimeters per minute (sccm), is controlled by a regulator (not shown) on support gas supply 130. Of course, the regulator may also be located anywhere between the support gas supply 130 and input port 134.
In closed-loop control, the gas pressure is sensed y a sensor (not shown) which may be located in cavity 150. This pressure is fed back to a control circuit or program that adjusts the gas flow using an automatic control valve at support gas supply 130 so as to maintain the pressure at a predetermined value. As before, the automatic control valve could also be located anywhere between the support gas supply 130 and input port 134.
In another embodiment, the position and design of the input port are more important. In this embodiment, as indicated in FIG. 5, the momentum of gas particles 32 emerging from the input port is used to provide a support to the substrate. In particular, the input port is a nozzle 38, and gas particles 32 emerge from the nozzle with a substantial velocity. They strike the backside 26 of the substrate 10 and transfer their momentum to it. By conservation of momentum, this imparts an upward force to substrate 10. This support gas can be pre-heated so that the substrate is not cooled by the impinging gas. A gas heater (not shown) in this embodiment may be located anywhere in the line between gas supply 30 and nozzle 38.
In this embodiment, for example, gas nozzle 38 may be any type of nozzled valve by which gas particles may be provided with a relatively high velocity. Nozzle 38 may be located at or near a position in-line with the center of the substrate 10. Of course, a plurality of nozzles 38 could also be used to support substrate 10 in different locations. For example, three nozzles located at the same radial distance from the center of substrate 10 and spaced 120° apart could be employed so long as the amount of gas flow were the same for each. Of course, each of the embodiments described above could be implemented using multiple input ports or nozzles. Alternative designs could be used, with the basic requirement of such systems being that the substrate not be overly tipped to any one side such that the support gas escapes from cavity 31.
In all of the above embodiments, the weight of the substrate on the edge ring is partially lifted. This provides an additional benefit because the substrate is less likely to suffer damage from the edge ring as the force between them is lessened by an amount equal to the force provided by the gas in the cavity. This results in a reduced amount of friction between the two, and thus less damage. Of course, this aspect of the invention is advantageous for wafers of all sizes, not just large wafers. For example, a 200 mm wafer may benefit from such relief from scratching.
The present invention has been described in terms of preferred embodiments. The invention, however, is not limited to the embodiments depicted and described. Rather, the scope of the invention is defined by the appended claims.
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A method of reducing stress on a substrate in a thermal processing chamber. The method includes the steps of supporting a first portion of a substrate by means of contacting the same such that a second portion of the substrate is not contacted, part of the second portion forming one wall of a cavity, and flowing a gas into the cavity such that the pressure of the gas exerts a force on the second portion to at least partially support the second portion.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application claims priority to European Patent Application No. 10003260.6, filed on Mar. 26, 2010, and European Patent Application No. 10 004 361.1, filed on Apr. 23, 2010. The entirety of each of these applications is hereby incorporated by reference.
BACKGROUND
[0002] 1. Field
[0003] Embodiments of the present disclosure concern pipe joints for connecting a first pipe to a second pipe and, in particular, to coupling of pipes such as thin walled tubes.
[0004] 2. Description of the Related Art
[0005] Connecting two pipes with each other is a common objective and diverse devices have been proposed to accomplish this objective. International Patent Publication No. WO 2007/002576 discloses fittings for use with different types of tubing. One such fitting of WO 2007/002576 includes a gripping member having a sharp tube indenting edge that provides a seal between the tube gripping member and the tube. Another such fitting of WO 2007/002576 includes a tube gripping member having a body indenting edge that provides a seal between the tube gripping member and a fitting body. However, this solution is not capable of use in the oil and gas industry, as the standards which apply for the oil and gas industry concerning the connection of pipes with each other require reusability of all single elements. This requirement is not fulfilled in the device disclosed in WO 2007/002576, as plastic deformation, such as an indentation, is experienced in one of the tubes.
[0006] Other solutions are disclosed in U.S. Pat. No. 4,844,517, European Patent No. 0309179, and European Patent No. 1065423. In U.S. Pat. No. 4,844,517, a nut member contacts a coupling union via mating threads, while the coupling union is connected to a tube via recesses and protrusions of the tube which are positioned in the grooves of the coupling union. During tightening, the nut member forces the coupling union to contact a sleeve member, which is attached to another tube via grooves and protrusions. However, this device has a drawback of being difficult to mount.
[0007] Similarly, in the solutions disclosed in EP 0309179 and EP 1065423, a plastic deformation, as in WO 2007/002576, is employed for achieving the sealing effect, which is not desirable for connection of pipes in the oil and gas industry.
[0008] Another pipe coupling is discussed in U.S. Pat. No. 3,889,989 that focuses on high pressure pipe couplings in which one end of a bored coupling body is externally threaded to receive a rigid nut. The body and the nut each have an internal tapering surface which is in contact with an asymmetrical bi-conical rigid bite-ring made of ductile metal. The ductile metal is compressed by ridges into circular grooves formed on the end of a pipe to be coupled. The bite-ring has, between its tapering sections, a central section that has a larger diameter than that of the tapering sections. The central section of the bite-ring incorporates a circumferential sealing lip which is arranged to bear against an end face of the coupling body.
[0009] This pipe coupling employs movement of the nut in relation to the coupling body. However, as above, plastic deformation, this time of the bite-ring, is used to achieve a fluid tight sealing between the respective elements.
[0010] Thus, while approaches to tightly couple a first pipe to a second pipe have been developed, each has drawbacks concerning fluid tightness and reusability. As such, these solutions do not satisfy the standards relevant in the oil and gas industry.
SUMMARY
[0011] Embodiments of the present disclosure provide systems and methods for joining pipes suitable for use in the oil and gas industry. Embodiments of the disclosed joints are easy to manufacture and safe for use in the field, with less fluid leakage resulting between the respective parts of the joint. As discussed in greater detail below, components of the joint may be reused, even after the pipe joint has been assembled for a first time. Methods are further disclosed to tightly couple a first pipe to a second pipe and substantially inhibit release of fluid contained within the first and second pipes.
[0012] For example, in one embodiment, a method of coupling a first pipe to a second pipe is provided. The method comprises inserting a first ring into a box member that is connected to an end of the second pipe. The box member may comprise first threads on an inner surface of the box member and the first ring may comprise inner threads on an inner surface of the first ring. The method further comprises inserting a second ring into the box member. The second ring may comprise outer threads on an outer surface of the second ring. The method additionally comprises inserting a pin member into the first ring. The pin member may be connected to an end of the first pipe and the pin member may comprise second threads on an outer surface of the pin member. The second ring may extend from the first ring in a direction opposite to an end of the pin member which is positioned adjacent to the box member.
[0013] In another embodiment, another method of fluidly coupling a first pipe to a second pipe is provided. The method comprises placing a second ring over a pin member, where the second ring comprises outer threads on an outer surface of the second ring. The pin member may be connected to an end of the first pipe and comprise second threads on an outer surface of the pin member. The method further comprises positioning a first ring on the outside of the pin member, where the first ring comprises inner threads on an inner surface of the first ring. The method also comprises inserting the combination of the pin member, the first ring and the second ring at least partially into a box member. The box member connected to an end of the second pipe and comprising first threads on an inner surface of the box member. The method additionally comprises inserting the second ring with its outer threads into the box member. The second ring may extend from the first ring in a direction opposite to an end of the pin member positioned adjacent to the box member.
[0014] A pipe joint for connecting a first pipe to a second pipe is also provided. The pipe joint comprises a hollow pin member connected to a first pipe. The pipe joint further comprise a hollow box member connected to a second pipe, the hollow box member configured so as to at least partially surround the pin member. The pipe joint also comprises a first ring positioned adjacent an end of said pin member. The pipe joint additionally comprises a second ring engaged with the box member. The second ring may abut axially against the first ring and extend axially from the first ring in a direction opposite to the end of the pin member. The first ring may abut axially against said box member.
[0015] Beneficially, according to the disclosed embodiments, thin walled pipes can be connected with each other. The pin member itself can be thin-walled. In certain embodiments, the pin member may also be an integral part of a first pipe or connected to this first pipe directly or indirectly.
[0016] The ability of the first ring to be screwed onto the second threads of the pin member at a production facility, such as a mill, provides significant advantages. For example, the threading operation can be avoided at the field, where the oil or gas rig is finalized. Thus, the operators in the field are not required to handle the threaded connection between the pin member and the first ring. In this manner, problems such as cross threading or overwinding can be avoided as the operator of the rig at the piping location (e.g., the field) will only have to screw of the second ring to the box member. Furthermore, as the second ring comprises an outer surface which is spaced apart from the outer surface of the pin member, the second ring does not necessarily have to be thin-walled. In further embodiments, a more robust thread can also be used between the second ring and the box member, thereby avoiding problems such as cross-threading or overwinding during the screwing operation.
[0017] Further advantages of the embodiments of the joint may include the following:
[0018] In an embodiment, the second ring may be releasably engaged with the box member.
[0019] In another embodiment, the first ring may be connected to the pin member by one or more of a threaded connection, a welding seam, an adhesive, and at least one circumferential groove. So configured, the joint may be long lasting and/or easy to be assembled. In further embodiments, the grooves may include a sawtooth-like configuration to make the connection safer and more long lasting.
[0020] In additional embodiment, the first ring may be an integral part of the pin member.
[0021] In further embodiments, the box member may comprise first threads on its inside. The first threads may be in contact with outer threads of the second ring. The second ring may be positioned between the pin member and the box member. The first ring may further comprise inner threads which are in mating contact with second threads on the outside of the pin member.
[0022] In other embodiments, the pin member may comprise a locating surface aligned in a transverse direction relative to the longitudinal axis of the pin member. The pin member may be in contact with the box member. The locating surface may further be orthogonally aligned relative to the longitudinal axis. By providing such a locating surface, a stop on the pin member can be provided to make the stopping of relative movement of the pin member in regards to the box member possible, as soon as the locating surface is in abutting contact with the box member.
[0023] In further embodiments, the box member may be directly and/or integrally connected to the second pipe. As such, the second pipe can be configured at the mill to be appropriately shaped for attachment with the second ring. In this manner, leakage between the box member and the second pipe may be inhibited.
[0024] In other embodiments, the first threads may be of different thread height and/or thread pitch and/or form the second threads. Beneficially, the handling of light threads, relative to heavy threads, can take place at a lower risk of damaging those light threads.
[0025] Though some elements of the joint may be pre-combined at the mill (e.g., those elements with the light threads to make conveyance of oil or gas possible), the overall joint may be finalized at the field. As an example, for a light thread, the standard API 8 round thread can be selected. However, in other embodiments, sawtooth threads and threads with non-helical geometries may be employed. Examples of light threads may include, but are not limited to, threads having consecutive circular protuberances that engage by actual make up instead of rotational make up. Such a light thread may be positioned in the contact area between the pin member and the first ring, for example, in the area of the second threads.
[0026] In certain embodiments, the first and second threads may be of the same thread type. As such, the manufacturing process can be simplified. The first threads on the inside of the box member and the outer threads of the second ring can be configured as a buttress-like thread. However, also different engagements can be used such as gripping or clamping devices.
[0027] It is especially advantageous if the first threads are of the sawtooth type. It has been experienced that those threads are relatively unlikely to become damaged and can still convey high forces and loads.
[0028] In an embodiment, when the first ring is configured with a smaller outer diameter than the inner diameter of the box member, an axial gap between the box member and the first ring may result, so that the manufacturing process can be simplified. In other embodiments, the first threads of the box member may not come in contact with the first ring when the box member is imposed onto the pin member, the first ring and the second ring. To heighten the fluid tightness, it is advantageous if a fluid tight seal is provided between the pin member and the box member, preferably in the vicinity of the locating surface of the pin member.
[0029] In embodiments where the second threads possess a thread height h t2 in their middle between about 20% and about 50%, especially about 35% of a thread height h t1 in the middle of the first threads, the thin wall of the pin member may avoid being corrupted by the first threads, though the first threads can still convey sufficiently high forces and loads.
[0030] Special beneficial effects may also be experienced if the fluid tight seal is configured as a resilient seal, such as an o-ring and/or configured as a metal-to-metal seal.
[0031] It is additionally advantageous in embodiments where the first ring is axially spaced apart from the box member.
[0032] In further embodiments, a pin shouldering nose of the pin member, such as a stop area, may be in contact with an o-ring in a groove-like recess in the box member.
[0033] In a further embodiment, the o-ring may be configured with a bigger outer circumferential diameter than the inner diameter of the groove-like recess in the box member. So configured, the o-ring can be easily introduced into the groove-like recess and does not fall apart during the manufacturing process.
[0034] In other embodiments, the first threads and the second threads, and their mating counterparts on the first and second rings, may be tapered. As such, the alignment of the respective threads with each other can be simplified so that damage to the threads can be minimized and costs during the manufacturing process can be lowered.
[0035] Standard components can be used if the pin member, the first ring, the second ring and the box member are having a generally angular cross section.
[0036] Additional advantages can be recognized in embodiments of the joint when, during the screwing of the second ring, only the second ring is moved relative to both the pin member and the box member. In this manner, substantially no relative movement between the pin member and box member may be experienced.
[0037] Manufacturing of the joint may be simplified as the pin member and the box member, which are respectively connected to the first pipe and second pipe, do not have to be rotated relative to each other. Only the second ring needs to be screwed into the box member so that the second ring abuts the first ring and forces the box member onto the locating surface of the pin member in the area of the stop.
[0038] In another embodiment, it may be advantageous when one or more threaded surfaces of the pipe joint are covered by at least one of a protective layer and a lubricant layer. In this manner, additional oil or grease is not needed to be inserted at a field site, when the relevant segments of the pipe joint are assembled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The aforementioned embodiments shall also be explained together in conjunction with the following figures:
[0040] FIG. 1 is a schematic illustration of a first embodiment of a joint of the present disclosure in cross section;
[0041] FIG. 2 is a schematic illustration of a second embodiment of a joint of the present disclosure in cross section;
[0042] FIG. 3 is a schematic illustration of a third embodiment of a joint of the present disclosure in cross section;
[0043] FIG. 4A is a schematic illustration of a fourth embodiment of a joint of the present disclosure displayed in cross section;
[0044] FIG. 4B is a schematic illustration of a detail of the groves between a first ring and a pin member of the embodiment of FIG. 4A ;
[0045] FIG. 5 is a schematic illustration of a fifth embodiment of a joint of the present disclosure in cross section; and
[0046] FIG. 6 is a schematic illustration of a sixth embodiment of a joint of the present disclosure displayed in cross section.
[0047] All figures are of a schematic nature in order to simplify the understanding of the disclosed embodiments. For the same elements, the same reference signs are used in the figures.
DETAILED DESCRIPTION
[0048] In FIG. 1 , a first embodiment of a pipe joint 1 is displayed. Such pipe joints may be used as joints suitable for use in the oil and gas industry (e.g., in oil and gas rigs, pipelines and drill rods).
[0049] The pipe joint 1 may be used to connect a first pipe to a second pipe. The first pipe may be in direct connection or integrally connected to a hollow pin member 2 . The hollow pin member 2 may have a relatively thin wall and an annular cross section. Outside of the pin member 2 , a hollow box member 3 may be arranged. The hollow box member 3 may be in direct connection or integrally connected to a second pipe. Between the pin member 2 and the box member 3 , a first ring 4 and a second ring 5 may be arranged. The box member 3 , the first ring 4 , and the second ring 5 may all possess a generally annular cross section.
[0050] The box member 3 may comprise a first thread 7 on an inner surface 6 . The second ring 5 may comprise outer threads 9 on an outer surface 8 . The outer thread 9 and the first thread 7 may be in contact with each other and mate with each other.
[0051] An annular gap 11 may be present between an outer surface 10 of the first ring 4 and an inner surface 6 of the box member. An inner surface 12 of the second ring 5 may be in contact with an outer surface 13 of the pin member 2 or may be spaced apart from the outer surface 13 .
[0052] Second threads 14 may be present on the outer surface of the pin member 2 . The second threads 14 may be in contact with inner threads 15 on an inner surface of the first ring 4 .
[0053] The first threads 7 of the box member 3 , the outer threads 9 of the second ring 5 , the second threads 14 of the pin member 2 , and the inner threads 15 of the first ring may each taper at their respective ends. As a result, the threads with the largest height may be positioned in the middle of the respective threads.
[0054] The first ring 4 and the second ring 5 may touch each other along an engaging surface 16 of the first ring 4 . This engaging surface 16 can have a transverse area. In the embodiment of FIG. 1 , two orthogonal steps may be connected via a beveled surface. It is not necessary that both the steps and the beveled surface are contacted by the second ring 5 . However, in embodiments where the first ring 4 and the second ring 5 contact each other along at least a part of the engaging surface, force can be transmitted from the first ring 4 to the second ring 5 and vice versa.
[0055] In certain embodiments, the first ring 4 may be in contact on one side with the box member 3 . However, this contact is not necessary and a radial gap can exist at this position.
[0056] The second threads 14 of the pin member 2 and the inner threads 15 of the first ring 4 may posses a smaller height than the first threads 7 of the box member 3 and the outer threads 9 of the second ring 5 . In fact, the height h t2 ( FIG. 1 ) may be about 20%-50% of the height h t1 of the first threads 7 of the box member 3 ( FIG. 3 ), preferably about 35% of the height h t1 .
[0057] In the embodiment of FIG. 1 , the first threads 7 of the box member 3 and the outer threads 9 of the second ring 5 may be sawtooth threads. In other embodiments, the second threads 14 of the pin member 2 and the inner threads 15 of the first ring 4 may be metrical threads.
[0058] The pin member 2 may comprise a stop area 17 with a locating surface 18 . The locating surface 18 may function to stop the movement of the pin member 2 towards the box member 3 . The locating surface 18 may end in a plane which is orthogonally aligned in regards to a longitudinal axis 19 of the pipe joint 1 .
[0059] The box member 3 may further comprise a groove-like recess 20 in which a compressible o-ring 21 may be positioned. Beneficially, this configuration may facilitate the establishment of a fluid tight seal between the box member 3 and the pin member 2 .
[0060] While the locating surface 18 may act to stop the movement of the pin member 2 towards the box member 3 , the o-ring 21 may be compressed to improve the fluid tightness between the pin member 2 and the box member 3 . The o-ring 21 may be configured with a larger outer diameter than the respective diameter of the recess 20 .
[0061] Referring now to FIG. 2 , another embodiment of the pipe joint 1 is illustrated. In the embodiment of FIG. 2 , the position of the o-ring 21 may be changed, as compared with the embodiment illustrated in FIG. 1 . The o-ring 21 in this second embodiment of the pipe joint 1 may be positioned between the locating surface 18 and a shoulder 22 of the box member 3 .
[0062] In further embodiments of the pipe joint 1 , instead of an o-ring formed from an elastic material, a metal-to-metal sealing connection between the pin member 2 and the box member 3 can be established.
[0063] In another embodiment, the pin member 2 may comprise a convex outer surface 13 in the stop area 17 . In alternative embodiments, instead of a convex configuration of the outer surface of the pin member 2 , a conical configuration may also be employed.
[0064] The box member 3 may also be configured with a convex surface adjacent to the stop area 17 . In alternative embodiments, instead of such a convex surface, a conical surface may be present. In any case, the abutting surfaces of the pin member 2 and the box member 3 may be pressed against each other when assembled to provide a fluid tight seal.
[0065] Referring now to FIG. 3 , another embodiment of the pipe joint 1 is illustrated. The locating surface 18 of the pipe joint 1 FIG. 3 may be configured in abutting alignment with the shoulder 22 of the box member 3 .
[0066] Referring now to FIG. 4A , another embodiment of the pipe joint 1 is illustrated. As compared to the embodiment of FIG. 1 , the embodiment of FIG. 4A may be configured such that the first ring 4 is pushed onto the pin member 2 . Alternatively, upsetting methods, such cold upsetting, or forging methods can be used to combine the first ring 4 with the pin member 2 . Furthermore, alternative connection methods, such as welding methods to achieve a welding seam between the first ring 4 and the pin member 2 , may also be employed. In a further embodiment, an adhesive can be placed between the first ring 4 and the pin member 2 .
[0067] In certain embodiments, circumferential grooves may also be incorporated either on the first ring 4 of the pin member 2 or both respective elements (e.g., on the first ring 4 and the pin member 2 ), so that a form fit can be achieved between those two elements. It is further possible that one or more of the grooves comprise a sawtooth configuration, as illustrated in FIG. 4B .
[0068] In FIG. 5 , another embodiment of the pipe joint 1 is illustrated. As illustrated in FIG. 5 , the first ring 4 may be integrally connected to the pin member 2 . Both elements may be formed from the same material.
[0069] Referring now to FIG. 6 , another embodiment of the pipe joint 1 is illustrated. In the embodiment of FIG. 6 , as in the embodiment of FIG. 5 , the first ring 4 and the pin member 2 may be formed of the same material and integrally connected to each other. However, an O-ring (e.g., o-ring 21 ) may be omitted from the embodiment of FIG. 6 . It may be understood, though, that such a fluid-tight seal can be inserted at an appropriate position of the pipe joint 1 of FIG. 6 .
[0070] Methods for achieving a fluid tight seal between a first pipe and a second pipe are discussed in detail below.
[0071] A first method for achieving a fluid tight seal between a first pipe and a second pipe is characterized as follows:
In a first operation, the second ring 5 may be pushed over the pin member 2 . In a second operation, the first ring 4 may be screwed onto the pin member 2 . In a third operation, the combination of the pin member 2 , the first ring 4 , and the second ring 5 may be pushed into the box member 3 . In a fourth operation, the second ring 5 may be screwed into the box member 3 . The second ring 5 may abut the engaging surface 16 of the first ring 4 . By this screwing movement of the second ring 5 , the box member 3 may be pushed against the pin member 2 . Consequently a fluid tight seal may be achieved between the box member 3 and the stop area 17 of the pin member 2 .
[0076] Beneficially, according to embodiments of the present disclosure, pin member 2 , box member 3 , first ring 4 , and second ring 5 may be reassembled even after a pipe joint has been tightly assembled and afterwards dismantled again.
[0077] A second embodiment of a method for achieving a fluid tight seal between a first pipe and a second pipe is characterized as follows:
In a first operation, the first ring 4 may be placed into the box member 3 . In a second operation, the second ring 5 may be partially screwed onto the box member 3 . In a third operation, the pin member 2 may be forced into the assembly, which has been configured in the previous two steps. In a fourth operation, the second ring 5 may be screwed into the box member 3 to its final position.
[0082] Embodiments of the above described methods may be suitable for metal components so that the pin member 2 , the box member 3 , the first ring 4 and the second ring 5 are of metallic material, such as steel. It may be understood, however, that embodiments of the joints of the present disclosure may be employed with joints formed from any materials, including, but not limited to, plastic materials. Furthermore, the same or different materials can be used instead for one or all components of the pipe joint.
[0083] During use, the pipe joint may experience tension and internal pressure, in combination with bending. Therefore, is relevant to see the actual behavior from the first pipe to the second pipe under said load conditions. Test conditions for such joints are, for example, defined by ISO 13670. This standard can be complied with by numerical modeling (e.g., finite element modeling, FEA) that simulates combinations of tension and internal pressure on a pipe joint. Such tests were applied to several samples formed in accordance with embodiments of the disclosed pipe joints. The samples all were configured with variations in the geometrical conditions, for example, taper, interference, diameter of the pipes and their thickness, as well as steel grades. Joints of embodiments of the present disclosure, according to the FEA (finite element analysis) analysis provide sealability against internal pressure under simulated loading conditions tested.
[0084] The design of embodiments of the joints was further verified by a full-scale testing program particularly developed to assess its performance. Based on the requirements of ISO 13670, this testing program evaluated sealability and a repeated loading in combination with bending. Embodiments of the joints of the present disclosure were found to successfully pass all stages of the testing program.
[0085] Table 1 presents the results of a sealability test (gas tightness) performed on pipes of 3½ inch outside diameter and 0.131 inches of wall thickness, under a bending of 20°/100 ft.
[0000]
TABLE 1
Internal
Tension
pressure
Gas-tightness
Load Condition
[Kips]
[psi]
of connection
Tension only
50
0
OK
Tension + internal pressure
30
2600
OK
Internal pressure only
0
3000
OK
1 psi = 6894.75 N/m 2 ;
1 Kip = 448.22N;
1 inch = 0.0254 m;
1 foot = 0.3048 m
[0086] The embodiments of pipe joint 1 can be also be used, advantageously, in association with surface treatments that do not include dope. For example, in certain embodiments, in order to improve the quality of the joint 1 , a surface treatment can be carried out, where the surface of the female threads 7 and 15 may be coated with Mn phosphate. A bare surface may be left on the male threads 9 and 19 . This treatment may improve galling resistance of the pipe joint 1 . In further embodiments, additional improvements may be achieved by using an API modified thread compound and an ecological thread compound together with Mn phosphate applied on a sand blasted surface.
[0087] In an embodiment of a surface treatment, in accordance with in EP 1554518, the entirety of which is hereby incorporated by reference, at least the surface of a threading may be configured with a surface roughness Ra comprised between 2.0 μm and 6.0 μm. The threading surface may further be covered by a first uniform layer of a dry corrosion inhibiting coating. This first layer may also be covered by a second uniform layer of dry lubricant coating.
[0088] The male threads 9 and 19 may be provided with a protective layer on the surface of the thread. The female threads 7 and 15 may be similarly configured or they can be made without the protective layer and be connected to the male threads 9 and 19 provided with the protective layer. The protective layer, in an embodiment, may comprise:
A first layer of dry corrosion inhibiting coating. The first layer may comprise an epoxy resin containing particles of Zn, deposited on the threading metal surface. These particles of Zn may comprise 99% pure Zn. The thickness of the first layer may vary within the range between 10 μm and 20 μm, preferably between 10 μm and 15 μm. A second layer of dry lubricant coating. The second layer may comprise a mixture of MoS 2 and other solid lubricants in an inorganic binder. The thickness of the second layer may vary within the range between 10 μm and 20 μm, deposited over the surface of the dry corrosion inhibiting coating.
[0091] In a second embodiment of a surface treatment, also disclosed in EP 1554518, at least the surface of one or more of the threaded portions of the pipe joint may be configured with a surface roughness Ra that varies within the range between 2.0 μm and 6.0 μm. The threaded surfaces may further be covered by a single, substantially uniform layer of a dry corrosion inhibiting coating. The layer of the corrosion inhibiting coating may include a dispersion of particles of solid lubricant. The thickness of this layer may vary within the range between 10 μm and 20 μm.
[0092] The male threads 9 and 19 may be configured with the single uniform protective layer on the surface of the thread. The female threads 7 and 15 can be similarly configured or they can be made without the single uniform protective layer and be connected to the male threads 9 and 19 provided with the single protective layer.
[0093] In both cases, the layer of dry corrosion inhibiting coating containing the dispersion of particles of solid lubricant can be applied by spraying, brushing, dipping or any other method in which the coating thickness can be controlled.
[0094] Regarding the embodiments of the first and second surface treatments, the relevant segments, such as the pipe members 2 , may be adapted to be assembled without the necessity of a further surface preparation prior to running in the field site or the addition of oil or grease. Furthermore, it is possible to transport and store relevant segments in the oilfield without risking that the segments lose their integrity because of corrosion on the threaded portions forming the connections. Beneficially, the connections can be assembled in the oilfield without removing the corrosion protection layer. Tests have identified that there is substantially no galling on either unthreaded areas or on threaded areas of the joint. Additionally, the tests identified that the connection had a very stable make up behaviour.
[0095] A third embodiment of a surface treatment is disclosed in WO 2007/063079, the entirety of which is incorporated by reference. The surface of the thread may be provided with a coating comprising, in a first variant, a first layer with high friction and anti-seize properties laid on the overall surface of the pin and a second layer with low friction properties laid on specific parts of the overall surfaces of either one of pin member 2 or box member 3 . In a second variant, the surface of the thread may be provided with a coating comprising a first layer laid on the overall surface of the box and a second layer laid on selected portions of the overall surfaces of either one of pin or box. The specific selected portions may be those adapted to produce reciprocal radial contact, for example, crests in the female threads 7 and 15 , roots in the male threads 9 and 19 , and unthreaded areas.
[0096] The female threads 7 and 15 matching the male threads 9 and 19 can have a similar first layer and second layer on their respective surfaces or the thread can be made without the protective layers. In alternative embodiments, the layers can be made with a different structure or materials. In further embodiments, it is also possible to have a coating only on the surface of the male threads 9 and 19 and no coating on the surface of the female threads 7 and 15 .
[0097] As one of ordinary skill in the art would understand, other coatings may be applied either below or above the coating without departing from the scope of the present invention. For example, a corrosion resistant layer can be applied over the coating, provided that the corrosion resistant layer does not affect the friction properties of the entire system. Additionally, the various coatings described herein may be applied to the overall surface of the male threads 9 and 19 or female threads 7 and 15 , or only to selected areas. For example, the coatings may be applied to the threaded portions of the male threads 9 and 19 and the female threads 7 and 15 , to unthreaded areas of the male threads 9 and 19 and the female threads 7 and 15 , or to the shoulder portion of the pin member 2 and the box member 3 without departing from the scope of the present invention.
[0098] In any case, any of the embodiments of the surface treatments can be provided in combination with a minimum amount of dope.
[0099] Although the foregoing description has shown, described, and pointed out the fundamental novel features of the present teachings, it will be understood that various omissions, substitutions, and changes in the form of the detail of the apparatus as illustrated, as well as the uses thereof, may be made by those skilled in the art, without departing from the scope of the present teachings. Consequently, the scope of the present teachings should not be limited to the foregoing discussion, but should be defined by the appended claims.
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Pipe joints and methods for connecting a first pipe to a second pipe are provided. The joint includes a first pipe and a second pipe. The first pipe includes a hollow pin member positioned at about an end of the first pipe. The second pipe includes a hollow box member positioned at about an end of the second pipe. The hollow box member is further configured to at least partially surround the pin member of the first pipe. The joint also includes a first ring placed adjacent an end of the hollow pin member and a second ring engaged with the box member. The second ring substantially axially abuts against the first ring and the first ring substantially axially abuts the box member. The second ring further generally extends from the first ring in a direction opposite to the end of the pin member adjacent to the box member.
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BACKGROUND OF THE INVENTION
The invention relates to an automotive construction machine, as well as a lifting column for a construction machine.
Such construction machinery is known, for instance, from DE 103 57 074 B3. The said construction machine shows a machine frame that is supported by a chassis, as well as a working drum that is mounted at the machine frame in an immovable and/or pivotable manner, and is used for working a ground surface or traffic surface. The chassis is provided with wheels and/or crawler track units which are connected to the machine frame via lifting columns and are individually adjustable in height relative to the machine frame.
The adjustment in height is made possible by a controller that raises or lowers the lifting columns by controlling the hydraulic input or hydraulic discharge of piston cylinder units in the lifting columns.
The construction machine described in DE 103 57 074 B3 is a recycler, and the disclosure of this publication is included in the present application to the extent that it is related to recyclers.
A chassis for a machine used for milling carriageway pavements is known from DE 196 17 442 C1, the front axle of the said chassis being, for instance, adjustable in height in the manner of a full-floating axle. The lifting columns of the chassis are capable of being raised or lowered respectively in a reciprocally opposed manner. The disclosure of this publication is also included by reference into the present application.
A known construction machine of the applicant is the recycler WR 2000 , the wheels of which are connected to the machine frame via lifting columns that are adjustable in height hydraulically. Each wheel is driven by an own hydraulic motor. The known construction machine is equipped with all-wheel steering, with the front and/or the rear wheels being capable of acting as the steered axle.
It is understood that the present application is not limited to wheel-driven construction machines, but also includes such construction machines that are provided with crawler track units or a mixture of wheels and crawler track units.
In the known construction machines, the lifting columns are adjusted manually via switchover valves, with sensors detecting that the piston of the piston cylinder unit adjusting the lifting column has reached pre-determined positions. The sensors may detect, for instance, the upper edge of the piston in the piston cylinder unit. A first sensor detects the position of the piston in an operating position for milling, and a further sensor detects the position of the piston in a transport position. In operating position, the machine frame therefore always has the same, pre-determined distance from the ground surface. When the piston has left the pre-defined sensor positions, the information about the position of the machine is lost. It is, in particular, not possible to adjust any other operating positions in a flexible manner without remounting the position sensors. It is not even possible to, for instance, adjust an operating position that is parallel to the pre-adjusted operating position but deviates from the same in height. What is more, it is not possible to adjust a defined transverse inclination or any other practical position of the machine frame or the machine respectively without cumbersome remounting efforts.
This creates the additional problem that the machine frame can adopt a different distance to the ground surface or traffic surface because of different loads or load distributions which are due to, for instance, a different filling level of the fuel tank or a water tank.
In case of wheels, deviations additionally result because of the filling pressure, the temperature and the interaction of the relatively soft wheel with the ground surface or traffic surface, which may, for instance, cause an alteration in distance of several centimeters. These alterations in distance of the machine frame relative to the ground surface require the position of the sensors to be displaced. Even though it is also possible to unlock the sensor for the operating position and to override this lifting position, the disadvantage results that the piston, at its front surfaces, touches the respective front surfaces of the cylinder when the mechanical limit stop of the piston cylinder unit has been reached, which may cause the piston of the piston cylinder unit to turn loose when carrying out steering movements of the wheels.
The purpose of the invention is to avoid the aforementioned disadvantages and to enable the vehicle driver to select any given lifting position of the lifting columns as operating position in particular for the working operation.
The invention provides in an advantageous manner that each individual height-adjustable lifting column is provided with a measuring device for measuring the current lifting state of the lifting column, the lifting columns comprise two hollow cylinders capable of telescoping which serve as guiding unit and accommodate at least one piston cylinder unit for height adjustment, preferably in a coaxial manner, on their inside, that each individual height-adjustable lifting column is provided with a measuring device for measuring the current lifting state of the lifting column, the measuring device is coupled with elements of the lifting column, which are adjustable relative to one another in accordance with the lifting position, in such a manner that a path signal pertaining to the lifting position of each lifting column is continuously detectable by the measuring device, and that a controller receiving the measured path signals from the measuring devices of all the lifting columns regulates the lifting state of the lifting columns in accordance with the measured path signals of the measuring devices and/or their alteration over time.
The invention provides in an advantageous manner for pre-selectable positions of the lifting columns to be adjusted in a regulated manner, permitting the use of the measured path signal, and of the velocity and acceleration signals which can be deduced therefrom. Recording of the measured values enables the lifting state of the lifting columns to be regulated automatically. A controller receiving the measured signals from the measuring device can adjust a desired lifting position of the lifting columns in a regulated manner without overshooting or with as little overshooting as possible in accordance with the measured signals of the measuring device and/or their alteration over time.
The measured signals may be suitable for supplying to an indicator device for the lifting position of the lifting columns. Because the vehicle driver receives information on the current lifting state of each lifting column via the indicator device, it is possible to adjust and define as operating position a freely selectable position of the machine frame without the need for limit switches or sensors to be displaced. Hence, the vehicle driver has the possibility to equalize different load situations that may arise due to, for instance, a different filling level of the fuel tank or the water tank. Furthermore, influences of the relatively soft wheels due to different temperatures, a different filling pressure or because of the interactions with the ground can be equalized individually for each wheel or crawler track unit.
The measuring device for the lifting position preferably includes a path measuring device, and all known path measuring systems like, for instance, capacitive, inductive, mechanical path measuring systems or laser measuring systems may be used.
The lifting columns comprise two hollow cylinders capable of telescoping which serve as guiding unit and accommodate at least one piston cylinder unit, preferably in a coaxial manner, on their inside.
A preferred path measuring device includes at least one wire-rope that is coupled with the elements of a lifting column, and one wire-rope sensor.
A wire-rope that is under tension and capable of being rolled up is coupled with elements of the lifting column, which are capable of being displaced relative to one another in accordance with the lifting position, in such a manner that a path signal pertaining to the lifting position of each lifting column is detectable continuously. The path signal transmitted to the indicator device may be used for manual control of the height adjustment by the vehicle driver with the aid of the indicator device, but also for automatic control or regulation.
The construction machine can be adjusted to a reference plane, where a desired spatial position like, for instance, a parallel position of the machine frame to the ground surface or traffic surface can be stored on the reference plane by storing the current measured signals of the measuring device in accordance with the current lifting positions of the lifting columns as a reference lifting position of the chassis.
By means of the reference plane, which is preferably a horizontal plane, the vehicle driver can bring the machine frame into a specific position which he can define as the reference lifting position. In case of a level machine frame, the said machine frame could, for instance, be brought into a precisely horizontal position which, with a pre-determined distance from the ground or the traffic surface, could be defined as the reference lifting position of the lifting columns. The vehicle driver can recognize the said reference lifting position by means of the indicator device and can approach it specifically as and when required. On the other hand, it is also possible to raise or to lower individual lifting columns or a combination of lifting columns by a specific amount. The vehicle driver can, for instance, also adjust an operating position which deviates from the reference lifting position by a specific amount, e.g. 100 mm, or a specific transverse inclination or a plane in space arbitrarily defined by the vehicle driver.
In a preferred embodiment, it is provided that at least one limiting value for the height adjustment monitored by the measuring device is adjustable for each lifting column, the said limiting value limiting the lowest and/or highest lifting position of a lifting column to a pre-determined position. It is thus ensured that the piston cylinder unit provided on the inside of a lifting column will not run up against its corresponding mechanical limit stops, as the piston cylinder unit may be damaged or may turn loose from the lifting column in these mechanical end positions, in particular in case of steering angles.
Consequently, it is provided that the lowest or highest lifting position in the direction of movement is positioned in front of the mechanical limit stop of the piston against the cylinder of the piston cylinder unit.
Recording of the measured values enables a controller, which receives the measured signals from the measuring devices, to regulate the lifting state of the lifting columns automatically in such a manner that the machine frame is subject to the smallest possible displacement due to the structure of the ground surface or traffic surface.
Alternatively, it is also possible for the controller to regulate the lifting state of the lifting columns by means of the measured signals in such a manner that the machine frame is subject to the smallest possible transverse inclination or transverse oscillation transverse to the direction of travel due to the existing structure of the ground surface or traffic surface.
It may additionally be provided that, when altering the lifting state of one wheel or crawler track unit, a neighbouring wheel or crawler track unit in transverse direction or longitudinal direction of the machine frame is adjustable in height in an opposite manner. Controlling of the lifting state may be effected, for instance, in accordance with the hydraulic method described in DE 196 17 442 C1. In case of a hydraulic forced coupling of neighbouring lifting columns, one single measuring device for both lifting columns is sufficient due to the identical amount of stroke adjustment.
There is, however, also the possibility of controlling the lifting state of each wheel purely electronically in the manner of a full-floating axle. With such a full-floating control, an additional stroke adjustment can be overridden by the vehicle driver.
With the reciprocal control of the lifting state, the neighbouring wheels or crawler track units are preferably adjusted in height by the same amount and in an opposite manner.
In case of a cold milling machine, the rear wheels or crawler track units when seen in the direction of travel are preferably adjustable in height in the manner of a full-floating axle by the same amount and in opposite direction.
In case of a recycler, the wheels or crawler track units arranged behind one another on one side of the machine when seen in the direction of travel may be adjustable in height in the manner of a full-floating axle by the same amount and in opposite direction.
A controller receiving the measured signals from the measuring devices can adjust a desired lifting position of the lifting columns without overshooting or with as little overshooting as possible in accordance with the measured signals from the measuring devices and/or their alteration over time.
The measured signals from the measuring devices may be calibrated to a unit of length, so that a specified stroke amount can be entered in millimeters for the purpose of height adjustment.
The controller may regulate the working depth of the working drum, in which case the controller receives the measured path signals from the measuring device and includes them into the regulation of the working depth of the working drum.
Each lifting column is provided at the lower end with a support for the wheel or crawler track unit, where a distance sensor measures the distance of the support to the ground surface and traffic surface, preferably in a pre-determined distance in front of or next to the wheel or crawler track unit, and transmits a measured signal to a controller for the lifting position of the lifting columns, and/or to a controller for the working depth of the working drum, and/or to the indicator device.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the following, embodiments of the invention are explained in more detail with reference to the drawings. The following is shown:
FIG. 1 is a side view of the construction machine in accordance with the invention, in which the working drum is in a working position,
FIG. 2 a top view of the construction machine in accordance with FIG. 1 , and
FIG. 3 a lifting column of the construction machine.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a road construction machine 1 for producing and working carriageways by stabilizing insufficiently stable soils or by recycling road surfaces, with a machine frame 4 supported by a chassis 2 , as it is basically known from DE 103 57 074 B3. The chassis 2 is provided with two each rear and front wheels 10 , which are attached to lifting columns 14 in a height-adjustable manner and can be raised and lowered independently of one another or also synchronously to one another. It is understood that other drive means like, for instance, crawler track units may also be provided in lieu of the wheels 10 . The wheels or crawler track units may also be referred to as ground engaging supports for supporting the construction machine on the ground surface or traffic surface 24 . The lifting columns 14 are attached to the machine frame 4 .
Both axles of the chassis, which are formed by the front and rear wheels 10 respectively, may be steerable.
As can be seen from FIGS. 1 and 2 , an operator's platform 12 for a vehicle driver is arranged at the machine frame 4 above the front wheels 10 or in front of the front wheels 10 , with a combustion engine 32 for the travel drive and for driving a working drum 6 being arranged behind the driver. In this manner, the operator's platform 12 can be ergonomically optimized for the vehicle driver.
The working drum 6 which rotates, for instance, in opposition to the direction of travel when seen in the direction of travel, and the axis of which extends transversely to the direction of travel, is mounted to pivot relative to the machine frame 4 in such a manner that it is capable of being pivoted from an idle position to a working position, as depicted in FIG. 1 , by means of pivoting arms 42 arranged on both sides. Each pivoting arm 42 is mounted in the machine frame 4 at one end and accommodates the support of the working drum 6 at its other end.
It is also possible to operate the machine 1 in reversing direction, with the milling operation then taking place synchronously to the direction of travel.
The working drum 6 is, for instance, equipped with cutting tools that are not depicted in the drawings in order to be able to work a ground surface or traffic surface 24 .
The working drum 6 is surrounded by a hood 28 which, as can be seen from FIG. 1 , is capable of being raised together with the working drum 6 by means of the pivoting arms 42 .
In operating position, the hood 28 rests on the ground surface or traffic surface 24 to be worked, as can be seen from FIG. 1 , while the working drum 6 is capable of being pivoted further down according to the milling depth.
It is understood that other embodiments of such a construction machine exist in which the hood 28 , or the hood 28 and the working drum 6 , are mounted at the machine frame 4 in a rigid manner. In the latter case, the working depth of the working drum 6 is adjusted via the lifting columns 14 , in all other cases through an adjustment in height of the working drum 6 .
FIG. 3 shows an individual lifting column 14 comprising two hollow cylinders 13 , 15 which are capable of telescoping in a form-fitting manner. The hollow cylinders 13 , 15 serve as guiding unit for the height adjustment of the machine frame 4 . The upper outer hollow cylinder 13 is attached at the machine frame 4 , and the lower inner hollow cylinder 15 is attached at a support 11 which may be coupled with a wheel 10 or a crawler track unit. The lifting column 14 is further provided with a hydraulic piston cylinder unit 16 for the stroke adjustment. The piston cylinder unit 16 acts between the machine frame 4 and the support 11 , so that the machine frame 4 is capable of being adjusted in height relative to the support 11 and thus, ultimately, relative to the ground surface or the traffic surface 24 respectively. In the embodiment shown in FIG. 3 , the piston element of the piston cylinder unit 16 is attached at the support 11 , and the cylinder element of the piston cylinder unit 16 is attached at the upper hollow cylinder 13 , which is attached at the machine frame 4 .
It is understood that more than one piston cylinder unit 16 may also be present in the lifting column 14 .
The piston cylinder unit 16 may also be force-coupled hydraulically with a neighbouring lifting column 14 , as has been basically described in DE 196 17 442 C1, in order to form a purely hydraulic full-floating axle.
The lifting column 14 is provided with a measuring device 18 for measuring the current lifting state of the lifting column 14 . In the embodiment, the said measuring device 18 includes a wire-rope 22 that is attached at the support 11 or the lower hollow cylinder 15 and is, on the other hand, coupled with a wire-rope sensor 21 that is attached at the cylinder element of the piston cylinder unit 16 or at the upper hollow cylinder 13 . The stroke path of the lifting column 14 can be measured by means of the wire-rope sensor 21 . The wire-rope sensor 21 , and the path signal produced by the same, is ultimately also suitable for being converted into a velocity signal or acceleration signal by including a time measurement.
The measured path signal of the wire-rope sensor 21 is transmitted to an indicator device 20 and/or a controller 23 by means of a signal line 26 . The indicator device 20 and/or the controller 23 receive measured path signals from each lifting column, as indicated in the drawing in FIG. 3 . With a total of four existing lifting columns 14 , four measured path signals can be displayed in the indicator device 20 , so that the vehicle driver is immediately informed about the current lifting state of each lifting column and can alter the lifting position, if required.
The measured path signals can additionally be supplied to a controller 23 , which enables overall control or regulation of the lifting position of the lifting columns 14 .
The controller 23 can, for instance, adjust a desired lifting position of the lifting column 14 without overshooting or with as little overshooting as possible in accordance with the measured path signals of the measuring devices 18 and/or their alteration over time.
In case of a full-floating axle, floating can be effected purely hydraulically through piston cylinder units 16 which are provided with a piston capable of being loaded from two sides, and the counter-operating cylinder chambers of which are force-coupled with the corresponding cylinder chambers of the piston cylinder unit of a neighbouring wheel 10 . Alternatively, a height adjustment in the manner of a full-floating axle may be effected with purely electronic control by means of the measured path signals detected.
The control or regulation may be such that, for instance, the machine frame 4 is subject to the smallest possible displacement.
The machine frame 4 may alternatively be regulated by means of the lifting state of the lifting columns 14 in such a manner that a pre-determined transverse inclination of the machine frame 4 transverse to the direction of travel is maintained.
A further alternative provides that the time sequence of the position of the machine frame 4 such as, for instance, a path-dependent transverse inclination sequence of the machine frame 4 , may also be regulated by means of the measured path signals and the piston cylinder units 16 in combination with a path or machine position measurement.
Ultimately, it is also understandable that a longitudinal inclination or a combination of a transverse and longitudinal inclination can also be regulated by means of the controller 23 .
The measured signals of the measuring device 18 may be calibrated to a unit of length like, for instance, millimeters. In this way, it is possible for the vehicle driver to also alter the lifting state of the lifting columns 14 through entering a specific stroke in millimeters.
Each lifting column 14 may be provided with a distance sensor 30 each at the supports 11 , which measures the distance of the support 11 to the ground surface and traffic surface 24 . By means of the measured signal of the distance sensors 30 , and in combination with the measured path signals of the measuring device 18 , the controller 23 for the lifting columns 14 can also calculate the current distance of the machine frame 4 from the ground surface and traffic surface 24 .
The distance sensor 30 can measure the distance of the support 11 to the ground surface and traffic surface 24 also in a pre-determined distance in front of or next to the wheel 10 or crawler track unit. Measuring in front of the wheel 10 offers the possibility of using the measured signal of the distance sensor 30 for the purpose of controlling the height adjustment of the lifting columns 14 in a manner that allows an immediate reaction to any ground irregularity. Finally, the distance sensors 30 are also capable of supplying measured signals for a regulation of the milling depth, where the measured signals of the distance sensors 30 and the measured path signals of the measuring device 18 are evaluated on a joint basis.
Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined by the appended claims.
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Disclosed is an automotive road construction machine, particularly a recycler or a cold stripping machine, comprising an engine frame that is supported by a chassis, a working roller which is stationarily or pivotally mounted on the engine frame and is used for machining a ground surface or road surface. The chassis is provided with wheels or tracked running gears which are connected to the engine frame via lifting column and are vertically adjustable relative to the engine frame. Each individually vertically adjustable lifting column is equipped with a device for measuring the actual vertical state of the lifting column.
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TECHNICAL FIELD
[0001] The present disclosure is directed to a burner that comprises a combustion chamber with a converging shape. In one embodiment, the combustion chamber comprises a conical shape that converges in diameter from its inlet to outlet. The disclosed burner may be used for various purposes, including the regeneration of a particulate trap within an internal combustion engine's exhaust system.
BACKGROUND
[0002] Internal combustion engines, including diesel engines, gasoline engines, and natural gas engines, for example, generally emit air pollutants. These air pollutants are generally composed of both gaseous matters and particulate matters. Particulate matter from a diesel engine typically includes ash and soot. Soot is composed of carbon particles that were not combusted during the combustion process.
[0003] Over the past several years, engine emission regulations have become increasingly stringent, driving engine manufacturers toward improving and developing new emissions-reducing technologies. Many of these technologies are aimed at minimizing particulate matters emitted from the engine.
[0004] In doing so, some engine manufacturers have developed systems to treat engine exhaust before it enters the environment. Some of these systems employ exhaust treatment devices such as particulate traps to filter particulate matter from the exhaust flow. A particulate trap generally includes a filter material designed to capture particulate matter. After an extended period of use, unfortunately, the filter material may become saturated with particulate matter, thereby hindering the exhaust gas that flows through the particulate trap.
[0005] The collected particulate matter may be removed from the filter material through a process called regeneration—burning. Because soot is composed of unburned hydrocarbons, soot has a propensity for combusting when exposed to oxygen and heat.
[0006] A particulate trap may be regenerated by increasing the temperature of the filter material and the trapped particulate matter above the combustion temperature of the particulate matter, thereby burning away the collected particulate matter. This increase in temperature may be effectuated by various means. For example, some systems may employ a heating element to directly heat one or more portions of the particulate trap (e.g., the filter material or the external housing). Other systems have been configured to heat exhaust gases upstream of the particulate trap.
[0007] Some of these systems that heat the upstream exhaust gases may work by altering one or more engine operating parameters, such as the ratio of air-to-fuel in the combustion chambers. Other systems may heat the exhaust gases upstream of the particulate trap with, for example, a burner disposed within an exhaust conduit leading to the particulate trap.
[0008] In systems that heat exhaust gases upstream of the particulate trap, the heated gases then flow through the particulate trap and transfer heat to the filter material and captured particulate matter. The transferred heat promotes regeneration of the filter by burning the accumulated soot.
[0009] U.S. Pat. No. 5,771,683 to Webb (“Webb”) discloses an auxiliary heat source including a cylindrical flame containment chamber. In particular, FIG. 3 of Webb discloses a relatively cylindrical chamber 42a. The efficiency—or completeness—of the combustion within the combustion chamber is effected by how the flame from the combustor mixes with the exhaust gas entering into the combustor housing. Further, the location of the combustion chamber in the cylindrical combustor housing may cause high flow resistance. This high flow resistance causes high backpressure on the turbine exit of the turbocharger. This high back pressure results in reduced fuel efficiency, lessened transient response, increased thermal loading, reduced high-altitude capability, and loss of engine rating capability, to name a few.
[0010] The disclosed regeneration assembly is directed toward overcoming one or more of the problems set forth above.
SUMMARY
[0011] In at least one embodiment, a device configured to at least partially regenerate a particulate filter is provided. The device comprises a housing, a fuel injector configured to inject fuel, and a combustion chamber. The device is characterized in that a cross section of the combustion chamber converges from an inlet to an outlet.
[0012] In at least another embodiment, a system for treating particulates of an engine's exhaust is provided. The system comprises a filter configured to collect particulate matter and a device configured to at least partially regenerate a particulate filter. The device comprises a housing, a fuel injector configured to inject fuel, and a combustion chamber. The device is characterized in that a cross section of the combustion chamber converges from an inlet to an outlet.
[0013] In yet another embodiment, an aftertreatment system for an engine is provided. The system comprises a filter configured to collect particulates from the engine's exhaust and a burner configured to regenerate the filter. In this embodiment, the burner comprising a conical combustion chamber.
[0014] In even yet another embodiment, an internal combustion engine is provided. The engine comprises an exhaust system configured to receive engine exhaust, a filter configured to collect particulate matter within the exhaust, a burner configured to regenerate at least some of the particulate matter within the filter, and an engine control module configured to control when the burner regenerates the filter. The engine is characterized in that the burner comprises a conical combustion chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic view of a portion of an embodiment of an internal combustion engine with exhaust system comprising an auxiliary regeneration device;
[0016] FIG. 2 is a cross sectional view of an auxiliary regeneration device comprising a cylindrical combustion chamber in accordance with one particular embodiment;
[0017] FIG. 3 is a cross sectional view of an auxiliary regeneration device comprising a partially conical combustion chamber in accordance with another particular embodiment; and
[0018] FIG. 4 is a cross sectional view of an auxiliary regeneration device comprising a fully conical combustion chamber in accordance with yet another embodiment.
DETAILED DESCRIPTION
[0019] Referring to FIG. 1 , an engine 10 connected to an auxiliary regeneration device (“ARD”) 20 and particulate filter 30 is shown.
[0020] Regeneration of filter 30 is controlled, at least in part, by engine control module (“ECM”) 40 . ECM 40 may sense engine speed 41 , engine load 42 , exhaust gas temperature 43 , and possibly other engine 10 parameters not shown. In this particular embodiment, ECM 40 also measures filter 30 temperature with temperature sensor 46 and detects whether a flame exists in ARD 20 with flame detection sensor 48 . ECM 40 may then use these measured parameters to generate signals for controlling regeneration, such as ARD 20 fuel control signal 44 , ARD 20 combustion air control signal 45 , and ignition control signal 47 to igniter 49 . The reader should appreciate that igniter 49 may be any device known in the art that may be used to ignite a combustible fuel 53 , such as a glow plug, plasma plug, multi-torch plug, or J-gap spark plug, for example.
[0021] ECM 40 generates ARD 20 fuel control signal 44 , ARD 20 combustion air control signal 45 , and ignition control signal 47 to control regeneration of filter 30 . Signal 44 controls the quantity of fuel 53 injected into ARD 20 provided by fuel supply 50 with fuel supply valve 51 . Signal 45 controls ARD 20 combustion air valve 52 , which controls the amount of pressurized air 101 sent to ARD 20 .
[0022] In this particular embodiment, ARD 20 receives pressurized air 101 in addition to exhaust gas 102 . By providing pressurized air 101 directly to ARD 20 , ARD 20 can regenerate filter 30 at most any engine 10 speed or load, including engine 10 idle. This particular design ensures that ARD 20 receives enough oxygen to ensure combustion at most all engine 10 loads.
[0023] Now referring to FIG. 2 , an ARD 20 with a cylindrical combustion chamber 240 is depicted.
[0024] ARD 20 comprises a combustor housing 210 , an inlet 211 where exhaust gas 102 enters, a fuel injector 230 for injecting fuel 53 , an igniter 49 for igniting the injected fuel 53 , a pressurized air inlet 271 for receiving pressurized air 101 , a combustor chamber 240 , and a flame stabilizer 250 . As can be seen, combustion chamber 240 is cylindrical and situated within and substantially coaxially with combustor housing 210 . The reader should appreciation, however, that combustion chamber 240 does not necessarily have to be positioned coaxially with combustor housing 210 .
[0025] In this particular embodiment, a flame stabilizer 250 is provided. Flame stabilizer 250 is well known in the art of combustors and provides the function of stabilizing the flame before exiting combustion chamber 240 . The reader should appreciate that any type of flame stabilizer 250 that is known in the art may be used and, in some cases, it may be desirable to not use any flame stabilizer 250 .
[0026] Another function of flame stabilizer 250 is as the flame passes through flame stabilizer 250 , the flow of gases accelerates and forms a high velocity flame jet in zone two 243 . The high jet momentum improves the turbulent mixing between the flame jet and the oxygen in the exhaust gas, thus enabling zone two 243 combustion to proceed more rapidly and more completely.
[0027] In this particular embodiment, an air swirler 244 is also depicted. Air swirler 244 aids in mixing of combustion air 101 with fuel 53 before the mixture is ignited. The reader should appreciate that air swirler 244 is generally known to one skilled in the art and that various air swirlers 244 may be used to achieve mixing of air 101 with fuel 53 . Furthermore, although FIGS. 2-4 depict an ARD 20 with flame swirler 244 , the reader should also appreciate that ARD 20 may also work without air swirler 244 .
[0028] During rich-burn combustion within chamber 240 , only a fraction of combustion air from pressurized air 101 required for complete combustion is supplied to combustion chamber 240 . Accordingly, in zone one 242 , there is excess fuel 53 during rich-burn combustion. This rich-burn combustion in zone one 242 within primary combustion chamber 240 results in the oxidation of fuel 53 into carbon monoxide, H 2 , and some other unburned hydrocarbon products. Combustion continues in zone two 243 when the incomplete combustion product from zone one 242 is discharged into combustor housing 210 , where it is mixed with O 2 from exhaust gas 102 . The efficiency—completeness—of the combustion in zone two 243 is significantly effected by how the flame jet from zone one 242 is mixed with exhaust gas 102 entering into combustion housing 210 .
[0029] Due to the constrain of the ARD 20 packaging, as well as the mixing requirements of the flame jet and the exhaust gas 102 jet, primary combustion chamber 240 within combustor housing 210 is often positioned directly in the path of exhaust gas 102 and inlet 211 . Locating combustor chamber 240 so that it intersects with inlet 211 and flow 102 generally increases the flow resistance of exhaust gas 102 . This increased flow resistance results in increased backpressure on the exit of turbine 100 , thus resulting in unacceptable performance penalties to engine 10 . Some of these performance penalties include a fuel consumption penalty, deteriorated transient response, increased thermal loading, reduced altitude capability, and loss of rating capability.
[0030] The conical combustion chambers 340 and 440 described in FIGS. 3 and 4 reduce the flow resistance of exhaust gas 102 within ARD 20 .
[0031] Referring now to FIG. 3 , an ARD 20 comprising a partially conical combustion chamber 340 is depicted. As can be seen, combustion chamber 340 comprises two sections, first section 341 and second section 342 . Second section 342 comprises a substantially cylindrical chamber with a constant diameter along its length. First section 341 , on the other hand, comprises a chamber with a converging diameter, which gives second section 342 a conical shape. Together, sections 341 and 342 give combustion chamber 340 a partially conical construction, which minimizes exhaust 102 flow resistance.
[0032] Referring now to FIG. 4 , an ARD 20 comprising a fully conical combustion chamber 440 is depicted. As can be seen, ARD 20 comprises a combustion chamber 440 with a shape that converges from its inlet to its outlet. In this embodiment, the diameter of chamber 440 converges along its entire length, thus giving chamber 440 a conical shape.
[0033] Although FIGS. 3 and 4 depict either a partially conical-shaped combustion chamber 340 or a fully conical-shaped combustion chamber 440 , the reader should appreciate that any combustion chamber 240 with a decreasing cross-sectional area may alternatively be used to achieve substantially similar results. For example, the combustion chamber 240 does not necessarily require a circular shape, thus giving it a cylindrical or conical shape. Instead, for example, the combustion chamber may have a square, rectangular, triangular, etc., cross sectional shape.
[0034] The partially conical combustion chamber 340 and fully conical combustion chamber 440 are depicted as being attached with flame stabilizers 250 . Although the depicted embodiments show the presence of flame stabilizers 250 , the reader should also appreciate that ARD 20 may be used without stabilizers 250 . Omitting flame stabilizers 250 from the design may reduce the cost of manufacture while providing for reduced exhaust gas 102 backpressure—for a combustion chamber 240 , 340 , and 440 of identical design, that is.
INDUSTRIAL APPLICABILITY
[0035] Referring again to FIG. 1 , a brief description of the operation of engine 10 with ARD 20 will be made.
[0036] In operation, fresh air 60 enters compressor 70 , where it is pressurized. From compressor 70 , pressurized air 101 is then either sent to combustion air valve 52 or to intake manifold 80 of engine 10 .
[0037] If sent to valve 52 , pressurized air 101 will be utilized—in part—to aid in combustion of fuel 53 in ARD 20 . If pressurized air 101 is sent to intake manifold 80 , pressurized air 101 will aid in providing combustion air within internal combustion engine 10 .
[0038] If the pressurized air was sent to intake manifold 80 , once air 101 takes part in the combustion process of engine 10 , exhaust gas 102 will enter exhaust manifold 90 . Exhaust 102 will be pressurized as a result of the combustion process and will be used to drive turbine 100 . In this embodiment, pressurized exhaust 102 drives turbine 100 , which is connected to compressor 70 for providing the energy required to pressurize fresh air 60 .
[0039] Once exhaust 102 exits turbine 100 , exhaust 102 enters ARD 20 , where, in combination with pressurized air 101 , it is used to provide the oxygen necessary for aiding in the combustion of fuel 53 in ARD 20 .
[0040] In this particular embodiment, ECM 40 receives engine speed signal 41 , engine load signal 42 , and exhaust gas temperature signal 43 from engine 10 . ECM 40 also determines whether a flame exists in ARD 20 via flame detection sensor 48 and the temperature of filter 30 via temperature sensor 48 . ECM 40 uses these parameters to generate control signal 44 for fuel supply valve 51 , control signal 45 to combustion air valve 52 , and control signal 47 for igniter 49 . Once ARD 20 generates combustion of fuel 53 , the heated regeneration air 290 is expelled towards filter 30 . The heated regeneration air 290 then facilitates burning of the soot and unburned carbon particles in filter 30 , thereby regenerating filter 30 . By controlling the amount of combustion air 101 and fuel 53 that is sent to ARD 20 , as well as ignition of igniter 49 , ECM 40 can precisely control regeneration of filter 30 .
[0041] It will be apparent to those having ordinary skill in the art that various modifications and variations can be made to the disclosed regeneration assembly without departing from the scope of the invention. Other embodiments of the invention will be apparent to those having ordinary skill in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the invention being indicated by the following claims and their equivalents.
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A system for treating particulates of an engine's exhaust is provided. The system comprises a filter configured to collect particulate matter and a device for regenerating the filter. The device comprises a housing, a fuel injector configured to inject fuel, an igniter configured to ignite the injected fuel, and a combustion chamber. The device is characterized in that the cross section of the combustion chamber converges from an inlet to an outlet.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to Korean Patent Application Number 10-2009-0113309 filed Nov. 23, 2009, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a parking lever cover for a vehicle, in detail, a technology associated with a cover making the external appearance of a parking lever bending a lot.
[0004] 2. Description of Related Art
[0005] A vehicle parking lever is a member that a user operates to park the vehicle that is usually disposed near console at the center of the vehicle.
[0006] Parking levers are recently modified in various ways to increase the volume of the console, prevent the parking levers from protruding, and improving the aesthetic appearance, while the bend angle has increased in the parking levers.
[0007] That is, the portion from the pivot axis to the end of the parking levers is not straight and bends, in which the bend angle reaches above 50°, even 60° to 70°.
[0008] When the bend angle of parking levers is too large, as described above, it is difficult to make the external appearance of the parking levers with a single cover as in the related art. This is because it is difficult to injection-mold a cover having a large bend angle from a single part and it also requires a very difficult work to attach the cover manufactured in this way to the lever frame.
[0009] The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
[0010] Various aspects of the present invention are directed to provide a parking lever cover for a vehicle which can be easily and firmly attached to a lever frame having a large bend angle, easily manufactured, and give the parking lever with an aesthetically elegant external appearance, thereby increasing commercial quality of the vehicle.
[0011] An aspect of the present invention provides a parking lever cover for a vehicle, which includes a lower cover covering the bend and the lower portion of the bend in a lever frame, a grip cover connected with the lower cover while covering the upper portion of the bend from the lower cover, and a fixing mechanism fixing the connected grip cover and the lower cover to the lever frame.
[0012] Another aspect of the present invention provides a parking lever cover for a vehicle, which includes a lower cover covering the bend and the lower portion of the bend in a lever frame, a grip cover connected with the lower cover while covering the upper portion of the bend from the lower cover, a fixing mechanism fixing the connected grip cover and the lower cover to the lever frame, and a cover cap fitted on the front end of the grip cover.
[0013] The present invention can be easily and firmly attached to a lever frame having a large bend angle, easily manufactured, and give the parking lever with an aesthetically elegant external appearance, thereby increasing commercial quality of the vehicle.
[0014] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a view illustrating a parking lever cover for a vehicle fitted on a lever frame.
[0016] FIG. 2 is a view showing the parking lever cover parts without the lever frame in FIG. 1 .
[0017] FIG. 3 is a cross-sectional view showing an assembly of the parts of FIG. 1 .
[0018] FIG. 4 is a view showing when a grip cover is combined with a cover cap, seen from above.
[0019] FIG. 5 is a three-dimensional cross-sectional view of the combined grip cover and the cover cap.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0021] Referring to FIGS. 1 to 5 , the present invention generally includes a lower cover 3 covering a bend S and a lower portion of bend S of a lever frame 1 , a grip cover 5 connected with lower cover 3 while covering an upper portion of bend S of lever frame 1 , and a fixing mechanism fixing connected grip cover 5 and lower cover 3 to lever frame 1 .
[0022] Grip cover 5 defines a straight portion that the driver grips, and lower cover 3 covers the outside of the lower portion from grip cover 5 of lever frame 1 , in which lower cover 3 covers most of bend S and is connected with grip cover 5 at the end of bend S in lever frame 1 . Grip cover 5 is connected with lower cover 3 , forming a slope.
[0023] Lower cover 3 has an integral arc shield 7 at the lower portion to cover the parking brake system and an integral locking hook 9 , which is secured to lever frame 1 , at the upper portion of the portion connected with grip cover 5 . The arc shield may be monolithically formed with the lower cover.
[0024] Lever frame 1 has groove or holes where locking hook 9 are fitted such that locking hook 9 is fitted, as shown in FIG. 3 .
[0025] In various embodiments, the fixing mechanism includes a locking rib 13 extending between grip cover 5 and lever frame 1 from the lower portion of the portion connected with grip cover 5 of lower cover 3 and having a locking hole 11 , and a fixing screw 15 tightened to lever frame 1 from under grip cover 5 through locking hole 11 of locking rib 13 .
[0026] Lower cover 3 is combined with grip cover 5 by, with lower cover 3 fitted on lever frame 1 , fitting grip cover 5 on lever frame 1 from the front end and tightening fixing-screw 15 to lever frame 1 through grip cover 5 and locking rib 13 of lower cover 3 .
[0027] Alternatively, the fixing mechanism may be configured by pressing a pin instead of fixing screw 15 .
[0028] A cover cap 17 is fitted on the front end of grip cover 5 and grip cover 5 has a fixing hole 18 and a fixing groove 19 which fix cover cap 17 .
[0029] Cover cap 17 is formed to smoothly take the outer shape of grip cover 5 , without protruding outside the outline of grip cover 5 . That is, cover cap 17 finishes by itself the outer shape of grip cover 5 for the entire design and has a different color from grip cover 5 to improve the external appearance of the parking lever.
[0030] Although cover cap 17 may differ only in color, it is possible to use a different material from grip cover 5 to give a more elegant feel.
[0031] Fixing hole 18 is formed inside fixing groove 19 in grip cover 5 and cover cap 17 is fitted to grip cover 5 by a snap 21 through the fixing hole at two or more positions such that fixing hole 18 and snap 21 are not exposed to the outside.
[0032] In various embodiments, cover cap 17 is fitted to grip cover 5 at the top and both sides by a snap 21 and a retaining protrusion 23 , which is inserted in grip cover 5 , is formed at the lower portion of cover cap 17 .
[0033] Retaining protrusion 23 prevent cover cap 17 from protruding down from grip cover 5 , with the bottom of cover cap 17 leveled with the bottom of grip cover 5 .
[0034] Accordingly, a grip groove 25 where retaining protrusion 23 is inserted is integrally formed in grip cover 5 . For example, the grip groove may be monolithically formed in the grip cover.
[0035] Lower cover 3 , grip cover 5 , and cover cap 17 each have a shape easily formed to injection-mold a single part and can be assembled while easily covering lever frame 1 having a large bend angle.
[0036] Further, in various embodiments including the embodiment described above firmly snap-fit the parts to lever frame 1 , using fixing screw 15 , snap 21 , and locking hook 9 and it is possible to implement aesthetically elegant external appearance of the parking lever, using the specific structure of cover cap 17 and grip cover 5 .
[0037] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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A parking lever cover for a vehicle can be easily and firmly attached to a parking lever frame having a large bend angle, easily manufactured, and provide the parking lever with an aesthetically elegant external appearance, thereby increasing commercial appeal of the vehicle.
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FIELD OF THE INVENTION
[0001] The present invention relates to an improved turbo encoder and related methods.
BACKGROUND OF THE INVENTION
[0002] Turbo coding is an advanced error correction technique widely used in the communications industry. Turbo encoders and decoders are key elements in today's communication systems to achieve the best possible data reception with least possible errors. The basis of turbo coding is to introduce redundancy in the data to be transmitted through a channel by serial/parallel concatenation of convolutional encoders. Using this redundant data the component decoders working in iterative passion helps to recover original data from the received data. This feature makes turbo encoding all the more popular.
[0003] FIG. 1 shows a WCDMA turbo encoder specified in 3GPP TS 25.212 specifications entitled “Multiplexing and channel coding (FDD)”. WCDMA turbo encoder is parallel-concatenated recursive systematic convolutional encoder (RSC) with random interleaver in between. The first RSC ( 3 ) works on actual input data and the second RSC ( 4 ) works on interleaved data provided by the interleaver ( 2 ).
[0004] The input to the turbo encoder ( 1 ) is a 32-bit packet and the output from the turbo encoder ( 1 ) is also a 32-bit packet resulting from multiplexed output of both RSCs ( 3 & 4 ) by puncturing the non-systematic bit of the second RSC ( 4 ). As one stream of input bit results in three output bit streams, the rate of this turbo code is 1/3. After finishing encoding of the input bits both the RSCs ( 3 & 4 ) are flushed out such that the state of both RSCs ( 3 & 4 ) becomes zero. While flushing the encoder ( 1 ), the output tail bits of the first RSC ( 3 ) systematic bit followed by parity bit are packed along with the encoded stream. Similarly the output tail bits of second RSC ( 4 ) non-systematic bit followed by parity bit are packed to the output stream.
[0005] In a conventional approach, the parity output of the RSC with respect to state, follows 1 st order Markov chain. The conventional approach uses a LUT which gives next state and the output for the given input and present state. The WCDMA turbo encoder table is given in FIG. 2 . The input to the 1 st RSC is given bit by bit from the input data and the input to the 2 nd RSC is given from the input data by using pre calculated interleaver table. The input systematic bit is packed with the output parity bits of both the RSCs in an output register.
[0006] As both input and output are 32 bit packed and each encoder parity output depends on the present state, the implementation involves many logical, shift and memory read/write operations. It requires at least one memory read for encoding single bit to get output or next state information for each RSC and also needs masking of the required bits and shifting to their respective positions and packing with the output register. The above steps are repeated 32 times to process each 32 bit packed input and whenever the output register is full of 32 bits it is stored to the output array.
[0007] Further the conventional approach used for implementing turbo coding processes one input bit at a time. This is not the best way and consumes lot of operations. A new approach, which works on four input bits at a time, has been proposed.
SUMMARY OF THE INVENTION
[0008] To obviate the aforesaid drawbacks, the object of the instant invention is to provide an improved turbo encoder
[0009] Another object of the invention is to provide an encoder that operates on multiple bits simultaneously.
[0010] To achieve the aforementioned objects the invention provides An improved turbo encoder comprising multiple interleaved parallel concatenated recursive systematic convolutional encoder wherein each recursive systematic convolutional encoder is provided with an LUT that simultaneously provides the output bit pattern as well as the next state value corresponding to a defined set of multiple input bits and present state for operating said recursive systematic convolutional encoder.
[0011] The said LUT is shared across multiple recursive systematic convolutional encoder.
[0012] An improved method for turbo encoding comprising the steps of:
determining a first output bit pattern corresponding to received multiple input bits of input bit stream employing an LUT; interleaving the said input bit stream to provide multiple interleaved output bit streams; determining a second output bit pattern for multiple bits of each said multiple interleaved output bit stream employing an LUT; generating the output bit stream from said primary and secondary output bit patterns wherein all the output bit patterns are generated using LUTs operating on a set of multiple bit at a time.
[0017] Each said output bit pattern of said LUT is generated by a state machine for multiple input bits.
[0018] The said LUT provides the next state information generated by said state machine as per multiple input bits and present state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows a WCDMA turbo encoder specified in 3GPP TS 25.212 specifications.
[0020] FIG. 2 describes a WCDMA turbo encoder table for calculating next state and parity output.
[0021] FIG. shows an output word format after completion of turbo encoding for 32 bit input word.
[0022] FIG. 4 shows a first RSC's LUT for calculating next state and the output pattern.
[0023] FIG. 5 shows a second RSC's LUT for calculating next state and the output pattern.
[0024] FIG. 6 shows an output word packing using patterns obtained from both RSCS.
[0025] FIG. 7 shows an output pattern for LUT 1 and LUT 2 .
[0026] FIG. 8 shows a CDMA2000 Turbo encoder specified in 3GPP2 C.S0002-D.
[0027] FIG. 9 shows an output pattern for LUT 1 and LUT 2 for rate 1/2 CDMA2000 turbo encoder.
[0028] FIG. 10 shows an output pattern for LUT 1 and LUT 2 for rate 1/5 CDMA2000 turbo encoder.
[0029] FIG. 11 shows an output pattern for LUT 1 and LUT 2 for rate 1/4 CDMA2000 turbo encoder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The instant invention is explained for encoding four bits simultaneously at the rate 1/3 as an example. However it is not limited to said values and any person skilled in the art can use it for other rates and different number of bits as well. The proposed approach can be extended to implement encoding in different applications like CDMA2000 turbo encoder.
[0031] FIG. 2 shows the input and output words being encoded at the rate of 1/3. The encoding of complete 32 bit word, results in three 32 bit output words. The S j is the j th systematic bit; P j 1 is parity output of first RSC and P j 2 is parity output of second RSC.
[0032] The systematic input, parity output of first RSC ( 3 ) and the second RSC ( 4 ) are distributed amongst the three output words, each separated by two bits. Thus four input bits are continuously encoded with each RSC ( 3 or 4 ) following its own LUT for calculating output pattern of 12 bits each. The result of both RSCs ( 3 & 4 ) is ‘OR’ed to obtain the actual output pattern. The abovementioned LUT also provides the next-state information apart from the output pattern.
[0033] The LUTs for both RSCs ( 3 & 4 ) of turbo encoder shown in FIG. 1 are shown in FIGS. 4 & 5 respectively for only few combinations of the input and the present-state. The LUT of first RSC ( 3 ) contains systematic and parity output bits for the four continuous input bits. The LUT of second RSC ( 4 ) contains only parity output bits for four continuous input bits as non-systematic bits are punctured. The description of the table formation is explained in detail in the next section.
[0034] The approach works in two parts. Since the input is an array of 32 bits, the input bits, which are complete 32 bit packed are handled in first part and the incomplete bits in last word are handled in the second part. The proposed new approach is used in the first part and the conventional approach is used for the second part.
[0035] Since a nibble of four bits is encoded at a time, the inner loop runs eight times to finish the encoding of 32 bits resulting in eight output patterns and the outer loop runs the number of times the number of words are to be encoded. The non-systematic input bits to the second RSC ( 4 ) are packed into 32 bit register using pre-calculated interleaver table before the onset of the encoding of the inner loop. Once encoding of the inner loop is completed, all the eight output patterns are packed into the three words. The output words are packed from patterns according to the word boundaries, as shown in FIG. 6 . Thus the outer loop includes the non-systematic bit packing and output packing apart from encoding the inner loop. The remaining bits in last incomplete word can at most be 31 bits, which can be processed one bit at a time with the conventional method.
[0000] LUT Generation
[0036] As described above, for every four bits, the output pattern results from both RSCs ( 3 & 4 ) and the parity output positions therein obtained from both the RSCs ( 3 & 4 ) are different thereby requiring individual LUTs for each RSC. Each element of the LUT requires 16 bits, upper 4 bits represent the next-state and the lower 12 bits represents the output pattern of the corresponding RSC. For a given state there are sixteen different combinations of inputs (2 4 =16), and eight such possible states in case of WCDMA turbo encoder, which is containing 3 memory elements (2 3 =8). Therefore the table size of each LUT is 256 bytes (128 elements and each of 2 bytes).
LUT 1 for First RSC
[0037] For all possible states and input bits, the parity output bits after every input bit and next state after four continuous input bits are calculated using FIG. 2 . As the output steam contains systematic bits, the input bits and parity bits are placed in respective positions to follow the output word format described in FIG. 3 . The positions where the parity output from second RSC is to be placed are filled with zeros. Accordingly the LUT 1 pattern ( 6 ) for first RSC ( 3 ) looks as described in FIG. 7 .
[0000] LUT 2 for Second RSC
[0038] The LUT 2 pattern ( 7 ) for second RSC ( 4 ) is shown in FIG. 7 . The party output bit after every input bit and the next state after four continuous input bits are calculated using FIG. 2 . In the second RSC ( 4 ), the output is only the parity output. Hence the parity output bits of second RSC ( 4 ) are placed in respective positions and the position where the systematic and parity output bits from first RSC are to be placed is filled by zeros.
[0000] Complexity Analysis and Comparison
[0039] The complexity of this approach is analyzed against the conventional approach. As per the proposed approach, it encodes 4 bit input pattern into 12 bit output pattern and requires two memory loads, a single ‘OR’ operation and a mask operation for the required pattern. The updating next state of each RSC takes one mask and one shift operations for every 4 input bits. Also, it consumes few more logical operations for packing of non-systematic bits and packing of output patterns into output words. Using conventional approach, each RSC requires one memory read, one mask operation for the required bit, and one shift operation for the respective position and ‘OR’ operation for packing to the result. Also few more logical operations are required for un-packing of systematic input word.
[0040] The proposed approach explained on WCDMA rate 1/3, however runs four times faster than the conventional approach, as it requires only one fourth of the operations. Further it can be extended to other standards such as CDMA2000 turbo encoding which supports various rates by puncturing.
[0041] The CDMA2000 turbo encoder shown in FIG. 8 supports various coding rates 1/2, 1/3, 1/4 and 1/5 with two feed forwards polynomials ( 8 & 9 ) (1+D+D 3 , 1+D+D 2 +D3) and one feed back polynomial ( 10 ) (1+D 2 +D 3 ). The proposed LUTs are used for encoding. The calculation of contents of both LUTs is explained further. Care should be taken according to the coding rate and puncturing while calculating output pattern of LUTs.
[0042] The output streams for different rates from CDMA2000 turbo encoder look as follows.
For rate 1/2: X 1 , Y 1 , X 2 , Y′ 2 , X 3 , Y 3 , X 4 , Y′ 4 For rate 1/3: X 1 , Y 1 , Y′ 1 , X 2 , Y 2 , Y′ 2 , X 3 , Y 3 , Y′ 3 , X 4 , Y 4 , Y′ 4 For rate 1/4: X 1 , Y 1 , Z 1 , Z′ 1 , X 2 , Y 2 , Y′ 2 , Z′ 2 , X 3 , Y 3 , Z 3 , Z′ 3 , X 4 , Y 4 , Y′ 4 , Z′ 4 For rate 1/5: X 1 , Y 1 , Z 1 , Y′ 1 , Z′ 1 , X 2 , Y 2 , Z 2 , Y′ 2 , Z′ 2 , X 3 , Y 3 , Z 3 , Y′ 3 , Z′ 3 , X 4 , Y 4 , Z 4 , Y′ 4 , Z′ 4
[0047] For rate 1/3, the LUTs remain the same as that of WCDMA as there is no difference in encoding. In case of rate 1/2, along with systematic bit X i either the parity of RSC 1 Y i or RSC 2 Y′ i is sent alternatively. Each element of LUT requires 16 bits, upper 4 bits represents the next-state while the lower 8 bits represent output pattern of the corresponding RSC as shown in FIG. 9 and remaining 4 bits are unused. Zeros in LUTs fill the unused portion of bits. After packing such eight output patterns, the output of complete 32 bit word input is formed into two 32 bit output words (8*8 bits=64 bits). The table size of each LUT required is 256 bytes (128 elements and each of 2 bytes).
[0048] For the rate 1/5 each element of LUT requires more than 16 bits so the element size can be 32 bits. The upper 4 bits represents the next-state while the lower 20 bits represents output pattern of corresponding RSC as shown in FIG. 10 . After packing eight such output patterns the output of complete 32 bit word input is formed into five 32 bit output words (8*20 bits=160 bits). The table size of each LUT required is 512 bytes (128 elements and each of 4 bytes).
[0049] For rate 1/4 also each element of LUT requires more than 16 bits so the element size can be 32 bits. The upper 4 bits represents the next-state while the lower 16 bits represents the output pattern of corresponding RSC as shown in FIG. 11 . After packing eight such output patterns the output of complete 32 bit word input is formed into four 32 bit output words (8*16 bits=128 bits). The table size of each LUT required is 512 bytes (128 elements and each of 4 bytes).
[0050] In this paper, improved turbo encoding has been proposed and compared against the computations required with conventional method. This improved turbo encoding handles 4 bits at a time, and the same logic can be extended for 8 input bits at a time, as the cost of 32 times memory, which is not advisable. The proposed approach is described in detail for WCDMA turbo encoder. A brief idea for implementing this in other standards such as CDMA2000, which can support other coding rates such as 1/2, 1/4 and 1/5 apart from 1/3, is also presented. The approach works efficiently for all coding rates, as the LUT inherently does the job of puncturing and multiplexing according to the coding rate.
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A turbo encoder comprising multiple interleaved parallel concatenated recursive systematic convolutional encoder wherein each recursive systematic convolutional encoder is provided with an LUT that simultaneously provides the output bit pattern as well as the next state value corresponding to a defined set of multiple input bits and present state for operating said recursive systematic convolutional encoder. Thus the approach works with improved LUTs, which do the job of both puncturing and multiplexing for four input bits at a time. Theoretically the proposed approach works almost four times faster than the conventional approach, which can handle only one input bit at a time.
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This application claims the benefit of Provisional Application No. 60/374,240, filed Apr. 19, 2002.
FIELD OF THE INVENTION
The present invention generally relates to storage and display items. More specifically, the present invention relates to shelving and even more specifically to adjustable shelving adapted to conform to a desired dimension.
BACKGROUND OF THE INVENTION
As our lifestyles become more and more complex, we desire devices that enable organization. This helps to bring our lives some sort of normality. Shelving products have evolved since the days of the uncovered “cup boards” in the late 18 th century to the modern cabinets with decorator doors and movable shelving as seen today. Though the shelving is typically “movable” it is not easy to move. The shelves must be unloaded, some sort of stop or mounting on two or more corners must be removed, and repositioned, the shelf reinstalled and then the shelf can again be loaded. This is a time consuming and labor-intensive project. As such, it is usually only done when the shelving is installed and never moved again. Many people are unaware that their shelving is movable.
As far a width adjustment, there are very few choices. For the most part this is restricted to buying or building the shelf or bookcase at the desired width. That will never be changed.
There are some “cup rack” type supports that offer a width adjustment. These usually include a base with an extension on one side. One of the problems is since there is an extension on a side the upper surface now has two levels, one for the base and one for the extension. This uneven surface is not only unattractive, but does not lend itself well to stacking items. Also, these devices do not provide for vertical or height adjustment.
SUMMARY OF THE INVENTION
In one aspect, the invention features a shelf with an adjustable height first leg and an adjustable height second leg positioned adjacent to the first leg. A leg extension is mounted to the first leg and the second leg, and positioned substantially orthogonal thereto. Also, a shelf portion is used that is capable of being received by the leg extensions, the shelf portion being movably mounted thereon, whereby width adjustment is enabled by varying placement of the shelf relative to the leg extensions. The shelf portion and the leg extensions may be movably mounted one to the other by a tongue in groove. In the preferred embodiment the leg extension includes the groove and the shelf portion includes the tongue.
The system may also include the adjustable height first leg and adjustable height second leg as each being comprised of a first portion and a second portion, which are movably mounted one to the other. The two-part construction of the legs may also include a lock releasably securing the first portion to the second portion. The lock may be a device such as a pawl, a screw or a pin. The pawl can be pivotally mounted to the first portion, and may include a bias, such as a spring or more specifically a spring coil. The second portion would include a rack and the bias applies a force to enable engagement of the pawl and the rack.
The device may also include a comprising an end cover, which is capable of receiving the leg extension and end cover may be modifiable in length. This can be accomplished by providing a plurality of undercuts on the end cover.
The first leg and the second leg may include a foot positioned on a distal end thereof and opposite to the shelf portion, as a support on which the shelf may stand. The feet can be mounted to the legs by providing the first leg and the second leg each with a mounting tab positioned on a distal end thereof and opposite to the shelf portion. A mounting tab receiver is then positioned adjacent to the shelf portion on the leg opposite to the mounting tab. This also enables stacking of one shelf on the other by removing the feet and inserting the mounting tabs of one shelf in the mounting tab receivers of another shelf, thus releasably securing one to the other.
In another aspect, the invention includes a method of providing an adjustable shelf as described, placing the device in said specific area and adjusting the height of the first leg and the second leg to provide a preferred vertical position of the shelf portion. The horizontal adjustment is then provided by adjusting the placement of the first leg and the second leg, thereby allowing the shelf portion to move relative to, and yet be supported by, the leg extensions.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects of this invention, the various features thereof, as well as the invention itself, may be more fully understood from the following description, when read together with the accompanying drawings, described:
FIG. 1 is an isometric front, upper view of an adjustable shelf produced in accordance with the present invention.
FIG. 2 is an isometric rear, lower view of an adjustable shelf produced in accordance with the present invention.
FIG. 3 is an isometric front, upper view of an adjustable shelf with the end covers shortened to allow access to the tab receivers thus enabling stacking of multiple shelves, the shelves made in accordance with the present invention.
FIG. 4 is an exploded isometric front, upper view of an adjustable shelf produced in accordance with the present invention.
FIG. 5 is an exploded isometric upper view of the upper portion of a leg, a leg extension and a section of a shelf portion, showing the assembly, the shelf produced in accordance with the present invention.
FIG. 6 is an exploded rear isometric view of a leg and foot assembly produced in accordance with the present invention.
FIG. 7 is an exploded isometric view of a pawl and rack height adjustment lock produced in accordance with the present invention.
FIG. 8 is an isometric view of a leg and foot assembly with a pin lock, the device produced in accordance with the present invention.
FIG. 9 is an isometric view of a leg and foot assembly with a screw knob lock, the device produced in accordance with the present invention.
FIGS. 10 a and 10 b are side views of an adjustable shelf in retracted and vertically extended positions respectively, the device produced in accordance with the present invention.
FIGS. 11 a and 11 b are rear views of an adjustable shelf in a vertically retracted position showing both compact and extended horizontal positions respectively, the device produced in accordance with the present invention.
For the most part, and as will be apparent when referring to the figures, when an item is used unchanged in more than one figure, it is identified by the same alphanumeric reference indicator in all figures.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is an adjustable shelf that enables both vertical and horizontal adjustment. The fully assembled shelf 12 is shown in FIG. 1 . This is a front, side, upper view that shows the preferred legs 14 which are comprised of a first portion 16 and a second portion 18 . This two-part telescoping leg assembly allows for compact storage and an elegant appearance. A lock 20 , shown here as a pawl 22 , provides a set leg length that can be determined by the user. On the bottom of the second portion 18 of the leg 14 , is positioned a foot 24 . The foot 24 is optimally releasably mounted to the end of the second portion 18 , but can be permanently fixed thereto. The advantage of the releasable mounting will be discussed later.
The upper end of the first portion 16 supports a planar surface including a shelf portion 26 and may include one or more end covers 28 . The end covers 28 and the shelf portion 26 comprise the supportive surface on which items can be stored.
In FIG. 2 the “under side” of the shelf 12 is shown from the back. Here in the preferred embodiment the shelf portion 26 is shown to be open from the bottom. Leg extensions 30 are supported to the upper portions of the legs 14 and extend toward the other leg. This provides a “track” that enables the shelf portion 26 to move with respect to, while being supported thereon. The inside edges of the leg extensions 30 can be moved closer to or further apart from each other thus enabling a variation in shelf width.
The height adjustment of the legs 14 is more clearly seen in this figure. In this, the preferred embodiment, the second portion 18 of the leg 14 includes a rack 32 . This rack 32 can be molded into the second portion 18 , as shown here or it can be a separate part that is mounted thereto. In either case, the rack includes teeth that provide a graduated vertical set of “steps” for attachment of the pawl to conditionally secure the first and second portions of the legs. This provides an easy and efficient method of adjustment of the vertical aspect of the shelf.
In FIG. 3 , at the top end of the first portion 16 of the leg 14 is a leg base 34 . The leg base 34 has a primary function of providing a cap for the upper edge of the first portion 16 of the leg 14 as well as providing an attachment for the leg extension (item 30 shown in FIG. 2 ). The leg base 34 can be exposed by either shortening the end covers 28 , or by extending the legs 14 further away from one another.
The leg base 34 may include one or more mounting tab receivers 36 . These receivers 36 can take a variety of shapes and configurations, but are intended to mate with mounting tabs (not shown here) on the bottom end of the second portion 18 of the leg 14 . The foot 24 is releasably fastened to the second portion 18 by the foot also including tab receivers, similar to those in the leg base 34 . This combination allows the user to stack a second shelf on a first shelf by remove the foot 24 from the second shelf and placing the mounting tabs exposed by removing the foot 24 , and placing the tabs into the receivers 36 on the leg base 34 of the first shelf. This allows secure stacking of one shelf on the other.
An exploded view of the invention 12 is shown in FIG. 4 to better shown the relationship between the parts. The leg extension 30 is shown here to be releasably secured to the leg base 34 . This is done to provide for a more efficient “knock down” of the product to reduce shipping costs. A locking tab 38 is used to articulate with a hole in the bottom of the leg extension 30 and they are supported together by the leg protrusions 40 that mate with the protrusion cavities 42 on the leg extension 30 . This is only one method of assembly of these parts and is not intended to limit the scope of the invention. The invention can also be manufactured such that the leg extensions and the leg base 34 are one part.
The shape of the leg extension 30 is shown here to mate with and allow movement of the shelf portion 26 relative thereto. The ability of the shelf portion 26 to slide against the leg extension 30 and yet be supported by the leg extensions 30 , allows for horizontal adjustment of the leg positions.
The vertical adjustment is provided by the second portion 18 , which is received by the first portion 16 of the leg 14 . The lock in the form of a pawl 22 is shown to also be exploded from the first portion 16 . The details of this and other locks will be discussed later.
At the lower distal end of the second portion 18 are more clearly shown the mounting tabs 44 . These tabs 44 are shown here to be substantially in the shape of a cylindrical pin, but this general shape and specific details are not critical to the novelty of the invention. The tab receivers 46 in the feet 24 are made to fit the tabs 44 , thereby releasably locking them together. In a similar manner each leg base 34 also includes a receiver 36 to allow for stacking of the shelves 12 , as previously noted.
Further detail of the function and assembly of the leg 14 via the leg base 34 to the leg extension 30 is shown in FIG. 5 . The leg protrusions 40 are received by the protrusion cavities 42 of the leg extension 30 . The locking tab 38 includes a pin 48 which extends downward from the underneath side of the tab 38 . This pin 48 also extends through a cavity 42 to be received by a hole in the bottom of the extension 30 . With the protrusions 40 positioned within the cavities 42 (as shown by the arrow 50 ) and the pin 48 securing them in place, the structure of the leg 14 with the leg extension 30 via the leg base 34 is functionally one rigid unit.
The shelf portion 26 is received by the leg extension 30 as shown by the second arrow 52 . Though the shelf portion 26 can take a variety of forms, what is shown is considered by the applicants to be the preferred embodiment. The bottom side of the shelf portion 26 is open except for the “C” shaped edges 54 . These “rails” run the length of the shelf portion 26 to provide for structural rigidity of the shelf portion 26 without excess material to cause potential part interference, added weight or cost. The shelf portion also includes a pair of tongues 56 . The tongue 56 has a multi-fold purpose. First the material placement adds to the section modulus of the shelf portion about the axis that would see flexion when the shelf is loaded. This adds to the strength of the shelf portion especially when the shelf is at an extended position where a minimal amount of contact is made between the shelf portion 26 and the leg extensions 30 .
The second purpose to the tongue 56 is as a tracking guide along the grooves 58 located within the leg extensions 30 . This tracking assistance reduces the likelihood for the shelf portion 26 to bind when moving along the leg extension 30 when the shelf width is being changed.
The third advantage to the tongue 56 and groove 58 combination is during the loading of the shelf. When items are placed on the shelf portion 26 , during its intended purpose of item storage, the weight of these items will cause the leg extensions 30 to flex slightly along an axis parallel to the long axis of the grooves 58 . This is due to the reduced section at the grooves due to the presence of the grooves 58 . The upper portion is open. When this happens the outside upper edges of the groove 58 will pinch together slightly, grabbing the tongue positioned there between. The friction due to the contact of the tongue and grooves acts as a “lock” to further stabilize the shelf and prevent it from moving from side to side when it is loaded. This eliminates the need for further locking of the shelf portion 26 to the leg extensions 30 when the shelf is in place. Under more extreme conditions, an additional lock mechanism may be used.
As such, it is understood that any form of locking mechanism known in the art can be added between the shelf portion 26 and the leg extensions 30 .
A single leg 14 is shown in FIG. 6 . Here the first portion 16 is shown with a pair of ears 60 , which hold the pawl 22 as it is pinned through the pawl hole 62 and the ear holes 64 . The pawl includes a pawl handle 66 and a pawl tip 68 . The handle acts to enable the user to manipulate the pawl tip 68 to disengage it from the rack teeth 32 in the second portion 18 of the leg. The mounting tabs 44 are received by the tab receivers 46 in the foot 24 . Also as previously noted, the mounting tabs 44 of another leg can be received by the receivers 36 in the leg base 34 .
A more detailed view of the locking mechanism is shown in FIG. 7 . The pawl 22 is shown as removed from the first portion 16 showing the rack window 70 . This window 70 allows access of the pawl tip 68 to the rack teeth 32 . The pawl 22 can be manufactured from an number of materials but is preferably made from a plastic. This is inexpensive and allows for good elastic properties. The elastic properties are relevant in that in the preferred embodiment the pawl also includes a spring coil 72 . This spring can be a separate item that is attached to the pawl 22 or as in this case a molded portion of the pawl 22 . The free end of the spring coil 72 is positioned on the ridge 74 located above the window 70 and on the first portion 16 . The spring then pushes the handle 66 of the pawl 22 out away from the rack 32 , about the pivot of the pawl hole 62 and the ear holes 64 , thus engaging the pawl tip 68 into the rack teeth 32 . To disengage the pawl tip 68 from the rack 32 , the handle 66 is pressed in toward the first portion 16 , pulling the tip away form the rack teeth 32 . This flexes the spring 72 so when the handle 66 is released by the user, the bias from the spring 72 reengages the tip 68 and the rack 32 , locking one to the other.
Another form of locking of the first portion 16 and the second portion 18 is accomplished by a pin 76 as shown in FIG. 8 . Here the pin 76 is shown as it would be assembled into a first hole 78 located in the first portion 16 and also one of a plurality of second holes 80 located in the second portion 18 . The first portion 16 is still able to move along the long axis of the second portion 18 , as previously noted, only the locking mechanism is comprised of the pin 76 positioned through a pair of properly aligned holes ( 78 and 80 ).
To achieve an infinite variety of height adjustments, a screw knob can be used for height adjustment. This is illustrated in FIG. 9 . Here a knob 82 with a pressure pin 84 mounted to the end also includes a threaded portion 86 . The threaded portion 86 is received by the mating threads 88 on a receiver 90 , which is mounted to the first portion 16 . A hole (not shown) is located within the receiver 90 to allow the pressure pin 84 access through the first portion 16 to contact the second portion 18 . The friction between the pin 84 and the second portion 18 is provided and varied by the amount of tightening of the knob 82 , thus pushing the pin 84 more firmly against the second portion 18 .
The height adjustment of the device is shown in a side view in FIGS. 10 a and 10 b . The minimum height of “Y 1 ” is shown in FIG. 10 a where the pawl 22 is at the bottom of the rack 32 . The highest position “Y 2 ” is shown in FIG. 10 b . The difference being the relative positioning of the first portion 16 to the second portion 18 and as held in place by the pawl 22 and rack 32 . The rack 32 design is also shown here to be of a saw-tooth design. This provides a vertical slant upward followed by a substantially horizontal “ledge”. The pawl tip 68 includes a shape that nearly matches this “V”, thus providing a locking of the pawl 22 to prevent downward movement of the first portion 16 . In this application, this design is beneficial in that little resistance is offered to restrict vertical movement of the first portion relative 16 to the second portion 18 . This allows the user to lift the shelf portion 26 , and the weight of the second portion 18 and the feet 24 will allow the second portion to “fall” away from the first portion 16 , thus “ratcheting” out to fit the height needs of the user. When the user desires a lower height, the user needs only to press the handle 66 of the pawl 22 in, releasing the pawl tip and allowing the first portion 16 to freely move relative to the second portion 18 .
FIGS. 11 a and 11 b show the horizontal width adjustment provided by the device. The narrow position is shown by the dimension “X 1 ” in FIG. 11 a and the widest dimension is depicted by “X 2 ” in FIG. 11 b . As can be seen here, the shelf portion 26 remains at a constant place in both positions. The relative position of the legs 14 and the gap between the leg extensions 30 increases from “Xa” to “Xb”. This provides the increased width. It is understood that both the height adjustment, as shown in FIGS. 10 a and 10 b , as well as the width adjustment, as shown here, can both be performed together in any combination allowed by the specific design of the elements of the device. Thereby providing both width and height adjustment in a single shelf to fit any of an infinite number of space requirements.
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A shelf stores items and provides for organized and attractive display with ease of item access. Conforming to a defined physical environment or variable storage space optimally requires the shelf to provide for both vertical and horizontal adjustment. Here this is accomplished by a pair of legs that are telescopic (to reduce size) and can be locked at a height (vertical adjustment) by use of a pawl, pin, screw or other fastener known in the art. The shelf includes a planar surface that is comprised of a shelf portion, which is supported on each distal end by a leg extension. The leg extensions are mounted to the upper area of the legs. The leg extensions are received by the shelf portion, being movably mounted thereto. This allows for horizontal (width) adjustment. An end cover can be used to provide a flat surface that is consistent with the upper surface of the shelf portion. Feet are added to provide a more solid footing, the feet being removable and providing a mounting tab at the end of the legs and a mounting tab receiver at the opposite end of the legs. This allows for multiple shelves to be securely mounted one on the other.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a divisional application of co-pending application Ser. No. 09/738,228, entitled Method for Building an Interposer onto a Semiconductor Wafer Using Laser Techniques, filed on Dec. 15, 2000 in the name of John L. Pierce.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of integrated circuits, and more particularly, to a wafer interposer assembly and a system for building the same.
BACKGROUND OF THE INVENTION
[0003] Without limiting the scope of the invention, this background of the present invention will be described with reference to building a semiconductor wafer-interposer, as an example. After the introduction of the integrated circuit, engineers have worked diligently to produce electronic devices that are smaller and more functional than the previous versions of the devices. Advances in manufacturing techniques allow more components to be integrated into a smaller semiconductor die. More components within the die enable engineers to design devices having greater efficiency and more convenient functions. However, increasing the number of components within the die can adversely affect the size and manufacturing costs of the device.
[0004] Each new device design often requires smaller, more efficient semiconductor packages to perform advanced functions and consume less power and space. Die size and number of contact pads influence the size of a semiconductor package. More components within the die require more contact pads, which facilitate electrical connections or interfaces between the die to other systems in the device. However, traditional connection techniques are not very space efficient.
[0005] Traditionally, die design was limited because all connections between the components of the die interfacing systems were through the peripheral edges of the chip (for wire bonding) or through a standard pin or pad layout defined by a standardization body, such as the Joint Electrical Dimensional Electronic Committee (JEDEC). The interconnection requirements, therefore, have traditionally driven the die layout.
[0006] Although space efficiency may be improved by using a semiconductor wafer-interposer, it is difficult to attached a separate interposer to a semiconductor wafer and maintain close dimensional tolerances. Close tolerance for package height is a requirement for many applications. Typically, thick packages are more reliable and have lower manufacturing costs. In contrast, thin packages may be required for applications where space and weight are at a premium. Additionally, manufacturing a thin package is usually costly because smaller components are more difficult to process and require more precise machinery.
[0007] Current manufacturing processes cannot precisely and efficiently control the final height of the package. After the wafer-interposer assembly is diced, the footprint of the resulting semiconductor package is almost the size of the die, which is as small as the package can be without making a smaller die. However, the height of the package cannot be as accurately controlled because it varies according to the method used to construct the wafer-interposer.
[0008] Another costly manufacturing process associated with assembling semiconductor packages having interposers is aligning the die with the interposer. The contact pads on the die and the interposer must be aligned and connected to result in a functional semiconductor package. Aligning minute contacts between the die and interposer is an expensive and time intensive process. Current available methods of alignment slow the manufacturing process and increase costs.
[0009] Accordingly, there is a need for a system, method and apparatus for building a semiconductor wafer-interposer assembly that overcomes the present manufacturing limitations and inefficiencies.
SUMMARY OF THE INVENTION
[0010] The present invention overcomes the existing manufacturing limitations and inefficiencies in the art by providing a wafer interposer assembly and system for building the same. The wafer interposer assembly includes a semiconductor wafer having a die and a redistribution layer pad, electrically connected to the die. An epoxy layer is deposited on the surface of the redistribution layer pad and the die. An opening is positioned through the epoxy layer and an interposer pad is positioned in the opening in electrical contact with the redistribution layerpad.
[0011] In one embodiment, the semiconductor wafer of the wafer interposer assembly includes a plurality of die. The redistribution layer pad may comprise a material reflective to laser frequencies, a material compatible with solder, or a material compatible with conductive polymer. The epoxy layer may be disposed on the surface by a deposition process selected from the group consisting of spraying, rolling and vapor deposition. Moreover, the epoxy layer may comprise a nonconductive material having a coefficient of thermal expansion similar to the wafer. The height of the cured epoxy layer may be at least the length of the redistribution layer pad. The curing may involve a processes selected from the group consisting of heat processes and chemical processes. The epoxy layer is trimmed by a laser process to achieve a flat surface and controlled height. Additionally, the interposer pad may comprise a conductive material that is positioned in the opening which may be formed by a laser process. An epoxy coat is disposed on a backside of the wafer.
[0012] In another aspect, the present invention is directed to a system for building a wafer interposer assembly. A depositor deposits an epoxy layer onto the surface of a semiconductor wafer having a plurality of die and a plurality of redistribution layer pads electrically connected to each die. A laser operates relative to the semiconductor wafer to trim the epoxy layer to a flat surface and controlled height and to bore a plurality of openings in alignment with the redistribution layer pads through the epoxy layer. A screener screens an interposer pad into the openings and into electrical contact with the redistribution layer pads.
[0013] In one embodiment, the depositor is selected from the group consisting of spraying depositors, rolling depositors and vapor depositors. The laser may operate under the control of a controller that comprises a computer-numerical-control machine that maneuvers and operates the laser in three dimensions. A curing means employing a heat process or chemical process may be employed for curing the epoxy layer. The screener may screen a conductive material into the openings to form the interposer pads. An alignment mark may be position on the semiconductor wafer to provide orientation to the laser. Additionally, the depositor may deposit an epoxy coat on the backside of the semiconductor wafer and the laser may adjust the height of the epoxy coat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which corresponding numerals in the different figures refer to corresponding parts and in which:
[0015] [0015]FIG. 1A is a perspective view of a semiconductor wafer in accordance with certain embodiments of the present invention;
[0016] [0016]FIG. 1B is a cross-sectional view of the semiconductor wafer of FIG. 1A taken along line 1 B- 1 B.
[0017] [0017]FIG. 2 is a cross-sectional view of a wafer-interposer assembly in accordance with certain embodiments of the present invention;
[0018] [0018]FIG. 3A is a cross-sectional view of a wafer-interposer assembly in accordance with certain embodiments of the present invention;
[0019] [0019]FIG. 3B is a cross-sectional view of a wafer-interposer assembly in accordance with certain embodiments of the present invention;
[0020] [0020]FIG. 4 is a cross-sectional view of a wafer-interposer assembly in accordance with certain embodiments of the present invention;
[0021] [0021]FIG. 5 is a cross-sectional view of a wafer-interposer assembly in accordance with certain embodiments of the present invention; and
[0022] [0022]FIG. 6 is a cross-sectional view of a wafer-interposer assembly in accordance with certain embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Although making and using various embodiments of the present invention are discussed herein in terms of using laser techniques to build an interposer onto a wafer, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not limit the scope of the invention.
[0024] Interposers allow greater freedom to die designers because the layout of a die and its contact pads can be defined according to the interaction of the functional elements of the die rather than according to the standardization requirements. The interposer can be designed with a standardized layout of contact pads on its upper surface and can electrically connect each die pad to a corresponding interposer contact pad without an interposer pad being directly above its corresponding die pad. Not only does the interposer provide for standardized interconnection, it also provides for the use of standard test hardware, software, cabling and connectors compatible with existing industry infrastructure.
[0025] An additional advantage of the interposer is that more than one interposer can be designed for each wafer. A manufacturer can then, by substituting a different interposer, modify the layout of the interposer pads to conform to a different layout or packaging standard. Alternatively, if the die and interposer are designed for modularity, a single interposer design may be useful on more than one chip design. A specific interposer design will typically be necessary for each unique die design.
[0026] [0026]FIG. 1A depicts a semiconductor wafer 10 having a plurality of die including a die 11 , which may have many circuits within its structure. Referring now to FIG. 1A and FIG. 1B, which is a cross-sectional view of FIG. 1A along line 1 B- 1 B, the wafer 10 may have several identical or different dice 11 , which eventually may be separated or diced into individual semiconductor chips. For clarity of illustration, dashed lines are used to represent the kerfs between die 11 . One or more die pads 12 electrically contact the circuits within die 11 . An underbump metalization may be deposited onto the die pads 12 . A redistribution layer (RDL) may then be deposited onto the wafer 10 . One or more known semiconductor processes, such as photolithography or etching for example, may be used to process the RDL into RDL pads 13 . The RDL pads 13 may then be connected to the die pads 12 by connectors 14 . The RDL pads 13 provide an interface between the circuits of the die 11 and an interposer. Each of the die pads 12 corresponds to a particular RDL pad 13 .
[0027] The RDL pads 13 may be a material that is reflective to laser frequencies to facilitate subsequent processes of the present invention. The RDL pads 13 may also be made from a material that is compatible with solder or conductive polymer. Copper, for example, may be one suitable material for RDL pads 13 . Other materials that are electrically conductive and compatible with solder or conductive polymers may also be used for the RDL pads 13 and will be apparent to those having ordinary skill in the art.
[0028] The layout and size of the RDL pads 13 may have the same configuration as the pad configuration of a finished semiconductor package. Designing the configuration of the RDL pads 13 to match the requirements of the finished package increases manufacturing efficiency. Multiple, identical dice 11 may be efficiently produced in large quantities and used in a variety of different applications by simply changing the configuration of the RDL pads 13 . Efficiency increases because the same die 11 may be used for multiple applications that require different semiconductor package configurations.
[0029] Next, the wafer 10 is coated with a layer of epoxy 20 as depicted in FIG. 2. The epoxy 20 may be applied using any of many semiconductor chip manufacturing techniques known in the art. Spraying, rolling or vapor deposition, for example, is used to apply the epoxy 20 to the wafer 10 . The epoxy 20 may be non-conductive and may have a coefficient of thermal expansion similar to the wafer 10 . The epoxy 20 may also be able to withstand the heat required to re-flow solder or other conductive material that is applied to the wafer 10 in subsequent processes. An epoxy material suitable for underfill, for example, may be used.
[0030] The epoxy 20 should be applied or deposited to a height that exceeds the upper surface of the RDL pads 13 by at least the diameter of the RDL pads 13 . The epoxy 20 is then cured as required by the particular properties of the epoxy 20 . Some curing methods may include infrared heat or chemical processes, for example. The cured epoxy 20 may have a relatively rough or undulating surface, as best seen in FIG. 3A. However, a desirable minimum thickness is one that extends past the upper surface of the RDL pads 13 by approximately the diameter of the RDL pads 13 .
[0031] [0031]FIG. 3B depict a trimming process that may vaporize the top of the epoxy 20 to achieve a very flat surface and controlled height. An exaggerated surface of the epoxy 20 is shown in FIG. 3A. The thinnest point of the epoxy 20 should be approximately at least as thick as the diameter 34 of the RDL pad 13 plus the height of the RDL pad 13 .
[0032] A controller (not shown) may be used to operate a laser 25 to vaporize selected areas of the epoxy 20 . The controller, for example, may be the type of controller utilized for computer-numerical-control (CNC) machining, which maneuvers and operates a tool in three dimensions. In this particular application, the controller maneuvers the laser 25 about the wafer 10 and selectively vaporizes portions of the epoxy 20 . The process of removing the epoxy 20 will be described in further detail below.
[0033] In FIG. 3B, the laser 25 may be aimed at initial elevation 31 and generally parallel to the surface of the wafer 10 . This initial elevation 31 of the laser 25 may be slightly above the highest point of the epoxy 30 . The controller begins sweeping the laser 25 across the wafer 10 and slowly lowers the laser 25 through excess epoxy 30 to final elevation 32 . As it is lowered, the laser 25 impinges on high points of the surface of the epoxy 20 and vaporizes the excess epoxy 30 as the laser 25 sweeps across the entire wafer 10 . The elevation 32 is at a point where the distance 33 between the surface of the epoxy 20 and the surface of the RDL pads 13 is approximately the diameter 34 of the RDL pads 13 . The distance 33 may be varied to optimize the aspect ratio for conductor screening, which will be described below.
[0034] Once the epoxy 20 is planarized, the laser 25 may also be used to create openings 40 , the locations of which are represent by dashed lines, in the epoxy 20 as depicted in FIG. 4. The laser 25 is first oriented to the wafer 10 using alignment marks 35 on the wafer 10 . If the alignment marks 35 have been covered during the epoxy coating process, a rough alignment can be made using a flat spot or other reference point on the wafer 10 . Next, the laser 25 may be used to etch away the epoxy 20 around the alignment marks 35 . After the alignment marks 35 are located, the location of RDL pads 13 can be very accurately determined by using the alignment marks 35 in conjunction with a coordinate map of the RDL pads 13 . The laser 25 creates the openings 40 by vaporizing the epoxy 30 . The laser 25 vaporizes the epoxy 20 down to the surface of the RDL pads 13 but does not affect the RDL pads 13 because of the reflective properties of the RDL pads 13 .
[0035] This process is similar to using the laser 25 as a drill. The controller determines drilling locations, which are generally above the RDL pads 13 , by moving the laser 25 relative to the alignment marks 35 . The laser 25 may then be activated to vaporize the epoxy 20 and “drill” the openings 40 . The RDL pads 13 act as “drill stops” because the RDL pads 13 reflect the laser 25 instead of being vaporized by the laser 25 .
[0036] [0036]FIG. 5 shows the openings 40 filled with a conductive material by screening, for example, to form interposer pads 50 . The aspect ratio of the openings 40 may be adjusted so that the conductive material easily flows into the openings 40 and adequately fills the openings without leaving any voids. Also, the aspect ratio facilitates the conductive material filling the openings 40 and contacting the RDL pads 13 . The conductive material may be solder, conductive polymer or any other suitable material and may be screened into the openings 40 . The conductive material forms a permanent and reliable electrical connection to RDL pads 13 . After screening into the openings 40 , the conductive material is re-flowed or cured. After re-flowing or curing, the wafer-interposer is at minimum thickness. If a thicker package is required or if it is desirable to protect the backside of the die 11 , then an epoxy coat can be applied to the back of the wafer 10 , as best seen in FIG. 6.
[0037] The interposer pads 50 may be used as contacts for testing and burn-in of the wafer 10 . The interposer pads 50 may also be used to connect and attach the resulting device to a printed circuit board or other structure after the interposer is diced into individual circuits.
[0038] [0038]FIG. 6 depicts the wafer-interposer having an additional layer of epoxy 60 , which may be added to the backside of the wafer 10 . The technique for applying the epoxy 60 , the composition of the epoxy 60 and the method for creating a dimensionally precise surface is similar to the process for the front side of the wafer 10 , which has been described above. The thickness 61 of the wafer-interposer may be adjusted by removing and leveling the epoxy 60 using the laser 25 . Because there are no electrical contacts on the backside of the wafer 10 , the thickness 61 may be adjusted without concern for maintaining a particular aspect ratio. After construction of the wafer-interposer is complete, testing and burn-in may be performed while all circuits are in wafer form. After final testing, the wafer-interposer may be diced into individual components.
[0039] While specific alternatives to steps of the invention have been described herein, additional alternatives not specifically disclosed but known in the art are intended to fall within the scope of the invention. Thus, it is understood that other applications of the present invention will be apparent to those skilled in the art upon the reading of the described embodiment and a consideration of the appended claims and drawings.
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A wafer interposer assembly and a system for building the same are disclosed. The wafer interposer assembly includes a semiconductor wafer ( 10 ) having a die ( 11 ) and a redistribution layer pad ( 13 ) electrically connected to the die ( 11 ). An epoxy layer ( 20 ) is deposited on the surface of the redistribution layer pad ( 13 ) and the die ( 11 ). An interposer pad ( 50 ) is positioned in an opening ( 40 ) in the epoxy layer ( 20 ) in electrical contact with the redistribution layer pad ( 13 ).
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for texturing a synthetic yarn.
Yarn nozzles are known from German DE-C 36 34 749 and corresponding to U.S. Pat. No. 4,796,340 and wherein the yarn nozzle is provided with a yarn duct which is supplied with hot air and terminates in an expansion chamber which has a larger cross section than the yarn duct. The expansion chamber possesses lateral outlets, for example axially extending slots, and is therefore connected with the atmosphere. The hot air which is supplied into the yarn duct expands with the yarn in the expansion chamber. Consequently, the multifilament yarn is expanded in the expansion chamber and compressed to a yarn plug thereby being deformed. This yarn plug is further advanced by the pressure in the expansion chamber, then deposited after leaving the expansion chamber on a slowly rotating cooling drum, and finally disentangled to a crimped yarn, note also DE-C 26 32 082 and corresponding to U.S. Pat. No. 4,118,843.
In the above nozzles, the hot air is generated in a heater. To regulate the process, the temperature of the hot air is measured in the supply line to the nozzle, and as a function of this measured value and a desired temperature, the regulator for the heater is controlled such that the temperature remains constant.
It has been found that in the above described method, the point of disentanglement at which the yarn plug unravels again to a textured yarn, may move along the cooling drum, without it being possible to notice and detect the process parameters which cause this instability.
It is accordingly an object of the present invention to provide a yarn nozzle of the described type and wherein a stability of the texturing process is ensured, in particular that the point of disentanglement is prevented from shifting.
It is also an object of the present invention to provide a yarn nozzle of the described type and which comprises two sections which are separated or opened to facilitate yarn thread-up, and wherein large fluctuations of the output of the heater are avoided when the nozzle is opened, and so that the temperature in the air supply line to the nozzle can be maintained relatively constant during opening.
SUMMARY OF THE INVENTION
The above and other objects and advantages of the present invention are achieved in the embodiments illustrated herein by the provision of a yarn texturing apparatus which comprises a nozzle including a duct through which the yarn is adapted to advance at high speed from an inlet end to an outlet end, passageway means for conducting a pressurized heating fluid into the duct during operation of the apparatus, and a perforated stuffer box disposed adjacent the outlet end of the yarn duct for receiving and forming a compressed plug from the advancing yarn exiting from the duct. Heating means is also provided which includes a temperature sensor disposed in the stuffer box for maintaining the temperature of the heating fluid at a predetermined level.
The present invention deviates from the widely held view that the highest temperature of the heated gaseous medium to which the yarn is subjected, determines the texturing result. Rather, the present invention takes deliberately into account that the temperature in the texturing nozzle is not proportional to the highest temperature of the heated gaseous medium. To this end, it should be noted that the temperature of the heated gaseous medium in the nozzle varies unsteadily as a result of the expansion. It has been shown that this determination of the temperature permits an excellent long-term stability of the texturing process and texturing quality to be achieved. Decisive therefor should be the fact that along with the temperature of the hot air in the expansion chamber also the air pressure in the expansion chamber, which compresses the yarn plug formed therein and pushes the same out of the expansion chamber, is influenced at the same time, and that consequently a self-regulating effect develops with regard to temperature and pressure.
The known yarn nozzle is designed and constructed such that it is possible to open the yarn duct and the expansion chamber along their entire length. This allows an advancing yarn to be inserted laterally into the yarn duct or expansion chamber respectively. A suitable embodiment of such a texturing nozzle is shown, for example, in EP-A 256,448 and U.S. Pat. No. 4,829,640. There, the yarn nozzle is divided in the longitudinal plane of the yarn duct, so that one half thereof can be opened relative to the other half about an axis parallel to the yarn duct.
A further problem associated with nozzles of this described type is the fact that the temperature in the expansion chamber drops drastically when the nozzle is opened. Consequently, the regulator for the air heater will increase the energy input in the meaning of raising the temperature and, thus, move the heater far out of its operating range.
It is impossible to prevent this negative result by the measure disclosed in DE-C 36 34 749, and U.S. Pat. No. 4,796,340, according to which the throughput of the air volume is kept constant, when the yarn nozzle is opened. Rather, it is necessary to stop the automatic regulation of the air heater. Thus, after the yarn thread-up, a long time will be needed until stable temperature conditions return.
In accordance with one embodiment of the present invention, the above problem is solved by the provision of a second temperature sensor which is positioned in the supply line between the heater and the yarn nozzle, in addition to the temperature sensor positioned in the expansion chamber. It is also possible to apply the measure known from DE-C 36 34 749 and U.S. Pat. No. 4,796,340 so that the throughput of the air volume through the heater is kept constant while the texturing nozzle is open.
In a further embodiment of the present invention, the measure known from DE-C 36 34 749 and U.S Pat. No. 4,796,340 is supplemented in that the heater control means, which includes a heater regulator for the heater of the heating medium, is controlled during the opening of the nozzle, and such that the heater regulator is operated in the control position which resulted before in the stationary operation of the yarn nozzle, and which is then definitely input, without a change, when the nozzle is opened. As a result, it is ensured that the volume of air or vapor, which remains constant, is continued to be heated with the same amount of energy and, accordingly, is continued to be heated to the temperature maintained during the operation. It should be noted that this method is useful and applicable, regardless whether the temperature sensor is arranged in the expansion chamber of the yarn nozzle or, as has been usual in the past, in the supply line for the heating medium between the heater and the yarn nozzle.
In the method of DE-C 36 34 749, and U.S. Pat. No. 4,796,340, the air flow supplied to the heater is throttled when the nozzle is opened. This measure serves to keep the throughput of the volume in the heater constant. However, this measure will not avoid having hot air continue to exit in the nozzle, which interferes with the servicing. In accordance with a further feature of the present invention, a valve is preferably positioned in the supply line between the second temperature sensor and the nozzle, and the valve is movable between a first position wherein the supply line is open to the nozzle, and a second position wherein the supply is open to an exhaust line. The valve is switched preferably by the device which unlocks and opens the texturing nozzle. This opening device also allows to switch the heater regulator from the first temperature sensor in the expansion chamber to a second temperature sensor in the supply line. However, as an alternative, it is also possible to switch the valve along with the following measure for switching the heater regulator.
The measures for switching the heater regulator from the first temperature sensor in the expansion chamber to the second temperature sensor in the supply line, which are described below, have the advantage that they allow to avoid large fluctuations in the energy supply to the heater of the gaseous medium. In general, the solution provides that the temperature conditions in the supply line can be kept constant. To this end, it is possible to make use of the temperature jump of the first temperature sensor, which occurs when the yarn nozzle is opened. However, it is also possible to solve the problem of effecting an automatic switchover, by monitoring the temperature difference between the indicated temperatures of the first and second sensors. This has the advantage that a very close relation exists between the operating temperature of the yarn nozzle and the operating temperature of the supply line at the time of the switchover. This relation is predetermined by the allowed temperature difference. Consequently, the temperature condition in the supply line, which exists during the operation of the yarn nozzle, is also maintained, when the latter is opened. Another consequence thereof is that, when the yarn nozzle is opened and the control of the temperature in the expansion chamber is again switched, the temperature in the expansion chamber approximates with a very close tolerance the temperature in the supply line and, consequently, assumes again substantially the same value as in the preceding operating phase. Thus, it is achieved that while the yarn nozzle is open, the operating condition of the supply line is maintained in the state in which it remained during the preceding operating phase, and that this state represents then again the reference for the new adjustment of the temperature in the expansion chamber during the next operating phase. In this manner, it is ensured that the operating conditions of successive operating phases substantially correspond to each other.
The automation of the yarn nozzle may also include provision for the automatic actuation of the valve. Thus, for example, the handle which is used to release the one nozzle section from the other, can simultaneously serve to actuate the valve, which disengages the supply line from the yarn nozzle and connects it to the exhaust line.
It should be emphasized that the provision of a throttle in the exhaust line is also useful and advantageous inasmuch as it completely avoids that the yarn nozzle, the operator and the surroundings are exposed to the hot air, when the nozzle is opened. It is easily possible to have the exhaust line terminate at a large distance from the yarn nozzle or the texturing machine depending on the accumulated volume of hot air.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds, when taken in conjunction with the accompanying drawings, in which
FIG. 1 is an axial sectional view of a yarn texturing nozzle in accordance with the invention;
FIG. 2 is an enlarged cross sectional view of the yarn nozzle taken substantially along the line 2--2 of FIG. 1;
FIG. 3 is a schematic view of the yarn nozzle, the temperature sensors, and the heater control system of the present invention; and
FIG. 4 is a schematic view of another embodiment of the present invention and which utilizes a single temperature sensor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 and the subsequent description are in part taken from EP-A 256,448, and U.S. Pat. No. 4,829,640, the disclosures of which are expressly incorporated herein by reference.
The texturing nozzle comprises two rectangular sections 1 and 2 with a stuffer box 3 positioned downstream thereof. The texturing nozzle and the stuffer box 3 are divided along a longitudinal plane 21. The nozzle section 1 shown on the left of FIG. 1 with the half of the stuffer box 3 attached thereto is mounted on the machine frame 6. The nozzle section 2 and its associated half of the stuffer box 3 are movable perpendicularly to the separating plane. The second nozzle section 2 comprises a guide member 4 and a piston 5. Formed into the guide member 4 is an elongate, cylindrical cavity 7. The piston 5 is fitted into this cylindrical cavity 7 in such a manner that it is movable in longitudinal direction. The movement of the piston relative to the guide member 4 is limited by a holder 8, which extends over the lateral projections of the piston. Formed into the back side of the piston are transverse grooves 15. The transverse grooves follow each other so closely that a desired flexibility of the piston is obtained in the longitudinal direction. In addition to the transverse grooves 15, it is possible to provide also longitudinal grooves 16 in the back side of the piston, so that the piston exhibits also a desired flexibility in the transverse direction.
On its back side directed into the cylindrical cavity 7, the piston is provided with a diaphragm 17, which is flexible. The shape of the diaphragm is adapted to the shape of the cylindrical cavity 7. The corner extending between the diaphragm 17 and the walls of the cavity 7 is sealed by a frame-shaped gasket 18. The gasket 18 is held in its position by a retaining frame 19, which is also adapted, with a greater tolerance, to the cross section of the cavity 7. The frame 19 has on one of its circumferential corners a groove, notch or the like, into which the frame-shaped gasket 18 is inserted. However, the gasket 18 projects beyond the periphery of the frame 19 such that the gasket contacts both the walls of cavity 7 and the diaphragm 17.
The cavity 7 is biased with a pressure medium supplied through a connecting duct 20. Preferably the medium is the heated medium which is also supplied to the texturing nozzle.
Both the first nozzle section 1 and the piston 5 are provided on their front side with a groove, which forms in the closed state (note FIG. 2) a duct 12 for the yarn. The yarn duct 12 receives hot air through a supply line 9, an annular duct 10 as well as tap bores 11. The openings of the annular duct 10 in the separating plane of both the first nozzle section 1 and the piston 5 are tightly superposed in the closed state, so that the hot air also flows into the piston. The tap bores terminate in the yarn duct 12 at an acute angle. The hot air flowing in the yarn duct exerts an impulse on the advancing yarn and simultaneously heats the yarn. As a result the yarn is compressed in the stuffer box 3 (expansion chamber) to a yarn plug. On the surface of the yarn plug, the hot air is able to escape through the slots 22 of the stuffer box 3. At the end of the stuffer box, the yarn plug 23 is advanced by delivery rolls 24 to a cooling drum 36 (FIG. 3).
The movable half of the stuffer box 3 is attached to the piston 5. Consequently, the guide member 4 is provided with a corresponding recess in the region where this half of the stuffer box passes through. The guide member 4 possesses an extension 25, which accommodates at its end a resilient support 26, which provides that in operation the two halves of the stuffer box 3 overlie each other sealably and free of movement.
It should be noted that the supply line 9 for the hot air and the connecting duct 20 are interconnected outside the texturing nozzle. However, it is also possible to connect the cavity 7 via the connecting duct 20 to a source of pressure, which is independent of the supply line 9 for the hot air. This permits the pressure which biases the piston 5 to be adjusted, independently of the pressure of the heated gaseous medium.
The means for opening and closing the nozzle are not illustrated. Such may include in particular cylinder-piston assemblies 31, which are indicated in FIG. 3, and which may be biased with pressure along with the cavity 7, so as to press the guide member 4 with the holder 8 firmly against the first nozzle section 1 and to push simultaneously the piston 5 into the separating plane 21. In any event, these cylinder-piston assemblies 31 are biased by an independent source of pressure. The following description proceeds from biasing the piston 5 by the heated gaseous medium.
For the purpose of threading a yarn in the present embodiment, the guide member 4 is moved away from the stationary first nozzle section in direction of arrow 27. In so doing, the supply of hot air to the connecting duct 20 and to the supply line 9 of the hot air is interrupted, as will be described below.
When the yarn is inserted into the region of the duct 12, the second section of the texturing apparatus is moved back, so that the first section 1 of the texturing nozzle and the piston 5 overlie in the separating plane 21. The centering pins 13 in the piston 5, which have a conical tip, as well as the centering bores 14 in the first section of the texturing nozzle ensure that the piston assumes in operation its position such that the two groove halves in the first half of the texturing nozzle and in the piston 5 overlap precisely in direction of the yarn duct 12. It is further ensured that also the openings of the annular duct 10 precisely overlie each other in the separating plane 21.
The connecting duct 20 is then connected with the heater. As a result, the cavity 7 is biased with pressure. The pressure medium first effects a sealing of the gasket 18 relative to the diaphragm 17 and the cavity wall. Further, the pressure medium pushes the piston 5 firmly against the separating plane 21 of the first texturing nozzle section 1.
The present invention will result from the following description of the embodiment of the texturing nozzle schematically illustrated in FIG. 3 and showing all elements decisive for the present invention. The yarn is supplied by a godet 35. As can be seen, the yarn duct 12 is substantially narrower than the expansion chamber 3. The forming yarn plug is delivered by wheels 24 not shown in FIG. 3 at a defined speed to the cooling drum 36, it being necessary to emphasize that the wheels 24 serve the purpose of influencing the exit speed for the yarn plug 23 from the expansion chamber 3 and keeping same constant. The cooling drum 36 is rotatingly driven at a slow speed corresponding to the exit speed of the yarn plug 23.
On its circumference, the cooling drum 36 possesses a groove with a perforated bottom. Except one air outlet end 37, the drum is closed impervious to air. The yarn plug 23 is guided over a partial range of the groove circumference. In so doing, an air current directed from the outside to the inside causes the yarn to adhere to the cooling drum and cools the yarn at the same time. Subsequently, the yarn is pulled out from the continuously advancing yarn plug 23 at a point of disentanglement 38. The position of the point of disentanglement is defined by the compactness of the yarn plug on the one hand and by the tension of the pulled-out yarn on the other, it being necessary to arrange the point of disentanglement 38 such that the yarn is still guided over a partial circumference of the cooling drum 36 or its grooves before it partially loops about a subsequent feed roll 41. This partial circumference between the point of contact 40.1 and the point of departure 40.2 will be described below as friction zone 39. After its looping about the feed roll 41, the yarn reaches a traversing mechanism 42 and a deflection roll 43, where it is wound to a package 44 which is held on a winding spindle 45.
The friction zone 39 results in a self-regulating effect. It is presumed that the surface speed of the cooling drum 36 corresponds to the speed of the yarn plug 23. Depending on the compression of the yarn in the plug 23, the yarn speed is several times higher. Consequently, frictional forces are operative on the yarn in the friction zone 39. As a result, the yarn tension between the point of disentanglement 38 and the point of contact 40.1 of the yarn on the surface of the cooling drum is less than the yarn tension between the point of departure 40.2 and the feed roll 41. As soon as the compression and compactness of the unraveling plug 23 lessen, the point of disentanglement 38 moves against the direction of rotation 56 of the cooling drum 36. Thus, however, the point of contact 40.1 moves likewise against the direction of rotation 56 with the result that the friction zone 39 becomes larger. As a result, the decrease of the yarn tension becomes greater in the friction zone 39, and the yarn tension lessens between the point of disentanglement 38 and the point of contact 40.1 Consequently, the point of disentanglement 38 and thus likewise the point of contact 40.1 move again in the direction of rotation 56.
What is endeavored is to reach an equilibrium. To this end it is necessary by experience that this shifting of the point of disentanglement 38 is kept within the narrowest possible limits. It has been found that too large shifting movements have a negative effect on the package buildup and the texturing quality.
This object has been accomplished in that the temperature sensor 47 which controls the heater control means 55 for the air heater 29, is positioned in the expansion chamber 3.
Referring again to FIG. 3, pressurized air from the source of compressed air 28 is heated in the heater 29. The compressed and heated air is then supplied via supply line 9 and valve 30 to the annular duct 10 of the nozzle. The heater 29 is controlled by a heater control means which is generally indicated at 55, and which includes a heater regulator in the form of a circuit breaker 54, which is connected via line 49 and suitable amplifiers with the temperature sensor 47. The duration of connection and disconnection of the circuit breaker 54 for the heater is controlled as a function of the measured temperature of sensor 47 so that the temperature on the sensor 47 in the expansion chamber remains substantially constant. It should be mentioned that in the place of the circuit breaker 54, it is also possible to have a continuous analog regulator.
It is found that with the arrangement of the temperature sensor 47 in the expansion chamber 3, the point of yarn disentanglement 38 barely moves, so that the previously described regulating process in the friction zone 39 proceeds within a very narrow range.
Along with the measurement of the temperature by sensor 47 in the expansion chamber, a regulation, which results in an always constant crimp, occurs as follows. As the plug 23 increases in length, the slots 22 of the stuffer box 3 are blocked. As a result, the pressure in the stuffer box increases and the expansion of the heated gaseous medium decreases. Due the increasing pressure in the stuffer box 3, the crimp is intensified. Since the decreasing expansion of the heated gaseous medium causes the temperature to rise, which is measured by sensor 47 in the stuffer box 3, the heating power of the circuit breaker 54, which is supplied to the heater 29, is decreased. Consequently, the temperature readjusts itself to the previously set desired value and accordingly decreases again, thereby also lessening the plasticization of the thermoplastic yarn and its crimp.
Thus, an equalization occurs automatically with regard to the intensity of the crimp. The arrangement of the temperature sensor 47 in the stuffer box 3 and the dependence of the energy supply to the heater 29 allow to automatically reverse the increasing intensity of the crimp due to the rising pressure by reducing the heating of the yarn and vice versa.
Furthermore, measures are provided which avoid having the surroundings of the nozzle and especially the operating personnel affected by the exiting hot air when the nozzle is opened. To this end, the valve 30 is provided, which is positioned in the supply line 9 between the heater 29 and the nozzle. The valve 30 is a two-way valve. In its normal position, the valve 30 opens the supply line 9 from the heater 29 to the yarn nozzle. In its other position, the heater is connected with an exhaust line 32. The exhaust line 32 terminates, via a throttle 33, at a suitable place in the open air. The throttle 33 is designed such that its air resistance for the hot air is substantially equal to the air resistance which the yarn nozzle has likewise in its operating condition.
The positioning of the valve 30 is effected by an adjusting unit 34. The adjusting unit 34 is connected with the locking mechanism 31 for the second, movable section of the yarn nozzle in the meaning of a synchronous actuation. As soon as the signal "yarn nozzle open" is sent through the common connecting line, the valve 30 is simultaneously brought to the position, in which the heater 29 is connected with the exhaust line 32, whereas the connection with the yarn nozzle 1 is closed. This ensures that the flow conditions remain substantially constant in the air heater 29.
However, at the same time it is also ensured that the heater 29 continues to operate with the heater control means 55 in its operating range, even while the yarn nozzle is opened and out of operation, and that its normal operation will not change, since the yarn sensor 47 is put out of operation and is disconnected at the same time.
A further regulation of the apparatus is illustrated in FIG. 3. To this end, a second yarn sensor 46 is provided in the supply line 9 between the heater 29 and the valve 30, or in the exhaust air duct 32. In the present embodiment, the last-mentioned alternative is shown. The first-mentioned alternative is shown in dashed lines, and the second temperature sensor is indicated at 46'.
Even when the yarn nozzle is closed, i.e. in operation, the temperature signals of the temperature sensors 46 and 47 are constantly supplied via lines 48 and 49 to the control means 55, which contains, among other things, a switching device (actual value switch) 51 and a switching device (set-point switch) 57 on the one hand, and a differential unit 50 on the other. In operation, a connection is made between the circuit breaker 54 and the temperature sensor 47. In the control circuit of the circuit breaker, the actual temperature IT47 is compared with the set temperature ST47.
It should be emphasized that the temperature on both sensors 46 and 47 is constantly measured also during the operation. In addition, devices are provided, which allow to acquire the considerable fluctuations of the temperature IT47 on the sensor 47, and which can be used to switch the actual value switch and the set-point switch 57. The differential unit serves as such a device.
During the operation, the difference between the temperatures IT46 and IT47 on the sensors 46 and 47 is formed in the differential unit 50, and compared with a set differential. This set differential is first input as empirical value IN.
When the circuit breaker 54 reaches its normal operating point, in which the temperature 47 remains substantially constant, a return signal is sent via line 58 to the differential unit 50. As a result, the temperature difference existing at this time between the actual values of the temperature sensors 46 and 47 is retained as a future set point in the place of the set point IN previously empirically input, and used for the further operation. During the following time, this set point can be actualized continuously or recurrently with a predetermined time delay as a result of comparing the temperature of the sensors 46, 47.
When the temperature difference exceeds this set point by more than an allowed measure, and when this condition continues for a certain predetermined period of time, a switching signal is supplied to the switches 51, 57. The actual value switch 51 and the set-point switch 57 are then switched simultaneously in the meaning that the control circuit of the circuit breaker 54 is connected with the temperature sensor 46 and with the set-point input ST46. This increased temperature difference will occur, as soon as the texturing nozzle is opened, because the temperature on sensor 47 will drop as a result of increased expansion.
However, it should be emphasized that the sensor 47 continues to measure the temperature even when the yarn nozzle is opened.
Thus, the switches 51 and 57 allow to connect alternately the lines 48 or 49 of the two temperature sensors 46 or 47 for the actual temperature values IT46, IT47, via lines 53, with the control circuit of the circuit breaker 54. Thus, when the yarn nozzle is open, the supply of energy to the heater 29 is adapted in such a manner that the temperature on the sensor 46 in the exhaust duct 32 remains constant. Since the rating of the throttle resistance of valve 30 ensures at the same time that the volume of the air throughput does not change substantially, the supply of energy to the heater 29 remains likewise substantially constant.
When the nozzle is closed, the temperature on the sensor 47 in the expansion chamber 3 rises again, since the expansion decreases and the pressure in the expansion chamber 3 increases. Also this temperature jump may be used for reversing the set-point switch 57 and the actual value switch 51. The temperature jump is again acquired by the formation and acquisition of the difference of the temperatures IT46 and IT47, because the temperature difference, which is measured on the sensors 46 and 47, decreases. As soon as the difference falls below the predetermined set difference IN or OP, the switches 51, 57 reverse in the meaning that the temperature sensor 47 and set-point input ST47 are again connected with the control circuit of circuit breaker 54. Thus, when the yarn nozzle is opened and closed, the following procedure occurs: when the nozzle is to be opened, the locking mechanism 31 is first actuated in the direction of opening, and the valve 30 is actuated at the same time. By actuating the valve 30, the heater is connected with the exhaust line 32. As a result of opening the nozzle 2, the temperature on sensor 47 in the expansion chamber 3 drops, and the temperature difference which is input as set point, is exceeded by more than an allowed extent. The set point and actual value are reversed. Thus, the heater 29 is now controlled as a function of the temperature measured on sensor 46 in such a manner that the temperature remains substantially constant.
This set point ST46 corresponds to the temperature, which empirically exists in the supply line 9 during operation and is input by hand. However, the set point ST46 can also be determined in the continuous operation of the nozzle and be stored. To this end, the current value IT46 measured on the temperature sensor 46 is constantly entered into the reference input unit 59 and stored therein as a reference value, as soon as the circuit breaker 54 signals via line 58 that the heater 29 has reached its stable operating condition. The reference value is thereafter continuously fed to switch 57 via the input line of the set point ST46. This allows to maintain the operating condition of also line 9, while the operation is interrupted. However, the linking of the reversal with the operating temperature difference between the sensors 46 and 47 allows to accomplish that the temperature in the supply line 9 always follows the temperature in the expansion chamber 3 with a certain tolerance, and that the temperature condition in the supply line, which existed directly before or during the opening of the expansion chamber 3, is frozen, i.e., maintained at this tolerance. Thus, during the opening the state of the flow and the temperature is maintained in the supply line, while allowing a predetermined tolerance.
When the yarn is inserted and the nozzle is again closed, the valve 30 is reversed at the same time as the locking mechanism 31 engages. The nozzle is again connected with the heater 29 and supplied with hot air. As a result, the temperature on the sensor 47 rises again until the differential falls below the predetermined differential reference value. Both the measured value and the reference value are switched respectively by switching unit 51 and set point unit 57.
The condition of the heated medium in the expansion chamber 3 readjusts itself to the condition maintained during the preceding operating phase due to the close linking via the temperature difference delta T, since, as aforesaid, this operating condition has been frozen, i.e. maintained, in the supply line 9.
In the embodiment of FIG. 4, no further regulation occurs, when the yarn nozzle is opened. Consequently, only a single temperature sensor 47 is needed for the yarn nozzle. However, it should be expressly noted that, in this embodiment, it is not absolutely necessary to arrange this temperature sensor in the expansion chamber 3. Rather, it can also be arranged in the supply line 9 between the valve 30 and the nozzle 1, or before the valve. Note to this end the temperature sensor 47' of FIG. 4, which is shown in dashed lines and represents an alternative.
The temperature signal of the temperature sensor 47 is constantly supplied, via line 49, to the control means 55, when the yarn nozzle is closed. The control means 55 includes, among other things, a switching element (actual value switch 57) and a circuit breaker 54 with a regulating circuit. The latter receives, via switching element 51 and line 52, the actual value IT47 of the temperature, which is constantly measured on the temperature sensor 47. The regulating circuit of the circuit breaker 54 is supplied, via switching element 57 and line 53 with the set-point value of the temperature ST47. In the regulating circuit of the circuit breaker, the actual temperature IT47 is compared with the set-point temperature ST47. As a function of the difference, the circuit breaker 54 is controlled such that the measured temperature IT47 remains constant during the operation.
At the same time as the yarn nozzle is opened, the valve 30 is reversed by means of an actuating element, such as a magnet 34. As a result, the heater 29 is connected, via line 9, with the exhaust line 32 and the throttle 33. As previously described, the throttle 33 is adjusted in such a manner that its resistance corresponds substantially to that of the yarn nozzle in operation. Consequently, the volume of the air or vapor, which flows through the heater 29, remains constant. At the same time as the yarn nozzle is opened and the valve 30 is reversed, the actual value switch 51 and the set-point switch 57 switch to their respective zero setting. Therefore, the regulation in the regulating circuit of the circuit breaker 54 discontinues. Instead, by a corresponding switching of the regulating circuit, the circuit breaker 54 is held in the operating position, which was previously determined and stored while the yarn nozzle is closed. Thus, the circuit breaker 54 does not change its operating position as a result of opening the yarn nozzle. Consequently, the energy supply to the heater 29 remains unchanged, when the nozzle is opened. Since the throughput flow rate of the heating medium also remains unchanged, the temperature does not change either.
When the yarn nozzle is closed, the valve 30 reverses automatically and likewise the switching elements 51 and 57. Consequently, the heater is again connected with the yarn nozzle. At the same time, the regulating circuit of the circuit breaker 54 receives again both the measured actual value of the temperature IT47 and the set-point value of the temperature ST47. Consequently, a regulation occurs again in the meaning that the temperature on sensor 47 remains constant.
In the drawings and specification, there has been set forth preferred embodiments of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A yarn texturing apparatus is disclosed which includes a nozzle having a yarn duct therethrough, and a perforated stuffer box at the outlet end of the duct. Heated air is introduced into the duct, and the air is heated by a heater which is positioned in the air supply line leading to the nozzle. The output of the heater is controlled by a temperature sensor which is positioned inside the stuffer box. Also, the nozzle comprises two confronting sections which can be separated to facilitate yarn thread-up, and a valve is provided in the supply line to divert the heated air to an exhaust line when the nozzle is opened. A second temperature sensor is positioned in the supply line and is operative when the nozzle is opened to regulate the output of the heater and avoid large fluctuations of its output. In a further embodiment, the heater is controlled by a circuit which stores the signal from the temperature sensor in the stuffer box, and this stored signal is utilized to control the heater when the nozzle is opened.
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This is a Continuation of application Ser. No. 040,948, filed April 21 1987 now abandoned.
BACKGROUND OF THE INVENTION
In the manufacture of paper, fabric belts are employed in the papermaking machines, such fabric belts may be formed from an endless loop which is woven as an endless loop or may be formed as flat segments whose ends are joined by a seam. Both methods have distinct advantages and disadvantages, typically endless belts are more complex to manufacture and more difficult to install. Installation of such endless belts or loops often requires partial disassembly of the papermaking machine for insertion. Such endless belts are employed however, because they do not have a seam which can effect product quality. Belts formed as flat segments whose ends are joined by a seam are much simpler to install in a papermaking machine. However, insertion of a pintle yarn or yarns which are employed to close the seam can be a difficult task. Also, the seam area can often result in undesirable marks on the product. Often, such pintle yarn or yarns are shaped for example flat or round having a flat side and two pintle yarns are employed one being inserted from each side of the belt. The proper alignment of the pintle within the fabric seam can be difficult to obtain, especially when pintles of other than circular cross sections are employed.
In the past, wire guides or leads have been attached to pintle yarns to assist in threading the pintle yarn through the fabric seam. Such guide wires were relatively stiff in comparison to the pintle yarn to make insertion easier. However, the attachment of a long relatively stiff guide wire to a pintle yarn results in a combination which is difficult to handle. Often, the guide wire and/or the attached pintle yarn can become tangled or kinked. Problems with tangling are especially prevalent when pintles with other than a round cross section are being employed which require a specific orientation within the seam. In order to properly orient the pintle in the seam, it is often necessary to remove the guide wire and start over, resulting in a free guide wire and pintle which easily becomes tangled or kinked.
SUMMARY OF THE PRESENT INVENTION
The present invention provides an easily manipulated pintle yarn and guide wire spool apparatus for use in seaming papermaking fabric. The present invention provides an apparatus which allows an operator inserting a pintle yarn to use a guide wire which may be easily respooled during repeated insertion or withdrawal to obtain a desired orientation and further can be reused after respooling of the guide wire and pintle yarn. The present invention further provides a convenient shipping and handling apparatus for a pintle yarn guide wire combination.
DESCRIPTION OF THE DRAWINGS
FIG. 1A is a plan view of a pin seam in a papermakers fabric.
FIG. 1B is a side view taken along line B--B of FIG. 1A.
FIG. 2 is a perspective view of the present invention.
FIG. 3 is a cross section taken along line 3--3 of FIG. 2.
FIG. 4 is an enlargement partially in cross section of the swedge connection of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1A is a top plan view of a typical seam in a papermakers' fabric. The seam 40 connects a first end 42 of a fabric belt to a second end 44 of the belt to form an endless loop. The seam 40 forms a part of a woven base onto which unwoven batts are needled. The woven base can be a single ply as shown or can be multi-ply. The woven base comprises cross machine direction threads 45 and machine direction threads 46. The exposed ends of the machine direction threads 46 are formed into loops 47 and 48 on fabric ends 42 and 44 respectively. The loops 47 and 48 intermesh in an alternating fashion to form a substantially tubular opening through which pintle 24 is inserted to close the seam.
The present invention comprises a generally ring shaped apparatus as shown in FIG. 2. In the preferred embodiment the apparatus is approximately 8 inches in diameter. The apparatus 5 is easily held in the hand while the guide wire is being inserted in a fabric seam 40 as more fully described herein below. The apparatus 5 includes a circular element, cover 10 having a "U" shape cross section with the uprights of the "U" shape 10a and 10b being substantially parallel. The opened end 10c of the "U" shape is preferably on a radial surface of the tubular shape rather than a circumferential surface. The cover 10 includes an opening 14 which extends through the outer circumferential upright 10a of the "U" shape. The base 10d of the "U" shape, formed opposite the opened end 10c can include means to mount or grip the cover 10 such as holes 16.
A spool 20 adapted to fit between the uprights 10a and 10b of cover 10, substantially filling the space therebetween is provided. Spool 20 is a circularly shaped element preferably having a substantially "U" shape cross section with the opening 20a of the "U" shape being oriented on the outer circumferential surface. Orientation of the spool 20 within the cover 10 defines a cavity 11 adapted to receive windings of pintle yarn 24 and guide wire 26, FIG. 3.
The spool 20 preferably fits closely within the cover 10 such that relative rotation between spool 20 and cover 10 is possible but with sufficient frictional contact that spool 20 is retained within cover 10. To provide the desired close fit between cover 10 and spool 20, the dimension of the cover 10 and spool 20 are carefully controlled during molding or machining of the parts. For example, the gap between leg 10a and base 20d can preferably range from 0.005 in. to 0.01 in. and is more preferably between 0.005 in. and 0.007 in. Similarly, the gap between the distal ends of uprights 20a and 20b and upright 10b can preferably range from 0.005 in. to 0.01 in. and is more preferably between 0.005 in. and 0.007 in.
While cover 10 and spool 20 are shown as having "U" shapes in cross-section which interfit to form cavity 11, the cover 10 and spool 20 can be easily adapted to other shapes. The required shapes of spool 20 and cover 10 are such that they define a cavity 11 adapted to receive pintle yarn/guide wire combination and allow relative rotation between the cover 10 and spool 20. The shapes of spool 20 and cover 10 also expose a portion of both cover 10 and spool 20 so that it is possible to rotate the spool 20 with respect to cover 10 in either direction. Also, it is preferable that spool 20 be releasably held in position by cover 10 or vice versa.
The spool 20 is adapted to receive windings of pintle yarn 24 and guide wire 26 thereon. The pintle yarn 24 is attached at one end to the spool and wound onto spool 20 with guide wire 26 attached to the free end of pintle yarn 24 and wound about the spool concentric with the pintle yarn 24. The guide wire 26 is attached to the pintle yarn 24 by a swedge 30 which is a tubular element adapted to receive the pintle yarn 24 in a first end 30a and the guide wire 28 in a second end 30b. The swedge 30 is then crimped, as at 37 and 38, to grip the pintle yarn 24 and the guide wire 26 respectively.
A sufficient length of guide wire 26 for the width of the seam to be joined is wound about spool 20 concentric with the windings of pintle yarn 24. The free end 32 of the guide wire 30 is oriented through opening 14 of the circumferential leg 10b of cover 10 as the spool 20 is oriented in cover 10. Spool 20 may include a hole 24 or other means to assist in rotating the spool when it is oriented within cover 10.
The preferred size and shape of the apparatus 5 of the present invention provides a convenient shipping and handling apparatus for use when seaming a papermakers fabric. The ring shape of the apparatus is easily held in one hand by an operator, freeing the other hand to insert the guide wire, or to rotate the spool 20 with respect to the cover 10 to respool the guide wire/pintle yarn combination if necessary. The preferred embodiment even allows the operator to use the thumb on the hand holding the apparatus to rotate the spool 20 with respect to cover 10 to allow more freedom in directing the guide wire/pintle yarn combination through a seam 40 with the free hand. The exposed first end 32 of the guide wire 26 is typically provided with a removable protective cover 34 during shipping and handling.
In use, the present invention greatly simplifies the insertion of a pintle yarn 24 into a fabric seam 40, as in joining the ends 42 and 44 of a belt in a papermaking machine. The apparatus 5 allows for the easy storage and handling of a variety of shapes and sizes of pintle yarn with an appropriately sized guide wire.
In use, protective cover 34 of the guide wire 26 is removed and the guide wire 26 is inserted into the fabric seam to be closed. As the guide wire 26 is being inserted into the fabric seam, the wire is withdrawn from the apparatus 5 by rotation of spool 20 in a clockwise direction with respect to cover 10 either by pulling on the guide wire or by manually rotating the spool 20 with respect to the cover 10 as described above. If during insertion, it is necessary to withdraw a portion or all of the guide wire from the seam, the withdrawn wire may be easily respooled by rotating the spool 20 counterclockwise with respect to cover 10 to prevent tangling or kinking of the pintle yarn/guide wire combination.
Relative rotation between spool 20 and cover 10 is facilitated by holes 24 and 16 respectively and by a cover 10 configuration which in combination with spool 20 defines a cavity 11 yet allows a portion of spool 20 to remain exposed for manipulation. Upon insertion of the guide wire 26 into the seam, the pintle yarn 24 is pulled through the seam by the guide wire 26. The pintle yarn 24 is then cut from the spool 20 and guide wire 26 and the ends trimmed and staked in a conventional manner.
Spool 20 and guide wire 26 may be reused. If sufficient pintle yarn remains on the spool, the guide wire may be reattached with a new swedge 30 and the guide wire 26 rewound upon spool 20 for reuse. Because many end users do not have the proper equipment to reattach a new swedge 30, it is preferable to supply a spool 20 and guide wire 26 with sufficient pintle yarn 24 to fill a number of seams. For example, a spool 20, guide wire 26 and pintle yarn 24 combination may include up to three times the pintle yarn 24 length required to fill a seam. Upon inserting the guide wire 26, the full length of the pintle yarn 24 is pulled through the seam. The excess pintle yarn 24 with guide wire 26 still attached is severed and respooled. Thus, a single original manufacturers swedge attachment between guide wire 26 and pintle yarn 24 may be employed in closing a number of seams. A typical pintle yarn 24 material exhibits an abrasion resistance and tenacity such that repeated pulling through the seams has substantially no effect on the integrity of the seam closed by a pintle yarn 24 which has been pulled through a number of seams in this manner.
The close frictional contact between cover 10 and spool 20 while surface 20d of spool 20 remains exposed allows for the manipulation of spool 20 to unwind or wind the guide wire 26 pintle yarn 24 combination. For example, if during insertion the guide wire 26 into a seam, there is some problem such as misalignment, the guide wire 26 can be completely removed from the seam and easily rewound upon spool 20 and the insertion process started over. Further, the frictional fit between the cover 10 and the present invention allows the cover 10 and spool 20 to be easily separated when the supply of pintle yarn is exhausted or so that a guide wire may be attached to the pintle yarn for spooling and reuse.
It should be understood that the foregoing description is not intended to be limiting but is only exemplary of the invention which is defined in the claims.
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An apparatus for a pintle yarn/guide wire combination used to close a seam in a papermakers fabric. The pintle yarn/guide wire combination is wound upon a spool which is partially enclosed by a cover. The spool and cover can be reversibly rotated with respect to each other to allow unwinding or respooling of the pintle yarn/guide wire combination during the seaming operation.
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CROSS-REFERENCE TO RELEVANT PATENTS
Finishing Apparatus, U.S. Pat. No. 3,318,051 issued May 9, 1967 to John F. Rampe, here the "Finishing Patent."
Finishing Apparatus, U.S. Pat. No. 3,337,997 issued Aug. 29, 1967 to John F. Rampe, here the "Orbital Patent."
Vibratory Finishing Machine, U.S. Pat. No. 3,449,869 issued June 17, 1969 to John F. Rampe, here the "Dual Shaft Patent."
Clamping Means For Tub Liners, U.S. Pat. No. 3,538,651 issued Nov. 10, 1970 to John F. Rampe, here the "Tub Liner Patent."
Continuous Feed Vibratory Finishing Machine With Discharge Rate Controlled By Operation Of Tub Discharge Closure, U.S. Pat. No. 3,831,322 issued Aug. 27, 1974 to John F. Rampe, here the "Continuous Feed Patent."
Finishing Apparatus With Improved End-Of-Tub Liner And Door Structure, U.S. Pat. No. 3,906,680 issued Sept. 23, 1975 to John F. Rampe, here the "Door Assembly Patent."
Finishing System Wih Cyclically Operable Closure Control, U.S. Pat. No. 3,959,932 issued June 1, 1976 to John F. Rampe, here the "Object Sensor Patent."
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to finishing machines and more particularly to vibratory finishing machines of the continuous feed type having discharge systems for controlling the retention time of workpieces within the tubs of the machines.
2. Prior Art
Vibratory finishing machines for smoothing and finishing workpiece surfaces by such operations as deburring, burnishing, descaling, and cleaning are well known, as is apparent from the disclosures in the referenced Finishing Patent, Orbital Patent, Dual Shaft Patent, and Continuous Feed Patent. Such machines commonly employ a movably mounted processing tub for receiving a quantity of workpieces and abrasive finishing media. A finishing action is imparted to the workpieces by vibrating the tub.
The type of abrasive media used in finishing operations varies substantially depending on the type of operation to be conducted. In many finishing operations, the abrasive finishing media comprises a multiplicity of modestly sized, generally triangular abrasive stones, and a small quantity of finishing liquid.
As is explained more fully in the above-cited patents, to which reference is made for a more complete description of finishing machines and techniques, the abrasive finishing media is conveniently separated from the workpieces after the media and the workpieces are discharged from the tub. After separation, the abrasive media is returned to the tub for reuse. The finishing liquid is usually drained off during separation of the media and workpieces and may also be returned to the tub for reuse. The finished workpieces are then normally conveyed to a separate unit or units for washing, drying, inspection and packaging.
Vibratory finishing machines are often categorized as being either of the batch type or the continuous feed type. In a batch-type operation, the machine is fully loaded, a finishing operation is carried out, and the machine is completely emptied. In continuous feed operation, media and workpieces are introduced into the tub near one end and are subjected to a finishing operation during orbital movement toward a discharge outlet at the opposite tub end. Continuous feed machines may be truly continuously fed, as by the use of charging conveyors or the like, or may periodically be fed with charges of media and workpieces. Regardless of how the machines are fed, they may continuously or periodically discharge quantities of the media-workpiece mixture through the tub outlet.
One problem with many prior continuous feed machine proposals is that the time during which workpieces are retained in the tub is not readily controllable. Workpieces of relatively soft metal or workpieces needing only minimal deburring require only short retention times to complete a finishing operation. Workpieces of harder metal or workpieces having many large burrs to be removed require longer retention times for satisfactory finishing. Where the required retention time of a particular operation differs from the design characteristics of the continuous feed machine in which the operation is to be performed, it may be necessary to operate the machine on a batch basis to effect adequate control of tub time.
The machines described in the referenced Continuous Feed Patent and Door Assembly Patent are provided with discharge systems for controlling retention time. These machines may be operated on a batch basis, if necessary, but are designed primarily for continuous operation wherein their discharge closures are opened and closed by a time control device preset to selected intervals of operation. Once a closure operating cycle has been decided upon, the operator adjusts the timing mechanism to close the discharge, typically for about 10 seconds, for processing workpieces in the tub. This is normally followed by a release period, typically about five seconds, for discharging part of the materials from the tub. This cycle of closure operation is continuously repeated and establishes an effective rate of material discharge from the tub which, in turn, determines the time span during which workpieces are retained in the finishing tub. In the event the finishing operation calls for longer or shorter processing times, the operator resets the time mechanism to provide correspondingly longer or shorter workpiece retention periods.
Although the closure control system described in the Door Assembly Patent operates quite satisfactorily to control workpiece retention time, the system is rather expensive. The control system required to vary the operating cycle and the associated safety systems (see the Object Sensor Patent) needed to prevent the crushing of workpieces trapped between the closure and tub outlet are relatively complex and add significantly to the cost of the machine.
SUMMARY OF THE INVENTION
The present invention overcomes the foregoing and other disadvantages of the prior art by providing a novel and improved discharge system including improved finishing methods and apparatus. One feature of the invention resides in the provision of a discharge structure of extremely simple construction which is capable of controlling workpiece retention time in continuous feed vibratory finishing machines.
A vibratory finishing machine is provided with a tub having a longitudinally extending wall closed at opposite ends. An outlet is provided through one of the tub ends at the level of the tub bottom. The longitudinally extending wall defines a generally horizontal path of workpiece-media mixture movement toward the outlet. The outlet is closed by a flap-type gate or closure. The media-workpiece mixture in the tub bears against the closure in an opening direction allowing the workpieces and media to discharge.
The tub outlet provides a terminal edge which is inclined at an acute angle to the horizontal. A flexible flap-type closure is mounted for movement toward and away from the terminal edge and is exposed to pressure forces generated by the weight of the media-workpiece mixture bearing against the closure. A set of adjustable, individually removable weights bias the closure toward engagement with the terminal edge to close the tub outlet.
The addition of media-workpiece mixture to the tub increases pressure forces exerted by the mixture on the closure until it overcomes the closing force applied by the weights. The closure accordingly opens and material discharges from the tub. Discharge continues until the closing force applied by the weights exceeds the opening force applied by the media-workpiece mixture. The closure then moves to a closed position and discharge stops. This action continues in a cyclical fashion providing periodic discharge of materials through the tub outlet and establishing an effective rate of material movement through the tub. As will be apparent, the rate at which materials move through the tub determines the period during which workpieces are retained in the tub, i.e., tub retention time.
In order to increase tub retention time, more weight is added to the closure thereby requiring greater pressure forces to discharge materials, and thereby lengthening tub retention time. In order to decrease tub retention time, weights are removed from the closure thereby permitting pressure forces of lesser magnitude to open the closure.
It has been found that the discharge system of this invention is particularly effective when the size and mass of the individual workpieces is substantially greater than the size and mass of the media.
It is an object of this invention to provide an improved vibratory finishing system, including finishing methods and apparatus for controlling the nature of a finishing action imparted to workpieces.
Other objects and a fuller understanding of the invention may be had by referring to the following description and the claims taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a vibratory finishing machine incorporating a preferred practice of the present invention;
FIG. 2 is an enlarged cross-sectional view of the machine of FIG. 1 as seen from a plane indicated by a line 2--2 in FIG. 1;
FIG. 3 is an enlarged portion of the illustration of FIG. 2; and,
FIG. 4 is a diagram illustrative of the forces acting on the outlet closure of the finishing machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a continuous feed vibratory finishing machine 10 comprises a frame 12 and a tub 14 mounted thereon for vibratory movement by a plurality of substantially cylindrical, resilient, elastomeric mounts 16. A vibratory drive system is provided to vibrate the tub 14. The drive system typically includes such elements as rotatable eccentric weights 18 disposed in elongated housings 20 on opposite sides of the tub 14. A suitable guard 22 encloses a power transmission system which rotates the eccentrics 18 in synchronism, as described in the referenced Dual Shaft Patent.
The tub 14 is of the type described in the referenced Dual Shaft Patent. Referring to FIGS. 1 and 2, the tub 14 has a bottom wall portion 24 and upstanding sidewall portions 26 which cooperate to define an elongated, generally U-shaped trough into which workpieces and finishing media may be deposited for finishing. Upper ends of the sidewall portions 26 have longitudinally extending flanges 28 which define a tub opening 30 therebetween. A pair of inlet and outlet end plates 32, 34 close opposite ends of the tub 14.
Inwardly facing surfaces of the wall portions 24, 26 are covered with a resilient layer of tub lining material 36, as described in the referenced Tub Liner Patent. Inwardly facing surfaces of the inlet and outlet end plates 32, 34 are covered by sheets of tub lining material, as described in the referenced Door Assembly Patent, one of which sheets is indicated by the numeral 38 in FIG. 2. Bolts 40 clamp the liner sheet 38 between the outlet end plate 34 and a flange-defining structure 42 which is welded to the end of the tub 14.
The outlet plate 34 provides an outlet opening 44 in alignment with the bottom of the tub 14 so that media, finished workpieces, and such other materials as may be present in the tub 40 may be discharged without obstruction. A discharge structure 46 comprising an important part of this invention is affixed to the outlet end plate 34, and periodically opens to allow the discharge of material from the tub 14.
The discharge structure 46 comprises a discharge spout 48 of generally U-shaped cross-section. The discharge structure 46 has a bottom wall portion 50 which is generally coplanar with the bottom tub wall portion 24, and has a pair of generally upright sidewall portions 52. The discharge spout 48 is welded to a mounting plate 54. The mounting plate 54 is secured to the tub end 34 by a plurality of suitable threaded fasteners 56. The tub end liner sheet 38 has portions 58 which extend into the spout 48 and line its interior surfaces.
The discharge spout 48 has a terminal edge 60 which defines a discharge opening 62 at one end of the discharge spout 48. All surface portions of the terminal edge 60 lie in a common plane which is inclined at an acute angle relative to the plane of the outlet end plate 34. The terminal edge 60 is positioned so that a closure 66 can be draped over it and can be biased into firm engagement thereagainst by its own weight, thereby closing the discharge opening 62.
The closure 66 preferably comprises a member 68 formed of any suitable resilient, flexible material, for example, an organic polymeric material such as urethane. The resilient character of the member 68 protects it from the abrasive action of material discharging through the discharge opening 62, and protects the materials from being scratched or otherwise damaged by the member 68. The member 68 is pivoted or swingably mounted on the outlet end plate 34 for movement toward and away from the terminal edge 60. In the preferred embodiment, a plurality of threaded fasteners 70 clamp upper portions of the member 68 into rigid engagement with the outlet end plate 34. Since the center of gravity of the closure 66 is spaced from the fasteners 70, it will be evident that a gravitationally induced clockwise moment is applied to the member 68 tending to force or bias lower portions of the member 68 into firm engagement with the terminal edge 60.
In operation, a mixture of media and workpieces to be finished is added to the tub 14 through the opening 30 at a location away from the tub outlet opening 44. The mixture migrates through the tub 14 in a helical, orbital fashion, precessing toward the tub outlet opening 44 as the eccentric mechanisms 18 vibrate the tub 14. The mixture ultimately passes through the outlet opening 44 and is received in the discharge spout 48. As the discharge structure 46 opens and closes periodically, it establishes an effective rate at which mixture discharges from the spout 48 through the discharge opening 62. The effective discharge rate established by the discharge structure 46, in turn, determines the effective average retention time for workpieces in the tub 14.
An adjustable weight arrangement 72 is provided on lower portions of the closure member 68. As is shown in FIGS. 2 and 3, the weight arrangement 72 includes two metallic plates 74 embedded in the member 68 and captivating thereunder the heads 76 of a plurality of bolts 78. The bolts 78 project through openings 82 formed in the plates 74 and carry nuts 80 on their threaded ends to clamp a plurality of weight plates 84 in place adjacent the member 68.
The size and placement of the weight plates 84 are selected to efficiently position the closure member 68 in engagement with the terminal edge 60 for closing the outlet opening 62. The weight plates 84 are of sufficient length to span the distance between the spout sidewalls 52, as is best seen in FIG. 1. The weight plates 84 are arranged in an upper and lower set, and the lowermost set is disposed in substantially the same horizontal plane as the bottom edge of the discharge opening 62. The uppermost set of the weights 84 is spaced only slightly above the lowermost set. Both of the sets of weights 84 are disposed toward the lower half of the discharge opening 62.
Referring to FIG. 4, there is illustrated a schematic representation of the forces acting on the closure 66 during operation of the finishing machine 10. For purposes of illustration, it may be assumed that the closure 66 is mounted for pivotal movement about an axis represented by a point 90. The effective weight of the closure 66 and of the weight arrangement 72 is represented by an arrow W. The weight force W acts through a center of gravity indicated by a point 92 to produce a force component indicated by an arrow F c . The force component F c tends to bias the closure 66 toward the terminal edge 60 and thereby produces a clockwise closing moment indicated by the arrow M c . The moment M c is the product of the force F c and its distance L c to the pivot axis 90.
Opposing the closing moment M c is an opening moment indicated by an arrow M o about the axis 90. The opening moment M o is caused by a component of the weight or mass of the workpiece-media mixture in the tub, which component can be thought of as a pressure force acting against the closure 66. While vibration of the mixture is occurring, the mixture assumes many characteristics of a fluid and essentially exerts a pressure force on such portions 94 of the closure 66 as are in contact with the media-workpiece mixture. This pressure force can be integrated with respect to the area of the region 94 to give a comparable horizontal force indicated by an arrow F h . The horizontal force F h includes a component or an opening force indicated by an arrow F o acting through a center 96 of the region 94. The magnitude of the opening moment M o is the product of the force F o and its distance L o from the pivot axis 90.
The closure 66 moves toward an open position whenever the opening moment M o exceeds the closing moment M c . The closure 66 moves toward a position closing the outlet opening 62 when the closing moment M c exceeds the opening moment M o . Because the closing moment M c is substantially constant unless the weight arrangement 72 is modified, it is apparent that the opening of the closure 66 is a function of the magnitude of the opening force F o and is accordingly a function of the pressure forces exerted by the media-workpiece mixture on the closure 66.
Since the closure 66 opens and closes as a function of the weight of the media workpiece mixture in the tub 14, it will be evident that the closure 66 opens and closes as a function of the rate at which workpieces and/or media are introduced into the tub 14. As workpieces and media are periodically or continuously added to the content of the tub 14, the weight of the mixture and hence the pressure forces applied to the closure 66 will increase, thereby increasing the horizontal force component F h and consequently increasing the opening moment M o . At some time during the addition of media and workpieces to the tub 14, and in view of the precessing action of workpieces and media in the tub 14, the opening moment M o will exceed the closing moment M c thereby causing the closure to move 66 to an open position allowing discharge of media and workpieces through the discharge opening 62. At some time during the discharge of workpieces and media from the tub 14, the pressure forces applied to the closure 66 by the mixture of media and workpieces decreases to a point where the closing moment M c exceeds the opening moment M o , thereby causing the closure 66 to move to a closed position.
The illustration and description relating to FIG. 4 is something of an oversimplification inasmuch as it assumes that the closure 66 is rigid, which of course, it is not. Due to the flexibility of the closure 66, the pivot axis 90 is not precisely fixed. Nonetheless, it will be understood that FIG. 4 and the discussion associated with it present a reasonably accurate description of the type of force interactions which cause the closure to periodically open and close.
An interesting and totally unexpected phenomena has been discovered in conjunction with the operation of the described discharge system. It has been found that small abrasive finishing media is apparently retained in the tub 14 with lower pressures than are required to retain large workpieces in the tub 14. Accordingly, the discharge structure 46 can be used, to some extent, to discriminate between relatively small media and relatively larger workpieces and to thereby provide a discharge mixture which has a relatively higher percentage of workpieces than would otherwise normally occur. Stated in another way, it is apparent that relatively large, massive workpieces are more effective in providing the force component F h shown in FIG. 4 than are relatively smaller abrasive finishing media, and the closure 66 will open more readily in response to these workpieces bearing against it than it will in response to the pressure of finishing media. While this phenomena is not fully understood, its discovery is significant in that it permits media to be retained in the tub 14 more effectively than would otherwise occur, while permitting workpieces to discharge without obstruction.
Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed. It is intended that the patent shall cover, by suitable expression in the appended claims, whatever features of patentable novelty exist in the invention disclosed.
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A vibratory finishing machine has an elongated tub including a longitudinally extending wall closed at opposite ends. A discharge passage is provided through one of the tub ends and communicates with a discharge spout having an inclined U-shaped terminal edge. A flexible closure is draped over the discharge spout and engages the terminal edge to retain workpieces and media in the tub. An adjustable weight arrangement is provided on the closure for selectively controlling the closing force operative between the closure and the terminal edge. Workpieces and media in the discharge spout bear against the closure and bias the closure in an opening direction. When the opening force imposed by the workpieces and media exceeds the closing force applied by the weight arrangement, the closure opens to discharge workpieces and media from the tub.
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BACKGROUND OF THE INVENTION
The instant application should be granted the priority dates of Oct. 18, 2005, the filing date of the corresponding German patent application 10 2004 030 063.1, as well as Mar. 8, 2005, the filing date of the International patent application PCT/EP2005/002441.
Rotating field machines of the type under consideration are also designated as bell-shaped rotors. They generally have a stationary inner and outer stator and a rotatably mounted rotor, whereby the latter is formed by a bell. Permanent magnet elements can be disposed in the bell for a magnetic bias.
The requirements regarding regulatability and the dynamics of electric motors constantly increase. A decisive criterion of the properties of electric motors is therefore the moment of inertia of the rotor or the quotient of generated torque and moment of inertia of the rotor. Particularly good characteristics in this regard are demonstrated by bell rotors, which, however, have a limited torque due to the unidirectional transfer of torque, since the rotor twists too greatly as the torque increases. In addition, bell-shaped rotors have problems with regard to heat dissipation, so that also for this reason the permissible power absorption is limited, which is particularly true if the bell is made of a polymeric material or a winding. In the article by W. R. Canders, H. Masebach, F. Laube “Technologies and Limits of High Torque Drives”, page 17ff, a bell-shaped rotor having a rotor provided of permanent magnets is described. The rotor is mounted on the end face bf the housing as well as on the shaft. The permanent magnets are disposed in the rotor between outer and inner stators, whereby not only the outer stator but also the inner stator each carry magnet or excitation coils. The described drives are slowly rotating drives having high torque, whereby the rotor for the most part is comprised of soft iron, resulting in a high moment of inertia. On page 19 of the article, a rotor having only one row of permanent magnets is illustrated, thus leaving to speculation how the permanent magnets are mounted in the rotor. With this embodiment, the outer and inner stators, together with the permanent magnets of the rotor, form a common magnet circuit.
No expedient nor reliable mounting of the permanent magnet elements is disclosed in the above mentioned article. In particular for rapidly rotating field machines, the mounting of the permanent magnet elements pursuant to the article by W. R. Canders is not suitable.
It is therefore an object of the present invention to provide a bell-shaped rotor drive for high speeds having great torque, according to which the permanent magnet elements are reliably mounted.
SUMMARY OF THE INVENTION
This object is inventively realized by an electrical drive having stationary outer and inner stators: a rotatably mounted rotor provided with at least one pot-shaped element having a cylindrical wall as well as a base wall, wherein the cylindrical wall is thin-walled and is made of a magnetic material, wherein the base wall extends perpendicular to an axis of a rotor shaft and the cylindrical wall extends coaxial thereto, and wherein the base wall is connected to the rotor shaft to enable transfer of torque; at least one electrical excitation coil; and a plurality of permanent magnet elements secured to the rotor for producing an excitation flux, wherein the permanent magnet elements rest only against a radially inner side of the cylindrical wall and in a circumferential direction are disposed next to one another, wherein the permanent magnet elements, together with the outer and inner stators, form magnetic circuits that pass radially entirely through the cylindrical wall, and wherein the permanent magnet elements have a radial thickness that is greater than the thickness of the cylindrical wall.
The present invention is based on the concept that a bell-shaped rotor having a small moment of inertia is required if the drive is to be designed for high speeds having high dynamics. A small moment of inertia with a simultaneously high torque and high reliability, as well as protection should the permanent magnet elements be destroyed, is advantageously achieved in that the permanent magnet elements rest at least against the inside of a cylindrical wall of a pot-shaped element. In this connection, the permanent magnet elements are advantageously disposed in only one layer, whereby the cylindrical wall is advantageously made of a magnetic material and has a thin-walled construction. In contrast to the known bell-shaped rotors, it is an essential feature of the inventive drive that the magnetic fluxes of the magnetic circuits that are formed pass radially entirely through the permanent magnet elements as well as the cylindrical wall, in other words, that the outer and inner stators, together with the rotor, form at least one common magnetic circuit. A magnetic short circuit via the rotor does not occur or is negligible.
A particularly good encasement, with a simultaneously easy assembly, can be achieved if the permanent magnet elements are disposed between two cylindrical walls that are coaxially disposed within one another. In this connection, the cylindrical walls are either parts of two pots that are coaxially disposed within one another, whereby their cylindrical walls are spaced from one another by the thickness of the permanent magnet elements. However, it is equally possible for the cylindrical walls to be formed on and/or secured to one and the same base wall. In this connection, at least one base wall is to be connected to the shaft for the transfer of force. A preferred embodiment results if the bell is formed by an outer pot having an inwardly disposed sleeve, whereby the permanent magnet elements are disposed between the sleeve and the outer pot. With this embodiment, the sleeve can be connected to the cylindrical wall or to the base wall of the outer pot, for example by welding.
The invention also provides for a plurality of pot-shaped elements or bells to be disposed axially next to one another on the shaft and to together form the rotor. In this connection, the base-shaped walls of two pots that are disposed next to one another are formed by a common base wall. It is also possible for the cylindrical wall of two adjacent pot-shaped elements to be formed by a common sleeve, whereby the transfer of force is then effected by a common base wall or by two or more base walls from the cylindrical wall to the shaft.
By dividing the magnets to a plurality of pot-shaped elements, the necessary length of the permanent magnets can advantageously be kept small.
It is, of course, also possible to dispose a plurality of permanent magnets next to one another in the axial direction in a pot-shaped element. The same also applies for the arrangement of a plurality of pot-shaped elements that are arranged axially next to one another and that also can respectively have a plurality of permanent magnets that are arranged axially next to one another. The axial length of the pot-shaped elements that are arranged axially next to one another can also differ from one another.
In the circumferential direction, it is particularly advantageous to support two magnets on an appropriate configuration of the pot, for example corrugations, and to fill the intermediate space with a material having a large temperature expansion coefficient (for example casting resin), so that upon transfer of the peripheral forces a temperature compensation is taken into account. This is necessary since the permanent magnets have a very small expansion coefficient.
The previously described pot-shaped elements have a configuration similar to the bells of known bell-shaped rotors. The cylindrical wall is, however, radially supported on the shaft only via the base wall. The cylindrical wall of the bell is preferably made of magnetic conductive material.
The electrical drive can be designed not only as an internal rotor but also as an external rotor, whereby the internal rotor is characterized in that the magnet or excitation coils are disposed on the outer stator. The external rotor is characterized in that the magnet or excitation coils are disposed exclusively on the inner stator. However, it is also possible to provide excitation coils not only on the outer stator but also on the inner stator.
The drive is used either as a continuously rotating motor, a stepping motor or a segmented motor. Similarly, it is also possible to use the drive as a linear drive, in which case the rotor does not rotate about its axis, but rather is displaced back and forth in the axial direction by the magnetic field.
It is also possible for the coils of the outer stator and the permanent magnets of the rotor to be disposed as they are with a transversal flux or flow motor. Such a transversal flux motor is described, for example, in the “Handbook for Electrical Small Drives”, Carl Hanser publisher. The inner stator is in this connection to be appropriately designed.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the inventive drive will be explained in greater detail subsequently with the aid of the drawings, in which:
FIG. 1 shows an inventive electrical drive having two bells as internal rotors;
FIG. 1 a is a detailed illustration of the construction of the bells;
FIG. 1 b is a cross-sectional illustration through a bell;
FIG. 1 c is a cross-sectional illustration through a bell having permanent magnet elements with a quadrilateral profile;
FIG. 2 shows an inventive drive with excitation coils on the outer as well as on the inner stator, whereby the excitation coils of the inner stator critically generate the magnetic flux;
FIG. 3 shows an inventive drive having excitation coils on the outer as well as on the inner stator, whereby the excitation coils of the outer stator critically generate the magnetic flux;
FIG. 4 shows the inventive drive as an external rotor having a single-wall bell;
FIG. 5 shows an inventive drive with permanent magnet elements that are radially encased on both sides;
FIG. 6 shows a drive with only a double-walled bell;
FIG. 7 shows an inventive drive as a segmented motor;
FIG. 8 shows an inventive drive as a linear motor.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows a longitudinal cross-section through a first embodiment of an inventive drive. To transmit the torque generated in the drive, a drive shaft 1 is provided that, via two roller bearings 2 , is rotatably mounted in the housing of the drive. The housing is composed of the two housing portions 4 and the housing cover 3 . The housing portions 4 are provided with cylindrical walls 4 a that are formed on the end housing walls 4 b . The cylindrical walls 4 a carry the inner stator 11 , 11 a , which is in two parts and forms an intermediate space Z in the middle. By means of the intermediate space Z, the base walls 8 b of the pot-shaped element 8 extend through and their outwardly directed collars 8 c is supported, for example in a positively engaging manner, on the central portion 1 a of the shaft 1 . In the axial direction, the pot-shaped elements 8 are prevented from shifting axially via retaining rings 13 that are positively disposed in grooves of the central portion 1 a of the shaft 1 . The disk-shaped base walls 8 b of the pot-shaped elements face one another, so that the inner stators 11 , 11 a , which are disposed on the cylindrical walls 4 a of the housing portions 4 , are axially insertable into the pots, which have permanent magnets 14 disposed thereon.
Each pot-shaped element 8 has a cylindrical wall 8 a that is formed radially outwardly on the base wall 8 b and that, together with the sleeve 9 that is disposed toward the inside, forms a chamber for the permanent magnets 14 . As can be seen from FIG. 1 a , the cylinder 9 is secured to the base wall 8 b of the pot-shaped element 8 via weld locations S. For this purpose, the inner cylinder 9 is provided with an inwardly directed collar 9 b . In addition, the inwardly disposed cylinder 9 a is provided with an outwardly directed collar 9 that holds the permanent magnets 14 in the axial direction. A construction that does not have a sleeve 9 is also possible (see FIG. 2 ).
The inventive drive illustrated in FIG. 1 is embodied as a so-called internal rotor, in other words, merely the outer stator 5 , 6 carries magnet or excitation coils 12 (disposed in the recesses 4 c of the housing walls 4 b ). The inner stator 11 , 11 a serves merely for the magnetic ground or return path. The poles of the outer and inner stators are embodied in such a way that, together with the permanent magnets 14 that are disposed in the pot-shaped element 8 , they form magnetic circuits that pass entirely through the cylindrical walls 8 a and 9 . In this connection, the permanent magnets 14 provide for a magnetic bias.
Due to the magnetic conductance, the magnetic resistance is predominantly formed by the air gaps.
FIG. 1 a shows only portions of the rotor, whereby the inner stator 11 carries magnet or excitation coils 15 . The outer stator is not illustrated in FIG. 1 a . The pot-shaped element 8 , as well as the inner cylinder 9 , can be interconnected by weld connections S or by rivets or adhesively. The magnets 14 are held in the bell by optional sleeves 9 . The sleeves can also be formed of a magnetically non-conductive material.
A thin-walled component as a bell is prone, in particular with additional deformations, as are described in conjunction with FIGS. 1 b and 1 c , to deviations in shape. This can be reduced in that, during assembly of the magnet, the bell is inserted into the bore of a device that reproduces the desired contour. After assembly of the magnet, a non-magnetic ring 8 g is then pressed in and embedded in casting resin or welded at the end face. In addition to the casting resin, this ring prevents a larger shape deviation when the component is appropriately removed from the device.
FIG. 1 b shows a cross-section through a segment of the rotor. The cylindrical wall 8 a of the outer pot is provided with corrugations or indentations 8 d that extend in the axial direction and between which are mounted the permanent magnet elements 14 . The spacing of the indentations 8 d relative to one another is somewhat greater than the widths of the permanent magnets 14 , whereby the remaining intermediate space is filled with a material or filler 16 , for example casting resin, that compensates for the expansion differences of the individual components relative to one another when temperature fluctuations occur. As is known, transverse to the direction of magnetization the magnets have very small or negative expansion coefficients. As an additional security, the inwardly disposed cylinder 9 can rest against the inside of the permanent magnets, as illustrated in the longitudinal cross-section of FIG. 1 .
The arrangement of magnet yoke and rotor pursuant to FIG. 1 represents a so-called internal rotor, which has a very small moment of inertia but due to the long pole surfaces and force development on both sides of the permanent magnets achieves a torque that is high relative to the state of the art. The same arrangement can also be embodied as an external rotor with considerably higher torque, but also moment of inertia. If the highest volume-specific torque is demanded relative to the installation space, the external rotor is the proper choice. However, if the smallest torque-specific moment of inertia is required, the internal rotor is the best approach.
The rotor of the inventive drive of FIG. 1 thus comprises two symmetrical, magnetically conductive bells, which on the inner side of the cylindrical surface carry the permanent magnets 14 . Providing two bells shortens the acquired length of the permanent magnets 14 in half, as a result of which these magnets can be produced in a more economical manner. By providing the inner cylinder 9 , the permanent magnets are additionally protected against breakage. Optionally, window-like cutouts or apertures F ( FIG. 1 b ) can be provided that extend over a large portion of the axial length of the cylindrical surface 8 a . The practical purpose of these apertures is to reduce the iron or core losses in the bell as well as the moment of inertia of the rotor. Between the cylindrical walls of the bell and the outer or inner stator respectively is a respective thin air gap 7 , 10 .
The pot 8 is preferably magnetically conductive, and the sleeve 9 is preferably non-magnetic, although it can also be conductive with a non-magnetic pot. This is necessary to avoid a magnetic short circuit in the rotor.
FIG. 1 c shows an outer contour of the bell 8 a , and also of the inner cylinder 9 , that is adapted to conform to the quadrilateral cross-section of the magnets. The corrugations 8 f in the central portion can be smaller, so that the magnets have a small spacing relative to the inner radius of the corrugations; this spacing must be as small as possible. The magnets that rest fully against the corrugations 8 d at this location have a small, not-illustrated chamfer in order not to rest against the inner radius of the corrugation.
FIG. 2 shows a further inventive embodiment, whereby the two bell-shaped elements 18 rest against one another along their base-shaped walls 18 b , and in particular are connected to one another. The permanent magnets 14 are disposed against the inside of the cylindrical wall 18 a , and are securely held in the axial direction by the inwardly directed collars 18 c . For securement to the cylindrical wall 18 a , the permanent magnet element can be glued thereto. However, it is also possible, by appropriate indentations in the cylindrical wall 18 a , to achieve a positive interconnection between permanent magnet elements 14 and cylindrical wall 18 . In contrast to the embodiment of FIG. 1 , not only the outer stators but also the inner stators carry magnet or excitation coils 12 , 15 . The sleeve described in conjunction with FIG. 1 is not used here. The structural build-up makes small air gaps 7 and 10 possible between the magnets and the stators.
The embodiment of FIG. 3 differs from the embodiment of FIG. 2 merely in that the excitation coils 12 on the outer stator are larger than the excitation coils 15 of the inner stator, which are carried by the inner stator 11 . By an appropriate design, as illustrated in FIG. 3 , smaller thermal problems result than with the embodiment of FIG. 2 .
The embodiment of FIG. 4 is in the form of an external rotor, whereby the construction principle corresponds to that of the embodiment of FIG. 3 .
FIG. 5 is also embodied as an external rotor, whereby an inner cylinder 9 is provided for additional securement and encasement of the permanent magnets 14 .
FIG. 6 shows a further inventive embodiment having merely one bell 28 , the base wall 28 b of which is secured to the portion 1 b of the shaft 1 by securement means 30 so as to be secure against rotation. The entire axial length of the bell 28 extends around the inner stator 11 , which carries the excitation coil 15 . The inner stator 11 is mounted on a cylindrical wall 24 a of the right housing portion 24 . The housing itself is closed off by the cylindrical surface 3 and the further housing portion 25 , whereby the shaft 1 is mounted in the housing via bearings 26 .
The bell 28 has an outer cylindrical wall 28 a on the inner side of which the permanent magnets 14 rest. On the inside, the permanent magnets are held by a sleeve 29 that is secured to the outer cylindrical wall 28 a via its collar 29 a . In addition, the side of the sleeve that is disposed in the region of the base of the pot can be connected with the cylindrical wall 28 a or the base wall 28 b . By means of a non-illustrated bearing position for the shaft in the housing 24 a , the housing portion 25 can be closed on this side.
FIG. 7 shows a further possible embodiment of the inventive drive in the form of a segmented motor, which has an asymmetrical bell 38 . The magnets 34 are disposed within the bell and are supported in the circumferential direction against the corrugations 38 d , whereby temperature compensation elements 36 are disposed at the adjacent permanent magnets 34 . The outer stator 31 carries the excitation coils 32 . Illustration of the inner stator has been dispensed with. It is similar to the inner stators of the previously described embodiments. The inner stator is not illustrated here. The bell 38 secured to the shaft 39 via its base wall 38 b , only a portion of which is illustrated. The transfer of force from the cylindrical surface 38 a to the shaft can be effected either at the end of the shaft or within the bell. In addition, it is possible to also use to bells for the segmented motor that have their base sides facing one another. The transfer of force from the shaft to a component that is to be adjusted can be effected via a pin 40 , which is pressed into a follower 42 and transfers its force to a coupling element 41 . For this purpose, the bell 38 has an appropriate opening 43 .
FIG. 8 shows a further embodiment of an inventive drive as a linear drive. The magnet system in the inner stator 55 and the outer stator 51 is not illustrated in detail in order to facilitate illustration. The magnets 54 are disposed in the bell 58 , whereby they are spaced from one another by temperature compensation elements 56 and are held in position by corrugations 58 d in the bell as well as by inwardly directed collars 58 c . The cylindrical wall 58 a is connected to the shaft W via the base wall 58 d . An air gap is between the cylindrical outer surface of the cylindrical wall 58 a and the outer stator 51 . Similarly, an air gap is between the inner stator 55 and the permanent magnet elements 54 . The magnetic flux passes through the cylindrical wall 58 a as well as through both air gaps and together with the permanent magnet elements 54 as well as the two stators, forms a plurality of magnetic circuits. The bell can have a round, oval or also right-angled or box-shaped configuration. It is preferably made of magnetically conductive material, and is mounted so as to be displaceable in the axial direction via the two bearings L and via the shaft W. A valve V of an internal combustion engine can, for example, be secured to the shaft W; the valve periodically opens or closes by the upwardly and downwardly moving rotor.
The specification incorporates by reference the disclosure of German application 10 2004 030 063.1 filed 23 Jun. 2004 as well as International application PCT/EP2005/002441 filed 8 Mar. 2005.
The present invention is, of course, in on way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
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An electrical drive comprising stationary outer and inner stators; a rotatably mounted rotor with at least one pot-shaped element having a cylindrical wall and a base wall, wherein the cylindrical wall is thin-walled and made of magnetic material, wherein the base wall extends perpendicular and a cylindrical coaxial to a rotor shaft axis and the base wall is connected to the rotor shaft for transfer of torque; at least one electrical excitation coil; and a plurality of permanent magnet elements secured to the rotor for producing an excitation flux, wherein the magnet elements rest only against a radially inner side of the cylindrical wall and in the circumferential direction are disposed next to one another, wherein the magnet elements, together with the stators, form magnetic circuits that pass radially entirely through the cylindrical wall, and wherein the radial thickness of the magnet elements is greater than the thickness of the cylindrical wall.
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BACKGROUND OF THE INVENTION
The invention relates to a sewing device for forming seams on similar workpieces, but of different length. The device is provided with two substantially symmetrically formed workpiece clamping holders adjustable relative to each other according to the length of the workpiece, a master cam comprising two symmetrically formed external segments which are connected by a bridging rail for forming a continued edge. Along the profile of the cam edge on the master cam rolls a driven magnetic roller which controls the sewing machine, and a device for the positioning control and for inserting the workpiece cuts to be sewn into the workpiece clamping holders and simultaneously removing the finished workpieces therefrom.
U.S. Pat. No. 3,216,380 discloses an automatic operating sewing machine for sewing of like patterns of different lengths, which comprises a fabric holder adjustable in a predetermined direction and in accordance with the desired shape of sewing, for effecting the movements of the fabric holders, a pattern including two end positions and a bridging intermediate portion which is adjustably movable along a straight line relative to each other by means of a threaded spindle operated by a hand wheel. However variation of the workpiece sizes requires a manual resetting of one of the two fabric holder parts.
There is further disclosed in U.S. Pat. No. 3,407,759 a sewing device which is provided with a rotary table and clamping means for receiving workpiece cuts to be processed and successively fed into the effective range of tooling machines, e.g. a sewing machine and a cutting machine due to the rotation of the rotatary table. The table is provided with radially disposed segments, each carrying templates for engaging with a magnetic roller which is coaxial with the needle of the sewing machine and the clamping means for a right and a left half of two neighbouring workpieces. These segments are radially displaceable as per a scale by means of a control adjusting device.
However, the aforesaid known devices do not include means for inserting of previously aligned workpiece cuts into the opened workpiece clamping means, quick-adjusting means for sewing similar workpiece cuts of different length, and for simultaneously removing of sewn workpieces out of the workpiece clamping means.
It is an object of this invention to provide an automatically operating sewing device of the above mentioned kind with central quick-adjusting means for the changeover to any different workpiece sizes or dimensions.
It is a further object of the invention to provide said sewing device with means for inserting workpiece cuts to be sewn into the opened workpiece clamping holders and simultaneously removing of a sewn workpiece out of the same holder.
Other objects and advantages of the present invention will become apparent from the following description in conjunction with the attached drawings which illustrate a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of an automatic sewing device provided with positioning and inserting means for feeding the workpiece cuts to be sewn into the workpiece clamping holders;
FIG. 2 is a section taken along line II--II of FIG. 1;
FIG. 3 is a partial right side elevation of the unit;
FIG. 4 is a partial section taken along line IV--IV of FIG. 1, on an enlarged scale;
FIG. 5 is a section taken along line V--V of FIG. 4;
FIG. 6 is a partial side elevation taken along line VI--VI of FIG. 1, on an enlarged scale, and
FIG. 7 is a perspective partial top view on the inserting device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Pivoted to the frame 1 of the sewing device having a left frame section 2 (FIG. 1), a right frame section 3 (FIG. 3) and two connecting girders 4, 5, is a link arm 6, which is linked by means of a connecting arm 7 to a supporting arm 9 carrying a sewing machine 8.
Mounted fixedly on the connecting girder 4 is a left carrier body 10 (FIGS. 1 and 2), in which is slidably received a tube 11 carrying a right carrier body 12 (FIGS. 1, 3, 4 and 6).
The tube 11 is slidably arranged on a rod 13, which is mounted on the connecting girder 4 of the frame 1 (FIG. 1) by means of a bearing block 14. On the tube 11 is located a clamping member 15, to which is hinged a connecting rod 16 connected with a lever 17. The latter is hinged to shaft 18 provided with a hand lever 19 and pivoted in a support 20, which is secured to the left carrier body 10. On the free end of the rod 13 is disposed a limit stop carrier 21 (FIGS. 1, 4 and 5) which is pivoted to a bush 23 clampled to the rod 13 and having a flange 22. Adjacent to the limit stop carrier 21 having a clamping slot 24 (FIGS. 4, 6) is arranged on the bush 23 a clamping member 25 which is also formed with a slot 27, for clamping the clamping member 25 and the bush 23 to the rod 13 by means of a clamping screw 26.
Received in a recess 28 in the clamping member 25, is a ball 29 tensioned by a pressure spring 30 and cooperating with bores 31, which serve as latches and are arranged at the front side of the limit stop carrier 21 facing the clamping member 25. Into the other frontal area of the limit stop carrier 21 are cut tapholes 33, in which the bores 31 terminate and which serve for receiving of adjustable limit stops 34, 34' 34" of different lengths. In the free ends of the adjustable limit stops are inserted adjustable stop screws 36, which are secured against rotation by means of springs 35 and can be brought into the path of motion of a stop 37 located in the right carrier body 12.
Arranged on the support 20 connected with the stationary left carrier body 10, is a plate 38 for receiving a stationary workpiece clamping half 38' comprising a left lower clamping plate 39 (FIG. 2) and a left upper clamping plate 40 liftable by means of a compressed air cylinder 41, and serving for receiving the left halves 42' of the workpiece cuts 42 to be sewn. For receiving the right halves 42" of the workpiece cuts 42, there is provided a movable workpiece clamping holder 43 (FIGS. 1 and 3), which is carried by a plate 44. The plate 44 is secured to a carrier 45 connected with the right carrier body 12 and provided with a right lower clamping plate 46 and a right upper clamping plate 48 liftable by means of a compressed air cylinder 47. The right workpiece half 42" is clamped between the lower and upper clamping plates 46, 48.
Both plates 38, 44 are bridged by a rail 49 (FIGS. 1 and 2) formed with an oblong hole 50 and displaceably secured by means of screws 51 to the plates 38, 44. The rail is laterally guided in guide pieces 52 secured to the plates 38, 44 by means of screws 53.
Disposed underneath the carrier bodies 10 and 12 are two master cam halves 54 and 55 (FIGS. 1 and 3) arranged along the profile of which rolls a motor-driven magnetic roller 56, which is located in the supporting arm 9 and the axis of which extends coaxially to the needle 57 of the sewing machine 8. Both master cam halves 54 and 55 are connected by means of a bridging rail 58 (FIG. 1) along which the magnetic roller 56 rolls when shifting from one cam half to the other one.
Disposed on the connecting girder 5 of the frame 1 is device 59 for properly inserting the workpiece, the workpiece cuts 42 to be sewn into and sewn workpieces out of the clamping holders 38', 42. The device 58 comprises a workpiece holding plate 60 receiving the workpiece cuts 42 and secured to a frame 61 (FIGS. 1 to 3), which is pivoted to two angle pieces 64, 65 and swingable into a horizontal position against the tension of springs 62, 63 (FIGS. 2 and 3). The angle pieces 64, 65 together with the workpiece holding plate 60 are displaceably supported by means of telescopic guides 66, 67 received in bearing blocks 68, 69, which are secured to the connecting girder 5.
In order to properly position the workpiece cuts 42 to be sewn on the workpiece holding plate 60 with respect to the stationary workpiece clamping half 38', there are provided stop dogs 70 which are adjustably and fixably received in oblong holes 71 formed in the workpiece holding plate 60, for determining the position for the front edge of the left half 42' of the workpiece cuts 42, and a swingable stop 72 for determining the position for the lateral workpiece cut edges 77. The swingable stop 72 comprises a two-armed lever 75 pivoted to the workpiece holding plate 60. One arm of the lever 75 is formed with a bearing surface 76 for the lateral workpiece cut edges 77, whereas, if the workpiece holding plate 60 is in the normal position as shown in FIG. 1, the free arm 78 rests under tension of a spring 79 against a stop 80 arranged on the connecting girder 5.
The workpiece holding plate 60 (FIGS. 1 and 7) is provided with two recesses 81, 82 in which are received supporting plates 84, 85 flushing with the workpiece plate 60 and having oblong holes 83 for adjusting and fixing stops 73 and 74 which determine the position for the front edge of the right workpiece cut halves 42". The supporting plates 84, 85 are disposed between two plates 86, 87 (FIG. 7) and secured to them by means of screws 88. Connected to the lower plate 87 is a rail 89 (FIGS. 3 and 7) extending downwards and engaging in a slot 90 formed in the end of an engaging piece 91 which is secured to the right carrier body 12.
Received in the workpiece holding plate 60 recesses 81, 82 are supporting plates 84, 85 having oblong holes 83 for securing the stops 73, 74 and flush with the workpiece holding plate 60. The supporting plates 84, 85 are disposed between two plates 86, 87 and secured to them by means of screws 88. Connected to the lower plate 87 is a rail 89 (FIGS. 3 and 7) extending vertically downwards from the latter.
Secured to the right carrier body 12 is an engaging piece 91 formed at its end with a slot 90 engaging in the rail 89.
Disposed on the workpiece holding plate 60 are two clamping devices 92, 93 (FIGS. 1 and 7). The clamping device 92 is fixedly mounted on the left side of workpiece holding plate 60, whereas the second clamping device 93 is received by the plates 86, 87 and displaceable with the latter and the supporting plates 84 85. The clamping devices 92, 93 are formed with an upper clamping arm 94 (FIG. 7) and a lower clamping arm 95, which are slidably received in securing members 96 clamped to a shaft 97. The shaft 97 is pivoted in a block 98 and in driving connection with an air cylinder 99 or magnet by means of a lever 100. The lower clamping arm 95 is offset and projects through the recess 82 formed in the workpiece holding plate 60 respectively through a recess 101 (FIG. 1) in order to cooperate with the underside of the workpiece holding plate 60, if the upper clamping arm 94 is in a lifted position.
Operation of the sewing unit is as follows:
The sewing device destined for sewing similar collars but of different length, is according to the FIG. 1 set for the smallest collar size. To feed the device, the workpiece cuts 42 are placed upon the workpiece holding plate 60, while the clamping arms 94 are lifted, in such a manner, that the lateral workpiece edge 77 abuts against the bearing surface 76 of the two-armed lever 75 and the longitudinal edge at the stops 70, 73, 74. Subsequently, the upper clamping arms 94 are lowered on the workpiece cuts 42, while simultaneously, the lower clamping arms 95 are lowered from the underside of the workpiece supporting plate 60.
By means of the shifting device, which is denoted in FIG. 2 with the Ref. No. 102, the angle pieces 64 carrying the workpiece holding plate 60 and thus also the workpiece cuts 42, are shifted to the workpiece clamping holders 38, 43, at this the upper clamping plates 40, 48 are lifted from the lower clamping plates 39, 46 by means of the compressed air cyliners 41, 47, in order to provide the required space between a sewn workpiece lying upon the lower clamping plates 39, 46 and the upper clamping plates 40, 48, for inserting the workpiece holding plate 60 and the workpiece cuts 42 to be sewn. After that, the upper clamping plates 40, 48 will be lowered upon the workpiece cuts 42 at which the latter are pressed tightly by means of the springs 62, 63 between the workpiece holding plate 60 and the upper clamping plates 40, 48. Now the upper clamping arms 94 will be lifted by means of the air cylinders 99 in order to release the inserted workpiece cuts 42 and simultaneously clamp the sewn workpiece with its longitudinal edge against the underside of the workpiece holding plate 60 by means of the lower clamping arms 95. Then the workpiece holding plate 60 together with the sewn workpiece can be removed into the normal position. After placing new workpiece cuts upon the workpiece holding plate 60 and clamping them by means of the clamping arms 94, the sewn workpiece 42 being clamped to the underside of the workpiece holding plate 60 is released from the lower clamping arms 95 in order to drop the workpiece downwards upon a stack or into a container (not shown).
During shifting of the workpiece holding plate 60 to the workpiece clamping holders, the swingable stop 72 with its bearing surface 76 determining the position of the lateral workpiece edge 77, will be swung into the dotted line position (FIG. 1) by means of the spring 79 in order to prevent a contact with the clamping plate 40. During laying workpiece cuts 42 upon the workpiece holding plate 60 of the inserting device 59, the sewing machine 8 controlled and moved by the magnetic roller 56, which rolls along the master cams 54, 55 and the bridging rail 58, is moved from one end of the cam to the other cam, in order to join the workpiece cuts 42.
To adjust the device to any different workpiece length, first the limit stop carrier 21 must be turned until the adjustable limit stop 34 with the stop screw 36 destining the desired length of the workpiece, lies in the path of motion of the stop 37 abuts against the stop screw 36 of the limit stop 34. At this, simultaneously the right movable clamping half 43 disposed on the carrier body 12, the master cam half 55 located below the movable workpiece clamping half 43 and the plates 84, 85 with the stops 73, 74 and the right clamping arms 94, 95 are displaced in accordance to the longer workpiece to be sewn.
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A sewing device for sewing similar workpieces of alternate sizes, the device is provided with means for the positioning control and the insertion of the workpiece cuts to be sewn, into the workpiece clamping holders. To adapt the device for workpieces of other sizes, there are provided adjusting means for the simultaneous displacement of two-piece clamping holders, master cams and the stop dogs of an inserting device.
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BACKGROUND OF INVENTION
[0001] The present invention relates generally to clips for retaining rods associated with vehicle closures.
[0002] For vehicle closures that open by swinging upward, it is usually desirable to provide some type of mechanical assistance for opening and holding such closures in an open position. For example, a torque rod counterbalance system may be employed since it is a cost-effective and reliable type of counterbalance system, and also because it is not susceptible to temperature variations as are other types of counterbalance systems.
[0003] One place where such torque rod counterbalance systems may be employed are passenger car deck lids that cover trunk openings. The torque rod engages the deck lid hinge and is pre-loaded with torque to counterbalance the weight of the deck lid and allow for initial lid movement upon release of a latch. One or more torque rods may be employed to engage the pair of deck lid hinges. The nature of torque rod counterbalance systems traditionally require the torque rods to be installed after the vehicle paint process is complete and the vehicle is in a general assembly area for further installation of other components. This is done because, if they are wound up (pre-stressed) in position prior to (and during) the vehicle painting process, the torque rods will lose some of the initial toque pre-stress due to the heat of the paint process. Also, it is undesirable to create stresses in the deck lid prior to (and during) paint processing, which can occur if the torque rods are pre-stressed during paint processing.
[0004] On the other hand, there are assembly process reasons that make it desirable to mount the torque rods to the vehicle prior to paint operations. Since it is still desirable to assure that the torque rods are not pre-stressed during paint operations, some means to retain the unstressed torque rods in position in the vehicle during paint operations is desired. Preferably, this means is relatively simple, quick, reliable and inexpensive since the torque rods will still have to undergo final assembly steps where they are wound up (pre-stressed) and engaged with the deck lid hinges after the paint operations are completed.
[0005] Some have attempted to provide such a means by employing a positive retention torque rod retaining clip. These clips typically include tabs that are plastically bent (crimped) to retain the torque rod in position during paint operations. But these devices are undesirable in that they require a relatively high insertion force and have been known to accidentally release the torque rods prior to being assembled to the final vehicle location. Thus, the clips tend to be less reliable as a retention method than is desirable. Also, the clips may be out of position at the time of torque rod insertion, so a two-hand operation (one to hold the clip in the correct position and one to hold the rod) is needed.
SUMMARY OF INVENTION
[0006] An embodiment contemplates a self-engaging rod retaining clip assembly for retaining a rod. The rod retaining clip assembly comprises a vehicle closure support and a rod retaining clip. The vehicle closure support component includes a main body defining an arcuate-shaped rod channel having a rod channel opening, and a clip support arm extending from the main body adjacent to the rod channel and the rod channel opening, the clip support arm having a first side and an opposed second side and including an arm pivot hole recessed in the first and second sides. The rod retaining clip includes a clip main body having a rod retention flange extending from the clip main body outside of the rod channel when the rod retaining clip is in a pre-rod installation position; a rod pivoting flange extending from the clip main body across a portion of the rod channel opening when the rod retaining clip is in the pre-rod installation position, with the clip main body, the rod retention flange and the rod pivoting flange defining a rod recess that is shaped to receive a rod therein; a pair of clip retention flanges extending from the main body and defining an arm slot therebetween, the clip retention flanges each having a hold-open portion where a width of the arm slot between the hold-open portions is about equal to a width of the support arm, a clip securing portion where the width of the arm slot between the clip securing portions is less than the width of the arm slot between the hold-open portions, and a tapered clip spreading portion extending between the respective hold-open portions and clip securing portions; and a pivot pin pivotally securing the rod retaining clip to the clip support arm.
[0007] An embodiment contemplates a method of pre-installing a torque rod to a vehicle closure support component, the method comprising the steps of: pivotally supporting a rod retaining clip on a clip support arm of the vehicle closure support component adjacent to a rod channel with a rod pivoting flange of the rod retaining clip extending across a portion of a rod channel opening and a rod retention flange extending outside of the rod channel; maintaining the rod retaining clip in a pre-rod installation position by trapping the clip support arm between a web of the rod retention flange and hold-open portions of a pair of clip retention flanges; pressing the torque rod against the rod pivoting flange to cause the clip retention flanges to flex around the clip support arm and the rod pivoting flange to pivot into the rod channel; and pressing the torque rod further into the rod channel until the clip retention flanges no longer align with the clip support arm, allowing the clip retention flanges to snap toward each other.
[0008] An advantage of an embodiment is that the self-engaging rod retaining clip assembly minimizes assembly operator installation efforts for insertion, but positively and reliably secures vehicle torque rods during assembly plant processing. This clip is also relatively inexpensive, and quick and easy to use. No crimping (plastically bending tabs) is needed for installation, and the clip is automatically maintained in the correct position for torque rod insertion until the torque rod is actually inserted.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 is a perspective view of a self-engaging rod retaining clip mounted on a vehicle closure support component, with the clip in a pre-rod installation (open) position.
[0010] FIG. 2 is a side view, on a reduced scale, of the clip and support component of FIG. 1 , and a rod shown initially contacting the clip in the pre-rod installation position.
[0011] FIG. 3 is a view similar to FIG. 2 , but illustrating the clip and rod in a partially installed position.
[0012] FIG. 4 is a side view similar to FIG. 2 , but illustrating the clip and rod in a fully installed (trapped) position.
[0013] FIG. 5 is a perspective view, on an enlarged scale, of the rod retaining clip assembly, in the installed position illustrated in FIG. 4 .
[0014] FIG. 6 is a perspective view of a self-engaging rod retaining clip, according to a second embodiment, mounted on the vehicle closure support component.
[0015] FIG. 7 is a side view of the clip of FIG. 6 .
[0016] FIG. 8 is a perspective view of the clip of FIG. 6 .
DETAILED DESCRIPTION
[0017] Referring to FIGS. 1-5 , a vehicle closure support component, indicated generally at 20 , is shown. The component 20 may be, for example, a hinge box or a hinge link (that drives a gooseneck strap) associated with a vehicle deck lid (not shown), or in a tailgate (not shown) or lift gate (not shown) counterbalance system. The component 20 includes a component main body 22 that defines an arcuate-shaped rod channel 24 having a rod channel opening 26 . A clip support arm 28 extends from the main body adjacent to the rod channel 24 and rod opening 26 . The support arm 28 includes an arm pivot hole 30 adjacent to the rod opening 26 , and has a first side 32 and an opposed second side 33 . A self-engaging rod retaining clip 34 is mounted on the support arm 28 . While one support component 20 and one rod retaining clip 34 are shown, there are preferably two (spaced apart) for supporting each torque rod 36 on the vehicle (not shown). However, since the second rod retaining clip 34 can essentially be the same as the first, only one is shown herein. The torque rod 36 may be conventional, if so desired, and so will not be shown in detail herein.
[0018] The self-engaging rod retaining clip 34 includes a clip main body 40 having a pair of clip pivot holes 42 coaxially aligned with the pivot hole 30 . A pivot pin 38 extends through the holes 30 , 42 , securing the clip 34 to the support arm 28 , while allowing the clip 34 to rotate relative to the support arm 28 . A rod retention flange 44 , having a central web 46 , extends from the clip main body 40 . An end 52 of the central web 46 defines an initial position retaining flange (discussed below). Also, a pair of rod pivoting flanges 48 extend from the clip main body 40 on opposed sides 32 , 33 of the support arm 28 . The rod retention flange 44 , pivoting flanges 48 and clip main body 40 define a rod recess 50 . A pair of clip retention flanges 56 also extend from the clip main body 40 on opposed sides 32 , 33 of the support arm 28 , defining an arm slot 64 .
[0019] Each clip retention flange 56 includes a rounded hold-open portion 58 on a first end 59 , a clip securing portion 60 extending adjacent to an opposed second end 61 , and a tapered clip spreading portion 62 extending between the hold-open potion 58 and the clip securing portion 60 . These portions 58 , 60 , 62 define the arm slot. A width 65 of the arm slot 64 between the hold-open portions 58 is about equal to or slightly smaller than a width 66 of the clip support arm 28 adjacent to the hold-open portion 58 when the clip 34 is in its pre-rod installation position. A width 67 of the arm slot 64 between the clip securing portions 60 is smaller than the width 65 , with a width of the arm slot 64 tapering from the width 65 to the width 67 . A pair of clip support flanges 68 may extend between the second end 61 and the pair of rod pivoting flanges 48 .
[0020] As an alternative, the tapered clip spreading portion 62 may incorporate the hold-open portion by having the clip spreading portions 62 near the first end 59 spaced apart about equal to or slightly wider than the support arm width 66 and then tapering towards each other as they extend to the clip securing portions 60 . Also, if so desired, the clip securing portions 60 may continue the taper rather than extending generally parallel to each other. This accomplishes a similar result in that the desire is to gradually flex the clip retention flanges 44 apart as the retaining clip 34 is rotated relative to the support arm 28 until the retention flanges 44 snap past the support arm 28 (discussed in more detail below).
[0021] The initial pre-paint-operations assembly of the torque rod 36 , with reference to FIGS. 1-5 , will now be described. The rod retaining clip 34 is installed onto the clip support arm 28 in its pre-rod installation position (shown in FIG. 1 ), with the end 52 of the central web 46 pressed against the clip support arm 28 and the hold-open portions 58 also pressed against the clip support arm 28 . Since the width 65 of the arm slot 64 between the hold-open portions 58 is about equal to or slightly less than the width 66 of the clip support arm 28 , the retaining clip 34 will inherently be held in this position. In the pre-rod installation position, the rod recess 50 faces outward away from the rod channel 24 , allowing for easy alignment of the torque rod 36 with this channel 24 . Positively holding the retaining clip 34 in this position makes assembly easier since the assembler knows what the clip position will be on each vehicle, and one hand will not have to be used to reposition the clip while the other hand moves the torque rod 36 into position in the recess 50 .
[0022] The initial torque rod installation continues by locating the torque rod 36 in the rod recess 50 (shown in FIG. 2 ). The assembler then pushes upward on the torque rod 36 . As the assembler pushes upward, the upward force will press the rounded hold-open portions 58 against the sides 32 , 33 of the support arm 28 , causing the clip retention flanges 56 to elastically flex away from each other. As the torque rod 36 is pushed farther upward, through the rod channel opening 26 , the clip 34 rotates relative to the clip support arm 28 . This causes the tapered clip spreading portions 60 to slide along the sides 32 , 33 , in turn causing the retention flanges 56 to gradually spread open farther (shown in FIG. 3 ). As the assembler pushes the torque rod 36 farther into the rod channel 24 , eventually the retaining clip 34 will rotate far enough that the clip securing portions 62 slide past the sides 32 , 33 of the support arm 28 , allowing the clip retention flanges 56 to spring back towards each other (shown in FIGS. 4 and 5 ). The initial torque rod installation is now complete.
[0023] With the clip securing portions 62 snapping back towards each other, the clip securing portions 62 self-engage to hold the retaining clip 34 in this fully installed (trapped) position without any further actions on the part of the assembler. Of course, the length of the rod retention flange 44 and the dimensions of the rod channel 24 are determined so that a final gap between the two is less than the diameter of the torque rod 36 . In this way, even though the torque rod 36 is not tightly retained in the rod channel 24 , the retaining clip 34 positively secures both itself and the torque rod 36 in the fully installed positions. Accordingly, this portion of the assembly process is relatively quick, simple, and reliable. Once the torque rod 36 is pushed into its desired position, the torque rod 36 will be positively retained in this desired position on the vehicle as the vehicle proceeds through paint operations—without requiring that the torque rod 36 be wound up during these operations.
[0024] After paint operations, the torque rod 36 is still positively retained in position, ready to be wound up (pre-stressed) during final assembly operations for the vehicle. After the torque rod 36 is wound up, the retaining clips 34 are no longer needed, but can be left in place since they do not interfere with the operation of the torque rod 36 or the vehicle closure. Thus, the relatively low cost of the retaining clip 34 is desirable since it is only used during a portion of the vehicle assembly process.
[0025] FIGS. 6-8 illustrate a second embodiment. Since this embodiment is similar to the first, similar element numbers will be used for similar elements, but employing 100-series numbers.
[0026] The vehicle closure support component 120 still includes a main body 122 defining a rod channel 124 having a rod channel opening 126 . A clip arm support 128 extends out and supports a self-engaging rod retaining clip 134 .
[0027] The rod retaining clip 134 still includes a clip main body 140 from which a rod retention flange 144 , having a central web 146 , and a pair of rod pivoting flanges 148 extend. The main body 140 , retention flange 144 and pivoting flanges 148 define the rod recess 150 , and the central web 146 has an end 152 for abutting the support arm 128 . A pair of clip retention flanges 156 still extend from the main body 140 , with each including a hold-open portion 158 , clip securing portion 160 and clip spreading portion that together define an arm slot 164 . Again, clip support flanges 168 may extend between the clip retention flanges 156 an the rod pivoting flanges 148 .
[0028] The rod retaining clip 134 differs from the first embodiment in that it now includes a pair of pivot pin flanges 138 , with each pivot pin flange 138 including a tapered surface. Preferably, the pivot pin flanges 138 are integral with the clip main body 140 . This clip 134 , then, may be molded from plastic, for example. The term integral, as used herein, means that the particular feature (portion) is made from the same piece of material as the area around it, forming a single monolithic part, rather than being formed separately first and then later attached by fasteners, welding, adhesive, etc. An advantage with this embodiment, then, is that no separate pin must be installed and secured in place. The clip 134 is slid over the support arm 128 with the clip oriented so that the thin side of the pivot pin flanges 138 engage the support arm 128 first. As the clip 134 slides further on, the tapered surfaces 170 will cause the clip to gradually flex open until the pivot pin flanges 138 align with and snap into a pivot hole (not shown in the second embodiment) of the support arm 128 . The clip 134 is now secured to and can pivot relative to the support arm 128 . The installation of a torque rod is the same as the first embodiment.
[0029] While certain embodiments of the present 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 as defined by the following claims.
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A self-engaging rod retaining clip assembly for retaining a rod and a method of retaining the rod to a vehicle closure support component is disclosed. The self-engaging rod retaining clip assembly holds a rod retaining clip in a desired position on a vehicle closure support component until the rod is installed. Installing the rod includes pressing the rod against a rod pivoting flange, which causes clip retention flanges to flex outward around a clip support arm until the rod is sufficiently retained inside a rod channel in the support component. The clip retention flanges then snap towards each other to retain the clip, and hence the rod, in the support component.
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FIELD OF THE INVENTION
This invention relates to means for counting and dispensing cards from a stack of cards. Typically, such cards may be in the nature of lottery tickets with a multi-layered structure whereby they are moderately thick and heavy.
BACKGROUND OF INVENTION
Card handling machines are well known, particularly for use in feeding cards from a stack. Generally speaking, the mechanisms fall into two classes according to whether the cards are dispensed from the top or the bottom of a stack. In bottom faced dispensing arrangements which most closely relate to the instant invention, some type of motorized oscillating mechanism is provided for intermittently controlling the movement of the bottom card and/or the adjacent card to prevent the latter being entrained by the movement of the lowest card. Although reliable, these mechanisms are relatively slow and are more useful for feeding cards for printing operations or for dispensing a small number of cards. The mechanisms are usually complex and may add appreciably to the cost of the apparatus. Although the cost factor may not be a problem for large operations, for example those used for counting in excess of 50,000 cards/hour, there is a need for a fast, reliable, relatively low price apparatus for smaller operations.
Given that the cards being dispensed may be in the nature of lottery cards each having a significant value, there is a requirement for accuracy and reliability.
It is an object of this invention to provide a relatively high speed apparatus which is typically capable of counting and dispensing cards at a rate of up to 1000 cards/minute.
It is another object of this invention to provide such apparatus which is simple, reliable and uses few mechanically driven parts and which is of relatively low cost.
It is yet another object of this invention to provide such apparatus that counts and dispenses cards with accuracy.
In accordance with one aspect of this invention, apparatus for counting and dispensing cards from a stack of cards comprises feed means including a feed roll having an axis of rotation and a pair of nip rolls disposed forwardly thereof (the direction being taken relative to the direction of movement of the cards through the rolls) and a hopper disposed above the feed roll serving to orient the cards relative to the feed roll. The apparatus further comprises a gate which is suitably supported from the hopper, the gate having a progressively decreasing clearance from the peripheral surface of the feed roll in the forward direction, and means for adjusting the clearance between the gate and the feed roll.
Preferably, the hopper is adapted to feed the cards tangentially onto the feed roll, and still further it is preferred that the tangential point of contact between the cards and the feed roll be forward of the apogee of the feed roll. Accordingly, the cards will be somewhat downwardly inclined as they engage the feed roll. It is also preferred that the hopper be forwardly canted at or proximate the angle at which the cards are downwardly inclined.
The apparatus includes a chassis from which the rolls are supported. Conveniently, the gate is secured to the hopper, and the hopper is pivotally secured adjacent one lateral side thereof to the chassis, and means is provided for adjusting the angle at which the hopper is laterally inclined, so providing the gate clearance adjusting means.
Preferably, the gate is in the form of a doughnut like circular button having a rounded edge profile and a central axis through which the gate is mounted with its axis transverse to the axis of rotation of the feed roll. Also preferably, the gate is mounted whereby it is rotatable so as to compensate for wear.
The apparatus of the invention includes a drive means for driving the feed roll and the nip rolls, and suitably this will be arranged to drive the nip rolls at a higher peripheral speed than the feed roll. Accordingly, when a card is being moved under the influence of the nip rolls, it will advance more rapidly than an adjacent rearward card which is moving under the influence of the feed roll, and open a gap which facilitates the detection of the leading and trailing edges of cards by a photodetector, the signal from which is used for counting purposes. The gap also facilitates the collection of the cards in a collector bin. The cards are ejected more or less horizontally from the nip rolls at an appreciable velocity to impinge on an upstanding wall of the collector bin in which they are settled under the influence of a spring finger which is biased by the passage of a card through the nip rolls.
The invention will be described in relation to a preferred embodiment from which the foregoing objects and aspects, together with other objects and aspects will be apparent, taken in conjunction with the drawings annexed hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 shows in perspective view, a card counting and dispensing apparatus in accordance with my invention in perspective view from the front fight side thereof (the front to rear direction being defined by the direction of travel of the cards being dispensed);
FIG. 2 shows the apparatus of FIG. 1 in fight side elevation with a fight side wall removed to reveal interior detail;
FIG. 3 shows the apparatus of FIG. 1 in rear elevation with a left side wall removed to reveal interior detail and other hidden detail shown in dashed outline;
FIG. 4 shows detail of the feed hopper and feed mechanism in right side elevation on enlarged scale, with lower ones of a stack of cards in position in the feed hopper;
FIGS. 5-7 show in fight side elevation in somewhat schematic form, the passage of two successive cards being dispensed by the apparatus of FIG. 1;
FIG. 8 is a schematic view of the collector bin from the fight side with a plurality of cards accumulated therein; and
FIG. 9 is a schematic of the electrical and electronic arrangements used in the apparatus of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in detail, the dispensing/counting apparatus of the invention is denoted generally therein by the reference numeral 10.
Apparatus 10 comprises a chassis 12 from which there is mounted a card feed means 14, including a live axle 16, having a feed roll 18 secured thereto for rotation therewith, and nip rolls 20 comprising a lower live axle 22 on which there is mounted for rotation therewith a first pair of rolls 24, spaced apart so as to be respectively disposed on laterally opposed sides of feed roll 18, and an upper dead axle 26 on which there is rotatably mounted a second pair of rolls 28 in opposition to lower rolls 24. The nip of rolls 24, 28 is set by adjusting the movement of dead axle 26 along slotted openings 30. A flat spring finger 32 is secured at one end to chassis 12, intermediate portions of the spring passing under dead axle 26 and over live axle 22 to project therebelow.
Apparatus 10 includes a self braking DC drive motor, 34 which is made to stop within approximately a quarter-turn by the application of a dynamic brake on the removal of power, and which accelerates rapidly to maximum speed on the application of power. A 4:1 speed reduction is provided by a belt-pulley system 36 through which motor 34 drives live axle 22. A further belt-pulley system 38 interconnects live axle 22 to live axle 1.6 to drive feed roll 18 at a peripheral speed of about two thirds that of nip rolls 20.
Apparatus 10 also includes a feed hopper 40, comprising a major upstanding wall 42 and a side wall 43 which extends along one lateral side of wall 42 at right angles thereto. Hopper 40 is adapted and disposed relative to feed roll 18 so as to feed the lowest card from a stack of cards C located in the hopper tangentially onto the peripheral surface 44 of feed roll 18, forwardly of the apogee 45 of the feed roll. For this purpose, hopper 40 is forwardly canted at an angle α of about 15°, which additionally has the effect of urging the forward edge of cards C into contact with major wall 42 under the influence of gravity. Hopper 40 is also inclined upwardly outwardly, conveniently at an angle of about 15°, which has the effect of urging a side edge of cards C into contact with the side wall of the hopper under the influence of gravity.
Hopper 40 includes a card support 46 for supporting rearward portions of the lowest one of the stack of cards C in approximately the desired tangential relationship with feed roll 18. Support 46 is suitably in the form of an upwardly rearwardly angled wall opposed to major wall 42, which forms a throat to support and urge the trailing edge of the lowest several cards progressively forwardly into contact with a gate 50 which is disposed forwardly of hopper 40, this action best being seen in FIG. 4. In the event that apparatus 10 is to be used with stacks of different widths of cards C, provision is made for adjusting the spacing of support 46 from major wall 42 by the use of thumb screws 47.
Gate 50 is in the form of a doughnut like circular disk having a rounded edge profile 52 and a central axis 54 through which the gate is mounted to major wall 42 externally of feed hopper 40, so as to project below the lower edge 56 of major wall 42. The perigee 58 of gate 50 is disposed in spaced apart opposed relationship to the peripheral surface 44 of feed roll 18 in the plane of a diameter D of feed roll 18, canted at the angle of cant α of hopper 40. Major wall 42 of hopper 40 is mounted from chassis 12 by a hinge pivot 60 which passes through major wall 42 adjacent side wall 43, and by a screw adjusting mechanism 68 disposed on major wall 42 externally of hopper 40, which thereby provides a simple means of adjusting the gap between gate 50 and the peripheral surface 44 of feed roll 18. A photodetector cell 70 is disposed intermediate gate 50 and nip rolls 20, and is suitably mounted from the proximal end of spring 32.
Chassis 12 and the various components mounted therefrom as hereinbefore described are generally constructed so as to be in rectilinear relationship other than in respect of major wall 42 of hopper 40 which is supported from chassis 12 in forwardly canted relationship. Chassis 12 is conveniently mounted from the cover of a housing 72 which slopes downwardly towards the left side of the apparatus at an angle of about 15°, thus serving to incline the hopper towards side wall 43 for the above mentioned purpose.
Apparatus 10 further includes an open-fronted collector bin 80 mounted from chassis 12 adjacently forward of nip rolls 20. Bin 80 comprises an upstanding major wall 82, contained in a vertical plane parallel to axle 16, and a floor 84 which is movingly supported by relatively long leaf spring 86 attached to fixed support arm 88. An adjusting screw 90 is provided on support arm 88 to regulate the spring pressure exerted on floor 84 by leaf spring 86, and thereby control the deflection of the spring and the floor therewith under the influence of cards delivered to bin 80 from the feed means 14. A proximity switch 92 is mounted on wall 82 externally of bin 80 in a position whereby it is toggled to a first condition by the proximity of leaf spring 86 when no card C is present in bin 80, and to a second condition when spring 86 is deflected under the influence of one or more cards supported on floor 84.
Considering now the operation of apparatus 10 as thus far described, prior to the dispensing and counting of cards using the apparatus, throat wall support 46 is adjusted using thumb screws 47 so that the lowest card C positioned in hopper 40 will be forwardly, downwardly angled towards the peripheral surface 80 of feed roll 18, and be more or less tangential thereto when the forward edge of the card is adjacent the perigee 58 of gate 50. The clearance of gate 50 is adjusted using screw adjusting mechanism 68 so that a card when angled in this manner will just pass between the gate and feed roll 18.
With apparatus 10 adjusted in this manner, a stack of cards C to be counted and dispensed is placed in hopper 40 with two edges of the cards respectively adjacent major wall 42 and side wall 43, and the inclination of these walls will urge the cards towards the walls under the influence of gravity. As will be best appreciated from a consideration of FIG. 4, the gravitational force on cards C in hopper 40 that is engendered by the forward canting of major wall 42 and by the inclination and spacing of throat wall support 46, together with the forward movement of the lowest card under the influence of feed roll 18, urge the lowest several cards forwardly into abutment with gate 50. The rounded edge profile 52 of gate 50 serves to position the leading edge of the lowest several cards C progressively forwardly, so that the penultimate card is positioned to make good contact with feed roll 18 as soon as the lowest card is withdrawn from the hopper 40, but not before and also provide a resultant downward force on the leading edge of the lowest several cards. The rotation of feed roll 18 urges the lowest card C forwardly towards nip rolls 20 at the peripheral speed of feed roll 18. As the leading edge of the first card passes beneath photodetector cell 70, this will generate a change of state in the detector cell which is carded on conductors 94 for processing as will be later described. The card C is accelerated in nip rolls 20, thereby creating a gap between the trailing edge of a first card passing through the nip rolls and the leading edge of the next card as it urged forwardly by the feed roll, which gap is at a maximum as the trailing edge of the first card is ejected from the nip rolls 20. Accordingly, photodetector cell 70 is desirably located between the feed roll 18 and nip rolls 20 somewhat closer to the entrance to the nip rolls than to the exit from the feed roll, in order to facilitate the detection of the trailing and leading edges of successive cards by the photodetector cell.
As a card C moves through nip rolls 20, the distal end of spring finger 32 is upwardly biased by contact with the card. Card C is typically expelled from the nip rolls 20 at a velocity of about 50 cms/sec, which is sufficient to project the card a short distance until the leading edge thereof strikes wall 82 of bin 80, thereby arresting further movement of the card, which, under the influence of upwardly biased spring finger 32, will be urged downwardly to fall a small distance and settle on floor 84. Assuming that this is the first card dispensed into bin 80, proximity switch 92 will be tripped and the output therefrom on conductors 96 will be used for detecting the presence or absence of a card in bin 80, as will be subsequently described.
With reference to FIG. 9, apparatus 10 further comprises a totalizer 100, which increments by one on the receipt of a pulse transmitted on conductors 94 from photodetector cell 70, on the detection of the trailing edge of a card C, and a display 102 which displays the total count. Totalizer 100 may be reset to zero by means of a reset switch 104. Conductors 94 also connect to a counter unit 106, which includes a count select register 108 actuated by set count switch 110, a count register 112 and a comparator 114. Typically count select switch 110 may include presettable positions for requesting the dispensing of preset numbers of cards C, for example twenty five, fifty or one hundred, or it may include means for setting any desired number of cards to be counted.
Power for driving DC motor 34 is derived from a bridge rectifier 120. Motor 34 is switched between a drive state and a dynamic brake state by means of power transistors 122, 124, which are respectively connected to the outputs 126, 128 of flip-flop 130 for control thereby such that when power transistor 122 is conditioned to an ON state, power transistor 124 will be conditioned OFF and vice versa. Power transistor 122 is conditioned ON by the receipt of a momentary input at RUN terminal 132 of flip-flop 130, which may arise from actuation of a momentary contact run switch 134 or auto switch 136, both of which are mounted from housing 72. The actuation of autoswitch 136 further serves to latch self latching switch 138 to an ON condition, which connects RUN terminal 132 to proximity switch 92 via conductors 96. Accordingly, each time that bin 80 is emptied, a RUN signal will be generated by proximity switch 92 and an input to RUN terminal 132, so providing for the automatic replenishment of bin 80.
Power transistor 124 is conditioned ON by the receipt of a momentary signal received at STOP terminal 140 of flip flop 130, which may arise from the actuation of a momentary contact stop switch 142, or a signal output from comparator 114 when the value of count register 108 is equal to that of count select register 112. An options plug 144 permits the external control of apparatus 10, for example by inhibiting count register 108 by a signal on conductor 146, and generating Run and Stop signals as appropriate.
The foregoing objects and aspects of the invention, together with other objects, aspects and advantages thereof will be more apparent from a consideration of the following description of the preferred embodiment thereof taken in conjunction with the drawings annexed hereto.
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A low cost high speed counter and dispenser of tickets includes a feed roll and a hopper for feeding cards tangentially onto the feed roll. A pair of nip rolls rotating at a higher peripheral speed than the feed roll opens a gap between the trailing edge of one ticket and the leading edge of the next ticket that is detected by a photodetector cell providing an input for a digital counter. A D.C. motor drive is used which is dynamically braked when a desired count is reached. A collector bin includes a detector for determining if the bin is empty to automatically initiate a new dispensing cycle, if desired.
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FIELD
[0001] The invention relates to a construction hanger for use in assembling concrete forms and, more particularly, tying the form members to a construction support member such as an I-beam. This invention provides an attachment of overhanging brackets, scaffolding, or other accessories to steel, concrete, or other bridge beams or construction support members.
BACKGROUND
[0002] In order to construct concrete sections of roads, bridges, buildings, or other components, a form is provided into which the concrete is poured and allowed to harden. These forms may take on a variety of shapes and configurations according to the use that they're put.
[0003] In creating overpasses, standing walls, or other sections, a framework of steel girders, I-beams, or other supporting structure is assembled before pouring the concrete to provide a structure from which to assemble the form. The form is supported on the girders or I-beams by means of construction hangers that support the weight of the form and concrete by distributing the load into the girder. Because the hangers may support the forms from within the volume of the form, they are usually unrecoverable after the concrete has been poured and allowed to harden. Therefore, it is preferable to provide economical hangers that can be inexpensively replaced as hangers are consumed.
[0004] These hangers may also be used to support scaffolding or other accessories to support structure.
[0005] An example of one prior art hanger generally includes a brace and a guide welded together to form the hanger. The brace may be formed from a steel bar bent around a beam flange to form a hook while the guide, which may be formed from a piece of stamped and bent steel, is welded to the bar opposite the hook. A support rod may be inserted through the guide and a form is attached to the support rod. By way of example, the support rod may be a threaded rod held in place by a hex nut or the like.
SUMMARY OF THE INVENTION
[0006] According to a first aspect of the invention, a construction hanger comprises a brace or bracket formed or cut from a substantially flat metal plate and an arm extending from its distal end and a proximal end where a guide having a channel is positioned and bonded or formed onto the brace. The term “brace” as used herein refers to that portion of the hanger 10 that engages the construction support member such as an I-beam. The term “hanger” refers to the brace in combination with the guide member that receives the hanger rod that ties the form to the support member. The term “hanger” does not include the rod itself.
[0007] According to one variation of the first aspect of the invention, the brace includes an arm that is shaped to receive and/or engage a beam profile. The beam profile may be the profile of any of a variety of construction elements such as a square or tapered I-beam, a C-channel beam, a square beam, an angle-beam, or other type of beam that is well known to those having skill in the art.
[0008] According to another variation, the guide member is bonded to the brace by means of welding, one or more fasteners, an interference fit, or other technique known to those having skill in the art. The guide member may have a variety of constructions, including but not limited to a round tube, a square tube, and a U-channel. The function of the guide is to retain the hanger rod by which form members are tied to the construction supports.
[0009] According to yet another variation, the guide includes a major axis that is at an angle to the brace. For example, the angle between the major axis and the brace may be at or about 45°. Other arrangements and angles are also anticipated, for example the angle between the clip and the brace may be 90°, and the brace and the guide need not be in the same plane.
[0010] According to yet another variation, the brace may include a bearing surface or extension that is typically triangular in shape at the proximal end of the brace to which the guide member is bonded.
[0011] In a second aspect of the invention the hanger includes one or more bearing plates. These bearing plates are optionally positioned on an underside of the brace and may be positioned between the distal and proximal ends. The bearing plates are positioned between the retainer or flange and the beam to provide surface area for load distribution. Alternatively, the bearing plates may be positioned on the upper surface of the arm forming the brace.
[0012] Another aspect of the invention is a novel method for forming the hanger in accordance with the above-described aspects. A substantially flat sheet of material, for example plate steel, is provided. A brace is cut from the material, the retainer having a distal end with a flange having a profile approximately complementary to a beam profile so that when attached to the beam profile the retainer fits accurately and tightly to the beam profile. A guide is provided and may include a circular, square, or U-shaped cross section. The guide is bonded to the brace at a proximal end of the retainer. The angle between the guide and retainer may be approximately 45°.
[0013] According to another variation, one or more bearing plates may be provided. These bearing plates are bonded to the brace in a perpendicular arrangement so as to distribute the load between the retainer and a beam to which the hanger may be attached. The bearing plates may be attached to the flange or directly to the brace and may either protrude to form a bearing surface corresponding to the beam profile or may be flush with a bearing surface of the brace.
[0014] Another aspect of the invention is a novel method for using the hanger in accordance with the above-described aspects. According to this aspect, a hanger is provided comprising a brace cut from a sheet of material and having an arm having a profile corresponding to a beam profile and a proximal end having a guide member. The hanger is provided on a beam having the beam profile such that the flange engages the beam profile to prevent movement along the length of the retainer or about an axis parallel to the major length of the beam. A support rod is provided that engages the guide. A load may then be applied to the support rod so that the force is transmitted axially through the support rod to the guide and subsequently to the retainer and beam.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIGS. 1A-1C respectively illustrate three embodiments of construction hanger braces in accordance with the invention.
[0016] FIGS. 2A-2D respectively illustrate brace elements useful in providing hangers in accordance with different embodiments of the invention.
[0017] FIG. 3 is a perspective view of a hanger in accordance with one embodiment of the invention.
[0018] FIGS. 4-6 illustrate embodiments of the invention in which the hange includes one or more barrier plates to distribute the forces acting on the hanger.
[0019] FIG. 7 illustrates a hanger in accordance with one embodiment of the invention in engagement with an I-beam.
[0020] FIG. 8 illustrates a further embodiment of the invention in which the hanger includes a pair of guide members.
DETAILED DESCRIPTION
[0021] FIG. 1A illustrates a partial view of a hanger 10 in accordance with one embodiment of the invention wherein the hanger includes a circular tube 12 that functions as a guide member for the hanger rod that is assembled with the hanger to assemble a concrete form member with a construction support member such as an I-beam. FIG. 1B on the other hand illustrates an embodiment in which the guide member is a square tube 14 and FIG. 1C illustrates an embodiment in which the guide member is a U-shaped channel member 16 . In each embodiment, the guide member 12 , 14 or 16 is carried on a brace 20 including an elongated bar 22 . The bar terminates in an end surface 26 ( FIG. 2 ). In the illustrated embodiment, the bar 22 is formed with a triangular extension 28 which provides additional support for the guide member and distributes the forces acting on the guide member over a longer lineal surface.
[0022] FIG. 2 illustrates four embodiments ( FIGS. 2A-2D respectively) for brace members 10 that can be used in constructing a hanger in accordance with various embodiments of the invention. The brace member 20 includes an elongated bar 22 from which an arm 24 extends. The arm 24 extending from the elongated bar 22 is shaped to engage a construction support member as discussed in more detail below. The brace 20 includes a sloped end surface 26 which can be bonded to or formed into a guide member such as members 12 , 14 and 16 illustrated in FIG. 1 . FIG. 2 illustrates an embodiment of the invention in which the guide member is carried on the sloped end surface 26 that is in the same plane as the brace member 20 . It is not essential that the hanger be constructed in this fashion. The end surface could be formed such that the guide member is located in at any desired angle with respect to the brace member within or out of the plane of the plate forming the brace 20 . In the embodiment shown in FIG. 2 , the brace members 20 each include a bearing extension 28 which is generally triangular in shape (note the dotted lines) and which further extends or widens the surface 30 of the elongated bar 22 and the end surface 26 . This facilitates bonding the guide member to the brace 20 and distributes forces over a larger surface area.
[0023] FIG. 3 illustrates an embodiment of the invention in which a tubular guide 12 is bonded to the brace 20 by a weld line 32 . However, those skilled in the art will appreciate that other techniques than welding may be used to bond and/or form the guide member 12 on the end of the brace 10 . The guide member can be formed separately and bonded to the brace 20 using an adhesive or weld, or the guide member can be a metal formed extension of the brace member 20 and the guide member is formed by bending the metal of the brace member. In this embodiment, there is no end surface 26 as shown in the embodiments of FIG. 2 . Instead the metal plate forming the end of the brace 20 would be formed into a tube.
[0024] FIG. 7 illustrates an example of the hanger 10 in position on an I-beam 36 . The arm 25 includes a right angle extension which receives the rectangular shape or profile of the I-beam. A threaded hanger rod 38 is inserted in and through the guide member 12 and retained by a threaded nut 40 . The rod member engages the construction form and ties or hangs the form in position from the the I-beam thereby transferring load from the support rod to the hanger and the beam.
[0025] FIGS. 4-6 illustrate embodiments of the invention in which hanger 10 includes one or more bearing plates 42 . In FIG. 4 the hanger is an assembly of rectangular plate members as shown which form a rectangular opening in the brace member similar in shape to the hanger illustrated in FIG. 3 which is formed from a cut metal sheet. The bearing plate 42 is situated on the lower portion of the arm 44 in this embodiment. In FIG. 5 , two bearing plates 42 and 42 ′ are attached to the lower surface of the elongated member 22 of the brace 20 . These bearing plates function to distribute the forces that are acting on the hanger over a larger surface area of the construction support member to prevent damage or premature failure of the support member. FIG. 6 illustrates an embodiment in which the bearing plate 42 is received in a cutout 46 in the elongated bar 22 forming the brace 20 . Alternative arrangements of bearing plates are also contemplated. For example, a single bearing plate may be utilized to engage the beam along the entire or major portion of the length of the brace. Alternatively, multiple bearing plates may be provided along the length of the brace. Finally, the retainer and flange may be constructed from components having an I- or T-shaped profile so that the bearing plate is integrally formed with the hanger.
[0026] FIG. 8 illustrates another embodiment of the invention in which the hanger is formed from a plate 60 optionally having apertures 66 therein. The plate 60 is rectangular in shape and has a pair of tubular guide members 68 a and 68 b extending from each of its side edges. A pair of hanging rods 70 a and 70 b are inserted through the guide members and retained by threaded nuts 72 a and 72 b . Optional bearing plate 62 extends from a cutout in the bottom edge of the plate 60 such that the hanger is stabilized on the top of the I-beam 36 .
[0027] Representative examples of construction support members with which hangers of the embodiments of the invention may be used include but are not limited to (a) an I- or T-beam; (b) a square or C-beam; (c) an I- or T-beam having a tapered top plate; and (d) any other type of beam having a square edge, including an I-beam, T-beam, C-beam, square beam, and angle beam. These variations are only proposed illustrations and are not intended to be limiting.
[0028] FIGS. 1A-1C show various embodiments of the guide (or tube) that may be used to engage and hold the support rod. According to these embodiments, the guide may be a round tube (top); square tube (middle); or C- or U-Channel (bottom). These embodiments are provided as illustrative and not intended to be limiting. For example, the guide may include an angle, hexagonal, or other shaped channels for accommodating a support rod. Alternatively, the support rod may be integrally formed with the hanger.
[0029] In FIG. 3 , the guide has been bonded to the brace by means of a fillet weld. However, it should be appreciated that other means of attaching the clip and braces together are anticipated. For example, the means may include bonding by an adhesive, tac or other type of weld, or other type of joint. Alternatively, the means may include physical attachment, including without limitation: screws, straps, interference fit, or other mechanical interface. Further, the guide may be integrally formed with the brace either in a finished state or additional machining, such as bending a guide to form a tube, may be performed to provide the guide. Further shown in FIG. 3 is that the brace may be cut from ¼″ steel plate.
[0030] FIGS. 5-7 show various alternative embodiments of the hanger, including the arrangement of the flange section and placement of optional bearing braces. The top (hereafter “FIG. 5 ”) and middle (hereafter “FIG. 6 ”) illustrations show the flange as a separately formed component formed from a number of flat bars which may be bonded (e.g. welded) or mechanically attached (e.g. screwed) to one another. The advantage of these arrangements is that the flange may be manufactured from several sections of steel bar. The bottom illustration (hereafter “FIG. 7 ”) shows the flange according to the embodiments illustrated in e.g. FIG. 2 as a single piece cut from a sheet of material, e.g. ¼″ steel plate. The advantage of this arrangement is that the number of steps for manufacture is reduced and the single-piece construction may be preferred to a welded multiple-piece construction in some applications.
[0031] FIG. 8 also illustrates several variations of the location of bearing plates. As shown in FIG. 5 , a single bearing plate is illustrated. This bearing plate is located on the portion of the flange that would engage the underside of an I-beam or similar. FIG. 6 illustrates two bearing plates that may be positioned at the proximal and distal ends of the brace and would engage the top plate of an I-beam or similar. FIG. 7 illustrates that a single bearing plate may be positioned at the proximal end (adjacent the guide) to engage the top of an I-beam or the like. Also shown in FIG. 5 is that the bearing plates may be either flush with or protruding from the profile of the brace and flange. FIG. 6 shows the bearing plates extending from the brace so that the bearing plates would contact the beam and the plate would not. FIG. 7 shows that the bearing plates may be recessed so that the load is shared between the bearing plates and the brace. In the first instance, it is necessary to design the profile of the brace and flange to account for the increased spacing between the brace and flange.
[0032] Having described the invention in detail and by reference to specific embodiments thereof it will be apparent that numerous variations and modifications are possible without departing from the spirit and scope of the disclosure.
|
A construction hanger comprising a brace including a first elongated member; an arm extending from one end of the first elongated member at an angle thereto, the arm and the elongated member cooperating to engage the surface of a construction support member; a guide at the end of the elongated member opposite the one end, the guide being capable of receiving a hanger member, the guide being positioned on or formed within the brace and at an angle thereto; the guide tying the hanging member to the construction support member by means of the brace.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to formulations of cathepsin K inhibitors.
[0002] A variety of cathepsin K inhibitors have been disclosed for the treatment of various disorders related to cathepsin K functioning, including osteoporosis, glucocorticoid induced osteoporosis, Paget's disease, abnormally increased bone turn over, tooth loss, bone fractures, rheumatoid arthritis, osteoarthritis, periprosthetic osteolysis, osteogenesis imperfecta, atherosclerosis, obesity, glaucoma, chronic obstructive pulmonary disease and cancer including metastatic bone disease, hypercalcemia of malignancy, and multiple myeloma Representative examples of cathepsin K inhibitors include those disclosed in International Publication WO03/075836, which published on Sep. 18, 2003, to Merck & Co., Inc. & Axys Pharmaceuticals, which is hereby incorporated by reference in its entirety.
[0003] Cathepsin K inhibitors can be formulated for oral dosing as tablets, by using a direct compression, wet granulation or roller compaction method. Similarly, cathepsin K inhibitors can be formulated for oral dosing as gelatin capsules, being a liquid in a soft capsule, or dry powder or semi-solid in a hard capsule. In addition, cathepsin K inhibitors can be formulated for intravenous dosing.
SUMMARY OF THE INVENTION
[0004] The instant invention relates to pharmaceutical compositions containing cathepsin K inhibitors. Also disclosed are processes for making said pharmaceutical compositions.
DETAILED DESCRIPTION OF THE INVENTION
[0005] A particularly effective cathepsin K inhibitor is N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide,
[0000]
[0000] which can be prepared by procedures described in: International Publication WO03/075836, which published on Sep. 18, 2003, to Merck & Co., Inc. & Axys Pharmaceuticals; International Publication WO2006/017455, which published on Feb. 16, 2006, to Merck & Co., Inc.; U.S. Publication US2006-0052642, which published on Mar. 9, 2006; U.S. Publication US2005-0234128, which published on Oct. 20, 2005, to Merck & Co., Inc.; all of which are hereby incorporated by reference in their entirety.
[0006] The invention contemplates the use of any pharmaceutically acceptable fillers/compression aids, disintegrants, super-disintegrants, lubricants, binders, surfactants, film coatings, and solvents. Examples of these components are set forth below and are described in more detail in the Handbook of Pharmaceutical Excipients, Second Edition, Ed. A. Wade and P. J. Weller, 1994, The Pharmaceutical Press, London, England.
[0007] The instant invention comprises a pharmaceutical composition comprising by weight, about 0.5 to 40% by weight of a cathepsin K inhibitor, or a pharmaceutically acceptable salt thereof, and from about 60% to 99.5% by weight of excipients selected from diluents, a binder, a lubricant, and a disintegrant.
[0008] In an embodiment of the pharmaceutical composition, the excipients comprise a diluent, a binder, and a disintegrant.
[0009] In an embodiment of the invention, the cathepsin K inhibitor is N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, or a pharmaceutically acceptable salt thereof.
[0010] In an embodiment of the invention, the diluents are selected from the group consisting of lactose anhydrous, lactose monohydrate, mannitol, microcrystalline cellulose, calcium phosphate and starch. In a class of the embodiment, the diluents are lactose monohydrate and microcrystalline cellulose.
[0011] In an embodiment of the invention, the binder is hydroxypropyl cellulose, polyvinylpyrrolidone or hydroxypropylmethylcellulose. In a class of the embodiment, the binder is hydroxypropyl cellulose.
[0012] In an embodiment of the invention, the lubricant is magnesium stearate or sodium stearyl fumerate. In a class of the embodiment, the lubricant is magnesium stearate.
[0013] In an embodiment of the invention the disintegrant is croscarmellose sodium, starch or sodium starch glycolate. In a class of the embodiment, the disintegrant is croscarmellose sodium.
[0014] The instant invention includes a process for the preparation of a tablet containing a cathepsin K inhibitor, which process comprises:
[0015] (a) forming a powder blend of the cathepsin K inhibitor with excipients,
[0016] (b) wet granulating the powder blend with hydroxypropyl cellulose to form granules,
[0017] (c) drying the granules, and
[0018] (d) compressing the dried granules in to a tablet.
[0019] In an embodiment of the process, the cathepsin K inhibitor is N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, or a pharmaceutically acceptable salt thereof.
[0020] In an embodiment of the process, the excipients comprise a diluent, a binder, and a disintegrant.
[0021] In an embodiment of the process, the diluents are selected from the group consisting of lactose anhydrous, lactose monohydrate, mannitol, microcrystalline cellulose, calcium phosphate and starch. In a class of the embodiment, the diluents are lactose monohydrate and microcrystalline cellulose.
[0022] In an embodiment of the process, the binder is hydroxypropyl cellulose, polyvinylpyrrolidone or hydroxypropylmethylcellulose. In a class of the embodiment, the binder is hydroxypropyl cellulose.
[0023] In an embodiment of the process, the lubricant is magnesium stearate or sodium stearyl fumerate. In a class of the embodiment, the lubricant is magnesium stearate.
[0024] In an embodiment of the process, the disintegrant is croscarmellose sodium, starch or sodium starch glycolate. In a class of the embodiment, the disintegrant is croscarmellose sodium.
[0025] The instant invention also includes a process for the preparation of a tablet containing a cathepsin K inhibitor, which process comprises:
[0026] (a) forming a powder blend of the cathepsin K inhibitor with excipients, using a mixer,
[0027] (b) wet granulating the powder blend with a binder to form granules,
[0028] (c) drying the granules in a fluid bed dryer,
[0029] (d) milling the dried granulate,
[0030] (e) lubricating the dried granules, and
[0031] (f) compressing the dried granules in to a tablet.
[0032] In an embodiment of the process, the cathepsin K inhibitor is N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, or a pharmaceutically acceptable salt thereof.
[0033] In an embodiment of the process, the excipients comprise a diluent, a binder, and a disintegrant.
[0034] In an embodiment of the process, the diluents are selected from the group consisting of lactose anhydrous, lactose monohydrate, mannitol, microcrystalline cellulose, calcium phosphate and starch. In a class of the embodiment, the diluents are lactose monohydrate and microcrystalline cellulose.
[0035] In an embodiment of the process, the binder is hydroxypropyl cellulose, polyvinylpyrrolidone or hydroxypropylmethylcellulose. In a class of the embodiment, the binder is hydroxypropyl cellulose.
[0036] In an embodiment of the process, the lubricant is magnesium stearate or sodium stearyl fumerate. In a class of the embodiment, the lubricant is magnesium stearate.
[0037] In an embodiment of the process, the disintegrant is croscarmellose sodium, starch or sodium starch glycolate. In a class of the embodiment, the disintegrant is croscarmellose sodium.
[0038] The instant invention also comprises a pharmaceutical composition comprising by weight, about 0.5 to 40% by weight of a cathepsin K inhibitor, or a pharmaceutically acceptable salt thereof, and from about 60% to 99.5% by weight of excipients selected from diluents and a lubricant.
[0039] In an embodiment of the invention, the cathepsin K inhibitor is N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, or a pharmaceutically acceptable salt thereof.
[0040] In an embodiment of the invention, the diluents are selected from the group consisting of lactose anhydrous, lactose monohydrate, mannitol, microcrystalline cellulose, calcium phosphate and starch. In a class of the embodiment, the diluents are lactose monohydrate and microcrystalline cellulose.
[0041] In an embodiment of the invention, the lubricant is magnesium stearate or sodium stearyl fumerate. In a class of the embodiment, the lubricant is magnesium stearate.
[0042] In an embodiment of the invention, the pharmaceutical composition also contains a binder. In a class of the embodiment, binder is hydroxypropyl cellulose, polyvinylpyrrolidone or hydroxypropylmethylcellulose. In a subclass of the embodiment, the binder is hydroxypropyl cellulose.
[0043] In an embodiment of the invention, the pharmaceutical composition consists of: 0.5 to 40% of a cathepsin K inhibitor or salt; 54% to 95.6% of a diluent or diluents; 1-2% of a lubricant. Optionally, the pharmaceutical composition can further include 3-4% dry binder. A class of the embodiment consists of 0.5 to 40% of N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide; 27% to 47.8% of lactose (as a diluent); 27% to 47.8% of microcrystalline cellulose (as a diluent); and 1-2% of magnesium stearate.
[0044] The instant invention includes a process for the preparation of a tablet containing a cathepsin K inhibitor, which process comprises:
[0045] (a) mixing together the cathepsin K inhibitor, diluents, and a dry binder,
[0046] (b) lubricating the mixture from step (a),
[0047] (c) dry granulating the lubricated mixture,
[0048] (d) size reducing the granules,
[0049] (e) lubricating the granules, and
[0050] (f) compressing the tablets on a rotary tablet press.
[0051] In an embodiment of the process, the cathepsin K inhibitor, diluent and dry binder are mixed together in a drum blender for 10 minutes. In a class of the embodiment, the drum blender is set at 46 rpm.
[0052] In an embodiment of the process, the mixture from step (a) is lubricated in a drum blender for 1 minute. In a class of the embodiment, the drum blender is set at 46 rpm.
[0053] In an embodiment of the process, the lubricated mixture from step (b) is dry granulated on a roller compactor. In a class of the embodiment, the roller compactor is set with a roll pressure of 400 MPa, a roll speed of 4.00 rpm and a screw speed of 55.5 rpm.
[0054] In an embodiment of the process, the granules from step (c) are size reduced by milling said granules through a screen and a round rasp screen. In a class of the embodiment, the screen measures 1 mm and the round rasp screen measures 1.27 mm.
[0055] In an embodiment of the process, the cathepsin K inhibitor is N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, or a pharmaceutically acceptable salt thereof.
[0056] In an embodiment of the process, the diluents are selected from the group consisting of lactose anhydrous, lactose monohydrate, mannitol, microcrystalline cellulose, calcium phosphate and starch. In a class of the embodiment, the diluents are lactose monohydrate and microcrystalline cellulose.
[0057] In an embodiment of the process, the binder is hydroxypropyl cellulose, polyvinylpyrrolidone or hydroxypropylmethylcellulose. In a class of the embodiment, the binder is hydroxypropyl cellulose.
[0058] In an embodiment of the process, the lubricant is magnesium stearate or sodium stearyl fumerate. In a class of the embodiment, the lubricant is magnesium stearate.
[0059] The instant invention also comprises an intravenous pharmaceutical composition comprising a cathepsin K inhibitor, or a pharmaceutically acceptable salt thereof, water, a modified cyclodextrin and a wetting agent.
[0060] In an embodiment of the invention, the cathepsin K inhibitor is N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, or a pharmaceutically acceptable salt thereof. In an embodiment of the invention, the modified cyclodextrin is sulfobutyl ether-7β-cyclodextrin (Captisol®) or Hydroxypropyl beta-cyclodextrin. In a class of the embodiment, the modified cyclodextrin is sulfobutyl ether-7β-cyclodextrin.
[0061] In an embodiment of the invention, the wetting agent is polysorbate 80, polysorbate 20, poloxamer 407, poloxamer 188, Cremaphor EL or a phospholipid. In a class of the embodiment, the wetting agent is polysorbate 80.
[0062] The pharmaceutical tablet compositions of the present invention may also contain one or more additional formulation ingredients that may be selected from a wide variety of excipients known in the pharmaceutical formulation art. According to the desired properties of the tablet, any number of ingredients may be selected, alone or in combination, based upon their known uses in preparing tablet compositions. Such ingredients include, but are not limited to, diluents, binders, compression aids, disintegrants, lubricants, flavors, flavor enhancers, sweeteners, preservatives, colorants and coatings.
[0063] The term “tablet” as used herein is intended to encompass compressed pharmaceutical dosage formulations of all shapes and sizes, whether uncoated or coated. Substances which may be used for coating include hydroxypropylmethylcellulose, hydroxypropylcellulose, titanium dioxide, talc, sweeteners and colorants.
[0064] The pharmaceutical compositions of the present invention are useful in the therapeutic or prophylactic treatment of disorders associated with cathepsin K functioning. Such disorders include: osteoporosis, glucocorticoid induced osteoporosis, Paget's disease, abnormally disease, tooth loss, bone fractures, rheumatoid arthritis, osteoarthritis, periprosthetic osteolysis, osteogenesis imperfecta, atherosclerosis, obesity, glaucoma, chronic obstructive pulmonary disease and cancer including metastatic bone disease, hypercalcemia of malignancy, and multiple myeloma.
[0065] The following examples are given for the purpose of illustrating the present invention and shall not be construed as being limitations on the scope of the invention.
Ranges of Conditions for Processing:
[0066] The wet granulation processes disclosed herein can be performed in (but not limited to) high shear mixer and fluid bed processor system. Granule is then milled through a size reduction mill, lubricant is added to the granule contained in a tote, and then mixed. Granule is then compressed into tablets.
[0067] The dry granulation process can be performed in (but not limited to) a roller compactor. Granule is then milled through a size reduction mill, lubricant is added to the granule contained in a tote, and then mixed. Granule is then compressed into tablets.
Example 1
Preparation of 50 mg Tablets
[0068]
[0000] Component % wt./wt. Mg/Tablet Weight (kg) N 1 -(1-cyanocyclopropyl)-4-fluoro- 12.5 50.00 5.0 N 2 -{(1S)-2,2,2-trifluoro-1-[4′- (methylsulfonyl)-1,1′-biphenyl-4- yl]ethyl}-L-leucinamide Microcrystalline Cellulose 40 160.00 16.0 Lactose Monohydrate 40 160.000 16.0 Croscarmellose Sodium 4 16.00 1.6 Hydroxypropyl cellulose 3 12.00 1.2 Magnesium Stearate 0.5 2.00 0.2 Purified Water* [35] [140.00] [14.0] Total 100 400.00 40.0 *removed during the during process (Batch = 100,000 tablet)
N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, 4% (wt./wt.) croscarmellose sodium, and a 1:1 (wt./wt.) mixture of microcrystalline cellulose and lactose monohydrate are dry blended in a high shear mixer, and then a 3% (wt./wt.) hydroxypropyl cellulose solution is sprayed onto the mixing powders to effect granulation. The wet granulate is dried in a fluid bed dryer, the dried granulate is then milled, and finally lubricated with 0.5% (wt./wt.) magnesium stearate in a blender. Tablets were then compressed on a rotary tablet press.
Example 2
Preparation of 5 mg Tablets
[0069]
[0000] Component % wt./wt Mg/Tablet Weight (kg) N1-(1-cyanocyclopropyl)-4-fluoro- 5 5 0.5 N2-{(1S)-2,2,2-trifluoro-1-[4′- (methylsulfonyl)-1,1′-biphenyl-4- yl]ethyl}-L-leucinamide Microcrystalline Cellulose 43.75 43.75 4.375 Lactose Monohydrate 43.75 43.75 4.375 Croscarmellose Sodium 4 4 0.4 Hydroxypropyl cellulose 3 3 0.3 Magnesium Stearate 0.5 0.5 0.05 Purified Water* [35] [140.00] [14.0] Total 100 100 10 *removed during the during process (Batch = 100,000 tablet)
N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, 4% (wt./wt.) croscarmellose sodium, and a 1:1 (wt./wt.) mixture of microcrystalline cellulose and lactose monohydrate are dry blended in a high shear mixer, and then a 3% (wt./wt.) hydroxypropyl cellulose solution is sprayed onto the mixing powders to effect granulation. The wet granulate is dried in a fluid bed dryer, the dried granulate is then milled, and finally lubricated with 0.5% (wt./wt.) magnesium stearate in a blender. Tablets were then compressed on a rotary tablet press.
Example 3
Preparation of 5 mg Tablets
[0070]
[0000] Component % wt./wt Mg/Tablet Weight (kg) N1-(1-cyanocyclopropyl)-4-fluoro- 5 10 1 N2-{(1S)-2,2,2-trifluoro-1-[4′- (methylsulfonyl)-1,1′-biphenyl-4- yl]ethyl}-L-leucinamide Microcrystalline Cellulose 43.75 87.5 8.75 Lactose Monohydrate 43.75 87.5 8.75 Croscarmellose Sodium 4 8 0.8 Hydroxypropyl cellulose 3 6 0.6 Magnesium Stearate 0.5 1 0.1 Purified Water* [35] [140.00] [14.0] Total 100 200 20 *removed during the during process (Batch = 100,000 tablet)
N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, 4% (wt./wt.) croscarmellose sodium, and a 1:1 (wt./wt.) mixture of microcrystalline cellulose and lactose monohydrate are dry blended in a high shear mixer, and then a 3% (wt./wt.) hydroxypropyl cellulose solution is sprayed onto the mixing powders to effect granulation. The wet granulate is dried in a fluid bed dryer, the dried granulate is then milled, and finally lubricated with 0.5% (wt./wt.) magnesium stearate in a blender. Tablets were then compressed on a rotary tablet press.
Example 4
Preparation of 10 mg Tablets
[0071]
[0000] Component % wt./wt. Mg/Tablet Weight (kg) N 1 -(1-cyanocyclopropyl)-4-fluoro- 10 10.00 1.00 N 2 -{(1S)-2,2,2-trifluoro-1-[4′- (methylsulfonyl)-1,1′-biphenyl-4- yl]ethyl}-L-leucinamide Microcrystalline Cellulose 42.5 42.50 4.25 Lactose Monohydrate 42.5 42.50 4.25 Croscarmellose Sodium 4 4.00 4.00 Magnesium Stearate 1 1.00 1.00 Total 100 100.00 10.00 (Batch = 100,000 tablet)
N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, and a 1:1 (wt./wt.) mixture of lactose anhydrous (type; direct tabletting), microcrystalline cellulose (type; Avicel PHI 02) are mixed together in a drum blender for 10 minutes at 46 rpm. The mixture is then lubricated by addition of 0.5% (wt./wt.) magnesium stearate and mixing in the same blender for 1 minute at 46 rpm. The mixture was then dry granulated on a roller compactor using the following conditions;
[0072] Roll Pressure=400 MPa
[0073] Roll Speed=4.00 rpm
[0074] Screw speed=55.5 rpm
[0000] The compacted ribbons are milled through a 1 mm screen, and then further size reduced in a cone mill equipped with a 1.27 mm round rasp screen. A final lubrication with 0.5% (wt./wt.) magnesium stearate was performed using the drum blender for 1 minute at 46 rpm. Tablets were then compressed on a rotary tablet press.
Example 5
Preparation of 25 mg Soft Gelatin Capsules
[0075]
[0000] Mg/ Component % wt./wt. Capsule Weight (kg) N 1 -(1-cyanocyclopropyl)-4-fluoro- 2.5 25.00 2.5 N 2 -{(1S)-2,2,2-trifluoro-1-[4′- (methylsulfonyl)-1,1′-biphenyl-4- yl]ethyl}-L-leucinamide PEG400 60 600.00 60.0 Water 10 100.00 100.0 Butylated Hydroxyanisole (BHA) 0.1 1.00 1.0 Soft gelatin capsule 27.4 274.00 27.4 Total 100 1000.00 100.0 (Batch = 100,000 capsules)
N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide is dissolved in a PEG400/10% H 2 O/0.1% BHA solution and then 1000 mg is filled into soft gelatin capsule. In the capsule filling process, the fill material is injected into the pocket as gelatin ribbon is molded into the capsule shape.
Example 6
Preparation of 10 mg Hard Gelatin Capsules
[0076]
[0000] Mg/ Component % wt./wt. capsule Weight (kg) N 1 -(1-cyanocyclopropyl)-4-fluoro- 10 10.00 1.00 N 2 -{(1S)-2,2,2-trifluoro-1-[4′- (methylsulfonyl)-1,1′-biphenyl-4- yl]ethyl}-L-leucinamide Microcrystalline Cellulose 42.75 42.75 4.275 Lactose Monohydrate 42.75 42.75 4.275 Croscarmellose Sodium 4 4.00 0.4 Magnesium Stearate 0.5 0.5 0.05 Total 100 100.00 10 Hard Gelatin Capsule n/a 40 4 (Batch = 100,000 capsule)
N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide, and the 1:1 (wt./wt.) mixture of lactose monohydrate, microcrystalline cellulose are mixed together in a drum blender for 10 minutes at 46 rpm. The mixture is then lubricated by addition of 0.5% (wt./wt.) magnesium stearate and mixing in the same blender for 1 minute at 46 rpm. The oral gelatin capsule formulation process is performed on a dry powder filling capsule machine.
Example 7
Preparation of 5 mg Hard Gelatin Capsules
[0077]
[0000] Mg/ Component % wt./wt Capsule Weight (kg) N 1 -(1-cyanocyclopropyl)-4-fluoro- 0.5 5 0.5 N 2 -{(1S)-2,2,2-trifluoro-1-[4′- (methylsulfonyl)-1,1′-biphenyl-4- yl]ethyl}-L-leucinamide PEG4000 89.4 894 89.4 Butylated Hydroxyanisole (BHA) 0.1 1 0.1 Water 10 100.00 10 Total 100 1000.00 100 Hard Gelatin Capsule n/a 75 7.5 *hopper maintained at 75° C. (Batch = 100,000 capsule)
PEG4000 is liquified at 70° C. in a non-hygroscopic environment then N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide is added with stirring to the PEG4000 until solubilized. The solution is added to the hopper* of a capsule filling machine, then hard gelatin capsules are filled with 1 g of solution.
Example 8
Preparation of IV Formulation
[0078]
[0000]
Component
Amount, mg/mL
N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -
0.1
{(1S)-2,2,2-trifluoro-1-[4′-
(methylsulfonyl)-1,1′-biphenyl-4-
yl]ethyl}-L-leucinamide
Captisol
350
Polysorbate 80
0.1
Water for Injection
Qs 1.00 mL
Vehicle Preparation Procedure:
[0079] Weigh the Captisol® (0.35 g for each 1 mL of vehicle), then add the Captisol®t with three times of rinse to a glass container (volumetric flask) with approximately 90% of the water. Stir the solution with a stirring bar at a speed that creates a vortex. Stir until all solid has dissolved (approximately 60 minutes). Add polysorbate 80 (0.0001 g for each 1 mL of vehicle), then Qs to the desired final volume with water. Mix well (inverting the flask by 5-6 times), and record the final pH. Filter through to the container by using Millipore GV filter unit (0.22 μm, sterile)
Formulation Preparation Procedure—0.1 mg/ml of N 1 -(1-cyanocyclopropyl)-4-fluoro-N-{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide) in 0.01% polysorbate 80, 35% Captisol®
[0080] Tare the volumetric flask on the balance, add polysorbate 80 (0.1 mg for each 1 ml of vehicle). Add approximately. 90% of the water weight in the formulation to a glass container (volumetric flask). Add 35% Captisol® (0.35 gram per 1 ml of water), add stirring bar to the solution, stir the solution at a speed that create a vortex, during approximately 30 minutes of stirring, invert the flask couple of times to wash off any particles on the wall of top flask. Weigh N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide (0.1 mg for each 1 ml of vehicle), then add N 1 -(1-cyanocyclopropyl)-4-fluoro-N 2 -{(1S)-2,2,2-trifluoro-1-[4′-(methylsulfonyl)-1,1′-biphenyl-4-yl]ethyl}-L-leucinamide to a glass container. Sonicate for approximately 5 minutes using a bath sonicator to breakdown the large particles. Continue to stirring at 400 rpm for overnight, invert the flask if any particles were on the wall of top flask. The formulation should be clear; otherwise, continue stirring until the solution is achieved (˜24 hours). Qs to volume with water. Filter using Millipore GV filter unit (0.22 μm, sterile). Label the IV formulation and move it to 5° C. or −20° C. refrigerator immediately.
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The instant invention relates to pharmaceutical compositions comprising cathepsin K inhibitors as the active ingredient with excipients which include binders, diluents, lubricants, and disintegrants. Also disclosed are processes for making said pharmaceutical compositions for oral and intravenous delivery.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a division of my prior, copending application Ser. No. 644,786 filed Dec. 29, 1975, now U.S. Pat. No. 4,048,248, Sept. 13, 1977.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved process for the conversion of an aromatic hydrocarbon in the presence of a titanium tetrafluoride catalyst system. The invention will be described with reference to alkylation, e.g., the synthesis of cumene by alkylation of benzene with propylene in the presence of the catalyst. The invention may also be used for alkylaromatic transalkylation and isomerization.
2. Description of the Prior Art
Conversion of aromatic hydrocarbons is well known in industry. Some of the aromatic conversion reactions which occur include alkylation of aromatic hydrocarbons with an alkylating agent such as an olefin, disproportionation or transalkylation of alkylaromatic hydrocarbons and isomerization of alkylaromatic hydrocarbons such as xylenes, and of dialkyl and higher substituted aromatics.
Of special interest, has been the propylation of benzene to cumene. Cumene is used for the production of phenol and acetone. Cumene is also dehydrogenated to form methylstyrene, in a process similar to that used to convert ethylbenzene to styrene. Cumene is also used as a blending component in aviation gasoline because of its high octane number. The consumption of cumene in the U.S.A. was about 350,000 metric tons in 1968. Of this total, 94% was used for the production of phenol or acetone.
It is well known that cumene can be synthesized from benzene and propylene using a catalyst of AlCl 3 , SPA or BF 3 . SPA is generally accepted abbreviation for solid phosphoric acid catalyst, or phosphoric acid which is adsorbed on kieselguhr or other support.
AlCl 3 is a very popular alkylation catalyst, because of its high activity. Unfortunately, the catalyst operates as a slurry or sludge which is messy to handle on a commercial scale, and also is corrosive. The highly reactive nature of this Friedel-Crafts metal halide catalyst, AlCl 3 , is desirable when attempting to alkylate benzene with ethylene, because less active catalyst systems do not work. However, for alkylation with propylene such highly reactive systems are not necessary.
Another highly selective catalyst system has been developed for the alkylation of benzene with olefins. This catalyst comprises boron trifluoride. The boron trifluoride catalyst system is exceptionally active and permits operation with dilute olefin streams, but it requires the continuous addition of BF 3 to maintain catalyst activity. High catalyst activity also leads to oligomerization of olefins so contact time of olefins with BF 3 catalyst should be as short as possible. This catalyst is also exceptionally water sensitive, as water not only destroys the catalyst, but produces very corrosive solutions which attack downstream processing units. BF 3 also frequently appears in the product and must be removed therefrom.
Because of the interest in alkylating benzene with propylene to make cumene, and because of the inadequacies of existing catalyst systems, I studied the work that others had done, and made exhaustive investigations to determine if it would be possible to find a catalyst which would have the activity and selectivity required to produce an acceptable cumene product, while making maximum use of existing petroleum resources and provide an improved process for the manufacture of cumene.
A high active catalyst was sought to operate with less catalyst and to reduce operating or construction cost. In new units this would mean smaller, and cheaper reactor vessels, while in existing units it would means that an increase in capacity could be obtained merely by changing catalyst in an existing reactor vessel with only minor modifications of the plant.
High selectivity is necessary, not only to permit operation with feedstreams which are not 100% pure propylene, but also to maximize production of the desired cumene product, and to minimize production of polymerized olefins, or polyalkylated aromatic compounds.
Accordingly, many catalyst systems were studied to find a catalyst with excellent activity and selectivity, which was not corrosive or destroyed by water.
There has been extensive work done with Ti catalysts, thought most work occurred in conjunction with studies of Ziegler-Natta catalysts. The closest prior art known in U.S. Pat. No. 2,381,481 (Class 260-683.15), U.S. Pat. No. 2,951,885 (Class 260-671), U.S. Pat. No. 2,965,686 (Class 260-671) and U.S. Pat. No. 3,153,634 (Class 252-429).
In U.S. Pat. No. 2,381,481, preparation and use of a catalyst prepared by treating alumina gel with fluotitanic acid is disclosed. This catalyst is used for polymerization of olefins to heavier hydrocarbons, and also for alkylation of paraffins with olefins, the latter when operating at high temperatures, between 700° and 900° F. no higher. No mention is made of alkylation of aromatics with olefinic hydrocarbons.
In U.S. Pat. No. 2,951,885, there is disclosed the use of titanium trihalide on activated alumina or other activated acidic oxide for alkylation of benzene with olefins. The catalyst is originally a tetrachloride, subsequently reduced to the trichloride with an alkali metal such as sodium, lithium, or potassium. The examples show that this catalyst will alkylate benzene with ethylene.
In U.S. Pat. No. 2,965,686, the thrust of the application was to develop a titanium subchloride catalyst. In Example II, a reaction between cumene and propylene was disclosed using titanium tetrachloride catalyst. The catalyst in Example II was not a subfluoride, but rather was a tetrachloride. The reaction occurred for almost 3 hours at 146° C. in a vessel containing 43 grams of catalyst and 128 grams of cumene. Almost 64% of the cumene was not reacted, while the isopropyl cumene yield was 27.3%, and 2.6% yield of heavier material. It is not certain if the results obtained in this patent are due solely to the use of the tetrachloride, as opposed to the tetrafluoride of applicant's process or whether the method of preparation of applicant's tetrafluoride also makes a contribution to the improved activity of applicant's catalyst.
In U.S. Pat. No. 3,153,634, there is disclosed the use of titanium subhalides in a polymerization reaction. The patentee is probably describing a form of catalyst to make high molecular weight polymer, as he discusses production of solid polymer products. The patentee in 3,153,634 taught the very antithesis of applicant's reaction. Thus, on page 3 line 65-75, the patentee mentions use of benzene as an inert solvent to hold dissolved olefins, rather than as a reactant.
Accordingly, work continued on developing an improved process for the catalytic conversion of aromatic hydrocarbons.
Accordingly, the present invention provides a process for the catalytic conversion of an aromatic hydrocarbon comprising contacting the aromatic hydrocarbon with a reactant in the presence of a catalyst comprising titanium tetrafluoride composited with a support which contains surface hydroxyl groups and recovering a converted aromatic hydrocarbon as a product of the process.
DETAILED DESCRIPTION
The catalyst of the present invention comprises a titanium tetrafluoride component, and a support containing surface hydroxyl groups, e.g., a Group III-A metal oxide. Use of titanium tetrafluoride alone, e.g., dispersed on an inert, high surface area support, such as silica, does not produce an active catalyst. It is only with the use of metal oxide possessing surface hydroxyl groups that the titanium tetrafluoride catalyst system produces satisfactory activity.
One of the best supports is alumina, especially gamma-alumina. The alumina preferably has a bulk density of 0.3 to 0.7 g/cm 3 and a surface area of 1 to 500 m 2 /g. It would also be possible to disperse the catalyst system of the present invention on an inert support and still have an active catalyst. Thus, titanium tetrachloride and gamma-alumina could be impregnated on a ceramic honeycomb, available as an article of commerce with the Dow-Corning Corporation. Use of titanium tetrafluoride alone on such a ceramic support would not produce an active catalyst. Other preferred Group III-A metal oxides which may be used include the oxides of gallium, indium, and thallium.
If the catalyst system is supported on an inert, carrier, any of the well known supports can be used. These include silica, clays, charcoal, gravel, sand, etc., though all of these will not give equivalent results.
It is also within the scope of the present invention to add one or more promoters to the catalyst system. It is believed that promoters from Group III and Group VI-B may be beneficial.
When it is desired to use the catalyst system in an alkylaromatic isomerization process, then alkylaromatic isomerization reaction conditions should be used. Reaction conditions are disclosed in U.S. Pat. No. 3,637,881 (Class 260-668a), the teachings of which are incorporated by reference. When it is desired to use the catalyst system of the present invention for alkylaromatic transalkylation then appropriate reaction conditions should also be used. These are disclosed in U.S. Pat. No. 3,720,726 (Class 260-672t), the teachings of which are incorporated by reference. Reaction conditions for the alkylation of aromatic hydrocarbons will be discussed in detail in a latter part of this specification.
Two different catalyst preparation techniques have been used, sublimation and impregnation.
In one sublimation procedure titanium tetrafluoride may be placed on top of a bed of gamma-alumina. Preferably the support is predried at 300° to 600° C. for 1 to 10 hours under hydrogen or an inert gas flow to activate the alumina and remove all water and water-forming compounds therefrom. Drying at higher temperatures depletes the alumina of hydroxyl groups and should be avoided. Non predried, commercial alumina may also be used but there will be a significant loss of TiF 4 to titanium oxide or titanium oxyfluoride. The titanium tetrafluoride and alumina should be maintained in a dry, inert atmosphere, after drying. While passing nitrogen downflow over the mixture of alumina and titanium tetrafluoride, the temperature is slowly increased to a temperature slightly above the sublimation temperature of titanium tetrafluoride, then the temperature is progressively increased to elevated temperatures. This thermal pretreatment step is preferably 250 to 350° C. for 1/2 to 2 hours, followed by treatment at 400° to 600° C. for one to ten hours.
Another way to prepare catalyst for use in the present invention is to impregnate the Group III-A metal oxide with a solution containing a compound which will decompose to form titanium tetrafluoride upon heating in an inert atmosphere while not converting TiF 4 to lower valence Ti compound. A preferred titanium tetrafluoride impregnating solution consists of an organic or aqueous solution of TiF 4 or an aqueous solution of M 2 TiF 6 , where M equals H, Li, Na, or K. In all impregnating methods it is preferred to contact the metal oxide with impregnating solution at room temperature and then progressively increase the temperature to evaporate the solution. The catatlyst is then preferably thermally treated at 100° to 200° C. for 1/2 to 2 hours and then at 250° to 350° C. for 1/2 to 2 hours and then at 400° to 600° C. for 1 to 10 hours under an inert atmosphere.
Unfortunately, the sublimation procedure requires excess amounts of titanium compounds to insure that all parts of the Group III-A metal oxide are contacted by titanium compounds. Because of the difficulties encountered with this procedure, the impregnation of the titanium compounds onto the Group III-A metal oxide is much preferred. In impregnation, it is of course possible to vary over a wide range the concentration of titanium compound in the finished catalyst system. A preliminary evaluation of the optimum amount of titanium tetrafluoride indicates that about the same amount of titanium should be added via the impregnation procedure as would be incorporated using a sublimation procedure. Adding more titanium than this does not seem to produce significantly increased catalytic activity, while having less titanium than this optimum amount impairs catalytic activity. At least about 0.5 weight percent titanium is believed necessary for a significant amount of reaction to occur. The upper limit on titanium is about 20 wt. %.
The ratios of reactants and other reaction conditions which occur when alkylating benzene with propylene are basically those well known in the art. Pressures may range from 1 to 100 atmospheres, or even higher. It is desirable to maintain pressures high enough to have a liquid phase in the reaction zone. Although it is possible to operate at very high pressure, little advantage is gained thereby, in fact, an increase in pressure seems to have a harmful effect. High pressure does not seem to effect the selectivity of the reaction to produce cumene, but rather seems to encourage the formation of non-aromatic compounds, possibly propylene trimers. Thus, operation at pressure above around 500 atm leads to the production of trace amounts of non-aromatic compounds, as determined by gas chromotography. Operation at pressures lower than 50 atm eliminated these. Preferred pressure seems to be around 20 to 60 atm, with an optimum pressure of about 35 atm.
Temperature effects both the conversion and selectivity of the reaction. Temperature may range between ambient and 250° C. At very low temperatures, the catalyst is not sufficiently active to permit the desired reaction to proceed at a satisfactory rate. At very high temperatures, it is believed that the catalyst may be damaged, either by stripping away of the titanium tetrafluoride component, or by deformation of carbonaceous materials on the catalyst.
If the reaction is kinetically controlled, an increase in temperature should increase the rate of reaction. As a general statement, this is true, but the temperature dependence is not as large as expected, so the reaction may be limited by mass transport of reactants and products to and from the catalyst surface. Preferred operating temperatures seem to be about 100° to 200° C. It was difficult to pick an optimum temperature, but this may be because conversion of olefins was so high. Further studies, with less conversion, may indicate an optimum temperature of this reaction.
The catalyst may be disposed in a reactor vessel as a fixed, fluidized or moving bed of catalyst. The reactants may contact the catalyst in upflow, downflow or crossflow fashion, through upflow of reactants over a fixed bed of catalyst is preferred.
The liquid hourly space velocity in the reactor may range from 0.1 to 20. However, higher LHSV is possible depending on the desired conversion level of propylene. Because catalyst of the present invention is very active for the alkylation reaction, significantly higher space velocities are possible then when using some prior art catalysts, e.g., SPA. To some extent, the liquid hourly space velocity is related to temperature in the reaction zone, in general, a higher LHSV will require higher temperature operation.
As used herein, conversion refers to the disappearance of reactants. Thus, conversion refers to percent disappearance of propylene feed. Selectively means the amount of cumene produced per mole of propylene that was consumed, expressed as percent. Thus 90% conversion means that for every 100 moles of propylene entering the reactor, 90 moles were converted to something else. A selectivity of 80% would mean that 72 moles of cumene were formed, e.g., that 80% of the 90 moles of propylene consumed were converted to cumene.
EXAMPLE I
This example shows how to make a catalyst via a sublimation technique. About 200 ml of gamma-alumina in the form of 1.6 mm spheres, prepared by the well known oil drop method, was dried at 550° C. for 300 minutes under H 2 flow. The apparent bulk density was 0.52 g/cc. The H 2 flow was replaced with N 2 flow and the alumina cooled to room temperature. About 30 grams of TiF 4 was placed on top of the predried alumina. Temperature was slowly increased to 310° C. while maintaining a downflow of N 2 over the alumina. This temperature was maintained for 90 minutes. Temperature was then increased to 350° C. for 15 minutes, then to 400° C. for 30 minutes.
EXAMPLE II
This example shows how to make an impregnated catalyst of the present invention. Gamma-alumina was impregnated with aqueous TiF 4 , solution. The solution was prepared by dissolving H 2 TiF 6 in deionized water. The alumina and impregnating solution were cold rolled in a rotating steam drier, then steam was turned on to evaporate the solution. These catalysts were then given further thermal treatments under N 2 flow. In one instance, a Cr promoter was added to the catalyst by dissolving CrO 3 in the impregnating solution. Details of the preparation of these catalysts are shown in Table I. These were catalysts A, B and C.
TABLE I__________________________________________________________________________ IMPREGNATION THERMAL TREATMENT Impreg. Solution (All With 2000 cc/min N.sub.2 Flow)Alumina 60% H.sub.2 TiF.sub.6 Volume Cold Roll First Second Third FourthCatalystcc g cc cc minutes ° C/hours ° C/hours ° C/hours ° C/hours__________________________________________________________________________A 200 12.44 7.55 250 60 150/1 200/1.25 300/1 500/5B 125 6.0 4.0 125 30 150/1 200/1 300/1 350/3.25C 300 16.5 10.0 300 30 140/1 300/1.5 500/3 --/--__________________________________________________________________________ Note: Catalyst A also contained Cr added by dissolving 5.15 g CrO.sub.3 to the impregnating solution
EXAMPLE III
In this instance a commercially available solid phosphoric acid catalyst was used for comparison purposes. This was catalyst D.
EXAMPLE IV
The catalysts were tested in a laboratory scale plant. The reaction studied was alkylation of benzene with propylene. Catalyst was maintained as a fixed bed, of 50 cc volume. The reactants were passed upflow over the catalyst bed. Benzene was dried by circulating it over high surface area sodium. Pure propylene was dried by passing it over type 4-A molecular sieves. Benzene and propylene were mixed together and then charged to the reactor. The reactions were all carried out at 120° to 245° C., 1 to 3 LHSV, and at 25 to 55 atmospheres pressure. The reactor was started up full of liquid benzene and then the mixture of propylene and benzene added. It is believed that if propylene alone is charged, or even propylene and benzene charged simultaneously, high molecular weight polymer may form.
Reaction conditions and test results are reported in Table II. Conversion (C) refers to conversion of propylene in the feed, while selectively (S) refers to moles of cumene produced per mole of propylene reacted, expressed as mole percent. Productivity (P) refers to weight percent cumene in product.
TABLE II__________________________________________________________________________SUMMARY OF RESULTReaction Conditions Hrs. onCatalystT(° C) P(atm) Bz/C.sub.3 = LHSV Stream C S P__________________________________________________________________________B 120 55 6.24 1.1 17-22 72.1 59.2 69.1" " " 6.10 2.1 38-43 52.1 63.3 75.0" 150 " 6.00 2.0 58-63 80.3 62.3 72.4" " " 5.5 1.1 78-83 86.0 57.6 67.2" 120 " 6.6 2.0 96-101 48.4 67.3 78.1" 150 35 4.6 0.9 116-121 84.2 57.5 67.4" " " 5.3 2.1 136-141 73.1 56.7 67.0" " 28 5.0 2.2 156- 161 75.1 58.7 68.4" " " 5.1 0.9 178-182 84.8 48.7 61.1" " 55 7.5 2.0 195-199 78.6 74.6 77.2" " " 9.0 3.1 215- 219 80.1 62.2 71.4" 150 35 8.1 3.1 229-233 79.1 71.9 79.5" " " 7.8 2.0 245-249 90.0 70.4 78.2" 120 55 5.3 2.1 266-270 81.1 63.7 74.9" 180 35 8.1 2.1 279-283 92.0 67.4 75.7" 180 " 4.9 2.1 299-303 90.0 56.8 66.8D 180 35 8.6 1.0 14-18 81.6 84.5 89.1" " " 7.9 2.0 35-39 75.5 87.8 91.5" " " 5.39 1.1 44- 48 83.1 83.4 88.4" " " 4.81 0.98 64-68 84.5 84.6 89.0C 120 35 4.68 1.1 13-17 95.5 62.1 71.0" " " 4.77 2.1 25-29 95.5 61.1 70.6" 150 25 5.17 2.1 41-45 93.8 61.1 70.8" " " 5.14 2.0 45-49 93.3 58.4 68.1" " " 4.95 1.1 61-65 96.5 57.7 67.4" " " 4.84 2.9 77-81 81.7 61.7 71.0" " " 8.59 2.1 89-93 92.8 71.5 78.8" 150 25 7.85 2.0 93-97 93.0 69.6 77.6" " " 7.48 1.0 105-109 93.7 73.8 81.1" " " 6.87 1.0 109-113 93.8 67.8 76.3" " " 2.86 1.1 125- 129 97.9 48.5 59.3" " " 2.88 2.3 141-145 96.6 46.7 57.5" " 35 3.07 2.3 157-161 95.6 49.9 60.5" " 35 3.06 1.2 173-177 94.6 50.0 60.6" 150 " 5.03 1.0 189-193 95.0 60.7 70.0" " " 5.08 2.0 197-201 96.6 65.0 71.9" " " 4.94 2.0 205-209 96.0 61.7 70.8" " 25 4.92 3.0 217-221 96.0 64.4 68.8" " 35 8.11 2.1 233-237 89.8 80.3 78.8" " " 8.10 2.0 237- 241 95.5 65.7 72.2" " " 7.35 1.0 249-253 92.4 78.7 80.1" 120 25 5.20 2.1 265-269 96.3 60.6 70.2" " " 4.94 2.0 269-273 96.1 57.7 67.3" " " 5.18 3.0 281-285 91.8 61.7 71.2" " " 4.93 3.0 285-289 95.5 56.9 69.4" " " 7.55 2.0 301-305 93.2 75.6 82.9" " " 7.69 3.0 317-321 94.7 74.6 81.4" 120 25 2.82 3.5 325-329 96.4 49.3 58.5" " " 2.76 2.1 349-353 95.2 47.2 58.2" " " 4.91 1.9 357-361 94.7 57.8 67.8" " " 4.82 1.9 361-365 96.3 63.1 70.2" " " 4.95 3.0 373-377 93.0 60.7 70.3" " " 5.27 3.2 377-381 91.6 59.8 69.5__________________________________________________________________________
Because of poor weight recoveries experienced when testing catalyst A, the results obtained with catalyst A are not recorded in Table II. However, the products obtained were analyzed, and it is believed that the analysis of products gives a good indication of the catalyst system's performance. Table III provides a comparison of the product streams produced by the different titanium tetrafluoride catalysts. From these data it can be observed that the catalyst containing chromium promoter is very selective for the production of cumene.
TABLE III______________________________________Comparisonof Various Supported Titanium Tetrafluoride Catalysts.CATALYST A C B______________________________________Hours of 10 20 40 70 190 200 140 300Operation*Light Ends 0.2 0.3 0.4 0.4 0.1 0.1 1.7 0.7Benzene 72.5 73.0 56.5 55.5 74.2 77.8 79.2 77.0Toluene Tr Tr Tr TrEthylbenzene 0.1 Tr 0.1 0.1Cumene 23.7 20.2 33.4 32.9 18.0 15.9 12.8 14.9n-Propyl- 0.1 Tr 0.1 0.1benzeneUnknowns 0.1 Tr 0.1 0.1 0.11.4-Dimethyl-2-Ethyl- 2.0 3.0 5.6 6.1benzeneUnknowns 1.3 3.5 3.8 4.8Dipropyl- 6.7 5.0 5.1 6.3benzeneTripropyl- 1.0 1.2 1.1 1.1benzeneC.sub.9 -- 93.8 88.9 88.4Unknowns 0.1 0.1C.sub.12Aromatics 5.6 9.9 10.4Unknowns 0.2 0.1C.sub.15Aromatics 0.5 0.5 0.6Unknowns 0.2 0.2C.sub.18Aromatics 0.1 0.1 0.1Heavies Tr 0.1 0.1Reaction ConditionT(° C) 180 180 245 245 150 150 150 180P(atm) 55 55 55 55 35 35 35 35C.sub.6 H.sub.6 /C.sub.3 H.sub.6 4.5 4.9 2.6 2.6 5.0 5.1 5.3 4.9LHSV 1.8 2.0 4.2 4.2 1.0 2.0 2.1 2.1______________________________________ *by gas chromatography **by boiling point
Based on these studies it is believed that the important factor in the thermal treating steps in the temperature, rather than the total time, as long as the total period for thermal treatment is reasonably long, around 5 or 6 hours. It is believed that the activity of the catalyst is effected by the thermal treatment temperatures because the desorption of water molecules from the catalyst surface may require higher temperature than certain initial temperatures. Water can compete for active sites with the reactants, thus water is to some extent a catalyst poison. However, if catalyst deactivation occurs due to water adsorption, the catalyst can be regenerated by appropriate further thermal treatment under inert gas flow. Any regenerative thermal treatments should probably approximate those of the original thermal treatments, in that heating which is too rapid, or too high a temperature, may cause hydrolysis of the TiF 4 component on the catalyst, which would reduce catalyst activity. Another danger of a rapid high temperature catalyst regeneration would be the formation of corrosive gases and liquids due to rapid evolution of H 2 O vapor and fluorine compounds.
Although water is discussed above as a catalyst poison, the titanium tetrafluoride catalyst system of the present invention is much less susceptible to attack by water than are corresponding titanium tetrachloride catalysts. For some reason, not yet fully understood, the fluoride is held much more tenaciously by the support than the corresponding chloride compounds.
The catalyst which contained a chromium compound in addition to TiF 4 showed superior selectivity to cumene when compared to non-promoted TiF 4 catalysts. From the data it may be seen that all of the catalysts of the present invention are at least 2 to 3 times as active as SPA catalysts. With the addition of Cr promoter, the catalyst system of the present invention has almost the same selectivity to cumene as SPA catalyst. It is not understood why the addition of Cr promotor is beneficial. The reaction may be more selective, but it is also possible that a certain amount of transalkylation also occurs. Although the sectivities to cumene of Ti catalyst were slightly lower than that of SPA, since these catalysts were able to transalkylate, it is possible to carry out the reaction with low benzene/C 3 H 6 mole ratio feeds by reintroducing polyalkylated benzene into the reactor or installing a separate reactor for transalkylation to produce high purity cumene product.
From the data it is also apparent that increasing the benzene to propylene ratio increases the selectivity of the reaction for cumene. This phenomenon was expected, and is typical of prior art processes using SPA or BF 3 catalysts.
The catalyst of the present invention is also believed more stable than prior art catalyst. The stability of a catalyst is technically very important. Ti fluoride is very stable compared with the titanium chloride (due to the lower value of heat of formation of fluoride than that of titanium chloride). My titanium catalyst is reasonably stable to air. A high water content in the feed or too long exposure to air will reduce catalyst activity. However, it is possible to restore the catalyst activity by simply passing dry inert gas on the catalyst at elevated temperatures.
Thus, it can be seen that the process of the present invention provides a viable alternative to existing catalyst systems. The process of the present invention permits operation at lower temperatures if desired, and with increased throughputs, while using a catalyst which is less corrosive and easier to handle than some prior catalyst systems.
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Process for the conversion of aromatic hydrocarbons. Especially useful for reaction of an alkylating agent, preferably propylene, with an aromatic hydrocarbon. Novel feature is use of a catalyst system comprising TiF 4 and a metal oxide which possesses surface hydroxyl groups.
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FIELD OF THE INVENTION
[0001] The invention relates to the manufacturing of rivets and in particular the adaptations making it possible to simplify the methods of manufacturing while optimising the technical characteristics of the latter.
DESCRIPTION OF PRIOR ART
[0002] Semi-tubular rivets exist in prior art of the type of those that include a preformed head and a rod provided with an axial drilling in order to form a tubular portion opposite the preformed head.
[0003] These rivets have the advantage of being particularly adapted for the carrying out of the assembly of parts made of soft or fragile materials in particular synthetic materials such as composite material.
[0004] One of these rivets described in patent FR 2587421 has for specificity to be arranged with a peripheral groove on the external surface of the rod on the tubular portion of the latter. A docking surface is preserved on said external surface at the end of the rod. This peripheral groove thus prevents the contact of this portion of the rivet with the edges of the hole arranged in the parts to be joined, contact which is likely to damage said part.
[0005] This rivet nevertheless has the disadvantage of requiring a machining of its external surface in order to arrange said peripheral groove and in order to create said docking surface.
[0006] This machining operation increases the cost of manufacturing the rivet while modifying its technical characteristics. Indeed, although the rivet is preformed by a cold heading technique the carrying out of such a groove is implemented by machining which has for effect to break the fibres of the metal which can contribute to a poor fatigue strength of the rivet.
DESCRIPTION OF THE INVENTION
[0007] In light of this fact, the applicants have carried out research aiming to reduce the cost of manufacturing these rivets while optimising the technical qualities.
[0008] This research has resulted in the designing of a method for manufacturing rivet that is particularly advantageous, resolving the problems of prior art.
[0009] This method for manufacturing a rivet is of the type of that comprising by deformation of the material of a substantial cylindrical metal section, the preformation operations of a countersunk head at the end of a rod and is remarkable in that it comprises the carrying out by deformation of the material (cold heading) the following operations:
creation of a portion with less diameter starting at the free end, creation of a substantially cylindrical hollow core in order to form a tubular portion, preformation as a truncated cone of the hollow core, preformation as a truncated cone of the external surface of less diameter.
[0014] By proposing an embodiment that does not require a machining operation for this portion of the rivet, the applicants have designed a method reducing the costs of manufacturing the rivet. Furthermore, such a method remains in the continuity of the cold heading operations participating in the manufacturing of the rivet and preceding the operations of carrying out the groove and the tube.
[0015] This characteristic is particularly advantageous in that it guarantees the fibre formation of the material and improves the metallurgical state of the rivet. This method further allows the size of the grains to be refined.
[0016] A non-negligible technical effect of this method resides in the pre-orientation of the fibres of the metal which favours the deformation of the rivet during its installation.
[0017] The fastening or the rivet are considered in a plurality of materials such as titanium, T40, titanium with columbium, steel, stainless steel, etc.
[0018] The method is furthermore remarkable in that it comprises softening the material used by heat treatment. The hard metals used thus undergo a softening operation.
[0019] According to another particularly advantageous characteristic, the method comprises preforming from a cylindrical surface the large base of the truncated cone formed exteriorly. As such, docking surfaces are also likely to be created via plastic deformation.
[0020] The use of such a method of realisation required a modification of the geometry of this rivet.
[0021] According to a particularly advantageous characteristic, this rivet is remarkable in that it is comprised of at least three parts:
a tapered head linked by its small base to the rod, a first cylindrical portion of a rod with diameter corresponding to the small base of the head, a tapered portion of the rod of which the small base with diameter less than the diameter, is linked to the first cylindrical portion and of which the large base adopts the same diameter as the first cylindrical portion.
[0025] According to another characteristic, the rivet comprises a fourth part, i.e. a second cylindrical portion with rod of likewise diameter as the first cylindrical portion.
[0026] Of course, the invention also relates to the method comprising the operations required in order to carry out a rivet such as described hereinabove.
[0027] As the basic concepts of the invention have just been exposed hereinabove in their most basic form, other details and characteristics will become clearer when reading the following description and with regards to the annexed drawings, provided by way of a non-limiting example, an embodiment of a method for manufacturing rivet and a rivet in accordance with the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a cross-section view of an embodiment of a metal section corresponding to a rivet in the process of being carried out,
[0029] FIGS. 2 a , 2 b , 2 c show the steps of the deformation of the metal section in FIG. 1 for the purposes of carrying out an embodiment of a rivet in accordance with the invention,
[0030] FIG. 3 is a cross-section view of an embodiment of a rivet in accordance with the invention,
[0031] FIGS. 4 a , 4 b and 4 c , show the steps of the installation of the rivet of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0032] Such as shown in the drawing in FIG. 1 , the method of the invention is of the type of that comprising beforehand the carrying out by plastic deformation of the material i.e. by forging starting with a substantial cylindrical metal section, the preformation of a countersunk head 100 at the end of a rod 200 appearing as short dashes.
[0033] The method of the invention is remarkable in that it always comprises by deformation of the material (cold heading) the creation of a portion 210 of rod with less diameter starting from the free end.
[0034] Furthermore, the method ensures the creation of a substantially cylindrical hollow core 220 in order to form a tubular portion. The part P obtained is that shown as thick lines in the drawing in FIG. 1 .
[0035] This part P is placed in a matrix M which, associated with a “punch”, ensures the following operations:
preformation as a truncated cone of the hollow core, preformation as a truncated cone of the external surface of lesser diameter.
[0038] This matrix M comprises a cylindrical housing of which one end is countersunk so that the head of the part P can be housed therein. Once in place the part P is maintained in position and a punch O with a tapered end penetrates into the hollow core 220 as shown in FIG. 2 b . In this movement, the edges of the tube forming this end of the part P separate in order to return to the tapered form of the punch until the external surface of said tube comes into contact with the surface of the housing of the matrix M as shown in FIG. 2 c . The external surface also takes the form of a truncated cone. The movement is continued until a cylindrical docking surface at the end of the external surface of the rod is created.
[0039] The rivet R obtained as such is shown in the drawing in FIG. 3 . It includes a countersunk head 100 ′ and a rod 200 ′ composed of a solid portion 210 ′ located under the preformed head 100 ′ and a semi-tubular portion 220 ′ located opposite the head.
[0040] As shown the semi-tubular portion 220 ′ is provided with an axial hole 221 ′ of tapered form expanding towards the opposite the preformed head and exiting at this end. The angle α taper is between 10 and 30 degrees. According to a preferred embodiment, the angle α is equal to 20 degrees.
[0041] As shown, the bottom 222 ′ of the hole adopts the form of a spherical dome and the hole 221 ′ extends over a little more than half of the length of the rod 200 ′.
[0042] On the tubular portion 220 ′, the external surface of the rod adopts a tapered form 223 ′ of which the angle β is between 10 and 30 degrees. According to a preferred embodiment, the angle is equal to 20 degrees. As such, according to a preferred embodiment, the rod 200 ′ is preformed interiorly and exteriorly on its tubular portion according to the same cone angle. The top 224 ′ of the truncated cone 223 ′ originates under the solid portion of the rod 210 ′ and adopts a diameter less than said rod. The base 225 ′ of the cone returns to the diameter of said solid portion 210 ′ of rod.
[0043] The correspondence between the top 224 ′ of the external cone with that 222 ′ of the internal cone 221 ′ makes it possible to create a zone of material of less thickness predisposed to the deformation required for the installation. It further allows for the formation of a withdrawn volume preventing the deformation of the tubular portion of the rivet from resulting in a bearing on the surfaces that is not provided for this purpose of the part to be fastened. The presence of this withdrawn volume further allows thicknesses of variable material to be assembled.
[0044] In fact, the embodiment shown for rivet has exteriorly four main parts:
a tapered head A linked by its small base to the rod, a first cylindrical portion B of rod with diameter corresponding to the small base of the head, a tapered portion C of rod of which the small base is linked to the first cylindrical portion and of which the large base adopts the same diameter as the first cylindrical portion, a second cylindrical portion D of rod with likewise diameter as the first cylindrical portion B.
[0049] This second part is not mandatory and an embodiment not shown of the rivet R is in three parts without final cylindrical portion.
[0050] This FIG. 3 also shows the orientation of the fibres of the metal. It clearly appears that the use of a method of forging for all of the operations of carrying out the rivet R makes it possible to obtain a rivet of which the fibres are not damaged and are pre-oriented for the deformation required when installing said rivet R.
[0051] According to a characteristic not shown, the thickness of the tube is constant from the end linked to the solid portion to the open end of the rod.
[0052] FIGS. 4 a , 4 b and 4 c show the installation of the rivet of the invention.
[0053] This installation is carried out for the purposes of fastening two parts 300 and 400 of material composite. These parts 300 and 400 are pierced by a hole 500 of which the bore corresponds to the external diameter of the rod of the rivet with a low spacing, identical tapered countersunk holes 510 and 520 are made on both sides of parts 300 and 400 which correspond to the ends exiting from hole 500 .
[0054] The riveting is carried out using two riveting dies 600 and 700 such as shown schematically in these FIGS. 4 a , 4 b and 4 c , one 600 playing the role of a counter bearing on the side of the head and the other 700 being subjected to a pressure in order to form the second head and carry out the riveting.
[0055] As shown in the drawing in FIG. 4 b , the rivet R is deformed first without docking then the surface corresponding to the end of the rivet R or the docking surface comes to be applied against the countersunk hole 520 as shown in the drawing in FIG. 4 c . As shown and in accordance with the characteristics sought for such a rivet, the presence of a withdrawn form on the external surface of the rivet causes a folding of its end without contact with the linking edge between the countersunk hole 520 and the hole 500 .
[0056] It is understood that the method and the rivet, which have just been described and shown hereinabove, have been described and shown in light of a divulgation rather than as a limitation. Of course, various arrangements, modifications and improvements can be made to the example hereinabove, without however leaving the scope of the invention.
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The invention relates to a method for making a rivet (R), of the type comprising, by deformation of the material of a substantially cylindrical metal segment, the operations of preforming a milled head ( 100 ) at the end of a rod ( 200 ), characterised in that it comprises, by deformation of the material (cold stamping) the following operations: creating a portion with a lower diameter ( 210 ) from the free end; creating a substantially cylindrical hollow core ( 220 ) for forming a tubular portion; preforming the hollow core ( 220 ) as a truncated cone; performing the lower diameter outer surface as a truncated cone. The invention also relates to the rivet obtained by said method.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a housing for the positioning of electric actuators for the formation of the shed on a loom, and particularly for the control of the harness threads of a Jacquard-type weaving mechanism, and to a loom.
2. Description of the Related Art
It is known to use a rotary motor, such as a stepping motor or a servomotor to linearly control a twine pertaining to a loom.
Taking into account the large number of harness threads that may comprise a Jacquard-type weaving mechanism, the actuators associated with these harness threads must be arranged with respect to each other in such a manner that they can be individually controlled by an electric control system, and that the harness threads would not interfere with each other. Further, it must be possible to selectively take out the actuators in question from the weaving mechanism for regular service, maintenance, or replacement operations. Lastly, the actuators must be positioned in a precise manner with respect to an electronic supply and control board.
The main objective of the present invention is to remedy these constraints by presenting a housing for the lodging of rotary electric actuators that would allow a precise positioning of the various actuators with a view to their interaction with the harness threads, a possibility of disassembly of one or of several of these actuators and their control by electric means.
SUMMARY OF THE INVENTION
With this in mind, the present invention relates to a housing for the positioning of electric actuators for the formation of the shed on a loom, comprising at least a compartment appropriate to house in a removable manner a last one actuator in such a position that a harness thread can be wound up on a pulley moved by said actuator.
Thanks to the present invention, the compartment or compartments constitute as many chambers for the rotary electric actuators, which facilitates a quick servicing of these actuators.
These compartments, whose geometry can be defined with precision, determine by interaction with the actuators the orientation of the latter.
In accordance with a first embodiment of the present invention, the compartments are arranged in rows and columns essentially perpendicular to the axis of rotation of the pulleys of the actuators. Thanks to this aspect of the invention, one housing can comprise an according number of compartments, while the pulleys of the actuators lodged in these compartments are arranged side by side which allows an easy access to the pulley assembly, particularly at the time of placing the harness threads.
In accordance with other embodiments of the invention, the compartment is appropriate for the retention of several actuators and comprises positioning means for the actuators inside the compartment. This allows to impart upon the housing great compactness but still obtaining the objectives of the invention. Several rows and columns of actuators can be provided inside the compartment. Depending on the variants of the embodiment, the means of positioning can be designed as ribs extending over a portion of the transversal dimensions of the compartment or as centering pieces.
In accordance with another advantageous aspect of the invention, the housing comprises a cover for enclosing the pulleys of the actuators. This cover facilitates the insulating of the pulleys and actuators against constant air-born fluff in the proximity of a textile machine in operation. This brings about an increased working life of these devices which, should they be exposed to the fluff, would tend to clog which would decrease their efficiency. The cover is provided with ribs to separate the actuators' pulleys. These separation ribs create an internal partitioning of the cover and facilitate the defining of the run of the harness threads that are being wound up on the pulleys with a view to ensure that no interference takes place between the harness threads or between the harness threads and the adjacent pulleys, including in the case of a harness thread breakage.
In this case and in accordance with another advantageous aspect of the present invention, it can be provided that when the compartments are arranged in rows or columns, some of the cover's ribs are oblique with respect to these columns or these rows; the oblique feature of the ribs make feasible the juxtapositioning of several harness threads, essentially parallel to each other. This type of design guarantees a minimum of interference between the harness threads and of friction on the stationary elements which limits their wear and tear.
In accordance with another advantageous aspect of the present invention, the housing comprises a guide bar provided with holes for the passing of the actuator-controlled harness threads. The function of this bar is to define the positioning of the harness threads with respect to the pulleys in order to ensure their best possible winding and unwinding, whichever their subsequent direction might be, in particular due to the position of the harness tie.
In accordance with another advantageous aspect of the present invention, each of the compartments is provided with a bottom deformation or rear wall with a hole for the power supply of the actuators housed in the compartments, which hole is on the opposite side of the pulleys secured to them. This facilitates the power supply of the actuators without any interference with the pulleys and the harness threads.
In accordance with another advantageous aspect of the present invention, this bottom deformation comprises a bearing surface for a bolting bracket firmly attached to the actuator in the corresponding housing. The interaction of the bearing surface and of the bolting bracket ensures a secure fastening of the actuator inside the compartment.
In accordance with another advantageous aspect of the present invention, the housing is provided with positioning means with respect to an electronic control device for the actuators positioned in the compartment, which electronic device comprises electric supply means and/or means for the detection of the angular position of the actuators. The housing can be connected to an electronic control device by a simple operation and, in particular, by clipping on. This ensures a satisfactory positioning of the actuators with respect to their pertinent control elements.
The invention also relates to a loom equipped with a weaving mechanism that comprises one or more housings such as described above. This loom is simpler to use and to maintain than the devices of known type, and it allows a thread by thread control of a Jacquard-type loom harness. Thus, its efficiency is considerably improved with respect to known techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and its other advantages will be shown more clearly through the below description of four embodiments of a housing for the lodging of rotary electric actuators in accordance with its principle, given only by way of example and making reference to the accompanying illustrations wherein:
FIG. 1 shows a view in perspective with a partial cutaway of a housing in accordance with the invention during creeling of bobbins with a rotary electric actuator;
FIG. 2 shows a longitudinal section of the housing of FIG. 1, after the creeling of bobbins;
FIG. 3 shows a sectional drawing along the line III--III of FIG. 2, in which II--II indicates the line of the sectional drawing in FIG. 2;
FIG. 4 is an exploded drawing along the line IV--IV of FIG. 2, at the time of the introduction of an actuator into a compartment;
FIG. 5 shows a drawing analogous to that of FIG. 4 with the actuator bolted into position;
FIG. 6 shows an exploded drawing along the line VI--VI of FIG. 3;
FIG. 7 shows a front view of a housing in accordance with a second embodiment of the invention;
FIG. 8 shows a front view of a housing in accordance with a third embodiment of the invention;
FIG. 9 shows a front view of a housing in accordance with a fourth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The housing 1 illustrated in FIG. 1 comprises sixteen compartments 2, arranged in four rows and four columns. The compartments 2 are separated by internal partitions 1a of the housing 1 that extent in two perpendicular directions, so that the compartments 2 present an essentially parallelepipedal section. Each compartment 2 presents an internal section essentially equal to the external section of a rotary electric actuator 3 which is to be housed in such compartment. Each actuator 3 is provided with a pulley 4 for the winding-up operation of a harness thread 5.
The actuator 3 may be positioned in the respective compartment 2 in a direction F essentially parallel to the axis of rotation XX' of the pulley 4. On its back, that is to say, opposite the pulley 4, the actuator 3 has an extension 6 provided with pins 7 for the electric connection to an electronic control device of a printed circuit board 8. Into a bottom of rear wall 9 of each compartment 2 is bored a hole 10 through which pass of the extension 6 and the pins 7.
As it can be seen more clearly in FIG. 2, the back edge of the housing 1 is provided with a first rabbet 1c for the housing and clamping of the board 8. Also provided is a second rabbet 1d for the housing of a second board 8'. Thus, the position of the boards 8 and 8' with respect to the housing 1 is defined with precision, so that the relative position of the actuators 3 with respect to the boards 8 and 8' is also precisely defined, which ensures a satisfactory functioning of the connector pins for the supply and the control of the actuators.
On its side opposite the pulley 4, the actuator 3 is also provided with a collar 11 rigidly affixed to the not represented rotor on which is mounted the pulley 4. The collar 11 is provided with notches 11a on its external radial surface. A clamping or braking force can be applied to the collar 11 essentially perpendicular to the axis of rotation XX' of the pulley 4. This force can be applied by any appropriate means while the notches 11a allow a blocking of the collar 1 in position. Further, teeth are cut into the collar 11 that delimit slots between them. The succession of these teeth and slots enable a scanner 12, be it of optical, infrared or the like type, to record the orientation of the collar 11 and of the pulley 4 around the axis XX'. The scanner is advantageously installed on the board 8.
As FIG. 2 illustrates it more clearly, when an actuator 3 is in place in the respective compartment, the pulley 4, lodged in such compartment, projects towards the outside of this compartment in order to allow the winding of the harness thread 5 it must control. Thus, each actuator controls the movement of a harness thread thanks to the pulley 4 provided on its front turned towards the left in FIG. 2, while it is controlled thanks to the pins 7 and the collar 11 positioned on its back turned towards the right in FIG. 2.
In this position, a cover 15 is intended to enclose the sixteen pulleys of the actuators 3 that are arranged in the sixteen compartments 2 of the housing 1. This cover prevents the accumulation of fluff or the contact with an operator's tool whilc the pulleys are functioning. The cover 15 is provided with primary internal ribs 15a that extend in the direction of the separating partitions 1a of the housing 1. As particularly illustrated in FIGS. 1 and 3, the ribs 15a extend in a first direction essentially perpendicular to the axis XX' of the pulleys 4 in which they are contained, while they are also provided with secondary internal ribs 15b, arranged essentially perpendicular to the primary ribs 15a. The design of the ribs 15a and 15b enables the separation of the pulleys 4 from the various actuators, which prevents the circulation of fluff between the various pulleys. The ribs 15b do not meet with the ribs 15a because they are truncated in order to leave a passage for one or several harness threads 5 between their free end and the adjacent primary rib 15a. FIG. 3 clearly shows that the secondary ribs 15b are of different lengths, and that they become gradually shorter with an increased number of harness threads for which they leave a passage. The function of the ribs 15b is to prevent that a harness thread of a pulley of an upper actuator comes into contact with a pulley of a lower actuator, particularly in the case of a malfunctioning when an elastic return movement system pulls the harness threads downwards.
The ribs 15a are oblique in their lower area with respect to the columns formed by the compartments 2. The oblique feature of the ribs 15a has the purpose of allowing the passage of the harness threads 5 in a parallel manner in direction towards a guide bar 16 provided on the lower part of the housing 1. As a matter of fact, if the harness threads 5 were arranged essentially parallel to the line II--II in FIG. 2, a harness thread intended to wind around an upper pulley 4 would interfere with the pulley or pulleys installed below it as illustrated in FIG. 3. Thus, the oblique positioning of the harness threads 5 results in a reduction of the risks of interference between the harness threads and the pulleys.
This oblique positioning is obtained thanks to the guide bar 16 which is provided with holes 16a for the passing of the harness threads 5, controlled by the actuators 3. The positioning of the holes 16a on the bar 16 is chosen depending on the angle of inclination or of pitch of the ribs 15a in their lower area.
As illustrated in FIG. 2, taken as a whole, the holes 16a are on the plane of the first turn formed by the harness threads 5 being wound up on the pulleys 4 of a column of actuators. This on the harness threads 5 at the holes 16a and of the cord of the harness threads being wound on the cord of the harness threads already wound-up.
As illustrated more clearly in FIG. 6, the holes 16a are arranged in zigzag, that is to say, alternately on two lines D and D' perpendicular to the axis of rotation XX' of the pulleys 4.
The cover 15 is also provided with the seats 15c for the front ends of the pulleys 4 in the position represented in FIG. 2. These seats define exactly the relative positioning of the various pulleys, so that the cover 15 cannot be mounted if one of the actuators 3 is not correctly installed in the pertinent compartment.
The cover is mounted on the housing 1 by means of screws represented by their lines of axes 15d and intended to enter into the threaded holes 1b of the housing 1.
In FIG. 1 can be noted that the actuator 3 is provided with two oblique slots 3a defining the movable wedges 3b with respect to the rest of the actuator 3 thanks to the elasticity of the material of which it is made. These movable wedges are pushed into the direction of the axis of rotation of the pulley 4 of each actuator when it is inserted into the pertinent compartment. They contribute to the blockage by friction of the actuator in its compartment.
Each actuator 3 is provided with an elastic catch or hook 17, illustrated in FIGS. 4 and 5, the extremity of which is provided with a nose or tip 17a intended to become wedged on a bearing surface 9a of the rear wall 9. When the actuator 3 reaches the bottom, of the compartment 2 into which it is inserted according to the direction F, the elastic catch 17 is slightly deformed when its tip 17a passes through the hole 10. Then, and as illustrated in FIG. 5, the tip 17a rests against the surface 9a so that the actuator 3 is firmly held in its position.
When all the actuators 3 are in place in the pertinent compartments 2, the housing 1 can be pushed backwards toward the board 8 which is represented by the arrow F' in FIG. 5. The pins 7 enter then into a classic connecting device 18.
When it becomes necessary to service one or several actuators 3, it is possible to remove the entire unit of the housing 1, eventually firmly attached to the board 8, from the rest of the weaving mechanism. One can then proceed with the regular replacement of the housing.
According to another alternative, it is also possible to remove the cover 15 from the housing 1 and to take out one or several actuators 3, thanks to a pierced cramp 19 provided on the front of each actuator 3 in the proximity of pulley 4.
Depending on the number of threads to be controlled on the loom, it is possible that one housing 1 is not completely equipped. Should it become necessary, it can be easily completed at any time with additional actuators.
In the second embodiment, illustrated in FIG. 7, the elements analogous to those of the embodiment of FIGS. 1 to 6 are identified by the same reference numbers but increased by 50. The housing 51 of this embodiment comprises one only compartment 52 appropriate to lodge four actuators 53, represented by dot-and-dash lines. The location of the actuators 53 in the compartment 52 are defined by ribs 71 that on the whole extend parallel to the sides of the housings 51 over one portion of the height (h) and the width (l) of the compartment 52. Thus, the ribs 71 facilitate a relative positioning of the actuators 53 inside of the compartment 52.
In the third embodiment of the present invention, illustrated in FIG. 8, the elements analogous to these of the embodiment of FIGS. 1 to 6 are identified by the same reference numbers but increased by 100. In this embodiment, the housing 101 comprises only one compartment 102 which can accommodate nine actuators 103, represented by dot-and-dash lines. In the compartment 102 are provided centering pins 122 in order to define the positions of the actuators 103 in the compartment 102. The pins 122 are represented by a round section. However, they can present a cross-shaped section in order to present angles for the seating of the wedges of the actuators 103.
In the fourth embodiment of the present invention, illustrated in FIG. 9, the elements analogous to those of the embodiment of the FIGS. 1 to 6, are identified by the same reference numbers but increased by 150. In this embodiment, the housing 151 comprises only one compartment 152 which can accommodate three actuators 153, 153' and 153", represented by dot-and-dash lines. The actuators 153 and 153' are simple, that is to say, they serve for the control of one only harness thread. On the other hand, the actuator 153" is double, that is to say, that it can control two harness threads, which is presented by dot-and-dash lines for the path of two pulleys. The relative positioning of the actuators 153, 153' and 153" inside the compartment 152 is obtained by the fact that the section of the compartment 152 corresponds precisely to the sum of the outside sections of the actuators 153, 153' and 153". In this case, the outside walls 151a, 151b, 151c, and 151d of the housing 151 are the only means of positioning for the actuators 153, 153' and 153" inside of the compartment 152.
Other variants of the present invention can also be contemplated, in which several simple or multiple actuators are lodged inside the same compartment. The compartments appropriate for the lodging of several actuators can be arranged in rows and columns, just like the compartments 2 of the first embodiment.
It is understood that the housings of the second, third and fourth embodiments can also be provided with a cover such as described for the first embodiment and, in general, with all the improvements of the first embodiment that are transposable.
Whichever the embodiment considered, the housing in accordance with the present invention facilitates a precise positioning of the actuators in the space, their tightness thanks to their cover, their cooling by energy dissipation, their electric connection to an electronic supply and control board, the support of their braking and safety device, the guiding of the harness threads, and its securing as well as the assembly on a support system such as, for example, a rail-shaped structural element.
In accordance with a not shown variant of the present invention, it would be possible to provide that the housing has a depth corresponding only to a portion of the length of the actuators 3, that is to say, of their dimension parallel to the axis XX', so that once installed in the housing, the actuators would project beyond the back of the housing. In such a case, a covering cap of parallelepipedal shape and without internal ribs can be installed on the back of the housing in order to cover the back parts of the actuators. This covering cap could be provided with means of electric connection. In this case, the positioning in the space of the actuators would be effectuated by the ribs or the pins of the housing that are between the actuators on their front.
The design can also be such, that it is also possible that the back of the housing is provided with skirts that extend parallel to the axis XX', with actuators in order to protect the electronic boards to which it is connected against the circulation of large amounts of fluff that is found in the operating environment of the actuators.
The housings of the invention were represented as lodging the rotary electric actuators. It must be understood that those housings allow the positioning of all types of electric actuators and, in particular, of linear actuators.
Whichever might be the considered embodiment, the housing is advantageously made out of a good thermal conductive material, particularly out of a metal such as aluminum or Zamak (registered trademark). This facilitates the cooling of the actuators that tend to heat up due to their electric power consumption.
Although essentially described as relating to an actuator for a Jacquard mechanism, the invention can also be applied to textile machines in general and, in particular, to machine-knitting for the control of the needles.
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A housing for the removable positioning of one or more rotary electric actuators used for formation of the shed of a weaving loom and which housing includes at least one compartment which allows the actuators to be received and removed therefrom by movement in a direction parallel to an axis of rotation of rotary elements associated with the actuators and which elements control the movement of the harness cords of the shed forming device. The housing allows harness threads to be moved relative thereto with respect to the rotary elements and may include a cover to encase the rotary elements associated with the actuators.
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This is a division of application Ser. No. 08/653,528 filed May 24, 1996, now U.S. Pat. No. 5,661,236.
The present invention is directed to a hybrid solar and fuel fired electrical generating system and more specifically, to where the fuel portion of the power plant is a gas turbine where in addition to generating electricity the hot exhaust gas of the turbine is used for producing steam in combination with the solar unit for driving steam turbine generators.
BACKGROUND OF THE INVENTION
Combined cycle electrical generating systems using solar and gas turbine units are probably known as illustrated in U.S. Pat. No. 5,444,972. In addition it is believed that Bechtel Corporation of San Francisco, Calif. have designs that have added to a standard General Electric gas turbine power plant (which by the way also used high pressure and low pressure steam turbines), a solar evaporator. However, in both of the above installations, there was no specific effort to optimize the overall system. Rather the solar energy portion of the system was merely added to the combined cycle, utilizing the original gas turbine steam generation equipment and cycle layout as originally designed for fuel firing.
OBJECT AND SUMMARY OF THE INVENTION
It is a general object of the present invention to provide an improved hybrid solar and fuel fired electrical generating system.
In accordance with the above object, there is provided an electric power generation system having a substantially closed feed water/steam path to provide a common mass flow comprising a gas turbine and generator having a hot exhaust gas stream. First heat exchanger means are at least partially located in a downstream portion of the hot exhaust gas for heating the feed water to substantially its evaporation temperature. Solar boiler means are connected to the first heat exchanger means for evaporating the feed water. A high pressure steam turbine generator is provided. Also a low pressure steam generator having a low pressure exhaust is connected to a condenser which thereby supplies the feed water. Second heat exchanger means located in an upstream portion of the hot exhaust gas of the turbine receives both evaporated feed water from the solar boiler means and also the low pressure exhaust of the high pressure steam turbine and superheats it to a predetermined temperature for driving both the high pressure and low pressure steam turbines. The absolute energy per degree of temperature rise supplied by the second heat exchanger means for superheating above the high pressure boiling point is substantially equal to the heat energy per degree of temperature rise provided by the first heat exchanger means to heat the feed water to the evaporation temperature and below the high pressure boiling point.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic representation of the total system.
FIG. 2 is a graph helping to explain the concept of the invention.
FIG. 3 is a characteristic curve illustrating the actual operation of the invention.
FIGS. 4 and 5 are curves similar to FIG. 3 illustrating theoretical nondesired operational modes.
FIG. 6 is a temperature-entropy diagram illustrating the present invention.
FIG. 7 is a schematic representation which is an alternative to FIG. 1.
FIG. 8 is the diagram of FIG. 6 modified to illustrate FIG. 7.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 illustrates the electrical power generation system of the present invention which has as its key components a fuel powered gas turbine driving a generator 12 and a solar boiler 13. As will become apparent the solar heat used in conjunction with the gas turbines exhaust gas heat, the gas stream being shown as the dashed line 14, will make much more steam power than can be made by using each separately, or in a combined or hybrid system as discussed above, which is not optimized. In general the present invention realizes that since the gas turbine exhaust heat has the characteristic of giving up one percent of its heat with a drop of one percent of its temperature from its given datum, it should not be used for boiling, which occurs at a constant temperature, but only for feed water heating to the evaporation temperature and also steam superheating. On the other hand, since solar heating occurs at close to a constant temperature it is best mainly used for boiling or bringing the feed water to its evaporation temperature. Thus as illustrated in FIG. 1, the solar boiler could as well be a nuclear boiler since that has the same type of characteristic; that is, a constant temperature even though heat is being removed from the system as contrasted with the gas turbine exhaust gas.
Referring now to the hardware implementation of the system of FIG. 1, the exhaust gas 14 of the gas turbine 11 first is routed to a high pressure super heater 16 and a low pressure reheater. As indicated these are actually interleaved heaters 18 in the form of tube sheets. High pressure super heater 16 superheats the high pressure steam generated by the solar boiler 13.
Thus the solar boiler temperature is near the evaporation temperature and super heater 16 heats the resultant steam up to the maximum approach temperature used to drive the high pressure steam turbine generator 21.
After expansion in the high pressure steam turbine 21 the exit line 22 is still superheated at the original exit temperature of solar boiler 13. The low pressure reheater 17 again reheats the steam to the maximum approach temperature and drives the low pressure steam turbine generator 23. The reheated steam is then expanded through the low pressure steam turbine to the condenser unit 24 and then after condensing the water is pumped by pump 26 to feed water heater (or heat exchanger 27). This is located in the downstream portion 28 of the gas turbine exhaust 14. With the use of this exhaust the feed water is again heated to up to near its boiling point and fed to the solar boiler 13 to complete the closed feed water/steam path. Since this is a closed path, of course, there is a common mass flow through the system. The super heater and reheater 16, 17 are located in the upstream or hotter portion of the hot exhaust gas stream 14.
Theoretically when using the exhaust gas heat of the gas turbine solely for water heating and super heating, it is desirable for the best thermodynamics to have close to a constant temperature difference between the turbine gas flow as it cools and the countercurrent water and steam flows as they heat up by taking heat from the gas flow. However, FIG. 2, which is a temperature-entropy (H) characteristic indicates an inherent problem. The exhaust gas has a specific heat (Cp) of about 0.25. On the other hand steam has a specific heat of about 0.5 and water of 1.00. This leads to an imbalance as the water has a specific heat of about twice the specific heat of the steam. Thus the amount of water flow heat pick up degree which would match the gas flow's heat pickup degree is only about half the amount of steam flow whose heat pickup per degree would match the gas flow's heat give up per degree.
As stated above the ideal optimum thermodynamic situation is where there is a constant temperature in the heat exchange between the turbine gas flows and the steam and water. This is illustrated in FIG. 3 where the steam, water, and gas curves are shown with the horizontal axis being heat exchange in BTUs per hour and the vertical axis being in ° F. temperature. Specific temperature values are indicated for one example to be discussed below. The ideal characteristics of FIG. 3 can be realized as will be discussed in detail below by heating each pound of steam twice over the same temperature range. However, if this is not done, the curves of FIGS. 4 or 5 show theoretical undesired results. These curves are conceptual only and simplified; thus they do not match a real situation. Thus in FIG. 4 the water and gas counterflows are matched leaving a mismatch with the steam; in FIG. 5 the steam is matched leaving a mismatch with the water.
The temperature-entropy characteristic of FIG. 6 succinctly illustrates the technique of the present invention which achieves the ideal characteristics of FIG. 3. The main curve 31 of FIG. 6 is a standard temperature-entropy curve where in the interior of the bell shaped curve is the wet region, on the left side is liquid and on the right is the dry region or superheat and vapor region.
Now relating the system of FIG. 1 to the chart of FIG. 6, the feed water heater 27 is illustrated by the curve 32 which heats the feed water up to its boiling point which is indicated at 33 and, for the example of the present invention is approximately 566° F. at a pressure of 1190 psia. The cross hatched portion A 1 under the curve up to 33 and going down to absolute zero temperature is the heat energy supplied by that stage. Then the horizontal line 35 is the latest heat of evaporation which occurs in the solar boiler 13 to change the phase of the water from liquid to vapor which occurs at 36. On the other side of the bell curve 31 the dashed line shown at 37 are isopressure lines at 5 psi, a 100 psia and 1000 psia. Substantially along the 1000 psi line the solid line 38 shows the operation of super heater 16 which superheats the steam up to the temperature indicated of 1050° F. at a pressure substantially similar to the original pressure 1130 psia. Then on line 22, this is dropped by typical valve means on the high pressure steam turbine and by the turbine action, per se, to the low pressure of 150 psia and 566°, the original evaporation temperature. The low pressure steam is again reheated by the low pressure reheater 17 as shown by the solid line 39 back to 1050° at substantially a pressure of 150 psi. And then the action of the low pressure turbine in conjunction with condenser 24 (see line 41) drops the exhaust down to substantially 1 psia at about 100° F. temperature. It is critical that this line 41 indicating the exhaust of the low pressure turbine 23 hits the curve 31 at the location indicated so that the temperature and pressure combination provides an exhaust which is not totally dry and not too wet.
Thus referring to the crosshatched portions, the heat added by the high pressure superheater 16 is shown by the area A 2 and the heat added by the low pressure reheater 17 by the area A 3 . As shown by the equation it is desirable for optimum efficiency that area A 1 divided by the temperature rise, T 2 -T 1 equal to the sum of A 2 and A 3 divided by the temperature rise, T 3 -T' 2 . When this is done it will effectively compensate for the difference between the specific heats of water and steam as discussed above to thus yield the idealized characteristic curves of FIG. 3.
To explain the foregoing by equation, the following three apply:
______________________________________ (1) M * Cp.sub.w = M * Cp.sub.g (2) ΣM * Cr.sub.s = M * Cp.sub.g (3) ΣM * Cp.sub.s = M * CP.sub.wwhere M = Mass flowCp = Average specific heat______________________________________
Equation (1) shows the matching of the product of mass flow and specific heat of water with gas flow, and equation (2) the matching of the superheating steam to gas. Finally equation (3) is the necessary condition for equations 1 and 2 to hold. Since the specific heats of gas and water are not equal, (one is double the other) by superheating the steam twice, first at high pressure and then at low pressure equation (3) is effectively satisfied.
Thus, in general the following are design criteria: 1) steam is reheated twice compared to water, 2) the same temperature range is used for both the high pressure superheater 16 and the low pressure reheater 17; 3) the temperature of the solar boiler, given in the example of 566°, is chosen to provide an inexpensive solar boiler of the trough type (also the pressure of 1190 psia is chosen for good compatibility with the solar boiler output; 4) the low pressure turbine drop to the condenser is neither dry or too wet, 5) the inlet pressure to the high pressure turbine 21, for example, 1130 psia, is not too high for a commercial turbine; 6) the pressures of heaters 16 and 17 are chosen to provide the desired equality with feedwater heating.
A theoretical system has been designed and the attached Table I illustrates the operating parameters.
As illustrated, for example, by the Table 1, the embodiment of FIG. 1 with the proper temperatures and pressures provides optimum efficiency. For example, in some installation a pressure of 2150 psia might provide superior efficiencies. However FIG. 7 illustrates an alternative which is a modification of FIG. 1 which uses an additional low pressure solar boiler 41 with a modified feedwater arrangement. This includes the existing feedwater heater which is now divided into low temperature/high pressure and high temperature/high pressure sections 40 and 42 and a low temperature/low pressure section 43. Sections 40 and 43 are fed via the high pressure pump 44 and low pressure pump 46, respectively, which receive feedwater from condenser 24. The high temperature section 42 again heats the feedwater to its evaporation temperature and then allowing the high pressure solar boiler 13 to change it to vapor. Then the output of boiler 13 goes to the high pressure superheater 16 as before. However in accordance with this modification the low temperature/low pressure section 43 now feeds the new low pressure solar boiler 41 which heats the feedwater to its evaporation point and then an additional new low temperature/low pressure superheater section 47 superheats the steam and couples it via line 48 to the input line 22 of the low pressure reheater 17.
The feedwater heating units 42 and 40 are sequentially in the high and low temperature portions of the exhaust stream 14 from gas turbine 11 as are superheater 47 and low temperature heater 43. Thus in effect two new heat supply sources have been provided as aptly illustrated by the temperature-entropy diagram of FIG. 8. Here the heat energy supplied to area 34 raising the feedwater to its evaporation temperature is that supplied by low pressure/low temperature heater 43; and then the low pressure solar boiler 41 supplies the latent heat of evaporation which then is fed to the superheater 47 and as illustrated by the line 48 merges with the isopressure line 39 which is actually the input 22 to low pressure heater 17 as illustrated in FIG. 7. The degree temperature rise supplied by superheater 47 is A' 1 . Referring to the equation of FIG. 6 this would be respectively added to the left of the equation with an adjustment for mass flow. In this embodiment the balance of the equation occurs at the high pressure boiling point, also known as the "pinch" temperature. Referring to FIG. 6 this is about 566° F. Although it is believed that the technique of FIGS. 7 and 8 may be less efficient, it is illustrative as to how the concept of the invention in balancing the heating perunit temperature rise of the feedwater with the superheating can be accomplished in many different ways.
Thus an improved hybrid solar and fuel fired electrical generating system has been provided.
TABLE 1______________________________________Superheater 16 Inlet Steam Temperature (F.) 566Superheater 16 Outlet Steam Temperature (F.) 1050Superheater 16 Inlet Gas Temperature (F.) 1109Superheater 16 Outlet Gas Temperature (F.) 591Reheater 17 Inlet Steam Temperature (F.) 567Reheater 17 Outlet Steam Temperature (F.) 1050Reheater 17 Inlet Gas Temperature (F.) 1109Reheater 17 Outlet Gas Temperature (F.) 591Feedwater Heater 27 Inlet Water Temperature (F.) 104Feedwater Heater 27 Outlet Water Temperature (F.) 554Feedwater Heater 27 Gas Inlet Temperature (F.) 591Feedwater Heater 27 Gas Outlet Temperature (F.) 150Solar Boiler 13 Duty (Btu/hr) 2.30E + 0.8Solar Boiler 13 Steam Production (lb/hr) 3.65E + 0.5Total Net Power (MW) 141.74GT 11 Power (MW) 70.95ST 21, 23 Power (MW) 70.8GT 11 Heat Input (Btu/hr) 6.84E + 0.8Plant Heat Rate (Btu/hr) 4828Plant Efficiency (%) 70.7Adjusted Heat Rate (Btu/hr) 6447.7Standard Steam Turbine Power 108.3Steam Turbine Outlet Quality 0.998Solar Boiler Pressure (Psia) 1190HP Steam Turbine Inlet Pressure (Psia) 1130.5HP Steam Turbine Reheat Pressure (Psia) 159LP Steam Turbine Inlet Pressure (Psia) 150.4Steam Turbine Condenser Pressure (Psia) 1______________________________________
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An electric power generation system combines a gas turbine generator with a solar power plant and utilizes the gas turbine exhaust for steam superheating and feed water heating only. The solar heater is only utilized for boiling or evaporation of feed water into steam, the feed water having previously been heated by a downstream portion of the turbine exhaust. In order to balance the disparity between the specific heats of water and steam to thus optimize the system, the steam is superheated by an upstream portion of the turbine exhaust to first drive a high pressure steam turbine and then reheated by the same exhaust over the same temperature range to drive a low pressure steam turbine.
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RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 10/256,866, filed Sep. 26, 2002, for “System and Method for Communicating Media Signals,” now U.S. Pat. No. 7,295,608, issued Nov. 13, 2007, which is a non-provisional of provisional application No. 60/325,483, filed Sep. 26, 2001. Both applications are fully incorporated herein by reference.
FIELD OF THE INVENTION
This invention is a system and method for communicating media signals between source and destination devices. More specifically, it is a system and method for compressing and decompressing streaming and static media signals for efficiently communicating those signals between source and destination devices using artificial intelligence mechanisms.
BACKGROUND OF THE INVENTION
The ability to efficiently communicate streaming and static media between remotely located devices is a significant need that has emerged exponentially with the advent of networked communications such as the Internet. This need has been recently addressed with substantial development resources on a worldwide scale.
The term “media” is herein intended to mean information that may be communicated in the form of a signal from a source device to a destination device for use by the destination device; and, where used herein, media is generally contemplated to comprise either streaming or static media signals. For the purpose of this disclosure, the term “use” as applied to a destination device's operation on media signals is intended to include playing (e.g. sounds, images, video), processing (e.g. telemetry data), or any other use or operation that is the intended purpose of the media signal.
The terms “streaming media” are herein intended to mean media signals that comprise information intended to be communicated to and used by a destination device in a temporal, streaming fashion. The term “streaming” as applied to streaming media signals is herein intended to include signals communicated and processed in a continuous manner over time, or signals that may be communicated in a series of discrete packets, pieces, or blocks that are interrelated and may be thereafter used by the destination device in a continuous, interrelated fashion. Examples of streaming media signals for the purpose of this disclosure therefore include, without limitation, the following types of media: video, audio, audio combined with video, and data strings such as temporal telemetry. The terms “streaming media” are most typically used by reference to digitized forms of data representing the subject media.
The terms “static media” are herein intended to generally mean media that is not “streaming” as defined above. Static media signals are of the type that generally may be communicated and are intended to be used as a single packet, block, or piece. Static media therefore may include for example, without limitation the following: a discrete image, an individual and relatively temporally short video clip, a sound or sound bite, or a piece or block of information such as telemetry information. It is contemplated, however, that such a “single piece” of static media may be of sufficient magnitude to consist of a plurality of smaller pieces or sub-parts, such as for example regions or pixels of an overall image, individual frames that together form a video clip, digital bits that together comprise a sound, a group of sounds that comprise a sound bite, or bits of information that together comprise a larger block of information.
Streaming media generally includes data files that are significantly larger than static media files, and also often represent many more variables over the temporal communication of such files than experienced with most static media files. Therefore, the ability to efficiently compress streaming media for appropriate communication to destination devices for use is often a much more complex and difficult to achieve goal. Accordingly, much of this disclosure is provided by reference specifically to streaming media communication, and the present invention has been observed to provide significant benefits for such communication. However, where streaming media is specifically referenced herein with respect to this background, and further with respect to the many benefits of the present invention herein disclosed, static media is also further contemplated where appropriate according to one of ordinary skill.
Many different “type-specific” media systems have been in use for quite a long time for transmitting specific types (e.g. video, audio, image, voice, etc.) of streaming and static media signals between sources and remote destinations. Typical examples of such type-specific media systems include television transmission systems, telephone line systems, and radio transmission systems, and every television, telephone, and radio is therefore a receiving device for media. Accordingly, the needs for efficient communication of streaming and static media touch upon many diverse communications industries, including for example the telephone, television, movie, music, and more recently interactive gaming industries.
Moreover, many medial communications systems, including the various long-standing type-specific systems, are also “format specific”, wherein the subject media signals are communicated in a particular format such that the source, transmission channel, and destination device must be specifically compliant to work within that format. Examples of format specific media systems include for example encoded cable television systems that work only for certain types of media and only delivered in particular encoded formats from the cable carrier. Therefore, these systems, in hardware and software, are generally dedicated to only the type and format of media to be provided by the content provider.
Society's needs have outpaced the abilities of these dedicated, content-specific and format-specific systems. In particular, these dedicated systems are not structured to accommodate the ever increasing client demand, real-time, for specified streaming media. Still further, technology developments in the recently interconnected world has tempted the palate of society for the ability to pull, receive, push, and send multiple types of media in multiple formats using one device. Moreover, content providers need to be able to deliver many different media signals to many different types of devices in their clients' offices, living rooms, and hands. Individuals and corporations also desire to communicate with each other using various different formats and using various different respective devices.
Accordingly, a significant industry has emerged for delivering streaming and static media over the centralized network of the Internet. Content delivery companies are currently delivering a wide range of streaming media, from live horse racing and entertainment to medical telemetry and education, over the Internet, and in video and audio formats. According to one published report from DFC Intelligence, video streaming on the Internet grew 215 percent in 2000 to over 900 million total streams accessed. This includes broadband streams, which made up almost 29 percent of total accesses. This same report also estimates that as much as 15 percent of available stream inventory is now being exploited with in-stream advertising. In another report published by Internet researcher Jupiter Media Metrix, business spending alone on streaming video technology will balloon from one-hundred forty million (US$140M) US dollars in 2000 to nearly three billion (US$3B) US dollars by 2005 as companies turn to electronic interaction in communicating with employees, consumers and other businesses.
Still further, the population explosion and increasing number of people transmitting on these systems has severely impacted the available bandwidth for available information. Therefore, the ability to stream media efficiently, using limited bandwidth resources and limited available transmission speeds, is of increased societal importance.
Compression/Decompression Algorithms (“CODECS”)
In view of the exponential demand for communicating the different types of media, various compression/decompression systems (“CODEC(s)”) have been developed over many years, and have in particular become the recent topic of significant research and development. Specific types of CODECS and systems for managing the operation of CODECS with respect to communicating streaming and static media signals have been developed for specific types of media, including for example still-frame images such as graphics and photographs, and streaming media.
Image CODECS
Various different types of static media CODECS have been developed, and a wide variety of these CODECS are widely known and used. One specific type of static media that has been the topic of particular attention includes images (though a long series of interrelated image frames such as in video context is generally treated as streaming media due to more complex variables, e.g. size and temporal relationship between frames, that significantly impact appropriate compression/decompression needs). Examples of static media CODECing is therefore herein exemplified by reference to certain specific types of conventional image CODEC technologies and methods.
The two most common file formats for graphic images on the world wide web are known as “GIF” and “JPEG” formats, generally considered the respective standards for drawings (e.g. line art) and photographs, and are further described together with other image compression modalities for the purpose of further understanding as follows.
“JPEG” is an acronym for “Joint Photographic Experts Group”, and is a graphic image file that complies with ISO standard 10918. Commonly used for photograph compression/decompression, a JPEG file is created by choosing from a range of compression qualities, or, as has also been described, by choosing from one of a suite of compression algorithms. In order to create a JPEG file, or convert an image from another format to JPEG, the quality of image that is desired must be specified. In general, because the highest quality results in the largest file, a trade-off may then be made, as chosen by the user, between image quality and image size. The JPEG mode of compression generally includes 29 distinct coding processes although a JPEG implementer may not use them all. A JPEG image is typically given a name suffix “.jpg”.
“GIF” is an acronym for “Graphics Interchange Format”, and is generally considered the de facto standard form of drawing image compression/decompression for Internet communication. GIF formatting uses a compression algorithm known as the LZW algorithm, which was developed by Abraham Lempel, Jacob Ziv, and Terry Welch and made commercially available by Unisys Corporation (though in general such algorithm has been made publicly available without requiring fee-bearing licenses). More specifically, a “LZW” compression algorithm takes each input sequence of bits of a given length (e.g. 12 bits) and creates an entry in a table, sometimes called a “dictionary” or “codebook”, for that particular bit pattern. The entry consists of the pattern itself and a shorter code. As input is read, any pattern that has been read before results in the substitution of the shorter code, effectively compressing the total amount of input to something smaller. Earlier approaches, known as LZ77 and LZ78, did not include the look-up table as part of the compressed file. However, the more recent LZW algorithm modality does include the table in the file, and the decoding program that decompresses the file for viewing is able to build the table itself using the algorithm as it processes the encoded input. The GIF format uses the 2D raster data type (associated with display screens using raster lines) and is encoded in binary.
Two versions of GIF formats include GIF 87a, and more recently GIF89a that allows for “animated GIF” file creation, or short sequences of images within a single GIF file that are played in sequence to present movement or change in the image (either in an endless loop or through a progression that reaches an end). GIF89A also allows for, and also for “interlaced GIF”, which is a GIF image that arrives and is displayed by the receiver first as a fuzzy outline of an image that is gradually replaced by seven successive waves of bit streams that fill in the missing lines until full resolution is reached. Interlaced GIF allows, for example, a viewer using 14.4 Kbps and 28.8 Kbps modems to observe a briefer wait-time before certain information in a subject image may be processed, such as for example to make decisions (e.g. to click on the image to execute an operation such as a link).
By presenting waves of resolution filling image sequences, interlaced GIF is similar to “Progressive JPEG”, which describes an image created using the JPEG suite of compression algorithms that will “fade in” in successive waves. While the progressive JPEG is often observed to be more appealing way to deliver an image at modem connection speeds, users with faster connections may not likely notice a difference.
“PNG” or “Portable Network Graphics” format has been more recently developed for image compression and that, in time, has been publicized to replace the GIF format for Internet use (though not generally the JPEG format allowing size/quality trade-offs). This format has been developed for public consumption and development. Similar to GIF, PNG is considered a “lossless” compression format, and therefore all image information is restored when a compressed file is decompressed during viewing. However, PNG formatted files are generally intended to be from 10 to 30 percent more compressed than with a GIF format. Further aspects of PNG file formats are provided as follows: (i) color transparency may not be limited to only one color, but the degree of transparency may be controlled (“opacity”); (ii) “interlacing” of images is improved versus standard GIF; (iii) “gamma correction” is enabled, allowing for “tuning” of images in terms of color brightness required by specific display manufacturers; (iv) images can be saved using true color, palette, and gray-scale formats similar to GIF; and (v) “animation” is generally not supported, though PNG is generally considered extensible and therefore software may be layered to provide for such scriptable image animation.
“TIFF” is an acronym for “Tag Image File Format”, and is a common format for exchanging raster graphics (or “bitmap”) images between application programs, such as for example graphics used for scanner images. A TIFF file is usually given a name suffix of “.tif” or “.tiff”, and had generally been developed in the mid-1980's with the support of Adobe Software, Microsoft, and Hewlett-Packard. TIFF files can be in any of several classes, including gray scale, color palette, or RGB full color, the descriptions and differences of which are further developed elsewhere herein this disclosure. TIFF files may also include files with JPEG, LZW, or CCITT Group 4 standard run-length image compression, which are also further described elsewhere herein. As one of the most common graphic image formats, TIFF files are typically used in desktop publishing, faxing, 3-D applications, and medical imaging applications.
Video CODECS
Video compression has been the topic of intense development for various applications, including, for example: pre-recorded video (e.g. “video-on-demand”), teleconferencing, and live video (e.g. broadcasts). “Desk-top” computers, wireless devices, conventional televisions, and high definition televisions are examples of the different types of receiving devices that an efficient video compression system must serve.
In general, video CODEC algorithms operate on either or both of an individual, frame-by-frame basis, and/or on a “temporal compression” basis wherein each frame is the most common video compression algorithms in conventional use are based on several mathematic principles, including the following: Discrete Cosine Transforms (“DCT”), Wavelet Transforms and Pure Fractals.
“Discrete Cosine Transforms” or “DCT's” are by far the most popular transforms used for image compression applications. In general, DCT is a technique for representing waveform data as a weighted sum of cosines. The DCT is similar to the discrete Fourier transform: it transforms a signal or image from the spatial domain to the frequency domain. The DCT helps separate the image into parts (or spectral sub-bands) of differing importance (with respect to the image's visual quality). Reasons for its popularity include not only good performance in terms of energy compaction for typical images but also the availability of several fast algorithms. DCTs are used in two international image/video compression standards, JPEG and MPEG.
“Wavelet transforms” are generally mathematical algorithms that convert signal data into a set of mathematical expressions that can then be decoded by a destination receiver device, such as for example in a manner similar to Fourier transform. Wavelets have been observed to enhance recovery of weak signals from noise, and therefore images processed in this manner can be enhanced without significant blurring or muddling of details. For this reason, wavelet signal processing has been particularly applied to X-ray and magnetic-resonance images in medical applications. In Internet communications, wavelets have been used to compress images to a greater extent than is generally possible with other conventional methods. In some cases, the wavelet-compressed image can be as small as about 25 percent the size of a similar quality image using the more familiar JPEG format, which is discussed in further detail elsewhere in this disclosure. Thus, for example, a photograph that requires 200 Kb and takes a minute to download in JPEG format may require only 50 Kb and take only 15 seconds to download in wavelet-compressed format. A wavelet-compressed image file is often given a name suffix “.wif”, and either the receiver (e.g. Internet browser on a computer receiver) must support these format specific files, or a plug-in program will be required to read such file.
Fractal image compression is a modern technique of lossy image coding that provides several improvements over existing Fourier series compression schemes. Edge depiction is improved since, when modeled as a step function, edges require a large number of Fourier series terms to properly depict. Other advantages of fractals include fast decoding time and scale independence. Fractal compression is based on Mandelbrot sets which take advantage of a self similar, scaling dependent, statistical feature of nature (Mandelbrot, 1983). Fractal compression and decompression involves a clustering approach to find regions which show the same characteristics as a sample region independent of rotation and scale. The fractal image compresses images as recursive equations and instructions about how to reproduce them. The equations describe the image in terms of the relationships between its components. The reduction in storage need is due to the fact that fractal compression saves equations and instructions instead of a pixel representation of the image.
“MPEG” is an acronym for Moving Picture Experts Group and has come to be used synonymously with certain evolving video and audio compression standards promulgated therefrom. In general, to use MPEG video files, a personal computer is required with sufficient processor speed, internal memory, and hard disk space to handle and play the typically large MPEG file, usually given the name suffix “.mpg”. A specified MPEG viewer or client software that plays MPEG files must be available on the client system, and generally can be downloaded shareware or versions of commercial MPEG players from various sites on the Web. The modes of operation for MPEG formatted media are herein described by reference to these sequentially evolved standards as follows.
More specifically, MPEG-1 standard was designed for coding progressive video generally at a transmission rate of about 1.5 Mbps. This was generally designed for the specific application for Video-CD and CD-I media. MPEG-1 audio layer-3 (“MP3”) has also evolved from early MPEG work. “MPEG-2” is a standard generally designed for coding interlaced images at transmission rates above 4 Mbps, and was generally intended for use with digital TV broadcast and digital versatile disk. Though it is generally observed that many MPEG-2 players can handle MPEG-1 data as well, the opposite is not generally observed to be true and MPEG-2 encoded video is generally incompatible with MPEG-1 players. Yet another progressive standard, “MPEG-3”, has also been proposed for use with high definition television (“HDTV”), though in general MPEG-3 has merged with MPEG-2 which is generally believed to meet the HDTV requirements. Finally, an “MPEG-4” standard has also been most recently developed and is intended to provide a much more ambitious standard to address speech and video synthesis, fractal geometry, and computer visualization, and has further been disclosed to incorporate artificial intelligence in order to reconstruct images.
MPEG-1 and -2 standards define techniques for compressing digital video by factors varying from 25:1 to 50:1. This compression is achieved according to these standards generally using five different compression techniques: (i) discrete cosine transform (DCT), which is a frequency-based transform; (ii) “quantization”, which is a technique for losing selective information, e.g. lossy compression, that can be acceptably lost from visual information; (iii) “Huffman” coding, which is a technique of lossless compression that uses code tables based on statistics about the encoded data; (iv) “motion compensated predictive coding”, wherein differences in what has changed between an image and its preceding image are calculated and only the differences are encoded; and (v) “bi-directional prediction”, wherein some images are predicted from the pictures immediately preceding and following the image.
Further more detailed examples of commercially available video compression technologies include: Microsoft Media Player™ (available from Microsoft Corporation), RealPlayer™ or RealSystem G2™ (commercially available from Real Networks™), Apple's QuickTime™ (commercially available from Sorenson™); and “VDO”. The Microsoft Media Player™ is generally believed to apply the MPEG standard of CODEC for compression/decompression, whereas the others have been alleged to use proprietary types of CODECS. Standard compression algorithms, such as MPEG4, have made their way into the hands of developers who are building embedded systems for enterprise streaming, security, and the like.
One example of a more recent effort to provide streaming video solutions over Wireless and IP networks has been publicized by a company named Emblaze Systems (LSE:BLZ). This company has disclosed certain technology that is intended for encoding and playback of live and on-demand video messages and content on any platform: PC's, PDA's, Video cell phones and Interactive TV. Emblaze Systems is believed to be formerly GEO Interactive Media Group. The following Published International Patent Applications disclose certain streaming media compression technologies that is believed to be related to Emblaze Systems to the extent that GEO Interactive Media Group is named as “Assignee”: WO9731445 to Cannel et al.; and WO9910836 to Carmel. The disclosures of these references are herein incorporated in their entirety by reference thereto.
Another company that has published CODEC technology that is intended to improve communication of streaming media for wireless applications is Packetvideo™ Corporation, more specifically intending to communicate streaming video to cellular phones. In addition, they are believed to be promoting CODEC technology that is intended to track temporal scalability and signal error resistance in order to protect video and audio streams from the hazards of the wireless environment. U.S. Pat. No. 6,167,092 to Lengwehasatit discloses further examples of certain streaming media compression/decompression technology that are believed to be associated with Packetvideo as the named “Assignee” on the face of this Patent reference. The disclosure of this patent reference is herein incorporated in its entirety by reference thereto.
Another prior reference discloses CODEC technology that is intended to provide a cost effective, continuously adaptive digital video system and method for compressing color video data for moving images. The method involves capturing an analog video frame and digitizing the image into a preferred source input format for compression using a combination of unique lossy and lossless digital compression techniques including sub-band coding, wavelet transforms, motion detection, run length coding and variable length coding. The system includes encoder and decoder (CODEC) sections, generally disclosed to use a “Huffman” encoder, for compression and decompression of visual images to provide high compression that is intended to provide good to excellent video quality. The compressed video data provides a base video layer and additional layers of video data that are multiplexed with compressed digital audio to provide a data stream that can be packetized for distribution over inter or intranets, including wireless networks over local or wide areas. The CODEC system disclosed is intended to continuously adjust the compression of the digital images frame by frame in response to comparing the available bandwidth on the data channel to the available bandwidth on the channel for the previous frame to provide an output data stream commensurate with the available bandwidth of the network transmission channel and with the receiver resource capabilities of the client users. The compression may be further adjusted by adjustment of the frame rate of the output data stream.
Further more detailed examples of CODEC systems that are intended for use at least in part for streaming video communication are disclosed in the following U.S. Pat. Nos. 6,081,295 to Adolph et al.; 6,091,777 to Guetz et al.; 6,130,911 to Lei; 6,173,069 B1 to Daly et al.; 6,263,020 B1 to Gardos et al.; 6,272,177 to Murakami et al.; and 6,272,180 B1 to Lei. The disclosures of these references are herein incorporated in their entirety by reference thereto.
Most if not all prior streaming video compression methodologies look to the extremely complex mathematical tools within such CODECS, and subtle changes to them, to carry “one size fits all” video over public and private networks of all types, from ultra-low bandwidth networks such as that found in wireless networks, to satellite communications to ultra-high speed fiber optic installations. Among the various conventional methods of compression, there are generally user-definable parameters, including tradeoffs between image size, frame rate, color depth, contrast, brightness, perceived frame quality, buffer length, etc. Further, within the algorithms themselves there are numerous non-user definable qualities and weighted calculations. It is up to the developers to set these one time for one “general” interest, and then package and ship the product.
However, while the video streaming market continues to grow rapidly, the world has not chosen one standard for compression as no one algorithm is ideal for all video sources, destinations, or transmission modalities. While a first CODEC may be best for one type of signal, or for a first portion of a signal (e.g. frame or scene comprising a series of frames), another second CODEC may be best for another type of signal, or even another second portion of the same signal. Still further, one CODEC may be best suited for compression/decompression of a particular streaming signal among send, receive, and transmission devices in a communications network; another second CODEC may be better suited than the first for the same streaming media signal but for another set of communication device parameters. For example, some video streams may deliver color to handheld devices while other video streams can take advantage of the loss of pixels in a black and white transmission to a cellular phone to increase frame rate. Required sound quality, frame rates, clarity, and buffering tolerance all decidedly impact the compression algorithm of choice for optimized video and audio delivery across multiple platforms.
In fact, certain communication device parameters may be sufficiently transient during the streaming media transmission such that an initially appropriate CODEC for an initial set of parameters may be rendered less efficient than another CODEC due to changes in those parameters during the same streamed signal transmission. Examples of such transient parameters include, without limitation: available band width in the data transmission channel, available memory or processing power in either the send or receiving devices, and dedicated display resolution/window in the receiving device (e.g. minimizing windows on a screen). These problems are compounded exponentially by a vast number of iterations of different combinations of such factors that may differentiate one CODEC from another as being most efficient for compression, decompression, and delivery of a specific streaming media signal along a particular communications device system.
As CODEC systems are “format-specific”, source and destination devices must be “pre-configured” to communicate media signals between each other according to common, specific compression/decompression modalities, else transcoders must be used. However, even if conventional transcoders are used, constraints in the communication system (e.g. source, transmission channel, destination device) are not generally considered and the communication may be significantly faulty. For the purpose of further illustration, FIGS. 1A and 1B show two different schematic representations of conventional methods for communicating media between source 110 - 120 and destination devices 130 - 140 . These illustrations specifically exemplify streaming video communication, though other media forms may be represented by similar systems.
It has been observed that CODEC algorithms can generally be modified for a specific application and then perform better than a similar unmodified set over that limited example. However, this generally must be done either for a series of frames, or ideally, for each individual frame. Some DCT based algorithms have as many as two billion mathematical operations occurring for each frame at higher resolutions and lower perceived quality. This is entirely too much math for average machines, even commercial servers, to perform thirty to sixty times in a single second. This is the reason for the advent of the dedicated compression board or ASIC.
Audio CODECS
In addition to society's recent interests in improving video compression, audio compression has likewise been the topic of significant efforts also for various live or pre-recorded applications, including audio broadcast, music, transmission synchronized with video, live interactive voice (e.g. telephone). Any and all of these audio compression applications must be compatible with a wide range of client-side receiver/players, such as on a multitude of handheld or desk-top devices having widely varied capabilities and operating parameters.
Conventional audio CODECS generally comprise several different types, a few of which are herein briefly summarized for the purpose of illustration.
“Code Excited Linear Prediction” or “CELP” is a type of speech compression method using waveform CODECS that use “Analysis-by-Synthesis” or “AbS” within the excitation-filter framework for waveform matching of a target signal. CELP-based CODECS have recently evolved as the prevailing technique for high quality speech compression, and has been published to transmit compressed speech of toll-quality at data rates nearing as low as about 6 kbps. However, at least one publication discloses that the quality of CELP coded speech is reduced significantly for bit rates at or below 4 kbps.
“Vocoders” are speech CODECS that are not based on the waveform coding scheme, but rather use a quantized parametric description of the target input speech to synthesize the reconstructed output speech. Vocoders have been disclosed to deliver better speech quality at low bit-rates, such as about 4 kbps, and have been developed for such applications. Low bit rate vocoders use the periodic characteristics of voiced speech and the “noise-like” characteristics of stationary unvoiced speech for speech analysis, coding and synthesis. Some early versions of vocoders (e.g. federal standard 1015 LPC-10, use a time-domain analysis and synthesis method. However, most of the more recent versions, which at least one publication labels “harmonic coders”, utilize a harmonic spectral model for voiced speech segments.
Notwithstanding the previous description of certain specific speech compression techniques, a vast number of speech CODECs and standards have been developed by industry and managed by industry and nonprofit groups. Examples of such groups include without limitation the following, and their standards are often used as reference types of CODECS: the European Telecommunications Standards Institute (“ETSI”); the Institute of Electrical and Electronics Engineers (“IEEE”); and the International Telecommunication Union Telecommunications Standards Sector (“ITU-T”), formerly the “CCITT”.
One more recently disclosed method and apparatus for hybrid coding of speech, specified at 4 Kbps, encodes speech for communication to a decoder for reproduction of the speech where the speech signal is classified into three types: (i) steady state voiced or “harmonic”; (ii) stationary unvoiced; and (iii) “transitory” or “transition” speech. A particular type of coding scheme is used for each class. Harmonic coding is used for steady state voiced speech, “noise-like” coding is used for stationary unvoiced speech, and a special coding mode is used for transition speech, designed to capture the location, the structure, and the strength of the local time events that characterize the transition portions of the speech. The compression schemes are intended to be applied to the speech signal or to the LP residual signal.
Another recently disclosed method and arrangement for adding a new speech encoding method to an existing telecommunication system is also summarized as follows. A CODEC is introduced into a speech transmitting transceiver of a digital telecommunications system in order to use a “new” CODEC and an “old” CODEC in parallel in the system. A CODEC is selected by implementing a handshaking procedure between transceivers where a speech encoding method is implemented in all transceivers and previously used in the telecommunications system concerned. The handshaking is used at the beginning of each connection. At the beginning of a phone call and after handover, the method checks whether both parties can also use the new speech encoding. The handshaking messages have been selected so that their effect on the quality of speech is minimal, and yet so that the probability of identifying the messages is maximal.
Still another relatively recent reference discloses a tunable perceptual weighting filter for tandem CODECS intended for use in speech compression. Specific filter parameters are tuned to provide improved performance in tandeming contexts. More specifically, the parameters used are 10 th order LPC predictor coefficients. This system is specified to use “Low-Delay Excited Linear Predictive” CODECS, or “LD-CELP”.
Further more detailed examples of streaming audio communications systems using CODECS such as according to the examples just described are provided in the following U.S. Pat. Nos. references: 6,144,935 to Chen et al.; 6,161,085 to Haavisto et al.; and 6,233,550 to Gersho. The disclosures of these references are herein incorporated in their entirety by reference thereto.
Artificial Intelligence (“AI”) and Neural Networks with CODECS
Various systems and methods have been recently disclosed that are intended to integrate artificial intelligence (“AI”) or neural networks with the compression and decompression of streaming media signals.
The terms “artificial intelligence” are herein intended to mean the simulation of human intelligence processes by computer systems, including learning (the acquisition of information and rules for using the information), reasoning (using the rules to reach approximate or definite conclusions), and self-correction. Particular applications of AI include “expert systems”, which are computer programs that simulate judgment and behavior of a human or organization that has expert knowledge and experience in a particular field. Typically, expert systems contain a knowledge base to each particular situation that is described to the program, and can be enhanced with additions to the knowledge base or to the set of rules.
The terms “neural network” are herein intended to mean a system of programs and data structures that approximates the operation of the human brain, usually involving a large number of processors operating in parallel, each with its own small sphere of knowledge and access to data in its local memory. Typically, a neural network is initially trained or fed large amounts of data and rules about data relationships, after which a program can tell the network how to behave in response to an external stimulus (e.g. input information). In making determinations, neural networks use several principles, including without limitation gradient-based training and fuzzy logic. Neural networks may be further described in terms of knowledge layers, generally with more complex networks having deeper layers. In “feedforward” neural network systems, learned relationships about data can “feed forward” to higher layers of knowledge. Neural networks can also learn temporal concepts and have been widely used in signal processing and time series analysis. Other published applications of neural networks include oil exploration data analysis, weather prediction, the interpretation of nucleotide sequences in biology labs, and the exploration of models of thinking and consciousness.
The terms “fuzzy logic” are herein intended to mean an approach to computing based upon “degrees of truth” rather than “Boolean logic” which operates within only a true/false (or “binary”, as 1 or 0) domain. Fuzzy logic was first advanced by Dr. Lotfi Zadeh of the University of California at Berkeley in the 1960's in relation to work on a problem of computer understanding of natural language, which is not easily translated into absolute Boolean logic terms. Fuzzy logic often does include the cases of 0 and 1 as extreme cases of truth, but also includes the various states of truth in between (e.g. a determination of that the state of being is at some threshold, such as 0.98, may assists in making a decision to assign a 1 with an acceptably low occurrence of error in an operation).
One example of a previously disclosed streaming media compression/decompression system intended to use with artificial intelligence through a neural network uses a Radon transform in order to compress data such as video data. Several previously disclosed AI and/or neural network systems are intended to use AI and/or neural networks for the purpose of error correction during use of certain specified lossless compression CODECS. For example, a learning system is employed to determine a difference between what was received by a receiver after compression and transmission and what is predicted to have been received at the transmission end. That difference is processed as learning to modify the tuning of the CODEC for an additional transmission.
Another example of a disclosed method and device is intended to extrapolate past signal-history data for insertion into missing data segments in order to conceal digital speech frame errors. The extrapolation method uses past-signal history that is stored in a buffer. The method is implemented with a device that is disclosed to utilize a finite-impulse response (“FIR”), multi-layer, feed-forward, artificial neural network that is trained by back-propagation for one-step extrapolation of speech compression algorithm (“SCA”) parameters. Once a speech connection has been established, the speech compression algorithm device begins sending encoded speech frames. As the speech frames are received, they are decoded and converted back into speech signal voltages. During the normal decoding process, pre-processing of the required SCA parameters will occur and the results stored in the past-history buffer. If a speech frame is detected to be lost or in error, then extrapolation modules are executed and replacement SCA parameters are generated and sent as the parameters required by the SCA. In this way, the information transfer to the SCA is intended to be transparent, and the SCA processing continues as usual. This disclosure alleges that the listener will not normally notice that a speech frame has been lost because of the smooth transition between the last-received, lost, and next-received speech frames.
Further more detailed examples of systems that are intended to use artificial intelligence and/or neural networks in systems for media compression and/or decompression, generally relating to media type-specific CODEC methods (e.g. speech, video), are variously disclosed in the following U.S. Pat. Nos. References: 5,005,206 to Naillon et al.; 5,041,916 to Yoshida et al.; 5,184,218 to Gerdes; 5,369,503 to Buret et al.; 5,598,354 to Fang et al.; 5,692,098 to Kurdziel; 5,812,700 to Fang et al.; 5,872,864 to Imade et al.; 5,907,822 to Prieto, Jr.; and 6,216,267 to Mitchell. Still further examples are provided in the following Published International Patent Applications: WO 01/54285 to Rising; EPO 0372608 A1 to Naillon et al. The disclosures of all these references cited in this paragraph are herein incorporated in their entirety by reference thereto.
Other disclosures of CODEC systems using feedback or other systems for operating CODECS for use in processing a variety of streaming media signals, but that are not believed to specifically use the labels “AI” or “neural networks”, are disclosed in the following U.S. Pat. Nos. 6,072,825 to Betts et al.; 6,182,034 B1 to Malvar; 6,253,165 B1 to Malvar; 6,256,608 B1 to Malvar. The disclosures of these references are herein incorporated in their entirety by reference thereto.
Notwithstanding the significant advancements in CODEC algorithms themselves, and despite prior intended uses of AI and other feedback systems for operating CODECS in order to improve compression efficiencies in communication, there is still a need for significant improvement in the ability to efficiently provide a wide variety of streaming media signals to a wide variety of destination receiver devices over a wide variety of transmission channels with varied bandwidths and communication protocols.
There is still a need to incorporate AI and/or neural networks to apply an appropriate CODEC for communication of a streaming media signal based upon a variety of parameters, including without limitation one or more of the following: (a) the automated choosing of an appropriately optimized CODEC from a library of available CODECS of different types and operation, including in particular based upon an intelligent knowledge of the chosen CODEC's operation compared to the other CODEC's operation and/or against a standard, (b) a pre-trained and/or iteratively learned knowledge of the particular CODEC's operation within a given set of operating parameters representative of the existing situation; and (c) a tuning of the appropriate CODEC based upon an intelligent knowledge of its operation with respect to either or both of the existing situation or a test situation with reference parameters.
In particular, there is still a need for such an intelligent CODEC system that bases an applied CODEC upon an existing situation that is defined by one or more of the following: parameters of the streaming media signal itself; parameters of the transmission channel capabilities and constraints; and parameters of the receiver device capabilities and constraints.
Still further, there is also still a need for such an intelligent CODEC system that operates based upon an intelligent knowledge with respect to all of these operations and situational parameters in order to optimize the appropriate compression, transmission, decompression, and playing of the subject streaming media signal.
Conventional Transcoders for Streaming Media
Also of recent interest in the field of streaming media communication is providing intercommunication between the wide array of “format-specific” encoding systems in present use. An existing field of various different format-specific systems and pre-encoded content has created a widely fragmented ability to process encoded content, resulting in a significant quagmire of compatibility issues between content providers and client users. If one client desires to see or hear streaming content from a particular source and that content must be put through a CODEC for compression, a compatible CODEC must be used on the client side for decompression to enjoy the signal. Unfortunately, source content is often married to only a few, and often only one, specific CODEC schemes. Therefore, if a client requests such encoded content (or if the source desires to push the encoded content to a particular client), one of two criteria must be met: (1) the client must download or otherwise possess the format-specified CODEC (decoder); or (2) the source media must be put through a “transcoder” in order to decode the source media from the first format into a second format that is compatible with the client's device/system. The term “transcoder” is herein intended to mean a system that converts a media signal from one encoded (i.e. compressed) format to another.
Various techniques for transcoding one media format into another have been previously disclosed. FIG. 1C shows one illustrative example of the general process that is characteristic of many known transcoding techniques. More specifically, a request 159 is first received from a particular type of device or player for content that exists in an initial, uncompatible format. According to the specific example shown in FIG. 1C , a request 159 from a Microsoft Media™ Player for Real™ Video Content is received. As the content is specifically requested, the content is decoded from the initial format (e.g. Real-encoded format), and is then “re-encoded” into the appropriate format for the requesting player (e.g. Microsoft Media™ format). This re-encoded media is then served to the requesting client for decoding within the resident system of that player.
This conventional system has significant scalability limitations, in that simultaneous feeds on multiple channels for multiple clients must be supported by an equal number of transcoders. For example, FIG. 1D shows a schematic implementation of the conventional transcoding technique just described as it manages four simultaneous stream requests from four Microsoft Media Players, wherein the requested content is initially encoded in Real™ format. The system architecture necessary to support the four encoders 151 - 154 and four decoders 155 - 158 requires significant computing resources. For example, it is believed that each encoder 151 - 154 provided in the example requires a computer having a 600 MHz (e.g. Pentium™ III) having 128 Mbytes of RAM available, or dual 400 MHz processors (e.g. Pentium II) with 256 Mb available RAM. It is further believed that each decoder 155 - 158 needs a 233 MHz machine (e.g. Pentium™ II) having 64 Mb of available RAM. So, four such streams requires the equivalent of a Quad 900 Xeon (available from Compaq, Hewlett Packard, Dell and IBM, estimated to cost at the time of this disclosure about $9K retail). This is for four simultaneous streams—society is presently demanding thousands upon thousands of simultaneous streams.
There is still a need for a transcoder system that efficiently converts multiple format-specifically encoded streaming media signals into multiple other formats using minimal computing resources and in a cost-efficient manner.
Parameters Affecting Media Communication
For the purpose of further illustrating the many variables that may impact the choice of an appropriate CODEC in order to communicate a particular streaming media signal to a desired target, the following is a brief summary of various different types of streaming video formats and processing systems. It is believed that these different systems each generally require different types of compression modalities (e.g. CODECS) in order to optimize communication and playing of streaming media signals in view of available transmission speeds and bandwidth, as well as receiver processing parameters.
Although certain specific types of communications formats and systems are further herein described in detail, the following Table 1 provides a summary of a significant cross-section of the various different communications systems and transmission carriers currently available or disclosed in view of available speed or bandwidth.
TABLE 1
Data Rates of Various Communications Carrier systems
Technology
Speed
Physical Medium
Application
GSM mobile
9.6 to
RF in
Mobile telephone for
telephone
14.4 Kbps
space
business and personal
service
(wireless)
use
High-Speed
Up to
RF in
Mobile telephone for
Circuit-
56 Kbps
space
business and personal
Switched
(wireless)
use
Data service
(HSCSD)
Regular
Up to
Twisted
Home and small
telephone
53 Kbps
pair
business access
service (POTS)
Dedicated
56 Kbps
Various
Business e-mail with
56 Kbps on
fairly large file
Frame Relay
attachments
DS0
64 Kbps
All
The base signal on a
channel in the set of
Digital Signal levels
General Packet
56 to
RF in
Mobile telephone for
Radio System
114 Kbps
space
business and personal
(GPRS)
(wireless)
use
ISDN
BRI: 64 Kbps to
BRI:
BRI: Faster home and
128 Kbps PRI: 23
Twisted-pair
small business access
(T-1) or 30 (E1)
PRI:
PRI: Medium and
assignable 64-Kbps
T-1 or
large enterprise access
channels plus control
E1 line
channel; up to 1.544
Mbps (T-1) or 2.048 (E1)
IDSL
128 Kbps
Twisted-pair
Faster home and
small business access
AppleTalk
230.4 Kbps
Twisted pair
Local area network for
Apple devices; several
networks can be bridged;
non-Apple devices can also
be connected
Enhanced
384 Kbps
RF in
Mobile telephone for
Data GSM
space
business and personal
Environment
(wireless)
use
(EDGE)
Satellite
400 Kbps (DirecPC
RF in
Faster home and
and others)
space
small enterprise
(wireless)
access
Frame
56 Kbps to
Twisted-pair or
Large company backbone
relay
1.544 Mbps
coaxial cable
for LANs to ISP
ISP to Internet infrastructure
DS1/T-1
1.544 Mbps
Twisted-pair,
Large company to ISP
coaxial cable, or
ISP to Internet
optical fiber
infrastructure
Universal
Up to 2 Mbps
RF in
Mobile telephone for
Mobile Tele-
space
business and
communi-
(wireless)
personal use
cations
(available in 2002
Service
or later)
(UMTS)
E-carrier
2.048 Mbps
Twisted-pair,
32-channel
coaxial cable, or
European
optical fiber
equivalent of T-1
T-1C
3.152 Mbps
Twisted-pair,
Large company to ISP
(DS1C)
coaxial cable, or
ISP to Internet
optical fiber
infrastructure
IBM
4 Mbps
Twisted-pair,
Second most commonly-
Token Ring/
(also 16 Mbps)
coaxial cable, or
used local area
802.5
optical fiber
network after Ethernet
DS2/T-2
6.312 Mbps
Twisted-pair,
Large company to ISP
coaxial cable, or
ISP to Internet
optical fiber
infrastructure
Digital
512 Kbps to
Twisted-pair (used
Home, small business,
Subscriber
8 Mbps
as a digital,
and enterprise access
Line (DSL)
broadband medium)
using existing copper lines
E-2
8.448 Mbps
Twisted-pair,
Carries four multiplexed
coaxial cable, or
E-1 signals
optical fiber
Cable
512 Kbps to 52 Mbps
Coaxial cable
Home, business,
modem
(see “Key and
(usually uses
school access
explanation”
Ethernet); in some
below)
systems, telephone
used for upstream
requests
Ethernet
10 Mbps
10BASE-T
Most popular business
(twisted-pair);
local area network
10BASE-2 or −5
(LAN)
(coaxial cable);
10BASE-F
(optical fiber)
IBM
16 Mbps
Twisted-pair,
Second most commonly-
Token Ring/
(also 4 Mbps)
coaxial cable, or
used local area network
802.5
optical fiber
after Ethernet
E-3
34.368 Mbps
Twisted-pair or
Carries 16 E-1
optical fiber
signals
DS3/T-3
44.736 Mbps
Coaxial cable
ISP to Internet infrastructure
Smaller links within
Internet infrastructure
OC-1
51.84 Mbps
Optical fiber
ISP to Internet infrastructure
Smaller links within
Internet infrastructure
High-Speed
Up to 53 Mbps
HSSI cable
Between router hardware and
Serial
WAN lines Short-range
Interface
(50 feet) interconnection
(HSSI)
between slower LAN devices
and faster WAN lines
Fast Ethernet
100 Mbps
100BASE-T
Workstations with
(twisted pair);
10 Mbps Ethernet
100BASE-T
cards can plug into
(twisted pair);
a Fast Ethernet LAN
100BASE-T
(optical fiber)
Fiber
100 Mbps
Optical fiber
Large, wide-range LAN
Distributed-
usually in a large
Data Interface
company or a larger ISP
(FDDI)
T-3D
135 Mbps
Optical fiber
ISP to Internet infrastructure
(DS3D)
Smaller links within
Internet infrastructure
E-4
139.264 Mbps
Optical fiber
Carries 4 E3 channels
Up to 1,920 simultaneous
voice conversations
OC-3/
155.52 Mbps
Optical fiber
Large company backbone
SDH
Internet backbone
E-5
565.148 Mbps
Optical fiber
Carries 4 E4 channels
Up to 7,680 simultaneous
voice conversations
OC-12/
622.08 Mbps
Optical fiber
Internet backbone
STM-4
Gigabit
1 Gbps
Optical fiber
Workstations/networks
Ethernet
(and “copper”
with 10/100 Mbps Ethernet
up to 100 meters)
plug into Gigabit Ethernet
switches
OC-24
1.244 Gbps
Optical fiber
Internet backbone
SciNet
2.325 Gbps
Optical fiber
Part of the vBNS
(15 OC-3 lines)
backbone
OC-48/
2.488 Gbps
Optical fiber
Internet backbone
STM-16
OC-192/
10 Gbps
Optical fiber
Backbone
STM-64
OC-256
13.271 Gbps
Optical fiber
Backbone
Comments & Key for Table:
(i)The term “Kbps” as the abbreviation for “thousands of bits per second.” In international English outside the U.S., the equivalent usage is “kbits s −1 ” or “kbits/s”.
(ii) Engineers use data rate rather than speed, but speed (as in “Why isn't my Web page getting here faster?”) seems more meaningful for the less technically inclined.
(iii) Relative to data transmission, a related term, bandwidth or “capacity,” means how wide the pipe is and how quickly the bits can be sent down the channels in the pipe. These “speeds” are aggregate speeds. That is, the data on the multiple signal channels within the carrier is usually allocated by channel for different uses or among different users.
Key: (i) “T” = T-carrier system in U.S., Canada, and Japan....
(ii) “DS” = digital signal (that travels on the T-carrier or E-carrier)...
(iii) “E” = Equivalent of “T” that uses all 8 bits per channel; used in countries other than U.S. Canada, and Japan....
(iv) “OC” = optical carrier (Synchronous Optical Network) “STM” = Synchronous Transport Modules (see Synchronous Digital Heirarchy).
(v) Only the most common technologies are shown.
(vi) “Physical medium” is stated generally and doesn't specify the classes or numbers of pairs of twisted pair or whether optical fiber is single-mode or multimode.
(vii) The effective distance of a technology is not shown.
(viii) There are published standards for many of these technologies.
Cable modem note: The upper limit of 52 Mbps on a cable is to an ISP, not currently to an individual PC. Most of today's PCs are limited to an internal design that can accommodate no more than 10 Mbps (although the PCI bus itself carries data at a faster speed). The 52 Mbps cable channel is subdivided among individual users. Obviously, the faster the channel, the fewer channels an ISP will require and the lower the cost to support an individual user.
Internet Carrier Systems
Communication of streaming video via the Internet may take place over a variety of transmission modalities, including for example digital subscriber lines (“DSL”), “T1” lines, cable modem, plain old telephone service (“POTS”) dial-up modem, and wireless carriers. While a description of the many different wireless transmission modalities is treated separately herein, a summary of various of these other transmission modes is herein provided immediately below for the purpose of further illustration as follows.
The terms “POTS” or “plain old telephone service”, or “dial-up”, as applied to communications transmission channels, are herein interchangeably used. These terms are intended to mean “narrow-band” communication that generally connects end users in homes or small businesses to a telephone company office over copper wires that are wound around each other, or “twisted pair”. Traditional phone service was created to let you exchange voice information with other phone users via an analog signal that represents an acoustic analog signal converted into an electrical equivalent in terms of volume (signal amplitude) and pitch (frequency of wave change). Since the telephone company's signaling is already set up for this analog wave transmission, it's easier for it to use that as the way to get information back and forth between your telephone and the telephone company. Therefore, dial-up modems are used to demodulate the analog signal and turn its values into the string of 0 and 1 values that is called digital information. Because analog transmission only uses a small portion of the available amount of information that could be transmitted over copper wires, the maximum amount of data that you can receive using ordinary modems is about 56 Kbps. The ability of your computer to receive information is constrained by the fact that the telephone company filters information that arrives as digital data, puts it into analog form for your telephone line, and requires your modem to change it back into digital. In other words, the analog transmission between your home or business and the phone company is a bandwidth bottleneck.
With “ISDN”, or “Internet subscriber digital network”, which some consider to be a limited precursor to DSL, incoming data rates up to about 128 Kbps may be achieved for some end user clients.
A “DSL” or “digital subscriber line” is generally defined as a “broadband” transmission carrier for communicating high-bandwidth communication over ordinary copper telephone lines. Many different types of DSL services have been disclosed, having generally varied data rates and intended applications. Though further discussion is herein provided about certain of these DSL types, the following Table 2 provides a summary of information for certain of these DSL types for the purpose of further developing an overview understanding:
TABLE 2
Types of known DSL services.
Data Rate
Downstream;
Distance
DSL Type
Description
Upstream
Limit
Application
IDSL
ISDN Digital
128 Kbps
18,000 feet
Similar to the
Subscriber
on 24
ISDN BRI
Line
gauge wire
service but
data only (no
voice on the
same line)
CDSL
Consumer
1 Mbps
18,000 feet
Splitterless
DSL from
downstream;
on 24
home and
Rockwell
less upstream
gauge wire
small business
service; similar
to DSL Lite
DSL
“Splitterless”
From 1.544 Mbps
18,000 feet
The standard
Lite
DSL without
to 6 Mbps
on 24
ADSL; sacrifices
(same
the “truck roll”
downstream,
gauge wire
speed for not having
as
depending on the
to install a splitter
G.Lite)
subscribed service
at the user's home
or business
G.Lite
“Splitterless”
From 1.544 Mbps
18,000 feet
The standard
(same
DSL without
to 6 Mbps,
on 24
ADSL; sacrifices
as DSL
the “truck roll”
depending on
gauge wire
speed for not having
Lite)
the subscribed
to install a splitter
service
at the user's home or
business
HDSL
High bit-rate
1.544 Mbps duplex
12,000 feet
T1/E1 service
Digital
on two twisted-pair
on 24
between server and
Subscriber
lines; 2.048 Mbps
gauge wire
phone company or
Line
duplex on three
within a company;
twisted-pair lines
WAN, LAN,
server access
SDSL
Symmetric
1.544 Mbps duplex
12,000 feet
Same as for HDSL
DSL
(U.S. and Canada);
on 24
but requiring only
2.048 Mbps
gauge wire
one line of
(Europe) on a single
twisted-pair
duplex line down-
stream and upstream
ADSL
Asymmetric
1.544 to 6.1 Mbps
1.544 Mbps
Used for Internet
Digital
downstream; 16 to
at 18,000 feet;
and Web access,
Subscriber
640 Kbps upstream
2.048 Mbps
motion video,
Line
at 16,000 feet;
video on demand,
6.312 Mpbs
remote LAN access
at 12,000 feet;
8.448 Mbps
at 9,000 feet
RADSL
Rate-
Adapted to the line,
Not provided
Similar to ADSL
Adaptive
640 Kbps to 2.2
DSL from
Mbps downstream;
Westell
272 Kbps to 1.088
Mbps upstream
UDSL
Unidirectional
Not known
Not known
Similar to HDSL
DSL proposed
by a company
in Europe
VDSL
Very high
12.9 to 52.8 Mbps
4,500 feet at
ATM networks;
Digital
downstream;
12.96 Mbps;
Fiber to the
Subscriber
1.5 to 2.3 Mbps
3,000 feet at
Neighborhood
Line
upstream; 1.6 Mbps
25.82 Mbps;
to 2.3 Mbps
1,000 feet at
downstream
51.84 Mbps
Typically published data rates for DSL service, which may vary depending upon distance from the central office of the offering service company, includes rates up to 6.1 Mbps (theoretically published at 8.448 Mbps), which is believed to enable continuous transmission of motion video, audio, and 3-D effects. More typical individual connections provide from 512 Kbps to 1.544 Mbps downstream and about 128 Kbps upstream. A DSL line can carry both data and voice signals and the data part of the line is continuously connected. DSL has been anticipated in some publications to replace ISDN in many areas and to compete with cable modem for multimedia communication to homes and businesses. DSL operates purely within the digital domain and does not require change into analog form and back. Digital data is transmitted to destination computers directly as digital data and this allows the phone company to use a much wider bandwidth for forward transmission. Meanwhile, if a client user chooses, the signal can be separated so that some of the bandwidth is used to transmit an analog signal so that a telephone and computer may be used on the same line and at the same time.
Most DSL technologies require that a signal splitter be installed at a home or business, requiring the expense of a phone company visit and installation. However, it is possible to manage the splitting remotely from the central office. This is known as splitterless DSL, “DSL Lite,” G.Lite, or Universal ADSL (further defined below) and has recently been made a standard. Several modulation technologies are used by various kinds of DSL, although these are being standardized by the International Telecommunication Union (ITU). Different DSL modem makers are using either Discrete Multitone Technology (DMT) or Carrierless Amplitude Modulation (CAP). A third technology, known as Multiple Virtual Line (MVL), is another possibility.
A variety of parameters of DSL operation are variable and affect the effective data rates that can be achieved. DSL modems generally follow the data rate multiples established by North American and European standards. In general, the maximum range for DSL without a repeater is 5.5 km (18,000 feet). As distance decreases toward the telephone company office, the data rate increases. Another factor is the gauge of the copper wire. The heavier 24 gauge wire carries the same data rate farther than 26 gauge wire. For destination devices beyond the 5.5 kilometer range, DSL may still be provided, though only generally if the respective phone company provider has extended the local loop with optical fiber cable.
To interconnect multiple DSL users to a high-speed network as a “backbone”, the telephone company uses a Digital Subscriber Line Access Multiplexer (“DSLAM”). Typically, the DSLAM connects to an asynchronous transfer mode (“ATM”) network that can aggregate data transmission at gigabit data rates. At the other end of each transmission, a DSLAM demultiplexes the signals and forwards them to appropriate individual DSL connections.
“ADSL” or “Asymmetric Digital Subscriber Line” is the form of DSL that will become most familiar to home and small business users. ADSL is called “asymmetric” because most of its two-way or “duplex” bandwidth is devoted to the downstream direction, sending data to the user. Only a small portion of bandwidth is available for upstream or user-interaction messages. However, most Internet and especially graphics- or multi-media intensive Web data need lots of downstream bandwidth, but user requests and responses are small and require little upstream bandwidth. Using ADSL, up to 6.1 megabits per second of data can be sent downstream and up to 640 Kbps upstream. The high downstream bandwidth means that a telephone line may carry motion video, audio, and 3-D images to destination computers or television displays. In addition, a small portion of the downstream bandwidth can be devoted to voice rather data, and phone conversations may be carried without requiring a separate line. Unlike a similar service over “cable” television lines, ADSL does not compete for bandwidth with neighbors in a given area. In many cases, your existing telephone lines will work with ADSL. In some areas, they may need upgrading.
“CDSL” or “Consumer DSL” is a trademarked version of DSL, to be made available by Rockwell Corporation, that is somewhat slower than ADSL (1 Mbps downstream, generally predicted to be lower upstream) but has the advantage that a “splitter” does not need to be installed at the user's end. Hardware may be required to carry CDSL by local phone companies to homes or businesses. CDSL uses its own carrier technology rather than DMT or CAP ADSL technology.
Various companies have worked with telephone companies in developing a standard and easier installation version of ADSL, called “G.Lite”, that is believed to be under deployment at the time of this disclosure. “G.Lite” or “DSL Lite” (also known as “splitterless ADSL”, and “Universal ADSL”) is believed to be essentially a slower ADSL that doesn't require splitting of the line at the user end but manages to split it for the user remotely at the telephone company, which is believed to lower costs. G.Lite, officially ITU-T standard G-992.2, is published to provide a data rate from 1.544 Mbps to 6 Mpbs downstream and from about 128 Kbps to about 384 Kbps upstream. At least one publication has predicted G.Lite to become the most widely installed form of DSL.
“HDSL” or “High bit-rate DSL” is believed to be the earliest variation of DSL to be widely used for wideband digital transmission within a corporate site and between the telephone company and a customer. The main characteristic of HDSL is that it is symmetrical: an equal amount of bandwidth is available in both directions. For this reason, the maximum data rate is generally lower than for ADSL. HDSL can carry as much on a single wire of twisted-pair as can be carried on a T1 line in North America or an E1 line in Europe (up to about 2.32 Mbps).
“IDSL” or “ISDN DSL” is somewhat of a misnomer since it's really closer to ISDN data rates and service at about 128 Kbps than compared with the much higher rates generally associated with ADSL.
“RADSL” or “Rate-Adaptive DSL” is an ADSL technology to be made available from Westell company in which software is able to determine the rate at which signals can be transmitted on a given customer phone line and adjust the delivery rate accordingly. Westell's “FlexCap2™” version system uses RADSL to deliver from about 640 Kbps to about 2.2 Mbps downstream and from about 272 Kbps to about 1.088 Mbps upstream over an existing line.
“SDSL” or “Symmetric DSL” is similar to HDSL with a single twisted-pair line, carrying about 1.544 Mbps (U.S. and Canada) or about 2.048 Mbps (Europe) each direction on a duplex line. It's symmetric because the data rate is the same in both directions.
“UDSL” or “Unidirectional DSL” is a proposal from a European company, and is generally believed to provide a unidirectional version of HDSL.
“VDSL” or “Very high data rate DSL” is believed to be a technology under development that promises much higher data rates over relatively short distances, for example between about 51 and about 55 Mbps over lines up to about 1,000 feet or about 300 meters in length. At least one publication has predicted that VDSL may emerge somewhat after ADSL is widely deployed and co-exist with it. The transmission technology (CAP, DMT, or other) and its effectiveness in some environments is not yet determined. A number of standards organizations are working on it.
“x2/DSL” is modem from 3Com that supports 56 Kbps modem communication but is upgradeable through new software installation to ADSL when it becomes available in the user's area. At least one publication cites 3Com as describing this technology to be “the last modem you will ever need.”
A “T1” transmission line is generally considered a “broadband” carrier and is defined as a type of “T-carrier” system, which is believed to have been first introduced by the Bell System in the U.S. in the 1960's as the first successful system that supported digitized voice transmission. The T-carrier system is entirely digital, using pulse code modulation and time-division multiplexing. Voice signals are typically sampled at about 8,000 times a second and each sample is digitized into an 8-bit word. With 24 channels digitized at the same time, a 192-bit frame, representing 8-bit words on each of 24 channels, is thus transmitted about 8,000 times a second. Each frame is separated from the next by a single bit, resulting in a 193-bit block. The T-1' s published data rate of 1.544 Mbps generally represents the 192 bit frame, and the 1-bit signaling bit, multiplied by 8,000.
A T-1 system typically uses 4 wires and provides duplex capability, with two wires dedicated for receiving and two for sending at the same time. The T-1 digital stream includes 24, 64 Kbps channels that are multiplexed, wherein the standard 64 Kbps channel is based on the bandwidth required for a voice conversation. The four wires were originally a pair of twisted pair copper wires, but more recent systems provide coaxial cable, optical fiber, digital microwave, and other carrier technologies. The number and use of the channels may be varied from the standard guidelines.
The original transmission rate (1.544 Mbps) for T-1 lines is in common use today in Internet service provider (“ISP”) connections to the Internet. Another level, the T-3 line, is published to provide 44.736 Mbps, and is also commonly used by Internet service providers. Another commonly used service is “fractional T-1”, which is the rental of some portion of the 24 channels in a T-1 line, with the other channels unused.
Display Capabilities/Constraints & Related Standards
Various different types of receiver display capabilities may also significantly impact the appropriate CODEC modality for efficiently communicating particular streaming media signals for display by the receiver. A brief summary of certain examples to illustrate such varied display parameters (e.g. resolution, clarity, color, depth, size, type/format-specific) is provided for a better understanding as follows.
One parameter that is highly variable between different types and makes of streaming media receiver devices, and therefore that may have significant impact on the appropriate CODEC to be used, is the range of colors that may be expressed by a display device, or “palette”. A standard “browser-safe” palette, which may be accommodated by most software for Internet-based streaming media display, may include for example about 216 colors, though for web-based streaming media the computer display capability as well as the browser software capability must be understood.
With respect to computer display technology, a color is set for each individual pixel or addressable illumination element on the screen. Each pixel has a red, green, and blue (RGB) component. By specifying the amount of intensity for each of these components, a distinct color is given to that pixel. A “true color” display generally defines the color of a pixel on a display screen using a 24-bit value, allowing the possibility of up to 16,777,216 possible colors. The number of bits used to define a pixel's color shade is called the “bit-depth”. True color is sometimes referred to as “24-bit color”, though many modern color display systems offer a 32-bit color mode. An extra byte, called the “alpha channel”, is typically used for control and special effects information. A “gray scale” (composed of discrete shades of gray) display setting is generally defined as having N bits of depth where N represents the saturation of black within the pixel. If N=1, the image is not called gray scale but instead monochrome, or black and white, as the bit can only be on or off and can contain no shading information.
Common computer resolutions include for example and without limitation the following:
(i) VGA or Video Graphics Array capable of displaying 640×480 pixels in 16 colors or 320×240 pixels in 256 colors in a 4:3 aspect ratio; (ii) SVGA or Super Video Graphics Array capable of 800×600×6 bits/pixel (16 colors) or 650×480×8 bits/pixel (256 colors). SVGA was created by the Video Electronics Association (VESA); and (iii) XGA (v1-4) or eXtended Graphics Array capable of 1024×768 pixels at 32,768 colors.
Additional standards have been added such as SXGA, defining pixel sizes above 1960×1440 and color depths of 32 bits/pixel and higher.
In the event that a larger range of colors (or palette) is used by a media signal than a particular display or browser can handle, most browsers are typically adapted to “dither” the colors, which is herein intended to mean that the browser will find colors within its palette that it can substitute for any color that is outside of its palette. To further illustrate the wide range of different system display capabilities, systems using Windows™ (commercially available from Microsoft Corporation) and Macintosh™ (commercially available from Apple Corporation) based operating systems do not have identical palettes; within the usual 256 color palette, 216 are common to both types of browsers, whereas 40 are different and therefore require dithering by a browser operating within one of the systems if an image signal is communicated to that type of system in a format specified by the other.
Many different technologies also exist with respect to how a visual display is enabled from electronic information. The terms “VDT” or “Video Display Terminals” are generally used within the computer industry and are herein intended to be used interchangeably with simple references to “display”. With respect to computer terminal use, VDT's comprise a computer output surface and projecting mechanism that shows text and graphic images to the computer user. VDT's may use a variety of specific display technologies, including for example cathode ray tubes (“CRTs”), liquid crystal displays (“LCDs”), light-emitting diodes (“LEDs”), gas plasma, or other image projection technology. The display is usually considered to include the screen or projection surface and the device that produces the information on the screen. In some computers, the display is packaged in a separate unit or “monitor”, or the display may be fully integrated in a single unit with the computer processor.
With respect to LCD's in particular, this technology generally requires minimal volume and physical depth compared to other VDT's, and therefore is typically used in laptop computers and cellphone/PDA's. LCD's consume much less power than LED and gas-display VDT's because they work on the principle generally of blocking light rather than emitting it. An LCD may be either “passive matrix” or “active matrix”, which is also known as “thin film transistor” or “TFT” display. The passive matrix LCD has a grid of conductors with pixels located at each intersection in the grid. A current is sent across two conductors on the grid to control the light for any pixel. An active matrix has a transistor located at each pixel intersection, requiring less current to control the luminance of a pixel. For this reason, the current in an active matrix display can be switched on and off more frequently, improving the screen refresh time and therefore efficacy for higher speeds of streaming media (e.g. action video). Some passive matrix LCD's have dual scanning, in that they scan the grid twice with current in the same time as one scan in earlier versions; however, the active matrix is still generally considered to be the superior technology of the two. Reflective color display technology—the integration of color filters into passive-matrix display construction—is a low-power, low-cost alternative to active-matrix technology. Because they reflect ambient light, reflective LCDs deliver particularly high performance during use outside in daylight. Various different display technologies, and therefore transmission formats, have also been specifically developed for television viewing. Thus several different standards have evolved for television transmission, and their differences may significantly impact the nature and extent of compression desired (and therefore the choice of a particular CODEC) for communicating streaming media signals in television environs. These standards include in particular and without limitation: standard definition television (“SDTV”); and high definition television (“HDTV”).
“SDTV” or “standard definition television” and “HDTV” or “high definition television” are the two categories of display formats for digital television (“DTV”) transmissions, which are becoming the standard. These formats provide a picture quality similar to digital versatile disk (“DVD”), and are summarized relative to their similarities and differences as follows.
HDTV provides a higher quality display, with a vertical resolution display from about 720p to at least about 1080i and an aspect ratio (the width to height ratio of the screen) of generally 16:9, for a viewing experience similar to watching a movie. In comparison, SDTV has a range of lower resolutions and no defined aspect ratio. New television sets will be either HDTV-capable or SDTV-capable, with receivers that can convert the signal to their native display format. SDTV, in common with HDTV, using the MPEG-2 file compression method in a manner that generally reduces a digital signal from about 166 Mbps to about 3 Mbps. This allows broadcasters to transmit digital signals using existing cable, satellite, and terrestrial systems. MPEG-2 uses the lossy compression method, which means that the digital signal sent to the television is compressed and some data is lost, but this lost data may or may not affect how the human eye views the picture. Both the ATSC and DVB standards selected MPEG-2 for video compression and transport. The MPEG-2 compression standard is elsewhere herein described in further detail.
Because a compressed SDTV digital signal is smaller than a compressed HDTV signal, broadcasters can transmit up to five SDTV programs simultaneously instead of just one HDTV program, otherwise known as “multicasting”. Multicasting is an attractive feature because television stations can receive additional revenue from the additional advertising these extra programs provide. With today's analog television system, only one program at a time can be transmitted. Note that this use of the term “multicasting” is distinct from its use in streaming video where it involves using special addressing techniques.
When the United States decided to make the transition from analog television to DTV, the Federal Communications Commission decided to let broadcasters decide whether to broadcast SDTV or HDTV programs. Most have decided to broadcast SDTV programs in the daytime and to broadcast HDTV programs during prime time broadcasting. Both SDTV and HDTV are supported by the Digital Video Broadcasting (DTV) and Advanced Television Systems Committee (ATSC) set of standards.
HDTV as a television display technology provides picture quality similar to 35 mm. movies with sound quality similar to that of today's compact disc (further with respect to audio quality, HDTV receives, reproduces, and outputs Dolby Digital 5.1). Some television stations have begun transmitting HDTV broadcasts to users on a limited number of channels. HDTV generally uses digital rather than analog signal transmission. However, in Japan, the first analog HDTV program was broadcast on Jun. 3, 1989. The first image to appear was the Statue of Liberty and the New York Harbor. It required a 20 Mhz channel, which is why analog HDTV broadcasting is not feasible in most countries.
HDTV provides a higher quality display than SDTV, with a vertical resolution display from 720p to 1080i. The p stands for progressive scanning, which means that each scan includes every line for a complete picture, and the i stands for interlaced scanning which means that each scan includes alternate lines for half a picture. These rates translate into a frame rate of up to 60 frames per second, twice that of conventional television. One of HDTV's most prominent features is its wider aspect ratio (the width to height ratio of the screen) of 16:9, a development based on a research-based belief that the viewer's experience is enhanced by screens that are wider. HDTV pixel numbers range from one to two million, compared to SDTV's range of 300,000 to one million. New television sets will be either HDTV-capable or SDTV-capable, with receivers that can convert the signal to their native display format.
In the United States, the FCC has assigned broadcast channels for DTV transmissions. In SDTV formats, DTV makes it possible to use the designated channels for multiple signals at current quality levels instead of single signals at HDTV levels, which would allow more programming with the same bandwidth usage. Commercial and public broadcast stations are currently deciding exactly how they will implement their use of HDTV.
Simulcast is the simultaneous transmission of the same television program in both an analog and a digital version using two different channels or frequencies. At the end of the DTV transition period, it is believed by that analog transmission will be substantially replaced such that current analog channels will be used solely for DTV. The extra channels that were used for digital broadcasting may for example then be auctioned and used for more television channels or other services such as datacasting. Simulcast is also used for the transmission of simultaneous television and Internet services, the transmission of analog and digital radio broadcasts, and the transmission of television programs in different screen formats such as the traditional format and the wide screen format. Simulcast broadcasting is used worldwide.
The transition to DTV is not an easy or inexpensive transition. For a television station to transmit DTV programming, it must build its DTV facilities, but a station must have revenue to build these facilities. Simulcast allows stations to continue receiving revenues from traditional analog programming and also gain extra revenues from the extra digital programming. Another obstacle in the transition to DTV is lack of interest among consumers. The need for special equipment is prohibiting viewers from seeing the difference between digital and analog programs, which is also slowing down public enthusiasm for DTV.
The equipment needed for operating DTV depends on whether terrestrial, cable, or satellite services are used as the transmission channel/carrier. In any event, and according to known or anticipated systems, it is generally believed that consumers will, at a minimum, have to purchase a converter to view DTV transmissions on their old television sets. In addition, consumers that use terrestrial services or antennas to receive television signals need an antenna equipped for digital signals. A consumer located in mountainous terrain in an ATSC-compliant country may not be able to receive terrestrial-based digital signals because of multipath effects. This is common even with today's analog television system. In DVB compliant countries, terrain does not affect the reception of digital signals. Satellite users are already enjoying DTV broadcasting, but a larger satellite dish might be needed to view HDTV programming.
A “set-top” box is herein defined as a device that enables a television set to become a user interface to the Internet and also enables an analog television set to receive and decode DTV broadcasts. DTV set-top boxes are sometimes called receivers. It is estimated that 35 million homes will use digital set-top boxes by the end of 2006, the estimated year ending the transition to DTV.
A typical digital set-top box contains one or more microprocessors for running the operating system, usually Linux or Windows CE, and for parsing the MPEG transport stream. A set-top box also includes RAM, an MPEG decoder chip, and more chips for audio decoding and processing. The contents of a set-top box depend on the DTV standard used. DVB-compliant set-top boxes contain parts to decode COFDM transmissions while ATSC-compliant set-top boxes contain parts to decode VSB transmissions. More sophisticated set-top boxes contain a hard drive for storing recorded television broadcasts, for storing downloaded software, and for other applications provided by the DTV service provider. Digital set-top boxes can be used for satellite and terrestrial DTV but are used mostly for cable television. A set-top box price ranges from $100 for basic features to over $1,000 for a more sophisticated box.
In the Internet realm, a set-top box often really functions as a specialized computer that can “talk to” the Internet—that is, it contains a Web browser (which is really a Hypertext Transfer Protocol client) and the Internet's main program, TCP/IP. The service to which the set-top box is attached may be through a telephone line as, for example, with Web TV or through a cable TV company like TCI.
To take advantage of Dolby Digital 5.1 channel for satellite broadcasts, a satellite receiver that provides a Dolby Digital output is necessary. For cable users, all digital set-top boxes are equipped with a Dolby Digital two-channel decoder. To use 5.1 channel sound, a 5.1 channel-compliant set-top box is needed or an external 5.1 channel decoder unit.
The most dramatic demonstration of digital television's benefits is through a high-end HDTV, because of the larger screen, wider aspect ratio and better resolution. Like most new technologies, however, HDTV is expensive. Nevertheless, less expensive digital TVs provide a markedly improved viewing experience over regular TV, and for those who choose to retain their old sets, even the addition of a set-top converter will deliver a discernibly improved picture and sound.
The FCC's schedule for transition to DTV proposes that everyone in the U.S. should have access to DTV by 2002 and that the switch to digital transmission must be completed either by 2006 or when 85% of the households in a specific area have purchased digital television sets or set-top converters.
In the early 1990s, European broadcasters, consumer equipment manufacturers, and regulatory bodies formed the European Launching Group (ELG) which launched a “DVB” or “Digital Video Broadcasting” project in order to introduce DTV throughout Europe. DVB is intended to provide an open system as opposed to a closed system. Closed systems are content-provider specific, not expandable, and optimized only for the system they were developed for. An open system, such as DVB, allows the subscriber to choose different content providers and allows integration of PCs and televisions. DVB systems are intended to be optimized for television, but as well as supporting home shopping and banking, private network broadcasting, and interactive viewing. DVB is intended to open the possibilities of providing crystal-clear television programming to television sets in buses, cars, trains, and even hand-held televisions. DVB is also promoted as being beneficial to content providers because they can offer their services anywhere DVB is supported regardless of geographic location. They can also expand their services easily and inexpensively and ensure restricted access to subscribers reducing lost revenues due to unauthorized viewing. Today, the DVB Project consists of over 220 organizations in more than 29 countries worldwide and DVB broadcast services are available in Europe, Africa, Asia, Australia, and parts of North and South America
Format-Specific Media
Various different formats for the streaming media signals themselves are also herein summarized by way of non-limiting example to also provide a further understanding of how CODECS may vary for a particular case.
“DVD” is an acronym for “digital versatile disc” is generally defined as a relatively recent optical disc technology that holds up to about 4.7 Gigabytes of information on one of its two sides, or enough for a movie about 133 minutes long on average. With two layers on each of its two sides, it may hold up to 17 Gigabytes of video, audio, or other information, compared to current CD-ROM discs of approximately the same physical size that hold about 600 Mbytes (DVD holds more than about 28 times the information). DVD players are required to play DVD's, though they will also play regular CD-ROM discs. DVDs can be recorded in any of three general formats variously optimized for: (i) video (e.g. continuous movies); (ii) audio (e.g. long playing music); and (iii) or a mixture (e.g. interactive multimedia presentations). The DVD drive has a transfer rate somewhat faster than an 8-speed CD-ROM player. DVD format typically uses the MPEG-2 file and compression standard, which has about 4-times the resolution of MPEG-1 images and can be delivered at about 60 interlaced fields per second where two fields constitute one image (MPEG-1 delivers about 30 non-interlaced frames per second. MPEG-2 and -1 standards are elsewhere herein defined in more detail. Audio quality on DVD is comparable to that of current audio compact discs.
“DVD-Video” is the name typically given for the DVD format designed for full-length movies and is a box that will work with a television set. “DVD-ROM” is a name given to the player that is believed by some to be the future replacement to CD-ROM drives in computers, as these newer drives are intended to play both regular CD-ROM discs as well as DVD-ROM discs. “DVD-RAM” is the name given to writeable versions of DVDs. “DVD-Audio” is the name typically given to players designed to replace the compact disc player.
“VHS” is an acronym for “Video Home System” and is generally defined as a magnetic videotape cartridge format, typically a half-inch wide, developed for home use with the ability to record and playback analog video and audio signals. VHS has become a popular format and the de facto standard for home movie distribution and reproduction mainly due to its pervasive presence and recordability. VHS stores signals as an analog format on a magnetic tape using technology similar to that of audiocassettes. The tapes are played back and recorded on using VHS video cassette recorders (VHS VCRs). VHS tapes store up to around two hours of video typically, although some VCRs are able to record to them at a slower speed allowing up to six or even eight hours of recording per tape.
The VHS format outputs a little over 200 lines of horizontal resolution. This compares to DVDs that output over 500 lines of horizontal resolution. Technically and perceptually, VHS is a format that has been surpassed by other formats, including for example DVD, S-VHS, Hi-8 and others. However, VHS remains a pervasive means for viewing video, and VHS tapes are still easily found across the country and around the world everywhere from movie rental stores to grocery stores making then easily accessible.
“CD” is an acronym for “compact disc” and is generally defined as small, portable, round medium for electronically recording, storing, and/or playing audio, video, text, and other information in digital form. Initially, CD's were only read-only; however, newer versions allow for recording as well (e.g. “CD-RW”).
“Super audio compact disc” or “SACD” is a high resolution audio CD format that, together with DVD-Audio (“DVD-A”), are the two formats competing to replace the standard audio CD (though most of the industry generally is backing DVD-A, with a general exception believed to be Philips and Sony). SACD, like DVD-A, offers 5.1 channel surround sound in addition to 2-channel stereo. Both formats improve the complexity of sound by increasing the bit rate and the sample rate, and can be played on existing CD players, although generally only at quality levels similar to those of traditional CDs. SACD uses Direct Stream Digital (“DSD”) recording, which is published as being proprietary to Sony, that converts an analog waveform to a 1-bit signal for direct recording, instead of the pulse code modulation (“PCM”) and filtering used by standard CDs. DSD uses lossless compression and a sampling rate of about 2.8 MHz to improve the complexity and realism of sound. SACD may also include additional information, such as text, graphics, and video clips.
Also for the purpose of further understanding, Internet-based communications also have particular protocols for communication that must be accommodated by a streaming media communications system using the Internet “superhighway”. These protocols, in particular with respect to streaming media communication, are briefly summarized immediately below for the purpose of providing a more detailed understanding.
With respect to Internet communication, streaming media signals are generally communicated in digital format via data packets. The terms “packets” are herein intended to mean units of data that are routed between an origin and a destination via the Internet or any other packet-switched network. More specifically, when a file is sent, the protocol layer of the communications system (e.g. TCP layer of TCP/IP based system) divides the file into chunks of efficient size for routing. Each of these packets is separately numbered and includes the Internet address of the destination. The individual packets for a given file may travel different routs through the Internet. When they have all arrived, they are reassembled into the original file, for example by the TCP layer at the receiving end. A packet-switching scheme is an efficient way to handle transmissions on a connectionless network such as the Internet. An alternative scheme, circuit-switched, is used for networks allocated generally for voice connections. In circuit-switching, lines in the network are shared among many users as with packet-switching, but each connection generally requires the dedication of a particular path for the duration of the connection.
Wireless Communications & the WAP Gateway
Of equal importance to the contemporary age of the Internet, the age of wireless communications has significantly extended society's ability to interact outside of the fixed confines of the home and office, allowing our remote communications to break free from the umbilical cords of wires and cables. For example, in 2000, the number of mobile subscribers grew by close to 50%.
However, wireless communications systems, protocols, and enabling technologies have developed in a significantly fragmented, “format-specific” market on a world-wide scale. This is particularly true in comparing systems in wide use in the United States as compared to the rest of the world. Therefore, much effort has been expended in overcoming compatibility issues between format-specific systems and between the related wireless devices operating on different platforms. For the purpose of further understanding wireless communication as it is later related to the present invention, the following is a brief overview of significant technologies, systems, and protocols used in the wireless communication industry.
In general, the progression of wireless communications systems for cellular telephones is colloquially given the terms “1G”, “2G”, “2.5G”, and “3G”, representing respectively first generation, second generation, and so-on. Initial systems were purely analog, known as the 1G phones and systems. However, with rapid growth, available bandwidth for cellular phone use quickly eroded, giving way to digital signal processing in the 2G, which significantly widened the available bandwidth and ability for complex signal processing for advanced telecommunications. However, as demand progressed for wireless Internet access, so went the technology development from 2G phones (generally not Internet enabled), to 2.5G and 3G (progressively more enabled). As will be further developed immediately below, the systems, protocols, and enabling technologies thus have developed toward a concentrated focus in bringing the 2.5G and 3G modes to industry and consumers.
In general, there are four major digital wireless networks based upon 2G technology: time division multiple access (“TDMA”), code division multiple access (“CDMA”), Global System for Mobile communication (“GSM”) and cellular digital packet data (“CDPD”). These are briefly herein described as follows.
Time division multiple access (“TDMA”) is a technology used in digital cellular telephone communication that divides each cellular channel into three time slots in order to increase the amount of data that can be carried. TDMA is used by Digital-American Mobile Phone Service (D-AMPS), Global System for Mobile communication (“GSM”), and Personal Digital Cellular (“PDC). However, each of these systems implements TDMA in a somewhat different and incompatible way. An alternative multiplexing scheme to TDMA and FDMA (frequency division multiple access) is code division multiple access (“CDMA”).
Code division multiple access (“CDMA”) refers to any of several protocols used in 2G and 3G wireless communications. As the term implies, CDMA is a form of multiplexing that allows numerous signals to occupy a single transmission channel, optimizing the use of available bandwidth. the technology is used in ultra-high-frequency (UHF) cellular telephone systems in the 800 MHz to 1.9 GHz bands. CDMA uses analog-to-digital conversion (ADC) in combination with spread spectrum technology. Audio input is first digitized into binary elements. The frequency of the transmitted signal is then made to vary according to a defined pattern (code), so it can be intercepted only by a receiver whose frequency response is programmed with the same code, so it follows exactly along with the transmitter frequency. There are trillions of possible frequency-sequencing codes, thus enhancing privacy and making cloning difficult. The CDMA channel is nominally 1.23 MHz wide. CDMA networks use a scheme called “soft handoff”, which minimizes signal breakup as a handset passes from one cell to another. The combination of digital and spread spectrum modes supports several times as many signals per unit bandwidth as analog modes. CDMA is compatible with other cellular technologies; this allows for nationwide roaming.
The original CDMA, also known as CDMA One, was standardized in 1993 and is considered a 2G technology that is still common in cellular telephones in the U.S. One version of cdmaOne, IS-95A, is a protocol that employs a 1.25 MHz carrier and operates in RF bands at either 800 MHz or 1.9 GHz; this supports data rates of up to 14.4 Kbps. Another version, IS-95B, is capable of supporting speeds of up to 115 Kbps by bundling up to eight channels.
More recent CDMA varieties, CDMA2000 and wideband CDMA offer data speeds many times faster. CDMA2000, also known as IMT-CDMA Multi-Carrier or IS-136, is a CDMA version of the IMT-2000 standard developed by the International Telecommunications Union (ITU). The CDMA2000 standard is a 3G technology that is intended to support data communications at speeds ranging from 144 Kbps to 2 Mbps. Companies that have developed versions of this standard include Ericsson and Qualcomm corporations. Wideband CDMA, or “WCDMA”, is an ITU standard derived from CDMA that is also known as IMT-2000 direct spread. WCDMA is a 3G technology intended to support data rates of up to 2 Mbps for local area access, or 384 Kbps for wide area access, and supports mobile/portable voice, images, data, and video communications at these speeds. WCDMA digitizes input signals and transmits the digitized output in coded, spread-spectrum mode over a 5 MHz wide carrier—a much broader range than the 200 KHz wide narrowband CDMA.
The Global System for Mobile communication (“GSM”) is a digital mobile telephone system that is widely used in Europe and other parts of the world; this system uses a variation of “TDMA” (introduced immediately below) and is the most widely used of the three digital wireless telephone technologies (TDMA, GSM, and CDMA). GSM digitizes, compresses, and then sends data down a channel with two other streams of user data, each in its own time slot. It operates at either the 900 Mhz or 1800 MHz frequency band. At the time of this disclosure, GSM is generally considered the wireless telephone standard in Europe, and has been published to have over 120 million users worldwide and is available in 120 countries. At least one company in the United States, American Personal Communications (Sprint™ subsidiary), is using GSM as the technology for a broadband personal communications services (“PCS”). PCS are telecommunications services that bundle voice communications, numeric and text messaging, voice-mail and various other features into one device, service contract and bill. PCS are most often carried over digital cellular links. This service is planned to have more than 400 base stations for various compact mobile handsets that are being made by manufacturers such as Ericsson, Motorola, and Nokia corporations; these devices generally include a phone, text pager, and answering machine. GSM is part of an evolution of wireless mobile telecommunications that includes High-Speed Circuit-Switched Data (HCSD), General Packet Radio System (GPRS), Enhanced Data GSM Environment (EDGE), and Universal Mobile Telecommunications Service (UMTS).
Cellular Digital Packet Data (“CDPD”) is a wireless standard providing two-way, 19.2 kbps packet data transmission over existing cellular telephone channels.
Several different protocols have also been put into use for communicating over the various wireless networks. Various specific such protocols are briefly introduced as follows.
“X.25” is a packet-based protocol, principally used at the time of this disclosure in Europe and adapted as a standard by the Consultative Committee for International telegraph and Telephone (CCITT). X.25 is a commonly used network protocol that allows computers on different public networks (e.g. CompuServe, Tymnet, or TCP/IP network) to communicate through an intermediary computer at the network layer level. X.25's protocols correspond closely to the data-link and physical-layer protocols defined in the Open Systems Interconnection (“OSI”).
“OSI” is a model of network architecture and a suite of protocols (a protocol stack) to implement it, developed by ISO in 1978 as a framework for international standards in heterogeneous computer network architecture. The OSI architecture is split between seven layers, from lowest to highest: (1) physical layer; (2) data link layer; (3) network layer; (4) transport layer; (5) session layer; (6) presentation layer; and (7) application layer. Each layer uses the layer immediately below it and provides a service to the layer above. In some implementations, a layer may itself be composed of sub-layers.
General Packet Radio Services (“GPRS”) is a packet-based wireless communication service that promises data rates from 56 to 114 Kbps and continuous connection to the Internet for mobile phone and computer users. The higher data rates will allow users to take part in video conferences and interact with multimedia Web sites and similar applications using mobile handheld devices as well as notebook computers. GPRS is based on Global System for Mobile (“GSM”) communication and will complement existing services such as circuit-switched cellular phone connections and the Short Message Service (“SMS”). SMS is a message service offered by the GSM digital cellular telephone system. Using SMS, a short alphanumeric message (160 alphanumeric characters) can be sent to a mobile phone to be displayed there, much like in an alphanumeric pager system. The message is buffered by the GSM network until the phone becomes active.
The packet-based service of GPRS is publicized to cost users less than circuit-switched services since communication channels are being used on a shared-use, as-packets-are-needed basis rather than dedicated only to one user at a time. It is also intended to make applications available to mobile users because the faster data rate means that middleware currently needed to adapt applications to the slower speed of wireless systems will no longer be needed. As GPRS becomes widely available, mobile users of a virtual private network (“VPN”) will be able to access the private network continuously rather than through a dial-up connection. GPRS is also intended to complement “Bluetooth”, a standard for replacing wired connections between devices with wireless radio connections. In addition to the Internet Protocol (“IP”), GPRS supports X.25 protocol. GPRS is also believed to be an evolutionary step toward Enhanced Data GSM Environment (“EDGE”) and Universal Mobile Telephone Service (“UMTS”).
Universal Mobile Telecommunications Service (“UMTS”) is intended to be a 3G, broadband, packet-based transmission of text, digitized voice, video, and multimedia at data rates up to 2 Mbps. UMTS is also intended to offer a consistent set of services to mobile computer and phone users no matter where they are located in the world. This service is based upon the GSM communication standard, and is endorsed by major standards bodies and manufacturers, and is the planned standard for mobile users around the world by 2002. Once UMTS is fully implemented, computer and phone users can be constantly attached to the Internet as they travel.
Enhanced digital GSM enterprise (“EDGE”) service is a faster version of the Global System for Mobile (GSM) wireless service, designed to deliver data at rates up to 384 Kbps and enable the delivery of multimedia and other broadband applications to mobile phone and computer users. The EDGE standard is built on the existing GSM standard, using the same time-division multiple access (TDMA) frame structure and existing cell arrangements. EDGE is expected to be commercially available in 2001. It is regarded as an evolutionary standard on the way to Universal Mobile Telecommunications Service (UMTS).
Wireless Application Protocol (“WAP”) is a specification for a set of communication protocols to standardize the way that wireless devices such as cellular telephones and radio transceivers, can be used for Internet access, including e-mail, the World Wide Web, newsgroups, and Internet Relay Chat (“IRC”). While Internet access has been possible prior to WAP, different manufactures have used “format-specific” technologies. WAP enables devices and service systems to intercooperate.
In most recent times, much effort has been expended to merge the fields of wireless communications and the Internet in order to bridge the gap of cords, wires, and cables that had before separated the “information superhighway” from reaching people on wireless devices. Such technology merger has developed for example within the home and office network setting itself, where wireless infrared and radio frequency communications systems have been developed for interfacing equipment within a “wireless” office or home. Another substantial effort has also been underway to communicate and share information with more remote wireless devices, such as cell phones and personal digital assistants (“PDA's”).
PDA's are typically small, mobile devices that may be “hand-held” and usually contain limited processors and display screens for managing, storing, and displaying telephone books, calendars, calculator, and the like. Recently available PDA's have been made “wireless enabled”, either by having wireless modems embedded within the PDA itself, or by coupling to wireless modem “plug-ins” such as a cell phone. Wireless enabled PDA's are also generally “Internet enabled” with limited “browser” capability allowing the PDA to communicate with server devices over the Internet. Examples of commercially available wireless “enabled” PDA's include the Palm VII (from Palm, Inc.), and the iPAQ™ (from Compaq, Inc.). These PDA's include a Windows CE™ operating system that provides the limited browser capability and screen display for content. These phones have processing capabilities from about 33 MHz to about 220 MHz and varied screen display capabilities, such as for example 320×240 pixel screen displays.
Similarly, cellular phones themselves have also been recently rendered “Internet enabled”, also with limited browser capability and screens to display content. Examples of “Internet enabled” cellular phones include, for example: Sanyo SCP-4000™, Motorola i1000plus™, among a wide range of others; this wide field represents hundreds of different processing and display capabilities.
In either the case of the PDA or the cellular phone that is “Internet-enabled”, compatibility with the Internet protocols of communication must be achieved. In general, wireless communications take place over a wireless applications protocol (“WAP”), whereas communications over the Internet proceed according to one of several different protocols, the most common being Transmission Control Protocol/Internet Protocol (“TCP/IP”). Therefore, a WAP Gateway, as shown in FIG. 1E , forms a bridge between the world of the Internet (or any other IP packet network) and the wireless phone/data network, which are fundamentally different in their underlying technologies. The gateway, in essence, does the interpretation between these two distinct entities, allowing the consumer to use their cell phone or hand held computing device (e.g. PDA) to access the Internet wirelessly.
However, streaming media that is formatted for transmission to higher power computing devices such as desk-top computers having significant display capabilities is not generally compatible for receipt and viewing on these devices that have severely limited processing and display functionality. Particular “format-specific” compression schemes have been developed for use specifically with only these devices, and only specific media content may be transmitted to these devices in those formats.
There is still a need for a streaming media communications system that is adapted to transmit a wide variety of streaming media signals in appropriate formats to be played by wireless devices such as cellular phones and PDA's having unique constraints, such as, for example, limited and variable processing, memory, and display capabilities.
SUMMARY OF THE INVENTION
The present invention addresses and overcomes the various limitations, inefficiencies, resource limitations, and incompatibilities of prior known methods for streaming media communication, and is provided in various beneficial modes, aspects, embodiments, and variations as follows.
The present invention according to one embodiment is a streaming media communications system that uses a computer implemented intelligence system, such as artificial intelligence, in a network system, such as a neural network, to communicate a streaming media signal between a transmission device and at least one destination device.
The present invention according to another embodiment is a system for communicating a streaming media signal between a transmission device and a plurality of destination devices each having different media signal processing capabilities.
The present invention according to another embodiment is a streaming media communications system that is adapted to communicate a streaming media signal from a single transmission device and at least one destination device over a plurality of different transmission channels, each having a different transmission capability or constraints with respect to communicating the streaming media signal.
The invention according to another embodiment is a neural network incorporating an artificial intelligence implementation that is adapted to be trained in an adaptive learning process with respect to the ability of a streaming media compression system's ability to compress a streaming media signal at a source into a compressed representation of the streaming media signal, transmit the compressed representation over a transmission channel to a destination device, and decompress the compressed representation into a decompressed representation of the streaming media signal which is adapted to be played by the destination device.
The invention according to another embodiment is a system for compressing streaming media signals according to a CODEC that is used at least in part based upon at least one parameter affecting communication of the streaming media signals. According to one aspect of this mode, the CODEC is used according to at least one of the following parameters: a previously learned behavior of the CODEC with respect to another reference signal, a previously learned behavior of the CODEC with respect to a prior attempt at compressing or decompressing the same streaming media signal, a comparison of the CODEC's operation with respect to the streaming media signal against a reference algorithm compression of the streaming media signal, a learned constraint of the transmission channel, and a learned constraint of the destination device. In one beneficial embodiment, the CODEC is used based upon more than one of these parameters, and in still a further beneficial variation is used based upon all of the parameters.
The invention according to another embodiment is a system for compressing streaming media signals using a CODEC library that is adapted to store multiple CODECS of different types and operations, and that is adapted to be searched and accessed by a network system, such as a neural network, in order to provide an appropriate CODEC from the CODEC library for use in compressing the input streaming media signal into a compressed representation for transmission to a destination device.
The invention according to another embodiment is a CODEC operating system that is adapted to interface with a CODEC Library and also with a neural network in order to use the neural network in a process, such as an artificial intelligence process, to choose an appropriate CODEC from the CODEC library and use the chosen CODEC for compressing the streaming media signal into a compressed representation of the streaming media signal for transmission to a destination device.
According to one aspect, the CODEC library is adapted to receive and store a new CODEC such that the new CODEC may be interfaced with the neural network in order to be chosen and applied to compress the streaming media signal as provided.
The invention according to another embodiment is a destination agent that is adapted to be stored by a destination device for use in decompressing a compressed representation of a streaming media signal. The destination agent is adapted to communicate with a remotely located, compressed streaming media transmission system in order receive and play streaming media signals therefrom. In a particularly beneficial aspect, the software agent is adapted to deliver information about the destination device to the compressed streaming media transmission system, and is also adapted to receive and decode certain encoded streaming media signals from the compressed streaming media transmission system.
The invention according to another embodiment is a system for communicating a streaming media signal having a destination agent that is adapted to be stored within a destination device for decompressing a compressed representation of a streaming media signal into a decompressed representation that may be played by the destination device.
According to one aspect of this embodiment, the destination agent has a diagnostic agent and also a decompression agent. The diagnostic agent is adapted to determine a value for at least one parameter of the destination device related to the capability for processing, storage, or display. The decompression agent is adapted to apply a CODEC decompressor to decompress the compressed representation of the streaming media signal into the decompressed representation using a CODEC based at least in part upon the value of the at least one parameter.
According to another aspect, the destination agent comprises a software agent. In one variation, the software agent is embedded within the destination device. In another variation, the software agent is adapted to be loaded onto the destination device at least in part by a remotely located source that is adapted to deliver the compressed representation of the streaming media signal to the destination device.
The invention according to another embodiment is a transcoder for transcoding streaming media signals between at least one initial format and at least one transcoded format. The transcoder includes a single thread for each of several streaming media signals.
The invention according to another embodiment is a video-on-demand streaming media system incorporating the embodiments shown in the Figures and otherwise described herein.
The invention according to another embodiment is a mobile telephone communications system incorporating the embodiments shown in the Figures and otherwise described herein.
The invention according to another embodiment is an interactive gaming system incorporating the embodiments shown in the Figures and otherwise described herein.
The invention according to another embodiment incorporates the various modes, embodiments, aspects, features, and variations herein disclosed above and elsewhere to static media, as well as to media that is stored locally after processing (e.g. compressing) and not transmitted.
BRIEF DESCRIPTION OF THE FIGURES
FIGS. 1A-B show schematic block diagrams representing two respective variations of prior media communications systems using conventional CODEC systems.
FIGS. 1C-D show schematic block diagrams representing two respective variations of prior media transcoder systems.
FIG. 1E shows a schematic block flow diagram of the various interrelated components in a prior WAP gateway communications system.
FIGS. 2-3 show schematic block diagrams of the transcoder system of one embodiment of the present invention during two respective modes of use.
FIGS. 4A-5 show block flow diagrams in various detail, respectively, of a media communications system according one embodiment of the invention.
FIG. 6 shows a schematic block flow diagram of various interrelated components of a “video-on-demand” streaming video communications system according one embodiment of the invention.
FIG. 7 shows a schematic block flow diagram of various interrelated components of a wireless streaming video communications system according to one embodiment of the present invention.
FIG. 8 shows a schematic block flow diagram of various interrelated components of a WAP gateway media communications system according one embodiment of the present invention.
FIG. 9 shows a schematic block flow diagram of various interrelated components of a wireless communications system during backhauling according to one particular mode of use of the media communications system of an embodiment the present invention.
FIG. 10 shows a schematic block flow diagram of various interrelated components of an interactive gaming communications system and set-top TV browsing of one embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention as illustrated variously through the embodiments below (and by reference to the Figures) provides a media communications system that includes a compression system, a delivery system, and a decompression system, and in another aspect includes a transcoder system. In general, the combination of these individual sub-systems provides a capability to efficiently transcode media between multiple encoding formats, in addition to customize the compression, delivery, and decompression of randomly selected streaming media signals based upon a large array of system parameters as variables. These variables include for example, without limitation, parameters related to the following: the source video signal, the source transmitting device, the transmission modality, and the destination device. The compression, delivery, and decompression of a media signal is thus customized to be optimally efficient for a given, and changing, environment of use. As a result, a wide range of complex streaming media signals may be communicated with a level of efficiency and range of device compatibility that is significantly improved over other known systems.
Notwithstanding the benefits of the overall streaming media communication system herein described, each sub-system described also independently provides beneficially useful results for streaming media communication. The various subsystems themselves, and the various iterations of combinations of these sub-systems apparent to one of ordinary skill based at least in part upon this disclosure, are also contemplated within the scope of the invention. In addition, various aspects of the overall communication system, as well as of each sub-system described, are also contemplated as useful for other applications other than specifically for streaming media communication in particular. Therefore, where apparent to one of ordinary skill, such additional applications are further contemplated within the scope of the invention, despite the particularly useful modes applied to improved streaming media communication.
Transcoder
A video/audio transcoder 200 is provided according to the invention that enables one incoming video source 210 to be streamed across multiple formats 215 (for example MPEG4, Real Video™, and QuickTime™) from one device without human intervention. The transcoder 200 according to the present embodiment provides substantially greater functionality at a fraction of the price of other commercially available transcoder systems. Moreover, because the system works “on-the-fly,” pre-compressing of the video source 210 is significantly diminished.
More specifically, the transcoder 200 system and method according to the invention is adapted to transcode digitized media originating from any compressed or uncompressed format to be reproduced into any other compressed format—on demand, real-time. The system 200 and method also enables efficient, simultaneous processing of multiple streams 215 of differing data from a multiplicity of different compressed or uncompressed formats into a multiplicity of different compressed formats.
The transcoder 200 of the present embodiment is herein described in an overall system by way of illustration by reference to FIG. 3 . As shown, a first player initially makes a connection to a server 300 that houses the transcoder 200 . The player format (e.g., Microsoft Media), connection speed (e.g., 32 Kbps) and protocol (HTTP) are identified. The server 300 pulls the live or pre-encoded video into a “live buffer” or “cache” 310 and encodes it as digitized but nearly uncompressed data (e.g., AVI or MPEG2). The server 300 then loads an appropriate CODEC thread (e.g. Microsoft Media™) at the connection speed (e.g. 32 Kbps). Next, the server 300 loads a HTTP/MS player thread that serves the first client Then, a second stream is requested by a client using M/S Player at 100 Kbps with MMS. The server loads the appropriate MS CODEC thread at the appropriate 100 Kbps rate. Then, the server 300 loads an MMS/MS player thread to serve the second client. Then, a third stream is requested by a client using Real Player at 40 Kbps with RTSP. The server 300 loads the appropriate Real CODEC thread at the appropriate 40 Kbps rate. Then, the server 300 loads an RTSP/Real player thread to serve the third client. Again, this illustration is exemplary, and other specific CODECS may be suitable substitutes, as well as other bit-rates, etc.
In order to provide still a further understanding of the present transcoder embodiment, FIG. 3 shows the transcoder 200 by way of further example as applied to serve multiple different video streams to different clients.
In brief, the present transcoder 200 shown and described uses “thread” communications instead of “IPC” or “Inter Processor Communications” that are used according to many conventional transcoding techniques. For the purpose of this transcoder 200 description, the term “thread” is herein intended to mean an encapsulation of the flow of control in a program. Single-threaded programs are those that only execute one path through their code “at a time”. Multithreaded programs may have several threads running through different code paths “simultaneously”. In a typical process in which multiple threads exist, zero or more threads may actually be running at any one time. This depends on the number of CPUs the computer on which the process is running, and also on how the threads system is implemented. While a machine or system with a number of n CPUs may be adapted to run no more than n threads in parallel, the threading operation according to the present transcoder invention may give the appearance of running many more than n “simultaneously” by sharing the CPUs among threads.
The transcoder 200 provides abstract APIs, and therefore the CODEC is accessed without the (much larger) native encoder overhead. Buffering 310 is created as a function of client pull for different video streams. Moreover, the transcoder 200 of the invention utilizes a network architecture—a single thread for each different connection, combining clients into same thread if they are at they are within the buffered segment of the same content. The transcoder's 200 use of threads in the manner herein shown and described is considered highly beneficial because a context switch between two threads in a single process is believed to be considerably cheaper (processing/memory/IO) than using a context switch between two processes. In addition, the fact that all data except for stack and registers are shared between threads makes them a natural vehicle for implementing tasks that can be broken down into subtasks that can be run cooperatively.
While various specific architectures may be built around the transcoder 200 embodiments just described in order to achieve particularly desired results on a case-by-case basis. However, for the purpose of further illustration, the following is an example of a more detailed system using the transcoder 200 described. The transcoder 200 is provided adapted to support a large number of simultaneous customer streams, each with differing formats. In particular, such system may support more than 5000 simultaneous streams, and in some circumstances more than 7000 simultaneous customer streams, each with differing video formats. Still further, the transcoder 200 may be implemented to convert any of a wide number of video sources to a format uniquely appropriate or required for many different individual clients each having differing needs. In one particular example, a transcoder 200 as herein described may be implemented to support such high demand simultaneously on any of the following formats: MPEG 1; MPEG 2; MPEG 4; Motion JPEG; AVI; H.261; H.263; H.263+; RealVideo™ G-8; QuickTime™; Shockwave Flash™; Indeo Cinepak™; ASF.
It is further contemplated that the transcoder 200 may be adapted in an overall communication system to be compliant with all existing and soon anticipated fixed and mobile terminals and devices. Moreover, the transcoder 200 may be implemented to adapt output stream format variables to dynamically accommodate the channel and platform conditions of each client. Still further, the system incorporating the transcoder is adapted to support load balancing servers and routers for multi-transcoder installations. Accordingly, it is believed that the transcoder 200 of the present invention delivers significantly greater functionality for significantly lower cost than other prior transcoding techniques and systems.
As described above, various different system architectures may incorporate the transcoder 200 of the invention without departing from the scope of the invention. However, more details of a particular architecture that is believed to suitably provide the beneficial level of support just described includes the following aspects: (i) dual P3-933 processor; (ii) any variant of Unix OS; (iii) 512 MB RAM; Redundant Firewire or Gigabit Ethernet; Redundant Power Supplies. Such system may be provided in a rack mounted configuration, or otherwise to suit a particular need.
The following aspects of the transcoder 200 of the invention should be contemplated as broadly beneficial, both independently and in various combinations as is apparent to one of ordinary skill based at least in part from this disclosure.
A system and method is provided for utilizing asynchronous software thread communication in both user and kernel space to perform efficient transcoding on multiprocessor and/or distributed computing platforms (such as clustering). It has been observed that this method is more efficient than utilizing traditional IPC methods to implement the transcoder. A shared library of CODEC algorithms is created and used to access the various CODEC algorithms, thereby incurring a lower processing overhead as well as lower memory utilization than that required by the traditional combined encoder functionality such as that used in the majority of commercial encoders. Of particular benefit, common threads may be used for multiple connections, and in fact even a single thread may be used for every individual connection using the present transcoder.
A system and method is also provided for combining multiple clients to be served by the same thread (for efficiency) whenever the same content is demanded and dynamic buffers (caches) can accommodate all of the data points demanded.
Media Compression and Delivery System
A data compression and delivery system 400 and method is also provided according to the invention for real time dynamic data signal processing for optimal reproduction of approximations of original media data over a given set of constraints. This system 400 and method is illustrated schematically by way of block flow diagrams in FIGS. 4A and 5 . Further description of the various beneficial features and operation of this system is provided as follows by way of exemplary embodiments generally incorporating by reference the description provided by these FIGS. 4A-5 .
FIG. 4 A is a block diagram illustration of one embodiment of the data compression and delivery system 400 of the present invention. As shown in FIG. 4A , the data compression and delivery system 400 comprises media module 405 , dynamic player module 407 , image processor 410 , baseline snapshot module 415 , classifier 417 , quality of standard (QoS) module 420 , network layer input module 425 and network output layer module 430 . The system 400 further comprises a neural network processing module 440 , timer 435 , CODEC library module 445 , dynamic client request module 450 , ICMP module 455 , device and network parameters measurement module 460 and delivery and transmit module 465 .
In one embodiment, the system 400 , resident at a server node(s), processes incoming uncompressed or previously compressed data. The system 400 employs neural networks 440 with artificial intelligence to monitor the incoming data to determine a plurality of key characteristics of each data segment. The system 400 correlates the incoming data characteristics with libraries 445 of pre-developed self-referencing experientially learned rules of the patterns in a scene in a sequence of frames in the input signal (e.g., a video signal) and with externally imposed constraints to optimally choose a preferred commercially available compression/decompression algorithm (e.g. CODEC) for each segment of the data. The system 400 then sets up an extensive array of usage controls, parameters and variables to optimize the chosen algorithm. Choice of algorithm and set up of parameters and variables will dynamically vary with each segment of incoming data depending upon the characteristics of the data as well as the evolving optimization process itself. The set of possible algorithms is numerous, limited only by availability and other commercial considerations. Each segment of data is encoded and compressed in the above manner and then served to a communications channel.
The compression system 400 just described is particularly useful as a streaming media compression engine, which, based upon information from the available CODEC's and the streaming media delivery system, performs frame-by-frame analysis of the incoming video using another artificially intelligent neural network 440 . The system 400 then chooses the most appropriate compression format and configures the compression parameters for optimal video compression based on the best quality as measured by, in one embodiment, a selection of a peak signal to noise ratio from the underlying system environment. The result is the “optimal” video and audio service for the device and conditions present.
A more specific account of the artificial intelligence/neural network 440 aspect of this system as applied to streaming media signals is provided as follows. Initially, a library of separate and distinct CODECs are added to the system as a searchable CODEC library 445 . Additional libraries of relevant reference information are also provided, including: a Network Transport Standards (NTS) library 443 ; and a Quality-of-Service (QoS) library 447 . Then, a video (media source) is introduced either in a digitized or non-digitized format (AD conversion is used) via image processor 410 . Image processor 410 then decompresses the source (if required) and employs various standard image processing algorithms used for “cleaning-up” the source image(s). The resultant source media is then passed to the baseline snapshot 415 repository where it will be used as a “perfect gold standard” for later comparison. Simultaneously, this resultant source media is also fed to the classifier 417 .
The classifier 417 analyzes the source media for temporal, spatial and logical features for the purpose of creating source media sub-segments which exhibit similar combinations of temporal, spatial and logical features. “Similar” is defined to mean a contiguous sub-segment of the source media that contains common temporal, spatial and logical features that would lend themselves to a particular encoding/compression algorithm (as found in the CODEC library 445 ). This source media sub-segment (or, in one embodiment, a group of contiguous video and audio frames) is referred to as a “scene”.
The neural network process 440 then operates upon this scene by employing CODECs from the CODEC library 445 to compress the scene. The internal configuration of each CODEC are manipulated/changed in accordance with inputs obtained from the NTS library 443 , QoS library 447 , Timer Process 435 , Network layer Input 425 , ICMP agent 455 and the Device and Network Parameter measurement agent 460 . The compressed scene is then decompressed and a comparison is made against the Baseline Snapshot 415 using a quality measurement made by the quality standard process 420 . In one embodiment of the present invention, the Quality Standard Process 420 employs a peak signal to noise ratio (PSNR) algorithm in order to perform the comparison of the decompressed scene against the baseline snapshot of the source media. The comparison process is repeated with various CODECs from the CODEC library 445 until the Neural Network Process 440 is satisfied with the quality of the resultant compressed scene, within the constraints of the inputs received from the NTS library 443 , QoS library 447 , Timer process 435 , Network Layer Input 425 , ICMP Agent 455 and the Device and Network Parameter Measurement Agent 460 . Finally, the resultant compressed scene is sent to the Network Layer Output 430 which transports the compressed scene to the Client using an appropriate Network Transport protocol and QoS algorithm.
The above process is repeated until the entire source media has been transmitted to the Client or until the process is aborted due to various possible conditions which may include: a Client request to abort, network transport failure, Client hardware failure, etc.
The NTS library 443 is a repository of network transport services that are selected and used by the Network layer output 430 to transport compressed source media to the Client and by the Network Layer Input 425 to receive information from the Client. The selection is based upon qualitative and quantitative inputs received from the Network Layer Input 425 , ICMP agent 445 and the Device and Network Parameter Measurement agent 460 .
The QoS library 447 is a repository of quality of service algorithms that are selected and used by the network layer output 430 to transport compressed source media to the Client. The selection is based upon qualitative and quantitative inputs received from the Network Layer Input 425 , ICMP agent 455 and the Device and Network Parameter Measurement agent 460 .
The ICMP agent 455 generates inputs to the neural network process 440 that dynamically provides it with the quantitative and qualitative characteristics of the transport in use between the processor and the client. In one embodiment of the present invention, the ICMP protocol is used for this purpose.
The Device and Network Parameters Measurement agent 460 generates inputs to the neural network process 440 that dynamically provides it with the qualitative and quantitative characteristics of the client's environment. In one embodiment of the present invention, these client environment characteristics include central processing unit (CPU) capacity, network interface characteristics, storage capacity and media rendering devices capabilities.
Still referring to FIG. 4A , the Network Layer Input 425 provides inbound (originating from the client) network transport services. The Network Layer Output 430 provides outbound (originating from the processor) network transport services. The Timer Process 435 provides a way for the user of the invention to limit the maximum amount of time that the Neural Network Process 440 will spend in processing a given source media.
FIG. 4B is a block diagram illustration of one embodiment of a CODEC selection scheme of the neural network processing module 440 of one embodiment of the present invention. The neural network processing module 440 shown in FIG. 4B comprises a video frame selection module 475 , CODEC parameters module 480 , input layer module 485 , hidden layers 486 - 487 and output module 488 . In one embodiment of the present invention, a CODEC representative signal suitable to be used as a reference baseline signal for incoming signals to the neural network processing module 440 is generated by the neural network processing module 440 . In one embodiment, the classifier 417 determines which scenes in segments of an incoming video signal represents the best scene in light of the available parameters of the underlying CODEC. A list of standards are used by the neural network processing module 440 to determine which scene in the signal represents the best scene. In one embodiment, the Neural Network Process 440 samples a number of pixels in a particular frame of video to determine changes in the number of pixels in that particular frame vis-à-vis the pre-determined parameters of the video signal. In another embodiment, significant motion changes in a particular scene in the video signal may be used as the baseline reference scene (“best scene”) for subsequent incoming video.
In one embodiment of the present invention, the neural network processing module 440 takes a segment of video from the classifier 417 as an input and subsequently takes a sample of this input to derive enough information that characterizes the video signal. For example, in the scheme illustrated in FIG. 4B , the Neural Network Process 440 takes a window snap-shot (e.g., a 176×144 pixel window) to examine. It is advantageous for the Neural Network Process 440 to look at the center of the sample window to generate enough information about the video signal. In one embodiment of the present invention, the Neural Network Process 440 uses a minimum of 8 frames to generate the requisite information about the video signal. Information from the sample window is presented with the particular CODEC parameters from parameter module 480 to the input layer 485 .
The input layer 485 is coupled to a plurality of hidden layers 486 - 487 via a plurality of neurons with each connection forming either a strong or weak synoptic link from one neuron to the other. In one embodiment, each CODEC supported by the neural network processing module 440 is provided with its own neural network to process the CODEC specific parameters that come with the particular CODEC. The Neural Network Process 440 generates the “best” video signal through a round-robin like process referred to as a “bake-off” from the plurality of CODECs processed during a video sampling capture period. In processing the best video representation from incoming signals, each of the corresponding neural networks for each of the CODECS generates the best representative sample from the hidden layers 486 - 487 and feed the signal to the output module 488 . In one embodiment of the present invention, the output data set of the best CODEC from each class of CODECS being processed by the Neural Network Process 440 has two possibilities. The first being the Neural Network Process 440 submitting the best results for each CODEC to the output module 488 to a “bake-off” neural network of the plurality of “best” samples for each of the plurality of CODECS which in turn generates the winning best CODEC from the plurality of best CODECS. The bake-off neural network is smaller and faster than the neural networks that handle the processing of the CODECS.
In a second processing scheme, the Neural Network Process 440 may implement a genetic algorithm processing of the best CODECS generated by the plurality of CODECS. The genetic algorithm follows the same statistical selection approach of a marble game. Thus, instead of feeding the winning output CODEC from the various neural networks into a “bake-off” neural network, a genetic algorithm processing may be applied to feed the output module 488 from the various neural networks into a bucket and picking the best CODEC representation from a collection of scenes at the end of the source media, for example, a movie, etc. In one embodiment of the present invention, the Neural Network Process 440 uses a combination of forward and backward propagating algorithm to process the CODECS.
Referring back to FIG. 4A , for the purpose of providing a further understanding of this artificial intelligence process, the following example of one particular application is provided. It is to be appreciated that the features and operation of the system provided by this exemplary application are to be considered as broadly descriptive of the neural network 440 aspect for data compression and delivery according to the invention. Other applications may be made and fall within the scope of the invention.
A video content provider installs the system of the present invention on its server. Sample videos are introduced to the system in order to perform an initial AI process as described above. A complex matrix of CODEC characterizations, e.g. for each bit rate, pattern of video, etc., is created to be drawn from later. Next, a client end-user connects to the content provider system in order to view a video M. The communication system of the invention residing on the server delivers a software agent to the client's device, thus enabling the client to connect to the communication system in order to deliver device-specific information and receive the appropriate compressed signal with decompression CODEC for playing. Next, the AI system begins loading the video M as a streaming signal into a buffer for the purpose of choosing the appropriate CODEC for each frame and compressing each frame appropriately for transmission. The time period of the buffer depends upon multiple variables, principally the processing power of the system, and may be generally for example approximately 15 seconds for systems having appropriate capability for pre-recorded but uncompressed video media. Within the buffer, each frame is compared against each CODEC according to the “types” of sequences pre-tested in matrix as depicted in the diagram.
Next, the system 400 looks at end-user parameters, e.g. screen resolution, memory available, via information received from the software agent in the client's device. The most appropriate CODEC is then chosen and configured/tuned for optimal performance by setting certain variables within the CODEC to fixed quantities (e.g. based on comparing source video vs. patterns in past, transmission channel capabilities or constraints, and destination device capabilities or constraints). The process just described is generally done frame-by-frame by the classifier 417 , but the CODECS are compared for temporal compression efficiency such that the process for each frame contemplates other leading and lagging frames. Once the appropriate CODEC is chosen and tuned for each frame (or block of frames where appropriately determined automatically by the system), the delivery system reports to the client agent and delivers the tuned CODEC ahead of the corresponding frame(s) to be decompressed and played.
It is to be appreciated that the neural network 440 of this system 400 continuously learns and remembers the performance and operation of the CODECS within the CODEC library 445 , and continuously uses its learning to improve the compression efficiency of the input media signal. The process of running a signal frame through the library, modifying CODEC operating parameters, comparing compression performance by the compare logic 525 ( FIG. 5 ) against reference standard compression, and running the loop again with further modifications, is an iterative 550 ( FIG. 5 ) one that generally continues to improve compression efficiency. In fact, compression with one or more CODECS in the library 445 may reach improved levels better than the reference compression algorithm(s).
Nevertheless, when time constraints 435 ( FIG. 4A ) are present (such as in real-time push or pull demand for the streaming media content), this process must eventually be stopped at some point so that a particular frame or series of frames being processed may be compressed 575 and delivered 580 to the destination without unacceptable delay by timer 435 . Then, the next frame or series may be operated upon by the neural network 440 within the CODEC operating system. These endpoints may be defined by reaching a predetermined desired result, such as for example but without limitation: (i) reaching a predetermined percentage (%) compression efficiency, such as for example as compared to the reference standard; or (ii) reaching a predetermined or imposed time limit set on the process, such as for example according to a time related to the buffer time (e.g. 15 seconds); or (iii) the earlier occurrence of either (i) or (ii). In any event, though an endpoint is reached for choosing the appropriate CODEC and performing the compression 575 and delivery 580 operations, this does not mark an endpoint for the neural network 440 training which continues. The information that is gathered through each loop in the process is stored 550 . When subsequent similar frames or system constraint parameters in an incoming frame are encountered 545 in the future, the stored information is remembered and retrieved by the neural network 440 for improving compression 575 and delivery 580 efficiency.
While many different communication protocols are contemplated, one particular embodiment which is believed to be beneficial uses a “full duplex network stack” protocol, which allows for bi-directional communication between the server and the client device. Again, while other protocols may be appropriate for a particular application, the full duplex system is preferred.
The system 400 just described addresses the difficulties encountered with previously known CODEC systems by utilizing the streaming media delivery architecture to overcome latency issues and the embedded neural network 440 to overcome speed concerns. The system 400 is then able to reconfigure the algorithms used for compression in the neural network 440 , the goal being to achieve optimum results every time over any network configuration.
A wide variety of CODECS may be used within the CODEC library 445 according to the overall compression systems and methods just described, though beneficial use of any particular CODEC according to the invention contemplates such CODEC taken either alone or in combination with other CODECS. For example, an appropriate CODEC library 445 may include one or more of the following types of CODECS: (i) block CODECS (e.g. MPEG versions, such as Microsoft Media™ or QuickTime™); (ii) fractal CODECS; and (iii) wavelet CODECS (e.g. Real™). According to another aspect, an appropriate CODEC library 445 may include one or more of the following types of CODECS: (i) motion predictive CODECS; and (ii) still CODECS. Still further, the CODEC library 445 may contain one or more of the following: (i) lossy CODECS; and (ii) lossless CODECS.
In one embodiment of the present invention, all of these different types of CODECS may be represented by the CODEC library 445 according to the invention; and, more than one particular CODEC of a given type may be included in the library. Or, various combinations of these various types may be provided in order to achieve the desired ability to optimize compression of a streaming media communication over a wide range of real-time variables in the signal itself, transmission channel constraints, or destination device constraints. Still further, an additional highly beneficial aspect of the invention allows for new CODECS to be loaded into the library 445 and immediately available for use in the neural network 440 compression/delivery system 400 . Nevertheless, one particular example of a CODEC library 445 which is believed to be beneficial for use in optimally communicating a wide range of anticipated streaming media signals, and of particular benefit for image signals, includes the following specific CODECS: MPEG versions 1, 2, and 4 (e.g. Microsoft Media™ and QuickTime™); DUCK TruMotion™; ON2; Real Media™; MJPEG: H.261; H.263; H.263+; GIF; JPEG; JPEG2000; BMP; WBMP; DIVX.
The following are further examples of various aspects of the compression system and method just described that should be considered as broadly beneficial, both independently and in various combinations as is apparent to one of ordinary skill based at least in part on this disclosure. Further examples of such broad aspects are elsewhere provided in the “Summary of the Invention” as well as in the appended claims.
Use of neural networks 440 with artificial intelligence to achieve the various CODEC operations described is broadly and uniquely beneficial. In particular, a system and method is provided for pre-processing 410 of source data determined by application of learned responses to the signal quality, data content and format of the data. A system and method is provided for processing each unit (e.g. frame or block of frames) of source data by selection and application of a suitable CODEC (from a set of all available CODECS in the CODEC library 445 ) dependent upon observed characteristics of the source data and application of past-learned responses to compressing similar data. A system and method is provided for processing each unit of source data by setting a multiplicity of compression characteristics within a chosen compression algorithm to optimize capture and preservation of the original data integrity. Still further, each or all of the aforementioned signal processing steps is applied to each unique, sequential unit of signal data, e.g., signal clip, video frame, or individual packet as appropriate.
It is further contemplated that a CODEC management system 400 according to the invention provides a system and method for image processing that is adapted to normalize original source data/images as well as to resize and resample original data to fit the specification of the neural network processing module 440 . An ability to serve any transmission or recording channel with a single system and with any source data stream is also provided. Moreover, the various systems and methods herein described, individually and beneficially in combination, are provided with compatibility to any connection or connectionless protocol, including but not limited to TCP, UDP, WTP/WDP, HTTP, etc.
The invention as herein shown and described also allows for highly beneficial applications for accelerating the learning rate of neural networks 440 while minimizing the data storage requirements to implement said networks. Different classes of data streams each have unique characteristics that require substantially greater processing by neural networks 440 . For example, video data streams differ by prevalence and degree of motion, color contrast, and pattern and visibility of details. Greater processing requires longer times to reach optimal functionality. Greater processing also requires more predictive library storage, often growing to unlimitedly large sizes. For real-time neural network processing, processing time and storage can be minimized to greatly increase functionality by providing pre-developed predictive libraries characteristic of the class of data stream.
Accordingly, the following are examples of aspects of the pre-trained neural network 440 aspects of the invention that should be appreciated as broadly beneficial, both independently and in combination (including in combination with other embodiments elsewhere herein shown and described). A system and method is provided that creates and uses artificial intelligence in a neural network 440 and pre-trains that intelligent network for use in solving a problem, which problem may be for example but not necessarily limited to streaming media compression according to a particular beneficial aspect of the invention. A system and method is also provided for subdividing the universe of problems to be solved into useful classes that may be processed according to a learned history by the intelligent network.
An intelligent streaming media delivery system and method is also provided according to the invention that manages content transmission based on end-user capabilities and transmission channel constraints, such as for example, but without limitation, available transmission speeds or bandwidth, and Internet congestion. The data compression and delivery system 400 utilizes a computer implemented intelligence process, such as an artificial intelligence process based on a neural network to analyze aspects of the connection (including without limitation differing bit rates, latencies, transmission characteristics and device limitations) to make modifications in the compression methodology and to manage Quality of Service (“QoS”) 420 issues. Compressed, digital, restorable and/or decompressible data streams may be therefore delivered to a multiplicity of different local and/or remote devices via a multiplicity of transmission mediums characterized by differing capabilities. In addition, a decompression system is provided for reproducing the decompressed data at the terminal device.
In one beneficial embodiment, a terminal device establishes a link with the system resident on a server node(s). Except for software normally required to establish communications, the terminal device might not initially have resident software embedded therein associated with the present system. Upon linking the terminal device to the server node, the system transmits a software agent to the terminal device that cooperates with other software modules on the server-side that together form the overall delivery system. The software agent informs the system of the terminal device configuration and processing capacities for decompressing and displaying the data. The software agent also reports certain relevant information to the system of the characteristics of the communication channel between the terminal and the server. Such information includes, without limitation: latency, bandwidth, and signal path integrity. Based upon terminal device configuration and real time updates of channel characteristics and capabilities, the system actively manages transmission of the compressed data stream by varying parameters such as buffer length, transmitted bit rate, and error correction. The system also feeds operating conditions to the compression system to dynamically alter encoding and compression settings to optimize delivery of the data. The delivery software agent resident on the terminal device decompresses the data stream that is composed of segment-by-segment variations in compression/decompression algorithm and settings thereof. Dependent upon the terminal device configuration, and especially for very thin clients, instructions may be refreshed on a segment-by-segment basis for each decompression algorithm and encoding setting combination. Instructions for decompressing may also be kept resident if appropriate to the terminal device.
The software agent described for transmission to and operation by the destination device is therefore also considered a highly beneficial aspect of the compression/delivery systems and methods described. By delivering the software agent to the device from the source, a wide range of existing destination devices may be used for communication according to methods that may include variable uses of one or more algorithms or other operations at the transmission source. In other words, the destination devices may not be required to be “format-specific” players as is required by much of the conventional streaming and static media communication systems. Also, by providing the destination agent with a diagnostic capability, diagnostic information may be gathered at the destination device and transmitted back to the source in a format that is compliant for use by the source in its neural network process for achieving the proper CODEC operation for a given set of circumstances.
The use of a client-side agent to supply quality of service information including client-side device data and communication channel status in real time is therefore also believed to be broadly beneficial beyond the specific applications and combinations of other aspects of the invention also herein provided. In addition, the processing of each unit of compressed, transmission-ready data to accommodate client-side device and real-time communication channel conditions is also broadly contemplated as having broad-reaching benefits. Still further, a system and method is described that provides instructions to a client-side agent to enable decompression of each sequential, uniquely compressed unit of data. Therefore, another broad benefit of the invention provides a destination device (such as from the transmission source as herein described for the particular embodiments) with a CODEC that is adapted to decompress a compressed representation of an original media signal into a decompressed representation based upon variable parameters related to at least one of the following: aspects of the original media signal, transmission channel constraints, and destination device constraints. In another broad aspect, the destination device is adapted to use a CODEC that is chosen from a library of CODECS based upon a parameter related to an aspect of the original media signal.
The systems and methods herein described are also considered applicable to the signal processing of each unique, sequential unit of signal data, e.g., signal clip, video frame, or individual packet as appropriate. In addition, the system and its various sub-systems may also be purely software that must be loaded into each appropriate device, or it may be embedded in a host hardware component or chip, e.g. on the server side, or in certain circumstances, on the client side (e.g. various aspects of the destination agent), or for example may be stored such as in flash memory.
The various aspects of the media compression system and method just described are considered beneficial for use according to a wide range of known and soon anticipated media communication needs, including for example according to the various communications devices, communication/transmission channel formats and standards, and media types and formats elsewhere herein described (e.g. in the “Background” section above).
However, for the purpose of further understanding, FIG. 6 shows a schematic view of the overall streaming media communications system 600 as specifically applied to “video-on-demand” aspects according to one embodiment of the present invention, wherein many different end users 610 - 620 at many different locations may request and receive, real-time (e.g. without substantial delay), pre-recorded video from a remote source. Further to the information provided in FIG. 6 , at least one specific implementation of the media communication system 600 delivers the following types of video at the following bit-rates (denotes compressed representations of original signals that are convertible by a destination device to decompressed representations having no or insubstantial loss as observed by the eye of the typical human observer): VHS-format video as low as about 250 Kbs; DVD-format video at about 400 Kbps; and HDTV-format video at about 900 Kbps. According to these speeds, it is believed that video-on-demand may be provided by telephone carriers over resident transmission line channels, such for example over existing DSL lines 630 - 640 .
However, as available bandwidth and mass communication continue to present issues, it is believed that even greater efficiencies may be achieved resulting in delivery of compressed representations of these types of video signals at even lower bit rates. Again, as elsewhere herein described, the compression efficiencies of the invention are closely related to and improve as a function of the processing power made available to the neural network 440 , and the neural network's 440 continued learning and training with respect to varied types of media. These resources may even make more remarkable compression efficiencies achievable without modification to the fundamental features of the present invention.
Therefore, the following are further examples of transmission rates for certain compressed video signals that are believed to be desirable and achievable according to one embodiment of the invention: VHS-format video as low as about 200 Kbps, more preferably as low as about 150 Kbps, and still more preferably as low as about 100 Kbps; DVD-format video as low as about 350 Kbps, more preferably as low as about 300 Kbps, and still more preferably as low as about 250 Kbps; and HDTV-format video as low as about 800 Kbps, and still more preferably as low as about 700 Kbps.
Moreover, at least one implementation of the media communications system 400 of one embodiment of the invention delivers 20-24 frames/sec color video at a transmission rate of 7 Kbps. This is believed to enable substantial advances in communication of streaming media signals via to wireless destination devices via the WAP Gateway, as is further developed elsewhere hereunder.
It is also to be appreciated that, while video communication has been emphasized in this disclosure, other types of streaming or static media are also contemplated. For example, at least one implementation of the compression and delivery embodiments has been observed to provide substantially CD-quality sound (e.g. via compressed representations of original signals that are convertible by a destination device to decompressed representations having no or insubstantial loss as observed by the ear of the typical human observer) at a bit-rate of about 24 Kbps. At these rates, audiophile-quality sound may be delivered for playing over dial-up modems. However, with further regard to available resource commitment and extent of neural network training, it is further contemplated that the invention is adapted to deliver CD-quality sound at speeds as low as about 20 Kbps, and even as low as about 15 Kbps or even 10 Kbps.
Wireless Audio Communications System
It is further contemplated that the streaming media communication system of the invention has particularly useful applications within wireless audio communications networks, and in particular cellular telephony networks. Therefore, FIGS. 7 and 8 schematically show, with respectively increasing amounts of detail, streaming media communications systems 700 and 800 respectively specifically applied to wireless audio communications systems according to certain specific, respective embodiments of the present invention. While particular devices, system parameters, or arrangements of communicating devices shown are believed to be beneficial in the overall application of the invention, they are not to be considered limiting and may be suitably replaced with other substitutes according to one of ordinary skill based upon this disclosure. The various wireless communications systems 700 and 800 , standards, and protocols referenced elsewhere in this disclosure are thus incorporated into this section for the purpose of integration with the various aspects of compression, delivery, decompression, and transcoding according to one embodiment of the invention.
Combination of the communications system 400 of one embodiment of the present invention with the other components of a cellular communications network allows for the enhanced compression, delivery, and decompression according to the invention to manifest in an increased quality of service for wireless audio communications. Improvements in cellular communications according to the invention include, without limitation, the following examples: increasing available bandwidth, extending range of reception, and providing graceful degradation while maintaining connectivity during periods of low signal quality or reception levels.
More specifically, cellular telephony signals are characterized by relatively high degrees of variability, due for example to the roaming positions of clients, and limited cell ranges, atmospheric conditions, and significantly limited and changing available bandwidths over daily use cycles. Therefore, a self-optimizing CODEC management system according to the present invention is particularly well suited to adjust the appropriate communications and compression modalities to the changing environment. At the very least, the increase in compression efficiency and resulting decrease in bandwidth used for given signals is a valuable achievement as wireless channel traffic continues to congest.
In one particular regard, the increased compression efficiency according to the present invention is well applied to improving bandwidth issues during “soft hand-offs” between cells, as illustrated in FIG. 9 . During cellular phone communications, whenever a transmitter or receiver migrates between cell coverage zones, communications bandwidth requirements and resultant costs are increased by systemic requirement to “pass off” active communications between cells. The act of passing off the communication results in a “backhaul” channel from the previously active cellular transmitter to a central office for forwarding to a newly active cellular transmitter. The backhaul channel represents a significant use of bandwidth. Savings will result from increased compression. As Figure shows, such “backhauling” may include a doubling (media sent back from first cell being left and resent to second cell for transmission) or even a quadrupling (overlapping communication from both first and second cells) in the bandwidth used for communicating a particular signal.
The media communications system 400 of the present invention may recognize when backhaul is occurring, such as according to the transmission channel diagnostics provided in the software agent(s), and may respond by adjusting the degree of compression to compensate.
WAP Video Gateway
With a particular view of the rapid growth observed and predicted in the wireless or mobile Internet, embodiments of the present invention contemplate application of the intelligent compression/delivery/decompression embodiments in combination with WAP Gateway functionality.
A system and method is therefore also provided according to the invention for encoding, compressing and transmitting complex digital media (e.g., video pictures) via bandwidth-constrained wireless communications systems utilizing Wireless Applications Protocol (WAP). In one embodiment, data is processed by the system, resident at a server node(s), employing neural networks with artificial intelligence. Sample segments of data are captured from the input stream and processed to comply with requirements unique to the class of clients. As is described in detail above, the system correlates the continuously varying digital data streams' characteristics with libraries of pre-developed experientially learned rules and with externally imposed constraints to optimally choreograph the coherence, continuity and detail of the data as ultimately received, decoded and presented at the client interface.
A gateway provided with the added functionality of the streaming media communications system herein described is shown schematically in FIG. 8 . According to the WAP gateway system 830 , a client agent is provided that is adapted to run on a variety of platforms, and requires no specialized hardware to decode the video streams. According to use of the streaming media delivery system of the invention elsewhere herein described, the viewer of the WAP device maintains constant communication with the system server upstream, such that the user-side client 825 may provide the encoding platform with relevant information for streaming media communication, including without limitation: available screen size, processing power, client operating system and browser version, connection speed and latency, thereby allowing the streaming media delivery system to tailor the stream to each individual client it “talks” to. Accordingly, an AI driven server 830 incorporating the AI compression as herein described may be combined with a WAP Gateway 830 , combining the necessary WAP to TCP/IP protocol (or other protocol, e.g. dual server stack) translation with a Video and Audio Server 835 employing compression, delivery, and decompression systems and methods herein described. The WAP Gateway 830 may further include a video transcoder, such as for example incorporating the transcoder systems and methods herein described. An appropriate host architecture according to this system (not shown) generally includes a rack mount system running Linux OS with a modified WAP Gateway 830 or as a software plug-in to existing servers.
This WAP gateway system 830 may be further provided in a Master/Slave relationship as another beneficial aspect of the overall streaming media delivery architecture (applicable to other delivery systems other than specifically wireless). Various content distribution networks, such as available through Akamai and Inktomi, have capitalized on the concept of improving data delivery over the Internet by using “smart caching” on servers which reside on the borders of the Internet. Such a Master/Slave relationship is maintained by the present system wherein a Master Server resides at the source of the content to be delivered and Slave Servers reside on the borders. These servers communicate “intelligently” to optimize the content delivery over the Internet and reduce latency, bandwidth and storage requirements, improving the overall quality of the video/audio stream to the end-user and decreasing the cost of media delivery to the content provider.
The WAP gateway 830 of the present invention supports continued growth in mobile communications, as large telecommunications operators are transitioning to multi-service broadband networks, and as the number of subscribers to the mobile Internet continues to expand rapidly. In particular, mobile communications is a broad class of systems and protocols, each having its own constraints and needs for interacting devices to communicate streaming media. The Gateway 830 in a particularly beneficial aspect may support a variety of “2G” systems with upgradability for upcoming “2.5G” and “3G” network technologies (numerical progression of systems generally represents progression of Internet-enabled capabilities).
The following Table 3 provides examples of known mobile communication standards, and provides certain related information used by the AI system of the present invention for optimizing communication of streaming media amongst the field of mobile destination devices as media players:
TABLE 3
Existing/Soon Anticipated Mobile
Communications Standards
MODE
BAUD RATE (generally)
GSM (2G)
9.6 Kbps
CDMA
9.6 Kbps
TDMA
14.4 Kbps
CDPD
14.4 Kbps
iMODE
128 Kbps
GPRS
144 Kbps
WCDMA or
144 Kbps to
CDMA2000
2 Mbps
GSM (3G)
2 Mbps
In addition, the present invention is particularly beneficial in its ability to stream a wide variety of media signals to various different types of wireless communications devices. Examples of wireless communications devices that are appropriate for use with the streaming media communications systems and methods of the invention, and which the systems and methods support interchangeably, are provided in the following Table 4:
TABLE 4
Examples of Internet-enabled PDA's
SCREEN
SCREEN
MODEM
CONNECT
DEVICE
MAKE
SPEED
MEMORY
DEPTH
SIZE
TYPE
SPEED
iPAQ
Compaq
206 MHz
16-64 Mb
12 b/pixel
320 x 240
External
9600-14.4
Kbps
color
(e.g. CDPD)
PalmVII
Palm
33 MHz
4-16 Mb
4 b/pixel
Internal
14.4
Kbps
b/w
8 b/pixel
color
Handspring
Palm
33 MHz
4-16 Mb
4 b/pixel
External
14.4
Kbps
b/w;
8 b/pixel
color
Blackberry
Research-
33 MHz
4 Mb
2 b/pixel
Internal
9.6-14.4
Kbps
In-Motion
b/w
Jornada
HP
133 MHz
16-32 Mb
18 b/pixel
320 x 240
External
9.6-14.4
Kbps
Casseopeia
Casio
150 Mhz
16-31 Mb
12 b/pixel
320 x 240
External
9.6-14.4
Kbps
Various specific examples are described later below that provide observations of actual wireless Internet applications of the invention as herein described. Such examples include use of a CODEC library according to varied parameters associated with at least the following (without limitation): destination wireless communication device; transmission channel; communications protocol; and the respective streaming media signals themselves. The various particular features of the systems and methods used according to these examples are contemplated as further defining independently beneficial aspects of the invention.
Shared Interactive Environment
A system and method is also provided according to the invention for enabling real-time remote client interaction with a high-definition, multi-dimensional, multi-participant simulated environment without the need for significant client-side processing capacity. More specifically, FIG. 10 shows an overall streaming media communication system as applied to shared interactive gaming according to the invention.
This system includes: (i) a proxy server; (ii) graphics rendering capabilities; (iii) a client software agent for feedback of client inputs to the game; (iv) a client software agent for supporting the delivery system of the invention; and (v) streaming from the server to the client. It is contemplated that for multiple clients, which typically represent shared interactive gaming by design, multiple components as just described are provided to support each client.
The interactive gaming embodiments contemplate implementation of data compression and delivery embodiments with devices that are also destination devices for compressed signals from other like, remotely located device systems. This arrangement is broadly beneficial, such as for example in further interactive media implementations such as video conferencing and the like. Accordingly, each remote system is both a source and a destination device, and sends and receives agents between it and other remote systems.
Destination Device
Although the communications systems of the present invention enables communication of streaming media signals to a wide variety of destination devices, a further contemplated feature of the invention provides a remote receiver to be housed as a destination device/player by client users. This set-top player may be adapted to serve at least one, though preferably multiple ones, and perhaps all, of the following: Video on Demand (VOD); Music on Demand (MOD); Interactive Gaming on Demand (IGOD); Voice Over Internet Protocol (“VoIP”), any technology providing voice telephony services over IP connections; Television Web Access; Digital Video Recording to record, pause, and playback live television; e-mail; chat; a DVD player; and other applications apparent to one of ordinary skill. All of this may be delivered to existing televisions in the comfort of users' own homes. Moreover, clients utilizing this box, or other systems interfacing with the communications system of the invention, may receive DVD quality video and surround sound over cable and DSL connections.
EXAMPLES
For the purpose of further illustrating the highly beneficial results that may be achieved according to the invention, the following are examples of specific embodiments that have been used for different types of streaming media communication, including observed results with pertinent discussion. These examples illustrate communication the same pre-recorded video over different transmission channels and to different destination devices, wherein the pre-recorded video has the following originating properties: 720 lines of resolution and 32 bits of color information, an originating file size of about 1.4 Gigabytes.
Example 1
An “iPAQ” model 3650 hand-held PDA (commercially available from Compaq, Inc. for approximately $500 at the time of this disclosure) was provided. The PDA was interfaced with a 14.4 Kbps (max) wireless CDPD modem (“AirCard 300” wireless external modem, commercially available from Sierra Wireless for approximately $200 at the time of this disclosure) using an extension assembly (iPAQ™ PCMCIA expansion sleeve from Compaq, Inc.) with a PCMCIA card slot that couples to the wireless modem. The iPAQ™ used is generally characterized as having the following processing parameters: 206 MHz processor; 32 Mb memory; 12 b/pixel color; 240X320 screen dimensions; PocketPC™ operating system version 3.0 from Microsoft Corp. and stereo sound. The iPAQ™ was connected to the Internet in San Francisco, Calif. via the interfaced CDPD modem over the AT&T cellular wireless carrier system at a connection bandwidth of about 13.3 Kbit/sec. A server located in San Jose, Calif. (approximately 50 mi away) was contacted by the PDA employing the http and rtsp protocols, and the PDA was used to initiate a request for a pre-recorded video having the following originating properties: 720 lines of resolution and 32 bits of color information, the originating file size was 1.4 Gigabytes. Within about seven seconds, a compressed approximation of the pre-recorded video was received, decompressed, and displayed by the PDA on the PDA's screen. The entire video was seen at 240×320×12 bpp resolution in full motion without observable delays or defects.
Example 2
A “Jornada™” model 548 hand-held PDA (commercially available from HP, Inc. for approximately $300 at the time of this disclosure) was provided. The PDA was interfaced with a 9.6 Kbps (max) wireless CDMA phone (“Motorola i85s” wireless external digital cellular phone, commercially available from Motorola authorized vendors for approximately $200 at the time of this writing) using adaptor cables (Motorola and HP RS-232 standard interface cables from Motorola and HP.) that couple the phone and PDA together to form a wireless modem. The Jornada model PDA device used is generally characterized as having the following processing parameters: 133 MHz processor; 32 Mb memory; 12 b/pixel color; 240X320 screen dimensions; PocketPC™ operating system version 3.0 from Microsoft Corp. and stereo sound. The Jornada™ was connected to the Internet in Newark, N.J. via the interfaced CDMA phone/modem over the Nextel digital cellular wireless carrier system at a connection bandwidth of 8 Kbit/sec. A server-located in San Jose, Calif. (approximately 2900 mi away) was contacted by the PDA employing the http and WDP protocols, and the PDA was used to initiate a request for a pre-recorded video having the following originating properties: 720 lines of resolution and 32 bits of color information, the originating file size was 1.4 Gigabytes. Within about seven seconds, a compressed approximation of the pre-recorded video was received, decompressed, and displayed by the PDA on the PDA's screen. The entire video was seen at 176×120×8 bpp in full motion without observable delays or defects.
Example 3
A “Set-top Box” model st850 book PC (commercially available from MSI, Inc. for approximately $300 at the time of this writing) was provided. The Set-top Box was interfaced with a 10 Mbps (max) ethernet/802.11 connection using CATS ethernet cables (Generic) that couple the Set-top Box to a broadband connection (DS3). The Set-top Box used is generally characterized as having the following processing parameters: 400 MHz processor; 64 Mb memory; 32 b/pixel color; 720 lines of screen resolution; Windows CE operating system version 2.11 from Microsoft Corp. and AC3 digital 6 channel surround-sound. The Set-top Box was connected to the Internet in Newark, N.J. via the interfaced shared DS3 connection over the Alter.Net Internet Backbone at a connection bandwidth of 376 Kbit/sec. A server located in San Jose, Calif. (approximately 2900 mi away) was contacted by the Set-top Box employing the http and rtsp protocols, and the Set-top Box was used to initiate a request for a pre-recorded video having the following originating properties: 720 lines of resolution and 32 bits of color information, the originating file size was 1.4 Gigabytes. Within
About nine seconds, a compressed approximation of the pre-recorded video was received, decompressed, and displayed by the Set-top Box on a commercially available reference monitor's (Sony) screen. The entire video was seen at 720 lines×32 bpp in full motion without observable delays or defects.
While various particular embodiments have been herein shown and described in great detail for the purpose of describing the invention, it is to be appreciated that further modifications and improvements may be made by one of ordinary skill based upon this disclosure without departing from the intended scope of the invention. For example, various possible combinations of the various embodiments that have not been specifically described may be made and still fall within the intended scope of the invention. According to another example, obvious improvements or modifications may also be made to the various embodiments and still fall within the intended scope of this invention.
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A system for encoding a video signal includes an input module to receive a media signal to be communicated to a destination device, the media signal being divided into a plurality of segments each comprising one or more temporally adjacent frames. The system also includes an a encoding module configured, for each of the plurality of segments, to test a plurality of different CODECs on a segment by encoding the segment using a plurality of CODECs to produce a respective plurality of encoded segments, the selection module being further configured to select the encoded segment having the highest image quality while satisfying at least one additional constraint. The system further includes an output module configured, for each of the plurality of segments, to deliver the selected segment to the destination device and report to the destination device which CODEC was used to encode the selected segment.
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FIELD OF THE INVENTION
[0001] The present invention is directed to an scanning probe microscopy device for mapping nanostructures on a sample surface of a sample, comprising a plurality probes for scanning the sample surface, and one or more motion actuators for enabling motion of the probes relative to the sample, wherein each of said plurality of probes comprises a probing tip mounted on a cantilever arranged for bringing the probing tip in contact with the sampling surface for enabling the scanning, the device further comprising a plurality of Z-position detectors for determining a position of each probing tip along a Z-direction when the probing tip is in contact with the sample surface, wherein the Z-direction is a direction transverse to the sample surface, for enabling mapping of the nanostructures.
BACKGROUND
[0002] Scanning probe microscopy (SPM) devices, such as atomic force microscopy (AFM) devices as described above are for example applied in the semiconductor industry for scanning of semiconductor topologies on a surface. Other uses of this technology are found in biomedical industry, nanotechnology, and scientific applications. In particular, AFM may be used for critical defect metrology (CD-metrology), particle scanning, stress- and roughness measurements. AFM microscopy allows visualization of surfaces at very high accuracy, enabling visualization of surface elements at sub-nanometer resolution.
[0003] The very high resolution and accuracy of this technology however comes at the cost of performance in terms of throughput. Atomic force microscopy is performed by tracing of a sample surface in a scanning motion using a probe tip touching or tapping (i.e. repeatedly touching) the surface, while accurately measuring disposition of the probe tip in a direction transverse to the sample surface (z-direction) using for example a high precision optical sensing system, e.g. using beam deflection or an interferometer. Scanning is performed by vibrating the tip in the z-direction, while performing the scanning motion across the surface to be mapped. To accurately map a given section of a sample surface, e.g. a structure on a wafer surface, the probe tip requires to be scanned such that every fraction of the section with sub-nanometer dimensions is touched or tapped by the probe tip at least once. As will be appreciated, this process may be rather slow.
[0004] Further development of the SPM technology has provided AFM systems comprising a probe head upon which a plurality of probes are mounted side by side. Each probe comprises a cantilever and a probe tip, and each probe tips position in z-direction is measureable independently. This allows for scanning of a plurality of ‘scanning lanes’ at one pass of the scanning head, and as will be appreciated, the speed at which a single section may be scanned is multiplied by the number of probe tips present on the head.
[0005] Even though the above has lead to an improvement in throughput, the scanning of multiple sites on a sample surface still takes a considerable amount of time. For this and other reasons, application of this technique in industrial environments, for example for the testing of wafers in semiconductor industry, is far from ideal.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to alleviate the abovementioned problems of the prior art, and to provide a scanning probe microscopy device that allows for high speed high throughput scanning of multiple sites on a sampling surface.
[0007] The above mentioned and other objects of the invention are achieved in that there is provided an scanning microscopy device for mapping nanostructures on a sample surface of a sample, comprising a plurality probes for scanning the sample surface, and one or more motion actuators for enabling motion of the probes relative to the sample, wherein each of said plurality of probes comprises a probing tip mounted on a cantilever arranged for bringing the probing tip in contact with the sampling surface for enabling the scanning, the device further comprising a plurality of Z-position detectors for determining a position of each probing tip along a Z-direction when the probing tip is in contact with the sample surface, wherein the Z-direction is a direction transverse to the sample surface, for enabling mapping of the nanostructures; wherein the plurality of probes are mounted on a plurality of heads, each head comprising one or more of said plurality of probes; wherein each of said heads is mounted on a support base associated with said head, each support base being arranged for individually moving its associated head relative to the sample; and wherein, for enabling said individual motion of the associated head, each support base comprises a plane actuator unit comprising at least one of said motion actuators for moving the head associated with the support base relative to the sample in at least one direction parallel to the sample surface, wherein the plane actuator unit is located at a first mounting position along said support base, said first mounting position being remote from a second mounting position, wherein the head associated with the support base is mounted on the second mounting position on the support base.
[0008] The scanning probe microscopy device of the present invention may for example be an atomic force microscopy (AFM) device. Although in the present document reference will be made to particularly the embodiment of an atomic force microscopy device, the teachings of this document are not restricted to such an application, and may be applied to similar devices in the field of: BEEM, ballistic electron emission microscopy; CFM, chemical force microscopy; C-AFM, conductive atomic force microscopy; ECSTM electrochemical scanning tunneling microscope; EFM, electrostatic force microscopy; FluidFM, fluidic force microscope; FMM, force modulation microscopy; FOSPM, feature-oriented scanning probe microscopy; KPFM, kelvin probe force microscopy; MFM, magnetic force microscopy; MRFM, magnetic resonance force microscopy; NSOM, near-field scanning optical microscopy (or SNOM, scanning near-field optical microscopy); PFM, Piezoresponse Force Microscopy; PSTM, photon scanning tunneling microscopy; PTMS, photothermal microspectroscopy/microscopy; SCM, scanning capacitance microscopy; SECM, scanning electrochemical microscopy; SGM, scanning gate microscopy.
[0009] In accordance with most embodiments, the support bases comprising the probe heads will be embodied as support arms. With respect to such embodiments, the term ‘support base’ used in this document is to be interpreted as ‘support arm’. As will be appreciated, the concept of the invention may be implemented using different type of support bases.
[0010] A scanning probe microscopy device, such as an atomic force microscopy device, uses actuators for enabling motion of it's probing tips in three orthogonal directions relative the sampling surface. As already indicated, the tip must be movable in the z-direction which is usually implemented by applying a vibration to the probe tip in this direction. For scanning the surface, the probe tip is to be moved in two orthogonal directions parallel to the sampling surface.
[0011] In accordance with the inventive principle, the actuators for moving a head comprising the at least one probe tip parallel to the sampling surface, are located remotely from the mounting position of the head on the support base or support arm. The plane actuator unit for moving the head in-plane with respect to the sampling surface is placed at a distance away from the head, where there is more room available for accommodating the actuators. This released constraints on the head, and enables to provide the head being much smaller. As a result, the inventive atomic force microscopy device can be equipped with multiple support bases or arms, each base carrying a head, and each head comprising one or more probes with probing tips. Each arm comprises its own plane actuator unit, allowing individual motion of each support base, independently from other bases.
[0012] As a result, the atomic force microscopy device of the invention allows for the simultaneous scanning of multiple remote sites on a single sampling surface, where each site may be scanned at the typical scanning speeds of a conventional microscope. The throughput is therefore multiplied by the number of support bases or support arms applied, which reduces the processing time considerably. For example, suppose that a convention AFM method requires 40 seconds for scanning a single site of 10 μm*10 μm. A wafer comprising 50 sites to be tested will take more than half an hour when it is tested using the conventional AFM method. Suppose the inventive AFM method is applied in an AFM device with 50 individually movable and controllable support bases or arms, this wafer may be tested in only 40 seconds. As will be appreciated, the amount of support bases or arms provided is only limited by the design of the device, and is not restricted to the specific example of 50 bases or arms. A device with 30 bases or arms would require 80 seconds for scanning all sites: the first 30 sites in the first pass, and the remaining 20 sites in a second pass.
[0013] In a specific embodiment, the first mounting position is located near a first end of the support arm, and wherein the second mounting position is located near a second end of the support arm. In this embodiment, the actuators may be placed aligned with the axial direction through the support arm, in the extended direction thereof. Most flexibility in the design is achieved in this manner, and it further allows more support arms to be placed adjacent each other (due to absence of actuators and control parts to the side of the support arms), thereby increasing throughput.
[0014] Although in principle, any two orthogonal directions according to any coordinate system may be used, in accordance with an embodiment of the invention, for one or more of said support bases or arms, the plane actuator unit of each of said one or more support arms comprises at least one of an X-direction motion actuator and a Y-direction motion actuator. Here the X- and Y-direction may be perpendicular directions parallel to the sampling surface corresponding to a Cartesian coordinate system.
[0015] In a particular embodiment, the X-direction actuator comprises a linear shift actuator for moving the second end along the X-direction. In another particular embodiment, the Y-direction actuator comprises a rotational actuator for pivoting the support base or arm such as to move the second end in the Y-direction. With respect to this latter embodiment, it is to be said that the pivoting action of the support bases or arms for providing the Y-directional motion avoids conflicts between support arms obstructing each other during scanning.
[0016] According to a particular embodiment, the rotational actuator comprises a hinge element for rotating the support arm in a plane parallel to the sample surface in use, said hinge element cooperating with a further linear shift actuator for providing the rotating action of the support arm. This allows for a very precise positioning of the probe tip relative to the sampling surface in the Y-direction. Moreover, to even increase precision, in accordance with a further embodiment, the hinge element comprises at least one element of a group comprising a cross hinge, a Haberland hinge, or a hinge comprising one or more leaf springs. Furthermore, again for allowing high precision positioning of the probe tip, in some embodiments the further linear shift actuator cooperating with the hinge element is arranged for acting on said support arm in a direction parallel to an axial direction through the arm and in an off-axis position thereof such as to enable pivoting of the arm by means of the hinge element.
[0017] In an atomic force microscopy device in accordance with embodiments of the invention, each support base or arm may further comprises a Z-direction actuator for moving the probing tip in the Z-direction. The Z-direction actuator may comprise a Z-positioning actuator for bringing the probing tip to and from the sample surface, and/or a Z-vibration actuator for vibrating the probing tip in the Z-direction adjacent the sampling surface for enabling said scanning of said sample surface. According to some embodiments, the Z-direction actuator is located at the second mounting position of the support base or arm, mounted on or near the head. Mounting the Z-direction actuator on the head allows for the very precise and accurate stroke required in this direction.
[0018] Embodiments of the atomic force microscopy device in accordance with the invention may further comprise a motion control locator unit arranged for determining in use a current position of each of the heads relative to the sample surface in at least a direction parallel to the sample surface. As will be appreciated, the motion control locator allows for controlling motion of the support bases or arms by providing precise information on the location of each head and associated arm. This may be implemented in that the motion control locator unit comprises a grid formed by an arrangement of optical references, and wherein each head comprises an optical sensor for detecting the optical references, wherein said grid is arranged substantially parallel to the sample surface at an opposite position of the support bases or arms relative to the sample surface, such that the support bases or arms are in between the sensor grid and the sample surface in use. The references may comprise optically contrasting regions, e.g. reflective regions and absorptive regions. In conventional AFM methods, the location of the head (i.e. X-Y-position) is measured from the side of the sampling surface with optical sensors. In the present invention, an optical path from the side to some of the heads may become obstructed by other arms and heads. Therefore, a new type of locator unit has been developed for use in some embodiments of the invention where the above problem of obstructed view may play part. The location is measured using a grid at an opposite side of the arm and head with respect to the sampling surface in use.
[0019] As will be appreciated, an atomic force microscopy device in accordance with the invention, may further comprise a sample carrier arranged for receiving said sample in use, such as a wafer. Moreover, in accordance with some particular embodiments, relative to a gravitational direction, the heads are located above the optical reference grid, and the sample carrier is located above the heads, wherein the sample carrier is arranged for exposing the sample surface at a side facing the heads. This is a very convenient arrangement of functional layers in the device, as having the sample carrier on top allows for easy access to the sample carrier such as to replace the sample efficiently. At the same time, having the optical reference grid directly underneath the arms, opposite to the sample surface allows for accurate determination of the location of the heads and the probe tips at close distance. As a further improvement, the support base associated with each head can be locked with high stiffness to the grid, thus providing a stable reference for the topography measurement. The term actuator used throughout this document may include any high precision actuator available and known to the skilled person, including piezo-electric actuators, stepper motors, and the like.
[0020] According to a further embodiment, the plane actuation unit associated with each support base is mounted directly on the support base, providing actuation forces between the support base and a support structure below the support base. As will be appreciated, the above is a mechanical reversion of the earlier embodiments, falling within the scope of the claims.
[0021] In accordance with another embodiment, the plurality of heads are mounted on a plurality of support bases, the support bases being arranged in a circular arrangement around a circumference of an area for receiving the sample for extending the support bases over or under the sample in use for enabling scanning of said surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will further be elucidated by description of some specific embodiments thereof, making reference to the attached drawings. The detailed description provides examples of possible implementations of the invention, but is not to be regarded as describing the only embodiments falling under the scope. The scope of the invention is defined in the claims, and the description is to be regarded as illustrative without being restrictive on the invention. In the drawings:
[0023] FIG. 1 schematically illustrates the working principle of a typical prior art atomic force microscope;
[0024] FIG. 2 schematically illustrates the working principle of an atomic force microscope in accordance with the present invention;
[0025] FIGS. 3A and 3B schematically illustrate an atomic force microscopy device in accordance with the present invention;
[0026] FIGS. 4A and 4B schematically illustrate a support arm of an atomic force microscope in accordance with the invention;
[0027] FIGS. 5A and 5B schematically illustrate an enlarged view of a probe head in an atomic force microscope in accordance with the present invention;
[0028] FIGS. 6A and 6B schematically illustrate a further embodiment comprising a circular placement of arms in an atomic force microscopy device in accordance with the present invention.
DETAILED DESCRIPTION
[0029] The scanning probe microscopy device of the present invention may for example be an atomic force microscopy (AFM) device. Although in the description below reference will be made to particularly the embodiment of an atomic force microscopy device, the teachings of this document are not restricted to such an application. As will be appreciated the teachings of the invention may be applied to any microscopy device that is based on the principles of scanning a surface region using a probe. Particular fields of applications have been mentioned earlier in this document.
[0030] FIG. 1 schematically illustrates the working principle of a typical prior art atomic force microscope. In FIG. 1 , a probe head 2 comprises piezo type drivers 3 for the X-, Y-, and Z-directional motion of a probe 8 . The probe 8 consists of a cantilever 9 having a probe tip 10 arranged for scanning a sample surface 5 . During scanning, a dither piezo (not shown) may drive the cantilever in vibrational mode, for example close to resonant frequency, to enable tapping of the probe tip on the surface. The manner of applying a vibrational motion to the probe tip is known to the skilled person.
[0031] Scanning of the sample surface 5 is performed by moving the probe tip 10 in the X- and Y direction parallel to the sample surface 5 (or alternatively, by moving the substrate surface while maintaining the position of the probe tip fixed in the X- and Y-directions). The probe tip 10 is brought in close proximity to the surface 5 by means of a z-directional piezo driver. Once in the position, the probe tip 10 is vibrated in the z-direction such that it repeatedly touches the surface 5 during scanning thereof. At the same time, a laser 16 illuminates the probe tip with laser beam 15 . The precise position in the z-direction is determined using photo diodes 18 which receive the reflected laser beam 15 .
[0032] The sample surface 5 is carried using a sample carrier 4 . Driving of the piezo drivers 3 located on the probe head 2 is performed using the detector and feedback electronics 20 . At the same time, the detector and feedback electronics 20 receive the detected z position as determined using photo diodes 18 . This principle allows for very precise mapping of surface elements, such as surface element 13 on the sample surface. As described herein above, since the mapping of the surface has to be performed with great precision, the speed at which the method is performed is rather slow.
[0033] FIG. 2 schematically illustrates an atomic force microscope device according to the present invention. FIG. 2 in particular illustrates the working principle of the AFM microscope of the present invention. In particular, AFM microscope of the present invention comprises a plurality of support arms 23 , each of the support arms 23 carrying a probe head 25 . The support arms 23 can be moved individually and independently from each other such that a plurality of sites 27 on the surface of the wafer 20 can be scanned by the plurality of arms 23 simultaneously. Although the AFM microscope illustrated in FIG. 2 only comprises 10 arms, it may be appreciated that the number of arms is only limited by the design of the AFM microscope. The microscope may easily comprise 20, 30, 40, 50, 60, 70 or more arms dependent on the size of the apparatus and the specific implementation of the principles of the present invention in the AFM microscope according to the embodiments.
[0034] FIG. 3 a is a schematic illustration of an atomic force microscope device in cross section is provided according to an embodiment of the present invention. In FIG. 3 a only two of the fifty arms in this embodiment are illustrated. In FIG. 3 a , a fixed frame 33 comprises a sample carrier 35 from which there is suspended a wafer 36 forming the sample surface to be scanned using the AFM microscope of the present invention. The elements 37 on either side of the sample carrier 35 provide for calibration of the arrangement, and for replacement of probe tips mounted on the respective probe heads 43 and 53 during the process. The AFM microscope 30 illustrated in FIG. 3 a comprises two support arms 41 and 51 . Each support arm ( 41 , 51 ) is mounted on a linear shift actuator 39 and 50 respectively arranged for moving the arms 41 and 51 in the x-direction relative to the sampling surface on wafer 36 . The x direction is indicated by arrow 31 . The z direction is indicated by arrow 32 in FIG. 3 a . Schematically illustrated in FIG. 3 a are the probes 45 and 55 comprising the probe tips for scanning the surface of the wafer 36 . Also schematically illustrated in FIG. 3 a is vision element 58 comprising an imaging unit 57 for visual inspection of the wafer 36 by an operator.
[0035] FIG. 3 b illustrates schematically a top view of the optical reference grid 48 including part of the support arms (e.g. arm 41 ). Visible in FIG. 3 b are the imaging unit 57 placed on the vision element 58 . As illustrated a linear shift actuator 59 allows for moving the imaging unit 57 around underneath the wafer 36 .
[0036] FIG. 4 a is s schematic illustration of a support arm 70 carrying a probe head 67 in an atomic force microscope device according to the present invention. The support arm 70 is moved in the x direction 74 by means of linear shift actuator 60 . The linear shift actuator 60 consists of two glider rails 63 and a moving element 64 that can be moved in the direction of the glider rails 63 .
[0037] In addition thereto, the support arm 70 is further connected to a further linear shift actuator 65 which is moved back and forth by means of element 68 . The further linear shift actuator 65 cooperates with hinge element 66 such as to provide a rotational motion schematically indicated by arrows 67 a and 67 b in FIG. 4 a . This enables to move probe head 69 of the support arm 70 in the y direction 73 such as to reach any site on the sample surface (not shown in FIG. 4 a ).
[0038] The hinge element 66 may be an elastic hinge, such as a cross hinge or a Haberland hinge. The specific position of the probe head 69 (in particular the probe tip (not shown)) can be monitored using the optical reference grid 72 underneath the probe head 69 . A side view of the schematic illustration of FIG. 4 a is provided in FIG. 4 b . This illustrates the rails 63 upon which the linear shift actuator 64 moves the support arm 70 back and forth in the x-direction. On the head 69 , the z-direction actuator 78 is present. The z direction actuator 68 is operated for moving the probe tip 76 on the cantilever 75 of the probe upward and downward in the z direction such as to move it to and from the sample surface. The actuator 78 is further arranged for applying a vibration to the probe tip 76 in the z direction during scanning of the sample surface. This enables mapping of the sample surface in great detail.
[0039] FIG. 5 a illustrates schematically an enlarged view of the head 69 on the end of the support arms 70 in an atomic force microscope device according to the present invention. The head 69 comprises the z-direction actuator 78 . On the z-direction actuator 78 , a carrier construction 79 comprises a further piezo element 83 for vibrating the cantilever 75 and the probe tip 76 . Also illustrated is the laser 15 used for accurately monitoring the z-position of the probe tip 76 upon touching the surface of the sample.
[0040] Underneath the head 69 two encoder heads 80 and 81 cooperate with the optical reference grid 72 for accurately determining the position of the probe head 69 . The probe head 69 rests on the optical reference grid plane 72 by means of an air bearing, i.e. by blowing air through small pinholes in the surface 72 . FIG. 5 b illustrates the foot print of probe head 69 on the surface 72 . In FIG. 5 b , encoder heads 80 and 81 and the z-direction actuator can be seen. In the invention, the support bases and other components are located in a general fixed frame with sufficient mechanical and thermal stiffness.
[0041] FIGS. 6A and 6B schematically illustrate a further embodiment comprising a circular placement of arms in an atomic force microscopy device in accordance with the present invention. In FIG. 6A , a wafer 20 ′ is being examined using an atomic force microscope (AFM) in accordance with an embodiment of the invention. The AFM device comprises a plurality of arms 23 ′ that are placed in a circular arrangement around the circumference of the wafer 20 ′. Although schematically, FIG. 6A only depicts a total six arms 23 ′ part of the arms are omitted in the drawing in order not to obscure the comprehensibility of FIG. 6A . In practice, any number of arms 23 ′ may be placed around the wafer 20 ′, not only in a part of the circumference but across its full circumference.
[0042] The radial arrangement of the arms 23 ′ and the heads 25 ′ attached thereto, allows for a large number of arms to be placed around the wafer (more than 50 heads if desired). Since the throughput of the AFM microscope multiplies with the number of heads (scanning with two heads is twice as fast as compared to scanning with one head), the system in accordance with this embodiment has a very large throughput for scanning wafers. Such a system may therefore be advantageously applied in an industrial environment (although it is not limited thereto). Moreover, the circular arrangement automatically provides sufficient space at the back end of the arm (outside the scanning area) where the actuator are placed.
[0043] FIG. 6B schematically illustrates how the arms are operated for enabling most efficient scanning of the whole surface without clashing of the arms in the second embodiment. The arrow 90 points from the edge of the wafer towards the center. In this direction the radius decreases, and therefore the chance of clashing usually increases. At the same time however, surface area to be scanned decreases and therewith the number of areas to be scanned also decrease. The arms are extended in a staggered manner. Arms 23 ′- 2 and 23 ′- 4 have their heads 25 ′- 2 and 25 ′- 4 scanning in the peripheral area of the wafer. In an area more closer to the center, arms 23 ′- 1 and 23 ′- 5 with respective heads 25 ′- 1 and 25 ′- 5 are actively scanning the surface. In the area most close to the center and in the center itself, head 25 ′- 3 of arm 23 ′- 3 is active.
[0044] The present invention has been described in terms of some specific embodiments thereof. It will be appreciated that the embodiments shown in the drawings and described here and above are intended for illustrative purposes only, and are not by any manner or means intended to be restrictive on the invention. The context of the invention discussed here is merely restricted by the scope of the appended claims.
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A scanning probe microscopy device for mapping nanostructures on a sample surface of a sample is provided. The device may comprise a plurality probes for scanning the sample surface, and one or more motion actuators for enabling motion of the probes relative to the sample, wherein each of the plurality of probes comprises a probing tip mounted on a cantilever arranged for bringing the probing tip in contact with the sampling surface for enabling the scanning. The device may further comprise a plurality of Z-position detectors for determining a position of each probing tip along a Z-direction when the probing tip is in contact with the sample surface, wherein the Z-direction is a direction transverse to the sample surface, for enabling mapping of the nanostructures.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application is a division of co-pending application Ser. No. 08/852,314, filed May 7, 1997, and titled CABINET AND SLIDING DRAWER HAVING SIMPLIFIED FEATURES.
This application is a division of application Ser. No. 08,852,314, filed May 7, 1997, pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cabinets generally and, more particularly, but not by way of limitation, to novel cabinet and sliding drawer with improved roller construction, improved manufacturability, and a drawer that remains essentially horizontal when fully extended from the cabinet.
2. Background Art
Cabinets with one or more drawers are universally used for the storage and ready accessibility of a wide variety of materials, small parts and business papers being common examples of such materials.
Some such cabinets and drawers are constructed with telescoping two- or three-piece drawer slides, with one of the slides being attached to the drawer and another of the slides being attached to the inside of the cabinet, such a drawer slide assembly being employed on either side of the drawer. In may cases, the slides have one or more wheels, or rollers, disposed between adjacent ones of the slides, the roller(s) being mounted inside the smaller of the slides. This greatly reduces the sliding friction between the slides, but the diameter of the roller is necessarily limited and, therefore, the reduction in sliding friction is limited to the capabilities of a roller having a given diameter. The width of the slides in which the rollers are mounted is somewhat narrow, leading to instability and the tendency for the roller and its corresponding slide to become disengaged.
Cabinet drawer slides are typically horizontally attached to the drawer and to the inside of the cabinet. This arrangement results in the outer end of the drawer dropping somewhat downwardly when the drawer is fully or nearly fully withdrawn from the cabinet, due to the weight of the drawer and because the slides have a certain amount of "play" therebetween as a result of wear or intentional design clearances, the latter being required so that the slides move freely.
Cabinets are typically constructed of metal, with an outer housing having side, rear, top, and bottom walls formed or permanently attached together, sometimes with front rails or a front wall extending between the side walls, separate members being welded together. Slides are usually spot welded to the inside surfaces of the side walls. If an error or defect in one of the members is discovered during manufacture or at final inspection, the entire work to that point must usually be discarded.
INVENTION TO PROVIDE
An improved cabinet and drawer slide construction that reduces the amount of material that must be discarded due to defects.
It is another object of the invention to provide an improved cabinet in which the foregoing features are economically manufactured.
Other objects of the present invention, as well as particular features, elements, and advantages thereof, will be elucidated in, or be apparent from, the following description and the accompanying drawing figures.
SUMMARY OF THE INVENTION
The present invention achieves the above objects, among others, by providing, in one preferred embodiment, a cabinet comprising: a generally hollow, rectilinear housing having opposite sides and top, back, and bottom walls; said side panels having rearwardly facing U-shaped channels formed along front edges thereof; inner side panels attachable to said side panels by insertion of front edges thereof into said U-shaped channels and rotating said inner panels about said U-shaped channels to parallel proximity with inner surfaces of said side panels and being removably secured in such position.
BRIEF DESCRIPTION OF THE DRAWING
Understanding of the present invention and the various aspects thereof will be facilitated by reference to the accompanying drawing figures, submitted for purposes of illustration only and not intended to define the scope of the invention, on which:
FIG. 1 is a fragmentary, side elevational view, partially cutaway, of one embodiment of a cabinet with sliding drawer, constructed according to the present invention.
FIG. 2 is a fragmentary, front elevational view of the embodiment of FIG. 1.
FIG. 3 is a fragmentary, side elevational view, partially cutaway, of another embodiment of a cabinet and sliding drawer, constructed according to the present invention.
FIG. 4 is a cutaway, side elevational view of a cabinet with sliding drawers showing another aspect of the present invention.
FIG. 5 is a side elevational view, in cross-section, of an external wrap for a cabinet, constructed according to one aspect of the present invention.
FIG. 6 is a fragmentary, top plan view showing a step in the manufacture of the cabinet.
FIG. 7 is a front elevational view showing a partially completed cabinet.
FIG. 8 is a cutaway side elevational view of the completed cabinet.
FIG. 9 is a side elevational, cross-sectional view of a partially completed cabinet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference should now be made to the drawing figures, on which similar or identical elements are given consistent identifying numerals throughout the various figures thereof, and on which parenthetical references to figure numbers direct the reader to the view(s) on which the element(s) being described is (are) best seen, although the element(s) may be seen also on other views.
FIG. 1 illustrates one embodiment of a cabinet and sliding drawer constructed according to the present invention, the cabinet being generally indicated by the reference numeral 20 and the drawer being generally indicated by the reference numeral 22. As shown, drawer 22 includes a compartment parts box 30 mounted covered with a hinged lid 32 for access to the interior of the box. Box 30 is attached to front and rear cradle members 34 and 36, respectively, by means of tabs, as at 38, the front and rear cradles being connected by a centrally disposed crossmember 40 extending therebetween and attached thereto. Cabinet 20 and drawer 22 are arranged so that box 30 may be fully withdrawn from the cabinet. It will be understood that the above is only one of a number of conventional cabinet/drawer arrangements with which the present invention may be employed.
Attached to the inner surface of cabinet 20 is a horizontal outer slide member 50 and attached to the one side of drawer 22 is an inner slide member 52. As with conventional drawer slides, inner slide 52 telescopingly engages the interior of outer slide 50. Accidental complete withdrawal of drawer 22 from cabinet 20 is prevented by the engagement of a loop 54 formed on inner slide 52 engaging a stop 56 attached to outer slide 50.
In the case of the present invention, there is no roller disposed between outer and inner slides 50 and 52. Rather, the present invention provides a roller 60 engaging inner slide 52, but having its axis disposed externally to outer slide 50. Roller 60 has its axle 62 attached to the inner surface of cabinet 20 and contacts the lower edge of inner slide 52 through an opening 64 defined through the lower edge of outer slide 50. FIG. 2 more clearly illustrates aspects of this arrangement. A ball bearing (not shown) may be disposed between roller 60 and axle 62.
FIG. 3 illustrates the elements of FIGS. 1 and 2 with the addition of a second roller 70, having its axle 72 disposed externally to outer slide 50, and contacting the upper edge of inner slide 52 through an opening 74 defined through the outer slide. Such an arrangement is particularly useful when the drawer is to contain heavy materials and, especially, when it is to be fully withdrawn as is shown on FIGS. 1 and 3. When used with two or more drawers, roller 70 can be offset rearwardly from roller 60 (as shown) to nest behind the equivalent of roller 60 (not shown) contacting an inner slide (not shown) above roller 70, in space not otherwise used.
The use of external rollers 60 (FIGS. 1 and 2) or rollers 60 and 70 (FIG. 3) offers several advantages over conventionally constructed cabinet/drawer arrangements. One of these is that wider rollers may be employed. In the typical construction, tabs 38 protrude into inner slide 52, limiting the width of a roller disposed within the inner slide. Use of external rollers 60 or 60 and 70 permits use of rollers of much larger diameters than internally disposed rollers. This permits a significantly higher O.D./I.D. ratio with inherently reduced friction. With the use of an external roller 60 or rollers 60 and 70, the rollers can be made wider, thus providing more stability while decreasing the I.D. requirement for a given load and enhancing the above ratio and reducing friction.
FIG. 4 illustrates a cabinet with sliding drawers, generally indicated by the reference numeral 80, and constructed according to another aspect of the present invention.
Cabinet 80 is shown as having a plurality of drawers, as at 82, which are similar to drawer 22 (FIGS. 1-3), although it will be understood that this aspect of the invention is not so limited and the invention may be used, as well, with other types of drawers and any number of drawers, including a single drawer. Cabinet 80 is also shown as employing external rollers, as at 84, although it will be understood that the invention may be used, as well, in cabinets using no rollers or cabinets with conventional rollers disposed internally of slides.
Cabinet 80 includes a plurality of outer and inner slides 90 and 92, respectively, having the same form and function of outer and inner slides 20 and 22 (FIGS. 1-3). Again, the present invention is not limited to the types of slides shown. As can be observed from FIG. 4, slides 90 and 92 are canted such that they slope downwardly inwardly from the front of cabinet 80. The angle of cant is chosen such that, when drawer 82 is withdrawn fully or nearly fully from cabinet 80, the drawer will be essentially horizontal, the angle of cant compensating for any wear or intentional design clearances.
In the present case, the fronts of boxes 94 remain orthogonal to the major axes of the boxes, the lips 96 of the lids 98 of the boxes offsetting the canted fronts appearancewise. With drawers having greater height and/or with a cabinet with a front panel, it may be desirable to mount the fronts of the drawers at an angle so they lie in the same plane as the front of the cabinet.
FIGS. 5-9 illustrate an aspect of the present invention whereby construction of a cabinet with sliding drawers is easily performed, while minimizing the amount of defective materials that must be discarded.
FIG. 5 illustrates an external wrap for a cabinet constructed according to the present invention, the wrap being generally indicated by the reference numeral 110. Wrap 110 includes a back panel 120 which will become the back panel of the cabinet and top and bottom panels 122 and 124 which will become, respectively, the top and bottom panels of the cabinet. The front edges of top and bottom panels 122 and 124 have rearwardly open U-shaped channels 126 and 128, respectively, formed therealong. It should be noted that wrap 110 is symmetrical about its central axis such that bottom panel 124 can serve as the top panel of the cabinet. This feature is advantageous when, for example, panel 122 is found to contain a visual defect that would preclude its use as a top panel for the cabinet. Wrap 110 can then be inverted 180 degrees, thus avoiding discarding the wrap. FIG. 5 also shows inwardly bent tabs 130 formed in back panel.
FIG. 6 illustrates back panel 120 with a right side panel 140 spot welded to the right edge of the back panel. It will be understood that there is a left side panel (not shown on FIG. 6), which is a mirror image of right side panel 140, and which is similarly attached to the left edge of the back panel. Right side panel 140 includes a rearwardly facing U-shaped channel 142 formed along the front edge thereof.
An inner panel 144 has an outer slide 146 attached thereto and has a sidewardly offset lip 148 formed along the front edge of the panel. To attach inner panel 144 to right side panel 140, lip 148 is inserted in channel 142, as indicated by the broken arrow on FIG. 6. Then, inner panel 144 is rotated about lip 148, as indicated by the solid arrow on FIG. 6 and until the rear edge (not shown) of the inner panel snaps behind the ends of tabs 130. Inner panel 144 can be easily removed by depressing tabs 130 and swinging the inner panel away from right side panel 140.
FIG. 7 illustrates wrap 110 with right side panel 140 attached thereto and inner panel 144 attached to the right side panel. Also shown is a left side panel 150 attached to wrap 110 in the same manner as right side panel 140 and an inner panel 152 attached to the left side panel. The front edge of inner panel 152 is attached to left side panel 150 in the same manner as inner panel 144 is attached to right side panel 140; however, the rear of inner panel 152 is removably attached to wrap 110 by means of tabs 154 formed on inner panel 152 snapping behind tabs 156 formed on the wrap. It will be understood that to maintain wrap 100 in a symmetrical shape, only one type of attachment means will be used on both sides of the wrap. No slides are shown; however, the usual method of construction is to attach slides to inner panels before attachment of inner panels to cabinet sides.
FIG. 8 illustrates that inner panels 144 and 152 are symmetrical and identical. It will be understood that, although drawers and rollers are shown which are identical to those described above, this aspect of the invention is applicable to cabinets with any type of drawers and with or without rollers. Registration holes, as at 160 are defined through the front and rear ends of the slides and through inner panel 152 to properly align the slides on the panel with a suitable fixture (not shown). When inner panel 152 is used as inner panel 144 (FIG. 6 and 7), the same registration holes 160 will be used for the same purpose; however, when rollers are used, a second set of holes, at 162, are provided in the panel for the axles of the rollers so that the panel can be used on either side of the cabinet. Outer and inner slides 164 and 166 are also symmetrical about their major axes, so that they may be used on either right or left inner side panels.
FIG. 9 illustrates that symmetry can be provided even when inner panels are to be used with canted slides (FIG. 4). Here, a left side inner panel 170 has attached thereto a canted outer slide 172. Inner panel 170 is provided with registration holes 174 defined therethrough for locating the front ends of outer slides 172 regardless of whether the inner panel is used on the left or the right side of a cabinet. If rollers are to be used, axle holes 176 are provided for use when panel 170 is used on the left side of a cabinet and axle holes 178 are provided for use when the panel is used on the right side of a cabinet. In a similar manner, registration holes are provided for the rear end of outer slides 172 so that panel 170 can be used on either the left or the right side of a cabinet, with registration holes 180 for left side use and registration holes 182 for right side use.
In conventional cabinet construction, final painting is done after assembly. This means that sliding surfaces are painted also; however, this increases friction between the surfaces. The present invention permits the slides and inner panels to be "finished" with zinc primer which provides greatly improved sliding friction.
The snap-in feature of the inner panels provides for more economical manufacturing and permits the inner panels to be easily removed for repair or replacement. Virtually all components are "mirrored" designs, such that right and left side components are the same parts used twice and the wrap can be used right side up or upside down. Repairs at the manufacturing, distributor, or consumer level can be made via panel or shell replacement, as required. Conventional cabinets cannot be repaired or, at least, not easily repaired in most cases, resulting in discarded completed or partially completed cabinets. The decision whether to use or not to use rollers in a particular cabinet can be made near the final step in manufacture or even easily changed in the event of a mistake, making overall production control a more efficient task.
It will thus be seen that the objects set forth above, among those elucidated in, or made apparent from, the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown on the accompanying drawing figures shall be interpreted as illustrative only and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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A cabinet, including: a generally hollow, rectilinear housing having opposite sides and top, back, and bottom walls; the side panels having rearwardly facing U-shaped channels formed along front edges thereof; and inner side panels attachable to the side panels by insertion of front edges thereof into the U-shaped channels and rotating the inner panels about the U-shaped channels to parallel proximity with inner surfaces of the side panels and being removably secured in such position.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a cotton module unwrapping method and apparatus.
[0003] The invention particularly relates, but is not limited to, a method of, and apparatus for, unwrapping round modules, or cylindrical rolls, of cotton wrapped in plastics-sheeting (e.g. polyethylene sheeting).
[0004] Throughout the specification, the term “cotton” shall be used to include other natural fibres (e.g. wool and flax) or fibrous materials (e.g. tobacco leaf).
[0005] 2. Prior Art
[0006] Conventionally, harvested cotton has been compressed into large rectangular modules for transport. These rectangular modules require large machines to form the rectangular modules in the field.
[0007] Due to the bulk and weight of the rectangular modules, large transport and handling systems are required to transport the rectangular modules to the cotton gin for processing of the cotton.
[0008] In recent years, there has been a transition to forming the harvested cotton in round modules (i.e. cylindrical rolls), which are wrapped in several layers of plastics-material (e.g. polyethylene) sheeting. Many cotton farmers are transitioning to round modules to reduce the amount of equipment and seasonal labour required to harvest the crop.
[0009] A major limitation with the plastics-sheeting wrapping is that the wrapping is easily damaged and can become a contaminant if introduced to the ginning process.
SUMMARY OF THE PRESENT INVENTION
[0010] It is an object of the invention to provide a method for releasing the cotton in a round module, or cylindrical roll, from the surrounding wrapping where the likelihood of the wrapping contaminating the cotton is overcome, or at least ameliorated.
[0011] It is a preferred object of the present invention to provide such a method where the release of the cotton in the round module from the wrapping is controlled and conducted in a safe manner.
[0012] It is a further preferred object to provide a method where the released wrapping is drawn, or otherwise moved, away from the released cotton.
[0013] It is a still further preferred object to provide an unwrapping machine for affecting the unwrapping method.
[0014] Other preferred objects will become apparent from the following description.
[0015] In one aspect, the present invention resides in a method of unwrapping a (preferably round) module of cotton (or other fibrous material) from a wrapping of at least one layer of (preferably plastics-) sheet material including the steps of:
[0016] a) raising the round module to a first (or elevated) position on a lift conveyor (or vertically-movable support surface);
[0017] b) advancing a plurality of gripper heads, mounted on a support frame, to an advanced position, into gripping engagement with the layer(s) of the sheet material wrapping;
[0018] c) lowering the lift conveyor (or vertically-movable support surface) from the first position towards a second (or lowered) position; and
[0019] d) retracting the plurality of gripper heads, to expand the wrapping to progressively release the cotton (or other fibrous material) from the lower portion to the upper portion of the round module.
[0020] Preferably, the method includes the further step of:
[0021] e) as, or after, the lower portion of the cotton is being released from the wrapping, the wrapping is engaged by a discharge apparatus on the support frame for delivery to a waste collection site.
[0022] Preferably, the wrapped round module is conveyed to a feed side of the lift conveyor with the central axis of the round module arranged substantially vertically, when the lift conveyor is in the second position.
[0023] Preferably, the released cotton falls into a heap or pile on the lift conveyor, and is discharged from a discharge side of the lift conveyor when the lift conveyor has returned to the second position (and is capable of receiving the next round module to be unwrapped).
[0024] In a second aspect, the present invention resides in an unwrapping machine for unwrapping at least one layer of (preferably plastics-) sheet material wrapping from a (preferably round) module of cotton (or other fibrous material), the machine including:
[0025] a support frame;
[0026] a lift conveyor (or vertically-movable support surface), within the support frame;
[0027] a lifting mechanism to selectively move the lift conveyor from a first (or raised) position to a second (or lowered) position;
[0028] a plurality of gripper heads, the gripper heads being mounted on movable support mechanisms; and
[0029] the support mechanisms are mounted on the support frame and are operable to selectively advance the gripper heads into engagement with the layer(s) of the sheet material wrapping; so arranged that:
[0030] as the lifting mechanism lowers the lift conveyor from the first position to the second position, the support mechanisms retract the gripper heads outwardly towards the support frame to cause the wrapping to be expanded to progressively release the cotton from the lower portion to the upper portion of the round module onto the lift conveyor.
[0031] Preferably, a feed conveyor delivers the unwrapped round modules to a feed side of the lift conveyor, when the lift conveyor is in the second position.
[0032] Preferably, a discharge conveyor receives the released cotton from a discharge side of the lift conveyor when the lift conveyor has returned to the second position. Preferably, the feed and discharge sides are opposed on the lift conveyor.
[0033] Preferably, the lift conveyor has a carriage mounted on substantially-vertical guides on the support frame, the carriage supporting a conveyor belt or conveyor rollers to support the wrapped round module and the released cotton; and a drive mechanism for the conveyor belt or conveyor rollers.
[0034] Preferably, the lifting mechanism employs cables and sheaves, or chains and sprockets, or hydraulic- or pneumatic-ram(s), to raise and lower the lift conveyor.
[0035] Preferably, the support frame has a plurality of posts or columns, where each column supports a respective support mechanism.
[0036] Preferably, each support mechanism incorporates a scissor-arms assembly, or like arrangement, to selectively advance/retract their respective gripper heads in a substantially-vertical orientation.
[0037] Preferably, each gripper head has a substantially-vertical engagement face or plate, and a plurality of gripper fingers or spikes extend there-from to engage the wrapping. The fingers or spikes may be selectively retractable behind the engagement face or plate to release the wrapping.
[0038] Preferably, a discharge apparatus is provided at, or adjacent, the top of the support frame, and has at least one pair of pinch rollers adapted to engage an upper portion of the wrapping when at least a portion of the cotton has been released from the wrapping, together with a drive mechanism for the pinch rollers.
[0039] In a third aspect, the present invention resides in a gripper finger or spike for a gripper head for an unwrapping machine, the gripper finger or spike including:
[0040] a shank mountable on the gripper head at an inner end; and
[0041] a chisel or knife-like cutting portion at the distal end of the shank, the cutting portion being locatable in a cutting position forwardly of the gripper head.
[0042] Preferably, the shank is mounted on a support rod in the gripper head and extends co-axially through a hole in an engagement face on the gripper head; and
[0043] the support rod is optionally mounted for movement between a retracted position, where the cutting portion is rearwardly of the engagement face, and the (extended) cutting position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] To enable the invention to be fully understood, preferred embodiments will now be described with reference to the accompanying drawings, in which:
[0045] FIG. 1 is a schematic top plan view of a first stage of the unwrapping method of the present invention;
[0046] FIG. 2 is a schematic side view of one method of orienting a round module with the feed conveyor;
[0047] FIG. 3 is a schematic end elevational view of a second method of orienting a round module with the feed conveyor;
[0048] FIG. 4 is a schematic top plan view of the second stage of the unwrapping method;
[0049] FIG. 5 is a schematic side view corresponding to FIG. 4 ;
[0050] FIG. 6 is a schematic top plan view of the third stage of the unwrapping method;
[0051] FIG. 7 is a schematic side view corresponding to FIG. 6 ;
[0052] FIG. 8 is a front isometric view of the unwrapping machine with the lift conveyor in a lowered position to receive the round module to be unwrapped;
[0053] FIG. 9 is a similar view, with the lift conveyor in a raised position, where the round module is partially-unwrapped;
[0054] FIG. 10 is a top plan view of the unwrapping machine after the commencement of the unwrapping operation;
[0055] FIG. 11 is a sectional side view taken on line Z-Z on FIG. 10 ;
[0056] FIG. 12 is an enlarged side view of Detail A on FIG. 11 ;
[0057] FIG. 13 is a similar view to FIG. 10 after the round module has been unwrapped;
[0058] FIG. 14 is a sectional side view taken on line Z-Z on FIG. 13 ;
[0059] FIG. 15 is an enlarged side view of Detail A on FIG. 14 ;
[0060] FIG. 16 is a front isometric view one of the scissor arm assemblies and associated gripper head of the machine;
[0061] FIG. 17 is a front elevational view of a first embodiment of the gripper head;
[0062] FIG. 18 is a side elevational view of the scissor arm assembly and gripper head, with a portion of the gripper head being shown in section on line A-A on FIG. 17 ;
[0063] FIG. 19 is an enlarged side view of Detail B on FIG. 18 ;
[0064] FIGS. 20 is an underside front view of a second embodiment of the unwrapping machine;
[0065] FIG. 21 is a top rear isometric view thereof;
[0066] FIG. 22 is a top plan view thereof;
[0067] FIG. 23 is a front elevational view thereof;
[0068] FIG. 24 is a rear sectional view thereof; and
[0069] FIG. 25 is a sectional side view of the unwrapping machine.
[0070] NB: Any annotations, dimensions, notes or other descriptive markings, on the drawings are for illustration purposes and to assist the skilled addressee in the understanding of the invention only, and are not limiting to the scope of invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0071] FIGS. 1 to 3 , 4 and 5 , and 6 and 7 , respectively, schematically illustrate the three primary stages of the method of unwrapping a round module 10 of cotton C, in accordance with the present invention.
[0072] In the first stage illustrated in FIGS. 1 to 3 , the wrapped round modules 10 , e.g. as received from the field, are placed on a feed conveyor 20 , the round modules 10 being re-oriented, if necessary, so that the central axes of the round modules 10 are substantially vertical and (preferably) aligned with the center-line of the feed conveyor 20 .
[0073] In the second stage, illustrated in FIGS. 4 and 5 , the wrapped round modules 10 are advanced into the unwrapping machine 30 sequentially, are raised to an unwrapping position by the lift conveyor 40 , and the wrapping W is engaged by the gripper heads 56 .
[0074] In the third stage illustrated in FIGS. 6 and 7 , the lift conveyor 40 is moved downwardly as the gripper heads 56 are retracted outwardly. The cotton C falls from the lower portion of the round module 10 onto the lift conveyor 40 . When the lift Conveyor 40 is fully lowered, the conveyor belt 41 on the lift conveyor 40 is operated to advance the released cotton C onto the discharge conveyor 90 , which transports the pile of cotton C to the disperser conveyor 95 for further processing.
[0075] The next wrapped round module 10 is advanced to the lift conveyor 40 , and the cycle is repeated.
[0076] It will be appreciated by the skilled addressee that the controls for the feed conveyor 20 , the unwrapping machine 30 , and the discharge conveyor 90 will be linked e.g. by a computer-based system, so that the respective machines 20 , 30 , 90 operate in the desired operating sequence within the unwrapping cycle.
[0077] As illustrated in FIGS. 2 and 3 , the unwrapped round modules 10 may not be forwarded to the feed conveyor 20 with the desired orientation. In FIG. 2 , where the central axis of the round module 10 is substantially aligned with the longitudinal axis of the feed conveyor 20 , but is “laid down” substantially horizontally, the module transporter (not shown) can rotate the round module through 90° to the desired orientation. Alternatively, in FIG. 3 , if the central axis of the wrapped round module 10 is transverse to the longitudinal axis of the feed conveyor 20 , the module transporter places the round module 10 in a tipping cradle 21 , which is raised to deposit the round module 10 on the feed conveyor 20 with the desired orientation.
[0078] The feed conveyor 20 may have a conveyor belt 22 to support/advance the round modules 10 to the unwrapping machine 30 . Alternatively, the feed conveyor 20 may have a plurality of driven rollers 23 , which allow any rubbish adhering to the exterior of the wrapping W to be dislodged and fall to the floor for collection, to minimize potential contamination of the released cotton C.
[0079] The discharge conveyor 90 has a conveyor belt 91 to support the heap or pile of loose cotton C received from the lift conveyor and conveys the loose cotton C to the disperser conveyor 95 , where the cotton C passes through between substantially star-shaped rotor blades 96 mounted at equal spacing across horizontal drive-shafts 97 journalled in bearings in vertical side plates (not shown).
[0080] Referring to FIGS. 8 and 9 , the unwrapping machine 30 has a substantially square support frame 31 in top plan view—see FIG. 10 —with vertical columns 32 at respective corners of a base frame 33 anchored to the floor via corner foot-plates 34 and anchor bolts (not shown). The columns 32 connect the base frame 33 to a head frame 35 ; and the pairs of columns 32 , along the opposed sides of the path of the round modules 10 /released cotton C, are interconnected by cross-bars 36 and stabilised by angle braces 37 .
[0081] The lift conveyor 40 has a carriage 42 , where parallel rollers (not shown) are journalled in bearings (not shown) in parallel side members 43 of a carriage chassis 44 , the rollers supporting the lift conveyor belt 41 , and the head and/or tail rollers are selectively driven by an electric- (or pneumatic-) motor (also not shown) to drive the lift conveyor belt 41 .
[0082] The carriage chassis 44 of the lift conveyor 40 is guided in its vertical path between the lowered- and raised-positions by guide rollers (not shown) which engage vertical guide rails 45 which are mounted on the cross-bars 36 and the base frame 33 .
[0083] A cable-and-pulley system 46 has respective head-pulleys 47 rotatably mounted on the intermediate cross-bars 36 and tail-pulleys 48 rotatably mounted on the base frame 33 . Each pair of head- and tail-pulleys 47 , 48 is provided with a lift cable 49 (as a continuous loop) to which is attached the carriage chassis 44 . One of the lift cables 49 is driven by the tail-pulley 48 connected to one end of a driveshaft 50 on a lift motor/transmission assembly 51 mounted on the base frame 33 . The other lift cable 49 is driven by a driving cable 52 which connects a driving pulley 53 , at the other end of the driveshaft 50 on the lift motor/transmission assembly 51 , to a driven pulley 54 on a driving shaft 55 to which the tail-pulley 48 is connected. The arrangement of the lift cables 49 ensures that both sides of the carriage chassis 44 are raised/lowered in unison.
[0084] As illustrated in FIGS. 8 to 11 , 13 to 14 , and in more detail in FIGS. 16 to 19 , respective gripper heads 56 are mounted on each column 32 of the support frame via respective support mechanisms 64 , each incorporating a scissor-arms assembly 65 .
[0085] Each gripper head 56 has a hollow body 57 with a substantially vertical engagement plate 58 connected to a backing plate 59 by side webs 60 . Gripper fingers or spikes 61 —see FIG. 19 —are mounted on support rods 62 behind the engagement plate 58 and extend through respective holes 63 in the engagement plate 58 . (The support rods 62 may be fixed relative to the engagement plate 58 ; or may be horizontally-movable relatives thereto to enable the gripper fingers or spikes 61 to be retracted so as to not project from the engagement plate 58 on initial engagement with the round module 10 .)
[0086] The gripper fingers or spikes 61 have chisel or knife-like cutting edges 161 , rather than a pointed tip, to cleanly cut the wrapping W. (Conventional pointed spikes tend to rip a hole in the wrapping W, leaving a small piece of plastic stretched over the end of the spike. At some time, the spike releases the piece of plastic in the round module, to thereby inject contamination into the cotton in the round module.)
[0087] The support mechanism 64 for each gripper head has a scissor-arms assembly 65 , with respective first- and second scissor arms 66 , 67 .
[0088] The first scissor arm 66 has its outer (upper) end hingedly connected to the adjacent column 32 by a hinge assembly 68 . The inner (lower) end is hingedly connected to a first traveler 69 slidably mounted on a vertical guide track 70 on the backing plate 59 of the gripper head 56 , via a hinge assembly 71 .
[0089] The second scissor arm 67 has its inner (upper) end hingedly connected to the backing plate 59 of the gripper head 56 ; and its lower (outer) end hingedly connected to a second traveler 72 slidably mounted on a vertical guide track 73 on the column 32 ; via similar hinge assemblies 74 , 75 .
[0090] A pneumatic actuator (or ram) 76 has the lower end of a cylinder 77 mounted on the column 32 and the distal end of the piston rod 78 is connected to a bracket 79 at the lower end of the second traveler 72 . By extending the pneumatic actuator 76 , the scissor arms 66 , 67 move the gripper head 56 inwardly towards the centre of the unwrapping machine 30 i.e. away from the column 32 .
[0091] Referring to FIGS. 10 to 15 , the discharge mechanism 80 is mounted on the head frame 34 above the discharge end of the lift conveyor 40 .
[0092] A pair of pinch rollers 81 has parallel rotational axes spring-mounted on the inwardly-directed portion of the body 82 of the discharge mechanism 80 , the pinch rollers 81 being driven by an electric unwrapping motor via a belt-and-pulley drive assembly 83 .
[0093] A pair of compression rollers 84 are mounted rearwardly (i.e. outwardly) of the pinch rollers 81 and rotate about horizontal axes, the compression rollers 84 being driven by an electric compression drive motor. A lower bag guide roller 86 is mounted forwardly of, and below, the lower of the compression rollers 84 . The axle of at least the upper compression roller 84 is journalled in bearings which are vertically movable within the discharge mechanism body 82 and are vertically movable via a compression roller cylinder 87 ; so that the compression rollers 84 apply a preset minimum compressive force on the unwrapped plastic wrap W as it is drawn away from the cotton C by the pinch and compression rollers 81 , 84 .
[0094] A bag pinch gripper 100 , in the form of a hook 101 , is hingedly mounted on, and extends inwardly from, a pinch gripper head 102 which can be extended inwardly, or retracted outwardly, by a pneumatic pull back cylinder 103 ; the bag pinch gripper 100 being able to be swung downwardly into engagement with the adjacent portion of the wrapping W.
[0095] A vertical wrap spindle 104 is mounted rearwardly (i.e. outwardly) of the compression rollers 84 to receive the waste wrapping W drawn from the round module 10 , and is driven by an electric wrap motor 105 .
[0096] An RF plastics-welding head 106 , with an extendible/retractable welding iron 107 , is located adjacent the wrap spindle 104 .
[0097] A pneumatic eject cylinder 108 vertically moves the wrap spindle 104 from a (raised) wrapping position to a (lowered) discharge position, where a waste roll R comprising one or more wrapped/welded waste wrappings on the wrap spindle 104 is transferred to a transverse waste discharge conveyor 109 for transport to a waste discharge location.
[0098] The waste discharge conveyor 109 is mounted on the head frame 34 of the unwrapping machine 30 and has a conveyor belt 110 to support and convey the waste rolls R.
[0099] The operational cycle of the unwrapping machine will now be described.
[0100] In the lowered position (see FIG. 8 ), the lift conveyor 40 receives a round module 10 to be unwrapped from the feed conveyor 20 , in the correct orientation, as illustrated in FIGS. 4 and 5 , where the lift conveyor belt 41 advances the round module 10 to the centre of the carriage 42 .
[0101] The lift motor/transmission assembly 51 is operated to drive the lift cables 49 to raise the carriage 42 to the raised position—see FIGS. 5 and 9 .
[0102] The pneumatic actuators 76 for each support mechanism 64 is extended, to cause the scissor arms 66 , 67 to advance the gripper heads 56 towards the round module 10 until the engagement plates 58 engage the wrapping W, which is pierced by the gripper fingers or spikes 61 . (When the gripper fingers or spikes 61 are movably mounted in each gripper head 56 , it is preferable they are retracted as the engagement plates 58 engage the wrapping W, and are then extended into engagement with the wrapping W.)
[0103] The bag pinch gripper 100 is also extended and swung down to engage the upper rim of the wrapping W.
[0104] The unwrapping step now commences.
[0105] The gripper heads 56 and the bag pinch gripper 100 are simultaneously retracted (i.e. moved outwardly) by the pneumatic actuators 76 and the pneumatic pull back cylinder 103 , while the lift motor/transmission assembly 51 is operated to slowly lower the lift conveyor carriage 42 —see FIGS. 10 to 12 .
[0106] The cotton C in the lower portion of the round module 10 is no longer supported by the lift conveyor belt 41 , and the four-way stretching of the wrapping W by the gripper heads 56 reduces the frictional contact between the cotton C in the round module 10 and the wrapping W.
[0107] The cotton C in the lower portion starts falling free from the roll module 10 , and the cotton C is gradually released from the lower portion to the upper portion, until all the cotton C is received on, and supported by, the lift conveyor belt 41 in a heap or pile.
[0108] As the bag pinch gripper 100 is retracted, it feeds the engaged portion of the upper rim of the wrapping W into engagement with the (driven) pinch rollers 81 (and over the lower bag guide roller 86 ) to the compression rollers 84 . The wrapping W is drawn away from the centre of the unwrapping machine 30 and is wound onto the vertical wrap spindle 104 .
[0109] When the entire wrapping W is received on the wrap spindle 104 , the RF welding head 106 , advances the welding iron 107 , to weld the wrapping W into a waste roll R about the wrap spindle 104 .
[0110] The eject cylinder 108 is extended to transfer the waste roll R to the waste discharge conveyor 109 for transfer to a waste discharge location. (NB: A number of the wrappings W may be formed into a waste roll Ron the wrap spindle 104 before transfer to the waste discharge conveyor 109 .)
[0111] The skilled addressee will appreciate the waste rolls R can be returned to a plastics manufacturer for recycling of the plastics-material.
[0112] When the lift conveyor carriage 42 is in the lowered position, supporting the heap or pile of released cotton C, the lift conveyor belt 41 is operated to transfer the cotton C to the discharge conveyor 90 —see FIGS. 6 and 7 .
[0113] The lift conveyor 40 is ready to receive the next round module 10 to be unwrapped, and the cycle is repeated.
[0114] FIGS. 20 to 25 illustrate a second embodiment of the unwrapping machine 230 where the bag pinch gripper 300 has a movable jaw 301 , moved by a pneumatic cylinder 302 , and co-operates with a fixed jaw, or anvil, 303 to grip the upper rim of the wrapping W, before the bag pinch gripper 300 is retracted by rams 376 to enable the wrapping to be received on the wrap spindle 304 .
[0115] The wrap W gripped by the bag pinch gripper 300 is guided towards the compression rollers 384 by vertical head rollers 382 driven by belts 381 and over a lower guide belt passing around the guide roller 386 . The belts 381 will assist in guiding the wrap W towards the compression rollers 384 .
[0116] The unwrapping method and apparatus 230 is arranged to direct the wrap W, in a single piece, to the wrapping spindle 304 to ensure none of the wrap W contaminates the cotton released from the module.
[0117] The skilled addressee will appreciate the following (but non-exhaustive) list of advantages of the present invention include:
[0118] a) the cotton is released from the round modules in a controlled manner;
[0119] b) by not cutting the wrapping, the problem of waste plastics contaminating the released cotton is overcome, or at least ameliorated;
[0120] c) the plastics-material is positively drawn away from the cotton, and is collected/transported for recycling;
[0121] d) the unwrapping machine can be easily integrated with existing feed and discharge conveyors at the cotton gin;
[0122] e) the feed conveyor, unwrapping machine and the discharge conveyor can be easily linked, and their respective operations timed/controlled by a master (programmable) control system;
[0123] f) the unwrapping machine can be constructed from many off-the-shelf components, at a reduced capital, cost, while providing a robust/reliable machine;
[0124] g) the cotton is released into a heap or pile which is easily handled/transported; and
[0125] h) the system is fully automated and does not require a dedicated operator.
[0126] The present invention, as hereinbefore described and illustrated, provides a relatively simple, but safe and highly efficient, method of, and apparatus for, the unwrapping of round modules of cotton or like materials.
[0127] Various changes and modifications may be made to the embodiments described and illustrated without departing from the present invention.
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A method of and apparatus for, unwrapping a module of cotton or other fibrous material from a wrapping having at least one layer of plastics-sheet material, the method including the steps of: raising the module to a first, or elevated, position on a lift conveyor or vertically-movable support surface; advancing a plurality of gripper heads, mounted on a support frame, to an advanced position, into gripping engagement with the layer(s) of the sheet material wrapping; lowering the lift conveyor or vertically-movable support surface from the first position towards a second, or lowered, position; and retracting the plurality of gripper heads, to expand the wrapping to progressively release the cotton or other fibrous material from the lower portion to the upper portion of the module.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of German Patent Application No. 10 2010 020 757.8, filed May 17, 2010, which is incorporated herein by reference as if fully set forth.
FIELD OF THE INVENTION
[0002] The invention relates to a method for determining a viscosity parameter of a motor oil in an internal combustion engine, wherein a plurality of operating parameters characterizing an operating state of the internal combustion engine are detected and/or determined for an electronic engine control. The invention further relates to a control device for an electronic engine control with reference to the detected and/or determined operating parameters.
[0003] The invention here concerns, in particular, that the viscosity of the motor oil being used has a not insignificant influence on the operating behavior of an internal combustion engine, but the current status is taken into account only insufficiently for an electronic engine control. Even for modern multi-grade oils with synthetic additives, the viscosity changes as a function of the period of use due to aging of the additives. For an electronic engine control, the oil viscosity plays a role especially when the internal combustion engine is controlled by components that can be actuated hydraulically, wherein the motor oil is used as the hydraulic fluid.
BACKGROUND
[0004] In modern engine vehicles, today for reasons of minimizing pollution and also reducing consumption, the so-called gas-exchange valves, that is, the intake and/or exhaust valves for the internal combustion engine, are controlled as a function of load. Here, different systems are used. All of the systems have in common that the closing and/or opening times of the gas-exchange valves are changed in relation to the crankshaft position (rotational angle) as a function of the operating state, in particular, as a function of load.
[0005] In engine vehicles today, camshaft adjusters that are hydraulically actuated are already in use that allow a setting of the phase position of the camshaft with respect to crankshaft as a function of the respective operating state. To this end, the camshaft adjuster comprises a stator unit that is locked in rotation with the crankshaft and in which is mounted a rotor unit that is connected rigidly to the camshaft. The rotor unit typically has rotor vanes that are arranged between pressure chambers that can be pressurized with the hydraulic fluid. By the use of inlet and outlet valves, hydraulic fluid can be fed to or bled from the pressure chambers, wherein the rotor vanes can be moved relative to the stator unit. As the hydraulic fluid, motor oil is typically used. For building up the pressure, existing oil pumps are used. The control valves provided for filling or emptying the pressure chambers are constructed, in particular, as solenoid valves.
[0006] A hydraulic camshaft adjustment system is to be taken, for example, from EP 1 544 419 A1.
[0007] From the article “Electrohydraulic valve control with the ‘MultiAir’ (MA) method” from the engine-technology journal MTZ 12/2009, an alternative, hydraulic control system for the direct control of the gas-exchange valves is to be taken. For this electrohydraulic valve control it is provided that the movement of the camshaft is transmitted via the hydraulic fluid to each gas-exchange valve. A control or switch valve constructed especially as a solenoid valve is provided for the control. In the closed state, the camshaft is connected to each gas-exchange valve by a so-called hydraulic linkage, so that the gas-exchange valve necessarily follows a cam of the camshaft. Through also partial opening of the switch valve, the hydraulic fluid can escape into a compensation or pressure space, so that the gas-exchange valve is decoupled from the cam movement. In this way, there is the possibility to vary the opening time, the closing time, and also the stroke of the gas-exchange valve within an envelope curve specified by the movement of the cam. This variation can be performed in a cylinder-selective way.
[0008] In view of the high efficiency required in modern internal combustion engines with simultaneously low pollutant emission, a correct control of the gas-exchange valves is very important. In hydraulic systems, in particular, the quality of the motor oil being used has a significant effect on the operation. In particular, in its effectiveness, the hydraulic control is sensitive to oscillations in the viscosity of the oil being used. Depending on the operation, such oscillations appear due to the different oil temperatures that appear. As emerges from the mentioned article “Electrohydraulic valve control with the “MultiAir” method,” the temperature-dependent oil viscosity oscillations have previously been taken into account in a model-based control algorithm that takes into account the measurement values of an oil temperature sensor. Here, however, the viscosity of the motor oil, as well as other influencing factors, such as, for example, aging of the motor oil, wear, or contamination, are not taken into account.
SUMMARY
[0009] Starting from this situation, the invention is based on the objective of providing a method for determining a viscosity parameter of a motor oil in an internal combustion engine, and also a corresponding control device for electronic engine control, wherein at least qualitative statements on the current viscosity of the motor oil can be obtained and processed accordingly as much as possible without additional expense.
[0010] The objective is met according to the invention by a method for determining a viscosity parameter of a motor oil in an internal combustion engine, wherein, for an electronic engine control, a plurality of operating parameters characterizing an operating state of the internal combustion engine is detected and/or determined. Here, at different times, several parameters allowing at least a rough conclusion on the viscosity of the motor oil are evaluated from these operating parameters for each individual prediction on the viscosity of the motor oil, changes in the individual predictions at comparable working points of the internal combustion engine relative to a state of new motor oil are detected, and the viscosity parameter is determined from the changes in the several individual predictions.
[0011] Here, the invention starts from the idea that in an electronic engine control, during the operation of the internal combustion engine, operating parameters characterizing the operating state are detected and/or determined continuously and input into the control. The value of a few of these operating parameters allows, in principle, at least one rough conclusion on the viscosity of the motor oil being used. Such a rough conclusion does not need to be an absolute value of the viscosity of the motor oil. Instead, in principle, there must be only a relationship between the parameter and a conclusion on the viscosity of the motor oil. Such a relationship or such a rough conclusion is given, for example, when the corresponding operating parameters can conclude, for example, whether the motor oil has a rather large or rather small viscosity in comparison with motor oils that are typically used or whether the viscosity is too small or too large for operating the internal combustion engine. Such a conclusion, however, could also already have a value that indicates a change in viscosity, for example, whether the viscosity has become smaller or larger.
[0012] A corresponding conclusion can be taken, for example, from a parameter that characterizes the engine friction and is derived in modern engine controls, for example, while idling, from the difference between the desired rotational speed and the actual rotational speed. A rather high friction value could provide evidence for a rather high viscosity. Conversely, a rather lower friction value gives evidence for a rather low viscosity. Likewise, for example, the time period that elapses after a starting process of the internal combustion engine until reaching a desired oil pressure permits a rough conclusion on the given viscosity of the motor oil. A small time span gives evidence for a rather low viscosity of the motor oil and vice versa.
[0013] The invention further assumes that the individual predictions obtained from individual rough conclusions on the viscosity of the motor oil could be compressed into a more precise conclusion on a viscosity parameter, if the parameters detected at different times or evaluated individual predictions at comparable operating points of the internal combustion engine are compared with each other and in this way changes over time are made visible over the operating period. From such changes, in particular, the direction of a change in viscosity could also be determined, which already represents useful information. By using the size of the changes observed per unit of time, it is further possible to determine the extent of a change in viscosity that has occurred. Here, in order to have a reference point for a possible calibration, the changes are detected with respect to a state of new motor oil. Here, a newly added motor oil is assumed, for example, after an oil change or in the case of a new vehicle, which has properties suitable for the internal combustion engine and is optionally already stored with these properties in the engine control.
[0014] A detection of the time changes of comparable parameters or comparable individual predictions with respect to the state of the new motor oil allows, in this respect, changes in the viscosity of the motor oil to be detected and these to be evaluated in terms of quality. Under certain preliminary conditions, a quantitative detection of the viscosity is also possible.
[0015] The phrase of comparable operating point of the internal combustion engine is here understood in that the additional factors decisively influencing the oil viscosity on the part of the detected parameter are essentially comparable. For example, if friction values of the engine are compared with each other at different times, then the oil temperature must be essentially equal, in order to make a qualitative and optionally quantitative conclusion on the changed oil viscosity.
[0016] The value of the determined viscosity parameter is further increased in that the changes in several suitable parameters or the changes in several individual predictions derived from these parameters are compared with each other. Thus, for example, several individual predictions indicating an equal change direction and an equal magnitude of the change in viscosity reinforce the overall conclusion. On the other hand, individual parameters that have a higher informational content with respect to oil viscosity are weighted higher in the determination of the viscosity parameter than other parameters whose informational content are lower with respect to oil viscosity or are loaded with higher errors.
[0017] In principle, the invention could be used for all internal combustion engines in which operating parameters are queried or made available for the querying of the respective operating state, that is, an electronic engine control with corresponding sensor systems is provided. Typically, operating parameters can always be retrieved here that allow at least a rough conclusion on the state of the viscosity of the motor oil.
[0018] The invention could be added as separate hardware to an existing engine control. Preferably, however, the invention is realized by a corresponding modification to the software of the existing engine control. In this respect, the invention allows a qualitative and optionally quantitative conclusion on the viscosity of the motor oil to be obtained without changing the existing installation of an already provided engine control, wherein this conclusion can be used, in particular, as an input parameter for the engine control itself. In this way, the control is trained to sufficiently take into account the current viscosity. The operating states optimized with respect to the consumption and the output of the internal combustion engine are actually also controlled despite the changed viscosity of the motor oil.
[0019] Through the plurality of observed operating parameters, as well as by the observation of the time changes in the individual predictions derived from these parameters, the current state of the viscosity of the motor oil is detected. The viscosity parameter derived from these values can be, for example, a viscosity grade of the motor oil, a quantitative change in the viscosity relative to the motor oil in the new state, optionally the viscosity itself, or, in the simplest case, for large detected changes, an indicating parameter for an oil change that has taken place or for a current viscosity in which the internal combustion engine no longer experiences sufficient lubrication or can no longer start due to viscosity that is too high.
[0020] The invention is especially also suitable for preventing damage to the internal combustion engine due to a possibly incorrect viscosity caused by aging, contamination, or wear of the motor oil.
[0021] The invention further offers the big advantage that it manages without a viscosity sensor that is associated with additional costs and also delivers measurement results that can be used only in certain temperature ranges. Thus, the invention offers, in particular, the analysis of the viscosity of the motor oil at relatively low oil temperatures. Changes in the motor oil caused by aging, wear, or the introduction of foreign particles lead, viewed absolutely, to the greatest changes to viscosity. The invention uses only the sensors already present in an engine control, so that no additional costs are generated. By deriving the individual predictions from the suitable operating parameters, the viscosity of the motor oil is also determined directly at each place of detection. This is important especially for a hydraulic control of the gas-exchange valves. It has been shown, namely, that their adjustment behavior gives a direct indication of the present oil viscosity. In contrast, a sensor for measuring the oil viscosity is typically placed away from the actual active components that are actuated hydraulically. For a corresponding measurement of the oil viscosity, such a sensor is to be placed in the oil pan.
[0022] In one preferred construction, the temperature of the motor oil is detected, wherein the available parameter range is calibrated, for temperatures above a specified limiting value, to a first range of prediction values for classifying the oil and is calibrated, for temperatures below the limiting value, to a second region of prediction values for classifying the oil.
[0023] This construction uses the fact that the temperature dependency of the viscosity of the motor oils, especially also of multi-grade oils, falls into two separate ranges that can each be described by a linear relationship with slopes that are different from each other. In a low-temperature range, the drop in viscosity relative to increasing temperatures is greater than in a high-temperature range. The boundary between these two ranges lies at a temperature of approximately 10° C. depending on the respective motor oil. This property of motor oils is condensed, for example, in the SAE classification that basically provides a designation of the type x W-y for multi-grade oils, wherein x specifies the low-temperature viscosity and y specifies the high-temperature viscosity. A motor oil of the classification SAE 10 W- 60 has, according to the classification, a low-temperature viscosity of SAE 10 and a high-temperature viscosity of SAE W- 60 . Different viscosity dependencies of the motor oils in a low-temperature range and in a high-temperature range are desired. In particular, at high temperatures, the viscosity should decrease only slightly, so that a sufficiently high reliability of lubrication is given at higher outside and engine temperatures. The correspondingly desired viscosity is here achieved for modern multi-grade oils through corresponding synthetic additives. However, these lose their effect more and more with aging and wear, so that the viscosity changes, in part drastically, in the course of the use of the motor oil.
[0024] If the parameter range available for the selected operating parameters, each dependent on a limiting value for the measured oil temperature, is calibrated once to a first range of prediction values for classifying the oil and once to a second range of prediction values for classifying the oil, then this allows qualitative and quantitative conclusions on the change in oil viscosity relative to the new state of the motor oil. In the simplest case, the calibration can be given by a simple linear relationship of both ranges. In this respect, prediction values for classifying the oil are mapped in a linear fashion onto the available parameter range.
[0025] If, for example, the friction value of the internal combustion engine is used as a suitable operating parameter, then, in the high-temperature range, the lowest parameter value can be allocated to an oil viscosity that is so low that engine damage could be generated due to a breaking-down lubricating film. The highest measurable parameter value is then allocated, in turn, to an oil viscosity that corresponds to a viscous high-temperature oil. For example, such an oil has, according to the SAE classification, a high-temperature viscosity of W 50 or W 60 . For temperatures below the limiting value, an oil viscosity that is so low that engine damage could be generated during operation is allocated, in turn, to the lowest available parameter value. The highest available friction value then corresponds to an oil viscosity that corresponds approximately to a viscous low-temperature motor oil, for example, a viscosity according to 20 W. By means of such a calibration also used for the other operating parameters or the prediction values derived from these parameters, changes can then be detected in the viscosity at comparable operating points of the internal combustion engine and thus can be evaluated qualitatively. By means of monitoring the corresponding parameter value, in the case of a new motor oil and through the corresponding reference to this case, for subsequently detected parameter values, a quantitative conclusion on the current state of the oil viscosity is also possible.
[0026] Preferably, the method for an internal combustion engine is used with a hydraulic adjustment of the gas-exchange valves, because just for such a control, the present oil viscosity has an affect on the actually achieved operating state of the internal combustion engine. A corresponding knowledge on the current state of the oil viscosity is thus meaningful for an improvement in the corresponding control. A change in the oil viscosity here leads to a change in the opening and closing times of the solenoid valves arranged in the hydraulic linkage for actuating the gas-exchange valves. From this results, in turn, a change in the opening and closing times of the controlled gas-exchange valves. Just the closing process takes place, in turn, against the hydraulic fluid that must be forced into a compensation chamber for braking the closing speed. Without taking into account the current oil viscosity, for a constant control, the actually desired operating state of the internal combustion engine is no longer achieved.
[0027] The same applies, to a certain extent, also for an internal combustion engine that has a mechanical camshaft adjuster. Because the rotor unit is adjusted hydraulically relative to the stator unit, the oil viscosity influences the timing that is needed for setting the phase angle between the camshaft and crankshaft. This influences, in turn, the opening and closing times of the gas-exchange valves, so that for constant control, in turn, the desired operating state cannot be reached correctly.
[0028] Preferably, from the detected changes in the individual predictions, an oil grade that is changed in comparison with the new motor oil is determined. Through the quantitative consideration of the change in the individual predictions during the operation of the internal combustion engine and by means of a corresponding allocation of the available parameter ranges it can be determined when the viscosity change has reached such a value that can be a result, in principle, from a viscosity of a motor oil of a different viscosity grade. If, for example, the viscosity grades are stored in the corresponding engine controls, then such a changed viscosity grade could be used directly in the corresponding control, wherein reference is then made to the current status of the oil viscosity.
[0029] In other words, the temperature profile of the viscosity of the motor oil being used is determined from the detected changes, that is, the type of motor oil is determined. It is also possible, however, to also determine the temperature profile of the viscosity in the current state by changes detected at different operating points of the internal combustion engine. In this respect, the system could have a self-learning construction in that it learns, over the period, viscosity profiles versus temperature or versus other parameters through corresponding storage of the detected data.
[0030] From the changes in the individual predictions, a viscosity that is too low or too high for the internal combustion engine can be determined, wherein further operation or startup of the internal combustion engine is blocked or at least a warning is issued. Here, within the available parameter ranges, the size of the observed change is analyzed and a viscosity that is too high and/or too low is determined for operation of the motor oil for correspondingly specified calibration when a limiting value is reached. If the oil viscosity for low temperatures is too high, then an attempt to start the engine, in particular, is blocked. For a viscosity that is too low according to the detected status for high temperatures, for example, the further operation of the internal combustion engine is blocked, so that engine damage is prevented. Alternatively, warning signals could also be output to the driver.
[0031] Preferably, it can be determined from a very rapid and large change in the individual predictions that an oil change has been performed. The method could have a self-learning construction in this respect in that it considers the status detected after a determined oil change to be a changed status for the state of a new motor oil and analyzes future parameter values or individual predictions relative to this state. Here, reference is then made to a possible mechanical wear of the affected engine components.
[0032] In one especially preferred construction, the parameters used for the evaluation for an individual prediction are selected from a group containing parameters for characterizing the adjustment speed of a hydraulic component, in particular, an electrically controllable switching valve, parameters for characterizing the exhaust-gas composition, in particular, the oxygen concentration, parameters for characterizing an oil change based on a model due to aging and/or wear, parameters for characterizing the oil pressure, parameters for characterizing the setting speed of a camshaft adjustment, as well as parameters for characterizing a friction value of the internal combustion engine. The temperature itself is not used as such a parameter. The change in oil viscosity taking place over the operating period of the internal combustion engine is detected.
[0033] For an engine with camshaft adjustment, the parameters listed here are available or can be derived, in principle, as operating parameters. In the case of a camshaft adjustment by a conventional camshaft adjuster, however, the parameters for characterizing the exhaust-gas composition, in particular, the oxygen concentration, cannot or, in any case, cannot sufficiently provide a conclusion on the current status of the viscosity of the motor oil being used. For engines that have both conventional camshaft adjustment and also a direct hydraulic actuation of the gas-exchange valves, all of the listed parameters are available or could be derived from the existing operating parameters for an engine control. The listed parameters can also provide sufficient evidence for a conclusion with respect to oil viscosity. For an engine that provides direct hydraulic actuation of the gas-exchange valves without camshaft adjustment, the parameters for characterizing the setting speed of a camshaft adjustment are eliminated for characterizing the oil viscosity.
[0034] The parameters for characterizing the adjustment speed of a hydraulic component, in particular, an electrically controllable switching valve, can relate, in particular, to the solenoid valve arranged in the hydraulic linkage between the cam and the associated gas-exchange valve or to the control valve for controlling the pressure chambers in a camshaft adjuster. The use of these parameters for characterizing the oil viscosity touches upon the basic idea that the movement sequence of a hydraulic component during an adjustment movement from a first position into a second position depends decisively on the viscosity of the oil being used. Through the use of the viscosity, a friction force counteracting the movement of the hydraulic component is basically exerted, so that the time period for the adjustment movement of the hydraulic component allows a conclusion on the viscosity.
[0035] The hydraulic component here involves, in particular, a component controlled by force, but not by mechanical force, from the first position into the second position, such that different friction resistances lead to different time periods for the adjustment movement. This free, not forced movement is also designated as ballistic movement. The force is here applied, for example, by a spring. Through the counteracting, viscosity-dependent friction force of the motor oil, the time period of the adjustment movements varies as a function of the viscosities.
[0036] Without the use of additional sensors, the viscosity can be determined from the time period for the adjustment movement of a hydraulic component during the ballistic movement. The hydraulic components used for charging the pressure chambers of a camshaft adjuster or for the hydraulic actuation of the gas-exchange valves are typically solenoid valves. The valve itself moves especially for the ballistic movement between a closed position and an open position that thus form the first and second positions of the switching valve. Because a closing element of the switching valve, like, for example, a valve plate, is guided within the flow path of the oil, the adjustment movement of the closing element is influenced by the viscosity of the motor oil. For a solenoid valve, typically the movement into one position, advantageously into the closed position, is actuated by magnetic force and after deactivation of the magnetic force, the valve travels back into the second position, in particular, into the open position, actuated by spring force.
[0037] According to one preferred refinement, the time or adjustment period or the activation period and/or deactivation period is determined from an inductive response of the excitation current. Thus no additional measurement devices are required. The current profile can be taken directly from the control provided here. Determining the viscosity or a corresponding parameter for this purpose is therefore performed just through evaluation (software), without requiring additional hardware components.
[0038] By monitoring the changes in the activation or deactivation periods taken, in particular, from the excitation currents, a quantitative change in oil viscosity can be determined directly. In principle, a shortening of a switching period is evidence for reduced oil viscosity. Here, it has been shown, in particular, that a linear relationship exists between the oil viscosity and the observed switching period. The precise determination of the viscosity from the switching periods can be drawn, in particular, from a German Patent Application with the title “Method and also control device for determining a viscosity parameter of an oil” and filed at the same time as the priority application by the same applicant.
[0039] The changes in the observed switching times are also here linked preferably with the information of viscosity grades in a low-temperature range and in a high-temperature range.
[0040] The parameters for characterizing the exhaust-gas composition, e.g., the oxygen concentration in the exhaust gas, exhibit, in particular, a dependency of the oil viscosity when the engine provides a direct hydraulic actuation of the gas- exchange valves. As already mentioned, by means of the opening and closing times of a solenoid valve located in the hydraulic linkage between the cam and the respective gas-exchange valve, the movement profile of the gas-exchange valve varies within the envelope curve specified by the cam. Through the given dependency of the switching period of the hydraulically actuated solenoid valve on the oil viscosity, the movement profile of the gas-exchange valve also changes. In addition, for a decoupling of the gas-exchange valve, this is closed by spring force against the hydraulic fluid, in order to brake the closing process sufficiently against the engine housing. In this way, however, the ballistic closing process of the gas-exchange valve changes as a function of the viscosity of the motor oil. If the oil becomes more viscous, for example, then an intake valve remains open longer due to the longer closing time. As a result, more oxygen is introduced into the piston space for a constant amount of fuel. The oxygen concentration in the exhaust gas increases.
[0041] Thus it is clear that, in particular, the oxygen concentration in the exhaust gas likewise contains evidence on the existing oil viscosity. If, in turn, the change in oxygen concentration in the exhaust gas is observed during the operating period of the internal combustion engine relative to a state with new motor oil, then from this, under consideration of the hydraulic control of the gas-exchange valves, a qualitative and quantitative change in oil viscosity can be determined. With corresponding calibration, an absolute determination of the oil viscosity is also possible here.
[0042] In one preferred construction, a control signal determined from a lambda controller from a measured oxygen concentration in the exhaust gas is used as the parameter for characterizing the exhaust gas composition. In this way, an already present, suitable operating parameter can be accessed directly. Additional sensors are likewise not required.
[0043] Preferably, a correction of the oxygen concentration performed by the lambda controller is used as the suitable parameter. In this concept, not the absolute value of the oxygen concentration is evaluated, but instead the control response of an existing lambda controller. This touches on the idea that, for example, due to aging phenomena, the viscosity of the motor oil increases and that in comparison to the previous state - by use of the lambda controller it results in a defective setting and the oxygen content measured in the exhaust gas deviates from the expected oxygen content—for unchanged oil properties. This error is corrected by the lambda controller. This correction that is eventually a correction of the oxygen concentration in the exhaust gas, is used for determining the viscosity parameter. Determining a viscosity parameter from the parameters of a lambda controller can be drawn, in particular, from a German Patent Application with the title “Method and also control device for determining a viscosity parameter of a motor oil” filed at the same time as the priority application by the same applicant.
[0044] The correction value or the oxygen concentration is preferably correlated, in turn, with respect to its possible parameter values with oil viscosities or with viscosity grades separated into a low-temperature range and into a high- temperature range. In a high-temperature range, for example, the lowest available correction value is correlated with a motor oil viscosity that is too low for the engine operation and the highest available correction value is correlated with a viscous high-temperature oil, for example, the SAE class W 50 or W 60 . In a low-temperature range, the highest available correction value is then correlated accordingly with the most viscous possible low-temperature oil, which is designated, for example, by SAE 20 W.
[0045] According to the already mentioned parameters for specifying an engine friction or for specifying the setting time of the desired oil pressure during a startup phase of the internal combustion engine, a parameter for characterizing the setting speed of a camshaft adjustment could also be used for characterizing the oil viscosity. A quicker setting speed here gives evidence of a low viscosity and a rather slow setting speed gives evidence of a rather high viscosity of the motor oil. Accordingly, in turn, the correlation of the lowest available parameter value with an oil viscosity that is too low for the operation of the internal combustion engine and the highest available parameter range (separated into a low-temperature range and into a high-temperature range) can be correlated with a viscous motor oil corresponding to summer or winter classifications.
[0046] In addition, for characterizing the oil viscosity, a model already used in the engine control can be referenced that describes the change in viscosity of the motor oil being used due to aging. Such a model is based on the assumption of the time expiration of the polymers added to modern multi-grade oils.
[0047] In addition to the actual operating parameters named above, for the specified method a parameter for indicating an oil change could be used. Such a parameter is to be taken directly from today's modern engine controls. By the use of these parameters, the system can directly determine a state of a new motor oil and thus relate future changes to this state.
[0048] In another preferred construction, the viscosity parameter is determined while adding a priority sequence or weighting to the parameters used for the individual predictions. In the case of the already mentioned, especially preferred parameters, weighting in the specified sequence is preferred. Thus, reference is made to the significance of each parameter with respect to oil viscosity.
[0049] The mentioned objective is further met according to the invention by a control device for the electronic engine control of an internal combustion engine that is constructed to detect and/or to determine a plurality of operating parameters characterizing an operating state of the internal combustion engine, to evaluate several parameters permitting at least a rough conclusion on the viscosity of the motor oil for each individual prediction on the viscosity of the motor oil at different times from these operating parameters, to detect changes in the individual predictions at comparable operating points of the internal combustion engine relative to a state of new motor oil, and to determine a viscosity parameter of a motor oil from the changes in the multiple individual predictions.
[0050] The control device can be used for obtaining a conclusion on the oil viscosity in the sensors already present in a modern engine control. The corresponding evaluations and calculations can be realized by software.
[0051] The control device is constructed, in particular, for performing the method described above. The advantages mentioned here can be transferred analogously to the control device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] Embodiments of the invention will be explained in detail with reference to the drawings. Shown are:
[0053] FIG. 1 schematically for an internal combustion engine with hydraulic actuation of the gas-exchange valves, a control device obtaining a viscosity parameter from several individual predictions,
[0054] FIG. 2 schematically for an internal combustion engine with camshaft adjustment, a control device for obtaining a viscosity parameter from several individual predictions,
[0055] FIG. 3 schematically, the profile of the excitation current for a hydraulically actuated solenoid valve, and
[0056] FIG. 4 schematically, the movement sequence of a hydraulically actuated gas-exchange valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0057] In FIG. 1 , a control device 10 for the electronic engine control of an internal combustion engine with a hydraulic actuation of the gas-exchange valves is shown schematically. In this case, the engine provides both camshaft adjustment and also a direct hydraulic actuation of the gas-exchange valves.
[0058] The control device 10 comprises a master computer 11 that is the core of the electronic engine control. A central analysis unit 13 that determines a conclusion on the current status of the oil viscosity by a plurality of selected operating parameters made available to the engine control is implemented as software or as additional hardware.
[0059] To this end, the central analysis unit 13 presently includes the parameters from the solenoid valve control for the hydraulic actuation of the gas-exchange valves. For this purpose, a corresponding solenoid valve analyzer 15 is formed by software that determines switching periods from the excitation currents of the solenoid valves and here outputs prediction values for a current oil viscosity. The central analysis unit 13 further includes operating parameters from an existing lambda controller 17 . In particular, access is made here to the correction value of the lambda controller that indicates a changed oxygen content in the exhaust gas relative to a new motor oil or relative to the originally set state.
[0060] In addition, the output of a forecast unit 18 is used by the central analysis unit as a parameter for the evaluation for an individual prediction. The forecast unit 18 is here part of the engine control 10 and includes an aging model for forecasting the oil viscosity with increasing operating period.
[0061] In addition, from the existing oil-pressure sensor of the engine control, an operating parameter is polled or determined that specifies the setting time, during a startup phase, until reaching the desired oil pressure. To this end, a corresponding oil-pressure analyzer 20 is constructed by software.
[0062] Furthermore, for determining individual predictions with respect to oil viscosity, a friction value of the engine is used as a suitable parameter. This friction value can be taken from the engine control that determines this value, for example, while idling, from the difference between the desired and actual rotational speeds. For determining the individual prediction for the oil viscosity, a friction analyzer 22 is implemented or realized by software.
[0063] Furthermore, the setting speed of the camshaft adjuster is used as a suitable operating parameter. The corresponding response times can be taken from existing sensors or can be derived from the corresponding, existing parameters. For determining a conclusion on the oil viscosity, a phase analyzer 21 is realized.
[0064] The central analysis unit 13 monitors time changes in the determined individual predictions with respect to each other, wherein individual predictions are compared with each other at comparable operating points of the internal combustion engine. From the corresponding changes, the central analysis unit 13 derives a viscosity parameter that describes qualitatively and optionally also quantitatively the current viscosity state of the motor oil. The viscosity parameter is, in particular, a viscosity grade, in particular, the SAE specification, and also indicates, in this respect, the current temperature response of the viscosity of the motor oil.
[0065] In FIG. 2 , a corresponding control device 10 for an internal combustion engine is provided with camshaft adjustment without direct hydraulic actuation of the gas-exchange valves. Consequently, the lambda controller 17 is eliminated for determining the viscosity parameter, as well as the solenoid valve analyzer 15 that analyzes the switching period of a solenoid valve in the hydraulic linkage between the cam and the corresponding gas-exchange valve. The other components are provided accordingly and designated in the same manner.
[0066] In both constructions, the control device 10 also detects, by use of the master computer 11 , a parameter that indicates that an oil change has been performed. With the parameter value indicating an oil change, the central analysis unit is reset to a certain extent. The subsequent individual predictions are allocated to a state that corresponds to a new motor oil. Subsequent individual predictions are calibrated or correlated in this way.
[0067] In FIG. 3 , a typical profile of the excitation current 1 is shown, how it is arranged between a cam and the allocated gas-exchange valve for controlling a solenoid valve in the hydraulic linkage. Typically, the coil is first loaded with an activation current I 1 at a time t 1 . This activation current I 1 merely leads to a magnetic bias, but not to a movement of the closing element. For activation, that is, closing of the valve that allows an oil flow into a compensation chamber, this is charged with a closing current I 2 at time t 2 . At this time, the closing element moves into its closed position. Due to an inductive response, the closing current decreases somewhat. After closing, the current is typically reduced to a holding current 13 at a time t 3 .
[0068] For opening the valve, at a time t 4 the current feed is deactivated. Based on a restoring spring, the closing element moves in the direction of the open position. Here, an inductive response is generated, in turn, that expresses itself in a current pulse following time t 4 . The profile of this current pulse correlates with the movement of the closing element of the controlled solenoid valve. A defined position of the closing element, especially its open position, can be derived unambiguously from the profile of the current pulse. This is achieved in the embodiment at time t 5 .
[0069] The times t 4 and t 5 therefore correspond to a first and a second position of the controlled solenoid valve. The time period At between t 4 and t 5 represents the deactivation time for the switching process and thus the adjustment process of the solenoid valve. The time period At is linked directly with the viscosity of the motor oil being used. Studies have shown that there is a linear relationship between the time period At and the kinematic viscosity.
[0070] In FIG. 4 , initially a typical excitation current I is shown like that used for activation of a solenoid valve for controlling the gas-exchange valves. This excitation current I corresponds in its profile essentially to that already shown in FIG. 3 . At a time t 3 , the current is typically reduced to a holding current I 3 that is greater than the activation current I 1 . The time t 4 is specified by the corresponding engine control as a function of the current requirements.
[0071] In addition, in FIG. 4 , the allocated profile of the stroke H of the gas-exchange valve controlled accordingly is plotted in a time profile. The dashed line reproduces an envelope curve h that reproduces the lifting movement of the gas-exchange valve for permanently closed solenoid valve. The envelope curve h therefore corresponds to the movement of the gas-exchange valve when this necessarily and directly follows the movement of the cam.
[0072] Through the deactivation of the excitation current I at time t 4 , the stroke movement of the gas-exchange valve deviates from the envelope curve h. The gas-exchange valve closes at an earlier time. The actual profile of the lifting movement of the gas-exchange valve for the illustrated profile of the excitation current I is shown by the continuous line. As is to be seen, after an initial phase that is identical with the envelope curve h, the profile of the lifting movement deviates from the envelope curve h. The falling movement, that is, the closing of the gas-exchange valve, is presently designated as the ballistic phase, because in this state the gas-exchange valve is retracted into the closed position based on just the spring force. The spring force here works against the system-dependent friction forces. These are caused decisively by the viscosity of the motor oil being used. The ballistic phase can here be divided into two sub-regions bl and b 2 . The first sub-phase b 1 is caused by a closing movement of the solenoid valve for which the same considerations apply as for the gas-exchange valve. Also here the adjustment of the valve is performed, actuated by spring force, against the friction force caused decisively by the viscosity. The second ballistic sub-phase b 2 is then caused just by the gas-exchange valve. The solenoid valve is located in its closed position at time t 5 .
[0073] The gas-exchange valve considered here is an intake valve. The surface area under the curve for the lifting movement of the gas-exchange valve thus correlates with the quantity of air drawn in for a combustion cycle and thus defines the mixture ratio between fuel and air—at a defined injection quantity of the injected fuel. Thus, the oxygen content in the exhaust gas is also simultaneously influenced. This operating parameter or an operating parameter derived from this can be drawn from a lambda controller and allows conclusions to be made on the oil viscosity.
[0074] At a higher viscosity of the motor oil, for example, the ballistic phase b 1 , b 2 shifts to the right, i.e., the gas-exchange valve closes more slowly. The basis for this is to be seen in the higher friction force caused by the higher viscosity. Accordingly, the oxygen concentration in the exhaust gas increases. The lambda controller must output a higher correction value for setting the same desired operating state.
[0075] The boxes of FIGS. 1 and 2 include the following text:
[0076] 11 Master computer
[0077] 13 Central analysis unit
[0078] 15 Solenoid valve analyzer: Detection of the oil state based on activation time and deactivation time
[0079] 17 Lambda controller: Function for detecting a typical lambda controller deviation as a consequence of the oil viscosity
[0080] 18 Forecast unit: Oil-degradation model
[0081] 20 Oil-pressure analyzer: Analysis of the oil-pressure signal
[0082] 21 Phase analyzer: Function for analysis of the camshaft-adjustment (response) time
[0083] 22 Friction analyzer: Estimation of the friction value of the engine
[0084] List of reference numbers
[0085] 10 Control device
[0086] 11 Master computer
[0087] 13 Central analysis unit
[0088] 15 Solenoid valve analyzer
[0089] 17 Lambda controller
[0090] 18 Prediction unit
[0091] 20 Oil-pressure analyzer
[0092] 21 Phase analyzer
[0093] 22 Friction analyzer
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A method for determining a viscosity parameter of a motor oil in an internal combustion engine, wherein a plurality of operating parameters characterizing an operating state of the internal combustion engine are detected and/or determined for an electronic engine control. Several parameters allowing at least a rough prediction on the viscosity of the motor oil are each evaluated for an individual prediction on the viscosity of the motor oil at different times from these operating parameters, and changes in the individual predictions for comparable working points of the internal combustion engine relative to a state of new motor oil are detected. The viscosity parameter is determined from the changes in the several individual predictions. A corresponding control device for the electronic engine control is also provided.
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BACKGROUND OF THE INVENTION
In sewing machines it is desirable in some sewing situations to be able to use more than one needle as in the case, for example, of multicolored embroidery stitching. When substituting two or more needles for a single needle in a zig-zag machine, it becomes necessary to limit the swing amplitude of the needles, or the bight stops, as the two or more needles would swing in a wider path than a single needle which could take the needles out of the area covered by the aperture in the needle plate resulting in a breaking of the needles during penetration of the fabric. It is known to limit the bight stops in mechanically controlled zig-zag machines when substituting multiple needles for single needles, such as for example shown in U.S. Pat. No. 3,296,987 granted Jan. 10, 1967. In such mechanically controlled machines the zig-zag motion is generally imparted to the needle bar by a cam mechanism which is connected to the needle bar mechanism through a cam follower and associated linkage. In order to adjust or limit the bight stops in such machines means are generally provided for altering the linkage between the cam mechanism and the needle bar mechanism.
In electronically controlled sewing machines of the type disclosed in co-pending U.S. patent application Ser. No. 431,649 filed on Jan. 8, 1974, cam mechanisms of the type mentioned above are completely eliminated and logic means are used to select and release stitch information stored in a memory means in timed relation with the operation of the sewing machine. Digital information from the memory means is converted to positional analog signals which control closed loop servo means including moving coil linear actuators directly controlling the position of conventional stitch forming instrumentalities such as the zig-zag mechanism for the needle bar. Therefore, it will be seen that in machines of this type, means other than those which have been provided heretofore must be used for limiting the bight stops. What is required in order to limit the bight stops in an electronically controlled machine is means for limiting the positional analog signals which control the closed loop servo means to thereby provide a signal to said servo means which is reduced in proportion to the reduction in swing amplitude or bight required for the situation wherein multiple needles or the like are used.
SUMMARY OF THE INVENTION
As briefly mentioned above, a machine of the type disclosed in this invention is controlled by electronic means including logic means which select and release stitch information from a stored memory in timed relation with the operation of the sewing machine and in accordance with a pattern selected by the operator. The signal from the memory is presented in digital form and is converted in a digital-to-analog converter and through suitable amplification is fed to a moving coil linear actuator which directly controls the position of the needle bar mechanism. A feedback circuit is also provided which senses the position of the linear actuator in accordance with time and location and modifies the input signal so that the actuator will accurately assume the position as called for by the original information released from the memory.
U.S. patent application Ser. No. 596,683 filed July 16, 1975 discloses a means for overriding the analog signal provided by the digital-to-analog converter for both feed and bight pattern information thereby providing a variable control of said signal to the linear actuator. Such a system is desirable for modifying the pattern information, as for example, to obtain an optimum button hole that would have a balanced appearance. However, it has been found that in situations where multiple needle use can be optionally selected on the machine, fixed bight stop limits should be provided so as to prevent any possibility of needle breakage or the like. In accordance with the present invention circuit means are provided which automatically impose a fixed limit on the analog signal at the output of the digital-to-analog converter when more than one needle is used. Such fixed limit is imposed prior to input to the linear actuator and also prior to the operation of any override controls, as described above, so that there is no danger in the operator modifying the signal with the override control to cause the needles to swing a greater amplitude than is desired.
Accordingly, it is one object of the invention to provide a novel and improved bight stop mechanism for a sewing machine.
It is another object of the invention to provide a novel and improved bight stop mechanism for an electronically controlled sewing machine.
It is a further object of the invention to provide a novel and improved bight stop mechanism for automatically limiting a swing amplitude of the needle bar in a zig-zag sewing machine when in a multiple needle mode.
Other objects and advantages of the invention will be best understood when reading the following description with the accompanying drawings as identified below.
DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a sewing machine showing fragmented portions of the sewing instrumentalities and control mechanisms necessary to illustrate the physical elements of the invention;
FIG. 2 is a general schematic block diagram for the bight control system of the invention;
FIG. 3 is a circuit diagram showing the bight control circuit of the invention; and
FIGS. 4 and 4a are front views showing a portion of the invention when in the single and multiple needle modes, respectively.
DESCRIPTION OF THE INVENTION
Referring to the drawings there is illustrated in FIG. 1, a sewing machine, partially in phantom, including a frame 10 having a bed 12 and a bracket arm 14 supported in an overhanging relationship to the bed by a standard 16. The free end of the bracket arm 14 includes a head portion 18 in which is supported a needle bar gate 20 which in turn supports a needle bar 22 for reciprocating motion in an endwise direction in the usual manner as found in sewing machines. Endwise reciprocating motion is imparted in the needle bar 22 through suitable connection with an arm shaft 24 driven in the conventional manner as by an electric motor or the like (not shown). A plurality of needles 26, as illustrated are supported in the lower extremity of the needle bar 22 and are disposed for cooperation beneath the bed 12 with suitable sewing instrumentalities such as a looper (not shown) or the like.
As is known in zig-zag sewing machines, the needle bar gate 20 is operatively associated with actuating mechanism for imparting lateral jogging motion to the needle bar 22, which, as illustrated in FIG. 1, includes a drive arm 28 pivotally connected to the needle bar gate as illustrated at 30. The drive arm 28 is operably connected to a reversible linear motor or actuator 32 for imparting a linear motion to the drive arm 28 and as a result jogging motion to the needle bar gate 20 through the pivot connection 30. Reference may be made to U.S. patent application Ser. No. 431,649 filed on Jan. 8, 1974 and assigned to the same assignee as the present invention for a more detailed description of the linear actuator. Disposed within the bed 12 and below the needle bar 22 for operation in association therewith is a needle plate 34 which includes a needle aperture 36 having a width sufficient to at least accommodate a single needle during maximum width zig-zag motion. Supported beneath the bed plate 12 is a feed mechanism for feeding the work across the surface of the bed plate and includes a feed dog 38 operably connected with suitable linkage generally indicated at 40 which in turn is connected to a second linear motor or actuator 42. As described in co-pending application Ser. No. 596,683 filed July 16, 1975 and assigned to the same assignee as the present invention, the feed mechanism is also electronically controlled so that electronic signals are fed to the linear actuator 42 to position the feed mechanism for the desired forward or reverse feed in accordance with a selected pattern. Reference may be made to the aforementioned co-pending application for a more detailed description of the operation and construction of the feed mechanism. The feed mechanism itself forms no part of the present invention and for purposes of the present invention other suitable feed mechanism may be incorporated herein.
Referring to FIG. 2, illustrated therein is a schematic block diagram for the bight control portion of the sewing machine. The feed control portion is not illustrated and is essentially the same as the bight control circuitry and reference to the bight control circuitry illustrated in FIG. 2 will be sufficient for purposes of understanding either of the aforementioned control circuits. For a more detailed description of the feed control circuit reference may be made to the aforementioned U.S. patent application Ser. No. 596,683. As previously mentioned, pattern information may be stored in a memory device which in the present invention is incorporated in a MOSFET Large Scale Integration (LSI) integrated circuit designated at 44 in FIG. 2. One method of extracting the information from the LSI 44 for presenting the same to the digital-to-analog converter for bight and feed control is disclosed in U.S. Pat. No. 3,855,956, assigned to the same assignee of the present invention. As disclosed therein digital information related to the positional coordinates for each stitch of a predetermined stitch pattern is stored in a static memory such as included in LSI 44. A pulse generator 46 (see also FIG. 1) is driven in timed relation with the sewing machine and produces a timing signal pulse between each successive stitch. The signal pulses are counted in a counter to provide a timed series of progressively increasing binary numbers corresponding to the progressively increasing number of stitches in the pattern. The output of the counter is applied as the address to the memory to recover as output therefrom the digital information related to the positional coordinates for each stitch of the predetermined pattern. The memory output is applied to control driving devices operatively connected to impart a control range of movement to the needle and the feed of the sewing machine to produce a specific predetermined position coordinate for the needle penetration during each stitch formation.
As further illustrated in FIG. 2, the pulses from the pulse generator 46 are counted by binary counter 48 and presented at address input to the LSI 44. The LSI is illustrated in FIG. 1 as being mounted on a logic printed circuit board 50. The output of the LSI 44 is presented as output digital information related to the positional coordinates for each stitch in pulse width modulated form to digital-to-analog converter 52 for the bight. The LSI 44 may also include a latch whereby the bight information may be held for timed release to the bight servo system at a time appropriate to the operation of the needle jogging mechanism in the stitching operation. Proper timing for the release of the bight information may be determined by the pulse generator 46.
The pulse width modulated signal presented along line 54 to the digital-to-analog converter 52 is filtered, offset by voltage divider 56 (FIG. 3) and scaled by a rheostat 58 in the converter in order to accommodate a specific LSI 44 to those components between the LSI and the load to account for manufacturing variability. Analog signals from the digital-to-analog converter 52 have an output on line 60 to a bight signal control amplifier 62 which outputs on line 64 to the summing point 66 of a low level preamplifier 68 of a servo amplifier system. Further reference to the servo amplifier system may be found in the aforementioned U.S. patent application Ser. No. 431,649.
The output from the bight signal control amplifier 62 is also connected by way of line 70 to FET 72 of the enhancement type, having its gate connected by gate line 74 to the LSI 44. On suitable command the LSI 44 will apply a gate voltage through a latch circuit to FET 72 by way of gate line 74 thereby to place and retain FET 72 in the conductive or ON condition. A feedback signal then passes through line 70 and FET 72 to a wiper of a rhoestat 78 supported on control block 76 (see FIGS. 1 and 3).
Thus, the gain of the bight signal control amplifier 62 may be controlled during pattern stitching or straight stitching through manual adjustment of the manual bight control rheostat 78. The manual bight control rheostat 78 which as seen in FIG. 1 is adjusted by a knob 80 and is mounted on a power supply and override printed circuit board 82. Energization of the circuitry to LSI 44 for applying a gate voltage to FET 72 may be accomplished by a proximity switch associated with knob 80 and may be of the type described in co-pending U.S. patent application Ser. No. 596,685, filed on July 16, 1975, entitled "Digital Differential Compacitance Proximity Switch" which is assigned to the same assignee as the present invention. Rotation of knob 80 rotates wiper 84 of rheostat 78 for adjustment of the bight control signal. Further details of the override arrangement may be had by referring to the aforementioned co-pending application Ser. No. 596,683, filed July 16, 1975. As also mentioned in the co-pending application just referred to, override controls may also be provided for the feed signals and to the balance of the feed and may be represented in the present application by knobs 86 and 88 which respectively control balance and feed through suitable rheostats and circuitry similar to that described in relation to the bight control circuits above. For purposes of the present invention it need only be understood that override circuit means may be provided for modifying the bight control signal after its amplification by bight signal control amplifier 62.
As further illustrated in FIG. 3, the bight signal control amplifier 62 is indicated as an operation amplifier with rheostat 78 providing the feedback to the input. A MOSFET module 90, such as RCA type TP 401A, comprises a plurality of dependent bilateral signal switches one of which is switch 72. The module may also be mounted on a printed circuit board 82 (see FIG. 1). As shown in the schematic of FIG. 3 a voltage signal from LSI 44 on line 74 will place FET 72 in an ON condition, inserting the wiper 84 of rheostats 78 in by-pass arrangement in the feedback circuit. Feedback resistance of the operational amplifier 62 may thereby be reduced to decrease the gain of the operational amplifier and reduce the analog signal to the summing point 66 of the low level preamplifier 68 of the servo amplifier system mounted on servo circuit board 92. Preamplifier 68 drives a power amplifier 94 which supplies direct current of reversible polarity to the electromechanical actuator 32, which in the broadest sense comprises a reversible motor, to position the actuator in accordance with the input analog voltage on line 64. A feedback position sensor 96 mechanically connected to the reversible motor 32 provides a feedback position signal on line 98 indicative of the existing output position. The input analog voltage and the feedback signal are algebraically summed at the summing point 66 to supply an error signal on line 100. The feedback signal from the position sensor is also differentiated with respect to time in a differentiator 102 and the resulting rate signal is presented on line 104 to the summing point 106 of the power amplifier 94 to modify the positional signal at that point. The position sensor 96 may be any device that generates an analog voltage proportional to position and may be a simple linear potentiometer connected to a stable reference voltage and functioning as a voltage divider. The differentiator 102 is preferably an operational amplifier connected to produce an output signal equal to the time rate of change of the input voltage.
While the reversible motor 32 may be a conventional low-inertia rotary d.c. motor, it is preferable, for purposes of the present invention that it takes the form of a linear actuator in which a lightweight coil moves linearly in a constant flux field and is directly coupled to the load to be positioned. This simplifies the driving mechanical linkage and minimizes the load inertia of the system. A suitable power supply circuit (not shown) may be connected to the AC house mains via a transformer for supplying twelve volt 60 hertz to the power supply. The supply, reduced to 12 volts a.c. undergoes full wave rectification and filtration to provide ±15 VDC to the power amplifiers and also to provide, through voltage regulators of a suitable type, ±7.5 VDC in the bight position potentiometer 96 as well as ±7.5 VDC to the digital-to-analog offset voltage dividers in the digital-to-analog converter 52. Although not shown, the power supply also provides ±7.5 VDC to LSI 44. As the power supply itself forms no part of the present invention, reference may be made to co-pending application Ser. No. 596,683 mentioned above for a more detailed description of the type power supply which may be used with the present invention. Also, reference may be made to the same co-pending application for a more detailed description of the construction and operation of the LSI itself.
When sewing ornamental patterns, such as in embroidery stitching or the like, wherein more than one color thread is desired, or in cases wherein parallel lines of ornamental stitches are desired, it is necessary to substitute a multiple needle holder for the single needle generally used with the machine. It will be readily apparent that when more than one needle is held in the needle bar, if the same swing amplitude or bight is used for zig-zag stitching as was in the case of a single needle, one or both of the needles in the case of using two such needles may not align itself with the needle plate aperture 36 during penetration of the fabric. Means must therefore be provided to ensure that the swing amplitude or bight of the needles does not exceed the width of the needle plate aperture. In accordance with the present invention additional circuit means are provided for automatically modifying the electronic pattern control signal for the bight so that when the machine is in a multiple needle mode the maximum bight will be reduced in proportion to the number of needles carried by the needle bar.
Referring to FIGS. 2 and 3, a switch 110 is provided and has its contacts connected in parallel through lines 112 and 114 with the output line 60 of the digital-to-analog converter 52. It will be recalled, as discussed above, the digital-to-analog converter 52 puts out an analog signal which is converted from the digital information from the memory to provide a control signal for the bight in accordance with a selected pattern. In order to reduce the signal from a digital-to-analog converter 52, a fixed resistance in the form of a resistor 116 is placed in line 114 which resistor 116 has a resistance selected so that it will reduce the analog voltage from the digital-to-analog converter in an amount proportion to the number of needles, which in the case of switch 110 and its associated circuit in the preferred embodiment illustrated is selected for twin or two needle sewing. Thus, for example, the resistance of resistor 116 may be such to reduce the output from the digital-to-analog converter by an amount of 50%. It will be further seen that the parallel circuit containing switch 110 and resistor 116 is inserted into the circuitry prior to the application of any override or feedback signals, as would appear on line 70 subsequent to amplification of the bight control signal through bight signal control amplifier 62. Therefore, when the switch 110 is closed to insert the resistance 116 into the circuit any modification of the signal thereafter as through the override controls or the feedback would only have an effect on a reduced value control signal. By this means any modification of the bight control signal would not give rise to any concern that the swing amplitude of the needles would exceed the width of the needle plate aperture 36. It will also be understood, that instead of a single position switch 110 a multiple position switch may be provided wherein multiples of resistance may be inserted into the circuit in the same manner as the resistor 116 for situations wherein more than two needles will be used in the needle bar.
Referring to FIGS. 4 and 4a, as shown therein the switch means 110 may be carried in association with the needle bar mechanism and cooperates with the needle holder so that when more than one needle is inserted into the needle bar the desired resistance will be automatically placed in the circuit. As shown in FIG. 4a, the switch 110 supported by a switch block 118 may be carried by the needle bar 22. The switch 110 includes a fixed contact 110a and a movable contact 110b supported on a flexible member, as illustrated. A collar member 120 is disposed around and in sliding relationship with the needle bar 22 and a frame member comprising a pair of depending legs 122 is fixed to the collar 120 for movement therewith. The legs 122 terminate in a bent portion 124 or form an aperture or passageway 125 through which the shank of a single needle or the post of a twin or multiple needle holder may pass without interference. However, the width of a twin or multiple needle holder will be greater than the width of passageway 123 and will abut the portion 124 during insertion thereof and cause the collar 120 to slide upwardly on needle bar 22 to close switch 110 as shown in FIG. 4a. The collar 120 is normally biased away from switch 110 by a spring 126 connected to a post 128 in collar 120 and to a fixed post 130 on the needle bar clamp 132. When a single needle is inserted, (FIG. 4) the shank will pass through passageway 125 without interfering with the bent portion 124 of the frame member so that collar 120 will not be raised in opposition to spring 126 and switch 110 will remain open. When a multiple needle is inserted, (FIG. 4a) the plurality of needles 26 will be wider than passageway 125 so that full insertion of the multiple needle will raise the frame member in opposition to spring 126 to close switch 110 and thereby automatically insert resistance 116 into the circuit for limiting the bight, as described above.
It will be seen from the above description that a novel and improved bight stop control mechanism is provided for a sewing machine for limiting the swing amplitude of a needle bar during zig-zag stitching when more than one needle is present in the needle bar. In particular, means are provided in an electronically controlled sewing machine for automatically modifying the electronic bight control signals when the sewing machine is placed in a multiple needle mode to limit the swing amplitude of the needle bar so as to prevent any damage to the needles or the work or other elements of the sewing machine. While the invention has been described in its preferred embodiment, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the spirit and scope of the appended claims.
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The present disclosure relates to zig-zag sewing machines including means for controlling the bight stops in order to produce ornamental patterns. In particular, the disclosure relates to electronically controlled sewing machines having storage means for storing stitch information and wherein logic means are used to select and release stitch information in timed relation with the operation of the sewing machine. The disclosure of the invention has particular application in those sewing situations wherein it is desired to use more than one needle in a single needle holder of the needle bar which therefore necessitates a limitation on the magnitude of the jogging or swinging of the needle bar in order to accommodate the multiple needles in the aperture of the needle plate. In accordance with the disclosure of the present invention, whenever more than one needle is used switch means responsive to the presence of more than one needle automatically puts the machine into a multiple needle mode of operation.
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RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 09/498,206, filed Feb. 4, 2000 (now U.S. Pat. No. 6,898,636), which claims the benefit of U.S. Provisional Application Ser. No. 60/118,633, filed Feb. 4, 1999.
BACKGROUND OF THE INVENTION
The present invention concerns generally a process and system for enabling electronic transmission, reception and management of confidential documents over a global communication network such as the internet.
More particularly, the invention is related to a method and system for distributing electronic documents containing sensitive information or data to selected entities, to a method and system for notifying intended recipients of the availability of such documents and to a method and system for tracking access, downloading and uploading of such documents.
People and businesses have become aware of the potential of the “Internet”, sometimes referred to as a “global communications network”, a digital communications network which connects computers all over the world. Unfortunately, security on the Internet remains imperfect, particularly since one of the Internet's design goals—an ability to route communications around damage to any node—makes it difficult to know or control the path by which any particular message will travel to reach its intended recipient, and who else will have access to it along the way.
Network software known as “groupware,” such as “Lotus Notes,” running on a computer network within a company (a “private network” or “Intranet”), permits individuals who have access to that particular network to work together efficiently by sharing documents, and editorial revisions to shared documents such as document updates, “redlined” revised drafts, and comments, as well as e-mail to create conference room collegiality and efficiency among employees actually separated in time and/or space without the security risks associated with the global network.
However, there is still no entirely satisfactory way for people at different companies or other entities to have the benefits of private network security, particularly for ad hoc alliances, i.e., different sets of entities coming together to function as one mega or meta entity, for the duration of some particular project. In such a case, the time and expense of actually wiring a network between two or more companies or other entities and agreeing on one common software package or standard presents a barrier to conventional network solutions. Simply using the Internet remains imperfectly secure for transmission of confidential information without some pre-arranged encryption and current methods for pre-arranging secure encryption processes have been cumbersome and unproductive.
Thus, there is a yet-unsolved problem of permitting different groups of companies or other entities to communicate securely over a global network for different projects, to quickly and inexpensively obtain the benefits of secure groupware in connection with each project, and to be able to add and drop entities without difficulty with respect to any particular project.
For example, in the banking industry, ad hoc syndicates are formed under the leadership of one or more lead banks to permit a number of agent or associate banks to participate in a major loan to a borrower. Such loans have become more common and may involve loans in excess of one billion dollars. Syndication of such large loans is used since any one bank is not prepared to lend such a large amount to a single customer. Conventionally, proposed terms of a loan are negotiated between the borrower and the lead banks, each in consultation with its advisors such as legal counsel, public-relations consultants, accountants and insurance carriers. In some instances, some advisors may be in-house advisors as employees of a given entity and thus constitute an internal team. However, the advisors in many instances may be independently associated with external entities such as law firms or major accounting firms and thus constitute either external teams or combinations of the above. The lead bank(s) negotiates with the borrower to arrive at terms and conditions for the loan, such as the interest rate, repayment schedule, security and the bank's fee for processing and syndicating the loan. The lead bank may agree to underwrite the entire loan in which case the lead bank uses syndication to create sub-loans between it and other banks to raise the funds for the loan. Generally, however, the lead bank(s) agree to lend some portion of the loan and to syndicate the balance, although even in such syndication, the associate banks independently negotiate with the lead bank on loan initiation fees. Each loan agreement between the lead bank and the associate lending bank constitutes a private document since the lead bank always attempts to make a profit by the difference between the loan initiation fee received by the lead bank and the loan initiation fee paid to any associate bank. In the general syndication type loan, where the lead bank only underwrites some portion of the loan, the lead bank will seek other banks to participate in the loan through its network of contacts with those other banks. Further, each negotiation requires transfer of relatively large volumes of documentation and data between the lead bank(s) and the associate banks or between the lead bank(s), the borrower and attorneys, accountants and other entities. While some documentation may be universally distributed, much of the documentation relating to interparty loan terms is desirably restricted to the involved parties.
Information about the borrower and the terms of the loan to be syndicated (except for the lead bank's fee) are assembled by the lead bank(s) in a loan information memorandum. Copies of the loan information memorandum are distributed to associate banks selected by the lead bank who are invited to participate in the loan. The material in the loan information memorandum is generally regarded as confidential business information by the borrower and is treated accordingly by the banks which receive it. Heretofore, loan information memoranda may have been prepared in the form of confidential paper documents or stored in compact-disk read-only memories (“CD ROMs”) forwarded by non-electronic, secure delivery, such as Federal Express, to the recipients.
After reviewing the loan information memorandum, generally in consultation with legal counsel, accountants, and other advisors of its own, an associate bank may notify the lead bank of its willingness or unwillingness to participate in the loan. The associate bank may request additional information about the borrower from the lead bank or may simply propose to take some portion of the loan under terms it proposes to the lead bank. Negotiations may then occur between the lead bank and the associate bank generating more confidential data. Heretofore, such communications between the associate banks and the lead bank may have been carried out by meetings, mail, telephone or telefacsimile.
With respect to a given syndicated loan transaction, one bank may be the lead bank and another an associate bank, whereas with respect to another loan transaction, the positions of the two banks may be reversed. At any given time, a large financial center bank may be concurrently serving as lead bank for dozens of syndicated loan transactions in various stages of the syndication process and as an associate bank for dozens more syndicated loan transactions. Clearly, extensive communications are necessary for engaging in and tracking such transactions. Similar communications needs exist for many other sorts of financial transactions as well as legal transactions and other business dealings.
One form of paperless communication arrangement for financial actions is illustrated by a computer-based system available from IntraLinks, Inc. under the name IntraLoan 1.0. Such system allows for concurrently interconnecting, on a project-by-project basis, members of a plurality of groups of parties. Each group is associated with a particular project so that members of the group can communicate among other members of the group over a global communications network which defines a “virtual network” associated with that project effectively for the duration of the project. Although the above-referred Intraloan I system has provided solutions to some of the foregoing drawbacks of hard-copy communications, one notable deficiency of the above described IntraLoan system is its limitation to an interface not readily conducive for conventional Internet communication. In particular. Interloan 1.0 requires that each participant use Lotus Notes groupware as its interface so that each bank or other institution connected to the system has to be running such Lotus Notes groupware. Further, such system does not have the capability of actively notifying a user as to whether a document is available to be retrieved by that user over a global data communications network.
Thus, it would be desirable to provide a system which enables secure document transmission between users over a global communication network without requiring the users to communicate in advance to establish an encryption method.
SUMMARY OF THE INVENTION
In general, the present invention provides a method and apparatus for enabling secure transmission of documents between multiple senders and receivers. More particularly, the invention includes a secure data storage facility and a computer program operable at such facility for enabling reception, storage and transmission of securely encrypted documents with access to the documents being enabled through a global computer network using conventional network browser software having encryption capability. For example, Microsoft Corporation Internet Explorer 4.0 having 128 bit encryption capability can be used to access the data storage facility. Any receiver can download a document to which he/she has access, make modifications as desired using conventional word processors and upload modified documents with comments to the storage facility. However, original documents at the facility may only be modified by selected persons having authorization to edit such originals. The invention may also provide read-only capability to selected users and preclude upload capability by other selected users. Further, the invention includes active notification to intended document reviewers of the presence of a document at the secure storage facility for review.
Additionally, the present invention provides a computerized method for actively notifying one or more of a plurality of receiving computers generally operated by unrelated business organizations of receipt by a predetermined host server of electronic documents from a sending computer. The sending computer and the receiving computers are each registered in the host server and each are interconnectable to the host server through the global computer network. The method allows for selecting one or more of the plurality of receiver computers to which the respective documents to be retrieved over the network are addressed and further allows for coding the respective documents to establish a level of access. The documents are transferred by the sender to the storage facility (a “network server”) for access by selected receiver computers.
Software resident at the server allows the sender to issue respective notification messages from the server to the selected receiver computers, each respective one of the notification messages indicating that documents are available in the server for their respective retrieval over the network. The selected receiver computers can access and retrieve, if permitted, documents resident at the server. During the access process, the server interfaces with the receiving computer to establish a secure data transmission process. Preferably, the communication process uses 128 bit encryption but can default to a lower encryption.
The present invention further fulfills the foregoing needs by providing a computer communication system for notifying a plurality of receiving computers generally operated by unrelated business organizations of receipt by a predetermined host server of respective electronic documents from a sender computer. The respective documents may be retrieved by each respective receiving computer over a global communications network. The sender computer and the receiving computers are registered in the host server and are interconnectable to the host server through the global communications network (the “internet”). The computer communication system may include software code or modules that allow for selecting one or more of the plurality of receiver computers to which the respective documents to be retrieved over the global communications network are addressed . A notification module allows for issuing a respective notification message from the predetermined server to the selected receiver computers. Each respective notification message indicates that documents are available for their respective retrieval over the global communications network. A retrieving module allows for retrieving the documents by the selected receiver computers over the global communications network upon a respective user of the selected receiver computers issuing a respective download command signal to the server.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing one exemplary embodiment of a communication system in accordance with the present invention;
FIG. 2 is a block diagram showing exemplary operational modules of a host server that may be used by the communication system shown in FIG. 1 ;
FIG. 3 is a block diagram showing exemplary operational modules that may be available to users authorized to access the host server of FIG. 2 ; and
FIGS. 4A–4J collectively show interface screens for communicating data among the various users of the communication system.
DETAILED DESCRIPTION OF THE INVENTION
As suggested above, the present invention can be used for many types of communications between different parties that are associating for a temporary transaction or project, but as competitors or for other reasons are not suitable for a permanent communication network (LAN or WAN) as might be used for a single government agency or single corporation. Projects involving financial transactions are particularly suitable, although not necessarily the only sort of project appropriate, for the method of the instant invention.
Financial transactions suitable for project-based usage-monitoring virtual networks of the invention include but are not limited to:
loan syndication bond underwriting equity underwriting high yield debt placement private placement asset/corporate financing mortgage finance municipal finance asset-backed finance primary insurance reinsurance acquisition or divestiture deals
For purposes of illustration and not of limitation, a preferred embodiment of the present invention in the context of a loan syndication will be described below. In this example, a network service provider (not to be confused with an internet service provider or ISP) which is preferably neither a bank nor a borrower, provides a central node for each virtual network in a collection of virtual networks corresponding to a plurality of different syndicated loan transactions. The network service provider advantageously can provide a suitable level of security with respect to each of the shared transactions, among companies that commonly may be vigorous competitors, with numerous confidential documents that the companies do not want uncontrollably shared among other members of the loan-project group or accessible by outsiders generally. While use of a separate network service provider is particularly preferred, alternatives within the scope of the instant invention are clearly possible, such as the lead bank, one associate bank, or the borrower client providing the central node of virtual networks, and thus constituting the network service provider for one or more transactions.
Some embodiments of the system, particularly in the context of loan or underwriting syndication, provide fast and easy access for associate banks. Associate banks can simply pay a monthly subscription fee to the network service provider for each location, each deal, or each person accessing the network service provider's network. Users can access the service via a communications link provided by a private network provider or a public Internet access provider such as AOL or Time Warner Cable.
Preferably, the system provides a fully provisioned, turnkey service for users, e.g., lead banks, or other underwriting institutions. Once the lead bank or other underwriting institution has established an account with the service provider, documents in electronic form can be uplaoded to the secure site maintained by the service provider. Within a relatively short period of time, the documents are accessible via an internet connection to the network service provider. A variety of collaborative communications options can be chosen by the underwriting institution including e-mail, video broadcasting, video conferencing, and “white boarding” to augment interactive access to the documents.
Any bank or financial institution can be connected to any other entity via a “virtual link” that is established only for a limited time, such as the loan offering period or the loan offering period through the time of closing of the loan followed by the period the loan remains outstanding. These banks become “associate banks” which are authorized by the network service company and the lead bank to access loan offering information by way of the network service provider service. Individuals within associate banks and other external organizations are issued passwords or other access codes which give them access only to those memoranda that are approved by their institution and the lead bank. The term “virtual link” is used to connote a system in which the user has essentially direct access using a password or other codes but which can be readily terminated by canceling the access codes.
Preferably, the network service provider provides a secure virtual network (or “intranet”) for the financial community that supports the secure electronic dissemination of confidential information documents, memoranda and related information and associated communications.
Any authorized bank or financial institution can access information on syndicated loans from any lead bank as long as they have internet access and are authorized by the lead bank.
As suggested above and illustrated in FIG. 1 , the network service provider may provide a web-based computer communication system 8 in accordance with the present invention for managing and developing transaction-related data, such as may be used for funding a syndicated loan, or for closing a business deal involving multiple unrelated business organizations. Communication system 8 can provide a virtual network connection among a lead bank 10 , a borrower 12 , and respective groups of associate banks 14 or investment entities 16 selected by the lead bank for each of a plurality of syndicated loan offerings. Communications between borrower 12 and lead bank 12 may include on the borrower's side various personnel such as its respective legal counsel team 18 , its respective financial advisors 20 , and other advisors including external advisors 22 to the borrower. Similarly, on the lead bank's side such personnel may include its respective legal counsel team 24 , its respective financial advisors 26 and other advisors including external advisors 28 relative to the lead bank. The foregoing communications among such diverse personnel may be in connection with negotiating the terms of a respective loan offering and, in accordance with the techniques of the present invention, may be carried out securely over the virtual network associated with the respective loan offering. In conjunction with negotiating the terms of the loan offering, a package of transaction offering documentation 30 , such as a loan information memorandum including applicable legal, regulatory and financial documentation can be prepared by the lead bank, with drafts and revisions of the memorandum and communications relative to it being passed over the virtual network among the lead bank, the borrower, and their respective advisors.
Once the loan information memorandum has been completed, it can be controllably distributed or disseminated electronically via a host server 32 loaded with suitable server software for permitting distribution of the information over the virtual network to associate banks 14 selected by the lead bank. The lead bank may then negotiate individually with each associate bank to arrive at separate agreements detailing the amount of the total loan which each bank will lend and the fee that each bank will charge for entering into the loan agreement.
FIG. 2 shows further details in connection with the server software which may be readily incorporated in host server 32 . For example, a distribution module 50 allows host server 32 to electronically distribute the loan information memoranda and other financial information related to syndicated loan offerings as well as secure communications among the banks to enable them to conclude the loan transactions efficiently. As suggested above, a usage module 52 allows host server 32 to monitor the usage of each virtual network to permit the borrower in the loan associated with the virtual network to be billed for the virtual network service used in connection with the syndication of the loan for that borrower. Communication system 8 can set up and manage a plurality of separate virtual networks concurrently, with each such virtual network handling a different loan syndication transaction.
Communication system 8 ( FIG. 1 ) through host server 32 can offer a high level of security for all documents and information by employing, as needed, a private communication network 34 , ( FIG. 1 ) such as the “IBM Global Network” (“IGN”), AT&T or MCI, or other providers of substantially secure Internet connections, and by means of security and encryption technologies developed for intranets such as may be readily incorporated in an encryption module 54 . It will be appreciated that the present invention need not be limited to a private communications network since the Internet could be used in lieu of the private network in situations where, for example, security considerations may not be as critical as the timeliness of the communication, as may occur if private network 34 is temporarily disabled and the like. Additionally, host server 32 provides highly secure access control by way of a user authorization module 56 which allows only authorized personnel to access individual memoranda and related documents and communications.
Host server 32 can give each lead bank the ability to electronically link or be interconnected via link module 58 with any number of associate banks or other external entities into a virtual network that may be established only for the time a loan information memorandum is active, or the time the loan transaction generally is active. Law firms, public relations firms, and other companies involved in the syndicated loan process can also be connected via the network service company's virtual network as easily as associate banks that are evaluating the offering. Although documents may be preferably formatted in a Portable Document Format (PDF), such as may be readily implemented with a commercially available document exchange programs such as an Adobe Acrobat program and the like, other formats could be optionally accommodated using a suitable format conversion module 68 . A multimedia module 78 may also be used to process any data to be sent over the virtual network suitable for presentation to the user in forms other than text such as audio, still or moving images, and the like. Further, a notarization module 70 is provided so that any syndicated desk managers have the ability to electronically certify any electronic document forwarded to the users. In a preferred embodiment, notarization module 70 may incorporate electronic signature technology owned and developed by Bell Labs and made commercially available through their sales organization. Thus, the investors and external users may readily verify the authenticity of the alleged source of a given documents and attachments, if any. Further, such users may verify that the document contents have not been changed without authorization. As suggested above, a Frequently Asked Questions (FAQs) module 72 , may conveniently allow authorized users to electronically create, post, and edit an electronic board containing FAQs in connection with a particular transaction. It will be appreciated that although the contents of a FAQ electronic board may contain some generic questions applicable to each transaction, in general the contents of such board may vary considerably based on the specific transaction being handled. A network service company module 74 may conveniently be used to display various data in connection with the network service company such as additional services that may be available by the network service company to the users.
As shown in FIG. 3 , a virtual-network viewer or browser 80 may conveniently provide the end user with an easy-to-use graphical interface to loan information memoranda and other particularly confidential information on the network service company's virtual-network service. The virtual-network service provides identification of services of the network service company available over the virtual network as well as a variety of options for accessing and retrieving financial information.
The virtual-network viewer includes a transaction identification module 82 that, for example, enables an associate bank to quickly find and access information with respect to those syndicated loan offerings for which the associate bank has been authorized to access by the appropriate lead banks. The virtual-network viewer can automatically provide any suitable connection to the user, such as a dial-up connection, to the virtual-network service through sign-on module 84 . The viewer can also prompt the user to input one or more passwords or identifications which should be recognized by either an authorized editor module 86 or an authorized reader module 88 in order to access information on database 38 ( FIG. 1 ).
The virtual-network viewer may also include a multimedia viewer module 90 configured to, for example, provide: viewing of interactive multimedia or mixed media memoranda through suitable decoders, such as audio decoders, Joint Photographic Experts Group (JPEG) still image decoders, and Moving Pictures Experts Group (MPEG) moving image decoders. The virtual-network viewer also supports various collaborative communications options such as e-mail, video conferencing and white boarding which are enabled for a given syndicated loan offering pursuant to instructions from the appropriate lead bank. Of course, the range of multimedia capability and the collaborative communications options will vary depending on the various groupware modules available to the end user. Depending of the level of authorization of a respective user, lead bank module 90 may conveniently allow that user to quickly determine which lead bank is responsible for a given transaction. Similarly, agent bank module 92 and external user module 94 may respectively inform the users of the respective agent banks and external users involved in a given particular transaction.
It will be appreciated that the end users may conveniently use commercially available Internet software browser utilities such as the “Netscape Navigator” or “Microsoft Internet Explorer” to access the virtual-network service, since the virtual-network viewer is presently designed for compatibility with such Internet browsers. Preferably, a plug-in and secure socket layer (“SSL”) can be provided by communication system 8 for additional security.
As will be appreciated by those skilled in the art, the browser software and plug ins in the user computers may conveniently provide the following functions:
Access
Access to the virtual-network-service host site through the subscribers existing Internet connection and Internet browser software, or through a suitable client software, such as “Lotus Notes” client software;
Automated response to security and password inquiries;
Activation
Prompt the user at a subscriber associated bank to enter a password and any other input required for verification, such as a digital signature or key encryption codes;
Automatically send the password and other information to the virtual-network-service host site;
Log the user into the virtual-network-service host site and the relevant authorized databases once verification of the password is successfully completed;
Security
Provide access security for both “Notes” and Internet browser clients using advanced security procedures;
Provide transmission security for both “Notes” and Internet browser clients including encryption/decoding of transmitted files;
Require frequent subscription renewal to restrict subscriber access to short intervals such as monthly intervals;
Viewing
For Internet browser clients, permit viewing of Standard Generalized Markup Language (SGML) pages, such as Hyper Text Markup Language (HTML) pages and play back of multimedia elements;
For “Notes” groupware clients, permit viewing of “Notes” pages and play back of multimedia elements;
Permit viewing of virtual-network-service company coded, multimedia loan information memoranda and related information by authorized users only;
Permit viewing of related documents and files such as e-mail Messages and attachments, and v-mail communications by authorized users only;
Communications
Transmit and receive e-mail for public forums and for private communications to the lead bank;
Receive and play back video-mail communications;
Enable participation in two-way, real-time collaborative communications such as video conferencing and white boarding regardless of client software being used.
Depending on a variety of factors, some users, such as associate banks, and some deals may require different communication bandwidths in order to access the virtual-network service and to download information with acceptable latency for their own unique needs. The network service company can consult with an associate bank to help the bank determine the best possible communications options for its particular needs, taking into account the bank's existing communications capabilities, connections to private communication networks and other factors.
A wide range of communication-link services and options are presently available to businesses. Many of these services are available almost ubiquitously throughout the United States. The communication link services generally vary in cost depending on bandwidth, distance between nodes, traffic, and other factors. Some common types of communication links today are:
modem, with a maximum bandwidth of 56.6 Kbps or so, Integrated Services Digital Network (ISDN), with maximum bandwidths of 64 Kbps and 128 Kbps, T-1, with a maximum bandwidth of 1.544 Mbps or so, Cable Modem, with a maximum bandwidth exceeding 30 Mbps.
Future improvements in high speed communication links and modems can be expected to further improve performance of the present invention.
ISDN and T-1 connections are substantially dedicated communication links and would enable the participant bank to link directly to communication system 8 for a fixed monthly fee. On the other hand, dial-up communications utilizing the public switched telephone network (PSTN) generally avoids such fixed monthly costs to the participant bank, although the communications speed over the public switched telephone network is slow relative to the ISDN and T-1 connections, especially for multimedia information. There are other high-bandwidth links available as well from a variety of carriers and Internet access providers.
As suggested above, a private communication network such as the “IBM Global Network” can also provide associate banks with additional security and with fast access to the virtual-network service. As will be appreciated by those skilled in the art, computer communication system 8 conveniently establishes an intranet or extranet when using such private communication network, as indicated generally in FIG. 1 . Such an intranet or extranet can have the look-and-feel of the Internet, without compromising the security of the information exchanged or distributed therethrough. Thus, while associate banks can have the option of accessing the virtual-network service of the network service company via their existing communications links and/or Internet access, they can also elect to have local access provided by the private communication network. Those companies that may not want to use their existing communications lines for access to the network service company or those companies that do not currently have access to the Internet or sufficient bandwidth to handle the virtual-network service in addition to their normal Internet access can utilize the services of the private communication network for access to the network service company intranet.
As suggested above, many companies access the Internet either through dial-up or dedicated communications lines. The virtual network is effectively an intranet or extranet, so anyone accessing the Internet can quickly become a user of the virtual-network service using their existing skills, software, and Internet access provider. However, in contrast to the public accessibility of the Internet, end users must have a subscription to the virtual-network service, and/or have a valid password assigned by their company for access to the service.
As will be appreciated by those skilled in the art, associate banks will want to ensure that their employees who have been authorized to use the virtual-network service are able to access the service and to view and download information quickly. Although most of the information that can be accessed and downloaded may be text data, there are a variety of factors that will impact the speed with which users can retrieve the information they want. Three important factors in communications are load factor, acceptable latency, and bandwidth. These three factors may be appropriately balanced so that generally optimal communications can be achieved in order to make the experience satisfying and convenient to the end user.
For example, one significant factor is the number of users at an associate bank who will be simultaneously using the communications link to the virtual network. The number of simultaneous users is called “load factor.” Each associate bank's load factor should be reasonably predicted in order to determine an appropriate bandwidth of the communications link to the virtual network. For example, if an associate bank authorizes 100 people in a given month to have a subscription to the virtual-network service and predicts that 20 of those 100 people will be using the service at any given time, then the bank has a load factor of 20. The more people using the link at any given time will impact the speed with which any one user can move through the service host site and retrieve the information he or she is seeking.
“Latency” refers to the time it takes to perform a function on the virtual network. For instance, if a user wishes to play a video clip over regular phone lines, it will take some time for that video clip to be transmitted at approximately 56 Kbps to the viewer. This delay, or latency, will vary depending on the function being performed and the bandwidth of the communications link between the end user and the host site of the network service company. When an associate bank has many users accessing the virtual-network service, the latency each of those users experiences will depend on the bandwidth of the communications link and the load factor. In general, the greater the bandwidth, the shorter the latency, other factors being equal. Acceptable latency periods should be reasonably determined in addition to predicted load factors in order to help associate banks determine the bandwidth needed to provide information with acceptable latency periods.
While bandwidth may be a flexible variable in the communications equation, high bandwidths can also be quite costly. It may be necessary from time to time and from user to user to make a trade-off between costs and latency in choosing a bandwidth for the communications link to any given virtual-network service.
For the convenience of the end users, some segments of the loan information memoranda offered through the virtual-network service may be designed as interactive multimedia documents that will include video, graphics, audio and other multimedia elements. Multimedia communications provide the end user with a wide variety of information in addition to that provided by a standard text memorandum. However, multimedia information can be substantially taxing on a communications virtual network. A bank should take this into consideration as it is assessing its communications requirements.
Lead banks may be able to choose from a variety of collaborative communications options that enable them to communicate with associate banks and other external entities via a virtual network of the network service company. The collaborative communications options let a lead bank take advantage of the flexibility of the virtual networks established by the network service company to speed and improve communications among the various banks and other entities on the network.
Collaborative communications can be supported on virtual networks of the network service company, notwithstanding that banks may vary in their ability to support the various communications options depending on their communications capability and particular interfaces to the virtual-network service.
By way of example, in the context of a syndicated loan, a syndication desk, i.e., one or more individuals authorized to be responsible for the management of any given syndicated loan, of a lead bank is able to broadcast and/or selectively send e-mail messages processed by a syndication desk module 60 to associate banks and vice-versa. For example, amendment data processed by an amendment module 62 may be used to effectively make changes to a loan information memorandum. The amended memorandum can be then conveniently distributed via e-mail using E-mail module 64 for providing associate banks with up-to-the-minute information about a loan offering. Amendments or messages can be appended to the loan information memorandum at the host site of the network service company where they can ordinarily be viewed by anyone accessing the virtual-network service who is authorized to access the loan information memorandum. E-mail messages or amendments can also be downloaded for printing or for attachment to local documents associated with the memorandum. Similarly, comment data in connection with a loan offering may be processed through a comment module 66 for appropriate distribution to authorized users.
E-mail messages sent from or to a lead bank's syndication desk are secure in transit over the virtual network. After receipt, responsibility for the security of e-mail messages rests with the party which received it. The network service company can provide rapid, secure delivery of a response to the associate bank once the response is transmitted by the lead bank.
Additionally, the lead bank may be responsible for amendments to the loan information memorandum and for posting e-mail and/or amendments to the memorandum. Posting of such messages or amendments can now be securely done through the communications system without having to expend substantial resources, such as paper for hard copies or the relatively large staff that would be required to generate and track such hard copies. Lead banks can send video clips to associate banks and to organize video conferencing sessions, either with all associate banks on the network or with selected associate banks. It will be understood however that sufficient bandwidth must be available at participating associate banks to support real time, full duplex video transmission in order for a video conferencing session to occur. Lead banks can set up connections with associate banks for white boarding and for real time collaborative annotation of documents.
As shown in FIG. 1 , a database management tool 36 using software techniques well known to those skilled in the art, allows for electronically coupling host server 32 to a database 38 made up of a first database section 38 A where the transaction-related data may be conveniently stored. Database 38 is further made up of a second database section 38 B for storing user categories data. For example, in addition to the authorized syndicate desk managers, agent bank user access to first database section 38 A may be selectively controlled or categorized at least into two types, Editor and Reader.
By way of illustration and not of limitation, agent users categorized as an agent editor may for the specific transactions for which they are authorized:
store summaries of transaction-related data or documents in database section 38 A; edit such summaries of transaction-related data or documents stored in database section 38 A; create a new user document requesting user access for investor or external users as well for additional agent editor and/or readers; authorize investor and external users to a given transaction; create additional contents of transaction-related data for storage in database section 38 A, including Frequently Asked Questions (FAQ) documents, and memoranda and reply documents; edit such additional contents, and FAQ documents; View activity reports in connection with a given transaction.
By way of comparison a user categorized as an agent reader may be granted access to transaction-related data stored in database section 38 A but has no authority to change such data, accordingly an agent reader could:
read summaries of transaction-related data or documents in database section 38 A; create a new user document requesting user access for investor or external users as well for additional agent readers. However, agent readers will not be able or authorized to create users with agent editor access rights; authorize only agent readers a given transaction; read contents of transaction-related data in database section 38 A, including Frequently Asked Questions (FAQ) documents; create memoranda and reply documents; view activity reports in connection with a given transaction.
FIGS. 4A–4F collectively show various illustrative browser interface screens that conveniently allow a respective user to communicate with other users via the host server. FIG. 4A shows an exemplary interface screen 100 for electronically submitting or registering a new user. For example, an authorized transaction sponsor may enter into a datafield 102 the full name of the new user. For example, the specific agent bank employer of the new user may be selected by scrolling through a list of agent banks with an agent bank scroll indicator 104 . The user access category may be similarly selected by selecting the appropriate category assigned to the user by scrolling through a list of categories with a user access scroll indicator 106 . Additional details in connection with the new user, such as address, telephone number, etc., may be readily entered in datafields 108 .
FIG. 4B shows an exemplary interface screen 110 for submitting a new transaction or deal into the system, and displaying the deal sponsor. Interface screen 110 includes respective scroll bars 112 and 114 for selecting participating deal agents and selecting a list of E-mail recipients approved to receive E-mail in connection with the deal.
FIG. 4C shows an exemplary interface screen 120 that allows an authorized user to distribute a document while permitting that user by scroll bars 122 and 124 respectively to select respective users that will have editor rights relative to the posted document and any attachments thereto, and further permitting that user to select users that will only be able to read the document and attachments but will not be able to make alterations to the posted document or its attachments.
FIG. 4D shows an exemplary interface screen 130 that allows an authorized user, such as a syndicate desk manager, to add or remove users in connection with each respective deal. FIG. 4E shows an exemplary interface screen 140 that allows one or more respective users, such as respective lead banks, to list or sort the various other users, such as agent banks or external users, cooperating with that lead bank on any given deal by clicking on respective links, such as links 142 and 144 . By way of example, other users participating all approved agents, to sort all such agents based on the particular deal in which they are participating.
In another feature of the invention, as illustrated by FIG. 4F an interface screen 150 may provide respective links, such as links 152 , 154 and 156 that would allow generation of an activity report in connection with any particular transaction task required to move forward the transaction or deal. By way of example, such reports may include data that would enable a requester to quickly determine who has or has not downloaded any specific transaction-related data, such as E-mail or documents attached thereto.
By way of example, reference is now made to FIG. 4G which shows one form of potential holding screen for a person accessing a secure website hosted by a network service company such as IntraLinks, Inc. In this instance, the user James has entered his assigned user name and password so that he is taken to a first opening screen which shows all the deals to which this user has access. In this instance, there is only one deal identified as intellectual property. When user James clicks on the intellectual property link, the screen opens to what is shown in FIG. 4H listing all the documents that are currently involved in the intellectual property deal. These documents may be broken down by category such as legal documents, status report or technical information. The screen actually prints whether this is a draft or original of the document, title of the document and the author of the document. User James can then select any of the documents to expand by simply clicking on the documents which will then open the screen shown in FIG. 4I . This screen gives various characteristics of the document including the author, the date it was created, the last time it was modified and who modified the document. In addition, the screen lists the editors of the document and all of the individuals who have access to read the documents. There may also be a message associated with the document such as is listed in body indicating that the document in question is an early draft. The low pat description is a link which allows the document to be opened by clicking.
At the top of the screen shown in FIG. 4I , there are various options that can be utilized by the document editor. In this case, James is listed as a document editor. In particular, the editor has the option of adding or removing document editors, adding and removing document readers and viewing access reports. The access report is a significant feature as shown in FIG. 4J since it allows the document originator to see a list of all the people who have access to the deal and whether they have been authorized to access the document or not authorized to access the document. In addition, for each person who is authorized to access the document, the system provides a report as to when that person actually did access the document.
Referring again to FIG. 4I , if the originator wishes to add or remove document editors or document readers, he can click on respective ones of the links at the top of the screen which will open up other screens (not shown) These other screens are essentially identical with one screen being used to add and remove document readers while the other allows adding and removing document editors. The difference between the two types of persons having access to the document is clearly that one has the ability to edit the document while the others only have the ability to read the documents. Of course, any reader can provide feedback using e-mail to send any comments to the originator concerning a document that has been read.
In addition to the actual documents that are available on the intellectual property deal site, there are also messages that have been transmitted from either editors or readers and those can be accessed by clicking on the messages icon. Each of the messages includes the sender's name, the date and actual time that the message was sent and the subject of the message. By clicking on each of the message links, the reader is taken directly to the message.
As can be seen, the system provides a secure site for placing documents and messages to be transmitted over the secure virtual network and allows authorized users to read or edit messages according to their level of authorization. Any documents that are edited are immediately available on the system so that other persons involved in a particular deal or loan scenario has access to the edited or modified documents immediately without having to wait for delivery of hard copies of these documents via a courier service. In addition, the system provides tracking of each document to allow the editors to see who has had access to the messages and documents and who has modified or edited any of the documents.
The web site powered by host server 32 may be accessible from all of the virtual networks supported by the network service company that features information about the company and the range of products and services it provides. Users of the virtual-network service can be directed to the appropriate virtual-network sites via the service host site. It is thus readily realizable to take users to the selected virtual network site automatically via a suitably coded hyperlink. The network service company can advertise its products and services on the virtual-network-service host site. In addition, advertising services may be provided to the lead banks or others in the form of marketing messages to users accessing either the service host site or the virtual-network service sites.
Each virtual-network site can be accessed independently or through the service host site of the network service company. Subscribers may use the virtual-network viewer in order to access the virtual-network service. The viewer may be used to arrange icons or links indicative of associate banks that participate in the virtual network in a way that is substantially equitable to all lead banks and give associate banks the ability to locate automatically a particular lead bank or loan information memorandum, for example, by searching by borrower's name.
Once becoming a respective authorized member of the virtual-network service, each associate bank can access each virtual network corresponding to each active syndicated loan offering for which the associate bank has been granted access authorization by the lead bank for the offering.
The host web site may provide a generic interface that lists all banks which are presently registered members of the virtual-network service of the network service company in a lead-bank capacity. Only authorized users at associate banks will then be able to access a particular database location corresponding to a given lead bank to see what loan information memoranda are available for their perusal. As suggested above, individual users will have a respective category of access level to the various loan information memoranda so that access to the various financial information is controlled based on the respective category or role assigned to that user. It will be appreciated that access to the transaction-related data may further be a function of the present stage of any given transaction. For example, in a pre-launch transaction stage access may only include agent editors, agent readers and external users, while in a launch stage access may further include investor users. Finally, once a transaction is closed no further access may be given to any user, except those who may be specifically involved in post-closing activities in connection with the transaction.
Each lead bank can include as many loan information memoranda and related information as desired for access by way of its assigned database location in the virtual-network service. A different virtual network is established for each loan information memorandum. Thus, access by associated banks may be controlled through passwords. An associate bank that may be authorized to access the virtual network associated with one syndicated loan offering from a particular lead bank might not be authorized to access the virtual network associated with a different syndicated loan offering, from the same or a different lead bank.
Additional information such as closing documents associated with a loan information memorandum may be added to the lead bank's site. The additional information is forwarded to the network service company which converts the information to an appropriate format and emplaces the new pages with the original loan information memorandum. The virtual-network service of the network service company can disseminate closing documents electronically over the virtual network to associate banks which have elected to become participant banks in the loan transaction. In the post-closing period during the term of the loan, payments under the loan can be managed over the virtual network, and information concerning compliance of the borrower with the terms of the loan generally can be disseminated to participant banks over the network.
For reducing security concerns, it would be preferred that the network services company be responsible for doing any required document conversion concerning a syndication offering within the appropriate virtual network. Typically, such information includes the loan information memorandum, lists of frequently asked questions, and amendments to the loan information memorandum. Information can be converted and emplaced on a virtual network using off-the-shelf Internet conversion and emplacement tools. For example, a loan information memorandum in text form can be converted into a format that can be placed in the lead bank's site. Duly authorized users at associate banks can then access the virtual network for that syndicated loan offering and read the memorandum on a computer display screen using the virtual-network viewer. The users can also download the memorandum, as well as import financial data from the memorandum into commercially available spreadsheet program such as “Excel” or “Lotus” 1-2-3.
If desired, the network service company may provide suitable software spreadsheet modules in the host server that can convert and emplace spreadsheet models associated with a loan information memorandum so that users can consider various financing scenarios without having to import the financial data into a local spreadsheet or create their own macros. Such a spreadsheet service can substantially improve a user's ability to evaluate a loan offering.
As will be appreciated by those skilled in the art, substantially secure communications is particularly of the utmost concern to all parties to a syndicated loan transaction: the borrower, the lead bank, and the associate banks. The virtual network system of the present invention may readily provide substantial intranet security to ensure that information and communications among all the various parties that may be on the virtual network are secure. There are several well-established security and encryption technologies which can be used by the network service company, including both secure socket layer for generic Internet or intranet communications and the security provided by groupware server management software for supporting communications between users of groupware, such as “Lotus Notes” groupware.
The system of the present invention conveniently provides a centralized firewall that may be employed to protect confidential information so that no unauthorized access to such information occurs. The firewall, such as may be effectively used for corporate intranets, can be applied in each virtual network created by the communications system 8 of the network service company. Associate banks and other external entities on a virtual network are treated like remote corporate offices and are restricted by the firewall from uncontrollable access to the information from each lead bank's site. In addition, if needed, respective inter-bank firewalls may be established between the host site of each lead bank to prevent one lead bank from accessing information in the host site of another lead bank. The architecture may be particularly suitable for communication among multiple unrelated entities, since a centralized firewall simplifies the logistics of each user having to separately provide access through their own respective local firewalls. In such a centralized architecture, server access security data is conveniently processed by a central processing module as opposed to being processed at each respective local site of the user. Similarly, system backup and recovery may be better handled by a centralized backup and recovery module as opposed to such recovery tasks being separately handled at a multiplicity of local sites.
As suggested above, usage module 52 (see FIG. 1 ) may provide substantially continuous monitoring of access and activity by associate banks and other entities throughout the virtual-network-service host site, the virtual-network service company site, each individual lead bank's site, and other sites. This information can be collected and made available to lead banks on a regular basis, and used for billing, planning, marketing, and utilization review.
The communications system of the present invention has the ability to quickly interconnect each designated associate bank to essentially form a virtual network which lasts only for the period that those banks need to access a particular syndicated loan information memorandum, for example, 60 days. Moreover, such system can establish and manage a virtually unlimited number of such virtual networks concurrently in support of a corresponding number of different syndicated loan offerings. Such concurrent virtual networks can be established in an intranet format via a private communications network such as the “IBM Global Network” which can provide substantially secure and reliable connectivity to globally-based businesses. The private communications network can also provide local access services for those companies that may not have Internet access or may want to expand their access for the virtual-network service of the network service company.
To better address the issues discussed above related to bandwidth, latency, etc., it is generally recommended that a dedicated T-1 or cable modem (1.544 Mbps) communications link or the like be established between each respective lead bank and the host site of the network service company for the purpose of high speed access to the virtual networks corresponding to the syndicated loan offerings of the lead bank, as well as updating information accessible over the virtual networks such as amendments to the loan information memorandum and taking part in collaborative communications such as e-mail and video conferencing.
The network service company can monitor each associate bank's access to a specific loan information memorandum. This monitoring capability enables the lead bank to bill accurately its borrower clients for electronic access to loan information by associate banks. As suggested above, the communication system preferably has a software module that can take raw data provided by the server and the network traffic monitoring software and through the use of well known statistical techniques provide detailed billing to the respective lead banks. The usage monitoring software may be readily configured to record the raw data necessary to track and record for example the following parameters:
Subscriber password, Location of subscriber activity by page, Time and duration of each activity, Type of activity (i.e., viewing site, downloading, communications, etc.), and Bandwidth consumed.
The network service company may readily configure a bill processor in the host server to route the basic telecommunications charges from a communications carrier and break them down into a bill that will give each lead bank the ability to bill back its borrower clients by each offering document. Such processor may also detail all activity by subscriber. The billing processor software preferably formats the raw data in a form that is readily acceptable to the lead bank. Additionally, the billing software can also apply any mark-up or tariffs to the basic telecommunications bill.
Each borrower can therefore be billed back accurately on a monthly basis directly by the network service company for communications services involving the borrower's syndicated loan offering. The bill can detail each associate bank's activity on the virtual network specific to each loan information memorandum, with detailed information about each accessing party, the time spent accessing each loan information memorandum, and each party's activity, such as reviewing the loan information memorandum, and e-mailing comments with respect to the memorandum.
The virtual-network-service host site can be distributed over a plurality of server computers and therefore host server 32 should be viewed as an illustrative example of one of such multiple servers. The server computers can work together to provide essentially seamless access to a large number of users on various platforms with varying communications speeds. The server computers of the network service company can run under server management software for groupware such as “Lotus Notes,” which in turn may be responsible for coordination of services, maintaining state and system status, monitoring, security, and other administrative functions.
In another advantage of the present invention, since a subscriber having a suitable Web browser may directly access any server computer, the network service company need not provide each subscriber with subscriber application software that includes software modules for access, activation, viewing, and communications relative to the virtual-network service. Further, such subscribers need not be sent a floppy disk or CD-ROM containing the subscriber application software specific to their requirements.
The user computers may conveniently be personal computers running any suitable operating system software such as a Windows operating system software, commercially available from Microsoft Corporation and should work in conjunction with the “Netscape Navigator” Internet browser, the “Microsoft Explorer” Internet browser, “Lotus Notes” client software and the like. The system operates on the basis that the subscriber's computer is loaded with an Internet browser such as “Netscape Navigator” or “Microsoft Explorer” or groupware client software such as “Notes” or “InterNotes” client software and is connected to a communications link such as a dial-up or dedicated connection to the “IBM Global Network’ or a dial-up or dedicated connection to an Internet service provider.
Once a suitably equipped personal computer is available to the user or subscriber, the subscriber should be able to connect to the virtual-network service of the network service company. As will be appreciated by those skilled in the art, the web browser and any required plug-ins can readily provide a virtual-network browser. The browser is conveniently used in order to download and view offering memoranda. The viewer provides subscribers with an interactive and graphic interface to offering memoranda and other associated documents such as annual reports and 10K reports. The virtual-network viewer should provide the ability to play back video clips and other multimedia components of a document. Additionally, the viewer may include the multimedia players or plug-ins that can be used to play back multimedia elements resident in generic HTML pages.
Subscriber access to the virtual-network-service host site and any lead bank's host site may optionally be controlled using “Lotus Notes” management software at the host facility. Each individual user at a subscriber associate bank should have an appropriate password assigned by the network service company after the subscriber bank is authorized by the lead band and the associate bank which employs the user in order to access the virtual-network-service host site. “Notes” management software uses a proprietary security process for access for “Notes” clients, and defaults to secure-socket-layer security for browser clients accessing the service through the Internet. When a user at a subscriber associate bank initiates the opening of a loan information memorandum, for example, the virtual-network-service viewer is preferably launched on a personal computer at the subscriber associate bank which enables the user to view the document.
“Notes” management software can provide the ability to make available select information to a subscriber depending on which transactions the subscriber is authorized to view. When a user at a subscriber associate bank accesses the virtual-network-service host site, he or she should be permitted to see only information from those lead banks concerning those respective loan offerings that the subscriber associate bank has been authorized to view. This security measure can ensure that a subscriber does not become privy to any loan offering transactions being conducted by means of the virtual-network service other than loan offering transactions for which the subscriber has been authorized to view.
The system may also support various collaborative communications capabilities, including video conferencing and white boarding for both Internet browser clients and “Lotus Notes” clients. Video-conferencing and white-boarding capabilities are embedded in “Notes” client software. Depending on the communications capabilities of the Internet browser software installed in the personal computer of a browser client, the plug-ins therein may have to be supplemented to enable Internet browser clients to participate in video conferences and white-boarding sessions.
Each user should first be authorized by both the lead bank as well as the subscribing associate bank which employs the user before the user is given a subscriber password and access to any virtual-network-service site which identifies syndicated loan offerings by the lead bank. The user computers may be interconnectable to the virtual-network-service host site by inputting the network-service company's Internet address into an appropriate field within the browser and initiating connection to the host site via the browser.
When a user at a subscriber associate bank is connected to the virtual-network-service host site, a suitable database management tool, such as management tool 36 ( FIG. 1 ), may search a subscriber database and ask for the subscriber's password. The management software can then compare the password entered by the user with the subscriber's password from the subscriber database to ensure that the two passwords are identical. If the passwords match, then the user is guided to a first navigation page of the virtual-network-service host site, which serves to welcome the user and to help prompt him or her through the host site to ensure that the user reaches his or her target destination.
The virtual-network-service host site, using, for example, the database management capabilities of the “Notes” management software, can assist a user from an authorized subscriber in accessing information quickly and easily while providing a high level of security. Using information in the database about each subscriber, the virtual-network service preferably presents custom screens or pages, generated essentially in real time, that list only those lead banks that have authorized that particular subscriber to gain access to the host sites of the lead banks in question. Once a desired lead bank is selected by the user, the user is preferably presented with a list of only those transactions that the subscriber which employs the user is authorized by the lead bank to see. Such a process serves not only as a navigation tool for users, but provides a high level of security in preventing personnel at a subscriber associate bank from learning about loan offerings being handled by the virtual-network service that the subscriber bank has not been authorized to view.
The user log-on screen preferably includes instruction or help scripts and menus that can communicate with the server software to move a user through the access security process. The user will be prompted to enter his or her password in order to access the virtual-network-service host site. The server software can verify automatically the password entered by the user with the password issued by the network-service company which is resident in a subscriber database. All access security procedures provided by the server software should be followed, but in a manner which is effectively transparent to the user. Essentially, all an authorized user from a subscriber bank needs to do in order to access the virtual-network service is to provide the correct password.
The virtual-network-service host site may for example use “Notes” management software to generate hard or soft pages in essentially real time for each subscriber which present only those lead bank sites that the subscriber is authorized to access. An authorized user from a subscriber bank can select a specific lead bank and is then preferably presented with those transactions—and only those transactions—he or she is authorized to see from that particular institution. The user can then select a specific loan offering transaction from the list of authorized transactions and can then view a list of all documents and communications related to the selected transaction. Preferably, the user can only view the loan information memorandum and related loan information if the subscriber which employs the user has the virtual-network viewer provided by the network service company. The virtual-network viewer can be automatically launched if it is present on the subscriber's personal computer.
Of course, the system should enable subscribers to transmit and receive all files in a secure manner. Internet browser clients may be provided with secure-socket-layer encryption and decoding software. Other security techniques which may be used include, for example, if using the “Notes” server software, to use such server software to support secure-socket-layer-encrypted communications as a default to the “Notes” security software. In particular, “Notes” server software can automatically detect whether a user is an Internet browser or a “Notes” client and automatically invokes the appropriate security measures. The secure-socket-layer software on the subscriber's personal computer should be launched automatically for communications if it is not already present in the subscriber's browser application software.
The preferable viewer is preferably an Internet browser software such as “Netscape Navigator” or “Microsoft Explorer” but it could be “Lotus Notes” client software. For example, the “Notes” management software can detect which viewer is being used, and, for users of Internet browser software, automatically convert the network-service company host pages into HTML using “Domino” server software. Subscribers may use all the standard features of the client software to view the documents and conduct communications. Multimedia elements in the pages may be played using the multimedia players embedded in the viewer.
A subscriber should be able to send e-mail messages relative to a specific document the subscriber is authorized to view back to the lead bank which prepared the document, as well as participate in discussion forums relative to the document. Such a discussion forum may be established by a lead bank, which can select which subscribers can participate in the forum. A lead bank may establish a substantially private forum for a specific transaction and limit participation to members of the relevant virtual network associated with the transaction. A lead bank may also establish a general public forum for communications that are not necessarily associated with any particular loan offering or other transaction. An authorized user will be presented with all forums available to him or her, whether related to a specific transaction or not.
E-mail is preferably implemented within the browser application software by presentation as a selection within the user interface—by an e-mail button, for example. Users may be able to click the e-mail button in the browser application software and send a communication back to the lead bank whether the subscriber which employs the user is an Internet browser client or “Lotus Notes” client.
Additionally, any authorized user at a subscriber associate bank should be able to conveniently retrieve e-mail messages sent by the lead bank. The user may be notified when he or she logs into the virtual-network service that there are unread e-mail messages in the subscriber's “in box” Subscribers should also have access to the e-mail messages sent by other subscribers as part of a forum.
E-mail communications may be managed by any commercially available database management system such as the “Notes” database management software. An e-mail message generated by a subscriber with respect to a particular loan offering may go either to 1) the lead bank for that offering, or 2) a forum established by the lead bank for that offering. E-mail messages specific to a transaction may be linked to the transaction as “threaded discussions” and may be hierarchically organized and presented within the virtual-network-service software. A specific screen or page should be created as part of the software application that lists each transaction and all related communications as posted by the lead bank. Preferably, only the lead bank should have the ability to post e-mail messages to a transaction offered by the lead bank or to establish a forum relative to one of its transactions. For a forum, e-mail messages should preferably be automatically posted in the forum and hierarchically organized as part of the “threaded discussion.”
An authorized user at a subscriber associate bank should be able to store e-mail messages locally which he or she generates as well as e-mail messages received from a lead bank or read as part of a forum. Preferably, the e-mail user interface includes an option to enable an authorized user to name and store the e-mail on a user-interface “desktop,” a hard disk, a floppy disk or other external storage device. Other standard housekeeping functions should also be provided, such as deletion of e-mail messages. Subscribers preferably should not have the option of forwarding e-mail messages in order to discourage users from forwarding an e-mail message relative to a specific transaction to a party not authorized to be privy to the transaction.
Lead banks should have the option of creating video clips which may be produced and encoded by the network-service company. Such video clips may be sent to select subscribers or broadcast to all subscribers. The video clip or other v-mail communication may be stored at the virtual-network-service host site and may be downloaded by those subscribers who are authorized to receive v-mail by the lead bank which originated the v-mail.
The ability to designate those subscribers that can receive a particular v-mail transmission may be determined by the lead bank using the syndicate-desk application which should enable a lead bank to designate recipients of v-mail transmissions on a case-by-case basis. A subscriber who is designated to receive a v-mail transmission may be notified via the “Notes” management software that a v-mail transmission is waiting in the subscriber's “in box” the same way that the subscriber is notified of unread e-mail messages.
Once a subscriber has been notified of a pending v-mail transmission, the subscriber should be prompted to download the transmission. Video clips or other video transmissions may be downloaded to a local e-mail server or to the subscriber's hard disk if no local e-mail server is present.
Subscriber application software should support video conferencing and white boarding communications between subscribers and the lead banks. Preferably, only a lead bank may establish a video conference or a white boarding session. The lead bank designates those subscribers that are authorized to participate in the session.
As should be appreciated from the above description of the features of the present system, the users are no longer confined to any specific groupware, such as Lotus Notes groupware, in order to obtain access to an external service provider. The present invention conveniently eliminates any specific groupware requirement by allowing Internet access using any commercially available Internet browser.
Reference is now made to an example architecture for a system of the present invention having a local domain, a server domain and a remote user. Within the local domain, a sender computer may use Lotus Notes to create a document or memoranda or control sending of an electronically loaded document destined for the remote user. The sender computer is used by a user to code the message using a secondary domain name such as @secure which causes a mailbox to transfer the message to an @ secure domain database. The message is then replicated over a dedicated connection to a transition database in the server domain. An email message is sent from the transition database via a conventional SMTP connection through the internet to the remote user. The remote user initiates a connection via the internet to the server domain where a programmed processor establishes an encryption connection to the remote user. Once the appropriate encrypted protocol is established and passwords and ID confirmed, the programmed processor allows the remote user to view or receive the message via encrypted transfer.
Referring now to an alternate architecture example in which security is established between the a sender computer and a server domain (using a similar encryption protocol as just described between the server domain and a remote user) it is noted that in this example information can be transmitted or accessed by mobile users. In this form, the server domain processes all messages in encrypted form and still sends email notification of available documents using conventional SMTP.
It will be understood that the specific embodiment of the invention shown and described herein is exemplary only. Numerous variations, changes, substitutions and equivalents will now occur to those skilled in the art without departing from the spirit and scope of the present invention. Accordingly, it is intended that all subject matter described herein and shown in the accompanying drawings be regarded as illustrative only and not in a limiting sense and that the scope of the invention be solely determined by the appended claims.
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A method for storing, accessing and interchanging voluminous confidential documents for review by a plurality of parties and for notifying selected ones of a plurality of receiving computers generally operated by unrelated business organizations of receipt by a predetermined host server of such electronic documents from a sender computer for review. The documents are reviewable by each respective receiving computer over a global communications network. The sender computer and the receiving computers are registered in the host server. The method comprises selecting one or more of the plurality of receiver computers to which selected documents are to be reviewed over the global communications network are addressed, storing the respective documents in a first database that is local relative to the sender computer, replicating the documents stored in the first database in a second database that is local relative to the predetermined server, issuing a respective notification message from the predetermined server to the selected receiver computers, each respective notification message indicating replicated documents available in the second database for their respective retrieval over the global communications network, and retrieving the replicated documents in the second database by the selected receiver computers over the global communications network upon a respective user of the selected receiver computers issuing a respective download command signal to the predetermined server.
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RELATED APPLICATION DATA
This application claims priority under 35 U.S.C. §119 and/or §365 to Japanese Application No. 2014-124609 filed Jun. 17, 2014, the entire contents is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a numerical controller for controlling machine tools and industrial machines, and more particularly, to a numerical controller having a function of switching a position control gain during synchronous control.
Description of the Related Art
In a synchronous controller configured so that the position of a master axis is fetched by means of a sensor or the like and a slave axis is synchronized with the master axis position, an actual position (real position) of the master axis is obtained and a command synchronized with the real position is given to the slave axis. If the synchronization command is given to the slave axis based on the real position of the master axis, a delay of a servomotor for the slave axis inevitably occurs as a synchronization error. To cancel this synchronization error, a position (expected position) at a future time corresponding to a position control gain of the slave axis is expected, and a synchronization command for the expected position is given to the slave axis.
Japanese Patent Application Laid-Open No. 2011-67016 discloses a technique for a machine or the like to which an electronic cam is applied. According to this technique, a phase lead circuit called a lead-angle control is added to a servo controller for positioning, whereby a delay of a control system is compensated to reduce a positional deviation, which is the difference between a position command value and a position detection value. Further, Japanese Patent Application Laid-Open No. 60-5306 discloses a technique in which a gain is switched during control.
If the position of the slave axis is falsely expected on account of a change of the speed of the master axis, the difference between the expected position and a synchronous position of the slave axis undesirably increases. Consequently, a correct synchronous position of the slave axis cannot be calculated, so that a synchronization error inevitably occurs. Thus, if the master axis speed changes, the slave axis cannot correctly synchronize with the motion of the master axis. In general, the longer an expectation time, the larger the difference between the expected position and the synchronous position tends to be. The lower the position control gain, the longer the expectation time is, the larger the difference between the expected position and the synchronous position is, and the higher the synchronization error is.
For example, a packing machine is configured so that goods are packed, by a holding device driven by a slave axis, into a box that is conveyed by a conveyor driven by a master axis. In the packing machine of this type, the position of the conveyor is obtained by a sensor or the like, and synchronous control is performed such that an axis for packing is driven in accordance with the position of the box on the conveyor. The packing machine cannot perform accurate packing unless the position of the axis (slave axis) for packing is correctly synchronized with an actual position (real position) of the axis (master axis) for driving the conveyor.
In order to synchronize the real position of the slave axis with that of the master axis without an error, in this packing machine, the synchronization command for the slave axis is compensated in consideration of a servo delay. The servo delay is compensated by, for example, expecting the position at the future time corresponding to the position control gain of the slave axis and commanding the expected position as the synchronous position.
If the speed of the synchronized master axis changes, the expected position is deviated from an actual synchronous position, and the deviation causes a synchronization error that results in a reduction in synchronization performance. As described above, this expectation time is determined depending on the position control gain, that is, the lower the position control gain, the longer the expectation time is. In general, the longer the expectation time, the more easily the difference between the expected position and the synchronous position occurs. In other words, the lower the gain, the longer the expectation time is, and the higher the synchronization error is.
Now let us suppose that the position control gain of the slave axis is constant during synchronization. If the position control gain is high when the master axis vibrates in a certain section during the synchronization, there is a problem that the synchronization performance is greatly affected by the vibration to cause a synchronization error in the vibration section, although it is satisfactory outside the vibration section. If the position control gain is low, in contrast, there is a problem that a synchronization error is caused by a speed change of the master axis, although the influence of the vibration is small.
SUMMARY OF THE INVENTION
Accordingly, in view of the above-described problems of the prior art, it is an object of the present invention to provide a numerical controller having a function of appropriately switching a position control gain during synchronous control.
A numerical controller according to the present invention outputs a position command corresponding to a synchronous position in consideration of a servo delay of a slave axis, to the slave axis from a real position of a master axis, in order to perform position control of the slave axis, thereby making a real position of the slave axis synchronously follow the real position of the master axis. In this numerical controller, a position control gain of the slave axis is changed based on a predetermined physical quantity during the synchronous control and a compensation value for the position command for the slave axis is varied depending on the amount of change of the position control gain of the slave axis.
The position control gain may be gradually increased and the compensation value is gradually reduced correspondingly. In contrast, the position control gain may also be gradually reduced and the compensation value is gradually increased correspondingly.
The predetermined physical quantity may be data on a synchronization error, an external input signal, a time elapsed since the start of synchronization, a master axis position, a slave axis position, a master axis speed, a slave axis speed, or a servo delay of the slave axis.
According to the present invention, there can be provided a numerical controller having a function of switching a position control gain during synchronous control.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will be obvious from the ensuing description of embodiments with reference to the accompanying drawings, in which:
FIG. 1 is a diagram showing a packing machine device configured to pack a bottle into a box conveyed by a conveyor;
FIG. 2 is a diagram showing a case where a synchronization error occurs in synchronization based on an expected compensation when a speed of a master axis is changed;
FIG. 3 is a diagram illustrating a second embodiment of a numerical controller according to the present invention;
FIG. 4 is a diagram illustrating a third embodiment of the numerical controller according to the present invention; and
FIG. 5 is a flowchart showing synchronous control processing performed by the numerical controller according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a diagram showing a packing machine device configured so that a bottle 4 conveyed by a second conveyor S is packed by insertion means 6 into a box 2 conveyed by a first conveyor M.
In the packing machine device of FIG. 1 , the first conveyor M is driven by a drive unit (not shown) different from that of the second conveyor S, which is driven by a servomotor Ms controlled by a numerical controller NC. An axis that drives the first conveyor M is assumed to be a master axis, while an axis that drives the second conveyor S is assumed to be a slave axis. The slave axis is synchronously controlled by the numerical controller NC so that it synchronizes with the master axis. The position and speed of the master axis can be detected by a position/speed detector 8 attached to the first conveyor M. Further, the position and speed of the slave axis can be detected by a position/speed detector (not shown) attached to the slave axis.
The numerical controller NC comprises a processor (CPU), memories such as a ROM and a RAM, input/output circuit, communication interface, and the like. The numerical controller NC performs position feedback control in response to a feedback signal from a sensor (not shown) attached to the servomotor Ms or the second conveyor S that is driven by the servomotor Ms.
In the packing machine of FIG. 1 configured so that the bottle conveyed by the second conveyor S driven by the slave axis (servomotor Ms) is packed into the box conveyed by the first conveyor M, for example, the position and speed of the first conveyor M are obtained by the sensor 8 or the like. Synchronous control of the slave axis is performed so as to align the position of the bottle conveyed by the second conveyor S with the position of the box on the first conveyor M. The packing machine can accurately pack the bottle by fetching an actual position (real position) of the first conveyor M as the position of the master axis and correctly synchronizing the position of the second conveyor S (slave axis) with the fetched position.
The following is a description of some embodiments of the numerical controller having a function of switching a position control gain during synchronous control to solve problems of the present invention.
First Embodiment of Numerical Controller
In a first embodiment of the numerical controller according to the present invention, position control gains individually suited for a vibration section of the master axis and an area outside the vibration section are set to switch the position control gain of the slave axis during synchronous control and change a compensation value correspondingly. By making a compensation according to the set position control gain, the numerical controller can improve tracking performance for a speed change while suppressing an influence on disturbance, thereby suppressing an increase in synchronization error. The start of the position control gain switching for the slave axis can be determined based on the synchronization error.
Second Embodiment of Numerical Controller
FIG. 2 is a diagram illustrating an operation in synchronization with the movement of the master axis, starting from a state where the slave axis is stopped. In FIG. 2 , the abscissa and ordinate represent time and position, respectively. Further, a full line (thick line) 10 represents the real position of the master axis, dotted line 12 represents a slave axis command position, full line (thin line) 14 represents a slave axis real position, and arrow 16 represents a servo delay. Furthermore, a square area 18 and an elliptical area 20 represent areas for a speed change and a synchronization error, respectively.
As indicated by the full line (thick line) 10 that represents the master axis real position, the master axis moves at a constant speed and slows down at a flexion point in the area 18 . On the other hand, the slave axis starts synchronization with a low gain in order to reduce mechanical shock attributable to sudden acceleration at the start of synchronous operation. Thus, the servo delay represented by the arrow 16 occurs between the dotted line 12 that represents the slave axis command position and the full line (thin line) 14 that represents the slave axis real position.
If the speed of the master axis is changed during the synchronous control, as indicated by the square area 18 (representative of a speed change) in FIG. 2 , the slave axis command position 12 of which expectation time is corrected cannot respond to the speed change of the master axis because of a long expectation time. Thus, the synchronization error 20 inevitably occurs between the slave axis real position 14 and the master axis real position 10 . The larger the expected amount, the greater the synchronous error 20 is.
As shown in FIG. 3 , in this second embodiment, a position control gain is increased during synchronous control and a compensation based on expectation is reduced correspondingly. In this way, synchronous tracking performance can be increased to suppress the synchronization error even when the speed of the master axis is changed. In FIG. 3 , an elliptical area 22 represents an area in which synchronization is smoothly started because of the low gain. Further, a circular area 24 represents an area in which the gain is increased to reduce the compensation for servo delay (i.e., to bring the command position close to the real position).
According to this embodiment, the start of movement is made smooth by suppressing the position control gain of the slave axis at the start of synchronization, the position control gain is gradually increased when the synchronization error is, for example, reduced to a predetermined value or less during the synchronous control (area 24 ), and the compensation based on expectation is reduced correspondingly. In this way, the synchronous tracking performance for the motion of the master axis can also be increased.
Third Embodiment of Numerical Controller
If an attempt is made to terminate synchronization with the position control gain remaining high while the master axis is moving, the slave axis suddenly stops, thereby causing mechanical shock.
As shown in FIG. 4 , in this embodiment, therefore, the position control gain is gradually reduced before the end of synchronous control, and compensation for servo delay is gradually increased correspondingly. In this way, the slave axis can be smoothly stopped even if synchronization is stopped while the master axis is moving. In FIG. 4 , a circular area 26 represents an area in which the gain is reduced to increase the compensation for servo delay (i.e., to separate the command position from the real position). Further, an elliptical area 28 represents an area in which the slave axis smoothly stops because of the low gain.
Fourth Embodiment of Numerical Controller
In this embodiment, the start of position control gain switching for the slave axis is determined based on any one of information including an external input signal, time elapsed since the start of synchronization, master axis position, slave axis position, master axis speed, slave axis speed, and servo delay of the slave axis, in place of the synchronization error.
FIG. 5 is a flowchart showing synchronous control processing performed by the numerical controller according to the present invention. The following is a sequential description of steps.
[Step sa 01 ] It is determined whether or not to switch the position control gain. If the position control gain is to be switched (YES), the processing proceeds to Step sa 02 . If not (NO), the processing proceeds to Step sa 04 . Whether or not to switch the position control gain can be determined based on the synchronization error, external input signal, time elapsed since the start of synchronization, master axis position, slave axis position, master axis speed, slave axis speed, or servo delay of the slave axis.
[Step sa 02 ] The position control gain is changed by a predetermined amount.
[Step sa 03 ] A compensation value for the slave axis, e.g., compensation for the time delayed by the gain, is calculated based on the position control gain.
[Step sa 04 ] The synchronization command position of the slave axis is calculated in consideration of the compensation value for the slave axis, based on the real position of the master axis.
[Step sa 05 ] An output amount of movement of the slave axis is obtained by calculating the difference between the synchronization command position and the command position of the slave axis.
[Step sa 06 ] The output amount of movement obtained in Step sa 05 is added to the command position of the slave axis, and the result of the addition is used as the command position of the slave axis.
[Step sa 07 ] The output amount of movement obtained in Step sa 05 is output.
[Step sa 08 ] It is determined whether or not to continue the synchronous control. If the synchronous control is to be continued (YES), the processing proceeds to Step sa 01 . If not (NO), the processing ends. Whether or not to continue the synchronous control can be determined based on, for example, a programmed command or an external command.
In the processing of the flowchart described above, clamp control or acceleration and deceleration control may be performed as required for the synchronous control of the slave axis.
As described above, the numerical controller according to the present invention may have the function of switching the position control gain during synchronous control. Further, the servo delay of the slave axis is reduced by increasing the position control gain, so that the expected amount is reduced. Thus, the synchronization error is small even when the master axis speed varies. At the start of synchronization, the start of movement can be made smooth by suppressing the position control gain. After a synchronization state is stabilized, the movement of the master axis can be promptly followed to improve the synchronization performance by increasing the position control gain. When the master-slave synchronization state is stabilized, e.g., when the master axis is in a constant-speed state, the position control gain is gradually increased, while the compensation based on expectation from a synchronization command is gradually reduced.
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A numerical controller outputs a position command corresponding to a synchronous position in consideration of a servo delay of a slave axis, to the slave axis from a real position of a master axis, in order to perform position control of the slave axis, thereby making a real position of the slave axis synchronously follow the real position of the master axis. A position control gain of the slave axis is changed based on a predetermined physical quantity during the synchronous control and a compensation value for the position command for the slave axis is varied depending on the amount of change of the position control gain of the slave axis.
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[0001] This application is a continuation of International Application No. PCT/EP00/10643, filed on Oct. 28, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to an adjusting armature for the back rest of vehicle seats, in particular, of motor vehicles seats, wherein the back rest, which is optionally adjustable about a first axis of rotation in an inclined position and lockable in the adjusted inclined position by means of an adjusting device, can be folded forwardly and backwardly about a second external axis of rotation, positioned at a distance from the first axis of rotation, and is secured in its folded-back position on a locking bolt receptacle, stationarily arranged on the seat, by means of a locking bolt, engaging releasably the locking bolt receptacle and axially moveably arranged on a rotary bracket pivoting with the back rest and spring-loaded in the locking direction, and is supported by means of a stop receptacle on a stop bolt stationarily arranged on the seat.
[0004] 2. Description of the Related Art
[0005] A similar device is disclosed in European patent application 0 937 603 A1. In this document an adjusting armature for the back rests of motor vehicle seats is described in which, on the one hand, the back rest is adjustable with regard to its incline about an axis and, on the other hand, is foldable about another axis. Locking is possible in the upright position of the back rest by means of a pin that is spring-loaded or receives a conical end which engages in a springy fashion a corresponding receptacle. A play-free arrangement is not ensured in all directions.
[0006] In an adjusting armature of the aforementioned kind of the present assignee, described in the German patent application 199 18 737.1-16, the armature component, which effects the adjustment and locking of the inclined back rest position and has a first axis of rotation, is arranged adjacent to a further armature component having a second axis of rotation. In order to transfer the back rest into a forwardly folded position which provides a table function, the second axis of rotation is arranged at a spacing above the first axis of rotation. For this purpose, generally on the frame of the seat part or on a locking plate fixedly connected thereto, an armature part of the armature component, which enables the inclination of the back rest in a position of use for the user of the seat, is secured detachably by means of a stop bolt and a locking bolt that is axially moveable in the locking direction and loaded by a force storing device.
[0007] Moreover, a bearing bracket of the second armature component is fixedly connected with the frame of the seat part or the locking plate and extends upwardly and past the first axis of rotation. This bearing bracket at its upper area is connected by means of an axle bolt with a rotary bracket to form a joint which provides the second axis of rotation of the adjusting armature. The rotary bracket is connected to the armature part that is detachably secured with the stop bolt and the locking bolt on the seat part and is pivotable therewith. As a result of the second axis of rotation being positioned higher, the back rest can be placed above the upholstery of the seat part in a table function position such that the backside of the back rest forms a horizontal plane without the upholstery of the back rest and of the seat part counteracting this. For securing this table function position, a pneumatic spring is arranged between the axis of rotation and the bearing bracket.
[0008] In this known solution, the axially movable locking bolt has a circular cross-section and engages in the locking situation a matching bore which, however must be slightly greater than the diameter of the locking bolt because of unavoidable tolerances. As a result of this unavoidable play, rattling cannot be prevented when the vehicle drives on bumpy roads.
SUMMARY OF THE INVENTION
[0009] It is an object of the invention to improve an adjusting armature of the aforementioned kind such that a securing or bracing is possible that eliminates play of the rotary bracket relative to the locking plate.
[0010] In accordance with the present invention, this is achieved in that the axially movable locking bolt has a guide section and a locking section and is subjected on its guide section, in addition to its axial guiding, also to a controlled rotational movement, based on which a radially changing support curve provided on the locking section can be supported on a planar support surface of the locking bolt receptacle so as to eliminate play.
[0011] By superimposing on the axially movable locking bolt a rotary movement such that its locking section with the adjustable radially changing support curve automatically readjust on a planar support surface of the locking bolt receptacle as a result of the spring loading action, a bracing that eliminates play is obtained in the locking situations so that the adjusting armature is free of rattling noises independent of its unavoidable tolerances.
[0012] For forming the radially changing support curve in connection with a support surface contacting it, the locking section of the annular pin has a periphery as follows: a first partial peripheral area extends about approximately 180° with a constant radius and is adjoined by a peripheral area of approximately 90° in which the support curve extends which, starting with the constant radius of the first partial peripheral area, has a continuously decreasing radial spacing from the center of the locking bolt, and then has a transition into at least one planar area which then adjoins finally the aforementioned first partial peripheral area with the constant radius. The locking bolt receptacle has, in addition to a circular circumferential area, a support surface which can be brought into contact with the support curve.
[0013] The support curve which has a continuously decreasing radial spacing from the center of the locking bolt can be designed as a logarithmic spiral with which the manufacturing tolerances and play can be compensated which do not reach the adjusting range resulting from the support curve and which are within the tolerances.
[0014] According to one embodiment of the invention, for axially guiding the locking bolt and providing a superimposed rotary movement derived from this axial movement, the guide section of the locking bolt is arranged axially slidably in a bushing secured on the rotary bracket and engages with at least one sliding block at least one sliding gate extending spirally in the bushing like a thread. In this connection, the bushing is advantageously surrounded by a trigger sleeve which has at least one guide groove ascending in the axial direction and whose slant or gradient is greater than the slant of the thread-like sliding gate of the bushing. The sliding gate is engaged by the sliding block which penetrates it and engages the guide groove of the trigger sleeve.
[0015] In order to prevent a malfunction which could possibly occur as a result of canting, according to a further embodiment of the invention the sliding gate as well as the guide groove are positioned on two locations of the bushing and the trigger sleeve which are diametrically opposite one another, wherein the sliding block is comprised of two guide pins which are arranged on the guide section of the locking bolt, penetrate through the sliding gate, and project into the guide groove. Moreover, an actuation device which is located remote from the locking mechanism for releasing the locking bolt can be realized in that the trigger sleeve has a connecting finger provided for attaching a pulling means thereto, such as a Bowden cable, for introducing a rotary movement into the trigger sleeve.
[0016] Since in the inactive position of the trigger sleeve the locking bolt projects from the bushing as a result of spring loading of the locking bolt in the locking direction, it is advantageous for the return movement of the back rest from its forwardly folded position when a guide rail is provided on the seat which projects into the pivot path of the locking bolt and has a slanted surface. This ensures that in the inactive state of the trigger sleeve the return pivot movement can be performed to such an extent until the locking bolt is able to drop into the locking bolt receptacle provided on the seat part.
[0017] Even though it is conceivable to arrange the guide rail and the locking bolt receptacle directly on the frame of the seat part, it may be advantageous for manufacturing-technological reasons when the bearing bracket together with the locking plate that is provided with the locking bolt receptacle as well as the guide rail is fixedly connected with the seat part.
[0018] In order for a safe correlation of the locking bolt to the locking bolt receptacle to be possible at the end of the return folding movement, on the one hand, and to provide a 3-point bracing of the rotary bracket relative to the seat part, on the other hand, the locking plate advantageously has underneath its locking bolt receptacle a stop for the rotary bracket and an armature part that is connected to the rotary bracket and comprises the first axis of rotation.
BRIEF DESCRIPTION OF THE DRAWING
[0019] In the drawing:
[0020] [0020]FIG. 1A shows a seat in a schematic side view, comprising an adjusting armature according to the invention arranged between the seat part and the back rest, wherein the back rest is in a position of use for the user of the seat;
[0021] [0021]FIG. 1B shows the seat illustrated in FIG. 1A in a schematic side view wherein the back rest has been pivoted forwardly into a table position;
[0022] [0022]FIG. 2 shows the adjusting armature according to the invention in a perspective view at an angle from behind;
[0023] [0023]FIG. 3 shows the adjusting armature, also in a perspective view analog to FIG. 2, in which however the bearing bracket and the trigger sleeve have been removed;
[0024] [0024]FIG. 4 shows the adjusting armature of FIG. 2 in a side view onto its exterior side;
[0025] [0025]FIG. 5 shows the adjusting armature shown in FIG. 4 in an end view;
[0026] [0026]FIG. 6 shows the adjusting armature of FIG. 4 in a section according to section line VI-VI of FIG. 4;
[0027] [0027]FIG. 7 shows the adjusting armature according to FIG. 4 in a side view onto its inner side;
[0028] [0028]FIG. 8A shows in section the area of the adjusting armature receiving a locking bolt, the adjusting armature in the position illustrated in FIG. 1A wherein, however, the locking bolt is illustrated in its release position;
[0029] [0029]FIG. 8B shows the locking area of the adjusting armature illustrated in FIG. 8A in a broken-away view onto the inner side;
[0030] [0030]FIG. 9A shows the sectional view illustrated in FIG. 8A of the locking area in which the locking bolt is shown in a position in which it has dropped into the locking bolt receptacle;
[0031] [0031]FIG. 9B shows the locking area illustrated in FIG. 9A in a broken-away view onto the inner side of the adjusting armature;
[0032] [0032]FIG. 10A shows the locking area of the adjusting armature illustrated in FIG. 8A in section, wherein the locking bolt has been positioned so far into the locking bolt receptacle that play in the system is eliminated;
[0033] [0033]FIG. 10B shows the locking bolt illustrated in FIG. 10A in the locking bolt receptacle in a broken-away side view of the adjusting armature;
[0034] [0034]FIG. 11A shows the locking area illustrated in section in analogy to FIG. 10A, wherein the locking bolt is in a rotary position which compensates tolerances and is play-free;
[0035] [0035]FIG. 11 b shows the locking bolt illustrated in FIG. 11A in a broken-away side view onto the inner side of the adjusting armature;
[0036] [0036]FIG. 12 shows the locking bolt of FIG. 10B in an enlarged representation relative to FIG. 10B, wherein the locking bolt is arranged in the locking bolt receptacle in a play-eliminating position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] [0037]FIG. 1A shows a vehicle seat with a seat part 10 and a back rest 11 wherein the back rest 11 , fastened on the seat part 10 by means of the adjusting armature 12 , is positioned at such an incline that a user can be seated in the seat. In this connection, on the seat frame of the seat part 10 the adjusting armature 12 comprised of two armature components 13 and 14 is fastened on each longitudinal side of the seat. With the adjusting armature component 13 the incline of the back rest 11 relative to the seat part can be adjusted and secured, for which purpose, for example, a so-called planetary armature can be used which comprises a simple planetary gear and whose armature part connected with the back rest 11 is pivoted about a first axis of rotation 15 in a self-locking way.
[0038] This first armature component 13 arranged on both longitudinal sides of the seat has arranged adjacent thereto a second armature component 14 which has a bearing bracket 16 secured on the frame of the seat part 10 and a rotary bracket 17 pivotably connected thereto by a joint 18 . The lower part of the rotary bracket 17 is bent and fixedly connected to the armature part 19 , correlated with the seat part 10 , of the armature component 13 of the seat part 10 .
[0039] In the position of use of the seat by a user, the armature part 19 and the rotary bracket 17 are connected by means of a stop receptacle 20 in connection with a stop bolt of a locking plate 22 and a locking bolt 21 releasably engaging it. The locking plate 22 , in turn, is fixedly connected together with the recessed fastening area 23 of the bearing bracket 16 with, for example, the frame of the seat part 10 . The joint 18 which connects the bearing bracket 16 and the rotary bracket 17 with one another has an external second axis of rotation 24 of the armature component 14 about which the rotary bracket 17 , together with the first armature component 13 remaining in its adjusted position, is pivoted together with the back rest 11 such that it can be transferred into a table function position as illustrated in FIG. 1B.
[0040] In the adjusting armature illustrated in FIGS. 1 through 5, the second external rotary axis 24 in the position of use of the seat illustrated in FIG. 1A is located at a spacing above the first axis of rotation 15 of the armature component 13 , wherein this spacing is selected such that, upon movement of the back rest 11 into the table position illustrated in FIG. 1B, the upholstery of the seat part 10 and the back rest 11 will not have a negative effect on the table function position.
[0041] For arresting the back rest in a position of use in which a user can sit in the seat, the rotary bracket 17 fixedly connected to the armature part 19 and the armature part 19 have a stop receptacle 20 on one side with which a stop bolt 25 secured on the locking plate 22 can be partially engaged. On the side opposite the stop receptacle, a bushing 26 is fixedly connected on the rotary bracket 17 and the armature part 19 connected thereto. The guide section 28 of the locking bolt 21 is axially moveably supported within the bushing 26 . A locking section 29 of the locking bolt 21 adjoins the guide section 28 and can engage a locking bolt receptacle 30 of the locking plate 22 . The guide section 28 of the locking bolt 21 has a hollow cylindrical recess 31 which is provided for receiving a pressure spring 32 . This pressure spring 32 is supported with one end on the bottom of the bushing 26 and loads the locking bolt 21 in the locking direction.
[0042] As illustrated in FIG. 7, 8 B- 11 B and most clearly in FIG. 12, the periphery of the locking section 29 on the locking bolt 21 has a constant radius about a partial area 33 of approximately 180° which is adjoined by a circumferential area 34 of approximately 90° in which a support curve 35 extends which, starting with the constant radius, has a continuously decreasing radial spacing from the center 36 of the locking bolt 21 and has a transition into at least one planar area 37 .
[0043] The support curve 35 is advantageously formed as a logarithmic spiral while the planar area 37 is comprised of two planar roof-shaped partial planes 38 and 39 abutting one another. The locking section 29 of the locking bolt 21 in the locking situation is surrounded by a locking bolt receptacle 30 which about a further circumferential area has a greater diameter than the diameter of the locking bolt 21 . This wide circular circumferential area of the locking bolt receptacle 30 is interrupted by a support surface 40 which extends as slanted plane whose normal extends at an angle of 90° at a slant to the front side of the seat part 10 and in a downward direction.
[0044] In order to enable a play-free bracing of the armature component 14 relative to the seat part 10 , a readjustment of the support curve as a result of the rotation of the locking section 29 of the locking bolt 21 relative to the support surface 40 on the locking plate 22 is required. For this reason, the bushing 26 in the illustrated embodiment has two diametrically oppositely extending thread-like (spiral) sliding gates 41 , which can be seen most clearly in FIGS. 3, 10A and 11 A. The sliding gate 41 is formed by thread-like slots in the cylinder mantle area of the bushing 26 . Guide pins 43 functioning as a sliding block 42 engage this sliding gate 41 and project past it outwardly, as is clearly illustrated in FIG. 3 and FIG. 9A.
[0045] The bushing 26 is engaged by a trigger sleeve 44 which also has guide grooves 45 ascending also in the axial direction. The guide pins 43 projecting from the sleeve 26 engage the guide grooves 45 . In order to ensure that, during a rotational movement of the trigger sleeve 44 , it rests always against the rotary bracket 17 as a result of the action of the pressure spring 32 , the guide grooves 45 also have an ascending course whose slant is however substantially greater than the slant of the slots of the bushing 26 forming the sliding gate 41 . The trigger sleeve 44 has at its circumference a connecting finger 47 which can be the point of contact for a pulling member, for example, in the form of a Bowden cable.
[0046] In order to automatically push back the locking section 29 of the locking bolt 21 projecting from the bushing 26 and the armature part 19 upon return movement of the back rest 11 without actuating the trigger sleeve 44 , the locking plate 22 has a guide rail 48 which projects into the pivot path of the locking bolt 21 and has at its side facing the armature part 19 a slanted surface 49 by which the locking bolt 21 in the last phase of the return movement is forced into the bushing 26 against the force of the pressure spring 32 . When the armature component 14 is returned in the locked position, a stop 50 is provided below the locking bolt 21 on the locking plate 22 against which stop the underside of the rotary bracket 17 and the armature part 19 rest. This stop 50 as well as the stop bolt 25 in the locking situation receive counter forces of the locking force exerted by the locking section 29 of the locking bolt 21 ; this is illustrated in FIG. 7 by the arrows. This results in a safe play-free 3-point support in the locking situation.
[0047] For explaining the locking function, FIGS. 8A and 8B will be used as a starting point. Here it is shown that the locking bolt 21 is retracted completely into the bushing 26 against the force of the pressure spring 32 loading it so that its end face does not project past the outer side of the armature part 19 . The locking bolt 21 is transferred by the trigger sleeve 44 into this position. This unlocking or release position can be seen in FIGS. 8A and 8B.
[0048] When the trigger sleeve 44 is now released, by means of the pressure spring 32 the locking bolt 21 is moved into the position illustrated in FIGS. 9A and 9B where it has dropped into the locking bolt receptacle 30 of the locking plate 22 . In this connection, the locking bolt 21 has been rotated by means of its guide pins 43 with the sliding gate 41 into the position illustrated in FIG. 9B; however, in this position there is still play all-around between the locking section 29 of the locking bolt 21 and the locking bolt receptacle 30 as can be seen, in particular, in FIG. 9B. Since however the pressure spring 32 still exerts its pressure force and moves the locking bolt 21 farther axially, it rotates accordingly in a clockwise direction because of the sliding gate 41 and the guide pins 43 engaging therein so that finally the support curve 35 will rest against the support surface 40 of the locking bolt receptacle 30 , as illustrated in FIG. 10B. In this position a tensioned locking action of the armature component 14 on the locking plate 22 connected to the seat frame results.
[0049] The tensioned position (bracing position) shown in the preceding FIGS. 10A and 10B is also present in FIGS. 11A and 11B in which, however, as a result of a different tolerance position of the locking bolt receptacle 30 relative to the position shown in FIG. 10B, locking bolt 21 has been moved farther.
[0050] As mentioned above, the illustrated and described configuration of the present invention is to be viewed only as an exemplary embodiment.
[0051] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.
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An adjusting armature for a back rest of a vehicle seat, wherein the back rest is incline-adjustable about a first axis and can fold relative to the seat part about a second axis, has a rotary bracket connected to the back rest for pivoting with the back rest. A locking bolt receptacle is stationarily arranged on the seat part and has a planar support surface. A locking bolt is axially moveably arranged on the rotary bracket and spring-loaded in a locking direction for engaging releasably the locking bolt receptacle. A stop bolt is stationarily arranged on the seat part and cooperates with a stop receptacle on the rotary bracket. The locking bolt has a guide section and a locking section having a radially changing support curve. The guide section can rotate causing the radially changing support curve to be supported on the planar support surface for eliminating play.
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FIELD OF THE INVENTION
[0001] The present invention relates to a system and method for generating a media play-list, especially to a system and method for generating a play-list according to the number of times a user selects the media file to be played.
DESCRIPTION OF RELATED ART
[0002] The continuous development of new digital technology has helped made digital devices such as digital audio, digital picture, and other digital medias become popular among people. Media can be stored digitally in various data storage medium such as a hard disk, a compact disc (CD), and a network server. These data storage medium can then be used with portable devices such as a personal digital assistant (PDA), a media player, and/or an electronic-book reader (e-book). A current standard CD can store up to 140 average sized MPEG layer three (MP3) media files, whereas a media player with a data storage medium of 10 Gigabytes can store up to 2000 MP3 files. The cost of data storage medium has continued to decrease, allowing the average person to more easily acquire more data storage capacity. Currently, a personal computer has a standard data storage capacity of 80 Gigabytes that can easily store up to 160,000 pieces of average sized MP3 files. As users continuously acquire their favorite media files, it is important that users can also quickly identify and select a desired media file from a humongous pool of stored files.
[0003] Most media players currently have an option to group and select media files by the media file's tag contents. Usually, the media file's title, artist, album, and genre identity are stored by the tags to allow media players to automatically search and categorize the files. A media file management program further allows users to select a combination of media files into a play-list file. The saved play-list is essentially a list of shortcuts (pointer to the directory path) of the media files stored within, and can be used by the media player instead of manually searching and selecting every desired media files each time the media player is executed. Each play-list can then be categorically stored by name. However, users are still required to remember the directory path where each play-list is stored. As a user creates more and more play-lists, remembering a desired play-list may not be easy, furthermore, skipping over an unwanted media file while playing a play-list still has to be done manually.
[0004] In order to solve the problems mentioned, there is a method available in the market in selecting favorite media files to generate a play-list. For example, U.S. Pat. No. 6,987,221 issued on Jan. 17, 2006 and entitled “AUTO PLAYLIST GENERATION WITH MULTIPLE SEED SONGS” provides a method for generating a play-list automatically. The method includes steps of: selecting one or more feed media files, the feed media files include desired media files and undesired media files; wherein the user can set a weight on each seed media file representing the importance level of each seed media file. Afterwards, the method compares each media file with each seed media file such that a media file can be analyzed and identified into a user defined preferred play-list. The play-list further allows manual edits by the user.
[0005] However, the above mentioned method requires manual inputs on the weight attributes on multiple seed files before the method can run comparison tests on each media files. These manual operations may be annoying and time consuming with no guarantee that the resulting selected media files would be tailored to a user's listening preferences.
[0006] Therefore, a heretofore unaddressed need exists in the industry to overcome the aforementioned deficiencies and inadequacies.
SUMMARY OF INVENTION
[0007] In order to solve said problems, the present invention provides a method and system for setting a weight value on each media file according to the play count of the media file, and then generating a play-list according to weight values of the media files. The present invention makes the play-list more suitable to the user's listening preferences.
[0008] The method for generating a play-list of media files, each of the media files includes a tag for holding relative information about the media files. The method includes the steps of: setting a play count field in the tag for storing a play count of the media file; setting a weight table for storing different play counts and corresponding weight values; updating the play count in the play count field of each media file during the course of the media files being played; obtaining the corresponding weight values of each media file from the weight table according to the play count thereof; and generating the play-list of the media files according to the weight values thereof.
[0009] The system for generating a play-list of media files, each of the media files includes a tag for holding relative information about the media files. The system includes a data storage unit, an input unit, a control unit and a file management unit. The data storage unit stores a plurality of media files and a weight table. The tag of each media file includes a play count field for storing a play count of the media file, and the weight table stores different play counts and corresponding weight values. The input unit generates commands in response to operations of a user. The commands include a command for generating a play-list. The control unit identifies the commands and executes corresponding control commands. The file management unit, under the control of the control unit, updates the play count in the play count field of each media file during the course of the media files being played, obtains the corresponding weight values of each media file from the weight table according to the play count thereof, and generates the play-list of the media files according to the weight values thereof.
[0010] Other systems, methods, features, and advantages will be or become apparent to one with skill in the art upon examination of the following drawings 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 present invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a schematic diagram of a user-interface of an media player such as a MP3 player in accordance with a preferred embodiment of the present invention;
[0012] FIG. 2 is a block diagram of hardware infrastructure of the media player of FIG. 1 ;
[0013] FIG. 3 ( FIG. 3A and FIG. 3B ) is a flowchart of a preferred method for generating a play-list and updating the play count in the play count field of each media file listed on the play-list in the media player of FIG. 2 ; and
[0014] FIG. 4 is a schematic diagram representing a relationship between a play count and a weight value.
DETAILED DESCRIPTION
[0015] FIG. 1 is a schematic diagram of a user-interface of an media player such as a MP3 player in accordance with a preferred embodiment of the present invention. The media player 10 is user-controllable to skip forward (e.g., to next item), play a media file, pause a playing media file, skip backward (e.g., to previous item), activate/deactivate the media player, adjust the volume output of the media player, and the like. Accordingly, the media player 10 provides a user-interface for selecting these functions. The user-interface sets a plurality of buttons thereon, such as a skip forward button 14 , a play/pause button 15 , a skip backward button 16 , a stop/power button 17 , a decrease volume button 18 , and an increase volume button 19 . The user-interface further sets a play in order button 12 for playing selected media files in a predefined sequential order, and a random play button 13 for playing the media files randomly. Moreover, the user-interface includes a locked button 11 for locking the buttons 12 to 19 thereby disabling the button functions therewith.
[0016] FIG. 2 is a block diagram hardware infrastructure of the media player 10 of FIG. 1 . The media player 10 includes a data storage unit 20 , an input unit 21 , a file management unit 22 , a control unit 23 , a decoder 24 , a digital/analog converter 25 , a gain control unit 26 , and a sound output interface 27 . The data storage unit 20 stores a plurality of media files, a weight table, a default play-list, and one or more favorite index tables for indicating favorite media files of a user. Each of the media files is composed of a plurality of frames; a frame can be viewed as a small segment of the media. Furthermore, each media file includes a tag for holding relative information of the media file. The relative information includes a play count (i.e. the number of times the digital media file is selected to play), a loading time, a frame length, and so on. Accordingly, the tag includes a play count field, a loading time field, a frame length field, etc., to store corresponding basic information. The weight table (described in detailed below) stores the play counts and their corresponding weight values. The weight values would indicate the user's preference level on a given media file. In addition, the data storage unit 20 can be a flash storage, a hard disk driver, and the like.
[0017] The input unit 21 includes a plurality of buttons (i.e., 11 to 19 ), thereby forming the user-interface of a preferred media player (as shown in FIG. 1 ) to compute commands in response to operational inputs. The control unit 23 receives and identifies the commands from the input unit 21 , and generates corresponding control commands to control the data storage unit 20 , the file management unit 22 , the gain control unit 26 , and the like. Wherein, the control commands include a control command for generating a play-list, and a control command for skipping the media file being played (namely a skipping control command).
[0018] When a control command is issued by the control unit 23 , the file management unit 22 obtains the play count of each media file from the play count field, obtains the weight value corresponding to the play count from the weight table, stores the weight values of each media file in a temporary file, generates a play-list of the media files according to the weight values in the temporary file, stores the play-list in the data storage unit 20 , plays the media files listed on the play-list, and updates the play count in the play count field of each media file being played. In addition, the media files listed on the play-list may be from digital media files stored in the data storage unit 20 , or may be from favorite digital media files indicated in the index table stored in the data storage unit 20 .
[0019] The decoder 24 decodes the media file from a coded digital format into a readable digital format to be played. The digital/analog converter 25 converts the decoded digital media file to analog media signals. The gain control unit 26 amplifies the analog media signals under the control of the control unit 23 . The sound output interface 27 outputs the amplified analog media signals to an earphone or a speaker (not shown).
[0020] FIG. 3 (including FIG. 3A and FIG. 3B ) is a flowchart of a preferred method for generating a play-list and updating the play count in the play count field of each media file listed on the play-list in the media player of FIG. 2 . In a power-off state of the medial player 10 , a user selects the stop/power button 17 to activate the media player 10 . In step S 30 , the input unit 21 generates a command in response to an input selection of the user, and sends the command to the control unit 23 . In step S 31 , the control unit 23 determines whether an inputted command is for updating a default play-list, namely generating a new play-list. If the command is not for generating a play-list, in step S 32 , the control unit 23 controls a corresponding unit to perform a corresponding operation according to the command, and the procedure is finished. If the command is for generating a play-list, in step S 33 , the file management unit 22 obtains the play count of each media file from the tag thereof. The play count can be a total play count, an average play count per week, an average play count per month, and the like. The total play count indicates total play times after the media file is loaded in the media player 10 . Correspondingly, the average play count per week/month indicates average play times per week/month after the media file is loaded in the media player 10 .
[0021] In step S 34 , referring to FIG. 5 , the file management unit 22 obtains the corresponding weight value from the weight table according to the play count. In step S 35 , the file management unit 22 stores the weight values of each media file in a temporary file in the data storage unit 20 . In step S 36 , the file management unit 22 generates the play-list of the media files according to the weight values thereof. For example, the file management unit 22 rearranges all the media files stored in the data storage unit 20 according to the weight values, thereby generating a play-list therefrom. That is, the file management unit 22 orderly rearranges the media files according to the weight values, or calls a random function, which employs the weight values of the media files as a parameter, to randomly rearrange the media files. I.e., the media files having the greater weight values would be listed on more front of the play-list.
[0022] Furthermore, the file management unit 22 may also directly select a plurality of media files each of which has a weight value being greater than a predetermined value, thereby generating another play-list therefrom. The file management unit 22 may also rearrange all the media files based on the weight values in descending order, and then selects a predetermined amount of media files on the top of the ordered list, thereby generating another play-list therefrom.
[0023] In step S 37 , the file management unit 22 fetches a media files listed on the play-list. In step S 38 , the decoder 24 decodes the media file from a coded digital form to a decoded digital form, the digital/analog converter 25 converts the digital media signals to analog media signals, the gain control unit 26 amplifies the analog media signals under the control of the control unit 23 , the sound output interface 27 outputs the amplified analog media signals to an earphone or a speaker (not shown). During the course of playing the media file, in step S 39 , the file management unit 22 determines whether a skipping control command is received from the control unit 23 . If the skipping control command is received, in step S 40 , the file management unit 22 obtains an amount of frames having been played, and a total amount of frames the media file has from the frame field thereof. In step S 41 , the file management unit 22 skips the media file being played. In step S 42 , the file management unit 22 divides the amount of frames having been played by the total amount of frames the media file has to obtain a percentage.
[0024] In step S 43 , the file management unit 22 determines whether the obtained percentage reaching a predetermined percentage, such as seventy-five percent. The predetermined percentage indicates the media file almost has been played over. If the obtained percentage is less than the predetermined percentage, the file management unit 22 maintains the play count of the media file as the same as that of before playing, and the procedure goes to step S 45 . If the obtained percentage reaches the predetermined percentage, in step S 44 , the file management unit 22 increases the play count of the media file by one and stores the increased play count in the tag of the media file. In step S 45 , the file management unit 22 determines whether all media files listed on the play-list are played. If all the media files listed on the play-list are played, the procedure is finished. If any media file listed on the play-list is not played, the procedure goes to step S 37 to fetch a next media file to play.
[0025] In step S 39 , If the skipping control command is not received, in step S 46 , the file management unit 22 determines whether the media file has finished playing. If the media file has finished playing, the procedure goes to step S 44 . If the media file has not finished playing, the procedure goes to the step S 38 to continually decode and play the media file. During the course of playing a media file listed on the play-list, if the control unit 23 receives a stop command from the input unit 21 , and then controls the file management unit 22 to stop playing the media file, and the procedure is finished.
[0026] FIG. 4 is a schematic diagram representing a relationship between a play count and a weight value. For simplicity, in such case, when the play count is between 0 and 4, the corresponding weight value is 0; when the play count is between 5 and 9, the corresponding weight value is 1; when the play count is between 24 and 29, corresponding weight value is −3; when the play count exceeds 29, corresponding weight value is −5. However, the relationship between the play count and weight value may vary. That is, the relationship between the play count and weight value can be set and adjusted.
[0027] It should be emphasized that the above-described embodiments, including preferred embodiments, are merely possible examples of implementations, and are set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments without departing substantially from the spirit and principles of the invention. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention, and be protected by the following claims.
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The present invention relates to a method for generating a play-list of media files, each of the media files includes a tag for holding relative information about the media files. The method includes the steps of: setting a play count field in the tag for storing a play count of the media file; setting a weight table for storing different play counts and corresponding weight values; updating the play count in the play count field of each media file during the course of the media files being played; obtaining the corresponding weight values of each media file from the weight table according to the play count thereof; and generating the play-list of the media files according to the weight values thereof. The present invention also provides a system for generating the play-list. The present invention makes the play-list more suitable for the user's favors.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The instant invention relates to the area of civil engineering and, more particularly, to a multi-use conduit system for the protection and integrated transmission or movement of various utilities, information or services whether solids, liquid, gas, fiber optic, magnetic, or electronic in nature. The same has particular application for location beneath transportation corridors and open space.
2. Description of Related Art
To the knowledge of the within inventors there has not existed in the prior art a multi-utility conduit system, and certainly has not existed a multi-purpose underground utility conduit system particularly adapted for disposition beneath the transportation corridor and open space. Therefore, to the knowledge of the inventors, the most applicable prior art relates to systems comprising a plurality of integral contiguous channels as, for example, exists in chemical engineering applications where it is desirable to simultaneously discharge or convey to a remote location a plurality of different fluids and gases, each typically hazardous or toxic, within a single integrated containment system. An example of such prior art appears in U.S. Pat. No. 4,751,945 (1988) to Williams, entitled Dual Containment Channel For Fluids. However, with respect to general civil engineering applications, that is, applications in which it is desirable to integrate into a single advantageously located utility conduit, substantially all utility and information services requirements of a community, e.g., electric power cables; drinking water, re-use water and sewer lines, storm water and drainage pipes; natural or synthetic gas lines; telephone, cable television, fiber optic and other communication and data transmission channels; pneumatic tubes; security services; fire services; a low current magnetic conductive track for vehicular propulsion, and storage, maintenance access or transit power equipment for the hybrid multi-use transit corridors, the prior art is entirely silent.
SUMMARY OF THE INVENTION
The present invention relates to a multi-purpose utility conduit system, definable in terms of an x, y, z Cartesian coordinate system, in which the utility conduit is typically symmetric about a yz or vertical plane, and in which an xz plane defines a truss-like structure having optionally removable lateral extremities. The inventive conduit system is proportioned to interface, at its x-axis extremities, with water drainage facilities and, proximal to said yz plane of the symmetry, with water main locations. Along the xy plane, that is, the ground level surface of the conduit system, is provided a layer of roadway material or equivalent thereof such as natural stone, tarmac or pre-manufactured brick, block or composite roadway material capable of supporting pedestrian, bicycle, and small greenway transit trains or service vehicles. Along the yz plane of symmetry is, in each embodiment of the invention, provided a central or primary, that is, large dimension sub-conduit together with smaller laterally (x-axis) disposed smaller sub-conduits within optional selectably attachable lateral extremities of the truss like structure of the conduit are included sub-conduits of smaller xz plane cross section which, thereby, are particularly suitable for use with all utility information and service requirements of a community such as: electric power cables; drinking water, re-use water and sewer lines, storm water drainage pipes; natural or synthetic gas lines; telephones service; cable television, and fiber optic communications and data transmission, pneumatic tubes; security services; fire services; low current magnetic inductive tracks for vehicular propulsion, and storage, maintenance access or transit power equipment for the ergonomic hybrid transit access corridors. The width (x-axis) and depth (z-axis) of the conduit system may be adapted in response to local ground conditions and design criteria, particularly relative to the parameters of the transportation corridor and open space which will typically overlay the conduit. In the y-axis or length dimension of the conduit are provided manhole-type points of access to the primary sub-conduit.
The invention is further definable as a method of housing a plurality of utility services within a single unitary channel, the method comprising the steps of: (a) disposing a plurality of utility services within a substantially integral longitudinal conduit having therein a plurality of sub-conduits each corresponding to a utility service or utility service group to be provided; (b) providing, to earth-embedded surfaces of said integral conduit, means for stabilization of said conduit within the earth; and (c) providing, to upwardly directed, non-embedded surfaces of said conduit, a substantially flat surface adapted in surface effect to aesthetically and functionally integrate into a surface environment associated with said conduit.
It is accordingly an object of the present invention to provide a conduit system having particular application underneath ergonomic hybrid transit access corridors as part of inner city and community center re-development efforts to effect the integration of all utilities aforementioned and services requirements of a planning region within a single utility delivery system.
It is another object to provide an integrated multi-purpose conduit system to provide, within a common conduit, all utilities, information and services requirement at an underground location which is easily accessible for purposes of service, maintenance and later modification thereof.
It is a further object of the invention to provide a conduit system of the above type which is compatible with, and integrable into, an ergonomic multi-use hybrid transit access corridor right-of-way.
It is a still further object to provide a conduit system of the above type which can be readily manufactured and simply installed at the construction site.
It is a yet further object to provide a conduit system of the above type which is modular and, at the ground level thereof, appears indistinguishable from the surface of a transportation corridor or other surfaces beneath which it is situated.
The above and yet other objects and advantages of the present invention will become apparent from the hereinafter set forth Brief Description of the Drawings and Detailed Description of the Invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a xz plane cross-sectional view of a standard width, standard depth embodiment of the instant invention, showing detachable lateral segments thereof.
FIG. 2 is a cross-sectional view of a second embodiment thereof adapted to shallow depth applications.
FIG. 3 is a further embodiment of the invention showing the same in standard depth, however, without use of the lateral extensions thereof.
FIG. 3A is a view showing use of the embodiment of FIG. 3 beneath a transportation corridor.
FIG. 4 is a cross-sectional view of a yet further embodiment showing the same without lateral extensions and at said shallow depth of the embodiment of FIG. 2 .
FIG. 5 is a top plan schematic view of the invention showing the appearance of an access segment thereof. FIG. 6 is a view, similar to that of FIG. 5, however showing the use of an access segment where x and y-axis adjoining conduit segments are not co-linear relative to each other.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, the instant inventive multi-purpose utility conduit system 10 may be seen in cross-section to comprise a truss-like structure which is largest along a yz plane of symmetry 12 and which tapers symmetrically outward along an x-axis until lateral end points 14 such that, in a preferred embodiment, the x-axis extent of the truss-defining conduit system is defined by corridor curbs 16 which may be integrated into drainage modules 18 which include drainage pipes 20 capable of accepting drainage from both the street and modular tree planter boxes 22 . Accordingly, in terms of x-axis delineation, the instant conduit 10 will typically have a lateral extent defined by a transit corridor 24 , the edges of which are typically defined by curbs 16 and associated drainage means. This x-axis delineation is typically in a range of 20 to 24 feet in the embodiment of FIG. 1 .
The depth of the conduit 10 and, thereby, much of the z-axis stability thereof, is defined by the disposition of a crushed rock base 26 within excavated earth 28 at the time of construction of the transit corridor 24 .
Integrally formed at the xy plane top of the conduit 10 is a naturally occurring or pre-manufactured road composite 30 which renders the utility conduit system functionally and aesthetically compatible to a base of an ergonomic hybrid transit access corridor 24 , as it would exist whether or not the present multi-use conduit 10 were employed. In other words, if, as will frequently be the case, a low speed, small transit vehicle is operated upon surface 30 , tracks will be disposed over a section 32 of the conduit, which section typically would have an x-axis width of up to eight feet. From the plane of symmetry 12 of section 32 , surface 30 which would have a typical depth of about eight inches and would slope symmetrically outwardly at a grade of about two percent to the x-axis end 14 of the conduit.
As may be noted in FIG. 1, there is provided a plurality of internal sub-conduits varying in size, geometry and position relative to the plane of symmetry 12 . Typically disposed within a large central sub-conduit 34 would be water main locations 36 from which drinking water is supplied to the community. The rest of the large central sub-conduit 34 is typically provided for storm water drainage as may become necessary in the event of a flood or water overflow during a fire fighting event or burst water main. Accordingly, central sub-conduit 34 may be understood to include the function of containment in the event of a break of either of the water mains 36 .
Viewed laterally outwardly from central sub-conduit 34 , there is, in the embodiment of FIG. 1, shown outer smaller sub-conduits 38 , 40 , 42 and 44 . Typically disposed within the lowestmost sub-conduits 40 and 42 would be those utilities that would require the least service and for which the highest degree of vibrational insulation from transit activity at surface 30 is necessary. Therefore, within conduit 40 might be disposed telephone and optic fibre cables, while within sub-conduit 42 might be disposed natural or synthetic gas lines for the transportation of propane or the like. In distinction, the upper sub-conduits 38 and 44 of central section 32 would contain cables for utilities likely to require more frequent service but which are not as vibrational sensitive as utilities disposed within sub conduits 40 and 42 . Thereby, within sub-conduit 38 might be disposed electric power cables within conduit 44 might be disposed cable television cables.
There is further shown in FIG. 1 are optional lateral extensions 46 which include sub-conduits 48 and 50 . Accordingly, where the lateral extensions 46 are employed, further differentiation of utilities may be provided. For example, residential application cables versus business and industrial application cables. Also, greater stability is provided to the central section 32 when lateral extensions 46 are provided.
With respect to the materials from which the inventive conduit system 10 may be formed, there exist a number of lightweight high strength materials that may be pre-manufactured using state of the art extrusion means. Such materials include high density polyethylene (HDPE) and so-called polyester concrete which is a concrete aggregate material containing quartz and inert mineral fillers bonded together with a polyester resin. The choice of material will generally be a function of the weight of the load applied to the conduit by the surface transit system operating thereon, whether or not a given site is earthquake prone, annual level of rain, and any toxicity or other hazard associated with the utilities carried within the inventive system. In terms of dimensions, a typical x-axis dimension of the system shown in FIG. 1 would be in said range of 20 to 24 feet while the depth thereof would typically be about six feet. Accordingly, a system of this dimension may be conveniently placed beneath or proximally to a transportation corridor without any requirement for change or enlargement of the right-of-way conventionally associated therewith.
In certain civil engineering applications as, more particularly, where the earth or ground is particularly hard, firm, or rock-like, a conduit system of lesser z-axis depth may be employed. Such a system is shown in FIG. 2 . Therein, the number of sub-conduits is reduced from nine to five. However, in many applications, five sub-conduits is an entirely adequate number, particularly where lateral extensions 46 a are included with central section 32 a of the system. It is noted that surface 30 a , in any of the embodiments, may be provided with any of a variety of several surface treatments, that is, blocks or special surface treatments to provide improved architectural integration with the surrounding site.
In FIG. 3 is shown a further embodiment the invention which consists of only three sub-conduits, that is, sub-conduits 34 b , 38 b and 44 b . Therein, no lateral extensions sections are employed and a parabolic crown 52 is provided upon the surface 30 b . This embodiment of the invention is applicable where smaller right-of-way, e.g., ten feet are employed for the public transit corridor 24 b and where a suitable depth, e.g., six feet of an excavation is available. In this embodiment, the sub-conduits 38 b and 44 b will contain multiple different utility service cables and piping.
In FIG. 4 is shown a further embodiment of the invention which is generally similar to the embodiment of FIG. 3 where however a shallower x-axis dimension, e.g., about four feet, is employed. This embodiment is applicable where the right-of-way is narrow and where the ground or earth is sufficiently dense to accommodate such a reduced depth of the system.
Thereby, from the embodiments of FIGS. 1 to 4 , it may be appreciated that the ratio of x to z axis dimension of the xz plane cross-section of the conduit may be in a range of about 1.5:1 to about 6.0:1 the latter or higher part of this range exists when lateral segments 46 / 46 a and 48 / 48 a are employed.
In FIGS. 5 and 6 are shown top plan views of the relationship between the central sections 32 of the present conduit system and the rest of the y-axis length thereof. In other words, it is to be understood that a point of entry 54 , substantially in the nature of a manhole, may be provided to a central sub-conduit 34 of central section 32 for purpose of access thereto for service purposes. In other words, since central sub-conduit 34 will typically be empty, and since said sub-conduit 34 will include holes or access points to all adjoining sub-conduits, i.e, sub-conduits 38 , 40 , 42 and 44 , the manhole 54 also provides a means of access thereto and for change in relative directionality of adjoining system segments.
Appropriate sealing 56 using, for example, a flexible sealed expansion gasket formed of a high density elastomeric polymer, may be employed. Central section 32 , viewed in the xy plane, will typically have a dimension of five feet on each edge. However, central section 32 may have a rectangular dimension 32 d as is shown in FIG. 6 . This is advantageous when connection of an angled section 58 to a y-axis linear section 60 is necessary. It is noted that such segments 60 of the inventive conduits, in any of their embodiments, will typically exhibit a length in a range of 16 to 40 feet.
While there has been shown and described the preferred embodiment of the instant invention it is to be appreciated that the invention may be embodied otherwise than is herein specifically shown and described and that, within said embodiment, certain changes may be made in the form and arrangement of the parts without departing from the underlying ideas or principles of this invention as set forth in the Claims appended herewith.
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A method of housing various utility services within a single unitary structure includes the steps of disposing such services within an integral longitudinal conduit having sub-conduits, each corresponding to a utility service or utility service group to be provided. Further providing, to earth-embedded surfaces of the integral conduit, elements for stabilization of the conduit within the earth; and providing, to upwardly directed, non-embedded surfaces of the conduit, a substantially flat surface including surface effects to aesthetically and functionally integrate into a surface environment associated with the conduit.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to cooling of electronic packages used in -computing system environments and more particularly to cooling of electronic components used in mid-range and high-end high volume servers.
[0003] 2. Description of Background
[0004] The industry trend has been to continuously increase the number of electronic components inside computing system environments. A computing system environment can simply comprise a single personal computer or a complex network of large computers in processing communication with one another. Increasing the components inside a simple computing system environment does create some challenges. Such an increase create many problems in computing system environments that include large computer complexes. In such instances many seemingly isolated issues affect one another, and have to be resolved in consideration with one another. This is particularly challenging in environments where the computers in the network are either packaged in a single assembly or housed and stored in close proximity.
[0005] One such particular challenge when designing any computing system environment is the issue of heat dissipation. Heat dissipation if unresolved, can result in electronic and mechanical failures that will affect overall system performance, no matter what the size of the environment. As can be easily understood, the heat dissipation increases as the packaging density increases. In larger computing system environments, however, not only the number of heat generating electronic components are more numerous than that of smaller environments, but thermal management solutions must be provided that take other needs of the system environment into consideration. Improper heat dissipation can create a variety of other seemingly unrelated problems. For example solutions that involve too heavy fans, blowers and other such components may lead to weight issues that can affect the structural rigidity of the computing system environment. In customer sites that house complex or numerous computing system environments, unresolved heat dissipation issues may necessitate other cost prohibitive solutions such as supplying additional air conditioning to the to customer site.
[0006] Heat dissipation issues have become a particular challenge in mid to large range computing system environments. FIG. 1 , illustrates a prior art example where a heat sink employing a vapor chamber spreader is used for thermal management. The problem with such arrangement is that the technology currently being practiced is reaching the end of its extendability, especially in regard to the newer microprocessor technology that uses metal oxide semiconductor (CMOS) packages. In recent years, current prior art arrangements are having difficulties resolving heat load and local heat flux issues and these have become a critical factor, especially in the design of mid to high-range, high volume server packages.
[0007] Consequently, a new and improved cooling arrangement is needed that can meet the current thermal management growing needs and address demands of next generation environments, especially those that incorporate CMOS technology in mid to high range, high volume servers.
SUMMARY OF THE INVENTION
[0008] The shortcomings of the prior art are overcome and additional advantages are provided through the provision of a method and incorporated hybrid air and liquid cooled module. The module is used for cooling electronic components and comprise a closed loop liquid cooled assembly in thermal, and preferably fluid, communication with an air cooled assembly, such that the air cooled assembly is at least partially included in the liquid cooled assembly. In one embodiment, the closed loop liquid cooling assembly includes a heat exchanger, a liquid pump and a cold plate in thermal communication with one another and the air cooled and the liquid cooled assembly are at least partially disposed on an auxiliary drawer which is turn disposed to a side of electronic cooling components. The air cooled assembly comprises the same heat exchanger disposed on one end of an auxiliary drawer and an air moving device disposed on another side of the auxiliary drawer such that air can pass easily from one side of the auxiliary drawer to another side. A liquid pump and a control card is also disposed over the auxiliary drawer between the heat exchanger and the air moving device side.
[0009] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] 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 objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0011] FIG. 1 is a prior art illustration showing an air-cooled server with an air cooled air sink having a vapor chamber base;
[0012] FIG. 2 a is an illustration of an overall depiction of one embodiment of the present invention; and
[0013] FIG. 2 b provide a more detailed illustration of the embodiment provided by FIG. 2 a;
[0014] FIG. 3 a and 3 b respectively illustrate the airflow and liquid flow cooling features as provided by the hybrid module of previous figures;
[0015] FIGS. 4 is an illustration of an alternate embodiments of the present invention;
[0016] FIG. 5 provide a more detailed illustration of the alternate embodiment of FIG. 4 ; and
[0017] FIG. 6 provides yet another embodiment, implementing a redundancy feature.
DESCRIPTION OF THE INVENTION
[0018] FIG. 2 a is an isometric illustration of a cooling module assembly 220 as per one embodiment of the present invention. FIG. 2 b , provides a more detailed look at the module 220 as provided in the embodiment of FIG. 2 a . The module 220 as provided in FIGS. 2 and 3 presents a hybrid liquid and air cooled module as will be discussed in greater detail below. FIGS. 3 a and 3 b are each designed to respectively discuss the air and the liquid cooling features of the module 220 .
[0019] As provided in FIGS. 2 a and 2 b , the module 220 uses a hybrid liquid and gaseous fluid cooled scheme and comprises of an auxiliary drawer 220 and a cold plate 230 . The liquid and gaseous fluid, such as air (also interchangeably referred to as air cooled scheme) schemes will be better understood if examined separately as will be discussed later in conjunction with FIGS. 3 a and 3 b . To illustrate components of each scheme independently, FIG. 2 b reflect references the liquid cooled as 201 , and the air cooled portion as 203 .
[0020] The liquid cooled portion 201 includes one or more cold plate(s) 230 and is thermally connected to a liquid pump 260 (hereinafter pump 260 ) and a heat exchanger 250 , which when thermally connected forms a closed loop liquid cooling assembly. The thermal connection between the pump 260 , heat exchanger 250 and the cold plate 230 , can be achieved through a number of means known to those skilled in the art such as through piping 290 illustrated.
[0021] In one embodiment, as illustrated, the heat exchanger and the pump 260 are disposed over an auxiliary drawer 215 , hereinafter drawer 215 . The heat exchanger 250 and the auxiliary drawer 215 are in thermal contact with the cold plate 230 . The heat exchanger 250 can also be fabricated such that it is an integral part of the auxiliary drawer 215 .
[0022] In a preferred embodiment, as illustrated in FIGS. 2 and 3 , the attached auxiliary drawer 215 , is side attached, to the cold plate. In another preferred embodiment, the auxiliary drawer 215 is also side secured to the main drawer 210 . In such mode(s) the module 220 may be interchangeably referred to as side module 220 or sidekick module 220 .
[0023] The heat exchanger 250 , whether disposed or integral to the auxiliary drawer 215 , is placed on the auxiliary drawer 215 with an air moving device 245 , also being disposed on the auxiliary drawer 215 (or integral to it). In one embodiment as illustrated, the heat exchanger 250 and the air moving device are disposed on opposing ends of the auxiliary drawer 215 . Together the air moving device 245 and the heat exchanger 290 form the air cooled portion 201 of the module 220 . In the embodiment illustrated in FIG. 2 a , the air moving device shown is a blower, but a fan or other similar devices can also be used. The auxiliary drawer 215 also includes a control card 270 close to the liquid pump 260 , both the pump 260 and the control card 270 are disposed between heat exchanger 250 and the air moving device 245 . It should be noted that the location of the pump 260 and control card 270 is only provided by way of an example in the figures and they can be disposed anywhere on the auxiliary drawer between the heat exchanger 250 and the air moving device 245 .
[0024] In one embodiment of the present invention as illustrated in the figures, the cold plate(s) 230 is further secured to the side of the auxiliary drawer 215 . In the illustrated embodiment, the cold plate 230 is also disposed in the main drawer 210 area as illustrated. In a preferred embodiment, the cold plate 230 is a high performance cold plate to further enhance thermal management of the computing system environment.
[0025] In the arrangement shown in FIG. 2 a , air is taken from the room by the blower 245 and pushed through the auxiliary tray or drawer 215 to remove heat from the heat exchanger 250 . The pump 260 circulates liquid from the heat exchanger 250 to the cold plate 230 . This fact can be better observed in reference with FIG. 3 a . FIGS. 2 a and 2 b can be useful in understanding the workings of the present invention as provided by FIGS. 3 a and 3 b.
[0026] As discussed above, FIG. 3 a provides an illustration of the air cooling side of the sidekick module 220 without focusing on the liquid cooled component of the module 220 . The arrows provided in FIG. 3 a and referenced as 300 illustrate the direction of air flow taken from the room. As illustrated, the air flows around the pump 260 (referenced by arrows as 301 ) and through the heat exchanger 250 as referenced by arrows 302 . The direction of airflow through the heat exchanger 250 is referenced by arrows 330 in the illustration.
[0027] In a preferred embodiment of the present invention, the heat exchanger 250 can be placed substantially horizontally but at an oblique angle in reference to the horizontal plane of the auxiliary drawer 215 to further facilitate airflow such that air, depending on the angle of placement, is either directed in an upward or downward flow upon entering the heat exchanger 250 .
[0028] FIG. 3 b , illustrates the liquid cooled portion of the module 200 without focusing on the air cooled scheme as was already discussed. In FIG. 3 b , the cold plate 230 is a liquid cooled cold plate. As illustrated in FIGS. 2 a through c , piping 290 provided thermal communication between the liquid cold plate 230 and the rest of the module 220 . In FIG. 3 b , the piping is shown in more detailed and is shown as having a plurality of sections, 391 , 392 and 393 . This sectioning and arrangement of piping is only one such example and other such embodiments can be designed as is apparent to one skilled in the art.
[0029] Cooling liquid is pumped from the cold plate 230 through the pump 260 through piping 391 in the direction of the arrows. This liquid is then circulated to the heat exchanger 250 through piping section 392 in the direction of indicated arrows. Liquid flowing through the pipes and internal to the heat exchanger rejects heat to the air provided by the blower. The cooled liquid is then returned to the cold plate to extract heat from electronic devices through piping section 393 , again as indicated by the direction of the arrows, thus establishing a closed liquid cooling loop. It should be noted that a variety of coolants can be used to supply the liquid air cooled portion of the module 200 , as known to those skilled in the art. Some coolant examples include but are not limited to refrigerants, brine, fluorocarbon and fluorocarbon compounds, water and liquid metals and liquid metal compounds.
[0030] While the advantages provided by a hybrid liquid-air cooled module is self explanatory in terms of providing maximum thermal management, some discussion should now be conducted to better illustrate the non-thermal related advantages provided by the working of the present invention.
[0031] In many large computing environments, electronic components are disposed over drawers, such as drawer 110 as illustrated in prior art FIG. 1 . These drawers are then disposed over one another in a rack to form a server package. In FIG. 1 , a traditional 19 inch drawer 110 was illustrated to be used in typical 1U or 2 U server package arrangements. The cooling element, such as the heat sink 115 , was then disposed in the main drawer 110 . While the illustration of FIG. 1 showed a 19 inch drawer, in many system environments that employ larger computers and servers, it is desirous to utilize a 24 inch rack arrangement.
[0032] The present invention, provides the flexibility of extending the horizontal size of the server from the traditional 19 inch for high volume applications to the 24 inch rack width used for mid to high end servers. Consequently, not only the present design does provide extendability to future high heat load microprocessors, but it also provides simplicity of application without impacting the layout of the original server and is sized to allow the implementation of the new packages into a standard sized rack.
[0033] Referring back to FIG. 2 a , the illustration of the example depicted in FIG. 2 a provides for an arrangement where a 1U drawer server package is used with the liquid cooled side module, which in this case now has been extended to accommodate a 24 inch wide drawer. It should be noted that the arrangement of the present invention as illustrated is such as to take advantage of a hybrid air and liquid cooling scheme, introduced at the server level. In the embodiment as illustrated by FIG. 2 a , as discussed the 19 inch drawer can be enlarged to fit in an industry standard 24 inch drawer so that the new cooling components do not disturb the electronics in the original drawer.
[0034] As was discussed in reference to the illustration of FIG. 3 a (and 3 b ), air becomes the final sink for the heat generated by the processors as previously discussed in conjunction with the discussion of the embodiment of FIG. 2 . This fact is particularly important because in the 19/24 inch width example, the sidekick module 220 performance add on for the 19 inch 1 and 2U servers will not require any new facilities at the data-center level as is the case with some prior art being currently practiced.
[0035] FIGS. 4 and 5 provide an alternate embodiment for the module 220 of FIGS. 2 and 3 . FIG. 4 , is a top down but slightly rotated view of the embodiment of FIG. 4 and provides the same kind of overall view as was discussed with the embodiment provided in conjunction with FIG. 2 a through FIG. 2 c.
[0036] As illustrated in FIG. 4 , another embodiment for a module 420 is provided. This embodiment as was the case with the embodiment discussed with conjunction with FIG. 2 a through c , also provides for a closed loop liquid system that includes one or more cold plate(s) 430 and an attached auxiliary drawer 415 . As illustrated in FIG. 4 and discussed with reference to the prior embodiment, the attached auxiliary drawer 415 is preferably side attached and therefore the module 420 will be interchangeably referred to side module 420 and/or sidekick module 420 .
[0037] The auxiliary drawer 415 , also referred to as side-attached drawer 415 , still comprises a heat exchanger 450 , a liquid pump 460 and a controller card 470 . However, as depicted in the illustration of FIG. 4 , the heat exchanger 450 has a modified geometry. In the previously discussed embodiment, the heat exchanger 250 was substantially coplanar in geometry with the auxiliary drawer 215 .
[0038] In this embodiment, however, the geometric orientation of the heat exchanger 450 is such that it is on a intersecting plane to the plane of the auxiliary drawer 215 . In a preferred embodiment, the geometric orientation of the heat exchanger is orthogonal with respect to the auxiliary drawer 415 . This change in geometry will enable an improved air flow process and provide space that can be used in housing other components.
[0039] As before, the auxiliary drawer 415 also includes an air moving device 445 (such as a fan) as before. In the embodiment illustrated in FIG. 4 , as was the case with the previous embodiment, the air moving device shown is a blower (also referenced as 445 ). However, unlike the embodiment discussed in conjunction with FIGS. 2 and 3 , in this embodiment the blower 445 is moved to provide a suction flow arrangement. The reason for this alternate embodiment, is to lessen the influence of blockages in the sidekick module 420 , namely those caused by the pump 460 , the connecting tubes/piping 490 or the control card 430 , on the heat exchanger 450 and to eliminate additional heat load caused by blower 445 .
[0040] It should be noted, however, that while two different embodiments and orientations were provided and discussed in conjunction with the embodiments of FIGS. 2 a through c and 4 , these orientations were only provided by way of example and the previous discussion of the orientation of the heat exchangers 250 and 450 should not in any way be limiting. For example the embodiment provided in FIG. 4 , can have a heat exchanger that is substantially perpendicular to the drawer 450 or turned in different angles. In the embodiment of FIGS. 2 a through c , the heat exchanger can also be raised, lowered, tilted or the like to accommodate different air flow arrangements. In short, many different heat exchanger orientations can be implemented selectively to address air flow needs and heat exchanger active area needs related to a particular situation as discussed in conjunction with the workings of the present invention and any discussion of a particular orientation was performed in conjunction with a preferred embodiment, for ease of understanding or both.
[0041] FIG. 5 provides a more detailed illustration of the sidekick module 450 that was previously shown in FIG. 4 . FIG. 5 provides a top down view of the module 450 without the other electronic components, similar to that of the illustration of FIG. 3 . In FIG. 5 , the cold plate(s) 430 is shown to not to be disposed over the auxiliary drawer but is in thermal connection and disposed to a side of it. This was also the case of the example provided in the illustration of FIG. 4 . In FIGS. 4 and 5 , where this arrangement is being used the cold plate 430 will be disposed in the main drawer 410 area as illustrated, similar to the arrangement previously discussed in conjunction with FIG. 2 . As before, in a preferred embodiment, the cold plate 430 is a high performance cold plate to further enhance thermal management of the computing environment.
[0042] FIG. 5 also provides details on other alternate embodiments that can be incorporated into different designs of the embodiments of the present invention, both those that can be incorporated into the first or alternate embodiments discussed in conjunction with FIGS. 2 and 4 . The hybrid nature of the module 220 as was provided in FIG. 2 can also be duplicated by the use of similar piping 490 as provided in FIGS. 4 and 5 , allowing thermal communication to be established between the cold plate 430 and other parts of the module 420 .
[0043] FIG. 6 is alternative embodiment of the present invention. It should be noted that while the alternative embodiment of FIG. 6 is illustrated in conjunction with that of the embodiments of FIGS. 4 and 5 , however, the embodiment of FIG. 6 can be equally incorporated into the embodiment discussed in conjunction with FIGS. 2 and 3 , and or other variations of the present invention.
[0044] In FIG. 6 , a second heat exchanger 600 is disposed over cold plate 430 . This second heat exchanger 600 is added to further improve the performance of the hybrid module. In one embodiment of the present invention, this second heat exchanger 600 is disposed over the cold plate 430 and is therefore already in thermal communication with the auxiliary drawer 415 through its placement over the cold plate 430 . In other embodiments, it is possible to add a plurality of additional heat exchangers such as the one illustrated in FIG. 6 . As before, the heat exchanger, such as the one illustrated in FIG. 6 , may alternatively be coplanar to that of the cold plate 430 , disposed at oblique angle or disposed on an intersecting plane in relation to the cold plate 430 . Alternatively, in some other embodiments, additional heat exchangers may be disposed in other locations in the main drawer 410 . Thermal communication may be established through placement (such as when disposed directly on the cold plate 430 ) of the additional heat exchanger 600 or may be provided by additional piping or other similar means as known to those skilled in the art.
[0045] The present invention, as discussed above provide for an improved cooling module that resolves the problems of prior art currently being practiced. The hybrid air and liquid cooled scheme achieves maximum performance results and introduces a cooling technology with greater heat dissipation capability that will not disturb other electronics in these computing system environments. The hybrid module of the present invention introduces superior cooling, especially to one or a plurality of microprocessors utilized in a larger computing system environment. This will allow the utilization of higher voltages and frequencies in these microprocessors, which in turn enables high-performance packages to be offered with minimal impact to customers and vendors. In addition, the present invention allows for a manner to extend a 19 inch drawer, when desired, to one that can be utilized with a 24 inch rack, a factor that will provide advantages to users of larger computing system environments.
[0046] While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.
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A method and incorporated hybrid air and liquid cooled module for cooling electronic components of a computing system is disclosed. The module is used for cooling electronic components and comprise a closed loop liquid cooled assembly in thermal communication with an air cooled assembly, such that the air cooled assembly is at least partially included in the liquid cooled assembly.
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BACKGROUND OF THE INVENTION
The present invention relates to gas turbine engines having afterburners and, more particularly, to a removable flameholder for use therein.
The invention herein described was made in the course of or under a contract, or a subcontract thereunder, with the United States Department of the Air Force.
Modern gas turbine engines for fighter aircraft application utilize afterburners (or augmenters) to augment the energy level of the hot gas stream exhausted from the engine nozzle, thus increasing the thrust level. In such augmenters, fuel is injected into a hot gas stream and ignited. Flameholders mounted downstream of the injectors establish a stable flame front or localized combustion zone for the augmenting fuel.
V-shaped sheet metal gutters have been found to be effective as flameholders, the apex of each gutter being oriented in an upstream direction toward the fuel injectors. These flameholders necessarily operate at very high temperatures and are among the shorter life components of a gas turbine engine. Therefore, it is especially desirable that these parts be easily installed and removed without removal of the engine from the aircraft or removal of the augmenter, or exhaust nozzle, from the engine.
Fan engines with mixed flow augmenters are generally equipped with multilobe mixers to comingle the hot core engine exhaust gases with the relatively cooler fan exhaust gases, and the flameholder is mounted within this mixer at its downstream end. Typically, the mixer envelopes the flameholder resulting in very difficult access to the fasteners attaching the flameholder to the remaining fixed nozzle structure; heretofore the fasteners had to be shielded from the extremely hot afterburning gases and were normally located on the back side (upstream side) of the gutter. Assembly and removal of this type of flameholder with twenty or more (for example) such inaccessible fasteners were extremely difficult, time consuming and costly. This method has been used for many years, however, since it was believed that any fastener accessible from inside the gutter would be overheated. Such fasteners located inside the gutters have, in fact, been tried and have melted. A simple means of mounting flameholders in mixed flow augmenters, therefore, is a needed improvement.
In order that high augmenter performance can be achieved, the flameholder diameter is often larger than the exhaust nozzle diameter. This means that the flameholder cannot be removed and replaced through the exhaust nozzle, thus requiring that the engine be removed from the aircraft and the entire augmenter removed in order to replace the flameholders. This is a time-consuming, costly maintenance procedure. Thus, simple means are needed for removing the flameholder through the exhaust nozzle.
SUMMARY OF THE INVENTION
Accordingly, it is the primary object of the present invention to provide an easily removable flameholder wherein all mounting hardware is protected from the intense heat generated by the augmenter.
It is a further object of the present invention to provide an improved and simple means for removing the flameholder through its associated exhaust nozzle.
It is yet another object of the present invention to provide a method for cooling a fastener connecting a flameholder gutter to nozzle support structure when the fastener protrudes into the gutter.
These and other objects and advantages will be more clearly understood from the following detailed description, drawings and specific examples, all of which are intended to be typical of rather than in any way limiting to the scope of the present invention.
Briefly stated, the above objects are accomplished by providing an augmenter with at least one generally V-shaped gutter for holding and stabilizing a flame. Fasteners passing through the gutter attach the gutter to a nozzle-supporting member. In order to protect the fastener from the intense heat generated inside the gutter, the fastener is recessed in a heat shield affixed to the inside of the gutter, thus limiting the fastener heating flux. In addition, the fastener is cooled by combustible gas passing through an aperture communicating the upstream gas flow with the interior of the heat shield. Since the augmenter fuel injectors are well upstream of the gutter, this coolant flow is carbureted and it might be expected that such a combustible mixture would ignite as it flowed through the aperture and into the heat shield, thus overheating the fastener. In fact, in the present invention, just the opposite occurs since the aperture and heat shield are so sized that the coolant velocity is sufficient to prevent flame propagation upstream to the fastener. Such a design allows very rapid installation and removal of the flameholder since the fasteners can be accessible from the downstream direction.
In order that the flameholder can be removed through the exhaust nozzle for rapid replacement, it is constructed in segments (i.e., circumferential segments when the gutter is substantially annular). The segments are provided with upstream protruding flanges such that the cooperating flanges of adjacent segments can be connected by a connector means such as a nut and bolt (example). In order that flow blockage pressure losses are minimized, the connector is on the upstream side of the gutter. To prevent two adjacent segments from becoming misaligned, alignment pins are provided between such segments.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as part of the present invention, it is believed that the invention will be more fully understood from the following description of the preferred embodiment which is given by way of example with the accompanying drawings, in which:
FIG. 1 diagrammatically depicts in partial cut-away an augmented gas turbine engine incorporating the subject invention;
FIG. 2 is an enlarged schematic view of the flameholder of the engine of FIG. 1 depicting in greater detail the subject invention;
FIG. 3 is a circumferential section of the flameholder taken along line 3--3 of FIG. 2;
FIG. 4 is a further enlarged view showing the flameholder support structure;
FIG. 5 is a top view of the support structure of FIG. 4;
FIG. 6 is a fragmentary view of the pin connection between adjacent flameholder segments taken along line 6--6 of FIG. 3;
FIG. 7 is a fragmentary top view of the structure of FIG. 6; and
FIG. 8 is an enlarged fragmentary view of the structure of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings wherein like numerals correspond to like elements throughout, reference is first directed to FIG. 1 wherein an engine depicted generally at 10 and embodying the present invention is diagrammatically shown. This engine may be considered as comprising generally a core engine 12, a fan assembly 14, including a stage of fan blades 15 and a fan turbine 16 which is interconnected to the fan assembly 14 by shaft 18. The core engine 12 includes an axial flow compressor 20 having a rotor 22. Air enters inlet 24 and is initially compressed by fan assembly 14. A first portion of this compressed air enters the fan bypass duct 26 defined, in part, by core engine 12 and a circumscribing fan nacelle 28 and discharges through a chuted mixer 30. A second portion of the compressed air enters inlet 32, is further compressed by the axial flow compressor 20, and then is discharged to a combustor 34 where fuel is burned to provide high energy combustion gases which drive a turbine 36. The turbine 36, in turn, drives the rotor 22 through a shaft 38 in the usual manner of a gas turbine engine. The hot gases of combustion then pass to and drive the fan turbine 16 which, in turn, drives the fan assembly 14. The combustion gases from the core engine, after exiting fan turbine 16, are discharged through the chuted mixer 30 where they are comingled with the air from bypass duct 26 in the known manner.
The engine of FIG. 1 is also shown to include an augmenter indicated generally at 40. The augmenter is shown to include at least one fuel injector 42 disposed upstream of a flameholder 44. Fuel injector 42 injects fuel into the gas stream upstream of the flameholder, the fuel becoming carbureted by the time it reaches the flameholder 44 where it is ignited and stabilized. The gases of combustion then pass to, and are discharged from, nozzle 46 to produce a propulsive force to the left in FIG. 1.
Referring now to FIGS. 2 and 3, there is depicted therein an enlarged view of the flameholder and nozzle structure of FIG. 1. It will be noted that a double annular flow path is shown, with a first duct 46 defined by nacelle 28 and chuted mixer 30 which serves to pass a limited portion of the bypass duct (26 in FIG. 1) flow around the mixer for purposes not relevant to the present discussion. The inner annular flow path 48 carrying the carbureted gas stream to the flameholder 44 is defined by the rigid mixer wall 50 and a central plug 52 (FIG. 1). As best shown in FIG. 3, the mixer is of the known "daisy" or chuted type which comingles alternating streams of core engine and fan gases, 48 and 52, respectively.
The flameholder includes an outer annular V-shaped gutter 54, preferably formed of sheet metal and having its apex pointed upstream relative to the combustible gas stream direction. An inner, coannular, V-shaped gutter 56 is located inwardly of gutter 54 and a plurality of radial gutters 58 extend therebetween. As can best be seen in FIG. 4, a slip joint 59 is provided to permit thermal expansion between the circumferential gutter 54 and radial gutters 58. These gutters provide a stabilized combustion zone for the carbureted mixture which is ignited by means not shown. Thus, in operation, a stabilized flame front is formed in the plane of the flameholder to ignite the carbureted gas mixture generated further upstream, significantly increasing the propulsive thrust.
The flameholder 44 is mounted to a supporting member, here mixer 30, by a means now to be described and which comprises, in part, the subject of the present invention. Referring primarily to FIGS. 2 and 4, there is depicted a relatively simple flameholder mounting or fastening means comprising a threaded bolt 60 passing through cooperating bolt holes 62 in the outer V-gutter 54 and a lug 64, the function of which will be described later. Nute 66 completes the connection of the gutter and the lug. Lug 64, in turn, is operatively connected to the rigid mixture structure 30 by means of a hinged link 68. A hole at 72 receives pin 76 passing through lug 64 and the pin, in turn, is captured by means of cotter pins or, as shown at 78, an S-shaped fastener passing therethrough (FIG. 8). This hinged link arrangement retains the flameholder while still permitting relative thermal expansion between the flameholder and the mixer 30. It will be recognized that such a provision is necessary since the mixer receives relatively cool fan air in alternating chutes while the flameholder serves to stabilize the extremely hot, augmenting flame front.
Upon first consideration, it may appear that the foregoing is so straightforward that it would present no advancement over the prior art. However, such an arrangement has not heretofore been adopted because there was no way to protect the head of bolts 60 from the intense heat inside the gutters. Therefore, in the past, lug 64 was formed integral with gutter 54 and the removal procedure for the flameholder consisted of disconnecting the link 68 from the lug 64 by removing S-shaped fastener 78. It becomes readily apparent from FIGS. 2 and 3 that since the mixer structure 30 envelopes the flameholder, access to fasteners 78 from the downstream direction (from the right in FIG. 2) is very difficult at best. Assembly and removal of this type of flameholder with twenty or more inaccessible fasteners (for example) was difficult, time consuming and costly. However, as previously noted, it was necessary to locate the fasteners behind the gutters to prevent them from becoming overheated. The present invention has overcome this problem.
The present invention makes use of a unique scheme for protecting the head of bolt 60 from overheating. In particular, referring now to FIG. 3, the bolt head is released in a cavity 79 formed by heat shield 80 which is disposed upon an inside surface of gutter 54. The heat shield limits the bolt heating flux and provides a first amount of thermal protection. Additionally, the bolt head is cooled by a portion of the carbureted gas mixture passing through an aperture 82 within gutter 54 which fluidly communicates the upstream gas mixture with the cavity 79. This aperture is preferably aligned with the upstream gas direction to capture as much of the gas flow dynamic head as possible.
Since the augmenter fuel injectors (not shown) are well upstream of the flameholders to caburet the gas mixture, it might be expected that such a combustible mixture would ignite as it flowed through aperture 82 and thus heat bolt 60. However, if the velocity of the flow between the bolt 60 and heat shield 80 is maintained at a value at least as great as the flame propagation velocity, the flame will be unable to propagate upstream to the bolt and the bolt will, instead, be effectively cooled. Thus, an arrangement has been provided which permits the rapid installation or removal of the flameholder since nut 66 can be held with a box wrench while the bolt 60 is driven with a speed wrench.
In order to maintain the proper orientation of link 68, lug 64 is positioned in close-fitting, generally elongated slot 84 on the reverse side of gutter 54 from heat shield 80, and generally aligned therewith (FIGS. 4 and 5). The lug, therefore, provides the means to orient the flameholder within the nozzle structure and, along with link 68 and bolt 60, provides the necessary structural connection between the flameholder and the rigid supporting structure.
Often, the flameholder diameter is larger than the exhaust nozzle diameter. In order that such a flameholder can be removed through the exhaust nozzle for rapid replacement, it is proposed to segment it. Referring now to FIGS. 3, 6 and 7, it can be seen that the circumferentially extending gutters 54 and 56 have been segmented along plane 86 which splits the flameholder in half. While only two segments are shown, it is clear that the flameholder may be split in as many segments as desirable in order to facilitate removal. FIGS. 6 and 7 show in detail the means for connecting the two halves of the flameholder. Referring to the outer gutter 54, it can be seen that adjacent segments are provided with cooperating flanges 88 which extend upstream from a point proximate the apex of the gutter in order that flow blockage pressure losses are minimized. These cooperating flanges are connected as by nut and bolt 90, for example. A single connector (nut and bolt) is used, again to minimize pressure losses. To prevent the two mating flanges 88 from rotating relative to each other about the single bolt, alignment pins 92 are used. The alignment pins extend between segments in the tangential direction and are received within appropriate cooperating holes in each segment. Obviously, a similar structure would appear for the inner gutter 56. Thus, according to the objects of the present invention, a flameholder apparatus has been provided which is easily removable and wherein the mounting structure is protected from the intense heat inside the gutters. Further, simple means are provided to remove the flameholder through a relatively small exhaust nozzle.
Additionally, a method of cooling a fastener, such as bolt 60, connecting a flameholder gutter 54 to a support member (i.e., mixer 30), has been provided. Such a method is seen to include the steps of recessing the fastener in a heat shield 80, disposed within the gutter, and then passing a portion of the combustible gas stream into the heat shield and over the fastener at a velocity at least as great as flame propagation velocity.
It will be obvious to one skilled in the art that certain changes can be made to the above-described invention without departing from the broad inventive concepts thereof. For example, the subject invention is not limited to engines incorporating mixers since the flameholder could be affixed to the nozzle casing which would provide the necessary structural support. Also, the specific fasteners and connectors discussed herein are merely illustrative of many alternatives which may be employed and still remain within the scope of the present invention. Further, the concept of cooling a fastener with a combustible gas mixture is not limited to afterburner flameholders, but may be employed equally effectively with any structure disposed within such an environment. It is intended that the appended claims cover these and all other variations in the present invention's broader inventive concepts.
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A flameholder apparatus for use in a gas turbine engine exhaust nozzle comprises at least one V-shaped gutter for holding a flame, with fasteners to mount the gutter to a nozzle support structure, the fasteners being accessible from the downstream flow direction and protruding into the gutter. To prevent the fasteners from overheating, the protruding portion is recessed in a heat shield affixed to the gutter and a portion of the combustible nozzle gas stream is passed into the heat shield and over the fastener at a velocity at least as great as the flame propagating velocity. In one embodiment, the gutter is segmented to facilitate removal through a smaller nozzle opening. Alignment pins between adjacent gutter segments provide proper gutter segment orientation, while adjacent segments are attached together through cooperating flanges on the upstream surfaces of the segments to minimize flow blockage pressure losses.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based upon co-pending and co-owned U.S. Provisional Patent Application Ser. No. 62/088,969 entitled “Undergarment with Support Structure,” filed with the U.S. Patent and Trademark Office on Dec. 8, 2014, the specification of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to sport undergarments, and more particularly to an undergarment that may be worn to provide male anatomical support during various physical activities.
BACKGROUND OF THE INVENTION
[0003] Athletes will often wear sporting apparel that is specialized to the activities in which they are engaged. Particularly, as many sports carry risk of impact injury to an athlete's groin, it has long been advised that athletes wear an athletic cup to protect their genitals against injury during such activities. Unfortunately, prior constructions that have sought to incorporate systems for holding an athletic cup, and for otherwise supporting the wearer's genitalia, have lacked comfort and have not been widely accepted. For instance, a survey of student athletes conducted by the Society for Pediatric Urology indicated that across all sports, 87.5% of those surveyed reported not wearing athletic cups during practices or games, evidencing that despite the need to protect against injury, athletes are typically not inclined to take adequate protection.
[0004] An often-cited reason for not wearing a protective athletic cup is the discomfort that an athlete often feels when wearing such equipment. Particularly, movement and shifting of the athletic cup during athletic movements tends to shift the orientation of the cup with respect to the wearer's genitalia, making it uncomfortable at best, and creating a crushing point-impact injury at worst.
[0005] In light of the shortcomings of such prior configurations, there remains a need in the art for an undergarment that is comfortable to wear and that provides sufficient support to the male wearer's genitalia during athletic movements, and that particularly can maintain an athletic cup in its intended position throughout even aggressive athletic movements.
SUMMARY OF THE INVENTION
[0006] Disclosed is an undergarment having a support system configured to comfortably support a male wearer's genitalia while ensuring constant alignment of an athletic cup held in an exterior pocket of the undergarment, even through aggressive athletic movements. In certain configurations, an athletic cup pocket may be provided at the front of the undergarment having an open bottom that allows the bottom of the athletic cup to extend through such pocket. Inside of the undergarment, an internal pocket is formed by a generally H-shaped insert that holds the male wearer's genitalia in a forward position and keeps the wearer's genitalia aligned with the internal portion of the athletic cup positioned at the front of the undergarment. Additionally, the H-shaped insert positions the male wearer's genitalia away from their legs, providing increased support and comfort for the wearer. More particularly, the internal compartment creates a fabric barrier between the top, inside portion of each leg and the central groin, decreasing the risk of chaffing. A cross-wall defining the back of the internal pocket not only holds the wearer's genitalia to prevent it from dropping backward or downward, but also presses against the wearer's perineum at its top edge to further aid in creation of a barrier that even further reduces the risk of chaffing. The side panels of the H-shaped insert are so positioned with respect to the wearer's anatomy so as to pull the back portion of the undergarment forward against the wearer's buttocks, and the bottom portion of the undergarment upward against the bottom of the wearer's torso (and particularly against the wearer's perineum), when worn. Moreover, placement of an athletic cup in the front of the undergarment, in combination with the position of the H-shaped insert, further this effect of pulling the interior of the undergarment against the wearer's body while both preventing chaffing of the wearer's upper thighs and holding the wearer's genitalia in a forward position.
[0007] In accordance with certain aspects of an embodiment of the invention, an undergarment is provided having a compression shorts exterior; an H-shaped insert attached to an interior of the compression shorts, the H-shaped insert further comprising a first side panel having a bottom edge affixed to an interior of the shorts, and a top edge opposite the bottom edge of the first side panel;
[0008] a second side panel having a bottom edge affixed to the interior of the shorts, and a top edge opposite the bottom edge of the second side panel, the second side panel extending parallel to the first side panel; and a central panel attached to and extending perpendicular to each of the side panels; wherein a front edge of each of the side panels is attached to an interior front side of the compression shorts, and a second edge of each of the side panels opposite the front edges is attached to an interior of the compression shorts at a location such that, when worn, the second edge aligns with a location on a wearer's body that is rearwardly adjacent to the wearer's femur bone socket.
[0009] In accordance with further aspects of an embodiment of the invention, an undergarment is provided comprising a compression shorts exterior, the compression shorts exterior further comprising a central shorts panel having a head region having a front top edge and two head region side edges, each head region side edge convexly curving inwardly to a mid-region point, and a tail region having a rear top edge and two tail region side edges, each tail region side edge concavely curving inwardly from the rear top edge to the mid-region point; and two leg panels, each of the leg panels having a leg panel top edge, a leg panel bottom edge, a lower cylindrical portion extending upward from the leg panel bottom edge, and a curved upper seam extending upward from the lower cylindrical portion, the curved upper seam having an upper seam front portion affixed to one of the head region side edges of the shorts central panel, and an upper seam back portion affixed to one of the tail region side edges of the shorts central panel; a curved side panel attached to the intersection of each leg panel curved upper seam with the shorts central panel, each curved side panel extending along the front upper seam of the leg panel and only a portion of the back upper seam of the leg panel so as to terminate at a position adjacent a wearer's perineum when worn; and a central genitalia support panel extending between and affixed to each curved side panel and extending over the central shorts panel at the mid-region point.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying drawings in which:
[0011] FIG. 1 is a top view of an undergarment in accordance with certain aspects of the invention.
[0012] FIG. 2 is a side view of the undergarment of FIG. 1 .
[0013] FIG. 3 is a front view of the undergarment of FIG. 1 .
[0014] FIG. 4 is a schematic view of a pattern suitable for use in forming the undergarment of FIG. 1 .
[0015] FIG. 5 is a top view of an undergarment in accordance with further aspects of the invention and showing representative dimensions for various elements of the undergarment.
DETAILED DESCRIPTION
[0016] The invention summarized above may be better understood by referring to the following description, claims, and accompanying drawings. This description of an embodiment, set out below to enable one to practice an implementation of the invention, is not intended to limit the preferred embodiment, but to serve as a particular example thereof. Those skilled in the art should appreciate that they may readily use the conception and specific embodiments disclosed as a basis for modifying or designing other methods and systems for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent assemblies do not depart from the spirit and scope of the invention in its broadest form.
[0017] Disclosed is an athletic undergarment configured to provide comfortable support to a male wearer during athletic activities. In certain configurations, such undergarment is configured to ensure that the wearer's genitalia are protected from impact during such activities. More particularly, the undergarment described herein includes an internal structure that creates a compartment to support male genitalia, and to optionally position the male genitalia with respect to an athletic cup held in an exterior pocket so as to at all times keep the wearer's genitalia within the perimeter of the athletic cup, even during aggressive athletic movements.
[0018] As shown in the top-down view of FIG. 1 , the undergarment comprises shorts that include, in general, outer compression shorts 100 having a waistband 102 and leg hole openings 104 a and 104 b. From the perspective of FIG. 1 , the top of the Figure represents the front of shorts 100 , and the bottom of the Figure represents the back of the shorts 100 . Compression shorts 100 are of traditional configuration, such that when worn, the front, back, and sides of the shorts are in close contact with the wearer's torso. A generally H-shaped insert 108 is provided on the interior of the compression shorts 100 extending generally from front to back, and is preferably formed of spandex or cotton. The H-shaped insert includes a first side 110 a adjacent first leg hole opening 104 a, a second side 110 b adjacent second leg hole opening 104 b, and a central panel 112 extending between first side 110 a and second side 110 b and generally perpendicular to those two sides. Central panel 112 and the front portions of first side 110 a and second side 110 b form an internal pocket 120 . When worn by a male, the front, upper portions of each of first side 110 a and second side 110 b of the H-shaped insert will sit immediately adjacent the wearer's legs and against their groin, so that internal pocket 120 will hold the wearer's genitalia in place in pocket 120 , even through athletic movements (such as squatting).
[0019] Additionally, a jock strap assembly (shown generally at 200 ) may be provided, the jock strap assembly being configured to hold an athletic cup of traditional configuration. Jock strap 200 includes a front, external pocket 202 on an exterior, front side of compression shorts 100 , which in certain configurations is sewn to the front of compression shorts 100 along a seam 204 at the top edge 206 of pocket 202 . In this configuration, the sides of pocket 202 are not sewn to the front of compression shorts 100 so that an athletic cup may be inserted into pocket 202 , and so as to have the cup-holding pocket 202 attached to the shorts only along seam 204 . Jock strap 200 narrows from top edge 206 towards its back edge 208 , and forms a generally triangularly-shaped pocket 209 at its base configured to receive the narrow, bottom end of a traditional athletic cup (not shown). A connecting member is provided, which may include straps 210 a and 210 b extending outward from the back edge 208 of jock strap 200 , and passing through an opening 106 in the bottom, back center of compression shorts 100 . Further, the free ends of each of straps 210 a and 210 b are sewn to the back ends of first side 110 a and second side 110 b of the H-shaped insert, respectively, where those first and second sides 110 a and 110 b are attached to the interior of compression shorts 100 . Thus, while external pocket 202 configured as shown in FIG. 1 is not detachable from shorts 100 , the bottom, rear portion of external pocket 202 may move relatively freely with respect to shorts 100 , with seam 204 acting essentially as a hinge for external pocket 202 , and allowing the bottom-most portion of external pocket 202 to vary position with respect to shorts 100 so as to accommodate wearers' differing body sizes.
[0020] Moreover, anchoring the top, front edge of the jock strap 200 to the front, exterior of compression shorts 100 , and anchoring the rear portion of straps 210 a and 210 b of jock strap 200 to the back, interior of compression shorts 100 , aids in pulling the bottom of the cup upwards so that it sits tighter against the wearer's body than it would in typical jock strap configurations. More particularly, the configuration of the instant invention creates and takes advantage of open space behind the wearer's genitals, with straps 210 a and 210 b extending through such open space, providing a more upwardly and rearwardly directed pull on back edge 208 of external pocket 202 . Further, as straps 210 a and 210 b pull the back edge 208 of external pocket 202 inward towards the wearer's groin, the back edge 208 of external pocket 202 (and thus the bottom-most portion of an athletic cup positioned within external pocket 202 ) extends rearward of central panel 112 as it is pulled toward the wearer's groin. In this position, the athletic cup held in external pocket 202 overlaps internal pocket 120 , such that the male wearer's genitalia is automatically positioned within the athletic cup. Further, the pulling force exerted on the back edge 208 of external pocket 202 by straps 210 a and 210 b when the shorts are worn ensures that the athletic cup is continuously pulled against the wearer's groin to ensure that the wearer's genitalia is both comfortably contained in internal pocket 120 and protected by the athletic cup positioned in external pocket 202 , and remains within the perimeter of an athletic cup positioned in external pocket 202 even during athletic exercises and movements.
[0021] While not shown in the Figures, a single fabric member may be provided in the general form of a triangle, joining back edge 208 of external pocket 202 to the back, interior of compression shorts 100 , instead of separate straps 210 a and 210 b, with the triangular fabric member being sewn across the back, interior of compression shorts 100 . In this optional configuration, straps 210 a and 210 b become the outline of the triangular fabric member, with the seam for such member running from the location of one strap to the other strap.
[0022] FIG. 2 is a side view of compression shorts 100 , and FIG. 3 is a front view of compression shorts 100 , each showing the above-described support system (the internal components of the system being shown in phantom). More particularly, external pocket 202 is shown attached at seam 204 to the front of shorts 100 , with seam 204 positioned preferably about 1.5 inches below waistband 102 . The sides of external pocket 202 remain open such that an athletic cup 300 ( FIG. 2 ) may be inserted into external pocket 202 from either of its open sides. The bottom most portion of athletic cup 300 sits within triangularly shaped pocket 209 formed at the back end 208 of external pocket 202 , and as back end 208 of external pocket 202 is not fixed to the exterior of shorts 100 , a degree of movement is available between pocket 202 and the interior of shorts 100 , and thus between the athletic cup 300 and the interior of shorts 100 , to accommodate the differing shapes and sizes of various wearers. Nonetheless, such freedom of movement exists primarily only during placement of the shorts 100 on the wearer, as when the shorts 100 are worn, straps 210 a and 210 b pull the back end 208 of external pocket 202 inward toward the wearer's groin and will hold the external pocket 202 , and any cup 300 held therein, in place in a fixed position against the wearer's groin.
[0023] FIGS. 2 and 3 also show sides 110 a and 110 b of H-shaped insert 108 , along with central panel 112 extending between sides 110 a and 110 b and positioned so as to align with the wearer's perineum, such that the resulting internal pocket 120 will hold the wearer's genitalia in a forward position and in alignment with the interior of cup 300 while the shorts 100 are worn, including throughout athletic movements.
[0024] It is not necessary that pocket 202 be formed with open sides and a closed top, or that straps 210 a and 210 b attach such pocket 202 to compression shorts 100 . Rather, in certain configurations, pocket 202 may be provided on the interior or exterior of compression shorts 100 with sewn sides and an open top to receive an athletic cup, and straps 210 a and 210 b eliminated from the undergarment. In this configuration, the specific placement of side panels 110 a and 110 b, and particularly the points at which side panels 110 a and 100 b attach to the interior of compression shorts 100 , will pull the back section of the compression shorts 100 forward against the wearer's buttocks and the bottom section of the compression shorts 100 upward against the wearer's perineum, such that the top portions of side panels 110 a and 110 b sit flush against the bottom of the wearer's torso, and the top of central panel 112 sits flush against the bottom of the wearer's torso and behind their genitalia, thus protecting the wearer's upper thighs against chaffing and holding the wearer's genitalia in a forward position. Moreover, placing an athletic cup into pocket 202 in this configuration further tightens the compression shorts 100 against the wearer's body, even further improving the protection against chaffing and holding the wearer's genitalia in a forward position and fully in alignment with the interior portion of such athletic cup.
[0025] FIG. 4 is an exemplary pattern that may be used to form the shorts 100 as described above. As shown in FIG. 4 , a shorts central panel 400 is provided and includes a wide head region 402 that narrows along curved side edges to a mid-region point 401 (the location at which central panel 112 crosses over shorts central panel 400 ), with each curved side edge joining to a front, upper seam 412 of each pant leg panel 410 . Central panel 400 also includes a tail region 404 extending from the end of wide head region 402 to the back end of central panel 400 , and having curved side edges that widen from the intersection with wide head region to the back end of central panel 400 . Further, each curved side edge of tail region 404 joins to a back, upper seam 414 of each pant leg panel 410 . Each pant leg panel 410 wraps into a generally cylindrical shape, such that the bottom leg seams 416 of each pant leg panel join to one another. Each pant leg panel 410 also includes a side 110 a or 110 b of H-shaped insert 108 (which may be separated into two segments when initially forming the pant leg panel 410 , but ultimately joining together into a single side of H-shaped insert 108 ). Likewise, one of pant leg panels 410 includes central panel 112 , which may be joined along its free edge 113 to the side 110 b of the other pant leg panel 410 when the two pant leg panels 410 are joined to central panel 400 .
[0026] As mentioned above, compression shorts 100 need not be formed with straps 110 a and 110 b , and may instead be provided with an athletic cup compartment sewn at both sides to either the interior or exterior of the front portion of compression shorts 100 , forming pocket 120 with an open top for receiving an athletic cup. In such configuration, pocket 120 is preferably open at the bottom so that the bottom portion of an athletic cup may extend through the bottom of pocket 120 so that it is positioned, when worn, behind central panel 112 .
[0027] In order to maximize the benefits of protecting against chaffing of the wearer's upper thighs and groin, and positioning the wearer's genitalia in a forward position throughout athletic movements, proper placement of side panels 110 a and 110 b and central panel 112 (and of their attachment to the interior of compression shorts 100 ) is an important aspect. FIG. 5 shows preferable dimensions that have been found to be optimal for such placement. As shown in FIG. 5 , the total distance from the bottom of the waistband 102 at the front of the compression shorts 100 to the bottom of the waistband 102 at the back of the shorts (dimension “C”) along upper seams 412 and 414 (where shorts central panel 400 attaches to each pant leg panel 410 ) is preferably 54 cm (representing the full length of the side edges of central panel 400 shown in FIG. 4 ), although such dimension may be modified to suit individuals of differing body sizes, with the points of attachment of H-shaped insert 108 proportionally altered to maintain the same alignment with the wearer's anatomy as discussed here. For compression shorts 100 having such a front to back length span of 54 cm, the rear portion of side panels 110 a and 110 b of H-shaped insert 108 are attached to the interior of compression shorts 100 a distance of 31-32 cm from the bottom of waistband 102 at the front of compression shorts 100 (dimension “A”) measured along upper seams 412 and 414 , with central panel 112 positioned a distance of 22-23 cm from the bottom of waistband 102 at the front of compression shorts 100 (dimension “B”) measured along upper seams 412 and 414 . In general, and so as to allow the foregoing dimensions to be proportionally varied for persons of differing body sizes, side panels 110 a and 110 b of H-shaped insert 108 extend preferably 65-68% of the distance from the bottom of waistband 102 at the front of compression shorts 100 (dimension “A”) to the bottom of waistband 102 at the rear of compression shorts 100 along upper seams 412 and 414 , with central panel 112 positioned preferably 40-43% of the distance from the bottom of waistband 102 at the front of compression shorts 100 (dimension “B”) to the bottom of waistband 102 at the rear of compression shorts 100 along upper seams 412 and 414 .
[0028] Such positioning of both the central panel 112 and side panels 110 a and 110 b of H-shaped insert 108 causes the back end of each of side panels 110 a and 110 b to be positioned just rearward of the wearer's femur bone socket in the pubic bone, with central panel 112 positioned just forward of the wearer's femur bone socket. More particularly, in such configuration, the back end of each of side panels 110 a and 110 b is positioned adjacent the portion of the wearer's pubis to which the adductor magnus muscle attaches, with central panel 112 being positioned forward of both the adductor magnus muscle and the femur bone socket, and aligned with the region of the wearer's pubis to which the wearer's gracilis muscle attaches. Moreover, each side panel 110 a and 110 b extends forward from such rear attachment point, so that the top edge of at least a portion of each side panel 110 a and 110 b maintains contact with the wearer's skin that covers the intersection of the wearer's gracilis muscle, adductor magnus muscle, and ischiocavernous muscle with the inferior ramus of the pubis. Likewise, the upper edge of central panel 112 is positioned to maintain contact with a region of bottom of the torso of the wearer's body that is both forward of the femur bone socket and that is in-line with the region in which the wearer's gracilis muscle attaches to the wearer's pubis. Such alignment between the upper edge of central panel 112 and this region of the wearer's body is maintained throughout even aggressive athletic movements, including for example during squatting and returning to a standing position.
[0029] It has been found that such positioning of side panels 110 a and 110 b and of central panel 112 results in forwardly positioning the male wearer's genitalia forward of and in contact with (and supported from behind by) central panel 112 , with side panels 110 a and 110 b sitting between the wearer's upper thighs at the intersection with the wearer's groin so as to maximize comfort in both standing and squatting positions while protecting against chaffing in all positions between the standing and squatting positions. Moreover, such positioning of side panels 110 a and 110 b has been found to pull the interior material of compression shorts 100 against the rear and bottom of the wearer's torso to maintain a tight fit and proper positioning of the side panels 110 a and 110 b and central panel 112 throughout such movements. It has been found that if the back end of side panels 110 a and 110 b are positioned too far rearward, the anchor point will perform poorly in both pulling the compression shorts 100 and H-shaped insert 108 tightly against the wearer's skin. Likewise, it has been found that if the back end of side panels 110 a and 110 b are positioned too far forward, the anchor point will perform poorly in ensuring constant and continuous contact of side panels 110 a and 110 b throughout their full length with the skin of the wearer's crotch, thus leaving that skin prone to chaffing. Furthermore, positioning central panel 112 too far forward will prevent central panel 112 from contacting the perineum as intended, and positioning central panel 112 too far rearward will result in improper positioning and support of the wearer's genitalia in a sufficiently forward position so as to provide comfortable support while avoiding chaffing of the wearer's perineum.
[0030] Still further, when provided with cup pocket 120 , placement of an athletic cup in such cup pocket 120 results in side panels 110 a and 110 b pulling the athletic cup snug against the wearer's body, with the bottom of the athletic cup extending rearward of central panel 112 to ensure that the male wearer's genitalia at all times is aligned with the interior of the athletic cup.
[0031] In still other configurations of compression shorts 100 , the undergarment may be provided without any pocket 120 . In this configuration, in the event that the wearer wishes to use the undergarment when engaging in sports activities, the compression shorts may be worn with a jock strap and still provide the benefits of protection against chaffing of the wearer's upper thighs and forward positioning of the wearer's genitalia as discussed in detail above.
[0032] Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein.
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An undergarment is provided having a support system configured to comfortably support a male wearer's genitalia throughout aggressive athletic movements. Inside of the undergarment, an internal pocket is formed by a generally H-shaped insert that holds the male wearer's genitalia in a forward position and keeps the wearer's genitalia aligned with the internal portion of the athletic cup positioned at the front of the undergarment. Additionally, the H-shaped insert positions the male wearer's genitalia away from their legs, providing increased support and comfort for the wearer. A cross-wall defining the back of the internal pocket holds the wearer's genitalia to prevent it from dropping backward or downward, and presses against the wearer's perineum at its top edge to further aid in creation of a barrier that even further reduces the risk of chaffing. The side panels of the H-shaped insert are so positioned with respect to the wearer's anatomy so as to pull the back portion of the undergarment forward against the wearer's buttocks, and the bottom portion of the undergarment upward against the bottom of the wearer's torso (and particularly against the wearer's perineum), when worn.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority, under 35 U.S.C. §119, of German application DE 10 2009 010 925.0, filed Feb. 27, 2009; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a start-stop system of a motor vehicle with an internal combustion engine. Such start-stop systems are described, for example, in U.S. Patent Publication No. US 2006/0208568 A1 (cf. DE 10 2006 000 114 A1, JP2006256562) and U.S. Pat. No. 6,371,889 B1 (cf. DE 100 40 094 A1, JP2001055940).
There, whenever the vehicle is at a standstill, that is to say the speed of the vehicle is equal to zero, the system checks on the basis of various deactivation conditions as to whether it is possible to shut down the internal combustion engine while at a standstill. If one or more deactivation conditions are met, the internal combustion engine is shut down and is only re-activated when the controller detects the presence of at least one activation condition.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a start-stop system which overcomes various disadvantages associated with the heretofore-known devices and methods of this general type and which provides for a start-stop system that is specifically improved as it further extends the advantages of the start-stop system with regard to fuel consumption and emissions.
With the foregoing and other objects in view there is provided, in accordance with the invention, a method of operating an internal combustion engine of a motor vehicle, the method which comprises:
automatically starting the internal combustion engine in dependence on at least one activation condition and/or automatically deactivating the internal combustion engine in dependence on at least one deactivation condition;
measuring the at least one activation condition and/or the at least one deactivation condition while the motor vehicle is at a standstill; and
storing a presence of the activation conditions and/or deactivation conditions in a memory and evaluating the presence of the activation conditions and/or deactivation conditions in order to diagnose a control of the internal combustion engine.
In other words, the objects are achieved according to the invention, with a method for operating an internal combustion engine of a motor vehicle, in which method the internal combustion engine is automatically started as a function of at least one activation condition and/or automatically deactivated as a function of at least one deactivation condition, with the at least one activation condition and/or the at least one deactivation condition being measured while the vehicle is at a standstill, in that the presence of the activation conditions and/or deactivation conditions are stored and evaluated in order to diagnose the control of the internal combustion engine.
By means of the storage, according to the invention, of the deactivation and activation conditions and associated parameters and/or time indications, it is possible to measure the efficiency of the start-stop system at the end of a driving cycle and/or over the entire operating duration of the vehicle.
It is thus possible, for example, for a characteristic regarding the use of the start-stop system to be displayed to the driver at the end of a driving cycle, and for recommendations to be shown as to how he can improve the efficiency of the system.
It is also possible, in the event of an inspection of the motor vehicle, and during the course of an on-board diagnosis, for the characteristics determined using the method according to the invention to be read out and evaluated by trained professionals. This may on the one hand lead to the identification and realization of improvement potential in technical components of the motor vehicle. Furthermore, it is also possible for the trained workshop personnel to give the driver of the motor vehicle indications as to how he can use the start-stop system more efficiently and thereby reduce fuel consumption and save on operating costs. Finally, the vehicle manufacturer gains information regarding how often the start-stop system has been used, and if appropriate, regarding why said start-stop system could not be used despite the vehicle being at a standstill.
In a further advantageous embodiment of the invention, it is provided that a first time counter starts running when the vehicle comes to a standstill, and in that the first time counter is stopped when the vehicle starts moving again. In this way, it is possible to measure the standstill times of the vehicle, which are an important dependent variable for the assessment of the efficiency of the start-stop system.
In a further advantageous embodiment of the invention, it is provided that a first group of conditions for the stop of the internal combustion engine is queried and that a first counter is incremented by a value if all the conditions of the first group are met.
In a further advantageous embodiment of the invention, a second group of conditions for the deactivation of the internal combustion engine is queried and a second counter is incremented by a value if all the conditions of the second group of conditions are met. The deactivation of the internal combustion engine is thereupon initiated.
From the ratio of the values between the first counter, which measures the presence of the first group of conditions, and the value of the second counter, which measures the presence of the additional conditions of the second group of conditions, it is already possible to draw a first conclusion regarding the efficiency of the start-stop system.
In a further advantageous embodiment of the invention, it is provided that a second time counter starts running when the internal combustion engine is deactivated, and that the second time counter is stopped when the internal combustion engine is re-activated.
From the ratio of the first time counter, which measures the duration for which the vehicle is at a standstill, and of the second time counter, which measures the duration for which the internal combustion engine is deactivated, it is possible to draw a further, very significant conclusion regarding the efficiency of the start-stop system.
In a further advantageous embodiment of the invention, the deactivation of the internal combustion engine is prohibited if the value of the first time counter is higher than a predefined limit value. In this way, it is ensured that erroneous deactivations of the internal combustion engine cannot occur.
Furthermore, it is provided according to the invention that the cause for the prohibition of the stop of the internal combustion engine is stored together with a time indication.
To re-activate the internal combustion engine after a deactivation has taken place, the internal combustion engine is automatically activated if at least one activation condition is present, and the cause for the presence of the at least one activation condition is stored together with a time indication.
By forming ratios between the first time counter and the second time counter and between the value of the first time counter and the value of the second counter, it is possible to draw important conclusions regarding the efficiency of the start-stop system. Said ratios also give an indication regarding the causes for a low efficiency of the start-stop system, and may also be used to improve efficiency.
It has proven to be particularly advantageous for the method to be carried out at the end of each driving cycle, that is to say when the vehicle is parked and the ignition key is removed. It is then possible, directly after the internal combustion engine is shut down, for an evaluation to be carried out and for an indication of a possible improvement potential to be given to the driver before he has left the vehicle.
In addition, it is also possible for the method according to the invention to be carried out over the entire operating duration of the vehicle, such that a declaration can be made, over the entire distance driven by the vehicle, regarding the efficiency of the start-stop system.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a method and computer program for operating an internal combustion engine, and control unit, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a first portion of a flow diagram illustrating an embodiment of the method according to the invention;
FIG. 2 is a second portion of a flow diagram illustrating the method according to the invention; and
FIG. 3 is a schematic illustration of an internal combustion engine.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the figures of the drawing in detail, we will first explain a functional principle of an internal combustion engine of a motor vehicle with a start-stop system on the basis of FIG. 3 , to which reference is hereby made, and which will be explained further below.
An exemplary embodiment of the method according to the invention will be presented and explained with reference to FIGS. 1 and 2 .
After the start of the method, a first functional block 41 checks whether the vehicle is in motion or at a standstill. If it is detected that the vehicle is at a standstill, a first time counter 43 starts running. The first time counter 43 therefore measures the duration for which the vehicle is at a standstill, during one driving cycle and over the entire operating duration of the internal combustion engine.
If it is detected in the first functional block 41 that the vehicle is at a standstill, then a second functional block 45 checks whether a first group of conditions for the deactivation of the internal combustion engine 40 are met.
Said conditions are base conditions which must imperatively be met in order to be able to deactivate the internal combustion engine 40 . Examples of such base conditions are:
Driver brings the vehicle to a standstill by means of a braking process
Vehicle has been moving at speed for a defined time
Vehicle has moved a minimum distance
Enablement by means of selector lever pending
If the base conditions are not met, the program branches back to before the first functional block 41 .
If the first group of conditions for the deactivation of the internal combustion engine are met, a first counter 47 is incremented by a value of 1. Furthermore, a third functional block 49 checks whether a second group of conditions for the deactivation of the internal combustion engine 40 are met. If the additional conditions for the deactivation of the internal combustion engine 40 are met, then the internal combustion engine 40 is deactivated and a second counter 51 is activated which measures the number of deactivations (D). In a second time counter 53 , the duration of the deactivation of the internal combustion engine 40 is measured.
If the second group of conditions for the engine stop are not met, the cause, that is to say the condition which has not been met, is stored together with a time indication in a third memory 55 .
Furthermore, the program then branches back to before the first functional block 41 .
If the second group of conditions for the deactivation of the internal combustion engine are met, then the internal combustion engine is deactivated in a fourth functional block 57 (cf FIG. 2 ).
Enablement of stop operation by external control units
Enablement of stop operation by diagnosis conditions, engine control unit
Enablement of stop operation if relevant sensors and actuators are without faults
Enablement of stop operation if relevant CAN communication is without faults.
A fifth functional block 59 checks whether at least one activation condition for the internal combustion engine is present. If this is the case, the internal combustion engine 40 is re-activated in the fifth functional block 59 . In a second memory 61 , the cause for the activation of the internal combustion engine is stored together with a time indication. At the same time, the second time counter 53 , which measures the duration for which the internal combustion engine is deactivated, is stopped.
A sixth functional block 63 detects whether the vehicle still remains at a standstill or has in the meantime started moving. Once the vehicle is moving, the first time counter 43 is stopped. Finally, in a sixth functional block 65 , the ratio between the values of the second counter 51 and the first counter 47 is formed for example at the end of each driving cycle for the directly preceding driving cycle or for the entire operating duration of the internal combustion engine.
Furthermore, it is possible to form a ratio from the values of the first time counter 43 (standstill time) and the second time counter 53 (deactivation time). From said ratios, it is possible to obtain the characteristic variables for evaluating the efficiency of the start-stop system. Said characteristic variables may on the one hand be taken into consideration for fault diagnosis of hardware components of the motor vehicle. This is advantageous in particular if the memories 55 and 61 are read out and the causes for the stop prevention or for the renewed deactivation of the internal combustion engine are taken into consideration in the evaluation.
Furthermore, from the efficiency of the start-stop system, it is also possible to provide the driver of the vehicle with recommendations on possible actions he can take to increase the efficiency and thereby reduce the fuel consumption of the vehicle.
FIG. 3 shows the technical field of the invention. In detail, FIG. 3 shows the internal combustion engine 40 having the combustion chamber 42 which is sealed off in a movable fashion by a piston 44 . A charge exchange of the combustion chamber 42 is controlled by at least one inlet valve 46 and one outlet valve 48 which, for this purpose, are actuated by corresponding actuators 50 , 52 . In the embodiment of FIG. 3 , an injector 54 serves to meter fuel into an air charge of the combustion chamber 42 . The resulting mixture of fuel and air is ignited by a spark plug 56 . The charging of the combustion chamber 42 with air takes place from an intake pipe 58 which has a throttle flap 62 , which is actuated by a throttle flap actuator 64 , and an air mass sensor 66 .
The internal combustion engine 40 is controlled by the control and regulating (i.e., closed-loop control) unit 72 which, for this purpose, processes signals depicting different operating parameters of the internal combustion engine 40 . In the illustration of FIG. 3 , such operating parameters are in particular signals mL from the air mass sensor 66 , the signal FW from a driver demand transducer 74 which measures a torque demand by the driver, and the signal n from a rotational speed transducer 76 which measures a rotational speed n of a crankshaft of the internal combustion engine 40 .
It is self-evident that modern internal combustion engines 40 are fitted with a multiplicity of further transducers and/or sensors, which are not illustrated here for clarity. Examples of such sensors are temperature sensors, pressure sensors, exhaust-gas sensors, et cetera. The listing of the transducers 66 , 74 and 76 is therefore not intended to be exhaustive. It is also not necessary for a separate sensor to be provided for each of the operating parameters processed by the control and regulating device 72 , because the control and regulating device 72 can model various operating parameters by means of mathematical models from other measured operating parameters.
From the received transducer signals, the control and regulating device 72 forms inter alia actuating variables for setting the torque to be generated by the internal combustion engine 40 . In the embodiment of FIG. 3 , such actuating variables are in particular an actuating variable S_K for activating the injector 54 , an actuating variable S_Z for activating the spark plug 56 , and an actuating variable S_L_DK for activating the throttle flap actuator.
The control and regulating device 72 is otherwise set up, in particular programmed, to carry out the method according to the invention or one of its embodiments, and/or to control the corresponding method processing.
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A method makes it possible to measure and evaluate the efficiency of a start-stop system of a vehicle having an internal combustion engine, and on the basis of the measurement, to optimize the efficiency in a vehicle-specific fashion or with regard to the driving behavior of the driver.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to melt-spinning apparatus and methods, and more particularly to a linear flow equalizer for a spin pack of a melt-spinning apparatus and methods of forming non-woven webs with a melt-spinning apparatus incorporating the linear flow equalizer of the invention.
BACKGROUND OF THE INVENTION
[0002] Non-woven webs are incorporated into a diversity of consumer and industrial products, including disposable hygienic articles, throwaway protective apparel, fluid filtration media, and household durables. Generally, non-woven webs are formed using melt-spinning technologies, such as spunbonding processes and meltblowing processes, that form continuous filaments or fibers composed of one or more thermoplastic polymers. Spunbond non-woven webs are relatively strong in both the machine and the cross-machine directions because of drawing that aligns the polymer molecules. The continuity of the filaments also contributes to the observed strength of spunbond non-woven webs. Spunbond non-woven webs also resist abrasion, have a high porosity, and may be soft and conformable.
[0003] Spunbonding processes generally involve pumping one or more molten thermoplastic polymers through a spin pack that distributes, filters, combines, and finally extrudes continuous filaments of the constituent thermoplastic polymer(s) through hundreds or thousands of spinneret holes or orifices in a spinneret. After extrusion, the filaments are cooled or quenched to increase their viscosity and then drawn or stretched by an impinging high-velocity airflow generally capable of orienting the molecules of each constituent thermoplastic polymer if the air velocity is sufficiently high. The airflow propels the drawn filaments toward a forming zone to form a non-woven web on a moving collector.
[0004] The spin pack distributes a flow of each constituent thermoplastic polymer from a few inlet ports to individual outlet ports that span the width of the spin pack. Specifically, the molten thermoplastic polymer from each inlet port is directed into a shared lateral flow passageway and individual portions of the incoming thermoplastic polymer are allocated from the lateral flow passageway to the outlet ports for subsequent distribution to the orifices in the spinneret plate. Because all of the inlet ports share a single lateral flow passageway, thermoplastic material streaming from adjacent inlet ports into the lateral flow passageway intersects, collides and mixes before arriving at the outlet ports. The intersecting streams of molten thermoplastic polymer may experience hold-ups, dead spots or stagnation zones, and/or recirculation within the lateral flow passageway. The individual streams of the polymer(s) from the outlet ports are ultimately supplied to the orifices in the spinneret.
[0005] The inability to uniformly divide the incoming stream of the molten thermoplastic polymer in the machine direction and in the cross-machine direction with uniform flow characteristics to the outlet ports causes unacceptable variations in the non-woven web formed by the spunbonding process. For example, non-uniform distribution of the molten thermoplastic polymer in cross-machine direction may cause the basis weight of the non-woven web to fluctuate in the cross-machine direction, which produces perceptible strips of varying basis weight extending parallel to the machine direction. In particular, the basis weight of the non-woven web originating from filaments extruded from spinneret orifices receiving thermoplastic polymer from outlet ports directly downstream of an inlet port has been observed to be significantly larger than the basis weight of the non-woven web originating from filaments extruded from spinneret orifices receiving thermoplastic polymer from outlet ports near the mid-point between adjacent inlet ports. The fluctuation in the basis weight is believed to arise from unequal flow path lengths in the shared lateral flow passageway. This results in non-uniform residence times and pressure drops for different portions of the non-Newtonian thermoplastic polymer exiting the outlet ports from the lateral flow passageway. The non-uniform flow path lengths also result in disparate shear histories for different portions of the thermoplastic polymer flowing in the lateral flow passageway reflected in the polymer properties and the characteristics of the non-woven web formed therefrom.
[0006] It would be desirable, therefore, to provide a spin pack for a melt-spinning apparatus capable of forming a non-woven web having improved basis weight uniformity in the cross-machine direction.
SUMMARY
[0007] In one aspect, the invention is directed to an apparatus for distributing thermoplastic material supplied to a spin pack of a meltspinning apparatus. The apparatus includes a linear flow equalizer having a plurality of flow passageways of substantially equal length that divide a flow of a thermoplastic material supplied from a plurality of liquid inlet ports into individual streams having a spaced relationship in a cross-machine direction.
[0008] In one specific embodiment of the apparatus of the invention, the linear flow equalizer includes an inlet plate having a plurality of liquid passageways spaced substantially equidistantly in a cross-machine direction of the meltspinning apparatus, a first equalizer plate positioned downstream from the inlet plate, and a second equalizer plate positioned downstream from the first equalizer plate. The first equalizer plate has elongated slots each centered about one of the plurality of liquid passageways. Each of the first plurality of elongate slots extends in the cross-machine direction and includes opposed closed ends substantially equidistant from one of the plurality of liquid passageways. The second equalizer plate has throughholes each substantially registered in alignment with one of the opposed closed ends of a corresponding one of the first plurality of elongated slots.
[0009] Another aspect of the invention is directed to a method of distributing thermoplastic material supplied to a spin pack to form a non-woven web. To that end, a flow of thermoplastic material is divided in a cross-machine direction of a spin pack among liquid passageways of substantially equal path length to form individual streams of thermoplastic material spaced in the cross-machine direction. The individual streams of thermoplastic material are shaped or formed into filaments, which are quenched, drawn, and collected to produce the non-woven web.
[0010] In accordance with the principles of the invention, the flows of thermoplastic material within the linear flow equalizer are partitioned homogeneously and symmetrically in the cross-machine direction and vertically in a downstream direction. The basis weight of the non-woven web produced by a melt spinning apparatus incorporating the linear flow equalizer of the invention is more uniform in the cross-machine direction. The improved uniformity in the basis weight is believed to arise from equal or nearly equal flow path lengths in the spin pack, which results in more uniform residence times and pressure drops for different divided portions of the thermoplastic polymer and approximately equal shear histories. As a result, the properties of the non-woven web are substantially independent of the lateral location of the outlet port from the final downstream equalizer plate relative to the individual inlets in the inlet plate. In accordance with the principles of the invention, the linear flow equalizer of the invention optimizes the flow distribution of the thermoplastic polymer(s) while achieving a uniform shear rate and a minimum residence time in the die pack.
[0011] These and other objects and advantages of the present invention shall become more apparent from the accompanying drawings and description thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0012] 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.
[0013] FIG. 1 is a perspective view of a spin beam assembly;
[0014] FIG. 2 is a partial cross-sectional view taken generally along lines 2 - 2 in FIG. 1 ;
[0015] FIG. 3 is an exploded view of a linear flow equalizer for a spin pack in accordance with the principles of the invention;
[0016] FIG. 4 is a bottom view of the inlet plate of the spin pack of FIG. 3 ;
[0017] FIG. 5 is a cross-sectional view taken generally along lines 5 - 5 in FIG. 4 ;
[0018] FIG. 5A is a cross-sectional view similar to FIG. 5 in accordance with an alternative embodiment of the invention; and
[0019] FIG. 6 is a diagrammatic view of the flow paths for molten thermoplastic polymer in the linear flow equalizer of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] With reference to FIGS. 1 and 2 , a spin beam assembly, generally indicated by reference numeral 10 , for forming filaments includes a chassis 12 holding drive pumps 14 , 15 , 16 , 17 each driven by a corresponding one of a set of motors 18 , 19 , 20 , 21 . The motors 18 - 21 are suspended from the chassis 12 by an open framework of beams 22 and generally overlie the drive pumps 14 - 17 . Extending from each of the motors 18 - 21 is a drive shaft 18 a 19 a, 20 a, 21 a that supplies a drive coupling with a corresponding one of the drive pumps 14 - 17 . The spin beam assembly 10 is incorporated into a melt-spinning apparatus that includes conventional components, such as a filament-drawing device for attenuating the filaments and a moving collector located on a forming table, for forming a non-woven web.
[0021] Drive pumps 14 and 16 receive a flow of a first polymer (Polymer A) furnished by a supply line 23 from an extruder (not shown) and drive pumps 15 and 17 receive a flow of a second polymer (Polymer B) furnished by a separate supply line 24 from another extruder (not shown). The invention contemplates that the drive pumps 14 - 17 may be supplied by a single supply line communicating with and service by a single extruder. The first and second polymers may differ in composition, such as polyethylene and polypropylene, or may constitute two polymers of identical composition that differ with respect to a property such as melt flow rate or the presence or absence of an additive. The two polymers are heated to a temperature sufficient to produce a liquid or semi-solid material having a viscosity suitable for flow through an arbitrary set of passageways.
[0022] With continued reference to FIGS. 1 and 2 , a pump plate 26 attached to the chassis 12 supports the pumps 14 - 17 . Extending through the pump plate 26 is a plurality of liquid passageways 28 , of which two liquid passageways 28 are shown in FIG. 2 , arranged in rows such that each is coupled in fluid communication with an outlet of one of the drive pumps 14 , 16 . Also extending through the pump plate 26 is a plurality of liquid passageways 30 , of which one liquid passageway 30 is shown in FIG. 2 , each coupled in fluid communication with an outlet of one of the drive pumps 15 , 17 . Accordingly, each pump 14 , 16 outputs a stream of polymer A to the liquid passageways 28 and each pump 15 , 17 outputs a stream of polymer B to the liquid passageways 30 .
[0023] The spin beam assembly 10 further includes a spin pack, generally indicated by reference numeral 32 , supported by support brackets 34 , 36 within a housing 38 of chassis 12 . The spin pack 32 receives separate flows of the two polymers from the liquid passageways 28 , 30 in pump plate 26 . The spin pack 32 is an assembly that incorporates, in order from a top or upstream side to a bottom or downstream side, a linear flow equalizer 40 , a combining plate 42 , and a spinneret plate 44 . A major or long axis of the spin pack 32 is aligned generally parallel to a cross-machine direction 45 ( FIG. 1 ), which is generally orthogonal to a machine direction 46 . A collector (not shown) collects the filaments discharged from the spinneret plate 44 of spin pack 32 .
[0024] With reference to FIGS. 2 and 3 , the linear flow equalizer 40 is an assembly constituted by an inlet plate 48 and three equalizer plate sets 50 a - c. The inlet plate 48 includes inlet ports or passageways 52 , visible in FIG. 3 , arranged in three spaced linear rows to coincide with the locations of liquid passageways 28 , 30 . Adjacent inlet passageways 52 in each of the rows are spaced at equal centerline-to-centerline intervals, or a uniform pitch, across the width of the inlet plate 48 . In one specific embodiment of the invention, the inlet plate 48 features three rows of eight inlet passageways 52 .
[0025] Inlet passageways 52 in the center row are registered for fluid communication at an upstream surface 54 of inlet plate 48 with the liquid passageways 30 in the pump plate 26 . Similarly, inlet passageways 52 in the two rows flanking the center row are registered in fluid communication at the upstream surface 54 of inlet plate 48 with the liquid passageways 28 in the pump plate 26 . Accordingly, each inlet passageway 52 in the center row receives an output stream of polymer B from one of pumps 15 , 17 and each inlet passageway 52 in the rows flanking the center row receives an output stream of polymer A from one of pumps 14 , 16 . The rows of inlet passageways 52 in inlet plate 48 adjacent the front and rear edges of the spin pack 32 distribute respective output streams of Polymer A to the equalizer plate sets 50 a, 50 c. The central row of inlet passageways 52 distributes an output stream of Polymer B to the center equalizer plate set 50 b.
[0026] In accordance with the principles of the invention, the fluid pathways in the linear flow equalizer 40 define approximately equal length lateral and vertical flow paths and, preferably, equal length flow paths, for each polymer stream in a flow path extending from the downstream side of the pump plate 26 to the downstream side of each of the equalizer plate sets 50 a - c. The approximately equal lengths of the lateral and vertical flow paths in the linear flow equalizer 40 result in approximately uniform residence times and shear histories characterizing the polymer flows through the linear flow equalizer 40 . Preferably, the lateral and vertical flow paths for the polymers in the linear flow equalizer 40 are equal in length for providing optimum filament properties. Consequently, material properties of the resultant non-woven, such as basis weight, possess an improved uniformity in the cross-machine direction 45 .
[0027] With reference to FIGS. 3-5 , the inlet plate 48 includes shallow rectangular recesses or cavities 56 , 57 , 58 partitioned from one another by dividing walls 59 , 60 . Each of the cavities 56 , 57 , 58 is dimensioned to receive one of the equalizer plate sets 50 a - c. A downstream surface of each cavity 56 , 57 , 58 includes a series of shallow multi-segment channels 62 each centered about an outlet of one of the inlet passageways 52 . The channels 62 define a second stage or level of lateral and vertical thermoplastic material distribution in the linear flow equalizer 40 .
[0028] Each channel 62 includes a linear segment 64 extending in the cross-machine direction 45 and centered or symmetrical about inlet passageway 52 . Linear segment 64 terminates at each opposed open end in fluid communication with the center of a corresponding one of a pair of linear segments 66 each extending in the machine direction 46 . The linear segments 66 are equidistant in the cross-machine direction 45 from the corresponding inlet passageway 52 . Each of the linear segments 66 is centered or symmetrical about the intersection with linear segment 64 and terminates at each open end in fluid communication with a slotted linear segment 68 . Each slotted linear segment 68 extends in the cross-machine direction 45 and includes a pair of opposed curved terminal or closed ends 69 , 70 . Each slotted linear segment 68 is centered or symmetrical about the intersection with the corresponding one of the linear segments 66 . Therefore, the flow path length for the flowable thermoplastic material in each channel 62 is substantially equal and, preferably equal, from the inlet passageway 52 to the closed ends 69 , 70 of each slotted linear segment 68 .
[0029] As each of the equalizer plate sets 50 a - c have identical constructions, only one equalizer plate set 50 a is shown in FIG. 3 and is described herein. Equalizer plate set 50 a includes a plurality of, for example, five equalizer plates 72 , 74 , 76 , 78 and 80 , a sheet-forming plate 82 , removable mesh filters 83 , 84 , and 85 , a filter support plate 86 , and a seal 87 arranged in juxtaposition from the top or upstream side to the bottom or downstream side. The filter support plate 86 has a peripheral rim 88 surrounding a generally rectangular recess that captures the filters 83 , 84 , 85 in the set assembly. The equalizer plates 72 , 74 , 76 , 78 and 80 are secured together and fastened to the inlet plate 48 by conventional fasteners 90 extending from countersunk openings in the inlet plate 48 through appropriately aligned bolt holes formed in each of the equalizer plates 72 , 74 , 76 , 78 and 80 and secured by nuts 91 situated in countersunk openings on the downstream side of the sheet-forming plate 82 .
[0030] Each of the equalizer plates 72 , 74 , 76 , 78 and 80 is formed by milling or drilling a thin rectangular sheet of a suitable material using computer numerically controlled (CNC) machining. For example, equalizer plates 72 , 74 , 76 , 78 and 80 may be formed by CNC machining from sheets of a metal alloy, such as 17-4 stainless steel, having thermal expansion characteristics compatible with the surrounding metal environment of the spin pack 32 . The equalizer plats 72 , 74 , 76 , 78 and 80 may also be fabricated by alternative manufacturing techniques, such as by laser or chemical machining or by stamping.
[0031] With reference to FIG. 3 , equalizer plate 72 is positioned downstream of the inlet plate 48 and includes a plurality of flow passageways in the form of circular bores or thoughholes 92 extending vertically through the thickness of plate 72 from an upstream inlet to a downstream outlet. Contact between the equalizer plate 72 and the inlet plate 48 closes the channels 62 to define flow paths in equalizer plate 72 to the throughholes 92 . The throughholes 92 are arranged in two spaced linear rows such that each throughhole 92 is registered on an upstream surface 93 of plate 72 in substantial vertical alignment with one of the closed ends 69 , 70 of one of the slotted linear segments 68 in equalizer plate 72 . Adjacent throughholes 92 in each of the rows are spaced at equal centerline-to-centerline intervals, or a uniform pitch, across the width of the equalizer plate 72 . The throughholes 92 receive flowable thermoplastic material from the channels 62 in inlet plate 48 and define individual liquid inlets supplying flowable thermoplastic material to equalizer plate 74 . The channels 62 and the throughholes 92 collectively define a second stage or level of lateral and vertical thermoplastic material distribution in the linear flow equalizer 40 .
[0032] Equalizer plate 74 is positioned downstream of equalizer plate 72 and includes a plurality of slotted flow passageways 94 extending vertically through the thickness of plate 74 from an upstream inlet to a downstream outlet. A major axis of each slotted flow passageway 94 is aligned generally in the cross-machine direction 45 . The center of each slotted flow passageway 94 is registered on an upstream surface 99 of equalizer plate 74 in substantial vertical alignment with one of the throughholes 92 in equalizer plate 72 . Throughholes 92 and channels 62 cooperate to also divide the flow of thermoplastic material into two separate laterally-extending rows. As a result, opposed curved terminal or closed ends 96 , 98 of each slotted flow passageway 94 are substantially centered or symmetrical in the cross-machine direction 45 relative to the corresponding throughhole 92 .
[0033] With continued reference to FIG. 3 , equalizer plate 76 is positioned downstream of equalizer plate 74 and includes a plurality of flow passageways in the form of circular bores or thoughholes 100 extending vertically through the thickness of plate 76 from an upstream inlet to a downstream outlet. Each throughhole 100 is registered on an upstream surface 101 of equalizer plate 76 in substantial vertical alignment with one of the closed ends 96 , 98 of one of the slotted flow passageways 94 in equalizer plate 74 . Adjacent throughholes 100 in each of the rows are spaced at equal centerline-to-centerline intervals, or a uniform pitch, across the width of the equalizer plate 76 . The throughholes 100 in equalizer plate 76 and the slotted flow passageways 94 in equalizer plate 74 define a third stage or level of lateral and vertical thermoplastic material distribution in the linear flow equalizer 40 .
[0034] Equalizer plate 78 is positioned downstream of the equalizer plate 76 and includes a plurality of slotted flow passageways 102 extending vertically through the thickness of equalizer plate 78 from an upstream inlet to a downstream outlet. A major axis of each slotted flow passageway 102 is aligned substantially in the cross-machine direction 45 . The center of each slotted flow passageway 102 is registered on an upstream surface 108 of equalizer plate 78 in substantial vertical alignment with one of the throughholes 100 in equalizer plate 76 , which define individual liquid inlets supplying flowable thermoplastic material to equalizer plate 78 . As a result, opposed curved terminal or closed ends 104 , 106 of each slotted flow passageway 102 are substantially centered or symmetrical in the cross-machine direction 45 relative to the corresponding throughhole 100 .
[0035] With continued reference to FIG. 3 , equalizer plate 80 is positioned downstream of equalizer plate 78 and includes a plurality of flow passageways in the form of circular bores or thoughholes 110 extending vertically through the thickness of equalizer plate 80 from an upstream inlet to a downstream outlet. Each throughhole 110 is registered on an upstream surface 112 of equalizer plate 80 in substantial vertical alignment with one of the opposed closed curved ends 104 , 106 of one of the slotted flow passageways 102 . Adjacent throughholes 110 in each of the rows are spaced at equal centerline-to-centerline intervals, or a uniform pitch, across the width of the equalizer plate 80 . The throughholes 110 in equalizer plate 80 and the slotted flow passageways 102 in equalizer plate 78 define a fourth stage or level of lateral thermoplastic material distribution in the linear flow equalizer 40 .
[0036] The sheet-forming plate 82 includes opposed concavely-curved surfaces 114 , 116 that integrate or merge the individual liquid flows streaming from the throughholes 110 of equalizer plate 80 . Sheet-forming plate 82 effectively eliminates gaps between adjacent streams of molten thermoplastic polymer exiting the throughholes 110 to form a substantially uniform sheet of flowable thermoplastic material that is provided to the combining plate 42 . The flowable thermoplastic material is subsequently filtered by the downstream filters 83 , 84 , 85 before being supplied to openings 86 a extending through the filter support plate 86 .
[0037] With reference to FIG. 5A , each of the equalizer plate sets 50 a - c may be provided in an equalizer plate 71 in which a set of channels 62 a is formed. Each of the channels 62 includes multiple linear segments, of which only linear segment 64 a is shown, arranged similarly or identical to channels 62 ( FIGS. 4 and 5 ). Channels 62 a are intended to replace channels 62 in inlet plate 48 ( FIGS. 4 and 5 ). Consequently, an inlet plate 48 a is modified to include three rows of inlet passageways 52 a each of which supplies thermoplastic material to the center of one channel 62 a for subsequent distribution to downstream equalizer plate 72 . Equalizer plate 71 is installed in recess 56 a of inlet plate 48 a between equalizer plate 72 and inlet plate 48 a and also in the other two recesses in inlet plate 48 a (not shown but similar to recesses 57 and 58 in FIG. 3 ).
[0038] The invention further contemplates that additional pairs of equalizer plates (not shown) may be disposed between equalizer plate 80 and sheet-forming plate 82 to provide additional symmetrical and equal divisions of the flowable thermoplastic material in the flow path through the linear flow equalizer 40 . The number of symmetrical and equal divisions will depend, among other variables, upon the width of the spin pack 32 in the cross-machine direction and, therefore, the width of the nonwoven web being formed by the spunbond system (not shown) with which spin beam assembly 10 is operative coupled.
[0039] With renewed reference to FIG. 3 , seal 87 provides a fluid-tight junction between a downstream side of the filter support plate 86 and an upstream side of the combining plate 42 . The combining plate 42 has internal liquid passageways 118 configured to receive the sheet-like flows of flowable thermoplastic materials from each of the linear flow equalizers 40 and to combine the flows to generate a bicomponent filament arrangement, such as a sheath/core arrangement or a side-by-side arrangement. In a sheath/core arrangement, for example, the flow path within the combining plate 42 of one of the two polymers is interposed and brought into coaxial alignment with the flow path of the other of the two polymers and directed the spinneret plate 44 . The spinneret plate 44 has multiple spinneret holes or orifices 120 registered with liquid outlets in the combining plate 42 from which bicomponent filaments 122 are extruded for subsequent solidification, attenuation and collection as a non-woven web.
[0040] With reference to FIG. 6 , the operation of the linear flow equalizer 40 will be further explained. The flow path for a flowable thermoplastic material 124 through the linear flow equalizer 40 in a downstream direction from each inlet passageway 52 in inlet plate 48 to each throughhole 110 in equalizer plate 80 is substantially equal to or, preferable equal to, all other flow paths for the flowable thermoplastic material in the linear flow equalizer 40 . Therefore, the linear flow equalizer 40 divides the flow evenly among all flow paths so that the residence time of any arbitrary volume of flowable thermoplastic material 124 flowing between inlet passageway 52 and the corresponding throughholes 110 is approximately equal and, preferably equal, and so that the properties (e.g., shear history) of the flowable thermoplastic material 124 exiting from each throughhole 110 are substantially identical and preferably equal.
[0041] In the exemplary embodiment, the flowable thermoplastic material 124 entering the inlet passageways 52 is divided by inlet plate 48 into eight substantially equal portions, each of which is further subdivided by equalizer plates 72 , 74 into two substantially equal portions. It is understood that the number of substantially equal portions created by inlet plate 48 is dependent upon the width of the inlet plate 48 and equalizer plate sets 50 a - c in the cross-machine direction. Equalizer plates 76 , 78 further subdivide the portions received from equalizer plate 74 again into two substantially equal portions and directed through equalizer plate 80 to the combining plate 42 ( FIG. 2 ). In the combining plate 42 , the thermoplastic material 124 , for example, Polymer A is combined with another thermoplastic material 126 , for example, Polymer B, which is subdivided uniformly in the linear flow equalizer 40 in a manner substantially similar to thermoplastic material 124 . The combined thermoplastic materials 124 , 126 form bicomponent filaments 122 , such as the sheath/core arrangement illustrated in FIG. 6 , that are discharged from the spinneret orifices 120 in the spinneret plate 44 as a curtain of filaments 122 for subsequent collection. The invention contemplates that additional thermoplastic materials may be combined with the thermoplastic materials 124 , 126 to form multicomponent filaments 122 with more than two constituent thermoplastic materials and that the constituent thermoplastic materials may have other configurations, such as side-by-side.
[0042] 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 applicant 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. For example, the principles of the invention may be applied for the formation of filaments composed of a single polymer or of filaments formed from more than two polymers. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept. The scope of the invention itself should only be defined by the appended claims, wherein I claim:
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A linear flow equalizer for distributing thermoplastic material to a spin pack of a meltspinning apparatus that provides for uniform apportionment of a flow of a flowable thermoplastic material at least vertically and in a cross-machine direction of the spin pack. The linear flow equalizer includes an inlet plate with multiple liquid passageways equidistantly spaced in the cross-machine direction that each provide flowable thermoplastic material to a set of equalizer plates. Elongated slots extending through alternating equalizer plates are registered with throughholes extending through adjacent plates in the equalizer plate set. Each throughhole in an upstream equalizer plate is registered with the center of a corresponding slot and each throughole in a downstream equalizer plate is registered with one of opposed closed ends of a corresponding slot.
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CLAIM OF PRIORITY
[0001] The present application claims priority from Japanese patent application P2007-198683 filed on Jul. 31, 2007, the content of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a network system in which information is communicated between a gateway and a plurality of base stations, and more particularly, to a network system that synchronizes timing of transmitting information among a plurality of base stations.
[0003] An IEEE 802.16e standard mobile WiMAX (Worldwide Interoperability for Microwave Access) regulates Multicast and Broadcast Services (MBSs). With an MBS regulated by IEEE 802.16e, one can provide a broadcast service through wireless access. IEEE 802.16e recommends synchronizing the timing of transmitting packets to subscriber stations among base stations in an MBS. However, exactly what algorithm is to be employed to synchronize the transmission timing is not standardized.
[0004] A gateway coupled over a network with a server that provides information sends packets of the information provided by the server to a plurality of base stations concurrently through multicast route. The packets sent out simultaneously by the gateway do not arrive at the base stations at the same time because the packets take different transmission paths leading to the respective base stations.
[0005] In multicast communication, subscriber stations that are stationary have no problems with packets arriving at different times from one another. On the other hand, in the case of subscriber stations that move as in mobile communication, specifically, when a subscriber station that is covered by one base station moves from an area in which the subscriber station can access the base station by radio (hereinafter, referred to as cell) to a cell that is covered by another base station, the subscriber station can miss some of sent packets unless the packet transmission timing is synchronized between the base stations.
[0006] A communication where the packet size is 1500 bytes and the communication speed is 10 Mbit/s is taken as an example. A base station in this case requires 1.2 milliseconds to send one packet.
[0007] When a subscriber station crosses the border between a cell covered by one base station and a cell covered by another base station, thereby causing hand over from the cell in which the subscriber station has been receiving packets to the other cell, the difference in transmission timing between the pre-hand over base station and the post-hand over base station has to be within 1.2 milliseconds in order that the same packet that the subscriber station has been receiving prior to the hand over can be received from the other base station.
[0008] 3GPP TS25.402 V5. 1.0 “Synchronization in UTRAN: Stage 2” (June 2002) regulates a method in which a radio Network controller controls the transmission timing of base stations by measuring a delay in packet communication between the radio controller and each base station. However, too large a difference in transmission timing among base stations in multicast communication causes a problem in that information is not easily passed over during hand over between cells in which a subscriber station receives packets.
[0009] JP 2005-210698 A discloses a solution to this problem in which the transmission timing is determined by setting synchronization precision specific to each controller that controls a cell. The synchronization precision include a cycle of performing transmission timing synchronization processing and a system of transmission timing synchronization processing.
[0010] However, the technology described in JP 2005-210698 A does not take into consideration concrete differences in delay among different paths from radio controllers to base stations.
SUMMARY OF THE INVENTION
[0011] It is therefore an object of this invention to synchronize the packet transmission timing among base stations in multicast communication over a wireless access network based on differences in packet propagation delay between a gateway and the base stations.
[0012] According to one embodiment of the invention, there is therefore provided a network system, comprising: a gateway coupled with a wired network; and at least two base stations coupled with the gateway over the wired network to communicate information between the gateway and each of the at least two base stations, the at least two base stations providing a wireless access method, wherein the gateway is configured to: calculate, for each of the at least two base stations, a delay in information transmission between the gateway and each of the at least two base stations; choose a maximum delay from among the calculated delays of each of the at least two base stations; calculate, for each of the at least two base stations, a difference between the chosen maximum delay and the delay of each of the at least two base stations; and notify each of the at least two base stations of the calculated delay difference of each of the at least two base stations.
[0013] According to an aspect of this invention, a packet loss can be prevented during hand over between base stations from which a subscriber station receives packets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The present invention can be appreciated by the description which follows in conjunction with the following figures, wherein:
[0015] FIG. 1A is a diagram showing a configuration of a network system according to an embodiment of this invention;
[0016] FIG. 1B is a diagram illustrating multicast communication over an access network according to the embodiment of this invention;
[0017] FIG. 2 is a block diagram showing a configuration of a gateway according to the embodiment of this invention;
[0018] FIG. 3 is a block diagram showing a configuration of the control processor which is provided in the gateway according to the embodiment of this invention;
[0019] FIG. 4 is a block diagram showing a configuration of a line interface which are provided in the gateway according to the embodiment of this invention;
[0020] FIG. 5 is a block diagram showing a configuration of base stations according to the embodiment of this invention;
[0021] FIG. 6 is a block diagram showing a configuration of an access network line interface which is provided in each base station according to the embodiment of this invention;
[0022] FIG. 7 is a block diagram showing a configuration of a delay circuit which is provided in the access network line interface according to the embodiment of this invention;
[0023] FIG. 8 is a diagram illustrating a multicast table according to the embodiment of this invention;
[0024] FIG. 9 is a block diagram showing a configuration of a control processor which is provided in each base station according to the embodiment of this invention;
[0025] FIG. 10 is a diagram illustrating a control packet according to the embodiment of this invention;
[0026] FIG. 11 is a sequence diagram of control packets for processing of measuring a delay according to the embodiment of this invention;
[0027] FIG. 12 is a diagram illustrating a delay table which is stored in the gateway according to the embodiment of this invention;
[0028] FIG. 13 is a flowchart for processing that is executed when the gateway receives control packets from the base stations according to the embodiment of this invention;
[0029] FIG. 14 is a flowchart for processing of determining a maximum delay according to the embodiment of this invention; and
[0030] FIG. 15 is a flowchart illustrating an operation of the delay circuit according to the embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] An embodiment of this invention will be described below with reference to the accompanying drawings.
[0032] FIG. 1A is a diagram showing a configuration of a network system according to the embodiment of this invention.
[0033] The network system of this embodiment has a gateway 1 , base stations 2 , a server 3 , and subscriber stations 4 .
[0034] The gateway 1 couples a core network or the Internet and an access network built by the base stations 2 . Details of the gateway 1 will be described with reference to FIGS. 2 to 4 .
[0035] The base stations 2 provide a wireless access method for enabling the subscriber stations 4 to access by radio. Details of the base stations 2 will be described with reference to FIGS. 5 to 9 .
[0036] The server 3 provides the subscriber stations 4 with information through streaming, World Wide Web (WWW), and the like.
[0037] The subscriber stations 4 , when located in cells which are areas within wireless access, can couple with the base stations 2 to receive packets of information provided by the server 3 .
[0038] FIG. 1B is a diagram illustrating multicast communication over an access network according to the embodiment of this invention.
[0039] The gateway 1 sends packets only to the base stations 2 - 1 , 2 - 2 , and 2 - 3 out of the base stations 2 - 1 , 2 - 2 , 2 - 3 , and 2 - 4 .
[0040] In this case, the same multicast address is set to the base stations 2 - 1 , 2 - 2 , and 2 - 3 .
[0041] The server 3 sends to the gateway 1 packets of information to be provided to the subscriber stations 4 . The packets sent by the server 3 contain multicast addresses.
[0042] Receiving the packets from the server 3 , the gateway 1 copies the received packets and transfers the packet copies to the base stations 2 - 1 , 2 - 2 , and 2 - 3 .
[0043] The base stations 2 - 1 , 2 - 2 , and 2 - 3 receive the transferred packets. The gateway 1 does not transfer the packets to the base station 2 - 4 because no multicast address is set to the base station 2 - 4 .
[0044] FIG. 2 is a block diagram showing a configuration of the gateway 1 according to the embodiment of this invention.
[0045] The gateway 1 has line interfaces 11 , a switch 12 , and a control processor 13 .
[0046] The line interfaces 11 are physical interfaces that couple the access network with the core network or the Internet. The line interfaces 11 determine to which line interface 11 a packet received by one line interface 11 is to be transferred. Details of the line interfaces 11 will be described with reference to FIG. 4 .
[0047] The switch 12 determines a transfer path leading to the line interface 11 that is determined as a transfer destination.
[0048] The control processor 13 performs overall control of the gateway 1 and executes processing on the control plane. Details of the control processor 13 will be described with reference to FIG. 3 .
[0049] FIG. 3 is a block diagram showing a configuration of the control processor 13 which is provided in the gateway 1 according to the embodiment of this invention.
[0050] The control processor 13 has a CPU 131 , a memory 132 , and a bus interface (I/F) 133 .
[0051] The CPU 131 executes various programs stored in the memory 132 . The memory 132 stores various programs. The bus I/F 133 is an interface that couples the control processor 13 with the switch 12 and the line interfaces 11 .
[0052] FIG. 4 is a block diagram showing a configuration of the line interfaces 11 which are provided in the gateway 1 according to the embodiment of this invention.
[0053] Each line interface 11 has a receiver 111 , a transmitter 112 , packet buffers 113 , a control processor interface (I/F) 114 , a CPU 115 , a memory 116 , a switch interface (I/F) 117 , a search engine 118 , and a retrieval table 119 .
[0054] The receiver 111 executes packet reception processing. Specifically, the receiver 111 terminates a physical layer and a datalink layer of a received packet. The transmitter 112 executes packet transmission processing. Specifically, the transmitter 112 terminates the physical layer and the datalink layer of a packet to be sent out.
[0055] The packet buffers 113 temporarily store received packets or packets to be sent out.
[0056] The control processor I/F 114 is an interface that couples the line interface 11 with the control processor 13 .
[0057] The CPU 115 executes various programs stored in the memory 116 to execute processing of setting the retrieval table 119 and processing of controlling the line interface 11 . The memory 116 stores various programs.
[0058] The switch I/F 117 is an interface that couples the line interface 11 with the switch 12 .
[0059] The retrieval table 119 is a table for registering addresses to which packets are transferred. The search engine 118 refers to the retrieval table 119 to obtain information about the transfer destination of a packet.
[0060] FIG. 5 is a block diagram showing a configuration of the base stations 2 according to the embodiment of this invention.
[0061] Each base station 2 has a wireless access line interface 21 , a wired access network line interface 22 , a control processor 23 , and a switch 24 .
[0062] The wireless access line interface 21 is a physical interface that enables the base station 2 to provide the subscriber stations 4 with a wireless access method. The access network line interface 22 is a physical interface that couples the base station 2 with the access network. The wireless access line interface 21 determines to which line interface 11 a packet received by one line interface 11 is to be transferred. Details of the access network line interface 22 will be described with reference to FIG. 6 . A detailed description will be omitted on the wireless access line interface 21 , which has the same configuration as that of the line interface 11 of the gateway 1 shown in FIG. 4 . The transmitter in the wireless access line interface 21 , however, executes processing of sending a packet to a wireless interface.
[0063] The control processor 23 takes charge of overall control of the base station 2 and executes processing on the control plane. Details of the control processor 23 will be described with reference to FIG. 9 .
[0064] The switch 24 executes processing of transferring a packet between line interfaces.
[0065] FIG. 6 is a block diagram showing a configuration of the access network line interface 22 which is provided in each base station 2 according to the embodiment of this invention.
[0066] The access network line interface 22 has a receiver 221 , a transmitter 222 , packet buffers 223 , a control processor interface (I/F) 224 , a CPU 225 , a memory 226 , a switch interface (I/F) 227 , a search engine 228 , a retrieval table 229 , and a delay circuit 250 .
[0067] The components of the access network line interface 22 are the same as those in the line interface 11 of the gateway 1 shown in FIG. 4 , except for the delay circuit 250 . Descriptions on the components common to the access network line interface 22 and the line interface 11 will be omitted here.
[0068] The delay circuit 250 is coupled between the receiver 221 and the packet buffers 223 . The delay circuit 250 delays the transmission of a received packet by a period of time equivalent to a delay difference, which is notified from the gateway 1 . The delay difference is calculated by the gateway 1 . Details of the delay difference will be described with reference to FIG. 11 . Details of the delay circuit 250 will be described with reference to FIG. 7 .
[0069] FIG. 7 is a block diagram showing a configuration of the delay circuit 250 which is provided in the access network line interface 22 according to the embodiment of this invention.
[0070] The delay circuit 250 has a buffer 2501 , a buffer controller 2502 , and a multicast table 2503 .
[0071] The buffer 2501 is logically partitioned into sections each of which is associated with a multicast address. A packet received by the delay circuit 250 is temporarily stored in a section of the buffer 2501 that is associated with the multicast address of the received packet.
[0072] The buffer controller 2502 refers to the multicast table 2503 to determine how long a received packet is to be stored in the buffer 2501 .
[0073] The multicast table 2503 is a table used to manage the delay difference for each multicast address. Details of the multicast table 2503 will be described with reference to FIG. 8 .
[0074] An operation of the delay circuit 250 will be described in detail with reference to FIG. 15 .
[0075] FIG. 8 is a diagram illustrating the multicast table 2503 according to the embodiment of this invention.
[0076] The multicast table 2503 contains in each entry a destination address 25031 and a delay 25032 .
[0077] A multicast address to which a packet received by the base station 2 is to be transferred is registered as the destination address 25031 . A delay for adjusting the timing of transmitting a packet to a multicast address that is registered as the destination address 25031 among the base stations 2 is registered as the delay 25032 .
[0078] FIG. 9 is a block diagram showing a configuration of the control processor 23 which is provided in each base station 2 according to the embodiment of this invention.
[0079] The control processor 23 has a CPU 231 , a memory 232 , and a bus interface (I/F) 233 .
[0080] The CPU 231 executes various programs stored in the memory 232 . The memory 232 stores various programs. The bus I/F 233 is a physical interface that couples the control processor 23 with the cell line interface 21 (wireless access line interface), the access network line interface 22 , and the switch 24 .
[0081] FIG. 10 is a diagram illustrating a control packet 500 according to the embodiment of this invention.
[0082] The control packet 500 contains a destination equipment ID 501 , a source equipment ID 502 , a type 503 , a sequence number 504 , setting information 505 , and a packet length 506 .
[0083] An identifier of equipment to which the packet is sent is registered as the destination equipment ID 501 .A multicast address or an identifier of equipment which sends the packet is registered as the source equipment ID 502 .
[0084] An identifier indicating the type of the control packet 500 is registered as the type 503 . The types of the control packet 500 include delay measurement request, delay measurement response, delay difference notification, and others. An identifier that indicates an order of the control packet 500 is registered as the sequence number 504 .
[0085] Setting information of the control packet 500 of various kinds is registered as the setting information 505 . In the case where the control packet 500 is a delay measurement request packet, the time when the gateway 1 transmits this control packet 500 is registered as the setting information 505 .
[0086] A data size of the control packet 500 may have a variable length. For example, giving the control packet 500 the same data size as that of a packet that is actually sent by the server 3 makes it possible to measure a delay resembling one in a traffic of actual transmission from the server 3 . The data size of the control packet 500 is registered as the packet length 506 .
[0087] The control packet 500 may be sent as an Internet Protocol (IP) packet or as an IEEE 802.3 frame.
[0088] FIG. 11 is a sequence diagram of control packets for processing of measuring a delay according to the embodiment of this invention.
[0089] First, the gateway 1 sends a control packet 500 - a , in which the time of transmission of the control packet 500 - a is set, to the base stations 2 - 1 , 2 - 2 , and 2 - 3 by multicast. The base stations 2 - 1 , 2 - 2 , and 2 - 3 are base stations to which packets sent from the server 3 are transferred through multicast route.
[0090] In the control packet 500 - a , a multicast address that identifies a multicast group consisting of the base stations 2 - 1 , 2 - 2 , and 2 - 3 is registered as the destination equipment ID 501 .
[0091] As the source equipment ID 502 , an identifier of the gateway 1 which has sent the control packet 500 - a is registered. An identifier indicating that this control packet 500 - a is a packet that requests a delay measurement is registered as the type 503 . A sequence number assigned to the control packet 500 - a is registered as the sequence number 504 . A time at which the gateway 1 has sent the control packet 500 - a is registered as the setting information 505 - 1 .
[0092] The control packet 500 - a is created by the control processor 13 in the gateway 1 .
[0093] Receiving the control packet 500 - a from the gateway 1 , each of the base stations 2 - 1 , 2 - 2 , and 2 - 3 sends a control packet 500 - b in which the time of reception of the control packet 500 - a is set to the gateway 1 .
[0094] In each control packet 500 - b , the identifier of the gateway 1 which has been registered as the source equipment ID 502 in the received control packet 500 - a is registered as the destination equipment ID 501 . An identifier of the base station 2 which has been registered as the destination equipment ID 501 in the received control packet 500 - a is registered as the source equipment ID 502 .
[0095] An identifier indicating that this control packet 500 - b is a packet that is a response to the delay measurement request is registered as the type 503 . The time of transmission of the control packet 500 - a from the gateway 1 is registered as the setting information 505 - 1 and the time of reception of the control packet 505 - a by the base station 2 is registered as the setting information 505 - 2 .
[0096] The control packet 500 - b is created by the control processor 13 in the gateway 1 or the control processor 23 in the base station 2 .
[0097] The gateway 1 and the base station 2 repeat the transmission and reception of the control packets a given number of times in the manner described above.
[0098] Next, the gateway 1 calculates how long it takes for the control packet sent from the gateway 1 to be received by the respective base stations 2 (delay).
[0099] Specifically, the gateway 1 refers to the received control packets 500 - b to calculate the difference between the time of transmission of the control packet 500 - a from the gateway 1 and the time when each base station 2 has received the control packet 500 - a sent from the gateway 1 .
[0100] The gateway 1 then calculates an average delay for each base station 2 .
[0101] The control packet 500 - a sent from the gateway 1 is created by the control processor 13 in the gateway 1 . The difference between the time of transmission of the control packet 500 - a from the gateway 1 and the time when each base station 2 has received the control packet 500 - a sent from the gateway 1 includes the period of time which it takes for the access network line interface 22 of the base station 2 to complete the processing of receiving the control packet 500 - a and the period of time required for processing of an upper layer such as the IP layer that is involved in processing of transferring data from the access network line interface 22 to the control processor 23 .
[0102] The gateway 1 then determines which base station 2 has the largest average delay value (maximum delay) among the base stations 2 for which an average delay has been calculated.
[0103] The gateway 1 next calculates, for each base station 2 , the difference between the determined maximum delay and the average delay of the base stations 2 (delay difference).
[0104] The gateway 1 notifies each base station 2 of the calculated delay difference by sending a control packet 500 - c to the base station 2 .
[0105] In the control packet 500 - c , identifiers registered as the destination equipment ID 501 and the source equipment ID 502 are the same as the identifiers registered as the destination equipment ID 501 and the source equipment ID 502 in the control packet 500 - a sent from the gateway 1 . Their descriptions therefor will not be repeated.
[0106] An identifier indicating that this control packet 500 - c is a notification of a delay difference is registered as the type 503 . A delay difference in transmission of a control packet is registered as the setting information 505 - 1 .
[0107] Thereafter, the gateway 1 starts multicast data communication.
[0108] The control packet 500 - a , which is sent from the gateway 1 to the base stations 2 - 1 , 2 - 2 , and 2 - 3 through multicast route, may be also sent through unicast route instead. In this case, the identifier of the base station 2 to which the control packet 500 - a is sent is registered as the destination equipment ID 501 .
[0109] When the gateway 1 transmits a control packet transferred through multicast route, the control packet takes the same path within the access network as that of a packet of information distributed by the server 3 and transferred through multicast route, which makes the precision of delay measurement even higher. The count of control packets sent from the gateway 1 in this case matches the count of multicast addresses of information packets distributed by the server 3 .
[0110] When the gateway 1 transmits a control packet by unicast, the delay is determined solely by the transmission distance of the control packet. The count of destinations of a control packet sent from the gateway 1 in this case matches the count of the base stations 2 .
[0111] The following description is about when to execute the delay measurement with control packets.
[0112] The delay measurement using control packets may be executed before multicast communication is started. The delay measurement using control packets may be executed also when multicast communication paths are changed, in other words, when the count of the base stations 2 that participate in multicast communication increases or decreases. Also, the delay measurement using control packets may be executed at regular intervals during multicast communication.
[0113] FIG. 12 is a diagram illustrating a delay table 1000 which is stored in the gateway 1 according to the embodiment of this invention.
[0114] The delay table 1000 is stored in the memory 132 which is provided in the control processor 13 .
[0115] The delay table 1000 contains in each entry a base station ID 1001 and a delay 1002 . The delay 1002 contains the value in the first delay measurement 10021 to the value in the N-th delay measurement 1002 N and the average value 1003 .
[0116] The identifier of each base station 2 is registered as the base station ID 1001 . A delay calculated from the first delay measurement is registered as the first delay 10021 . A delay calculated from the n-th delay measurement is registered as the N-th delay 1002 N. An average delay which is obtained by averaging the first to N-th delays is registered as the average 1003 .
[0117] In the case where a delay measurement request packet is transmitted by unicast, one delay table 1000 is created in the control processor 13 .
[0118] On the other hand, in the case where a delay measurement request packet is transferred through multicast route as is the case for the control packet 500 - a requesting a delay measurement, as many delay tables 1000 as the count of multicast addresses are created in the control processor 13 . This is because different multicast addresses mean different destination base stations 2 and different paths within the access network and, even when the destination base station 2 is the same, a control packet could be transferred from the gateway 1 to the base station 2 with different delays.
[0119] FIG. 13 is a flowchart for processing that is executed when the gateway 1 receives control packets from the base stations 2 according to the embodiment of this invention.
[0120] Receiving a control packet from one base station 2 (S 3 - 10 ), the gateway 1 first calculates the delay by calculating the difference between the time of reception which is registered by the base station 2 as the setting information 505 - 2 in the control packet and the time of transmission which is registered by the gateway 1 as the setting information 505 - 1 in the control packet. The gateway 1 registers the calculated delay in the delay table 1000 as one of the delays 10021 to 1002 N that corresponds to the number of times of the calculated delay (S 3 - 20 ).
[0121] The gateway 1 next judges whether or not as many control packets as necessary to calculate an average delay (in this embodiment, N control packets) have been received from the base station 2 (S 3 - 30 ).
[0122] When it is judged that the N-th control packet has been received, the gateway 1 calculates for each base station 2 an average of the first to N-th delays (S 3 - 40 ), registers the calculated average as the average 1003 in an entry for the base station 2 in question, and ends the processing.
[0123] When it is judged that the N-th control packet has not been received, the gateway 1 sends a control packet that requests a delay measurement to the base station 2 (S 3 - 50 ), and ends the processing.
[0124] FIG. 14 is a flowchart for processing of determining the maximum delay according to the embodiment of this invention.
[0125] First, the gateway 1 executes initial setting processing (S 1 - 10 ). Specifically, the gateway 1 sets the value of tMAX, which indicates the maximum delay, to 0 and the value of i, which indicates a base station, to 0 .
[0126] Next, the gateway 1 adds 1 to i (S 1 - 20 ). The gateway 1 judges whether or not an average delay (t(i)) of a base station that is identified by i to which 1 is added in S 1 - 20 is equal to or larger than tMAX (S 1 - 30 ).
[0127] When it is judged that t(i) is equal to or larger than tMAX, the gateway 1 updates the value of tMAX with the value of t(i) (S 1 - 40 ). When it is judged that t(i) is smaller than tMAX, on the other hand, the gateway 1 proceeds to S 1 - 50 .
[0128] The gateway 1 judges whether or not the value of i matches the count of the base stations 2 (S 1 - 50 ).
[0129] When it is judged that the value of i matches the count of the base stations 2 , the gateway 1 ends the processing (S 1 - 60 ). When it is judged that the value of i does not match the count of the base stations 2 , the gateway 1 returns to S 1 - 20 .
[0130] FIG. 15 is a flowchart illustrating the operation of the delay circuit 250 according to the embodiment of this invention.
[0131] The description given here takes as an example a case in which multicast communication is conducted with the use of IPv4 and a control packet is transferred from the gateway 1 through multicast route.
[0132] First, a packet received by the receiver 221 in the access network line interface 22 is transferred to the delay circuit 250 (S 2 - 10 ).
[0133] Receiving the packet from the receiver 221 , the delay circuit 250 judges whether or not the received packet is a packet transferred through multicast route(S 2 - 20 ).
[0134] Specifically, the delay circuit 250 judges whether or not the first four most significant bits of a destination address (IPv4) set in the packet header of the received packet is “1110”. In the case where the first four most significant bits of the destination address is not “1110”, the packet is transferred through unicast route.
[0135] When it is judged that the received packet is not a packet transferred through multicast route, the received packet is a packet transferred through unicast route and there is no need to take a delay into consideration. Then the delay circuit 250 sets a delay td to 0 (S 2 - 70 ) and proceeds to S 2 - 80 .
[0136] When it is judged that the received packet is a packet transferred through multicast route, the delay circuit 250 refers to the type 503 of the received packet to judge whether or not the received packet is a control packet (S 2 - 30 ).
[0137] When it is judged that the received packet is a control packet, the delay circuit 250 replaces the destination address with the identifier of the base station 2 in order to make the base station 2 terminate the received control packet (S 2 - 50 ). The delay circuit 250 then sets the delay td to 0 (S 2 - 60 ) and proceeds to S 2 - 80 .
[0138] When it is judged that the received packet is not a control packet, the delay circuit 250 searches the multicast table 2503 for an entry whose destination address 25031 matches the destination address of the received packet, and reads a value registered as the delay 25032 of this entry. The delay circuit 250 sets the read value to the delay td of the received packet (S 2 - 40 ).
[0139] The delay circuit 250 sends the received packet to the packet buffer 223 - 1 with the set delay td (S 2 - 80 ), and ends the processing (S 2 - 90 ).
[0140] Through the above processing, the packet transmission timing can be controlled among the base stations 2 based on differences in delay in packet transmission from the gateway 1 to the base stations 2 .
[0141] This embodiment has described a case in which a control packet with the time of transmission set by the gateway 1 is sent to the base stations 2 and a control packet with the time of reception of the former control packet set by each base station 2 is sent to the gateway 1 . This invention can be carried out also by the following method.
[0142] A control packet with the time of transmission set by each base station 2 is sent to the gateway 1 . The gateway 1 receives the control packet and calculates the delay from the difference between the time of transmission set in the received control packet and the time of reception of the control packet by the gateway 1 . The gateway 1 then calculates a delay difference in the manner described in the embodiment of this invention.
[0143] The timing of transmitting multicast packets from base stations can thus be synchronized among the base stations despite differences in delay with which the base stations receive a packet from a gateway. A packet loss is accordingly prevented during hand over between base stations from which a subscriber station receives packets.
[0144] While the present invention has been described in detail and pictorially in the accompanying drawings, the present invention is not limited to such detail but covers various obvious modifications and equivalent arrangements, which fall within the purview of the appended claims.
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To prevent a packet loss during hand over, provided is a network system including: a gateway coupled with a wired network; and at least two base stations coupled with the gateway over the wired network and providing a wireless access method, in which the gateway is configured to: calculate, for each of the at least two base stations, a delay in information transmission between the gateway and each of the at least two base stations; choose a maximum delay from among the calculated delays of each of the at least two base stations; calculate, as a delay difference of each of the at least two base stations, a difference between the chosen maximum delay and the delay of each of the at least two base stations; and notify each of the at least two base stations of the calculated delay difference of each of the at least two base stations.
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The present application claims priority under 35 U.S.C. §119 to U.S. Provisional Application No. 60/658,370, filed Mar. 4, 2005, the entire disclosure of which is herein expressly incorporated by reference.
BACKGROUND OF THE INVENTION
The popularity of wireless networks has resulted in a desire for wireless network operators to increase the capacity of their networks. One way to increase capacity is to use more frequencies over the air interface between base stations and mobile stations. However, most frequencies are allocated by governments bodies and most, if not all, available frequencies have been allocated. Another way to increase capacity is to add cell stations by decreasing the size of existing cells. However, adding base stations requires time consuming and expensive zoning approvals from local government bodies. It also requires additional costs for the equipment for the additional base stations, as well as costs associated with leasing space for the equipment.
SUMMARY OF THE INVENTION
One technique for increasing network capacity with minimal increased costs is to deploy a so-called overlay-underlay networks, such as that described in U.S. Pat. No. 5,953,661, the entire contents of which are herein expressly incorporated by reference. In the overlay-underlay networks a base station supports concentric cells, including an inner cell and an outer cell. Exemplary embodiments of the present invention are directed to improvements to overlay-underlay and similar types of networks.
In accordance with exemplary embodiments of the present invention, traffic on an inner cell and outer cell is monitored. When traffic on one of the inner or outer cells exceeds a threshold value, the traffic can be adjusted to avoid call blocking. The traffic can be adjusted by handing off calls from the inner or outer cell with traffic exceeding a threshold value to the other of the cells of a base station, or to cells of another proximately located base station.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIGS. 1 a and 1 b illustrate exemplary inner and outer cell arrangements in accordance with the present invention;
FIGS. 2 a - 2 c illustrate an exemplary reuse pattern for inner and outer cell frequencies in accordance with the present invention;
FIG. 3 illustrates an exemplary base station in accordance with the present invention; and
FIG. 4 illustrates an exemplary method in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 a and 1 b illustrate exemplary inner and outer cell arrangements in accordance with the present invention. Specifically, FIG. 1 a illustrates an exemplary single sector base station with an outer cell 110 and an inner cell 150 . The inner and outer cells 110 and 150 are generated by a single base station, thereby eliminating the additional expenses associated with adding base stations. Specifically, existing antennas and base station radios can be divided between the inner and outer cells 110 and 150 , further reducing additional equipment costs. FIG. 1 b illustrates an exemplary three sector inner and outer cell arrangement in accordance with the present invention. The outer cell includes sectors 112 - 116 and the inner cell includes sectors 152 - 156 . In some implementations the sectors can be supported by three antennas, where two antennas are receiving antennas and one antenna is a transmit/receive antenna. Although FIGS. 1 a and 1 b illustrate only two concentric cells, the base station can support more than two concentric cells. The base station can support dispatch voice, interconnect voice, short message service (SMS), and/or packet data on the inner and/or outer cell. In addition, the base station can handoff dispatch voice, interconnect voice and/or packet data calls from the inner cell to the outer cell, from the outer cell to the inner cell, from one sector of the inner cell to another sector of the inner cell, from one sector of the outer cell to another sector of the outer cell, and to inner or outer cells of other base stations.
FIGS. 2 a - 2 c illustrate an exemplary reuse pattern for inner and outer cell frequencies in accordance with the present invention. As illustrated in FIGS. 2 a - 2 c , a “tighter” frequency reuse pattern can be deployed for the inner cells than the outer cells. Specifically, the inner cells have a reuse pattern of K=3, while the outer cells employ a reuse pattern of K=9.
FIG. 3 illustrates an exemplary base station in accordance with the present invention. The base station 310 is coupled to a mobile switching center 305 and to antennas 315 and 320 . Mobile switching center 305 can be coupled to other base stations (not illustrated). Antenna 315 can be used for the inner cell by downtilting the antenna to control its radiation pattern, while antenna 320 can be used to support the outer cell. Base station 310 includes a memory 325 and processor 330 . Memory can be any type of memory, including a random access memory, read only memory, flash memory, hard disk and/or the like. Processor 330 can be a microprocessor executing programmable code provided by memory 325 , an application specific integrated circuit (ASIC), field programmable gate array and/or the like. Processor 330 includes various logic 335 - 355 which will be described in more detail below in connection with FIG. 4 .
It should be recognized that base station 310 can include hardware in addition to that illustrated in. FIG. 3 . For example, base station 310 can include a number of base radios, diplexer, baseband processing units, upconverters/downconverters and the like.
FIG. 4 illustrates an exemplary method in accordance with the present invention. Logic 335 monitors the inner and outer cells in order to determine the amount of traffic at the cells (steps 405 and 410 ). Logic 340 receives and processes signal quality reports from mobile stations (step 415 ). The signal quality reports can include a received signal strength indicator (RSSI), carrier-to-interference ratio (C/I) and/or the like. The signal quality reports can include signal quality of the inner and outer cells of the base station, as well as signal quality of inner and outer cells of proximately located base stations. Logic 345 compares the traffic of the inner and outer cells to a threshold to determine whether the traffic exceeds a predetermined threshold value (step 420 ). The predetermined threshold value is selected to be some value below where call blocking will occur, and can the same for the inner and outer cells or can be different. When the traffic on the inner or outer cells does not exceed a threshold value (“No” path out of decision step 420 ), then the base station continues to determine the amount of traffic on the inner and outer cells and receive signal quality reports (steps 405 - 415 ).
When the traffic on the inner or outer cells exceeds a threshold value (“Yes” path out of decision step 425 ), then logic 350 identifies mobile stations as candidates for handoff (step 430 ). Mobile stations are candidates for handoff when they can receive an acceptable signal from the other of the inner or outer cells and/or from inner or outer cells of another base station. Logic 355 then instructs at least some of the identified mobile stations to handoff to inner or outer cells of the base station or to inner or outer cells of another base station (step 430 ). Additionally, or alternatively, some mobile stations can handoff between sectors of the inner and/or outer cells. The base station then continues monitor the traffic on the inner and outer cells.
Although FIG. 4 illustrates particular acts being performed in particular order, some of these acts need not necessarily be performed in this order. For example, the determination of the amount of traffic on the inner and outer cells and receipt of the signal quality reports from the mobile stations can be performed in parallel, and can also be performed while identifying the mobile stations and/or while instructing the identified mobile stations to handoff. Although the logic of FIG. 3 are illustrated as separate elements, the logic can be combined in various manners. For example, the logic for identifying mobile stations 350 and logic for instructing mobile stations to handoff 355 can be part of a logic for adjusting traffic of the inner or outer cells.
Although exemplary embodiments have been described above with processor 330 of base station 310 determining the amount of traffic, monitoring the traffic to determine whether it exceeds a threshold value and instructing mobile stations to handoff, some or all of this processing can be performed in other network elements, such as the mobile switching center 305 .
The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
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Systems and methods for wireless networks with inner and outer cells are provided. A base station determines an amount of traffic on an inner and outer cell. When the traffic exceed a predetermined threshold value, traffic is adjusted on the inner or outer cell. Traffic can be adjusted by handing off some of the traffic from the inner cell to the outer cell, from the outer cell to the inner cell, between sectors of the inner or outer cells and/or by handing off traffic to a proximately located base station.
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TECHNICAL FIELD
The present invention relates to use of an internet-based system for diagnosing a vehicle's performance.
BACKGROUND
The Environmental Protection Agency (EPA) requires vehicle manufacturers to install on-board diagnostics (OBD-II) for monitoring light-duty automobiles and trucks beginning with model year 1996. OBD-II systems (e.g., microcontrollers and sensors) monitor the vehicle's electrical and mechanical systems and generate data that are processed by a vehicle's engine control unit (ECU) to detect any malfunction or deterioration in the vehicle's performance. Most ECUs transmit status and diagnostic information over a shared, standardized electronic buss in the vehicle. The buss effectively functions as an on-board computer network with many processors, each of which transmits and receives data. The primary computers in this network are the vehicle's electronic-control module (ECM) and power-control module (PCM). The ECM typically monitors engine functions (e.g., the cruise-control module, spark controller, exhaust/gas recirculator), while the PCM monitors the vehicle's power train (e.g., its engine, transmission, and braking systems). Data available from the ECM and PCM include vehicle speed, fuel level, engine temperature, and intake manifold pressure. In addition, in response to input data, the ECU also generates 5-digit ‘diagnostic trouble codes’ (DTCs) that indicate a specific problem with the vehicle. The presence of a DTC in the memory of a vehicle's ECU typically results in illumination of the ‘Service Engine Soon’ light present on the dashboard of most vehicles.
Data from the above-mentioned systems are made available through a standardized, serial 16-cavity connector referred to herein as an ‘OBD-II connector’. The OBD-II connector typically lies underneath the vehicle's dashboard. When a vehicle is serviced, data from the vehicle's ECM and/or PCM is typically queried using an external engine-diagnostic tool (commonly called a ‘scan tool’) that plugs into the OBD-IL connector. The vehicle's engine is turned on and data are transferred from the engine computer, through the OBD-II connector, and to the scan tool. The data are then displayed and analyzed to service the vehicle. Scan tools are typically only used to diagnose stationary vehicles or vehicles running on a dynamometer.
Some vehicle manufacturers also include complex electronic systems in their vehicles to access and analyze some of the above-described data. For example, General Motors includes a system called ‘On-Star’ in some of their high-end vehicles. On-Star collects and transmits data relating to these DTCs through a wireless network. On-Star systems are not connected through the OBD-II connector, but instead are wired directly to the vehicle's electronic system. This wiring process typically takes place when the vehicle is manufactured.
SUMMARY
Embodiments of the invention can provide a wireless, internet-based system for monitoring a vehicle. For example, embodiments of the invention can access data from a vehicle, analyze it, and make it available to organizations (e.g. an automotive dealership or service center) over the internet so that the vehicle's performance can be analyzed accurately and in real-time. Data are accessed through the same OBD-II connector used by conventional scan tools. In this way, the invention collects data similar to those collected by scan tools, only they are collected in real-time while the vehicle is actually being driven. The invention also provides an Internet-based web site to view these data. The web site also includes functionality to modify the type of data being collected, e.g. the type of diagnostic data or the frequency at which it is collected. The data can be collected and viewed over the Internet without having to bring the vehicle in for service. The data include, for example, DTCs and mechanical and electrical data stored in the vehicle's engine computer.
In one aspect, the invention features a system for monitoring operational characteristics of a vehicle. The system includes a computer in the vehicle, and a wireless appliance in electrical contact with the computer. The wireless appliance includes a data-transmission component configured to transmit data associated with the operational characteristics over a network to a host computer system, and to receive over the network data from the host computer system.
In another aspect, the invention features a device for monitoring operational characteristics of a vehicle. The device includes a wireless appliance including a data transmission component configured to communicate data associated with the operational characteristics over a network to a host computer.
In another aspect, the invention features a device for monitoring operational characteristics of a vehicle. The device includes a wireless appliance including a data transmission component configured to receive data associated with the operational characteristics over a network from a host computer.
In a further aspect, the invention features a system for monitoring operational characteristics of a vehicle. The system includes a host computer and a wireless appliance including a data transmission component configured to communicate data associated with the operational characteristics over a network to the host computer. In some embodiments, the wireless appliance is in the vehicle. In certain embodiments, the host computer is external to the vehicle.
In one aspect, the invention features a system for monitoring operational characteristics of a vehicle. The system includes a host computer and a wireless appliance including a data transmission component configured to receive data associated with the operational characteristics over a network from the host computer. In some embodiments, the wireless appliance is in the vehicle. In certain embodiments, the host computer is external to the vehicle.
Embodiments of the invention can include one or more of the following features and/or advantages.
The ‘wireless appliance’ used in the above-described invention features a data-transmitting component (e.g. a radio or cellular modem) that sends out the data packet over an existing wireless network (e.g., Cingular's Mobitex network). Such a wireless appliance is described in the application WIRELESS DIAGNOSTIC SYSTEM FOR VEHICLES, filed Feb. 1, 2001, the contents of which are incorporated herein by reference.
In embodiments, the communication software supported by the data-collection component features a schema component that identifies the diagnostic data to be collected from the vehicle's computer. The schema component features an address that describes a location of a diagnostic datum in the vehicle's computer memory. It can also describe a time or frequency that the data-collection component collects data from the vehicle's computer, or a time or frequency that the data-transmission component transmits an outgoing data packet. The schema component is typically an ASCII or binary data file that is configured to be processed by the communication software.
In the above-mentioned description, the term ‘supported’ means that an executable version of the communication software can run as a computer program on a microprocessor, microcontroller, or comparable, semiconductor-based device resident on the data-collection component.
The host computer system typically features at least one web-hosting computer that hosts the web site, and at least one, separate gateway computer that receives the outgoing data packet and sends the incoming data packet. In this embodiment the web site features a first web page that displays at least a single vehicle diagnostic datum. For example, the first web page can include data fields describing: i) a name of the diagnostic datum; ii) units corresponding to the diagnostic datum; and iii) a numerical value corresponding to the diagnostic datum. Multiple sets of diagnostic data, each received by the host computer system at a unique time and date, can also be displayed on the web page. The page can also include a graphical representation of the sets of diagnostic data, e.g. a time-dependent plot of the data.
In typical applications the set of diagnostic data includes at least one of the following: diagnostic trouble codes, vehicle speed, fuel level, fuel pressure, miles per gallon, engine RPM, mileage, oil pressure, oil temperature, tire pressure, tire temperature, engine coolant temperature, intake-manifold pressure, engine-performance tuning parameters, alarm status, accelerometer status, cruise-control status, fuel-injector performance, spark-plug timing, and a status of an anti-lock braking system.
In other embodiments the web site further includes a login web page, in communication with a database component, where a user enters a user name and password. The database component is configured to verify if the user is associated with multiple vehicles. If this is the case, the web site includes a second web page that displays vehicle diagnostic data corresponding to each vehicle.
In still other embodiments the web site includes a third web page that features a mechanism for sending the incoming data packet over the network. For example, the third web page can include a mechanism for selecting a new schema wherein a list of parameters is provided, each of which can be extracted from the vehicle's computer.
The gateway computer that receives the outgoing data packet and sends the incoming data packet is connected to the network, typically through an Internet-based connection or a digital communication line.
The system can also include a secondary computer system that connects to the host computer system through the Internet to display the web site. Alternatively, the system includes a hand-held device, e.g. a cellular telephone or personal digital assistant, which connects to the host computer system through the Internet. The host computer system can also be configured to send an electronic mail message that includes all or part of the vehicle diagnostic data.
In other embodiments, the wireless appliance is configured to send an outgoing data packet that indicates a location of a transmitting base station. In this case, the host computer system includes software that analyzes this location to determine an approximate location of the vehicle, which can then be displayed on a web page.
In the above-described method, the term “airlink” refers to a standard wireless connection (e.g., a connection used for wireless telephones or pagers) between a transmitter and a receiver. This term describes the connection between a data-transmission component and the wireless network that supports data transmitted by this component. Also in the above-described method, the ‘generating’ and ‘transmitting’ steps can be performed at any time and with any frequency, depending on the diagnoses being performed. For a ‘real-time’ diagnoses of a vehicle's engine performance, for example, the steps may be performed at rapid time or mileage intervals (e.g., several times each minute, or every few miles). Alternatively, other diagnoses (e.g. an emissions or ‘smog’ check) may require the steps to be performed only once each year or after a large number of miles are driven. Alternatively, the vehicle may be configured to automatically perform these steps at predetermined or random time intervals. As described in detail below, the transmission frequency can be changed in real time by downloading a new ‘schema’ to the wireless appliance through the wireless network.
The term ‘web page’ refers to a standard, single graphical user interface or ‘page’ that is hosted on the Internet or world-wide web. Web pages typically include: 1) a ‘graphical’ component for displaying a user interface (typically written in a computer language called ‘HTML’ or hypertext mark-up language); an ‘application’ component that produces functional applications, e.g. sorting and customer registration, for the graphical functions on the page (typically written in, e.g., C++ or Java); and a database component that accesses a relational database (typically written in a database-specific language, e.g. SQL*Plus for Oracle databases). A ‘web site’ typically includes multiple web pages, many of which are ‘linked’ together, that are accessed through a series of ‘mouse clicks’.
The invention has many advantages. In particular, wireless transmission of data from a vehicle, followed by analysis and display of these data using a web site hosted on the internet, makes it possible to diagnose the performance of a vehicle in real-time from virtually any location that has internet access. This ultimately means the problems with the vehicle can be efficiently diagnosed, and in some cases predicted before they actually occur. Moreover, data from the vehicle can be queried and analyzed while the vehicle is actually in use to provide a relatively comprehensive diagnosis that is not possible using a conventional scan tool. An internet-based system for vehicle diagnoses can also be easily updated and made available to a large group of users simply by updating software on the web site. In contrast, a comparable updating process for a series of scan tools can only be accomplished by updating the software on each individual scan tool. This, of course, is time-consuming, inefficient, and expensive, and introduces the possibility that many scan tools within a particular product line will not have the very latest software.
The wireless appliance used to access and transmit the vehicle's data is small, low-cost, and can be easily installed in nearly every vehicle with an OBD-II connector in a matter of minutes. It can also be easily transferred from one vehicle to another, or easily replaced if it malfunctions.
The wireless appliance can also collect data that is not accessible using a scan tool. For example, data that indicates a vehicles performance can be collected while the vehicle is actually driven. For example, it may be required to collect data while a vehicle is driving up a hill or pulling a load. Scan tools, in contrast, can only collect data from a stationary vehicle in a service bay. Service technicians using the wireless appliance, for example, can analyze DTCs and diagnostic data while the vehicle is being driven. The system described herein also makes data available in real-time, thereby allowing the technicians to order parts and schedule resources for service appointments before the vehicle is actually brought into the dealership.
Moreover, software schemas that update the type or frequency of the vehicle's data can be directly downloaded to specific wireless appliances or groups of wireless appliances (corresponding, e.g., to a fleet of vehicles or a group of vehicles having the same year, make, or model). This makes it possible to collect data that specifically elucidates a problem with the vehicle that may occur only under certain driving conditions.
The resulting data, of course, have many uses for automotive dealerships, vehicle-service organizations, vehicle-renting firms, insurance companies, vehicle owners, organizations that monitor emission performance (e.g., the EPA), manufacturers of vehicles and related parts, survey organizations (e.g., J.D. Power) and vehicle service centers. In general, these data yield information that benefits the consumer, vehicle and parts manufacturers, vehicle service centers, and the environment.
These and other advantages of the invention are described in the following detailed disclosure and in the claims.
DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention can be understood by reference to the following detailed description taken with the drawings, in which:
FIG. 1 is a schematic drawing of system of the invention featuring a single vehicle transmitting data across an airlink to an Internet-accessible host computer system;
FIG. 2 is a flow chart describing a method used by the system of FIG. 1 to diagnose vehicles;
FIG. 3 is a schematic drawing of the system of the invention featuring multiple vehicles, each transmitting data across an airlink to an Internet-accessible host computer system;
FIG. 4 is a schematic drawing of a web site with a login process that renders a series of web pages associated with either a dealer or customer interface;
FIG. 5 is a screen capture of a web page from the web site of FIG. 4 that shows a list of customers corresponding to a single dealership;
FIG. 6 is a screen capture of a web page related to the web page of FIG. 5 that shows diagnostic data for a customer's vehicle; and
FIG. 7 is a screen capture of a web page from the web site of FIG. 1 that shows several time-dependent sets of diagnostic data from a customer's vehicle.
DETAILED DESCRIPTION
FIG. 1 shows a schematic drawing of an Internet-based vehicle-diagnostic system 2 according to the invention. The system 2 measures diagnostic data from a vehicle 12 and transmits it over an airlink 9 to a web site 6 accessible through the Internet 7 . The system 2 functions in a bi-directional manner, i.e. in addition to receiving data from a vehicle, a user logged onto the web site 6 can specifically select the diagnostic data to be measured and the frequency at which it is measured. These properties are sent through the airlink 9 to the wireless appliance 13 that re-measures the diagnostic data from the vehicle 12 . In this way, the invention functions effectively as an Internet-based ‘scan tool’ that diagnoses any vehicle that includes a wireless appliance. The host vehicle can be diagnosed at any time it is being driven using an Internet-accessible web site.
The wireless appliance 13 disposed within the vehicle 12 collects diagnostic data from the vehicle's engine computer 15 . The engine computer 15 retrieves data stored in its memory and sends it along a cable 16 to the wireless appliance 13 . The appliance 13 typically connects to the OBD-II connector located under the dash in all vehicles manufactured after 1996. It includes a data-collection component (not shown in the figure) that formats the data in a packet and then passes the packet to a data-transmission component, which sends it through a cable 17 to an antenna 14 . To generate the data, the wireless appliance 13 queries the vehicle's computer 15 at a first time interval (e.g. every 20 seconds), and transmits a data set at a longer time interval (e.g. every 10 minutes). These time intervals are specified in a data-collection ‘schema’, described in more detail below.
The antenna typically rests in the vehicle's shade band, disposed just above the dashboard. The antenna 14 radiates the data packet over the airlink 9 to a base station 11 included in a wireless network 4 . A host computer system 5 connects to the wireless network 4 and receives the data packets. The host computer system 5 , for example, may include multiple computers, software pieces, and other signal-processing and switching equipment, such as routers and digital signal processors. Data are typically transferred from the wireless network 4 to host computer system 5 through a TCP/IP-based connection, or with a dedicated digital leased line (e.g., a frame-relay circuit or a digital line running an x0.25 protocol). The host computer system 5 also hosts a web site 6 using conventional computer hardware (e.g. computer servers for a database and the web site) and software (e.g., web server and database software). A user accesses the web site 6 through the Internet 7 from a secondary computer system 8 . The secondary computer system 8 , for example, may be located in an automotive service center.
The wireless appliance that provides diagnostic data to the web site is described in more detail in WIRELESS DIAGNOSTIC SYSTEM FOR VEHICLES, filed Feb. 1, 2001, the contents of which have been previously incorporated by reference. The appliance transmits a data packet that contains information of its status, an address describing its destination, an address describing its origin, and a ‘payload’ that contains the above-described diagnostic data from the vehicle, or a schema from the web site. These data packets are transmitted over conventional wireless network, such as Cingular's Mobitex network.
FIG. 2 shows a method 21 describing how the system 2 in FIG. 1 typically operates. As described above, the wireless appliance includes a data-collection component that, in turn, includes a microcontroller that has software and a data-collection ‘schema’ loaded in the microcontroller's memory. The schema is essentially a ‘map’ that describes the data that the wireless appliance collects from the vehicle's engine computer, and its corresponding location in the computer's memory. A schema specific to a given type of vehicle is typically loaded onto the microcontroller before the wireless appliance is installed in the vehicle (step 22 in FIG. 2 ). During operation, the appliance communicates with the vehicle's engine computer as described above (step 23 ). The appliance collects diagnostic data defined by the schema, formats these data in a data packet, and then sends an outgoing packet over the airlink to a wireless network (step 24 ). The network transfers the data packet to the host computer system as described above (step 25 ). There, the host computer system analyzes the data packet using a ‘map’ that corresponds to the schema to generate a data set (step 26 ). Every schema has a corresponding map. The map includes, for example, a list of the collected data, an acronym and unit for each datum. The data set, acronym, and units are then displayed on the web site (step 28 ) where they can be viewed by any ‘registered’ user (i.e., a user with a username and corresponding password) with Internet connectivity.
In one mode of operation, a technician working at a vehicle-service center logs into the web site and analyzes the data set corresponding to a particular vehicle to diagnose a potential mechanical or electrical problem (step 30 ). Specific web pages that display the data set are shown in FIGS. 5-7, below. Based on the analysis, the technician may decide that additional data are required, or that data need to be collected and transmitted at a higher or lower frequency. In this case the technician uses the web site to select a new schema (step 32 ) and then sends an incoming data packet that includes a new schema over the wireless network to the wireless appliance included in the vehicle being diagnosed (step 34 ). In typical applications, the vehicle is specifically addressed using a serial number that corresponds to the data-transmitting component. This serial number is typically an 8 or 10-digit number that functions effectively as a ‘phone number’ corresponding to the data-transmitting component. This number is included in the data packet, and is used by the wireless network to transfer the packet to the host vehicle (step 35 ). The host vehicle receives the packet and processes it to extract the new data-collection schema (step 36 ). The wireless appliance uses the updated schema to extract a revised set of data from the vehicle's engine computer, or send out data at a revised frequency (step 38 ). In other applications, the new schema can be used to query a set of data that is relevant to a DTC registered by the vehicle, or to ‘clear’ a DTC when it is deemed to no longer be problematic. Once these data are collected, the method 21 can then be repeated as described above to further diagnose the vehicle.
The above-described system is designed to work with multiple vehicles and multiple secondary computer systems, each connected to the web site through the Internet. FIG. 3 illustrates this point, showing a system 20 , similar to the system 2 of FIG. 1, used to diagnose a set of vehicles 12 a - 12 c. The system 20 operates similarly as that described above: a wireless appliance 13 a - 13 c disposed in each vehicle collects data from the vehicles'respective engine computers 15 a - 15 c, formats these data into data packets, and then sends the data packets using antennae 14 a - 14 c over a series of airlinks 9 a - 9 c to a base stations 11 a - 11 b featured in a wireless network 4 . Each vehicle may include a unique schema. In this case, two vehicles 12 a, 12 b send their respective data packets to a single base station 11 b, while a single vehicle 12 c sends its data packet to a single base station 11 a. The number and location of the base stations depends on the wireless network; in the Mobitex network there is typically one base station per zip code in most major cities. Once the data packets are received, the wireless network 4 routes them to the host computer system 5 . They are then processed with a corresponding map and consequently formatted as a series of data sets and displayed on the web site 6 . A series of secondary computer systems 8 a - 8 c, 8 n view the web site using separate connections over the Internet 7 a - 7 c, 7 n. Users of the secondary computer systems 8 a - 8 c, 8 n associated with organizations containing a series of vehicles (e.g., a vehicle dealership) can view data from all vehicles associated with the organization. In contrast, individual vehicle owners can only view data from their particular vehicle.
FIG. 4 illustrates this concept in more detail. The figure shows a schematic drawing of a login process 40 for a web site 42 that displays diagnostic data for a series of ‘customer’ vehicles associated with a vehicle ‘dealership’. Within each vehicle is a wireless appliance that retrieves data from the vehicle's engine computer, and then sends these data, formatted in a data packet, through a wireless network. The data eventually are transferred from the network, through a host computer system, to the web site 42 where they are formatted, displayed and processed as described below.
A user ‘logs’ into the web site 42 through a login interface 44 by entering a username and password that, once entered, are compared to a database associated with the web site. The comparison determines if the user is a dealer or a customer. If the user is determined to be a dealer, the web site renders a dealer interface 46 that contains, e.g., diagnostic information for each purchased vehicle. Users viewing the dealer interface 46 do not have access to data corresponding to vehicles sold by other dealerships. If the user is determined to be a customer, the web site 42 renders a customer interface 48 that contains diagnostic information for one or more vehicles corresponding to the customer. Each customer using the web site 42 is associated with a unique customer interface.
FIG. 5 is a screen capture of a web page 50 included in the dealer interface indicated in FIG. 4 . The host computer system renders this page once the user is determined to be a dealer following the login process. The screen capture features a customer list 52 corresponding to a single dealership that includes: customer names 56 for each customer; a vehicle description 58 that includes the vehicle's year, make and model; a unique 17-digit vehicle identification number (‘VIN’) 60 that functions as the vehicle's serial number; and an ‘alert’ listing 62 that provides a number of alerts for each vehicle. The ‘alerts’ are described in more detail in the application entitled ‘INTERNET-BASED SYSTEM FOR MONITORING VEHICLES’, filed Mar. 15, 2001, the contents of which are incorporated herein by reference. In general, an alert is generated when data, sent from the vehicle's wireless appliance to the host computer system, indicates either 1) a mechanical/electrical problem with the vehicle; or 2) that a scheduled maintenance is recommended for the vehicle. For example, the customer list 52 includes a data field 54 that lists the user ‘Five, Loaner’ with an associated 2001 Toyota Corolla. The data field 54 also includes the number ‘1’ in the alert listing 62 , indicating the presence of a single alert.
FIG. 6 shows a web page 120 that lists a detailed data set 122 transmitted from the vehicle-based wireless appliance to the host computer system. The host computer system receives the data set 122 at a time described by a time/date stamp 72 listed in the header 61 . The data set 122 includes a data parameter name 125 , a corresponding numerical value 127 , and a description of the units 129 of the numerical value 127 . As described above, these values are specified in the map corresponding to the data-collection schema used to extract the data from the vehicle. Some of the numerical values (e.g., the status of the ‘MIL light’ 131 ) are dimensionless, i.e. they do not have units. To generate the numerical values 127 , the wireless appliance queries the vehicle's ECU at a set time interval (e.g. every 20 seconds), and transmits a data set 122 at a longer time interval (e.g. every 10 minutes). Thus, the numerical values in the data set can represent ‘instantaneous’ values that result from a single query to the ECU, or they can represent ‘average’ values that result from an average from multiple sequential queries.
The data parameters within the set 122 describe a variety of electrical, mechanical, and emissions-related functions in the vehicle. Several of the more significant parameters from the set are listed in Table 1, below:
Pending DTCs
Ignition Timing Advance
Calculated Load Value
Air Flow Rate MAF Sensor
Engine RPM
Engine Coolant Temperature
Intake Air Temperature
Absolute Throttle Position Sensor
Vehicle Speed
Short-Term Fuel Trim
Long-Term Fuel Trim
MIL Light Status
Oxygen Sensor Voltage
Oxygen Sensor Location
Delta Pressure Feedback EGR Pressure Sensor
Evaporative Purge Solenoid Dutycycle
Fuel Level Input Sensor
Fuel Tank Pressure Voltage
Engine Load at the Time of Misfire
Engine RPM at the Time of Misfire
Throttle Position at the Time of Misfire
Vehicle Speed at the Time of Misfire
Number of Misfires
Transmission Fluid Temperature
PRNDL position (1,2,3,4,5=neutral, 6=reverse)
Number of Completed OBDII Trips
Battery Voltage
Table 1—Parameters Monitored from Vehicle
The parameters listed in Table 1 were measured from a Ford Crown Victoria. Similar sets of data are available for nearly all vehicles manufactured after 1996 that have an OBD-II connector. In addition to these, hundreds of other vehicle-specific parameters are also available from the vehicle's computer.
The data set 122 shown in FIG. 6 represents the most recent data sent from the vehicle's wireless appliance to the host computer system. Data sets sent at earlier times can also be analyzed individually or in a group to determine the vehicle's performance. These ‘historical data’, for example, can by used to determine trends in the vehicle's performance. In some cases data analyzed in this manner can be used to predict potential problems with the vehicle before they actually occur.
Referring to FIG. 7, a web page 130 includes a historical data set 132 containing data parameter names 125 ′, units 129 ′ and a series of data sets 127 a - 127 c transmitted at earlier times from the in-vehicle wireless appliance. Each of these data sets is similar to the data set 122 shown in FIG. 6, but is received by the host computer system at an earlier time as indicated by a time stamp 140 a - 140 c. For example, the first two data sets 127 c, 127 b where transmitted with time stamps 140 b, 140 c of 11:42 and 11:52 on Feb. 12, 2001; the last data set 127 a was transmitted the next morning with a time stamp 140 a of 6:05.
Other embodiments are also within the scope of the invention. In particular, the web pages used to display the data can take many different forms, as can the manner in which the data are displayed. Web pages are typically written in a computer language such as ‘HTML’ (hypertext mark-up language), and may also contain computer code written in languages such as java for performing certain functions (e.g., sorting of names). The web pages are also associated with database software (provided by companies such as Oracle) that is used to store and access data. Equivalent versions of these computer languages and software can also be used.
Different web pages may be designed and accessed depending on the end-user. As described above, individual users have access to web pages that only show data for their particular vehicle, while organizations that support a large number of vehicles (e.g. dealerships or distributors) have access to web pages that contain data from a collection of vehicles. These data, for example, can be sorted and analyzed depending on vehicle make, model, odometer reading, and geographic location. The graphical content and functionality of the web pages may vary substantially from what is shown in the above-described figures. In addition, web pages may also be formatted using standard wireless access protocols (WAP) so that they can be accessed using wireless devices such as cellular telephones, personal digital assistants (PDAs), and related devices.
The web pages also support a wide range of algorithms that can be used to analyze data once it is extracted from the data packets. For example, the above-mentioned alert messages are sent out in response to a DTC or when a vehicle approaches a pre-specified odometer reading. Alternatively, the message could be sent out when a data parameter (e.g. engine coolant temperature) exceeded a predetermined value. In some cases, multiple parameters (e.g., engine speed and load) can be analyzed to generate an alert message. In general, an alert message can be sent out after analyzing one or more data parameters using any type of algorithm. These algorithms range from the relatively simple (e.g., determining mileage values for each vehicle in a fleet) to the complex (e.g., predictive engine diagnoses using ‘data mining’ techniques). Data analysis may be used to characterize an individual vehicle as described above, or a collection of vehicles, and can be used with a single data set or a collection of historical data. Algorithms used to characterize a collection of vehicles can be used, for example, for remote vehicle or parts surveys, to characterize emission performance in specific geographic locations, or to characterize traffic.
Other embodiments of the invention include algorithms for analyzing data to characterize vehicle accidents and driving patterns for insurance purposes; algorithms for determining driving patterns for use-based leasing; and algorithms for recording vehicle use and driving patterns for tax purposes. In general, any algorithm that processes data collected with the above-described method is within the scope of the invention.
In other embodiments, additional hardware can be added to the in-vehicle wireless appliance to increase the number of parameters in the transmitted data. For example, hardware for global-positioning systems (GPS) may be added so that the location of the vehicle can be monitored along with its data. Or the radio modem used to transmit the data may employ a terrestrial GPS system, such as that available on modems designed by Qualcomm, Inc. In still other embodiments, the location of the base station that transmits the message can be analyzed to determine the vehicle's approximate location. In addition, the wireless appliance may be interfaced to other sensors deployed in the vehicle to monitor additional data. For example, sensors for measuring tire pressure and temperature may be deployed in the vehicle and interfaced to the appliance so that data relating the tires′ performance can be transmitted to the host computer system.
In other embodiments, the antenna used to transmit the data packet is embedded in the wireless appliance, rather than being disposed in the vehicle's shade band.
In still other embodiments, data processed using the above-described systems can be used for: remote billing/payment of tolls; remote smog and emissions checks; remote payment of parking/valet services; remote control of the vehicle (e.g., in response to theft or traffic/registration violations); and general survey information.
Still other embodiments are within the scope of the following claims.
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The invention provides a system for monitoring a vehicle that includes a wireless appliance in electrical contact with an in-vehicle computer. The wireless appliance features: 1) a data-collection component that supports communication software that collects diagnostic data from the computer; and 2) a data-transmission component, in electrical communication with the data-collection electronics, configured to transmit an outgoing data packet comprising the diagnostic data over a network and receive over the same network an incoming data packet that modifies the communication software. The wireless appliance communicates with a host computer system that is configured to: 1) receive the outgoing data packet from the network; 2) process the outgoing data packet to generate a set of vehicle diagnostic data; 3) host a web site on the Internet that displays the vehicle diagnostic data; and 4) send out the incoming data packet over the same network to modify the communication software.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to methods for controlling the degradation of transduction molecules in trace gas sensors.
[0003] 2. General Background
[0004] Trace gas analysis is a promising tool for many applications. For instance, in the medical field, changes in exhaled nitric oxide (NO) concentration in exhaled breath can indicate a change in the level of inflammation in the airway of an asthmatic, indicating an increase in the likelihood of an asthma attack. Trace gas analysis may also be useful in measuring other trace constituents of exhaled breath, such as carbon monoxide. Also, there is a need for means to measure trace gases in the atmosphere, for environmental assessment, and to measure trace gases in manufacturing and industrial settings.
[0005] To quantify the concentration of trace gases, various sensors have been developed. Some of these sensors detect and measure changes in substances in response to the trace gas analyte. For instance, a sensor developed by the present inventors measures the optically-quantifiable changes in xerogel (stabilized sol-gel) encapsulated cytochrome-c in response to nitric oxide (NO). This sensor and related technology are disclosed in the following U.S. patent applications, the disclosures of which are hereby incorporated herein by reference: Ser. No. 10/334,625, filed 30 Dec. 2003, and Ser. No. 10/767,709, filed 28 Jan. 2004.
[0006] However, previous work with transduction molecule trace gas sensors has revealed a potential vulnerability: rapid degradation of the sensor. In particular, the applicants have found that in normal circumstances (when attempting to measure trace concentrations) their cytochrome-c sensor would degrade rapidly. The degradation time depends on many parameters, such as temperature, etc., but this unpredictability would make such a sensor impracticable for commercial use, since the sensor may not be usable by the time it reached the end user.
[0007] For purposes of this patent, degradation is defined to include any loss in the sensor's functionality, including the sensor's loss in responsivity to the analyte of interest (e.g. NO) in both magnitude and time-course. It is also defined in the case of cytochrome-c/NO as the loss in the soret peak, which is the spectral peak of the iron porphyrin (the active part of the heme-protein). Thus, one can measure the loss in reactivity to NO or the loss in the magnitude of the soret peak centered around 400 nm. The technology of this application is designed to work with sensors that have sensing elements with transduction molecules, where such molecules undergo optical or electrical changes in response to the analyte.
[0008] The cause or causes of this degradation were previously unknown, but the applicants have now discovered the primary mechanism that causes the degradation, and therefore have created the present invention which preserves transduction molecule trace gas sensors for a sufficient period of time to allow for the creation of a viable commercial product.
SUMMARY OF THE INVENTION
[0009] The present invention is a method of reducing the degradation of a transduction molecule in a trace gas sensor by controlling the exposure of the protein to oxygen. Through their research, the applicants have discovered that oxidation is responsible for the rapid degradation of the sensor. To combat this degradation, the sensor can be stored in a low-oxygen or a substantially oxygen-free environment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a graph showing the degradation of a cytochrome-c NO sensor over time. The y-axis on this graph represents the change in absorbance in a NO sensor in 90 seconds when the humidity surrounding the sensor is fixed at 200 ppm water and the sensor is reacted with 500 ppb NO.
[0011] FIG. 2 is a graph comparing the NO response after 7 days at 70° C. for sensors aged in an ambient environment, and those aged in an oxygen free environment.
DETAILED DESCRIPTION
[0012] The applicants discovered that oxidation was causing the unacceptable degradation of the sensor. The applicants made this discovery in the context of developing a transduction sensor comprised of cytochrome-c encapsulated in a sol-gel matrix. The applicants left sensors in the ambient air, and the sensors had a detectable loss in optical density within 24 hours. When the sensors were left in a nitrogen purged environment, the sensors retained all optical density and substantially all responsivity. This indicated that a constituent in the atmosphere besides nitrogen caused the degradation.
[0013] Next, the applicants performed experiments to isolate the cause of the degradation. The applicants measured percentage of degradation in various environmental conditions, as shown below.
Experimental Groups Stability (% degradation) 1. Initial @ 6% RH −> −78% O2, salt @ 6% RH (control) 2. Initial @ 6% RH −> −10% No O2, 16% 3A @ <0.1% RH
[0014] In the first experimental group, which is the control, a sensor was taken from an initial ambient environment with 6% relative humidity and then placed in an environment with ambient oxygen and salt at 6% relative humidity for a period equivalent to 220 days at room temperature. The 6% RH was maintained by a saturated solution of LiBr. Under these storage conditions a degradation of 78% in sensor performance was observed, meaning that this sensor was 78% less sensitive to NO after exposure to the tested environment. To determine percentage of degradation, the applicants first made a baseline measurement of the reactivity of the sensor to 500 ppb NO in air, and then measured the degree to which the reactivity was lost after exposure to the testing environment.
[0015] In the second experimental group, a sensor was placed in an environment with no oxygen and a relative humidity of 0.1% and a 3 A molecular sieve for the equivalent to 220 room temperature days. This sensor experienced a 10% degradation rate. This confirms that oxygen is the primary cause of the degradation, and that RH also contributes to the problem.
[0016] The discovery that oxygen is a major cause of degradation is surprising, since the applicants are aware of no prior art teaching that protein-based gas sensors need to be stored in an oxygen-deprived environment. For instance, to the applicants' knowledge, previous protein based sensors have not been stored in oxygen-deprived environments, but instead typically only require removal of moisture for storage.
[0017] The applicants believe that their sensing element is especially sensitive to oxygen degradation because it is has a high surface area, and this increases the susceptibility of the device to oxygen. In one embodiment, the applicant's sensing element is cytochrome-c in a sol-gel with a surface area of approximately 400 m2/g.
[0018] A number of different techniques can be used to control the degradative effects of oxygen. In one embodiment of the present invention, nitrogen or another suitable substance can be used to purge oxygen from the sensor housing, and then the sensor housing can be sealed in an oxygen-free (i.e. oxygen-purged) packaging environment. For instance, the purging can be accomplished with five cycles of nitrogen, based on sensor volume and sensor housing volume. Or a vacuum can be created within the housing, either with our without nitrogen purging.
[0019] In a second embodiment, an oxygen absorber can be used to remove oxygen from a sealed sensor housing. The oxygen absorber could be OS film from Cryovac of Cerritos, Calif., or one of the oxygen absorbers (such as PharmaKeep®) from Sud-Chemie of Belen, New Mexico, or any other suitable oxygen absorber. In this embodiment, the oxygen absorber could be placed in the packaging with the sensor. The sealed sensor housing could be made of permeable material that allows the exit of oxygen into the packaging environment and from there into the oxygen absorber. Purging of oxygen from the sensor housing is optional in this embodiment.
[0020] In a third embodiment, an oxygen absorber can be used to remove oxygen from an unsealed sensor housing. This embodiment is similar to the second embodiment, except that the sensor housing is unsealed to facilitate diffusion of oxygen to the absorber. Purging of oxygen from the sensor housing is also optional in this embodiment.
[0021] One skilled in the art will appreciate that the present invention can be practiced by other than the preferred embodiments, which are presented for purposes of illustration and not of limitation.
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A method of avoiding or delaying degradation of a transduction molecule in a trace gas sensor by controlling oxygen exposure is disclosed. Degradation of the gas sensor can be avoided by storage of the sensor in a low-oxygen or substantially oxygen-free environment.
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BACKGROUND OF THE INVENTION
The present invention relates to a workpiece guide rail for a sewing machine, and more particularly to a guide rail which includes a sewing material stretching device for spreading out the material of the workpiece along the course of a seam prior to sewing.
In a known workpiece guide rail, disclosed in Federal Republic of Germany Pat. No. 20 22 735, the base of the guide rail is divided into short sections, each with spring action. Narrow leaf springs arranged alongside of each other are provided on its bottom, as a result of which the bottom of the workpiece guide rail can adapt itself to an accumulation of material in the region of the seam and also can cover locations directly adjacent the accumulation of material. This known workpiece guide rail, however, does not make it possible for the workpiece to be stretched in the region of the intended course of the seam prior to the sewing.
Accordingly, an important object of the present invention is to provide a guide rail with which it is possible, before sewing, to automatically elongate the workpiece which is to be sewn to a predetermined extent.
To carry out this and other objects, the invention includes a workpiece guide rail for a sewing machine for guiding a workpiece past a stitch formation point to determine the course of a seam, comprising a frame and a plurality of holding elements movably mounted on the bottom of the frame. Each holding element has a bottom surface adapted for gripping the workpiece. Means are provided for temporarily increasing a spacing between the holding elements by a predetermined amount in order to stretch the workpiece, and decreasing the spacing between the holding elements to their previous spacing in order to allow the workpiece to return to its previous dimensions. According to another aspect, the invention comprises means for interlinking the holding elements, and means for retaining each holding element movably mounted on the frame.
With the guide rail of the invention it is possible to sew multi-layer workpieces smoothly and free of wrinkles, by stretching the workpiece and thereby ensuring that for each stitch there is used a controlled amount of thread. Thus, a taut, wrinkle-free seam remains after sewing, when the workpiece has again resumed its original length.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention will be seen in the following detailed description of preferred embodiments thereof, with reference to the drawings, in which:
FIG. 1 is a front view of a guide rail according to an embodiment of the invention, having a sewing-material stretching device provided on its bottom;
FIG. 2 is a perspective view of one of the holding elements with an offset as in FIG. 1;
FIG. 3 is a cross-sectional view of a chain of holding elements for a sewing-material stretching device according to a second embodiment of the invention, also including offset holding elements;
FIG. 4 is a cross-sectional view of a chain of holding elements for a sewing-material stretching device according to a third embodiment of the invention, which has flat holding elements; and
FIG. 5 is a cross-sectional view of the guide rail of FIG. 1, taken along the section line A-B; and
FIG. 6 is an elevational view of a sewing machine equipped with a guide rail according to any of the previous embodiments, showing the guide rail in its forward position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 and 5 show a guide rail 2 according to a first embodiment of the invention, which is connected displaceably in a known manner to a sewing machine, for instance an automatic long seamer, for defining the instance an automatic long seamer, for defining the desired course of a seam. The workpiece is placed on the work table and displaced by the guide rail 2, and is thus moved past the stitch-formation point of the sewing machine. The bottom 1 of the guide rail 2 has a groove 10 which extends parallel to its longitudinal edges.
FIG. 6 is an elevational view of a sewing machine equipped with a guide rail 2 according to an embodiment of the invention. As seen therein, the guide rail reciprocates between two extreme positions. The position in solid lines at the right of FIG. 6 is occupied by the guide rail prior to a sewing operation and will be referred to as the "forward" position. The position at the left of FIG. 6 shown in phantom will be referred to herein as the "rearward" position. As the guide rail moves from the forward position to the rearward position, the entire workpiece is moved past the stitch-formation point of the sewing machine.
A sewing-material stretching device 3 on the bottom 1 comprises a plurality of holding elements 4 arranged in an overlapping manner one behind the other. Each of the holding elements 4 has two arms 5, 6, which are separated by an offset so that the respective surfaces of the arms 5, 6 define distinct, substantially parallel planes. The distance between the respective top surfaces of the arms 5, 6 advantageously corresponds to the thickness of the material of the arm 5.
On the top of the arm 6 there is provided, as shown in FIG. 2, a pin 7 which is firmly attached to the holding element 4 in a known manner by riveting, soldering or cementing, for example. The width of the groove 10 is such that it receives the pins 7 which are freely movable within it.
Within the arm 5 of the holding element 4 is a hole 8, which receives the pin 7' of an adjacent holding element 4' (see generally FIG. 3). The hole 8 is so dimensioned that the pin 7' can move back and forth sufficiently within the hole 8 in the longitudinal direction of the holding elements 4 and 4'.
A piece of elastic material 9 having a rough surface is firmly connected to the bottom of the arm 6. Alternatively, the holding element 4 could be provided with sufficient skid resistance by providing the bottom of the arm 6, for example, either with raised fluting or with protruding conical or pyramidal points.
By inserting the pin 7' of the adjacent holding element 4' into the hole 8, there is produced a chain of variable length consisting of a plurality of holding elements 4, all of the pins 7 of said elements being received by the groove 10. Said chain is connected in form-locked manner to the guide rail 2 by a plurality of angle members 11. The vertical arm of each of said angle members is firmly attached, as shown in FIG. 5, to the guide rail 2 while its other arm partially covers the bottom of the arm 6. In this way, the holding elements 4, which are arranged in overlapping manner one behind the other, are prevented from dropping out of the groove 10.
Referring now to FIG. 3, in a second embodiment of the holding elements 4, each pin 7 has, extending through it, a hole 16 arranged in the longitudinal direction of the holding element 4, through which hole a spring-steel wire 15 is inserted. In this way, a flexible chain-like connection of all holding elements 4 is made possible. One end member 12 of this chain is firmly attached to the guide rail 2, while an actuator 14 (see FIG. 1) pulls the holding elements 4 apart by acting on the spring-steel wire 15, which is attached to the opposite end member 13, as indicated by the arrow. A suitable actuator 14 may be a single-acting or double-acting cylinder, actuated by pressure fluid (compressed air in the embodiment of FIG. 1), which is attached to the guide rail 2. The movable piston rod of the actuator 14 either acts directly on the end member 13 or acts indirectly on the end member 13 via the spring-steel wire 15.
The actuator 14 may also take the form of a one-directional device such as a solenoid which draws the holding elements 4 apart against the force of a spring. Such solenoid may act directly on the end member 13, or preferably may act indirectly via the spring-steel wire 15 that extends through the pins 7.
FIG. 4 shows a third embodiment of the invention, in which the sewing-material stretching device 3 comprises flat holding elements 17 arranged in a row one behind the other, each of them having two pins 7. Between every two adjacent holding elements 17, 17' there is provided a strap 18 in which there are two holes 8. By the arrangement of the holding elements 17 and the straps 18 one behind the other, a chain of variable length is produced which, as in the previous embodiments, is attached in form-locked manner to the guide rail 2 by the groove 10 and at least one angle member 11.
The manner of operation of a guide rail 2 according to any of the preceding embodiments, having the sewing-material stretching device 3 mounted beneath it, will now be described.
A multi-layer workpiece is first placed in proper position on the work table at a receiving station adjacent to the stitch-formation point, and the guide rail 2 which is in its forward position is then moved downward until its bottom 1 presses flat against the workpiece. In this way, the workpiece is held between a slide plate, which is firmly attached to the work tabletop and has a very smooth surface, and the guide rail 2. By the action of pressure fluid on the actuator 14, the holding elements 4 or 17 of the sewing-material stretching device 3 are pulled apart a predetermined amount. In this way, the workpiece is stretched by the rough bottom surfaces of the holding elements 4 or 17. The guide rail 2 is now moved rearward by conventional means toward and past the stitch-formation point of the sewing machine for sewing of the stretched workpiece. After completion of the sewing process, the guide rail 2 is raised and moved back to the receiving station. During the return movement, the actuator 14 is evacuated so that the holding elements 4 or 17 again move together.
After the lifting of the guide rail 2 and evacuation of the actuator 14, the multi-layer workpiece contracts to its original length. In this way it is possible to make stitches which are slightly loosely formed, and thus tension wrinkles, which occur particularly often when sewing thin sewing material, are prevented. Of course, the invention is useful in sewing other types of material as well.
Although illustrative embodiments of the invention have been described herein, it is to be understood that the invention is not limited to such embodiments. Rather, modifications and variations of the invention may occur to one skilled in the art within the scope of the invention, as defined in the claims.
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A workpiece guide rail for a sewing machine, and more particularly a guide rail which includes a sewing material stretching device for spreading out the workpiece along the course of a seam prior to sewing. The guide rail includes a frame and a plurality of holding elements movably mounted on the frame, each holding element having a lower surface adapted for gripping the workpiece. The holding elements are interlinked to form a chain, one end of the chain being fixed to the frame, and an actuator is provided on the frame for pulling the other end of the chain for separating the holding elements in order to spread out the workpiece.
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BACKGROUND OF THE INVENTION
Petri dishes, filled with agar-agar or other culture growth medium, are employed in vast numbers in many types of testing and research laboratories, and various types of apparatus have been proposed heretofore for the mass production of such filled dishes. In general, the rate of feed of growth medium in such apparatus must be restricted in order to prevent spillage from the dishes, and therefore the prior apparatus require either the intermittent stopping of each dish while it is filled with medium, or the speed of movement of the dishes is restricted to allow proper filling. Typical of such apparatus are those described in U.S. Pat. Nos. 3,050,915; 3,513,621; 3,719,023; and 4,170,861. In both types of apparatus the rate of production of filled dishes is limited, resulting in correspondingly high production cost.
SUMMARY OF THE INVENTION
In its basic concept, the dish filling apparatus of this invention provides a pair of feed nozzles spaced apart in the direction of movement of spaced apart dishes and operated alternately such that the trailing nozzle first feeds culture growth medium or other fluid material into a dish while the leading nozzle is shut off during its registry with the space between adjacent dishes, and the leading nozzle then feeds the fluid material into the same dish while the trailing nozzle is shut off during its registry with the space between said dish and the next succeeding dish.
It is by virtue of the foregoing basic concept that the principal objective of this invention is achieved; namely, to overcome the aforementioned production limitations of prior filling apparatus.
Another object of this invention is to provide apparatus of the class described by which Petri dishes may be filled with culture growth medium at about twice the production rate of prior apparatus.
A further object of this invention is the provision of apparatus of the class described in which the feeding of medium is controlled by cooperative relationship between the positions of a Petri dish and a photoelectric cell.
The foregoing and other objects and advantages of this invention will appear from the following detailed description, taken in connection with the accompanying drawings of a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a foreshortened perspective view of Petri dish filling apparatus embodying features of this invention.
FIG. 2 is a fragmentary plan view of the apparatus shown in FIG. 1, with the protective cover removed.
FIG. 3 is a fragmentary, foreshortened, longitudinal section taken on the line 3--3 in FIG. 2.
FIG. 4 is a foreshortened side elevation of a Petri dish, a portion being broken away to disclose structural details.
FIG. 5 is a fragmentary side elevation of a feed nozzle control component of the apparatus.
FIG. 6 is a fragmentary sectional view as viewed from the top in FIG. 5.
FIGS. 7, 8 and 9 are fragmentary sectional views taken on the lines 7--7, 8--8 and 9--9, respectively, in FIG. 3 and showing progressive stages of upward lifting of Petri dish covers during movement of the dishes through the filling stage.
FIGS. 10, 11, 12 and 13 are fragmentary plan views in schematic form illustrating the relationships between the pair of spaced feed nozzles and adjacent Petri dishes and photoelectric cell feed control, during continuous movement of spaced dishes through the filling cycle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the apparatus of this invention may be employed to fill various types of fluid materials into various forms of dishes, it is particularly suited to the filling of agar-agar or other bacterial culture growth base medium into Petri dishes. The following description of the apparatus refers to this latter use merely for the purpose of illustration.
The apparatus of this invention includes a hollow housing which forms a base support for the components of the apparatus. The housing includes the top panel 10 supported by downwardly extending end walls 12, a front wall 14, and a rear wall 16. The housing also has a bottom wall (not shown).
Within the housing there is supported a pair of longitudinally spaced rotary sprockets 18 and 20 mounted on shafts and supporting an endless conveyor chain 22. A plurality of drive lugs 24 are secured to and project outwardly from the conveyor chain at longitudinally spaced intervals. The lugs on the upper working stretch of the chain project upwardly through a longitudinal slot 26 in the top panel of the housing for engaging and moving Petri dishes in a manner described more fully hereinafter. An electric motor (not shown) is connected to the downstream, or leading sprocket 20 i.e. the sprocket leading in the direction of movement of the upper working stretch of the conveyor chain, for effecting continuous movement of the chain and drive lugs.
Secured to the top panel of the housing and overlying the slot 26 adjacent the trailing end of the conveyor chain is an upwardly elongated hollow hopper 28 dimensioned to freely confine a vertical stack of Petri dishes with covers. FIG. 4 illustrates such a conventional Petri dish D and cover C. Thus, the dish includes a bottom wall and an upwardly extending peripheral wall, while the cover includes a top wall and a downwardly extending peripheral wall. The cover is dimensioned to fit loosely over the dish and both the dish and cover are made of transparent material such as glass, or, preferably inexpensive and therefore expendable synthetic resin.
As illustrated, the upwardly elongated hopper 28 is open at the rearward side for convenient access to the interior for filling with Petri dish and cover assemblies.
It is to be noted that the feed hopper is positioned relative to the upstream end of the conveyor such that each lug 24 on the conveyor chain projects upward through the slot in the housing top panel at the trailing end of the chain and engages the rearward side of the bottom-most dish and cover of the stack in the hopper. Thus, as the conveyor chain continues its downstream movement the trailing lug pushes the bottom-most dish and cover from under the stack and moves it forwardly out of the hopper. When the bottom-most dish and cover clears the hopper, the stack within the hopper drops by gravity so that the next bottom-most dish and cover is ready for engagement by the next succeeding lug that appears through the slot at the trailing end of the conveyor.
Means is provided for guiding the dishes and covers in the downstream direction of movement of the conveyor, while simultaneously effecting upward tilting of the covers from one side of the associated dishes. For this purpose an elongated dish guide and cover retainer strip is secured to the housing cover panel a spaced distance rearwardly of and parallel to the conveyor slot 26. This guide and retainer strip preferably is formed with a rearwardly extending base flange 30 for mounting on the housing top panel, a vertical intermediate wall 32 extending upwardly from the forward edge of the base flange, and a top flange 34 extending from the upper end of the vertical wall horizontally forward toward the conveyor slot. The base flange preferably is provided with a plurality of slots 36 elongated in the direction perpendicular to the longitudinal dimension of the flange and arranged to freely receive securing screws 38 therethrough for threaded engagement in a tapped opening in the housing top panel. By this means the retainer strip may be adjusted toward and away from the conveyor slot.
On the side of the conveyor slot opposite the retainer strip is located an elongated dish guide and cover lifting strip. It also extends parallel to the conveyor slot and includes a forwardly extending base flange 40 and an upstanding vertical wall 42. The base flange is provided with a pair of longitudinally spaced and longitudinally elongated slots 44 each arranged to freely receive a securing screw 46 therethrough for threaded engagement in tapped openings in the housing top panel. It is by this means that this dish guide and cover lifting strip is adjustable in the longitudinal direction, rather than the transverse direction of adjustment of the dish guide and cover retainer strip described hereinbefore.
The vertical walls 32 and 42 of the dish guide strips function to confine freely between them Petri dishes being moved by the conveyor in the downstream direction. Lateral adjustment of the retainer strip by the transverse slots 36 facilitates proper dimensioning of the space between the walls 32 and 42 for free movement of the dishes.
Associated with the vertical wall 42 is a contoured ramp configured for engagement of the adjacent portion of the underside of the side wall of covers C and raise them upwardly from their underlying dishes D, to create a space between the dishes and covers. At the upstream end adjacent the hopper the ramp is formed by the top edge 48 of the vertical wall 42. An adjacent portion 50 of this top edge then is angled upwardly in the downstream direction so as to initiate upward tilting of the cover.
During upward tilting of the cover by the ramp, the diametrically opposite portion of each cover is retained under the upper flange 34 of the retainer strip, so as to prevent disengagement of the cover from the associated dish. Accordingly, the drive lug 24 which initially abutted the rearward side of the cover as it engaged the bottom-most assembly in the hopper, now abuts the dish since the cover has been tilted upward out of engagement with the lug (FIG. 8). Since the top flange 34 of the retainer strip prevents disengagement of the cover from the associated dish, the cover is moved in the downstream direction with its associated dish as the latter is driven by the engaging conveyor lug.
As the ramp tilts the cover further upward, the peripheral wall of the cover is moved away from the top edge of the vertical wall 42 of the guide strip. Accordingly, the ramp is continued in the downstream direction by an inwardly projecting side extension of the vertical wall. This extension may be formed as a separate plate secured to the inner side of the vertical wall, or may be formed as an integral part of the vertical wall, as desired. This portion of the ramp is formed of the upwardly inclined portion 52 and the terminal, horizontal portion 54.
The purpose of raising the cover from each dish is to provide a space between them sufficient to receive a pair of longitudinally spaced feed nozzles 56 and 58 for introducing agar-agar or other desired culture growth medium into the dish. The paid of feed nozzles extend through openings 60 in the vertical wall 42 of the guide strip, in the area of greatest elevation of the cover by the ramp, i.e. under the ramp portion 54. The pair of nozzles are mounted in a support block 62 which is secured to the outer side of the vertical wall 42, as by means of a screw 64 threaded into a tapped opening in the vertical wall.
The longitudinally elongated slots 44 in the base flange 40 of the guide strip accommodates longitudinal adjustment of the latter and corresponding longitudinal adjustment of the cover lifting ramp and feed nozzles, for purposes described more fully hereinafter.
Means is provided for delivering culture growth medium alternately to each of the feed nozzles. In the embodiment illustrated, the outer ends of the feed nozzles are connected to one end of a pair of flexible hoses 66 and 68, the opposite ends of which merge into communication with a single flexible feed hose 70. The opposite end of the feed hose is connected to the outlet of a pump (not shown) the inlet of which communicates with a supply of agar-agar or other bacterial culture growth base material which is solid at room temperature but liquid at supply temperature. Although a variety of types of pumps may be utilized, a conventional peristaltic pump has been found to be quite suitable.
The pair of flexible hoses extend from the outer ends of the feed nozzles downward along the outer side of the front wall of the housing and between a pair of support plates 72 and 74 which extend outwardly through the front wall 14 of the housing. The portions of the support plates inwardly of the front wall mount a pair of guide bars 76 between them which slidably mount an elongated pinch bar 78. The pinch bar extends outwardly through an opening in the front wall of the housing, between the longitudinally spaced support plates.
The portion of the pinch bar inwardly of the front wall is secured to the projecting piston rod 80 of a fluid pressure cylinder 82, preferably an air cylinder, mounted on one of the support plates. Thus, by the application of fluid pressure selectively to the opposite ends of the cylinder, the pinch bar is moved toward one or the other of the spaced support plates. The flexible hoses leading from the feed nozzles are positioned on opposite sides of the pinch bar and between the support plates, and therefore movement of the pinch bar selectively toward one or the other of the support plates functions in the manner of a pinch clamp to pinch closed one of the flexible hoses while opening the other hose. In this manner, culture growth medium is delivered alternately to the pair of feed nozzles. The air cylinder drive for the pinch bar may be replaced with an electric solenoid, or other drive mechanism, as desired.
Means is provided for controlling the movement of the pinch bar in relation to the movement of spaced Petri dishes in the downstream direction past the pair of feed nozzles. In the embodiment illustrated, a photoelectric cell 84 is mounted on a transparent protective cover 86 which retractably overlies the guide strips downstream from the hopper. As illustrated, the protective cover is secured to the top panel of the housing by means of hinges 88, so that the cover may be retracted to expose the underlying components of the apparatus.
The photoelectric cell includes a light source 90 and a reflected light detector 92, and is positioned on the cover so as to provide the mode of operation illustrated in FIGS. 10-13 and described hereinafter. For this purpose the detector is arranged in the electric circuit of a solenoid valve in the air supply to the air cylinder 82. The arrangement is such that when the detector receives light reflected from the light source, it activates the solenoid valve to move the pinch bar toward the right in FIGS. 5 and 6 to close the right hand flexible hose 68 and open the left hand flexible hose 66 and thus allow delivery of growth medium to the left hand, or upstream feed nozzle 56. Similarly, when the detector receives no light reflection from the light source, it activates the solenoid valve to effect movement of the pinch bar toward the left in FIGS. 5 and 6 to close the left hand flexible hose 66 and open the right hand hose 68. Growth medium thus is delivered to the right hand, or downstream feed nozzle 58.
In FIG. 10 the Petri dish has been moved by the associated conveyor lug 24 to the position in which the light source 90 of the photoelectric cell impinges on the bottom of the dish and thus is reflected back to the detector 92. In the manner described hereinbefore, this effects movement of the pinch bar 78 toward the right in FIG. 5 to initiate delivery of bacterial culture growth medium to the left hand, or upstream feed nozzle 56. Since the Petri dish is moved continuously by the conveyor, it has moved toward the right to the broken line position illustrated in FIG. 10 before the medium is ejected from the nozzle into the dish.
Simultaneously with the movement of the pinch bar toward the right in FIG. 5, the delivery of growth medium to the next preceeding Petri dish D' has been stopped, by the time the Petri dish D has moved to the broken line position illustrated.
FIG. 11 illustrates the importance of preventing delivery of growth medium from the right hand, or downstream nozzle 58 while the latter registers with the space between the adjacent Petri dishes, as the latter are conveyed toward the right.
When the Petri dish D reaches the position illustrated in FIG. 12, the light source 90 of the photoelectric cell no longer reflects from the bottom of the dish. Instead, the light source is projected through an opening 94 in the housing top panel and into the interior of the housing, where it is deflected by an angularly disposed mirror 96 or other deflection surface so as to prevent it from reflecting back to the detector 92. Accordingly, the pinch bar is moved toward the left in FIG. 5 to close the left hand hose 66 and open the right hand hose 68. Delivery of growth medium to the left hand feed nozzle 56 is stopped, but is simultaneously initiated to the right hand feed nozzle 58. Thus, growth medium continues to be filled into the Petri dish D by the right hand feed nozzle while the left hand feed nozzle is in registry with the space between the Petri dish D and the next succeeding dish D".
The foregoing cycle of operation is repeated continuously to effect the filling of each Petri dish as it moves continuously toward the right. Since each dish receives a supply of growth medium from each of the pair of feed nozzles, first from the left hand or upstream feed nozzle 56 and then from the right hand or downstream feed nozzle 58, the speed of movement of the dishes by the conveyor may be substantially greater than possible heretofore. Indeed, it has been determined that the rate of production of filled Petri dishes is about twice the rate of production achieved by apparatus of the prior art.
After each Petri dish has been filled to the desired level with growth medium, its continued movement toward the right (FIGS. 2 and 3) carries the associated cover C with it beyond the terminal end of the cover-elevating ramp portion 54. The cover then falls by gravity back onto the associated Petri dish.
Referring primarily to FIG. 3 of the drawings, it is to be noted that the conveyor is mounted in the housing to provide a slight downward inclination of the conveyor chain in the downstream direction of movement thereof, so that the downstream lug 24 disengages from the Petri dish as the lug begins to move clockwise around the downstream sprocket. This arrangement prevents the downstream lug from flinging the filled and covered Petri dish violently forward as the associated lug acelerates in speed as it moves around the sprocket. The disengaged covered Petri dish is moved further forward by the next succeeding covered and filled dish. An offbearing conveyor (not shown) receives these filled and covered dishes and delivers them to refrigeration equipment where the growth medium is cooled to room temperature and thus is solidified in preparation for packaging for transport or storage.
It will be apparent to those skilled in the art that various changes may be made in the size, shape, type, number and arrangement of parts described hereinbefore, without departing from the spirit of this invention and the scope of the appended claims.
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Spaced apart and covered Petri dishes are moved continuously toward a pair of spaced feed nozzles while the covers engage a ramp and are tilted upward away from the dishes to provide a space for reception of the feed nozzles. A photoelectric cell detects the passage of the dishes beneath the feed nozzles and controls the feeding of bacterial culture growth medium alternately from the nozzles into the dishes as the latter move continuously past the nozzles. The covers are replaced over the dishes after filling.
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BACKGROUND OF THE INVENTION
The invention concerns a safety brake which is releasable via an electromagnet.
A safety requirement issued by regulatory bodies demands technical equipment to be provided with two separate braking circuits so that if one braking circuit should fail, a braking operation from the other braking circuit can be provided. This is the case for elevators constructed in accordance with elevator regulation TRA 200 DIN EN 81.
In accordance with the subject matter of German Gebrauchmuster 295 10 828 two brakes are spacially integrated. In this arrangement there are two armatures, two brake disks, two spring arrangements that press the armature disks against the brake disks, and a single electromagnet with a magnetic coil arranged between the armature disks and brake disks. This arrangement provides a functionally safe, inexpensive and compact system that provides two brakes that are independent of one another.
In order to save space and to simplify the brakes while maintaining the safety function of a braking operation, and thereby reduce the cost of brakes, these brakes were further developed as shown in German Gebrauchmuster 296 11 732.3. In this brake the electromagnet comprises a magnetic coil and coil carrier that surrounds a central shaft that is arranged to be axially displaceable, but not rotatable in the brake. In addition, a single armature disk 3 that is axially displaceable, but cannot be rotated in the brake, is arranged axially between one of two brake disks 2 , 11 and the magnetic coil/coil carrier. Springs are tensioned axially between the magnetic coil/coil carrier and the single armature disk 3 .
A disadvantage of this twin circuit brake is that, on account of the placement of the magnetic coil in the region between the rotating brake disks, the heat that is generated on the brake disks during braking bears upon the coil from two sides. Thus, the coil is heated in accordance with the amount of frictional work done during braking. This heating can become significant, particularly in a high temperature environment, for example in warm countries. In order to prevent overheating of the coil it is necessary to limit the braking power correspondingly.
A further disadvantage of this twin circuit brake is that it is necessary to change the entire coil when the brake linings are changed. This means that an inconvenient amount of effort needs to be expended in order to change the parts subject to wear.
Obviously, this twin circuit brake also needs to comply with the aforementioned safety requirement. In particular, malfunction situations (jamming or seizure situations) that can affect the movable parts of the brake should be accounted for.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a two circuit brake that satisfies the aforementioned safety requirement.
Further, it is an object of the invention to provide a two circuit brake in which the heat generated by braking effect of the brake, in particular in the vicinity of electrical components, is as small as possible.
A further object of the invention is to reduce the amount of effort expended in servicing the brake, in particular in the changing of the wearable parts of the brake, such as the brake linings.
The brake should also be constructed in the simplest possible way, so that it is easy to manufacture.
These objects are achieved in accordance with the following description of the invention.
In the two circuit brake in accordance with the invention, the heat that is generated on the brake linings during braking is only conducted to one side of the coil carrier, and then only via the armature disk. The heat can thereafter be released to the environment via the exposed outer side of the coil carrier. In this way the temperatures that occur in the coil carrier are kept relatively low.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments for the invention will be described in the following, making reference to the figures, in which:
FIG. 1 is a longitudinal cross sectional view of the preferred exemplary embodiment shown in a non-energized condition, i.e. in the braked condition.
FIG. 2 is a longitudinal cross sectional view of an alternative exemplary embodiment of the invention, also in the braked condition.
FIG. 3 is a side view of a third embodiment of the invention.
FIG. 4 is a sectional view along the line A-B in FIG. 3 of the third embodiment of the invention.
FIG. 5 is a sectional view along the line C-D in FIG. 3 of the third embodiment of the invention.
FIG. 6 is a side view of a fourth embodiment of the invention.
FIG. 7 is a sectional view along the line A-B in FIG. 6 of the fourth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a two circuit brake in accordance with the preferred embodiment of the invention, wherein the two circuit brake is in a the braked condition. The two circuit brake is attached to a machine wall or back-bearing plate 3 of a motor (not shown) in order to brake a rotatable shaft 7 . The shaft 7 has a collar 9 with longitudinal splines 11 .
A first friction lining rotor or brake disk 14 that is disposed closer to the machine wall 3 and is rotates with the shaft 7 , and a second friction lining rotor or brake disk 16 that is disposed further from the machine wall 3 and also rotates with the shaft 7 , are mounted on the collar 9 by virtue of longitudinally disposed splines 13 , 15 that mesh with the longitudinal splines 11 . The mounting being such that the brake disks 14 , 16 are displaceable longitudinally but are not rotatable with respect to the collar 9 .
Between the first brake disk 14 and the machine wall 3 there is provided an annular flange plate 21 . Between the first brake disk 14 and the second brake disk 16 there is provided an intermediate disk or plate 23 , and on the side of the second brake disk 16 that is facing away from the machine wall 3 there is provided an armature disk or plate 25 . The intermediate disk 23 serves as a friction surface for both the first brake disk 14 and the second brake disk 16 . The flange plate 21 serves as friction surface for the first brake disk 14 , and the armature disk 25 serves as friction surface for the second brake disk 16 .
On the side of the armature disk 25 that faces away from the machine wall 3 there is provided an annular coil carrier 30 , through a central opening 31 of which the shaft 7 projects coaxially.
The flange plate 21 , the intermediate disk 23 , the armature disk 25 and the coil carrier 30 are arranged coaxially with respect to one another and have essentially the same diameter. The shaft 7 passes through all of these components.
The coil carrier 30 is mounted a fixed distance from the flange plate 21 by an arrangement consisting of several connection screws 35 and associated spacing bushes 36 . For this purpose the coil carrier 30 has several, preferably three, bores 32 around its circumference that extend in an axial direction therethrough. At the end of each bore 32 of the coil carrier 30 , that is furthest from the machine wall 3 , there is a countersink 34 provided for the head of the corresponding connecting screw 35 . In addition, in the flange plate 21 coaxial with these bores there are provided corresponding threaded bores 33 . A spacing bush 36 is provided between each threaded bore 33 of the flange plate 21 and each bore 32 of the coil carrier 30 , respectively. The spacing bushes 36 , with their connecting screws 35 , pass through respective bores 23 b in the intermediate disk 23 and concentrically placed notches 38 in the armature disk 25 . Furthermore, an O-ring 39 is provided around each spacing bush 36 where it passes through the bore 23 b . The O-ring 39 serves to guide the spacing bush 36 in the bore 23 b of intermediate disk 23 , and thereby provides radial location for the flange plate 21 and the coil carrier 30 .
The coil carrier 30 is spaced a predetermined distance from the flange plate 21 by virtue of the spacing bushes 36 , and is held by virtue of the connecting screws 35 which extend between the threaded bores 33 in the flange plate 21 and the countersinks 34 in the coil carrier 30 .
The intermediate disk 23 disposed between the first brake disk 14 and the second brake disk 16 is fixed to and spaced from the machine wall 3 a predetermined distance by virtue of a plurality of fixing screws 37 equally distributed in a circular arrangement in the machine wall 3 and coaxial with the shaft 7 . For this spacing, bushes 37 a are disposed between the intermediate disk 23 and the machine wall 3 . The fixing screws 37 are screwed into corresponding threaded bores 41 provided in a circular arrangement, and pass through the spacing bushes 37 a. Furthermore, bores 42 are provided in the intermediate disk 23 also in a circular arrangement, with the bores 42 being coaxial with the threaded bores 41 when the intermediate disk 23 is mounted to the machine wall 3 . The fixing screws 37 pass through these bores 42 .
Each fixing screw 37 , as seen from the side of the machine wall 3 , further passes through a respective bore 44 in the armature disk 25 , and the head or the end of each fixing screw 37 projects away from the machine wall 3 and penetrates respectively to a small extent into a bore 45 provided in the coil carrier 30 . At the head or end of each fixing screw 37 , or more exactly, between the head or end of each fixing screw 37 and a respective circular depression 46 provided on the intermediate disk 23 , an intermediate sleeve 47 is disposed that penetrates at least to a substantial extent into a respective associated bore 44 in the armature disk 25 .
Preferably, the connecting screws 35 and the fixing screws 37 are provided in the same circular arrangement, and alternate with each other with equal spacing.
The coil carrier 30 is partially open on the side facing the armature disk 25 , and is provided with an end wall 51 on the side that is furthest from the machine wall 3 . A magnetic coil 55 is immovably embedded, by virtue of a molding resin or a substance having similar properties, in an appropriately formed cut-out 53 in the coil carrier 30 . The magnetic coil 55 together with the coil carrier 30 form the electromagnet of the brake.
The armature disk 25 serves as the reaction surface for the second brake disk 16 in the braking condition. In the braking condition, shown in FIG. 1, a plurality of springs 57 that are insert in the coil carrier 30 , press the armature disk 25 away from the coil carrier 30 and against the second brake disc 16 in order to apply the desired braking effect. The springs 57 are disposed at equal spacing with respect to one another, and are located radially inside of the magnetic coil 55 .
In the following, the function of the embodiment of the two circuit brake described with respect to FIG. 1 will be described.
FIG. 1 shows the brake in the braked condition. This occurs when electrical energy is not applied to the magnetic coil 55 in the coil carrier 30 such that the springs 57 press the armature disk 25 against the second brake disk 16 . Because the connecting screws 35 maintain the coil carrier 30 at a predetermined distance from the flange plate 21 , which lies between the machine wall 3 and the first brake disk 14 , the pressing of the armature disk 25 against the brake disk 16 causes the latter to press on the intermediate disk 23 . The distance of the intermediate disk 23 to the machine wall 3 is fixed by the spacing bushes 37 a so that the intermediate disk 23 cannot move towards and be forced against the first brake disk 14 .
The distance between the coil carrier 30 and the flange plate 21 is fixed by the spacing bushes 36 . Thus, in operation of the brake the springs 57 urge the armature disk 25 and the coil carrier 30 apart, and in particular press the coil carrier 30 away from the armature disk 25 , such that the flange plate 21 is urged against the first brake disk 14 , which in turn is urged against the intermediate disk 23 .
In this way during operation of the brake, both the first brake disk 14 and the second brake disk 16 are braked from both sides.
In the released condition of the two circuit brake in accordance with the invention, the magnetic coil is energized so that the armature disk 25 is pulled towards the coil carrier 30 against the force of the springs 57 . Because the distance between the coil carrier 30 and the flange plate 21 is fixed by the fixing screws 35 and the spacing bushes 36 , the distance between the flange plate 21 and the armature disk 25 increases. The relative position of the intermediate disk 23 to the machine wall 3 is fixed by the spacing bushes 37 a and the fixing screws 37 . Both brake disks 14 and 16 are axially displaceable on the shaft 7 by virtue of their longitudinal splines 13 and 15 and the longitudinal splines 11 of the shaft collar 9 . In the released condition of the brake, the first brake disk 14 and the flange plate 21 on one side, and the second bake disk 16 and the armature disk 25 on the other side, are therefore, moveable to a small extent relative to the intermediate disk 23 .
In the transition from the braked condition to the released condition, the assembly consisting of the flange plate 21 and the coil carrier 30 , held apart by the connecting screws 35 and the spacing bushes 36 , moves slightly towards the machine wall 3 . At the same time the spacing bushes 36 with their O-rings slide and are guided within the bores 23 b of the intermediate disk 23 .
The two circuit brake in accordance with the invention as shown in FIG. 1 compensates for both malfunction conditions (jamming conditions) set out below, that can occur in the transition from the released to the braked condition. In both malfunction conditions braking is achieved.
Firstly, a jamming of the armature disk 25 with respect to the guide sleeve 47 is overcome. In this case the armature disk 25 does not move further towards the second brake disk 16 , however, the springs 57 effect a pressing apart of the armature disk 25 and the coil carrier 30 to the same extent as in the normal condition. Because the connecting screws 35 and the spacing bushes 36 hold the coil carrier 30 and the flange plate 21 at a predetermined distance from one another, the flange plate 21 , on account of the urging away of the coil carrier 30 from the armature disk 25 , moves in a direction away from the machine wall 3 towards the first brake disk 14 . In this way the flange plate 21 presses against the first brake disk 14 , which thereby presses against the intermediate disk 23 on account of the slideability of the first brake disk 14 on the collar 9 . In this way a braking by at least one of the braking circuits is achieved during this jamming condition.
Secondly, during transition from the released to the braked condition, a jamming of at least one of the spacing bushes 36 in the corresponding bore 23 b in the intermediate disk 23 is overcome by the arrangement in accordance with the invention. If a seizure jam) occurs at this location at least the armature disk 25 is pressed against the second brake disk 16 by virtue of the springs 57 , so that one of the braking circuits of the two circuit brake functions.
In the two circuit brake in accordance with the invention and shown in FIG. 1 there are the following force flux lines.
In the normal situation, a force flux line extends from the spring 57 through the armature disk 25 and the second brake lining 16 to the intermediate disk 23 . This force flux line is closed by a force flux line that begins at the end of the spring 57 remote from the armature disk 25 and proceeds through the coil carrier 30 to the connecting screws 35 and the spacing bushes 36 . From there it reaches the intermediate disk 23 via the first brake disk 14 to close the force flux path.
In the first jammed condition, that is upon seizure of the armature disk 25 with the guide sleeve 47 , a force flux line that begins at the end of the spring 57 remote from the armature disk 25 runs through the coil carrier 30 to the connecting screws 35 and the spacing bushes 36 to the flange plate 21 . From there it reaches the intermediate disk 23 via the first brake disk 14 . This force flux line is closed by a force flux line that reaches the intermediate disk 23 from the springs 57 through the armature disk 25 , and from there, on account of the seizure, through the guide sleeves 47 to the intermediate disk 23 .
In the second jammed condition, that is upon seizure of at least one of the spacing bushes 36 in its corresponding bore 23 b of the intermediate disk 23 , the closed force flux line runs from one of the springs 57 , to the armature disk 25 , and from there through the second brake disk 16 to the intermediate disk 23 to the other end of the spring 57 , i.e. the end facing away from the armature disk 25 through the coil carrier 30 to the connecting screws 35 , and from there, on account of the seizure of the spacing bushes 36 likewise to the intermediate disk 23 .
The following modifications of the two circuit brake embodying the invention and described with respect to FIG. 1 are envisaged.
An adjustment of device, for example a set screw 71 could be used for adjustment of the springs 57 .
The number of springs 57 , connecting screws 35 and bushes 36 , as well as the number of fixing screws 37 with bushes 37 a, and guide bushes 47 can be different from that described above.
Now follows a description of a two circuit brake embodying the present invention and shown in FIG. 2 . In this embodiment, components which have the same function are identified by the same reference numerals as in the above described embodiment.
In this embodiment, in the released state of the brake an outer ring or a drum 3 rotates about a shaft 7 . The shaft has a collar 9 on which there is mounted a bearing 4 to support the drum 3 . In the braked condition, shown in FIG. 2, the drum 3 is stationary with respect to the shaft 7 .
The intermediate disk 23 is secured onto the collar 9 by virtue of several collar screws or fixing screws 37 that are screwed into the radial side of the collar 9 that faces away from the drum 3 , and are distributed evenly around the circumference of the intermediate disk 23 . Thereby, the intermediate disk 23 is axially located not only relative to the drum 3 , but also relative to the shaft 7 . The intermediate disk 23 has evenly distributed in a circular arrangement several bores 23 b through which the connecting screws 35 with spacing bushes 36 penetrate. On the outer surface of the spacing bushes 36 in the vicinity of the bore 23 b there is an O-ring 39 for the purpose of guiding the spacing bush 36 within the bore 23 b.
The connecting screws 35 connect a cylindrically shaped flange plate 21 , that is disposed between the drum 3 and the intermediate disk 23 , to the coil carrier 30 . The flange plate 21 has for this purpose several threaded bores 33 to receive the connecting screws 35 . In the direction facing away from the drum 3 are, in addition to the intermediate disk 23 , an armature disk 25 and the coil carrier 30 . The coil carrier 30 has bores 32 with countersinks 34 disposed at their ends away from the drum 3 for receiving corresponding heads of the connecting screws 35 . The armature disk 25 has recesses 38 . Bores 32 , 33 , 23 b and recess 38 correspond with each other in their number and also their radial and circumferential position, so that the connecting screws 35 and their spacing bushes 36 penetrate through the intermediate disk 23 and the armature disk 25 , and at the same time hold the flange plate 21 a predetermined distance from the armature disk 30 . Thus, the arrangement consisting of the flange plate 21 , the coil carrier 30 , the connecting screws 35 and the spacing bushes 36 is slidably disposed relative to the shaft 7 and to the intermediate disk 23 .
The intermediate disk 23 further has bores 44 that are also evenly distributed in a circular arrangement having a radius larger than that of the circular arrangement of the bores 23 b for the spacing bushes 36 . Guide pins or bolts 47 , at least partly, pass through these bores 44 and are pressed into corresponding bores in the armature disk 25 . The guide pins 47 serve as guides for the armature disk 25 with respect to the intermediate disk 23 .
The flange plate 21 , the intermediate disk 23 , the armature disk 25 and the coil carrier 30 are coaxially disposed with respect to one another and have essentially the same outer diameter. The shaft 7 passes through the flange plate 21 , the intermediate disk 23 , the armature disk 25 and the coil carrier 30 .
Along the outer circumference of the drum 3 are several fastening screws 10 that are evenly distributed about the circumference of the drum 3 and penetrate through a respective bush 11 disposed between the head of the fixing screw 10 and the drum 3 . The bushes 11 hold a first friction lining carrier 14 a and a second friction lining carrier 16 a in a slidable manner. The friction lining carriers 14 a, 16 a are ring shaped and have corresponding bores along their circumferences, so that they fit on the bushes 11 . A respective brake lining 14 b, 14 c; 16 b, 16 c is glued on both sides of each friction lining carrier 14 a, 16 a at respective inner peripheries thereof. The intermediate disk 23 has an outer edge portion or a tongue 23 c that has a smaller thickness than the rest of the intermediate disk 23 . The tongue is, however, of constant thickness over its radius. The respective brake lining 14 b, 14 c; 16 b, 16 c of the friction lining carrier 14 a, 16 a is, when viewed radially disposed in the region of the tongue 23 c, and extends not quite as far as the inner radius of the tongue 23 c. In addition the first friction lining carrier 14 a is disposed on the side of the tongue 23 c nearest the drum 3 between the flange plate 21 and the tongue 23 c, while the second friction lining carrier 16 a is disposed on the side of the tongue 23 c that is furthest from the drum 3 between the armature disk 25 and the tongue 23 c. With this arrangement a braking effect can be achieved when the brake lining 14 b facing the flange plate 21 is pressed against the flange plate 21 , the brake linings 14 c and 16 b facing the tongue 23 c is pressed against the tongue 23 c, and the brake lining 16 c facing the armature disk 25 is pressed against the armature disk 25 .
The coil carrier 30 is, as in the exemplary embodiment described with respect to FIG. 1, on the side facing the armature disk 25 partially open and is provided with an end wall on the side facing away from the drum 3 . In the coil carrier 30 is a correspondingly shaped cut-out 53 in which a magnetic coil 55 is embedded by virtue of a casting resin or equally effective material. The magnetic coil 55 together with the coil carrier 30 forms the electromagnet of the brake.
Furthermore, a plurality of springs 57 are provided in corresponding bores in the coil carrier 30 , with the bores being evenly spaced around the circumference of the coil carrier 30 and open on the side facing the armature disk 25 . If the magnetic coil 55 is not energized the springs 57 press the armature disk 25 away from the coil carrier 30 .
The axial position of the intermediate disk 23 is fixed in the embodiment shown in FIG. 2, as it is in the embodiment described with respect to FIG. 1 . The assembly consisting of the flange plate 21 , the coil carrier 30 , the spacing bush 36 and the connecting screws 35 are displaceably disposed with respect to the intermediate disk 23 . Also, the armature disk 25 is moveable with respect to the coil carrier 30 in response to the force exerted by the springs 57 and the magnetic coil 55 . The brake linings 14 b, 14 c and 16 b, 16 c are positioned axially to abut the flange plate 21 and the armature disk 25 .
Now follows a description of the two circuit brake embodying the present invention and described with respect to FIG. 2 .
The non-energized or braked condition of this embodiment is shown in FIG. 2 . With a non-energized magnetic coil 55 the springs 57 press the armature disk 25 against the second friction lining carrier 16 a that, on account of its displaceability on the bush 11 , presses against the intermediate disk 23 . The springs 57 exert a force on the coil carrier 30 in a direction away from the intermediate disk 23 . This force is conducted via the connecting screws 35 and the spacing bushes 36 to the flange plate 21 , and thereby via the first friction lining carrier 14 a to the intermediate disk 23 . In this condition all of the brake linings 14 b, 14 c and 16 b, 16 c exert a braking effect.
In the released condition of the brake current flows into the magnetic coil 55 and the armature disk 25 is pulled against the spring 57 and then against carrier 30 . Thus, the distance between the flange 21 and the armature disk 25 increases while, on account of the slideability of the spacing bushes 36 in the intermediate disk 23 , the friction lining carriers 14 a and 16 a with their associated brake linings 14 b, 14 c , 16 b, 16 c release from their braking engagement with the intermediate disk 23 .
The two circuit brake in accordance with the invention and described with respect to FIG. 2 covers the following two malfunction (jamming) conditions.
First, if the spacing bushes 36 seizes in the bore 23 b there is at least a braking effect caused by the armature disk 25 , the second friction lining carrier 16 a and the intermediate disk 23 .
Second, in the event of the seizure of the guide pin 47 in the intermediate disk 23 a braking effect is provided by virtue of the flange plate 21 , the first friction lining carrier 14 a and the intermediate disk 23 as the spring 57 , in reaction to this seizing condition exerts a pressure on the coil carrier 30 in a direction away from the drum 3 , whereby a force is conducted via the spacing bushes 36 onto the flange plate 21 . In the embodiment of FIG. 2 there are the following closed force flux lines.
In the normal situation there is a force flux line emanating from the spring 57 that transfer its force via the second friction lining carrier 16 a to the intermediate disk 23 . Also emanating from the spring 57 there is a flux line via the coil carrier 30 , to the spacing bushes 36 and to the flange plate 21 , and from there via the first friction lining carrier 14 a, onto the opposite side of the intermediate disk 23 .
Further in the first mentioned jammed condition, a force flux line from the spring 57 passes onto the armature disk 25 , and from there to the second friction lining carrier 16 a and then onto the intermediate disk 23 . At the same time a force flux passes from the spring 57 onto the coil carrier 30 , and via the spacing bushes, on account of the seizure, onto the intermediate disk 23 .
In the second mentioned jammed condition, (seizure of the guide pins 47 ) a force flux line runs from the spring 57 onto the armature disk 25 and the guide pin 47 , and from there, on account of the seizure, onto the intermediate disk 23 . At the same time a force flux line runs from the spring 57 onto the coil carrier 30 and from there, via the spacing bushes 36 and the first friction lining carrier 14 a, onto the intermediate disk 23 .
The following alternative arrangements of the two circuit brake of the embodiment of the invention described in respect to FIG. 2 are envisaged.
For the adjustment of the springs 57 there can be provided an adjustment device, for example an adjustment screw 71 .
The number of fixing screws 37 , of springs 57 , of connecting screws 35 with spacing bushes 36 , and the number of fixing screws 10 with bushes 11 can also differ from that described above.
Instead of fixing screws 37 there can be provided other connections between the shaft 7 and the intermediate disk 23 .
The embodiment described with respect to FIG. 2 can also be constructed with a fixed drum 3 and a rotating shaft 7 .
In the following, the third embodiment of the invention will be described with reference to FIGS. 3, 4 and 5 . Components that have the same function as corresponding components in the first or second embodiments will be given the same reference numbers.
The third embodiment shown in FIGS. 3, 4 , 5 has, in common with the embodiment of FIG. 1, a rotating shaft 7 of a motor (not shown) with a collar 9 , on which an intermediate disk 23 is fixed by virtue of several fixing screws 37 uniformly positioned around the circumference of the intermediate disk 23 . Between the machine wall or an end bearing 3 of the motor and the intermediate disk 23 is a flange plate 21 . On the side of the intermediate disk 23 that is furthest from the machine wall 3 there is provided an armature disk 25 and a coil carrier 30 with a magnetic coil 55 and several springs 57 distributed uniformly around the circumference of the coil carrier 30 .
In a manner analogous to the arrangement shown in FIG. 2, the axial spacing between the flange plate 21 and the armature disk 25 adjusts itself on several spacing bushes 36 a which extend in the axial direction and are distributed around the circumference of the brake. On the end of each spacing bush 36 a that is furthest from the machine wall 3 there is provided a bush 36 b. The end of each bush 36 b that is furthest from the machine wall 3 projects into a respective bore of the coil carrier 30 . To provide further guiding of the bush 36 b an O-ring 39 is fixed to the outer surface of the bush 36 b. This O-ring 39 fills the space between the bush 36 b and the corresponding bore of the coil carrier 30 at an appropriate place.
Each spacing bush 36 a together with the bush 36 b is fixed by virtue of a fixing screw 37 to the machine wall 3 . It is also envisaged that there is provided a spacing sleeve 61 between the spacing 36 a and the machine wall 3 . Between the spacing sleeve 61 and the spacing bush 36 a is an arc shaped first spring lamella or leaf spring 63 that is centrally secured therebetween. Around the entire circumference of the brake there are preferably provided three uniformly distributed first spring lamella or leaf springs 63 , each extending the same arc. On a free end of each first spring lamella or leaf spring 63 the flange plate 21 is fixed by virtue of rivets 65 . The flange plate 21 is thereby suspended on the first spring lamella or leaf spring 63 in a resilient manner and is axially displaceable with respect to the machine wall 3 and the intermediate disk 23 . Along a circumferential edge portion of the flange plate 21 , a first brake lining 14 is glued on the side of the flange plate 21 facing the intermediate disk 23 .
Between each spacing bush 36 a and each bush 36 b a second spring lamella or leaf spring 67 is fixed at its middle. On free ends of each second spring lamella or leaf spring 67 there is suspended the armature disk 25 by virtue of rivets 69 in a manner such that the armature disk 25 is resiliently and axially moveable with respect to the intermediate disk 23 . Along a circumferential edge of the armature disk 25 on the side facing the intermediate disk 23 there is glued a second brake lining 16 .
Between each two rivets 65 (or 69 ) are disposed the spacing bushes 36 a which extend between the flange plate 21 and the coil carrier 30 . Provided for each spacing bush 36 a is a corresponding bore in the flange plate 21 , a respective bore in the coil carrier 30 and a corresponding screw.
The assembly consisting of the flange plate 21 , the spacing 36 a and the coil carrier 30 , and in the same manner the armature disk 25 , are independently axially displaceable with respect to the intermediate disk 23 .
An adjustment screw 71 is screwed in the rear side of the coil carrier 30 , which adjustment screw 71 positions the end of each spring 57 that is remote from the armature disk 25 , so as to adjust the spring force acting on the armature disk 25 . As shown in FIG. 5, in addition to the springs 57 , that are radially inward of the magnetic coil 55 and extend in an axial direction, there are also springs 57 a that also extend in an axial direction in the coil carrier 30 .
In the following there will be described the function of the third embodiment according to FIGS. 3, 4 and 5 .
In the braked condition shown in FIGS. 3, 4 and 5 , the magnetic coil 55 is not energized and therefore the springs 57 , 57 a press the armature disk against the intermediate disk 23 . As soon as this happens the coil carrier is moved by the springs 57 , 57 a in a direction away from the intermediate disk 23 . This causes the flange plate 21 , on account of the spacing bushes 36 a, to move into braking engagement with the intermediate disk 23 . In the normal situation both the armature disk 25 and the flange plate 21 are in braking contact with the intermediate disk 23 by virtue of their associated brake linings 14 , 16 .
In the released state of the brake, the magnetic coil 55 is energized and attracts the armature disk 25 . The space between the armature disk 25 and the flange plate 21 thereby increases. In this situation neither the flange plate 21 nor the armature disk with its brake lining 14 , 16 are in braking engagements with the intermediate disk 23 .
The embodiment according to FIGS. 3, 4 and 5 overcomes all of the jammed conditions that can be imagined affecting the moveable parts, and that correspond to the jammed situations described with respect to the earlier described embodiments.
In this third embodiment, in a place of the leaf springs or spring lamella 63 , 67 other spring elements can be used.
Also the number of springs 57 , the number of rivets 65 , 69 the number of fixing screws 37 with their spacing sleeves 61 , and the number of bushes 36 b, 36 a can also differ from that described.
In the following, a fourth embodiment will be described with reference to FIGS. 6 and 7. Components that have the same function as corresponding components in the first, second or third embodiments bear the same reference numerals.
In a manner analogous to the embodiment described with respect to FIGS. 3 to 5 , the fourth embodiment has a machine wall 3 , a shaft 7 with a splined collar 9 that rotates but is fixed in an axial direction, a coil carrier 30 with armature disk halves 25 a, 25 b, and a rotatable intermediate disk 23 between the machine wall 3 and the armature disk halves 25 a, 25 b. A first brake lining 14 is glued at a circumferential edge portion of the intermediate disk 23 on the surface of the intermediate disk 23 facing the machine wall 3 . In addition, on the side of the intermediate disk 23 facing away from the machine wall 3 there is a coil carrier 30 , and between this coil carrier 30 and the intermediate disk 23 there are the first armature disk half 25 a and the second armature disk half 25 b. The armature disk halves 25 a, 25 b form essentially two separate semi-circular or arcuate segments extending for about 180°. On the circumferential edge portion of each armature disk half 25 a, 25 b on the surface facing the intermediate disk 23 there is glued a second brake lining 16 . The coil carrier 30 houses a magnetic coil 55 and several springs 57 extending in an axial direction and located radially inside of the magnetic coil 55 , and several springs 57 a extending in an axial direction and located radially outside of the magnetic coil 55 . For each spring a respective axially extending bore is in the coil carrier 30 . The springs 57 that are radially inward with respect to the magnetic coil 55 are adjusted by virtue of an adjustment screw 71 that is screwed into the side of the coil carrier 30 that faces away from the machine wall 3 .
The intermediate disk 23 has on its radially inward side longitudinal splines 13 that mesh with longitudinal splines 11 on the radially outer surface of the splined collar 9 .
The coil carrier 30 is fixed in the axial direction to the machine wall 3 by virtue of several fixing screws 35 each having a corresponding spacing sleeve 61 and a spacing bush 36 . The spacing sleeve 61 is disposed between the machine wall 3 and the coil carrier 30 . Between the spacing sleeve 61 and the spacing bush 36 are a total of two arc shaped spring lamella or leaf springs 67 a, 67 b that each extend half of the circumference of the brake. Each spring lamella or leaf spring 67 a, 67 b has the same length. The design of each spring lamella or leaf spring 67 a and 67 b is such that its outer radius is equal to the outer radius of the coil carrier 30 . In its relaxed condition, the longitudinal disposition of the spring lamella or leaf springs 67 a and 67 b is in the circumferential direction of the coil carrier 30 . At two spaced apart locations on the longitudinal extent of each spring lamella or leaf spring 67 a, 67 b there is fixed by virtue of two rivets 69 a the half of the armature disk half 25 a, and by virtue of two rivets 69 b the armature disk half 25 b, so that these armature disk halves 25 a, 25 b are suspended so as to be axially displaceable and resiliently mounted with respect to the coil carrier 30 . In the preferred embodiment the rivets 69 a and 69 b are arranged, when viewed in the circumferential direction, alternating and with the same spacing as the fixing screws 37 .
In the braked condition, as shown in FIGS. 6 and 7 the magnetic coil 55 is not energized, the springs 57 a, 57 b, press both armature disk halves 25 a and 25 b and the second brake linings 16 against the intermediate disk 23 . The brake lining attached to the intermediate disk 23 is pressed against the machine wall 3 , which performs the function of the flange plate of the other embodiments.
In the released condition, the magnetic coil 55 is energized and both armature disk halves 25 a and 25 b attracted to the inner side of the coil carrier 30 . In this way the armature disk halves 25 a and 25 b no longer press against the intermediate disk 23 , and thus the intermediate disk no longer presses against the machine wall 3 so that the brake is released.
Also, in this embodiment all simple jammed conditions that can affect the moving parts and that can occur in the transition to the braked condition are accounted for.
Upon seizure of one armature disk half, for example the armature disk half 25 a, the other armature disk half 25 b is moveable.
In accordance with the embodiment of FIGS. 6 and 7 there are in particular the following alternatives that are possible.
In place of the splines between the collar 9 and the intermediate disk 23 , there could be a lamella or plate which is able to transmit torque and yet remain axially moveable.
In place of the lamella springs or leaf springs 67 a, 67 b other spring elements can be used.
The number of springs 57 a, 57 b, the number of rivets 69 a, 69 b and the number of fixing screws 35 with spacing bushes 36 can be different from that described.
The features of each component of one described embodiment can alternatively be replaced by the features of this component from another embodiment, as long as the corresponding described braking function is not changed.
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A friction safety brake which is released by virtue of an electromagnet is disclosed. Extending from a machine wall is a shaft that is rotatable relative to the machine wall. The shaft is to be braked by the friction safety brake. The brake includes: a first assembly comprising a coil carrier, a coupling element, a flange plate, at least one first brake disk and an intermediate disk; and a second assembly comprising an armature disk, at least a second brake disk and the intermediate disk. The flange plate is coupled in an axial direction with the coil carrier by virtue of coupling elements and is independently movable relative to the armature disk in the axial direction such that two braking circuits are available. The first braking circuit includes the armature disk, the coil carrier and the flange plate ( 21 ) coupled to each other in the direction of rotation. And, the second braking circuit includes the intermediate disk being relatively axially displaceable with respect to the coil carrier and the machine wall.
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DOMESTIC PRIORITY
[0001] This application is a continuation of U.S. patent application Ser. No. 14/245,301, filed Apr. 4, 2014, the content of which is incorporated by reference herein in its entirety.
BACKGROUND
[0002] The present invention relates generally to computer systems, and more specifically, to delaying execution in a processor in order to increase power savings potential.
[0003] In computer systems with multiple interconnected components (e.g., processors, accelerators, memory) it is often the case that some components are busy while others are idle. A standard method of reducing power usage by components during inactive intervals is to use power gating to activate sleep or power down modes. According to this method, the logic is built of low-threshold transistors, with high-threshold transistors serving as a footer or header to cut leakage during the quiescence intervals. During normal operation mode, the circuits achieve high performance, resulting from the use of low-threshold transistors. During sleep mode, high threshold footer or header transistors are used to cut off leakage paths, reducing the leakage currents by orders of magnitude. Another method of reducing the active power is transparent clock gating (TCG). TCG takes advantage of bubbles in a pipeline to avoid clocking latches when a pair of data items are separated by more than one clock cycle (i.e. not back-to-back), potentially reducing clock power by fifty percent in some units for normal workloads.
[0004] A general drawback associated with such techniques of power savings is that periods of idleness (or pipeline bubbles) for a given resource are often not long enough to support the overhead associated with activating and deactivating the power savings technique, even when the fraction of idle cycles relative to the total number of execution cycles is rather large.
SUMMARY
[0005] Embodiments include computer implemented methods, systems and computer program products for storing data in memory. A method includes applying a power savings technique to at least a subset of a processor. Pending work items scheduled to be executed by the processor are monitored. The pending work items are grouped based on the power savings technique. The grouping includes delaying a scheduled execution time of at least one of the pending work items to increase an overall number of clock cycles that the power savings technique is applied to the processor. It is determined that an execution criteria has been met. The pending work items are executed based on the execution criteria being met and the grouping.
[0006] Additional features and advantages are realized through the techniques of the present embodiment. Other embodiments and aspects are described herein and are considered a part of the claimed invention. For a better understanding of the invention with the advantages and features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The subject matter that 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 are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0008] FIG. 1 illustrates a block diagram of a system in accordance with an embodiment;
[0009] FIG. 2 illustrates block diagrams of various sequences of activity bits in accordance with embodiments;
[0010] FIG. 3 illustrates a block diagram of a central processing unit that is configured to delay instruction execution in accordance with an embodiment;
[0011] FIG. 4 illustrates a process flow for delaying instruction execution in accordance with an embodiment;
[0012] FIG. 5 illustrates a block diagram of a system that includes power management in accordance with an embodiment; and
[0013] FIG. 6 illustrates a process for rescheduling off-chip memory accesses in accordance with an embodiment.
DETAILED DESCRIPTION
[0014] Embodiments of the present invention relate to delaying non-critical instructions in order to increase power gating efficiency. In an embodiment, the issuance of ready instructions in an issue queue can be delayed when there are less than a specified number of ready instructions in the issue queue and when the ready instructions have been waiting for less than a specified maximum number of clock cycles. This can allow the idle period for the resource that executes the ready instructions to be elongated. In addition, pending requests to off-chip memory can be delayed and sent in bursts. In addition, data being sent through a pipeline can be grouped and non-critical data items delayed to take advantage of transparent clock gating (TCG).
[0015] Referring now to FIG. 1 , a block diagram of a computer system in accordance with embodiments is generally shown. The computer system includes a multiprocessor chip 102 , an accelerator chip 104 , and memory devices 114 . As used herein, the term “chip” refers to an integrated circuit, i.e., a set of electronic circuits on one small plate (chip) of semiconductor material (e.g., silicon). As shown in FIG. 1 , the multiprocessor chip 102 can include one or more cores 106 (also referred to as “core processors”) and corresponding level two (L2) caches 108 , one or more level three (L3) caches 110 , and one or more memory controllers 112 . The memory controller 112 can connect to the memory devices 114 and the accelerator chip 104 via one or more memory links. The multiprocessor chip 102 shown in FIG. 1 is a multi-core processor that is implemented by a single computing component with two or more independent actual central processing units (CPUs) (referred to as “cores 106 ” in FIG. 1 ). The cores 106 can include level one (L1) cache, and they can read and execute program instructions (e.g. via execution units). The instructions can include ordinary CPU instructions such as add, move data, and branch, but the multiple cores 106 can run multiple instructions at the same time, increasing overall speed for programs amenable to parallel processing. Embodiments described herein can be implemented by program instructions executing on the multiprocessor chip 102 .
[0016] As shown in FIG. 1 , the accelerator chip 104 can be implemented, for example, by a hybrid memory cube (HMC). The accelerator chip 104 can include memory controllers 112 that are connected, via memory links to memory devices 114 .
[0017] The memory devices 114 can be implemented by, but are not limited to: a combination of various types of computer readable storage media, such as a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, and the like, to store executable instructions and associated data.
[0018] Referring now to FIG. 2 , a sequence of activity bits 202 (each bit representing a clock cycle) of an execution unit, or unit, operating on a core 106 is generally shown. Examples of units include, but are not limited to: an arithmetic logic unit (ALU), a multiply/add-accumulate unit (MAAC), and a control unit (CU). The power gating potential of a unit depends on the idle interval size as well as the number of idle intervals. The sequence of activity bits 202 shown in FIG. 2 has three idle intervals. As shown in legend 206 , activity bits labeled “1” indicate active cycles and “0” indicate idle cycles. Assuming an overhead value of three cycles for activating a power gating mode (includes several overhead values, like for example, the activation of the header or footer transistor, among others), the unit can be power gated for up to six (calculated as (5−3)+(4−3)+(6−3)) cycles out of a total of fifteen idle cycles, thereby achieving a forty percent power gating potential (calculated as 6/15).
[0019] Also, in dealing with such small duration idle sequences, the performance overhead could be large. For example, if we assume a latency of one cycle to deactivate a power gating mode (Twakeup penalty), then there would be three additional cycles added to the execution time. This would represent a nine point four percent (calculated as 3/32) performance overhead. More power savings with less performance overhead could be achieved if the idle duration times were made longer.
[0020] An embodiment described herein increases the power gating potential of a unit by delaying the execution of non-critical operations. In the example shown in FIG. 2 , it is assumed that the “1s” that are contained in a circle are critical and cannot be delayed without impacting performance. It is also assumed that the “1s” that are not contained in a circle are not critical and could be delayed, for a short period, without impacting performance. In an embodiment, the operations can be grouped (e.g., by a compiler, by hardware issue logic) to achieve an execution profile such as that indicated by the modified sequence of activity bits 204 shown in FIG. 2 . In the modified sequence of activity bits 204 , the power gating interval is twelve cycles (calculated as (15−3)), with a three point one percent performance overhead (calculated as 1/32) assuming a Twakeup penalty of one cycle. This translates into a new PGE of eighty percent (calculated as 12/15) when three cycles are required each time the power gate is activated.
[0021] Also shown in FIG. 2 a sequence of activity bits 208 representing data items being sent to a pipeline within a unit (e.g., a MAAC) in a core 106 is generally shown. The TCG potential of a unit can depend on the idle interval size as well as the number of idle intervals. For example, the sequence of activity bits 208 shown in FIG. 2 has alternating idle and active intervals. A data item propagating through a normally clocked pipeline would require “S” clock cycles, where S is the number of pipeline stages. A data item “D1” propagating through a TCG pipeline is clocked only floor(S/c), where “c” is the number of cycles separating data item D1 from the next upstream data item “D2.” In sequence of activity bits 208 , where S=3, a normally clocked pipeline would require twenty-one clocks (calculated as 7 active bits multiplied by 3 stages) to be generated. In contrast, a TCG pipeline would require only twelve clocks (calculated as 4*floor(3/1)+2*floor(¾)+1*floor(¾)=12+0+0=12) to be generated. However, embodiments described herein can further improve the clocking in a TCG pipeline by altering the spacing between adjacent data items. As shown in sequence of activity bits 210 , the second, third, fifth, and sixth data items can each be delayed by one clock cycle. In this example, the normally clocked pipeline still requires twenty-one clocks, but the TCG pipeline now only requires six clocks (calculated as 6*floor(3/2)+1*floor(¾)=6+0=6) to be generated. By grouping and delaying some of the data items (thus rearranging the bubbles in the pipeline), for the sequence of activity bits 208 , the TCG pipeline can thus reduce its clocking requirements by fifty percent while still providing the same data throughput (note that the number of clock cycles between the first and last data item is not changed).
[0022] Turning now to FIG. 3 , a central processing unit that is configured to delay instruction execution is generally shown in accordance with an embodiment. Shown in FIG. 3 is a core 106 that includes a delay execution mechanism 304 , an issue queue 302 , and execution units 306 . In an embodiment, the delay execution mechanism 304 can be implemented at the instruction issue stage to: monitor the issue queue 302 and to enable/disable issuing; and to actuate clock/power gating when issuing is delayed. In addition, the delay execution mechanism 304 can communicate with the issue queue 302 to monitor a number of ready instructions in the issue queue 302 and an average age (e.g., average index of ready instruction) of the ready instructions in the issue queue 302 .
[0023] Turning now to FIG. 4 , a process flow for delaying instruction execution is generally shown in accordance with an embodiment. The processing shown in FIG. 4 can be implemented by the delay execution mechanism 304 executing on a core 106 such as, but not limited to a super scalar, out-of-order processor. As shown in FIG. 4 , an issue queue 302 feeds instructions to an execution unit 306 , and the number of ready instructions in the issue queue 302 as well as a wait time the issue queue 302 can be used as proxies to decide when to delay. The process starts at block 402 , with a mechanism located in, or accessed by, the issue queue 302 (e.g., the delay execution mechanism 304 ) keeping track of the number of ready instruction in the issue queue 302 . Ready instructions, as known in the art, are those instructions that are ready to be issued (e.g., all dependencies have been resolved). At block 404 it is determined whether the number of ready instructions in the issue queue 302 is less than a threshold number. If the number of ready instructions in the issue queue 302 is not less than the threshold number as determined at block 404 , the processing continues at block 410 where the issue queue 302 starts issuing the ready instructions to an execution unit 306 . It is determined, at block 412 , if the issue queue 302 is empty, if it is not empty, then processing continues at block 410 . In an embodiment the loop of blocks 410 - 412 can be continued until the issue queue 302 is empty. Once the issue queue 302 is empty, as determined at block 412 , processing can continue at block 404 . Thus, once the issue queue 302 starts to issue instructions it can continue until the issue queue 302 is empty.
[0024] In an embodiment, the threshold can be programmable and/or modified during system operation based on factors such as workload, performance, quality of service, and other metrics. When the number of ready instructions in the issue queue 302 reaches the threshold, the instructions can be issued to execution pipes in the execution units 306 . With this approach, the ready instructions will be clustered for execution instead of issuing independently in different times, thus possibly creating a long idle interval from execution unit point of view.
[0025] Still referring to FIG. 4 , if it is determined at block 404 , that the number of instructions in the issue queue 302 is less than the threshold number, then processing continues at block 406 . Block 406 is performed to mitigate possible performance losses due to critical instructions being in a ready status in the issue queue 302 . Critical instructions can be those which have several other instructions dependent on them that may get delayed for execution by waiting for the number of ready instructions in the issue queue 302 to reach the threshold number. These critical instructions can be identified by determining if any of the ready instructions in the issue queue 302 have been waiting longer than a maximum number of cycles reflected in a wait time threshold number. If it is determined, at block 406 , that any of the ready instructions have been waiting longer than the specified wait time threshold, then processing continues at block 410 , where the issue queue 302 begins to issue the ready instructions. If it is determined, at block 406 , that the ready instructions in the issue queue 302 have been waiting less than the maximum number of cycles, then processing continues at block 408 and the instructions continue to be held in the issue queue 302 . Processing continues at block 404 . Thus, the issue queue 302 does not start issuing the ready instructions until one of two things happen: a number of ready instructions in the issue queue 302 reaches the threshold number or a ready instruction has been in the issue queue 302 for longer than a maximum threshold number of clock cycles.
[0026] In an embodiment, the processing at block 410 can also include removing (or requesting removal of) power gating and/or clock gating from the execution unit 306 . In an embodiment, if it is determined at block 412 , that the issue queue 302 is empty, a power gate and/or clock gate is activated (or requested to be activated) for the execution unit 306 . As used herein the term power gating refers to using a header or footer transistor to cut off the power supply for the unit 306 to reduce both its dynamic and leakage power dissipation. As used herein the term clock gating refers to disabling the clock of unit 306 to reduce its dynamic power dissipation.
[0027] In an embodiment, block 406 of FIG. 4 can be skipped resulting in issuance decisions being made solely on a number of ready instructions in the issue queue 302 .
[0028] In an embodiment, the processing shown in FIG. 4 is performed for each execution unit 306 connected to the issue queue 302 and the processing takes into account a target execution unit 306 and keeps track of counts and wait times for different execution units separately 306 . Thus, instructions may be issued from the issue queue 302 for one execution unit 306 while being held for another execution unit 306 . In addition, different thresholds may be utilized for the different execution units.
[0029] Similar to the power gating example shown above, there are several techniques to delay execution for TCG. The concept and techniques are the same both for power gating and TCG, with the only difference being that the algorithms are tuned to separating the instructions in the TCG case, rather than clustering the instructions as in the power gating case. For example, an embodiment of a technique can use information from an issue queue 302 in an out-of-order processor to delay execution of instructions based on a power/performance tradeoff. For example, when a non-critical instruction is ready to issue the cycle after another instruction has been issued, the non-critical instruction can be delayed by one or more cycles.
[0030] Another technique utilized by embodiments is to distribute instructions to different units in a round-robin fashion when there are not enough instructions ready to issue to fill up all units so that additional bubbles are created.
[0031] In another embodiment, for cache pre-fetch engines, delays can be inserted between sequential pre-fetches to create bubbles in the pre-fetch and cache/memory pipelines without much impact to performance. In in-order or very long instruction word (VLIW) machines, the compiler can group instructions based on criticality information such that units will see more bubbles. Compilers may be able to achieve this to some degree even in out of order execution machines. In low power modes of operation or power emergencies, bubbles can also be inserted more judiciously even between critical instructions.
[0032] Referring now to FIG. 5 , a block diagram of a computer system that includes power management in accordance with an embodiment is generally shown. The computer system includes a multiprocessor chip 502 and memory devices 516 . As shown in FIG. 5 , the multiprocessor chip 502 can include a power management controller (PMC) 504 , one or more cores 508 (also referred to as “core processors”) and corresponding L2 caches 510 , one or more L3 caches 512 , and one or more memory controllers 514 . The memory controller 414 can connect to the memory devices 516 via one or more memory links. Embodiments described herein can be implemented by program instructions executing on the multiprocessor chip 102 . The PMC 504 shown in FIG. 5 is connected to the cores and can send power savings mode instructions to the cores 508 . In addition, the PMC 504 shown in FIG. 5 is connected to the power controllers 506 located in the memory controller 514 for receiving power management data.
[0033] In an embodiment, the power controllers 506 in the memory controllers 514 can include computer instructions to delay off-chip requests to memory devices 516 . The power controllers 506 can send pending requests in bursts, and when a power controller 506 initiates a burst it can notify the PMC 504 . The PMC 504 can then decide to activate a core-level power savings mode such as, but not limited to dynamic voltage and frequency scaling (DVFS) and per-core power gating (PCPG). In addition, the power controllers 506 can notify the PMC 504 when memory responses begin to arrive to allow the PMC 504 to begin a wake-up process for the cores 508 in advance.
[0034] Referring now to FIG. 6 , a process for rescheduling off-chip memory accesses to increase low-activity periods at the core level is generally shown in accordance with an embodiment. Processing starts at block 602 and then moves to block 604 where it is determined whether a queue associated with a memory controller 514 has been empty for more than a threshold number of cycles, “T IDLE”. Block 604 continues to be performed until it is determined that the memory controller queue (MCQ) has been empty for more than the threshold number of cycles. Once this is determined, processing continues at block 606 where a link power savings mode is initiated for memory links associated with the memory controller 514 . In addition, the associated memory devices 516 can also be notified that nothing will be sent so that the memory devices 516 can enter a power savings mode. At block 608 , it is determined whether the size (number of entries) of the MCQ is greater than a threshold size, “T_SIZE.” If a number of entries in the MCQ are not greater than the threshold, then block 620 is performed to determine whether a time since the last burst to the memory devices 516 is more than a threshold, “T_TIMER.” If the number of entries in MCQ is not greater than the threshold T_SIZE and the time since the last burst is not greater than the threshold T_TIMER, then processing continues at block 608 to continue to test these two values. If either the number of entries in MCQ is greater than the threshold T_SIZE as determined at block 608 or the time since the last burst is greater than the threshold T_TIMER as determined at block 620 , the processing continues at block 610 . At block 610 , the links between the memory controller 514 and the memory devices 516 are activated. Next, block 612 is performed and the PMC 504 is notified that the links are being activated. In an alternate embodiment, block 612 is skipped and the PMC 504 is not notified of the links being activated.
[0035] Processing continues at blocks 614 - 616 where all of the contents (requests) of the MCQ are sent to the off-chip memory devices 516 for processing. Once MCQ is empty, processing continues at block 618 where the time is cleared and processing continues at block 604 .
[0036] Technical effects and benefits include delaying non-critical instruction execution at the pipeline level which can lead to reduced power at the execution units. In addition, rescheduling off-chip accesses to increase low-activity periods at the core level can lead to reduced power at the cores, caches and interconnections.
[0037] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
[0038] 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 act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
[0039] The present invention may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.
[0040] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.
[0041] Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device.
[0042] Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention.
[0043] Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions.
[0044] These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.
[0045] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0046] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.
[0047] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
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Embodiments relate to storing data in memory. An aspect includes applying a power savings technique to at least a subset of a processor. Pending work items scheduled to be executed by the processor are monitored. The pending work items are grouped based on the power savings technique. The grouping includes delaying a scheduled execution time of at least one of the pending work items to increase an overall number of clock cycles that the power savings technique is applied to the processor. It is determined that an execution criteria has been met. The pending work items are executed based on the execution criteria being met and the grouping.
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FIELD OF INVENTION
This application is a continuation of 13/177,458, filed Jul. 6, 2011, now U.S. Pat. No. 8,455,423, which is a divisional of 11/920,787, filed Nov. 20, 2007, now abandoned.
The invention concerns the use of bleaching solutions.
BACKGROUND OF THE INVENTION
Raw cotton (gin output) is dark brown in colour due to the natural pigment in the plant. The cotton and textile industries recognise a need for bleaching cotton prior to its use in textiles and other areas. The object of bleaching such cotton fibres is to remove natural and adventitious impurities with the concurrent production of substantially whiter material.
There have been two major types of bleach used in the cotton industry. One type is a dilute alkali or alkaline earth metal hypochlorite solution. The second type of bleach is a peroxide solution, e.g., hydrogen peroxide solutions. This bleaching process is typically applied at high temperatures, i.e. 80 to 95° C. Controlling the peroxide decomposition due to trace metals is key to successfully using hydrogen peroxide. Often Mg-silicates or sequestering agents such as EDTA or analogous phosphonates are applied to reduce decomposition. A problem with the above types of treatment is that the cotton fibre is susceptible tendering.
Wood pulp produced for paper manufacture either contains most of the originally present lignin and is then called mechanical pulp or it has been chiefly delignified, as in chemical pulp. Mechanical pulp is used for e.g. newsprint and is often more yellow than paper produced from chemical pulp (such as for copy paper or book-print paper). Further, paper produced from mechanical pulp is prone to yellowing due to light- or temperature-induced oxidation. Whilst for mechanical pulp production mild bleaching processes are applied, to produce chemical pulp having a high whiteness, various bleaching and delignification processes are applied. Widely applied bleaches include elemental chlorine, hydrogen peroxide, chlorine dioxide and ozone.
Whilst for both textile bleaching and wood pulp bleaching, chlorine-based bleaches are most effective, there is a need to apply oxygen-based bleaches for environmental reasons. Hydrogen peroxide is a good bleaching agent, however, it needs to be applied at high temperatures and long reaction times. For industry it is desirable to be able to apply hydrogen peroxide at lower temperatures and shorter reaction times than in current processes. Towards this end, the use of highly active bleaching catalysts would be desirable.
As a particular class of active catalysts, the azacyclic molecules have been known for several decades, and their complexation chemistry with a large variety of metal ions has been studied thoroughly. The azacyclic molecules often lead to transition-metal complexes with enhanced thermodynamic and kinetic stability with respect to metal ion dissociation, compared to their open-chain analogues.
United States Application 2001/0025695, discloses the use of a manganese transition metal catalyst of 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN); the transition metal catalyst has as a non-coordinating counter ion PF 6 − . United States Application 2001/0025695A1 also discloses a manganese transition metal catalyst of 1,2-bis-(4,7-dimethyl-1,4,7-triazacyclonon-1-yl)-ethane (Me 4 -DTNE); the transition metal catalyst has as a non-coordinating counter ion ClO 4 − . The solubility, in water at 20° C., of the Me4-DTNE complex having non-coordinating counter ion ClO 4 − is about 16 gram/Liter. The solubility, in water at 20° C., of the Me4-DTNE complex having non-coordinating counter ion PF 6 − is about 1 gram/Liter.
US 2002/0066542 discloses the use of a manganese transition metal complex of Me 3 -TACN in comparative experiments and makes reference to WO 97/44520 with regard to the complex; the non-coordinating counter ion of the manganese transition metal complex of Me 3 -TACN is PF 6 − . The X groups as listed in paragraph [021] of US 2002/0066542 are coordinating.
EP 0458397 discloses the use of a manganese transition metal complex of Me 3 -TACN as bleaching and oxidation catalysts and use for paper/pulp bleaching and textile bleaching processes. Me 3 -TACN complexes having the non-coordinating counter ion perchlorate, tetraphenyl borate (BPh 4 − ) and PF 6 − are disclosed. The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion ClO 4 − is between 9.5 to 10 gram/Liter. The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion BPh 4 − is less then 0.01 gram/Liter.
WO 95/27773 discloses the use of manganese transition metal catalysts of 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN); the transition metal catalysts have as a non-coordinating counter ion ClO 4 − and PF 6 − .
1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN) has been used in dishwashing for automatic dishwashers, SUN™, and has also been used in a laundry detergent composition, OMO Power™. The ligand (Me 3 -TACN) is used in the form of its manganese transition-metal complex, the complex having a counter ion that prevents deliquescence of the complex. The counter ion for the commercialised products containing manganese Me 3 -TACN is PF 6 − . The Me 3 -TACN PF 6 − salt has a water solubility of 10.8 g per liter at 20° C. Additionally, the perchlorate (ClO 4 − ) counter ion is acceptable from this point of view because of its ability to provide a manganese Me3-TACN that does not appreciably absorb water. Reference is made to U.S. Pat. No. 5,256,779 and EP 458397, both of which are in the name of Unilever. One advantage of the PF 6 − or ClO 4 − counter ions for the manganese Me 3 -TACN complex is that the complex may be easily purified by crystallisation and recrystallisation from water. In addition, for example, the non-deliquescent PF 6 − salt permits processing, e.g., milling of the crystals, and storage of a product containing the manganese Me 3 -TACN. Further, these anions provide for storage-stable metal complexes. For ease of synthesis of manganese Me 3 -TACN highly deliquescent water soluble counterions are used, but these counterions are replaced with non-deliquescent, much less water soluble counter ions at the end of the synthesis. During this exchange of counter ion and purification by crystallisation loss of product results. A drawback of using PF 6 − is its significant higher cost compared to other highly soluble anions.
U.S. Pat. Nos. 5,516,738 and 5,329,024 disclose the use of a manganese transition metal catalyst of 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN) for epoxidizing olefins; the transition metal catalyst has as a non-coordinating counter ion ClO 4 − . U.S. Pat. No. 5,329,024 also discloses the use of the free Me 3 -TACN ligand together with manganese chloride in epoxidizing olefins.
WO 2002/088063, to Lonza AG, discloses a process for the production of ketones using PF 6 − salts of manganese Me 3 -TACN.
WO 2005/033070, to BASF, discloses the addition of an aqueous solution of Mn(II)acetate to an aqueous solution of Me 3 -TACN followed by addition of a organic substrate followed by addition of hydrogen peroxide.
Use of a water-soluble salt negates purification and provides a solution, which may be used directly, and reduces loss by purification.
SUMMARY OF INVENTION
We have found that there is an advantage in using a preformed transition metal complex of azacyclic molecules over in situ generation, for example by mixing the appropriate ligand with the MnCl 2 , MnSO 4 or Mn(OAc) 2 salts in an industrial process. Further, the addition of one product to a reaction vessel reduces errors in operation.
We have found that for certain applications the use of a highly water-soluble salt of the manganese azacyclic complex is preferable. We have found that the dominant factor in the solubility of these transition metal complexes is the non-coordinating counter ion(s). In the solubilities given herein for (Me 3 -TACN) the co-ordinating counter ions are three O 2− and for Me 4 -DTNE the co-ordinating counter ions are two O 2− and one acetate.
The invention is particularly applicable to industrial bleaching of paper/pulp, cotton-textile fibres, and the removal or degradation of starches. By using a transition metal catalyst that is significantly water soluble the synthesis negates the preparation of significantly water insoluble salts and hence reduces cost. The transition metal catalyst may be shipped in solution or as a solid form of transition metal catalyst which is easily dissolved in water.
In order to avoid the use of costly non-coordinating counter ions required for isolation, formulation and stabilisation, one might form the transition metal catalyst in situ. U.S. Pat. No. 5,516,738 discloses the use of free Me 3 -TACN ligand with Mn(II)Cl 2 in epoxidizing olefins. However the in situ preparation has some drawbacks, for example, it is a more complicated process and uncontrolled side reactions occur which result in less efficient formation of the catalyst and undesirable side products like MnO 2 . Fast decomposition of hydrogen peroxide, catalysed by some of the undesirable side products might occur, reducing the efficiency of the bleach process.
In one embodiment the present invention provides a method of catalytically treating a substrate, the substrate being a cellulose-containing substrate or starch containing substrate, with a preformed transition metal catalyst salt, the preformed transition metal catalyst salt having a non-coordinating counter ion, the method comprising the following steps:
(i) optionally dissolving a concentrate or solid form of a preformed transition metal catalyst salt in an aqueous medium to yield an aqueous solution of the preformed transition metal catalyst salt; (ii) adding the aqueous solution of the preformed transition metal catalyst salt to a reaction vessel; and, (iii) adding hydrogen peroxide to the reaction vessel,
wherein the preformed transition metal catalyst salt is a mononuclear or dinuclear complex of a Mn (III) or Mn(IV) transition metal catalyst for catalytically treating the substrate with hydrogen peroxide, the non-coordinating counter ion of said transition metal selected to provide a preformed transition metal catalyst salt that has a water solubility of at least 30 g/l at 20° C. and wherein the ligand of the transition metal catalyst is of formula (I):
wherein:
p is 3;
R is independently selected from: hydrogen, C1-C6-alkyl, CH 2 CH 2 OH, and CH 2 COOH, or one of R is linked to the N of another Q via an ethylene bridge;
R1, R2, R3, and R4 are independently selected from: H, C1-C4-alkyl, and C1-C4-alkylhydroxy, and the substrate is bought into contact with a mixture of the aqueous solution of the preformed transition metal catalyst salt and the hydrogen peroxide. The dinuclear complex may have two manganese in same or differing oxidation states.
R is preferably C1-C6-alkyl, most preferably Me, and/or one of R is an ethylene bridge linking the N of Q to the N of another Q.
The reaction vessel may be part of a continuous flow apparatus or a vessel used in a batch process. Preferably pulp and cotton are treated in a continuous flow process. Steps (ii) and (iii) provide a mixture of the aqueous solution of the preformed transition metal catalyst salt and the hydrogen peroxide; the substrate is bought into contact with this mixture and hence is treated with such within the reaction vessel.
The preformed transition metal catalyst salt is one which has been provided by bringing into contact the free ligand or protonated salt of the free ligand and a manganese salt in solution followed by oxidation to form a Mn (III) or Mn(IV) transition metal catalyst. Preferred protonated salts of the ligand are chloride, acetate, sulphate, and nitrate. The protonated salts should not have undesirable counterions such as perchlorate or PF 6 − . The contact and oxidation step is preferably carried out in an aqueous medium, at least 24 hours before use, preferably at least 7 days before use.
The rate of formation of the transition metal catalyst depends upon the ligand. The formation of a transition metal catalyst from Me 3 -TACN ligand is typically complete within 5 min. The formation of a transition metal catalyst from Me 4 -DTNE ligand requires about 20 to 30 min for optimal complexation. After complex formation an aqueous solution of H 2 O 2 /NaOH may be slowly added to form a desired Mn(IV)/Mn(IV) or Mn(IV)/Mn(III) species. This second step, the oxidation step, provides a sufficiently stable complex for storage.
In another aspect the present invention provides the preformed transition metal catalyst salt as defined herein, wherein the preformed transition metal catalyst salt has been formed by a contact and oxidation step that is carried out at least 24 hours previously, preferably 7 days previously, and is stored in a closed, preferably sealed, container.
The present invention also extends to the substrate treated with preformed transition metal catalyst and hydrogen peroxide.
DETAILED DESCRIPTION OF THE INVENTION
The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion acetate is more than 70 gram/Liter. The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion sulphate is more than 50 gram/Liter. The solubility, in water at 20° C., of the Me 3 -TACN complex having non-coordinating counter ion chloride is 43 gram/Liter. It is most preferred the preformed transition metal catalyst salt is a dinuclear Mn(III) or Mn(IV) complex with at least two O 2− bridges.
The method of treating paper/pulp, cotton-textile fibres, or starch containing substrate is most applicable to industrial processes. Other examples of such processes are laundry or mechanical dish washing applications, fine chemical synthesis. Most preferably the method is applied to wood pulp, raw cotton, or industrial laundering. In this regard, the wood pulp is bleached which has not been processes into a refined product such as paper. The raw cotton is in most cases treated/bleached after preparation of the raw cotton cloths or bundled fibres. Preferably the method of treatment is employed in an aqueous environment such that the liquid phase of the aqueous environment is at least 80 wt % water, more preferably at least 90 wt % water and even more preferably at least 95 wt % water. After treatment of the substrate the reactants may be recycled back into the reaction vessel.
In addition, poly-cotton may also advantageously be treated in the form of a thread or a woven garment. Another preferred utility is in the industrial bleaching market of laundry, for example, the bleaching of large amounts of soiled white bed linen as generated by hospitals and gaols.
Preferably R is independently selected from: hydrogen, CH 3 , C 2 H 5 , CH 2 CH 2 OH and CH 2 COOH; least preferred of this group is hydrogen. Most preferably R is Me and/or one of R is an ethylene bridge linking the N of Q to the N of another Q. Preferably R1, R2, R3, and R4 are independently selected from: H and Me. Preferred ligands are 1,4,7-Trimethyl-1,4,7-triazacyclononane (Me 3 -TACN) and 1,2-bis-(4,7-dimethyl-1,4,7-triazacyclonon-1-yl)-ethane (Me 4 -DTNE) of which Me 3 -TACN is most preferred. The manganese ion is most preferably Mn(III) or Mn(IV), most preferably Mn(IV).
The water solubility of the preformed transition metal catalyst salt is at least 30 g/l at 20° C., more preferably at least 50 g/l at 20° C. Even more preferably the water solubility of the preformed transition metal catalyst salt is at least 70 g/l at 20° C. and most preferably the salt is deliquescent. The high solubility provides for concentrates whilst avoiding precipitation or crystallisation of the preformed transition metal catalyst salt. The preformed transition metal catalyst salt (cationic) used in the method is most preferably a single species. In this regard, the aqueous solution used comprises at least 90% of a single species. The non-coordinating counter ions may, for example, be a mixture of acetate and chloride.
The non-coordinating anion of the transition metal catalyst salt is preferably selected from the group consisting of chloride, acetate, sulphate, and nitrate. Most preferably the salt is acetate. The salt is other than the perchlorate.
Co-ordinating counter ions for the transition metal complexes are O 2− and/or carboxylate (preferably acetate). It is preferred that the transition metal complexes have at least one O 2− co-ordinating counter ion. In particular, for Me 3 -TACN three O 2− co-ordinating counter ions are preferred or one O 2− co-ordinating counter ion and two carboxylate co-ordinating counter ions are preferred, with two acetate moieties as co-ordinating counter ions being most preferred. For Me 4 -DTNE two O 2− co-ordinating counter ions and one acetate co-ordinating counter ion are preferred.
It is preferred that the transition metal catalyst salt is present in a buffer system that maintains the solution in the pH range 2 to 7, and preferably in the pH range 4 to 6. The buffer systems is preferably phosphate or carboxylate containing buffers, e.g., acetate, benzoate, citrate. The buffer system most preferably keeps the transition metal catalyst salt in the range pH 4.5 to 5.5.
The catalyst solution may also be provided in a reduced volume form such that it is in a concentrate, solid or slurry which is then dispatched to its place of use. Removal of solvent is preferably done by reduced pressure rather than the elevation of temperature. Preferably the solution, solid or slurry is stored over an inert atmosphere, e.g., nitrogen or argon, with little or no headspace at 4° C. For storage purposes a preformed transition metal catalyst salt concentration range of 0.1 to 10% is desirable, more desirable is between 0.5 and 8%, and most desirable is between 0.5 and 2%. The concentrate or solid or solid most preferably has the pH means as described above before reduction of water volume.
In the bleaching process it is preferred that the substrate is contacted with between from 0.1 to 100 micromolar of the preformed transition metal catalyst and from 5 to 1500 mM of hydrogen peroxide.
Preferably the preformed transition metal catalyst salt and hydrogen peroxide are mixed just before introduction to the substrate.
EXPERIMENTAL
Examples on the syntheses of Mn 2 O 3 (Me 3 -TACN) 2 complexes with different anions are provided. Synthesis of the Mn 2 O 3 (Me 3 -TACN) 2 PF 6 salt is disclosed in U.S. Pat. No. 5,153,161, U.S. Pat. No. 5,256,779, and U.S. Pat. No. 5,274,147. The solubility of the Mn 2 O 3 (Me 3 -TACN) 2 PF 6 salt in water at 20° C. is 1.08% (w/w).
Preparation of Aqueous Solution of [Mn 2 O 3 (Me 3 -TACN) 2 ].(Cl) 2
To 10 mmol (1.71 gram Me 3 -TACN in 10 ml water was added 10 mmol (1.98 gram) solid MnCl 2 .4H 2 O while stirring under nitrogen flow. The mixture turned white/bluish. After 5 minutes stirring a freshly prepared mixture of 10 ml 1 M hydrogen peroxide and 2 ml of 5 M (20%) NaOH was added drop-wise over 5 minutes. The mixture turned immediately dark brown/red. At the end of the addition some gas evolution was observed. After completion of the addition the nitrogen flow was stopped and the stirring was continued for 5 minutes and pH was set with to neutral/acidic (pH 5 paper) with 1 M hydrochloric acid. The mixture was filtered through G4 glass frit, washed with water and the collected red filtrate and wash diluted to 50.00 ml in a graduated flask. From this solution a 1000× dilution was made and from the absorbtion in the UV/Vis spectrum at 244, 278, 313, 389 and 483 nm the concentration in the stock was calculated and the yield (based on extinction of the PF 6 analogue in water) Extinction of 1000× diluted sample gave
244 nm
1.692
278 nm
1.619
313 nm
1.058
389 nm
0.108
485 nm
0.044
Calculated yield 91%, solution contains 5.2% (on weight basis) of the catalyst.
Preparation of Aqueous Solution of [of [Mn 2 O 3 (Me 3 -TACN) 2 ].(OAc) 2
To 10 mmol (1.71 gram Me 3 -TACN in 10 ml water was added 10 mmol (2.47 gram) solid MnCl 2 .4H 2 O while stirring under nitrogen flow. The mixture turned to a bluish solution. After 5 minutes stirring a freshly prepared mixture of 10 ml 1 M hydrogen peroxide and 2 ml of 5 M (20%) NaOH was added drop-wise over 5 minutes. The mixture turned immediately dark brown/red. At the end of the addition some gas evolution was observed. After completion of the addition the nitrogen flow was stopped and the stirring was continued for 5 minutes and pH was set with to neutral/acidic (pH 5 paper) with 1 M acetic acid. The mixture was filtered through a G4 glass frit, washed with water and the collected red filtrate and wash diluted to 50.00 ml in a graduated flask. From this solution a 1000× dilution was made and from the absorption in the UV/Vis spectrum at 244, 278, 313, 389 and 483 nm the concentration in the stock was calculated and the yield (based on extinction of the PF 6 analogue in water)
244 nm
1.689
278 nm
1.626
313 nm
1.074
389 nm
0.124
485 nm
0.051
Calculated yield 88%; solution contains 5.2% (on weight basis) of the catalyst.
Preparation of Aqueous Solution of [Mn 2 O 3 (Me 3 -TACN) 2 ].SO 4
To 10 mmol (1.7 gram Me 3 -TACN in 10 ml water was added 10 mmol (1.98 gram) solid MnCl 2 .4H 2 O while stirring under nitrogen flow. The mixture turned to a white suspension. After 5 minutes stirring a freshly prepared mixture of 10 ml 1 M hydrogen peroxide and 2 ml of 5 M (20%) NaOH was added drop-wise over 5 minutes. The mixture turned immediately dark brown/red. At the end of the addition some gas evolution was observed. After completion of the addition the nitrogen flow was stopped and the stirring was continued for 5 minutes and pH was set with to neutral/acidic (pH 5 paper) with 1 M sulphuric acid. The mixture was filtered through a G4 glass frit, washed with water and the collected red filtrate and wash diluted to 50.00 ml in a graduated flask. From this solution a 1000× dilution was made and from the absorption in the UV/Vis spectrum at 244, 278, 313, 389 and 483 nm the concentration in the stock was calculated and the yield (based on extinction of PF 6 analogue in water)
244 nm
1.648
278 nm
1.572
313 nm
1.022
389 nm
0.103
485 nm
0.042
Calculated yield 98%; solution contains 5.2% (on weight basis) of the catalyst.
Stability Experiments
Stability of aqueous solutions of chloride, sulphate and acetate salts are provided. Solutions of the bleach catalyst with chloride, sulphate and acetate anion were brought to pH 2, 3, 4 and 5 by hydrochloric acid, sulphuric acid and acetic acid respectively. For the acetate this could only give pH 5. For the lower pH values sulphuric acid was used in the case of acetate. The solutions were kept at 37° C. and after 2 weeks the stability was monitored from the absorptions in the UV/Vis spectra of 1000× diluted solutions.
2 week results at 37° C.
pH 2
pH 3
pH 4
pH 5
Chloride
% (UV/Vis)
100
100
97
94
(Precipitate is formed at all pH's)
Acetate
% (UV/Vis)
87
91
93
95
(No precipitate is formed)
Sulphate
% (UV/Vis)
78
96
94
98
(Precipitate only at pH = 5)
For the two weeks results it is clear within experimental error (ca 5%) at pH 3 and higher no instability issue occurs.
Softwood chemical mill pulp obtained after the D0 bleaching stage (abbreviated as softwood D0 pulp) was used. The bleaching experiments were conducted on small scale in 100 ml vessels using the pulps at 5% consistency (i.e., 5% oven dry wood pulp; 95% aqueous bleaching liquor). The mixture contained 2.5 microM of the catalyst (as chloride, sulfate, acetate and PF 6 salts—see Table), 1 kg/t of MgSO 4 , 8 kg/t of NaOH and 10 kg/t of H 2 O 2 (kg/t: kg chemicals per ton oven dry pulp). The mixture was manually stirred to ensure good distribution of the bleaching chemicals. Then the vessel was placed in a water bath and stirred regularly at 50° C. for 1 h. All experiments were carried out at least 6 times. As a reference the experiment was conducted without catalyst. The dosages and exact reaction conditions are given in the sections below. After the allocated bleaching times the pulp batches were removed from the vessels, filtered using a Buchner funnel, and washed with 100 ml of water. From the resultant samples of bleached pulp 4×4 cm discs were made having a flat surface on one side. The softwood D0 pulp samples were dried using a L&W Rapid Dryer (Lorentzen and Wetter) at 90° C. for 20 minutes. Whiteness of the bleached pulps was determined using L, a*, b* values as defined by CIE (Commission Internationale de l'Eclairage) of the dried pad was measured using a Minolta spectrophotometer.
Results (all whiteness values show a standard deviation of 0.3 points.
Complex
Whiteness
[Mn 2 O 3 (Me 3 —TACN) 2 ]•(PF 6 ) 2
84.4
comparative example
[Mn 2 O 3 (Me 3 —TACN) 2 ]•Cl 2
84.3
[Mn 2 O 3 (Me 3 —TACN) 2 ]•(OAc) 2
84.0
[Mn 2 O 3 (Me 3 —TACN) 2 ]•SO 4
84.1
Blank (only H 2 O 2 )
77.0
The data presented in the table show clearly that the bleaching effect is the same for all different catalyst-salt complexes.
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The present invention concerns bleaching of substrates with an aqueous solution of a water soluble salt of a preformed transition metal catalyst together with hydrogen peroxide.
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This application is a continuation in part of U.S. patent application Ser. No. 12/050,789 filed Mar. 18, 2008.
BACKGROUND
1. Field of the Invention
The invention relates to helical textiles.
2. Description of the Related Art
One of the primary purposes of helical or spiral shaped material is to reinforce a composite material. Therefore, the fiber selection, fiber orientation and other features of the textile material must be considered to maximize the effectiveness of the textile material as a reinforcement to the final product.
Others have described woven helical fabrics, such as that disclosed in U.S. Pat. No. 5,222,866 that was issued to LaBrouche et al. on Jun. 29, 1993, and which is not admitted to being prior art by its mention in this Background section (the '866 patent). In the '866 patent the yarns in the warp (circumferential direction of the spiral) and yarns in the weft (radial direction of the spiral) are interlaced in the manner used with traditional weaving processes and typical weave designs, such as plain weave, satin weave, and basket weave.
One example is shown in FIG. 1 . The interlacings produced in the weaving process are necessary to hold the fabric together, and result in a lack of straightness in the yarns in either or both of the warp or weft directions called crimp. Crimp is introduced at fiber interlacings as illustrated in 106 a through 106 e between warp yarns 102 and weft yarns 104 . The crimp reduces the efficiency of the fibers to translate their properties to the ultimate composite structure or textile material.
Knitting processes can be divided into two categories: warp knitting and weft knitting. Weft knitting results in a textile structure where the yarns are interlocked to adjacent yarns resulting in very tortuous fiber paths. This does not allow for effective reinforcement for high performance composites.
What is needed, therefore, is a helical textile for reinforcing composite materials that does not crimp the fibers, but has uniform thickness, and process for making the same.
SUMMARY
The invention is a helical textile that does not have interlaced warp and weft fibers yet has uniform thickness for reinforcing composite materials. The invention is a warp knit helical textile having a repeating pattern of weft fibers of varying lengths such that the overall textile has a uniform thickness. The warp layers and weft layers are secured with non-reinforcing knitted stitches. The process of making the same includes a warp knitting machine modified to have conical take-up rolls and a means for inserting the repeating pattern of weft fibers of varying lengths. These and other features, advantages, and benefits of the present invention will become more apparent with reference to the appended drawings, description, and claims.
DRAWINGS
FIG. 1 is a side elevation of a textile of the prior art.
FIG. 2 is a side elevation of a textile according to the present invention.
FIG. 3 is an orthogonal view of a take-up roll and textile of the prior art.
FIG. 4 is an orthogonal view of a take-up roll and textile of the present invention.
FIG. 5 is a plan view of a helical textile having a uniform length of weft fibers.
FIG. 6 is a plan view of a helical textile according to the present invention having uniform thickness.
FIG. 7 is a plan view of another embodiment of a helical textile having a single weft yarn and is made using three weft insertion devices.
FIG. 8 is a graph of how the prior art weft volume fraction increases from OD to ID.
FIG. 9 is graph showing weft fiber volume fraction according to the present invention.
FIG. 10 is a perspective view of a weft section of non-uniform thickness.
FIG. 11 is a cross section view of a textile having the weft section of FIG. 10 and warp fiber bundles having uniform width and varying height.
FIG. 12 is a cross section view of a textile having the weft section of FIG. 10 and warp fiber bundles having width varying inversely with height.
FIG. 13 is a plan view of a weft fiber layer embodiment having three weft fiber bundles at discreet radial distances between the textile ID and OD, and where the spacing between the bundles is constant.
FIG. 14 is a plan view of a weft fiber layer embodiment having three weft fiber bundles at discreet radial distances between the textile ID and OD, and where the spacing between the bundles decreases from OD to ID.
DESCRIPTION
The invention is a warp knit helical textile having a repeating pattern of weft fibers of varying lengths such that the overall textile has a substantially uniform thickness and more consistent warp to weft fiber distribution from ID to OD. Warp knitting uses manufacturing methods to orient the fibers in layers that are not interlaced. Rather, warp and weft fibers are constructed in discrete layers, one above the other.
The warp and weft fibers, in their respective layers, are straight, not crimped, and are parallel to adjacent fibers in the same layer. Turning to FIG. 2 , warp fibers 102 and those next to it are shown in cross section, and are interpreted as coming out of the page. The warp fibers 102 are in the circumferential direction, and are circumferentially parallel to each other. The weft fibers 104 are in the radial direction, and are radially parallel to each other. Unlike the prior art, no interlacing between warp fiber layer and weft fiber layers are needed. The warp fibers 102 and weft fibers 104 are secured to each other or bound together with a third fiber direction. This third direction is inserted with knitted stitches 108 . This third direction is not generally considered as a third reinforcing direction and is usually a non-reinforcing yarn type and in very low concentration compared to the warp and weft. The purpose of the knitted yarn is to hold the warp and weft layers together and to avoid the need to interlace the warp and weft. This third direction of yarn does not equate the resulting textile product to a three dimensional textile material since the resulting material described here is a single layer of knitted textile material. Contrast this to three dimensional weaving techniques that are used to manufacture multilayered textile materials.
The process of manufacturing the helical textile material utilizes modified warp knitting machinery. The modifications that are introduced are necessary to accommodate two issues: the take-up means to introduce the helical shape, and the weave design to accommodate the varying geometry of the textile structure from the inside diameter (“ID”) to the outside diameter (“OD”) of the helical material produced. In the present invention it is desired that the resulting material have an as constant as practical ratio of warp to weft fibers from ID to OD. This requires that the weft end count at the OD be higher than at the ID.
A warp knitting machine 120 of the prior art is shown in FIG. 3 . The knitting machine 120 has a cylindrical take-up roll 116 and produces a straight woven textile 114 . The warp knitting machine other than the take-up roll is shown as a black box in this drawing.
To make the helical textile 100 of the present invention, a warp knitting machine 122 is modified so that the cylindrical take-up rolls are replaced by conical take-up rolls 118 as shown in FIG. 4 . The warp knitting machine is also shown as a black box in this drawing. The angle of the conical roll or rolls is designed to produce the desired ID and OD ratio of the resulting helical textile material 100 . In this manner, the usual machine features necessary to adjust the take-up speed and such are maintained. A similar result is possible with a take-up mechanism that is a separate device from the knitting machine such that the material being knitted avoids the normal cylindrical take-up rolls. This separate device is controlled with mechanisms or electronic controls or both activated by features such as cams on the knitting machine.
The ratio of warp to weft fibers will depend on the particular final application of the composite structure. Most applications envisioned will require an as uniform as practical ratio of warp to weft from ID to OD regardless of what that ratio is. This requires that not all weft (radial) fibers continue from OD to ID. For example, if we assume that the full width weft fiber length for a particular design was intended to be three inches, in a straight weave, all weft fibers would be three inches long. If in the same example but with a helical textile as shown in FIG. 5 , and the weft fibers 104 are all three inches long, the spacing between adjacent weft fibers would be greater at the OD than at the ID. Therefore the weft fiber density near the ID would be greater than the OD and the thickness of the fabric near the ID would be greater than the OD. This would lead to non-uniform properties, which are undesirable.
This can be improved by introducing weft fibers 104 of less than three inch length, as shown in FIG. 6 . The intent is to make the final textile material as uniform as practical from OD to ID. The weft fibers will have one end at the OD of the textile, and the other end will proceed to some predetermined location part way from the OD to ID and then terminate or return towards the OD. If individual weft fibers were inserted, then they would terminate. If a continuous weft fiber were inserted, then it would bend and return towards the OD.
In a helical textile, the repeating sequence of weft fiber insertions might be three inches 104 a , one inch 104 b , two inches 104 c , one inch 104 b , and finally three inches again 104 a . This would allow more constant ratio of warp to weft from OD to ID. This also translates to a more constant thickness of the knitted material 100 across the width from ID to OD. It is understood that this is only an example of the different lengths of weft that can be used. A more uniform fabric can be made by increasing the number of different weft lengths, until it is no longer cost effective. The embodiment shown in FIG. 6 uses one weft insertion device.
More complex patterns having a single weft yarn of different lengths instead of pairs is shown in FIG. 7 . In this embodiment, three weft insertion devices are required.
The length of the weft insertion, also referred to as the shot or throw direction in knitting, can be controlled with cams, pins, knuckles, or electronically, depending on the style and age of the knitting machine used. The level of control generally available in all machines of this type is such that each weft insertion (shot or throw) can be tailored to be of different length. The combination, therefore, of variable length weft insertion and conical take-up will produce the material intended.
The helical fabric of the present invention has been said to have a “more constant” thickness than that of the prior art. The thickness of a single layer of fabric is not perfectly uniform or constant, but varies by the width of a weft fibers and insertion length. FIG. 8 is a graph that shows that the weft volume fraction 124 in the prior art increases from OD to ID. This increases the thickness. FIG. 9 shows that the weft volume fraction is more constant from the OD to the ID, and the thickness will be substantially more uniform.
FIG. 9 has a curve that represents weft fiber volume fraction from OD to ID 126 . The curve 126 has three peaks that correspond to the use of weft fibers of three different lengths. The difference between the peaks and troughs is the thickness “t”. The thickness “t” is not exactly the same as the thickness of a weft fiber, but it is related. The thickness “t” is also related to how closely the weft fibers are inserted together. The average thickness 128 is a flat line instead of a rising line like that in FIG. 8 . As defined in the specification and claims, therefore, the term “substantially” uniform shall be construed to mean uniform to within the thickness “t”.
There are other ways to form helical textiles having a substantially uniform thickness. FIG. 10 is a perspective view of a weft bundle 206 having uniform cross sectional area from the textile ID 202 to textile OD 204 . The thickness T 1 at the ID 202 is greater than the thickness T 2 at the OD 204 . The weft bundle width can be narrower at the ID 202 than at the OD 204 so that the cross sectional area can be constant along its length.
FIG. 11 is a cross sectional view of a helical textile showing the weft bundle 206 of FIG. 10 with progressively larger warp yarns 208 a through 208 g from ID to OD. Like the earlier embodiments, the warp and weft are not interlaced or crimped. The width of the warp bundles 208 a through 208 g are substantially constant, but their height increases from ID to OD. Combined with the properties of the weft 206 , the overall height of the textile T 3 remains substantially constant. The larger warp yarns have a larger cross sectional area as shown. This embodiment is very beneficial in that it permits the manufacturer to use yarn denier or filament counts that are already available.
FIG. 12 is a cross sectional view similar to FIG. 11 , except that the warp bundles 210 a through 210 h are the same size and have the same cross sectional area. They are merely spaced closer together toward the OD than the ID. This makes the width of the warp bundles 210 a through 210 h decrease from ID to OD, but makes the height increase because the cross sectional area of the warp bundles is constant. This is another embodiment that results in a helical textile having a substantially constant thickness T 3 .
FIG. 13 is a plan view of a weft fiber layer embodiment having three weft fiber bundles 212 , 214 , 216 at discreet radial distances between the textile ID 202 and OD 204 . The radial spacing “w” between the bundles is constant. As used herein, a “bundle” is a continuous fiber or group of fibers that is shown going back in forth in an “S” shape. In this embodiment generally shown in FIGS. 13 and 14 , no weft bundles traverse entirely from ID 202 to OD 204 . FIGS. 13 and 14 show three bundles, but two or more could be used. In FIG. 14 , the bundles are numbered 218 , 220 , and 222 from ID to OD.
The bundle closest to the OD 216 has a greater concentration of weft yarn than the mid-wall bundle 214 , and the mid-wall bundle 214 has a greater concentration than the bundle closest to the ID 212 . This can be done in two ways: 1) use the same or similar bundle spacing but use larger yarns in the weft at the OD 216 versus mid-wall 214 versus ID 212 , such as that shown in FIG. 13 , or 2) turning to FIG. 14 , use the same yarn bundle size in each bundle but use a closer bundle spacing “w” at the OD 222 versus mid-wall 220 versus the ID 218 .
In FIG. 13 the weft bundles 212 , 214 , 216 can be separated by a radial distance “D” or they can actually overlap, as design issues dictate. In FIG. 14 the weft bundles 218 , 220 , 222 can also be separated by a radial distance “D” or they can actually overlap, as design issues dictate.
The benefit of using different yarn denier or filament counts is that one can use stock that is at hand. This can be a great cost savings.
The features shown in FIGS. 13 and 14 can also be used with either or both the warp modification options shown in FIGS. 11 and 12 , namely, constant warp yarn spacing from OD to ID but change the yarn bundle size/cross sectional area, or use a constant yarn bundle size from OD to ID but change the spacing between adjacent warp yarn bundles. In other words, spacing is closer as one progresses from ID to OD.
Typical applications of a textile according to the present invention would use multiple layers, i.e. a coil, of helical textile. Another application might cut 360 degree pieces and then stack them to achieve multiple layers, alternating the position of the cut and splice. Other applications would use a continuous length of helical textile without cuts and splices.
The textile can be used to reinforce composite structures, or it could be used as a textile for non-composite applications, such as for a circular gasket. The fiber types that can be used include, without limitation, carbon, graphite, glass, and ceramic.
Although the present invention has been described with reference to particular embodiments, it will be apparent to those skilled in the art that variations and modifications can be substituted therefor without departing from the principles and spirit of the invention.
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A helical textile of uniform thickness having uniform radial weft fibers from a textile ID to a textile OD; and non-interlaced circumferential warp fiber bundles having equal width and height that increases from the textile ID to the textile OD, thereby forming a helical textile having a uniform thickness from textile ID to OD. Other embodiment includes non-interlaced circumferential warp fiber bundles having an equal cross section area, a height that increases from the textile ID to the textile OD, and a width that decreases from textile ID to textile OD. Yet another embodiment includes a helical textile of a uniform thickness having circumferential warp fibers; and more than one radial weft fiber bundles, each radial weft fiber bundle occupying a zone between two selected radial distances between the textile ID and OD, wherein the cross sectional areas of the radial weft fiber bundles increases from helical textile ID to OD.
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FIELD OF THE INVENTION
This invention relates to new compositions and to a method of preparing branched polymers of conjugated dienes or branched block copolymers of vinyl-substituted aromatic compounds and conjugated dienes, which possess one or more of the following attributes: broadened molecular weight distribution, enhanced Mooney viscosity, negligible cold flow, increased styrene solution viscosity and good processability. This is accomplished by reacting organoalkali metal or organomagnesium catalyzed non-terminated polymers or block copolymers of conjugated dienes with cyclic organic compounds selected from the group of cyclic organic carbonates, cyclic organic thiocarbonates and cyclic organic sulfites. In the case of these cyclic carbonates, thiocarbonates and sulfites a ring-opening reaction of the cyclic compound occurs during the coupling process. This reaction is designated as ring-opening coupling.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,135,716 teaches the preparation of terminally reactive polymers through the reaction of living (i.e. non-terminated) polymers with reagents such as oxygen, sulfur, halogen, sulfuryl chloride, carbon disulfide, carbon, dioxide, and carbonyl chloride.
U.S. Pat. No. 3,598,887 teaches a process for making multi-block copolymers by coupling living block copolymers with carbon dioxide, carbonyl sulfide, or carbon disulfide.
U.S. Pat. No. 3,281,383 teaches a method of making a branched polymer by reacting a mono-lithium non-terminated polymer with a compound having at least three reactive sites capable of reacting with the carbon-lithium bond to produce a "radial" polymer, i.e. a polymer having long chain branches. The types of treating compounds used included polyepoxides, polyisocyanates, polyimines, polyaldehydes, polyketones, polyanhydrides, polyesters, and polyhalides.
U.S. Pat. No. 3,349,071 teaches a process for reducing the cold flow of diene polymers by terminating lithium catalyzed diene polymers with carbon disulfide.
U.S. Pat. No. 3,427,364 teaches a process for preparing polymers of increased molecular weight by reacting lithium catalyzed non-terminated homopolymers and copolymers of conjugated dienes and mono-vinyl arenes with carbon monoxide as a coupling agent.
In the Journal of Polymer Science, A-1, 6 859 (1968) there is reported the use of diethylcarbonate in an attempt to couple "living" lithium polystyrene for the formation of a ketone-containing polymer i.e., ##STR1## which could be further used for a grafting reaction. With "living" lithium polystyrene of viscosity average molecular weight, Mv, of 31,500 and an equivalent amount of diethyl carbonate, there was obtained a very modest increase in Mv to 42,800. However, the fractionated polymer from the diethyl carbonate reaction yielded very little graft polymer and therefore, it was concluded in this article that diethyl carbonate was ineffective as a coupling agent. The product resulting from the reaction of "living" lithium α-methylstyrene polymer of Mv=31,500 and diethyl carbonate had Mv=29,200, representing no coupling. No mention is made of conjugated diene polymers in this article, nor are any additional data or discussion given which would even suggest that diethyl carbonate could function successfully as a coupling agent for broadening the molecular weight distribution of "living" lithium polydienes.
The present invention of ring-opening coupling of cyclic organic carbonates, thiocarbonates, and sulfites by reaction with living polymers of conjugated dienes is quite novel and yields new compositions and a process for making conjugated diene polymers having one or more of the following: broadened molecular weight distribution, enhanced Mooney viscosity, negligible cold flow, and better processability. In another aspect, it relates to a process for preparing branched block copolymers having a broadened molecular weight distribution and negligible cold flow. During packaging, shipping and storage of elastomeric hydrocarbon polymers, the tendency of these materials to undergo cold flow in the unvulcanized state can present severe handling difficulties. If a package of polymer is punctured, the resulting polymer can flow out, leading to product loss, contamination, or sticking of the packages together. Furthermore, hydrocarbon polymers of conjugated dienes of relatively high Mooney viscosities are frequently difficult to process. Their low Mooney viscosity counterparts on the other hand have a tendency to cold flow in the uncured state. This restricts the use of hydrocarbon polymers of conjugated dienes in the manufacture of high impact plastics, such as polystyrene. Linear polybutadienes frequently do not possess the necessary combination of rheological and viscosity properties such as Mooney viscosity, styrene solution viscosity, and cold flow needed in the manufacture of reinforced polystyrene.
We have discovered that ring-opening coupling of cyclic organic carbonates, cyclic thiocarbonates, or cyclic organic sulfites by reaction with organolithium catalyzed non-terminated conjugated diene polymers produces new polymers possessing broadened molecular weight distribution, greatly increased molecular weight, enhanced Mooney viscosities, negligible cold flow and greater styrene solution viscosities compared to the untreated polymers. The polymers resulting from our invention possess the desirable processing properties so necessary for conjugated diene polymers used in the manufacture of reinforced polystyrene and for making rubber goods such as tires, conveyor belts and hose.
Although the use of only organolithium initiators for synthesizing non-terminated polymers has been shown in the experimental portion, the scope of the invention covers the use of other organoalkali metal and organomagnesium initiators.
The microstructures of the polymers prepared from conjugated dienes may be modified by employing polar compounds, known in the art, during polymerization. Some examples of polar compounds are: diglyme (dimethyl ether of diethylene glycol), tetrahydrofuran, triethylamine, and, N,N,N',N'-tetramethylethylene diamine.
SUMMARY OF THE INVENTION
One aspect of the invention is a process for the preparation of block copolymers of vinyl-substituted aromatic compounds and conjugated dienes of broadened molecular weight distribution comprising:
(a) polymerizing a vinyl-substituted aromatic compound in the presence of an initiator selected from organoalkali metal or organomagnesium initiators until the consumption of the monomer is substantially complete,
(b) adding one or more conjugated diene monomers and polymerizing until substantially complete conversion of monomer(s) to polymer has taken place, and
(c) reacting the resulting block copolymer from said steps (a) and (b) by ring-opening coupling with a compound of the general formula: ##STR2## wherein, Z is a 1,2-phenylene, 1,2-cyclohexylene, or ##STR3## grouping wherein n=0 or 1 and R 1 , R 2 , R 3 , R 4 , R 5 and R 6 are the same or different and are selected from hydrogen or a hydrocarbyl group containing 1 to 12 carbon atoms and A, B and Y are oxygen or sulfur and X is carbon or sulfur, with the stipulation that when X is sulfur, Y must be oxygen, in an amount of from 0.2 to 3 moles of compounds per mole of said organoalkali metal or organomagnesium initiator.
Another aspect of the invention is a process for the preparation of polymers of conjugated dienes of broadened molecular weight distribution and negligible cold flow comprising:
(a) polymerizing a conjugated diene or a mixture of conjugated dienes in the presence of an initiator selected from organoalkali metal or organomagnesium initiators until substantially complete consumption of the monomer(s) and
(b) reacting the resulting polymer from said step (a) by ring-opening coupling with a compound of the general formula: ##STR4## wherein Z is a 1,2-phenylene, 1,2-cyclohexylene, or ##STR5## grouping wherein n=0 or 1 and R 1 , R 2 , R 3 , R 4 , R 5 and R 6 are the same or different and are selected from hydrogen or a hydrocarbyl group containing from 1 to 12 carbon atoms and A, B and Y are oxygen or sulfur and X is carbon or sulfur, with the stipulation that when X is sulfur, Y must be oxygen, in an amount of from 0.2 to 3 moles of the coupling compound per mole of said organoalkali metal or organomagnesium initiator.
Still another aspect of the invention is conjugated diene polymers of broadened molecular weight distribution and negligible cold flow prepared by:
(a) polymerizing at least one conjugated diene in the presence of an initiator selected from organoalkali metal or organomagnesium initiators until the consumption of monomer is substantially complete,
(b) reacting the resulting polymer from said step (a) by ring-opening coupling with a compound of the general formula: ##STR6## wherein, Z is a 1,2-phenylene, 1,2-cyclohexylene, or ##STR7## grouping wherein n=0 or 1 and R 1 , R 2 , R 3 , R 4 , R 5 and R 6 are the same or different and are selected from hydrogen or a hydrocarbyl group containing 1 to 12 carbon atoms and A, B and Y are oxygen or sulfur and X is carbon or sulfur, with the stipulation that when X is sulfur, Y must be oxygen, in an amount of from 0.2 to 3 moles of the coupling compound per mole of said organoalkali metal or organomagnesium initiator.
Also included are block copolymers of vinyl-substituted aromatic compounds and conjugated dienes of broadened molecular weight distribution prepared by:
(a) polymerizing vinyl-substituted aromatic compounds in the presence of an initiator selected from organoalkali metal or organomagnesium initiators until the consumption of monomer is substantially complete,
(b) adding one or more conjugated diene monomers and polymerizing until substantially complete conversion of monomer(s) to polymer has taken place, and
(c) reacting the resulting block copolymer from said steps (a) and (b) by ring-opening coupling with a compound of the general formula ##STR8## wherein, Z is a 1,2-phenylene, 1,2-cyclohexylene, or ##STR9## grouping wherein n=0 or 1 and R 1 , R 2 , R 3 , R 4 , R 5 and R 6 are the same or different and are selected from hydrogen or a hydrocarbyl group containing from 1 to 12 carbon atoms and A, B and Y are oxygen or sulfur and X is carbon or sulfur, with the stipulation that when X is sulfur, Y must be oxygen, in an amount of from 0.2 to 3 moles of compound per mole of said organoalkali metal or organomagnesium initiator.
It is noteworthy that in our invention for the coupling of "living" block copolymers, the hydrocarbon portion of the "living" chain end is always derived from a conjugated diene.
As is well known in the art, the weight ratio of vinyl-substituted aromatic compound to conjugated diene in the "living" block copolymer can be varied widely, for instance 5:95 to 95:5.
The molecular weight of the non-terminated polymers can be controlled by a judicious selection of the amount of monomers consumed during polymerization and the amount of initiator. The number average molecular weights may vary in the range of 30,000 to 350,000, the preferred range being 60,000 to 200,000.
DETAILED DESCRIPTION OF INVENTION
Generally, the polymers that can be treated by the process of this invention are the "living" polymers of conjugated dienes containing from 4 to 12 carbon atoms, preferably 4 to 8 carbon atoms, such as 1,3-butadiene, isoprene, piperylene, 1,3-hexadiene, 1,3-heptadiene, 1,3-octadiene, 2-ethyl-1,3-butadiene, 2,3-dimethyl-1,3-butadiene, 2-methyl-1,3-octadiene, 2-methyl-1,3-pentadiene, 3-methyl-1,3-pentadiene, 4-methyl-1,3-pentadiene, 4-methyl-1,3-heptadiene, 2-phenyl-1,3-butadiene and the like. Mixtures of dienes may also be used. The conjugated dienes can be polymerized alone or in mixtures with vinyl-substituted aromatic compounds to form homopolymers, copolymers or block copolymers. Block copolymers can be formed by sequentially polymerizing a vinyl-substituted aromatic compound with an organoalkali metal compound and then adding a conjugated diene compound to produce a block copolymer having a terminal carbonalkali metal bond which can be sequentially reacted with a coupling agent. Vinyl-substituted aromatic compounds containing 8 to 16 carbon atoms, preferably 8 to 12 carbon atoms, can be polymerized with the dienes. Examples of vinyl-substituted aromatic compounds are styrene, α-methylstyrene, p-isopropyl-α-methylstyrene, vinyl toluene, 3-methylstyrene, chlorostyrene, 4-cyclohexylstyrene, 4-p-tolylstyrene, 1-vinylnaphthalene, 2-vinylnaphthalene and the like.
The polymers are prepared by contacting the monomer or monomers in an inert solvent with an organoalkali metal or organomagnesium compound. One of the preferred classes of these compounds can be represented by the formula RLi, wherein R is a hydrocarbon radical selected from the group consisting of aliphatic, cycloaliphatic, and aromatic radicals containing from 1 to 20 carbon atoms. Examples of these initiators are methyllithium, n-butyllithium, sec-butyllithium, tert-butyllithium, n-decyllithium, phenyllithium, cyclohexyllithium, p-tolyllithium, n-eicosyllithium, and the like. Another class of initiators is the dilithium initiators, such as DiLi-1™ and DiLi-3™ (Trademarks of Lithium Corporation), 1,4-dilithio-1,1,4,4-tetraphenylbutane, 1,4-dilithio-1,4-dimethyl-2-butene and the like.
Examples of other initiators which are useful in this invention are: sodium naphthalene, sodium biphenyl, benzyl sodium, cumyl potassium, cumyl cesium and cumyl rubidium. When employing organosodium, organopotassium, organocesium and organorubidium initiators, it is preferable to use them in an ether solvent such as tetrahydrofuran to avoid side reactions.
It has been found (U.S. Pat. No. 3,822,219) that dialkylmagnesium compounds in combination with organoalkali metal compounds in hydrocarbon solvents catalyze the polymerization of conjugated dienes to predictable molecular weights. Some examples are: n--C 4 H 9 MgC 2 H 5 - RM and (n--C 6 H 13 ) 2 -Mg - RM, where M is an alkali metal such as lithium, sodium or potassium, and R is an alkyl or aryl group.
The amount of initiator used varies, depending upon the desired molecular weight of the end product. The polymers are normally prepared at a temperature in the range between -100° and +150° C., preferably -75° and +75° C. It is preferred to carry out the polymerization in the presence of a suitable inert solvent, for instance, a hydrocarbon diluent such as benzene, cyclohexane, cyclopentane, n-pentane, hexane, heptane, octane, isooctane, and isopentane.
For environmental reasons, it is preferred that benzene be avoided (limitations on exposure to benzene vapors imposed by the Occupational, Safety and Health Administration). Aliphatic and cycloaliphatic solvents are preferred.
The microstructures of the polymers prepared from conjugated dienes may be modified by employing polar compounds, known in the art, during polymerization.
The general class of coupling agents for ring-opening coupling are the cyclic carbonates, thiocarbonates, and sulfites of the general formula: ##STR10## wherein, Z is a 1,2-phenylene, 1,2-cyclohexylene, or ##STR11## grouping wherein n=0 or 1 and R 1 , R 2 , R 3 , R 4 , R 5 and R 6 are the same or different and are selected from hydrogen or a hydrocarbyl group containing from 1 to 12 carbon atoms and A, B and Y are oxygen or sulfur and X is carbon or sulfur, with the stipulation that when X is sulfur, Y must be oxygen. Examples of the compounds belonging to this class include ethylene carbonate, propylene carbonate, o-phenylene carbonate, 1,2-cyclohexylene carbonate, ethylene trithiocarbonate, O,O-ethylene monothiocarbonate, O,S-ethylene monothiocarbonate, O,S-ethylene dithiocarbonate, S,S-ethylene dithiocarbonate, ethylene sulfite, propylene sulfite, o-phenylene sulfite, 1,2-cyclohexylene sulfite, and mixtures thereof.
The amount of a coupling agent used may be expressed in relation to the amount of polymerization initiator used above the scavenger level, which theoretically corresponds to the number of live polymer ends present in the solution. Generally, the molar ratios of a coupling agent to carbon-metal bond, for instance, carbon-lithium bond, useful in this invention are from 0.05:1 to 5:1, preferably 0.2:1 to 3:1.
The coupling agent may be used neat or dissolved in an inert solvent. The ring-opening coupling reaction is normally carried out with the solution containing non-terminated polymer. However, for convenience and other considerations, the solution may be further diluted with the solvent used during polymerization or with another desirable inert solvent.
The ring-opening coupling reaction may be carried out under atmospheric, subatmospheric or supraatmospheric pressures. The reaction temperature may be varied over a wide range, for instance, from about -50° to about 200° C. It has been found that a temperature of 0° to 100° C. is convenient for carrying out the ring-opening coupling reaction.
Cold flow was measured by extruding the polymer through a 1/16 inch orifice under constant pressure at a temperature of 122° F. After allowing 10 minutes at 122° F. to reach steady state, the rate of extrusion was measured by weighing the amount of polymer extruded in 30 minutes and recording the values in milligrams per minute.
BEST MODE OF THE INVENTION
The practice of this invention is illustrated by reference to the following examples which are intended to be representative rather than restrictive of its scope.
EXAMPLE I
To each of ten 8-oz. bottles under nitrogen, 7.3 g (0.135 mole) 1,3-butadiene, 139 ml. benzene, and 0.075 millimoles sec-butyllithium above the scavenger level were added. After polymerization for 24 hours at 25° C., the specified amount of a coupling agent (Table I) was added, and the ring-opening reaction allowed to continue at 25° C. for 24 hours. The resulting polymer solutions were precipitated in five-times the volume of methanol containing 0.1 percent 2,6-di-tert-butyl-p-cresol stabilizer. The polymers exhibited the data shown in Table I. These data show that a variety of cyclic carbonates and thiocarbonates are effective coupling agents for living polybutadiene. This also is the case with ethylene sulfite.
TABLE I__________________________________________________________________________ Molar Ratio Polymer Inherent Increase inCoupling Coupling Conversion, Viscosity,.sup.(a) Inherent %PolymerAgent Agent/BuLi % dl/g Viscosity, % Gel --Mw.sup.(c) --Mn.sup.(c) H.I..sup.(d)__________________________________________________________________________1 none 0 (control) 86 1.25 -- 0 200,000 140,000 1.422 Ethylene 0.333 84 1.40 12 0carbonate3 Ethylene 0.50 86 1.65 32 0carbonate4 Ethylene 1.0 82 1.64 31 0carbonate5 Ethylene 0.50.sup.(b) 86 1.85 48 0carbonate6 O,S-Ethylene 0.333 86 1.97 58 0 331,000 217,000 1.53monothio-carbonate7 O,S-Ethylene 0.50 86 1.70 36 0 273,000 194,000 1.41monothio-carbonate8 O,S-Ethylene 1.0 87 1.65 32 0 258,000 170,000 1.52monothio-carbonate9 Ethylene 0.50 86 1.60 28 0trithio-carbonate10 Ethylene 0.50 84 1.65 32 0sulfite__________________________________________________________________________ .sup.(a) Toluene solvent, 30° C. .sup.(b) After coupling agent was added, the reaction was allowed to continue at 50° C. for 24 hours. .sup.(c) Determined by gel permeation chromatography in tetrahydrofuran solvent. .sup.(d) Heterogeneity Index, --Mw/--Mn ##STR12## ##STR13## ##STR14##
EXAMPLE II
In a manner similar to Example I, 8.9 g. (0.165 mole) 1,3-butadiene and 185 ml. of cyclohexane were added to each of four bottles. After scavenging impurities with sec-butyllithium, a solution of 2.5 g. of nonterminated lithium polystyrene in cyclohexane (number average molecular weight 12,500 and prepared by polymerizing styrene with sec-butyllithium) was added to each butadiene solution. The polymerizations were allowed to proceed at 50° C. for 17 hours. To the resulting nonterminated lithium styrene-butadiene block copolymers were added the specified amounts of coupling agents (Table II), and the ring-opening reactions allowed to proceed at 50° C. for 6 hours. After isolation and drying, the polymers exhibited the data shown in Table II. These examples illustrate coupling of a block copolymer containing living polybutadiene block with ring-opening coupling agents, thereby resulting in greatly broadened molecular weight distribution.
TABLE II__________________________________________________________________________ Molar Ratio Coupling Cold Agent/ Polymer Inherent Increase in Flow Coupling Lithium Conversion, Viscosity,.sup.(a) Inherent %.sup.(a) Index,Polymer Agent Polystyrene % dl/g Viscosity, % Gel --Mw.sup.(b) --Mn.sup.(b) H.I..sup.(c) mg/min.__________________________________________________________________________11 none 0 (control) 99 0.84 -- 2 81,000 29,000 2.79 0.612 O,S-Ethylene 0.5 99 1.34 60 0 106,000 26,000 4.17 0 monothio- carbonate13 Ethylene 0.5 94 1.64 95 0 187,000 31,000 6.03 0 carbonate14 Ethylene 0.5 94 1.07 23 0 -- -- -- -- sulfite__________________________________________________________________________ .sup.(a) Toluene solvent, 30° C. .sup.(b) Determined by gel permeation chromatography in tetrahydrofuran. .sup.(c) Heterogeneity Index, --Mw/--Mn.
While certain representative embodiments and details have been shown for the purpose of illustrating the invention, it will be apparent to those skilled in this art that various changes and modifications may be made therein without departing from the spirit or scope of the invention.
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New compositions and a process for the preparation of conjugated diene polymers of broadened molecular weight distribution by reacting non-terminated lithium catalyzed conjugated diene polymers with cyclic organic compounds selected from the group of carbonates, thiocarbonates and sulfites. The resulting new compositions are suitable for use in making high impact plastics and for fabricating rubber goods.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device for fairways with changing salt concentrations or suspended sediment concentrations in brackish water areas as a result of tidal flows, with a lateral branch or enlargement in the manner of a lock entrance or a harbor basin, to prevent deposits of silt/sand, whereby in the vicinity of the beginning of the branch or enlarged portion, with respect to an incoming flood current, by means of a current deflection wall that is located at some distance from the bank, a channel is realized, the cross section area of which equals a small portion of the inlet cross section area of the branch or enlargement, and the inlet opening of which lies in the fairway in the vicinity of the beginning, and the outlet opening of which lies in the vicinity of the branch or enlargement.
In other words, and according to at least one embodiment of the present invention, this invention relates to an arrangement for minimizing the deposit of silt and/or sand in brackish fairways characterized by changing salt concentrations and/or suspended sediment concentrations resulting from tidal flows and having a lateral branch or enlargement, such as a lock entrance or a harbor basin, whereby a current deflection wall is placed offshore in the vicinity and downstream of the entrance to the lateral branch or enlargement so that a channel is formed having an inlet opening lying in the fairway in the vicinity of and downstream of the entrance to the lateral branch or enlargement and an outlet opening lying in the vicinity of the branch or enlargement, the cross sectional area of the channel equaling a small portion of the cross sectional area of the entrance to the branch or enlargement.
2. Background of the Invention
On lateral branches or enlargements of this type, one problem is that for the major part of the flood tide, the salt concentration or suspended solids contents in the watercourse is greater than in the body of water of the lateral branch or enlargement, and thus a density current originates from the fairway to the branch or expansion, which is active primarily close to the bottom and thereby carries large amounts of silt or sand along with it which, it is well known, can result in large deposits of sediment. As a result of the sediment deposits formed, there are high maintenance costs for dredging and deposition of the dredged material.
The density of a tidal fairway can vary both as a function of changes in the salt concentration as well as changes in the suspended sediment concentration. Salt concentrations can change because, during flood tide, the highly salty sea water can penetrate farther into a tidal flow, and during ebb tide, can be kept farther out to sea. The suspended sediment concentration changes during flood and ebb tide as a result of the varying location of the turbidity zone, or by the increase and decrease of the turbulent tidal currents. All these effects are caused by the tide.
Because increases in the salt content and also in the suspended sediment concentration in the fairway can be achieved a great deal more rapidly than in lateral branches or expansions, the density differences described above occur over the total length of time involved in a tide, with the result that density currents are realized, by which large amounts of sand or silt are deposited in the lateral branches.
German Patent No. 37 07 074 C1 describes a system of the prior art to prevent circulation currents in fairways by installing current deflection walls at harbor entrances, thereby reducing the resulting lenticular sedimentary deposits.
These realizations, however, cannot be used to solve the problems described above, because the object of such a system is merely to reduce the eddy currents caused by the tidal flow.
Attempts have also been made to prevent density by means of a air bubble curtain or underwater skirts suspended on buoys, thereby preventing the ingress of silt and sand. Both methods have been found to be unsatisfactory.
OBJECT OF THE INVENTION
The object of the present invention, according to at least one embodiment, is to develop an arrangement and a method for diverting tidal flows in brackish fairways that substantially solves the problems encountered in systems of the known art.
SUMMARY OF THE INVENTION
The invention teaches that the baffle partition is located in the upper portion with reference to the water depth and an additional deflection wall is located in the lower portion of the water depth in the watercourse. This additional deflection sill diverts a near-bed density current of the fairway toward the middle of the fairway, starts at the bank in the vicinity of the current deflection wall and projects into the fairway.
In other words, and according to at least one embodiment of the present invention, the invention teaches that a current deflection wall is located in the fairway at an upper level and an additional deflection sill is located at a lower level, the upper and lower levels having reference to the water depth. The additional deflection sill, which starts at the bank in the vicinity of the current deflection wall and projects into the fairway in the direction of the incoming flow, diverts a near-bed density current of the fairway toward the center of the fairway and away from the lateral branch or enlargement.
As a result, a simple deflection and filling current control system is created, whereby a near-bed density current in the lower portion of the watercourse at the beginning of the branch or enlargement is diverted by the deflection sill toward the watercourse, In the upper portion of the water area, a channel is formed in the form of a filling current control system with the bank, by means of which the quantities of water at the flood tide to fill the branch or enlargement and create a counter current for an incoming density current, and thus prevents the entry of silt and sand that is carried along near-bed into the lateral branch or enlargement.
In other words, and according to at least one embodiment of the present invention, as a result, a simple deflection and filing current control system is created, whereby a near-bed density current in the lower portion of the fairway at the beginning of the branch or enlargement is diverted by the deflection sill toward the center of the fairway while the channel at the upper level of the watercourse foams a filling current control system so that quantities of water with the incoming flood tide to fill the branch or enlargement creating a counter current to the incoming density current with the result that the silt and sand normally carried along near-bed is prevented from entry into the lateral branch or enlargement.
In one advantageous embodiment, in particular to control the ebb current, the invention teaches that in the vicinity of the end of the branch or enlargement opposite the area of the current deflection wall, starting from the bank in the fairway, a deflection sill that extends toward the middle of the fairway is located at least in the lower portion with regard to the water depth.
In other words, and according to at least one embodiment of the present invention, in one advantageous embodiment, to control in particular an ebb current, the invention teaches that a deflection sill projecting from a bank of the fairway toward the center of the fairway is located offshore in the vicinity and upstream of the entrance to the lateral branch or enlargement and opposite the site of the current deflection wall. Such a sill is located at least in the lower level with regard to the water depth.
To prevent the formation of turbulence behind the deflection sills, the invention teaches that an area between the deflection wall and bank is backfilled with material.
For this purpose, in a refinement of a realization that has favorable flow conditions, one outer edge of the area of the deflection sill filled with material is rounded
The invention also teaches that the current deflection wall is located on columns, at least in the area outside the area filled with material.
In one preferred embodiment, each deflection sill is realized in an S-shape to divert the flow without creating turbulence.
The invention further teaches that the areas of the current deflection wall and the deflection sill partially overlap.
The invention further teaches that the point of the bank that lies in the vicinity of the end of the branch or enlargement opposite the current deflection wall is cut off in the downstream direction.
In other words, and according to at least one embodiment of the present invention, the invention additionally teaches that the point of the bank in the vicinity of and upstream of the entrance to the branch or enlargement opposite the baffle partition is cut off in the downstream direction.
The above discussed embodiments of the present invention will be described further hereinbelow with reference to the accompanying figures. When the word “invention” is used in this specification, the word “invention” includes “inventions”, that is, the plural of “invention”. By stating “invention”, the Applicants do not in any way admit that the present application does not include more than one patentably and non-obviously distinct invention, and maintains that this application may include more than one patentably and non-obviously distinct invention. The Applicants hereby assert that the disclosure of this application may include more than one invention, and, in the event that there is more than one invention, that these inventions may be patentable and non-obvious one with respect to the other.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in greater detail below with reference to the exemplary embodiments illustrated in the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a device in action during flood tide;
FIG. 2 is a schematic diagram of a device in action during ebb tide with deflection sills on both sides of a branch;
FIG. 3 shows a realization like the one illustrated in FIG. 1 as a detail with backfilling and a rounded edge of the bank as well as a rounded edge of the backfilled area;
FIG. 4 is a sectional drawing along Line IV—IV in FIG. 3, on an enlarged scale;
FIG. 5 is a sectional drawing along Line V—V in FIG. 3, on an enlarged scale, with a partly elevated filling current control system and rounded edge on the end of the backfilled area behind the deflection system; and
FIG. 6 shows a realization of a lateral enlargement with a streamlined shape of the bank point and a backfilled area on the ebb-side end of the branch.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the illustrated systems, there is a river 1 as the fairway, from which a harbor basin 2 branches off. The river 1 , when there is flood tide, has the tidal current 4 , and also, as a result of the incoming seawater, a near-bed density current 3 . At ebb tide, the arrows show the ebb current 19 and the near-bed density current 18 . The arrows also show the density equalization currents at the flood tide (Arrows 17 ) and ebb tide (Arrows 22 , which are active whenever the salt or suspended sediment concentration in the fairway 1 is greater than in harbor basin 2 .
In other words, and according to at least one embodiment of the present invention, in the illustrated systems of FIGS. 1 and 2, river 1 is shown as the fairway from which a harbor basin 2 branches off. When there is flood tide, river 1 has the tidal current 4 , and also, as a result of the incoming seawater or turbidity zone, a density current 3 near the bottom. At ebb tide, the illustrated arrows represent the ebb current 19 and the density current 18 flowing in the downstream direction The arrows 17 and 22 also show the density equalization currents during flood tide and ebb tide, respectively, which are active whenever the salt or suspended sediment concentration in fairway 1 is greater than in harbor basin 2 .
In the vicinity of the beginning 20 of the branch 2 , there is a filling current control system with a current deflection wall 6 in the upper portion, and a deflection sill 5 in the lower portion. With the bank 23 , with the current deflection wall 6 , a channel 24 is formed in the upper portion of the water depth. As a result of channel 24 with the inlet opening 8 in the river area 1 and the outlet opening 9 in the transitional area between the fairway 1 and the harbor basin 2 , at flood tide, a quantity of water is guided in the current direction 7 . This quantity of water is split into the tidal filling volume 11 for the harbor basin 2 and a return flow portion 10 which flows back into the fairway 1 , and displaces a density equalization current 17 back into the fairway 1 .
In the area 20 , a deflection sill 5 is also located in the lower portion of the water depth behind which, up to the bank 23 , a space 13 is backfilled up to an approximately vertical closing wall 26 with material, e.g. with sand or rocks. During flood tide, the S-shaped deflection sill 5 that begins at the bank 23 and extends in the fairway 1 in the vicinity of the beginning 20 of the branch 2 displaces the density current 3 close to the bottom as shown by the arrows 12 away from the harbor entrance 2 .
The density current 12 that is diverted in this manner, in connection with the partial outflow 10 , causes a density equalization current 17 during flood tide to be displaced so far from the harbor entrance 2 that it remains in the fairway 1 . As a result of this displacement, the deposits of sand and silt that would otherwise be carried along by the density equalization current in the vicinity of the bottom of the fairway, and the resulting high sedimentation in the harbor basin 2 , can be prevented. At the end of he branch 2 , beginning at the bank 25 , there is a deflection sill 14 which is located in the lower portion of the water depth, and extends in an S-shaped curve into the fairway 1 . The area 15 between the deflection wall 14 and the bank 25 , like the area 13 , is backfilled with material up to the vertical closing wall 16 .
The purpose of the deflection sill 14 , during ebb tide, with the tidal current 19 and the density current 18 , is to deflect this density current 18 as shown by the arrows 27 , so that in combination with an outflow 28 from the harbor basin 2 , the penetration of a density equalization current 22 is prevented, and in this manner a deposit of silt or sand in the harbor basin 2 that would otherwise occur during ebb tide can be prevented.
Steel, reinforced concrete or wood are suitable materials for the construction of the deflection systems.
The closure wall 26 of the backfilled area 13 for the deflection sill 5 is realized in a streamlined rounded shape 29 .
FIG. 6 illustrates a streamlined variant of a bank point 21 in connection with the deflection sill 14 and a streamlined closure wall 16 of a backfilled area 15 and a likewise =streamlined, cut-off bank point 21 ′, which work together at flood tide to improve the outflow of a partial current 10 .
In the exemplary embodiment illustrated in FIG. 5, the current deflection wall 6 is located outside the backfilled area 13 of the deflection sill 5 on elevated pilings in the form of columns 30 .
One feature of the invention resides broadly in the device for a fairway that has changing salt concentrations and/or suspended sediment concentrations in brackish water as a result of tidal flows, with a lateral branch or expansion in the manner of a lock entrance or a harbor basin, for the prevention of silt and/or sand deposits, whereby in the vicinity of the beginning of the branch of expansion, with respect to a flood tide current; by means of a current deflection wall that is located at some distance from the bank, a channel is formed, the cross sectional area of which represents a small portion of the inlet cross sectional area of the-branch or expansion, and the inlet opening of which lies in the fairway in the vicinity of the beginning and the outlet opening of which lies in the vicinity of the branch or expansion, characterized by the fact that the current deflection wall 6 is located in the upper area with respect to the water depth, and in the lower area with respect to the water depth in the fairway there is an additional deflection sill 5 , which diverts a near-bed density current toward the center of the river, runs outward from the bank 23 in the vicinity of,the current deflection wall 6 and projects into the fairway 1 .
Another feature of the invention resides broadly in the device characterized by the fact that in the vicinity 21 of the end of the branch or enlargement 2 opposite the current deflection wall 6 , starting from the bank 25 in the fairway 1 there is a deflection sill 14 that extends toward the middle of the river, at least in the lower portion with respect to the water depth.
Yet another feature of the invention resides broadly in the device characterized by the fact that an area 13 , 15 between the deflection wall 5 , 14 and the bank 23 , 25 is filled with material.
Still another feature of the invention resides broadly in the device characterized by the fact that one edge 16 , 26 of the area 13 , 15 of the deflection sill 5 , 14 backfilled with material is rounded on top.
A further feature of the invention resides broadly in the device characterized by the fact that the current deflection wall 6 is located on columns 30 at least in the vicinity outside the area 13 that is backfilled with material.
Another feature of the invention resides broadly in the device characterized by the fact that each deflection sill 5 , 14 is realized in an S-shape to divert the current without forming turbulence.
Yet another feature of the invention resides broadly in the device characterized by the fact that the areas of the current deflection wall 6 and the deflection sill 5 partly overlap .
Still another feature of the invention resides broadly in the device characterized by the fact that the bank point 21 ′ that lies in the vicinity 22 of the end of the branch or expansion 2 opposite the current deflection wall 6 is cut off in the downstream direction.
Some examples of rounded or streamlined structures in tidal streams and the may be found in the following U.S. Pat. Nos.: 4,330,224, 4,498,806, 4,665,578, 4,846,004, 4,881,848, 4,887,361, 4,923,335, 5,067,851, 5,165,357, 5,707,265 and 5,725,326.
The components disclosed in the various publications, disclosed or incorporated by reference herein, may be used in the embodiments of the present invention, as well as, as equivalents thereof.
The appended drawings in their entirety, including all dimensions, proportions and/or shapes in at least one embodiment of the invention, are accurate and to scale and are hereby included by reference into this specification.
All, or substantially all, of the components and methods of the various embodiments may be used with at least one embodiment or all of the embodiments, if more than one embodiment is described herein.
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses, if any, are intended to cover the structure described herein as performing the recited function and not only structural equivalents but also equivalent structures.
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 intention.
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Arrangement for fairways in brackish water tidal zones to prevent or minimize deposits of silt and/or sand in a branch or enlargement of such fairways. The invention is realized by the installation of a flow wall system. At the entrance to the branch or expansion, a current deflection wall is submerged in the fairway at an upper level some distance from the bank so that a channel is formed near the entrance to the branch or enlargement to direct an flood tide into the branch or enlargement and a deflection sill is juxtaposed with the partition at a lower level to divert an incoming near-bed current of the fairway away from the entrance to the branch or enlargement. The cross sectional area of the channel is small when compared with the cross sectional area of the entrance to the branch or enlargement.
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This is a continuation-in-part of application Ser. No. 942,470, filed Sept. 14, 1978, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a digital frequency divider having a divider input for electrical input pulses and a divider output for an electrical output signal and comprising an N-position counter having a counter input and at least one counter output, wherein the divider input is coupled to the counter input and the divider output is connected to the counter output, which frequency divider further comprises a signal polarity switch and a B-position auxiliary counter of which an auxiliary counter input is coupled to a counter output of the N-position counter and an auxiliary counter output commands the signal polarity switch of which a switch input is coupled to the divider input and a switch output is coupled to the counter input of the N-position counter.
2. Description of the Prior Art
Frequency dividers of this type are commonly used to obtain pulse sequences with a lower pulse repetition frequency from a pulse source with a relatively high pulse repetition frequency, comprising a n-bit counter with N possible positions for dividing the higher frequency by a rational non-integer factor of the general form
N-A/B in which A, B and N are positive integers and in which A And B have no common divisor.
A frequency divider of the type mentioned above is described in the U.S. Pat. No. 3,896,387, especially in the embodiment as described in relation to FIGS. 7 and 8 of that specification, which frequency divider divides by a factor 4-(1/2)=31/2 in that example. For this purpose, the frequency divider comprises a signal polarity switch and a 2-position auxiliary counter of which an auxiliary counter input is coupled to the counter output of the N-position counter and an auxiliary counter output commands the signal polarity switch of which a switch input is coupled to the divider input and a switch output is coupled to the counter input of the N-position counter.
For the B-position auxiliary counter clearly b bits are necessary with B≦2 b .
Every time the output of the auxiliary counter output signal changes its polarity, the signal polarity switch switches the polarity of the incoming pulses, introducing a 180° phase-lead. This has the same effect as adding one counting pulse at the output of the signal polarity switch for every output pulse of the auxiliary counter.
Considering a time interval in which the signal polarity switch presents B×N pulses at the counter input of the N-position counter, then in this time interval this number will be divided by N so that B pulses will be generated at the counter output of the N-position counter, enabling the B-position counter to count through a full B-position cycle. During such a cycle the auxiliary counter output generates an integer number of A 1 pulses with A 1 ≦B, depending on the way counter positions are decoded. Therefore, in the time interval considered, a number A 1 of pulses generated by the auxiliary counter commanding the signal polarity switch has effected A 1 extra pulses at the output of the signal polarity switch.
If the original number of pulses at the divider input during the time interval considered is denoted as P o , then clearly
B×N=P.sub.o +A.sub.1
or
P o =B×N-A 1
In the same time interval the divider output receives B pulses from the counter output of the N-position counter, so that the ratio between the incoming and outgoing pulse frequencies is ##EQU1##
The embodiment in which the auxiliary counter is a divide-by-2 circuit is especially adapted for division by a factor N-1/2 as needed for video timing circuits for NTSC-video systems, as used in video games, Viewdata decoders or other digitized displays.
Although any rational non-integer divisor can be implemented with the embodiment as described above, this may lead to a costly implementation in some cases. For example: in the PAL-video system a colour subcarrier of 4433618.75 Hz nominal and a video line frequency of 15625 Hz nominal are required.
The first frequency can be derived from a standard PAL crystal oscillator for a frequency of twice the subcarrier frequency f sc using a divide-by-2 circuit. The second frequency would require a division by ##EQU2## which can be written as ##EQU3##
This means that the auxiliary counter seems to need 11 bits for counting through B=1250 positions.
SUMMARY OF THE INVENTION
The aim of the invention is to provide a frequency divider in which this result is obtained in a simpler and straightforward way. To this end a frequency divider according to the invention is characterized in that the frequency divider comprises a delay circuit with a delay input for electrical delay pulses, which delay circuit delays the action of the frequency divider for at least one half period of a sequence of electrical input pulses at the divider input for each single delay pulse.
This has the effect that periodically at least one of the phase leads that would otherwise have been obtained is left out, which gives the same result as if less pulses are seemingly added or as if pulses from the clock signal are made inoperative.
In the example as given for the PAL-system it is possible to suppress 100 phase-leads per second using 100 Hz or 50 Hz delay pulses so that the frequency divider seems to function as if it received
(2×4,433,618.75-50) pulses per second.
Using now a frequency divider for a divisor of 567.5, with only a one-bit auxiliary counter, the resulting output will have an average frequency of ##EQU4##
It is also possible to use a digital frequency divider for a divisor 2.5 according to this embodiment. This gives a frequency of ##EQU5##
Dividing this with a normal divide-by-227 circuit gives again ##EQU6##
Although the total number of counting bits required is exactly the same, this solution has the added advantage that an intermediate frequency of about 3.5 MHz is available which is the usual clock frequency for U.S. video NTSC systems, so that it is possible to easily use large scale integrated circuits designed for the NTSC clock frequency as parts in a European PAL-system.
Using the standard PAL oscillator frequency of 8,867,237.5 Hz nomianl in the examples given above means that the 15,625 Hz line-frequency f h is derived from 2(f sc -25)Hz, usually indicated as the 25 Hz offset required by the PAL-system. ##EQU7##
283.75f.sub.H =f.sub.sc -25
or
f.sub.sc =283.75f.sub.H +25
Several specific embodiments of this general nature will be discussed hereunder.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in detail with the help of the drawings.
In the drawings:
FIG. 1 shows a simplified block diagram of a first embodiment of a frequency divider according to the state of the art;
FIG. 2 shows the same embodiment using a slightly different binary notation;
FIG. 3 shows a timing diagram for a frequency divider of FIG. 1 or 2 for N=3, B=3, A 1 =1;
FIG. 4 shows a simplified block diagram of a second embodiment;
FIG. 5 shows a timing diagram for a frequency divider of FIG. 4 for N=4, B=3, A 1 =2, A 2 =2;
FIG. 6 shows an example of a 2.5 divider, using J-K flipflops;
FIG. 7 shows an example of a 2.5 divider using an N=3 counter which will count up to 4 periodically, once for each delay pulse;
FIG. 8 shows an example of a 2.5 divider according to the invention with a delay switch for suppressing electrical pulses from the N-position counter to the auxiliary counter, once for each delay pulse;
FIG. 8a showing a simplified delay circuit;
FIG. 9 shows a timing diagram for a frequency divider according to FIG. 8;
FIG. 10 shows an example of a 2.5 divider comprising a delay circuit for suppressing clock pulses;
FIG. 11 shows a simplified block diagram for a video timing circuit comprising a 2.5 divider;
FIG. 12 shows a simplified block diagram for a video timing circuit comprising a 567.5 divider.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 the basic set-up of a frequency divider uses a clock oscillator 1 having two outputs 3 and 5 for a clock signal CLK and its inverted or antiphase signal CLK' respectively. Output 3 is connected to an input 7 of an AND-gate 9 of which an output 11 is connected to an input 13 of an OR-gate 15. Oscillator output 5 is connected to an input 17 of an AND-gate 19 of which an output 21 is connected to a further input 23 of the OR-gate 15. The output 25 of the OR-gate 15 is connected to a counting input 27 (indicated by CN) of a N-position counter 29 of which an output 31 is connected to the output 33 of the frequency divider and to the input 35 (indicated by CB) of a B-position auxiliary counter 37 having two antiphase outputs B and B', 39 and 41 respectively, usually the outputs of the last flip-flop of the auxiliary counter, or the only flip-flop if B=2. Output 39 is connected to a further input 43 of the AND-gate 21 and output 41 is connected to a further input 45 of the AND-gate 9.
The clock oscillator may consist of a symmetrical circuit with two antiphase outputs, or may consist of a single output oscillator combined with a common inverter to generate CLK' from CLK.
Depending on the counting position of the auxiliary counter 37 either B="0" and B'="1" or B="1" and B'="0".
In the first case the output 11 of the AND-gate 9 will follow the CLK signal and the AND-gate 19 is blocked by B="0" on its input 43. Therefore the output 25 of the OR-gate 15 will also follow the CLK signal so that CN=CLK. In the other case clearly CN=CLK' will be found.
Assuming that the content of the B-position counter only changes somewhere between two edges of the CLK signal, every time such a change occurs the signal CN will have an extra polarity reversal when changing from in phase with CLK to antiphase with CLK or vice-versa.
For each output pulse of the auxiliary counter this happens twice, at the front edge and at the end edge of the pulse so that the signal CN contains one more pulse than the signal CLK contained within a period in which one B pulse is generated.
A full counting cycle requires B-positions for the auxiliary counter and each counting step is originated just after a full cycle of N positions of the N-position counter. Counting through such a full cycle therefore requires a number of B×N pulses CN. Defining the number of B-pulses generated as the number A then the number of CLK pulses in the same full cycle period has been B×N-A. In the same full cycle the number of output pulses f out at the divider output 33 clearly is the number of CN-pulses divided by N ##EQU8##
The frequency divider therefore operates with a reduction factor or divisor ##EQU9##
The signal CN is formed as CLK.B' or CLK'. B, the period symbol indicates the AND-function. Using the + sign for an OR-function the Boolean notation becomes in full:
CN-CLK.B'+CLK'.B
This is the well known EXCLUSIVE-OR-function, as shown in FIG. 2. In this Figure and in the other Figures the same position indicators are used throughout for corresponding elements.
The schematic notation as used in FIG. 2 where the gates 9, 19 and 25 have been replaced by the EXOR-gate 47 is also used in the further diagrams. This must be seen as a simplified notation for the signal polarity switch but does not imply that an actual EXOR-gate has to be used. It is also possible to combine elements of the signal polarity switch such as 9, 19 and 25 with other gates to larger logical circuits as may happen in large scale integrated circuits. These however will still comprise the signal polarity switching function.
The frequency dividers as shown in FIGS. 1 and 2 are inherently the same.
An example of a timing diagram for such a frequency divider is shown in FIG. 3. The chosen example has two counters each having two flip-flops, each counting modulo-3, each going through the binary positions 00, 01 and 11 successively indicated in the figure as "0", "1" and "3" and N 1 are used as the flip-flop outputs for first and second flip-flop respectively, and similarly B o and B 1 .
Assumed is, again by way of example, that the flip-flops change their contents at the end edge or negative edge of a pulse, but this is not essential and may depend on the actual realization of the counters for which many types of flip-flops such as D-, RS- or positive edge JK-flipflops may be used.
It can be seen that the signal CN has an extra polarity change shortly after each edge of a B 1 -pulse. The full cycle contains 3×3=9 CN pulses, one "B 1 -pulse" and 8 CLK pulses. The output signal N 1 connected to f out on output 33 shows three pulses, therefore the divisor is 8/3.
In this example N=3, B=3 and A=1 so that ##EQU10##
In FIG. 4 another embodiment is shown in which the input 35 of the auxiliary counter 37 is not connected to the output 31 of the N-position counter but to a further output 48 of this counter.
This output 48 is connected to a counter decoding circuit in the N-position counter generating A 2 pulses for every full cycle of the N-position counter.
The number of output pulses from the auxiliary counter is given as A 1 for every complete cycle of the B-position counter.
A full divider cycle is again taken as B×N palses CN.
The output 48 generates in this example ##EQU11## pulses during this period.
This gives ##EQU12##
complete cycles of the auxiliary counter and therefore A 1 ×A 2 B-pulses, so that the number of clock pulses CLK in this same period now equals
B×N-A.sub.1 ×A.sub.2.
The number of output pulses on the outputs 31, 33 is still ##EQU13## the divisor becomes thus ##EQU14## if A=A 1 ×A 2 Normally we will use A 1 <B and 1<A 2 <N, larger numbers for A 1 and A 2 are neither necessary nor easily generated, A 1 =B and A 2 =N are clearly trivial, these would indicate the use of divide-by-1 circuits which would be meaningless. The value A 2 =1 seems trivial in so far that the output 31 also gives one pulse per N positions, which would reduce FIG. 4 to FIG. 2, but it may be useful to reach a particular synchronisation if outputs 48 and 31 are in antiphase, so that A 2 =1 in FIG. 4 may be sensible in some cases (A 2 =N').
FIG. 5 shows a timing diagram for a frequency divider according to FIG. 4. By way of example the following values have been chosen:
N=4 (positions "0", "1", "2" and "3")
B=3 (positions "0", "1" and "3")
A 1 =2
A 2 =2
The N-position counter has its flip-flop N o connected to output 48 giving an output pulse for each odd position ("1" and "3").
A signal A 1 =N o .B' 1 is generated to obtain two pulses during positions "0" and "1" of the B-counter, that is two per cycle of the B-counter, that is the signal A 1 has a number A 1 of output pulses per cycle of the B-position counter.
The timing diagram is shown on an extended scale, so that the detailed sequencing of pulses due to (transistor) delay-times can be shown.
Again the signal A 1 is found at output 39 of counter 37 and it is clear that the signal CN reverses its polarity twice for each A 1 pulse, i.e. A 1 ×A 2 times in every full divider cycle. The first two extra polarity reversals have been indicated by an arrow in FIG. 5.
FIG. 6 shows an actual implementation of a divide-by-2.5 circuit using JK-flip-flops such as the Signetics 54113 or similar. These dual JK-flip-flops are negative edge triggered. Again this is only by way of illustration and not essential for the invention. Other types of flip-flops can be used, including positive edge triggered JK-flip-flops, the necessary changes in circuit details being routine matter for the common expert in the field.
The N-position counter consists of two flip-flops 50 and 52 interconnected in a standard way to form a modulo-3 counter, due to the fact that the K o input 54 of flip-flop 50 is connected to the N l output of flip-flop 52.
The B-position counter 37 consists of one single flip-flop generating one B-pulse for every two N l pulses.
In this example we have N=3, B=2 and A=A l =1 so that the divisor becomes ##EQU15##
The timing diagram for this divider is not shown but is of similar nature as that of FIG. 3.
The further JK-inputs 56.58 and 60 receive a logical "1" permanently, in practice this usually means that these inputs are connected to the divider power supply, not shown in the diagrams.
In the case that input 54 or K o is also receiving a permanent "1" instead of being connected to the output 31, the N-position counter would be cycling through all four possible positions resulting in a divide-by-3.5 frequency divider.
As indicated above in the introduction of this description, the divisors needed in practice will not always be as simple as 2.5 or 3.5 so that following the procedure as illustrated in FIGS. 2, 4 and 6 will lead to very large B-positions counters, possibly comprising even more flip-flops that the main N-positions counter.
Assume that a divisor is needed which is only slightly larger than 2.5. Such a divisor can be obtained by either periodically delaying the sequence of extra polarity reversals, or by periodically suppressing an extra polarity reversal.
An example according to the invention of the first possibility is shown in FIG. 7. This frequency divider is easily understood with the insight that the sequence of extra polarity reversals can be delayed for one CLK period by letting the N-position counter counting up to N+1 once. In the example of FIG. 6 this means that sometimes the clock frequency is divided by 2.5, sometimes by 3.5 by keeping k o "1" for one N+1 position cycle. By choosing the number of times per time-unit, e.g. per second that we divide by 3.5 instead of 2.5, any divisor between 2.5 and 3.5 can be obtained.
For this purpose the frequency divider comprises a function switch 62 that switches the N-position counter into a (N+1)-position counter once for every delay pulse DP fed to an input 64 of a delay circuit 66 having an output 68 connected to an input 70 of the function switch 62 and having a synchronization input 72.
In this example the function switch 62 is formed by a single OR-gate its two inputs forming the input 70 and a further input 73 of the function switch 62, its output forming the output 76 of the function switch 62. This output 76 is connected to the K o input 54 of the counter flip-flop 50 and the further input 73 is connected to the counter-output 31.
If the output 68 indicated as signal D is "0" then k o will follow N 1 and tne N-position conter is identical to the one of FIG. 6, dividing by 2.5. If, however, the signal D is a 37 1" at least during the end of the "01" position of the counter, its next position will be "10" instead of "11", followed again by a "11"-position, the N l -output being "0" during the "00" and "01" positions of the counter, and "1" during the "10" and "11" positions, so that N o will toggle from "10" to "11" to "00".
Using simple numbers for an example, a CLK frequency of 10.000 Hz would be required to get a f out frequency of 4000 Hz with the 2.5 frequency divider of FIG. 6.
Assuming that in FIG. 7 50 Hz pulses are fed to the function switch input 70, 50 times per second one more clock pulse is needed for every full cycle of the N-position counter, so 10.000+50 clock pulses result again in 4000 output pulses. This equals a division by ##EQU16## In a frequency divider according to FIG. 2 this already would require an 80-position auxiliary counter having 7 counting flip-flops or bits.
The delay pulses can be supplied by any suitable source, possibly derived from f out . If the phase relation is known no special synchronisation is required, especially when operating with high CLK frequencies. A simple example of a synchronising method is shown in the delay circuit 66 of FIG. 7, comprising two flipflops 80 and 82 interconnected as shown in the figure.
Assume that an asynchronous DP (delay pusle) of unknown length is fed to the input 64 of the delay circuit. At the end of this pulse, a negative edge, flipflop 80 will toggle, J r =K r being a permanent "1". If the starting position of the flip-flop 80 is the position in which the output R'="0", or flip-flop content "1", it will toggle to "0" corresponding with R'=1. Flip-flop 82, normally in the posiiton "0" or D="0", will toggle to D="1" on a negative edge of signal N' o which occurs when the counter N steps up from "00" to "01". Now D'="0" will preset flip-flop 80 to the starting position "1" again in which position it remains until the negative edge of a later DP. D="1" is now true during position "01" of the N-counter, which will step-up to "10" on the next CN-pulse, making N l ="1" so that D is irrelevant for the next counting step. At the moment the N-counter steps from "10" to "11" again the signal N o will have a negative edge. Since J D ="0" again and K D ="1" permanently, flip-flop 82 will be reset to "0" or D="0". All further N o negative edges before the next DP will only reconfirm this reset.
Again the invention is not limited to the example given in FIG. 7. Many variations lie within easy reach of the common expert. Any state of the art synchronization circuit can be used, with a rather wide margin for the timing, the only requirement being that a D-pulse always overlaps at least the last part of a counting position such as position "01" in this example, up to a whole cycle.
The function switch may have many possible forms, mainly depending on the choice of N and on the chosen flip-flop technology.
A very common way is to use a separate reset signal RS, so if by way of example a 4-bit counter has to be reset when reaching position "13" a simple AND-gate will be used to
RS=N.sub.3 ·N.sub.2 ·N'.sub.1 ·N.sub.o ("1101").
The counter can be reset when reaching position "14" instead of "13" with
RS=N.sub.3 ·N.sub.2 ·N.sub.1 ·N'.sub.o ("1110").
The function switch would again be an OR-gate combining these two, using the D-signal:
RS=N.sub.3 ·N.sub.2 ·N'.sub.1 ·N.sub.o ·D'+N.sub.3 ·N.sub.2 ·N.sub.1 ·N'.sub.o ·D,
as usual the least significant counting flip-flop is denoted as N o with outputs N o , N' o ; and so on.
An example of the second possibility, skipping one extra polarity reversal for each DP is shown in FIG. 8. In this case a frequency divider similar to that of FIG. 6 is combined with a delay circuit 66. In the example the delay circuit is functioning identically to that used in FIG. 7 but here an output 84 for the signal D' is used.
Here too the normal starting position is D="0" and therefore D'="1".
The JK-inputs 58, 60 of the auxiliary counter 37 are connected to the D' signal output 84 of the delay circuit 66 instead of being connected to a permanent "1" signal like the power supply voltage.
As long as D'="1" however, the frequency divider operates in exactly the same way as that of FIG. 6.
If however D'="0" for one counting cycle or less, but at least overlapping the negative edge of the N 1 -output signal on counter output 31, this suppresses the effect of this edge, because the JK-flipflop will not toggle when J B =K B ="0".
The signal B will therefore not switch over at the usual moment, no extra signal polarity reversal occurs, therefore the N-position counter functions as a normal divide-by-3 circuit, once for every signal DP pulse. Depending on the frequency of DP any divisor between 2.5 and 3 can be obtained in this way.
Each DP-pulse results in omitting one of the extra 180° phase leads, two DP pulses therefore have the same effect as if one clock pulse CLK had been omitted or suppressed.
For the same example as given before, needing an extra 50 CLK pulses to obtain the same 4000 Hz output, now 100 Hz DP pulses have to be fed to the delay circuit input 64.
The delay circuit is synchronised with the N' o signal on the synchronisation input 72 of the delay circuit 66 in exactly the same way as described for FIG. 7.
Again it will be clear that if the signal DP is already a synchronous signal of correct length then the delay circuit can be much more simple. Assuming DP to be positive, going a simple inverter 86 will generate a negative going DP' which can be connected via output 84 of the delay circuit to the JK-inputs 58, 60 of the auxiliary counter 37, as indicated in FIG. 8A.
FIG. 9 shows a timing diagram for a frequency divider according to FIG. 8. At the moment indicated by the arrow the expected extra polarity reversal is missing due to D="1" and therefore D'=J B =K B ="0". The N-position counter remains in the "00" position for a full CLK period instead of for half a CLK period.
A full N-cycle generally has the length of 2.5 CLK periods, but of 3 CLK periods if a DP pulse results in a D pulse, i.e. the divider dividing by 3 instead of 2.5.
The timing of DP, R and D is exactly as described above for FIG. 7.
Another way to delay the action of the frequency divider for one clock pusle period is shown in FIG. 10. In this example the N-position counter and the auxiliary counter are identical to FIG. 6, the delay circuit 66 is identical to that of FIG. 8.
The D'-output 84 of the delay circuit is connected to an input 86 of an AND-gate 88 of which a further input 90 is connected to the CLK-input 3 and its output 92 is connected to the signal polarity switch 47.
The synchronization input 72 of the delay circuit 66 is also connected to the CLK-input 3.
As long as D'="0" the output 92 of the AND-gate 88 will be identical to the clock signal CLK and the frequency divider operates in the same way as that of FIG. 6.
If however the negative edge of a DP-pulse is followed by a positive going R' the flipflop 82 will toggle just after the first negative edge of CLK during R'="1", which then will preset the flipflop 80 to R'="0" and switch back to D'="1" just after the next negative CLK edge.
As long as D'="0" the output 92 of the AND-gate is a binary 0", so that a single CLK pulse is suppressed in this way.
If DP occurs e.g. 50 times per second again, the CLK frequency must be increased with 50 Hz to obtain the same f out frequency as would be obtained without delay pusles DP.
The timing diagram is self-evident and is not illustrated therefore.
The same result can be obtained if a CN-pulse is suppressed or made inoperative instead of a CLK pulse, by inserting the AND-gate 88 between the signal polarity switch 47 and the CN input 27 of the N-position counter. The synchronization input 72 of the delay circuit 66 may be controlled by CLK or CLK', or the output signal of the signal polarity switch 47, these variations are not illustrated in a Figure but will be clear from FIG. 10 assuming gates 47 and 88 being interchanged.
The common expert will be able to adapt a digital frequency divider to any specification by using combinations of counters of suitable length with a signal polarity switch, using if necessary for complicated divisors a function switch or a suppressor circuit similar to those explained with the Figures with or without synchronization means in the delay circuit.
Furthermore any type of counter may be used in any type of semiconductor or even vacuum tube technology.
As stated in the introduction of this description an important application of digital frequency dividers according to the invention is in timing circuits for video displays using a standard television receiver.
Two examples of implementations for applications in combination with a standard PAL-TV-receiver are shown.
FIG. 11 shows a divide-by-25 circuit essentially the same as that of FIG. 8, with the exception that the delay circuit is implemented with a S-R latch 94, and NAND-gate 96 and an invertor 98 instead of the flipflop 80. For the S-R latch one of a Signetics 54279 guad latch can be used, or any similar S-R latch.
The normal position of the flipflops just before a DP pulse arrives is Q="1", D="0", D'="1" with DP="0". Due to D'="1" the frequency divider divides normally by 2.5 as explained with FIG. 6. D'="1" makes R="1" and DP="0" makes S="0", Q will remain "1".
When DP changes to "1" it follows that S=R="1" so that Q remains in its position according to the S-R latch truth table as given in the Phillips Data Handbook for Signetics Integrated Circuits 1976, part 1, page 221 (top).
DP="1" and Q="1" result K D ="0" and J D ="1" so that the flipflop 82 will switch to D="1", D'="0" just after a negative edge of the N l output 31 at the end of a full N-position cycle when the counter changes from position "11" to position "00".
Now S="1" and R="0" therefore the flipflop 94 switches to Q-"0" giving K D ="1" and J D ="0", so that flipflop 82 will be reset by the next negative edge of N l . During the period in which D="1" and D'-"0" the frequency divider will divide once by 3 instead of 2.5 as explained for FIG. 8.
When D'=R="1" and S="1", Q="0" will remain until the end of DP when S becomes "0"and flipflop 94 will be preset to Q="1".
Now however Q="1" and DP="0" still result in K D ="1" and J D ="0" so that D"="1" will remain for all following negative N l edges until a new DP restarts the delay circuit cycle.
Although the synchronization input 72 of the delay circuit 66 is connected to the N l output 31 in this example, synchronization by N 0 could be used as well, advancing the D-pulse slightly but still having a length equal to 3 clock periods.
The output 31 of the divide-by-2.5 circuit is connected to the input 100 of a further frequency divider 102 for an integer divisor, 227 in this example, thus needing 8 flipflops N 2 through N 9 , the output 104 generating a frequency ##EQU17##
Furthermore the CLK input 3 is connected to the input 106 of a divide-by-2 circuit 108 of which an output 110 generates a frequency ##EQU18##
Using a nominal f CLK =8,867,237.5 Hz thus f sc =4,433,618.75 Hz nominal, which is the nominal PAL sub-carrier frequency.
Using 100 Hz DP-pulses as explained with FIG. 8 has the effect as if the frequency divider operated with a CLK frequency of 8,867,237.5-50=8,867,187.5 Hz and dividing this frequency by 2.5 so that ##EQU19## nominal or approximately 3.5 MHz, a frequency that can be used as a clock frequency for integrated circuits designed for application in the U.S.-NTSC video-system.
A further division by 227 results in ##EQU20## the nominal PAL video line-frequency.
As stated before this results in an apparent divisor equal to ##EQU21## A straight frequency divider according to FIG. 2 or FIG. 4 would require an eleven bit auxiliary counter for B=1250 positions, so that the use of delay pulses DP already available in the circuit requiring only three flipflops.
The second example of a video timing circit is shown in FIG. 12. This digital frequency divider is based on a circuit according to FIG. 7 using a N-position counter 29 with a function switch 62. The counter will cycle normally through 568 positions, but will cycle through N+1=569 positions once for every delay pusle, using a delay circuit as described in FIG. 7, FIG. 11 or similar. Again a divide-by-2 circuit 108 is incorporated as in FIG. 11 to obtain fsc=FCLK/2.
Using 50 Hz delay pulses will have the effect as explained with FIG. 7, i.e. as if (8,867,237.5-50) Hz pulses were divided by 568-1/2=567.5 resulting in ##EQU22##
Again many variations using the same inventive steps can be easily designed, each resulting in simple and error free video timing circuits.
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A simple and reliable digital frequency divider for non-integer rational divisors using a signal polarity switch commanded by an auxiliary counter which derives its counting pulses from a main N-position counter. For such complex divisors the generation of phase leads by toggling the signal polarity switch can be delayed or some phase leads can be suppressed by using relatively low-frequency delay pulses, to avoid large auxiliary counters. Video timing circuits are described based on digital frequency dividers of such types.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for powder coating plastic substrate parts using a conductive adhesion promoter.
BACKGROUND OF THE INVENTION
[0002] In the automotive industry, as well as other manufacturing related industries, there is often a need to replace existing materials to reduce cost, environmental impact of production methods and part production time. With regard to automotive components, exterior and interior parts have typically been wet painted, creating serious environmental concerns due to the use of wet paint and the substantial cost of equipment and paint to provide a suitable finish on the painted part. There is a growing need to eliminate partially or wholly all use of wet paint on automotive parts and replace it with a system that is more environmentally friendly as well as cost and time efficient.
SUMMARY OF THE INVENTION
[0003] The present invention is directed to a method for powder coating plastic substrate. The substrate in one embodiment is a formed part for a vehicle made from a polypropylene base, polyolefins or acrylonitrile butadiene styrene. The method also further involves providing a conductive adhesion promoter, such as a chlorinated polyolefin that includes a conductive carbon black filler. However, it is also within the scope of the invention for other adhesion promoters to be used provided they have suitable conductive properties. The method also provides a powder coat material which can be a powder clear coat material, a powder base material, or a powder primer material.
[0004] The steps of the method include cleaning the substrate to remove contaminants and subsequently drying the substrate. Next, the conductive adhesion promoter is applied to the surface of the substrate, followed by the step of applying a layer of liquid basecoat to the substrate using a sprayer. The next step involves electro-statically applying the powder coat material to form a powder coat layer on the substrate with the adhesion promoter and the liquid basecoat. Lastly, the step of heating the substrate with the adhesion promoter, liquid basecoat layer and powder coat layer occurs in order to bring the substrate and various layers of material to a temperature suitable to melt the powder coat layer and cross-link the adhesion promoter with the powder coat layer and the substrate. The steps of applying the conductive adhesion promoter, applying the layer of liquid basecoat and applying the powder coat material to the substrate all occur at ambient room temperatures in the absence of a heat source for applying heat to the part.
[0005] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. 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
[0006] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0007] FIG. 1 is a schematic view of the method for powder coating plastic substrate parts in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0008] 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.
[0009] FIG. 1 is a schematic view of a method for powder coating plastic substrate parts in accordance with one embodiment of the present invention. The method shown in FIG. 1 is used for describing a method of applying powder clear coat material to a substrate, which in one embodiment of the invention is a part for a vehicle. However, it is within the scope of this invention for the method to be used for applying powder clear coats, powder basecoats or both to automotive vehicle components. Additionally, the method is used for automotive vehicle components that are exterior components, interior components or non-automotive applications such as marine, aviation, railroad, appliances or construction industries where parts are painted on a paint line. The method of powder coating is generally shown in FIG. 1 . The method begins at a step 12 wherein a substrate is loaded onto the paint line 10 . The paint line is a conveyor system that moves parts between stations. The substrate, as described above, is a part for a vehicle, and is generally formed from plastic material. In one embodiment of the invention, the substrate is made of one material selected from the group comprising polypropylene, polyolefin and acrylonitrile butadiene styrene. However, it is within the scope of this invention for other polymer materials to be used in forming the substrate.
[0010] At a step 14 , the substrate is washed with a cleaning solution to remove unwanted dirt or contaminants on the surface of the substrate and then at a step 16 the substrate is dried using either heat or filtered air blown onto the substrate to dry off the substrate prior to further steps. It is also within the scope of this invention to heat the substrate in an oven and then allow the substrate to cool.
[0011] At a step 18 , a conductive adhesion promoter material is sprayed onto the surface of the substrate. Prior to beginning the step 18 of applying the conductive adhesion promoter, the part temperature may range from 24° C. to 38° C. as a result of heat inducted onto the substrate during the steps 14 , 16 . The conductive adhesion promoter contains a chlorinated polyolefin and conductive carbon black solid filler material suspended in a suitable solution that is sprayed onto the surface of the substrate at the step 18 . At a step 20 , the substrate with the layer of conductive adhesion promoter applied is allowed to dry for 1.5 minutes. The step of drying can be carried out using filtered air blown onto the substrate, heating the substrate and layer of adhesion promoter to cause evaporation of the liquid portions of the solution or by simply allowing the substrate with the conductive adhesion promoter layer to sit at ambient temperatures for a suitable period of time to allow evaporation of liquid from the surface of the substrate.
[0012] At a step 22 , a liquid basecoat layer is applied to the substrate using a sprayer. The liquid basecoat in one embodiment is liquid paint. However, it is within the scope of this invention for the liquid basecoat to be substituted with a powder basecoat similar the powder clear coat material that will be described at a later step. Once the step 22 of applying the liquid basecoat layer is completed at a step 24 , the substrate with the layer of adhesion promoter and the layer of liquid basecoat is allowed to flash dry for 1.5 minutes. This step 24 of flash drying can be carried out using filtered air blown onto the substrate, heating the substrate with layers of adhesion promoter and liquid basecoat to cause flash drying of the layers of liquid basecoat or allowing the substrate with the layer of conductive adhesion promoter and layers of liquid basecoat to sit at ambient temperatures for a suitable period of time to allow evaporation of liquid from the surface of the substrate.
[0013] At a step 26 a second layer or application of liquid basecoat is applied to the substrate. The liquid basecoat at a step 26 can be substituted with a powder basecoat material similar to the powder clear coat material described at a later step. The step 26 of applying the second application of liquid basecoat occurs in order to ensure that the substrate has been sufficiently painted. The application of the second liquid basecoat layer at the step 26 is optional since it is possible for only a single application to be necessary.
[0014] At a step 28 , the substrate with the adhesion promoter layer and liquid basecoat layers, is allowed to flash dry for seven minutes at ambient temperature. This step of flash drying can be carried out using filtered air blown onto the substrate, heating the substrate with layers of adhesion promoter and liquid basecoat to cause flash drying of the layers of liquid basecoat or allowing the substrate with the layer of conductive adhesion promoter and layers of liquid basecoat to sit at ambient temperatures for a suitable period of time to allow evaporation of liquid from the surface of the substrate.
[0015] Step 30 is an alternate step to the step 28 wherein the substrate passes through a heated flash tunnel for a predetermined time or temperature. In certain applications, it may be necessary to carry out this step in order to sufficiently dry the substrate before applying the clear coat layers in the subsequent steps.
[0016] Steps 32 , 34 , 36 are optional steps wherein a particular application may require the application of a liquid clear coat material in addition to or without the application of a powder clear coat material. At step 32 a layer of liquid clear coat is applied to the surface of the substrate at ambient temperature. At step 34 , the substrate with the newly sprayed layer of liquid clear coat is flash dried for 1.5 minutes. The flash drying can be carried out using filtered air blown onto the substrate, heating the substrate and layer of liquid clear coat to cause evaporation of liquid portions of the clear coat or by simply allowing the substrate with the liquid clear coat layer to sit at ambient temperatures for a suitable period of time to allow evaporation and drying of liquid clear coat layer. At step 36 , a second liquid clear coat layer is applied. The application of a second liquid clear coat layer at step 36 is optional since it may be suitable for the single liquid clear coat layer applied at step 32 to provide sufficient coverage of the substrate.
[0017] If the above optional steps 32 , 34 , 36 are carried out or omitted, the substrate is then moved to a step 38 where a powder clear coat layer is applied to the surface of the part that were not liquid clear coat. The powder clear coat material is applied to the substrate using an electro-static sprayer that applies an electro-static charge to the powder clear coat material as the powder clear coat material leaves the sprayer. The powder clear coat material includes one selected from the group comprising acrylic polymers and cross-linked polymers; however, it is suitable for other types of polymers to be used. Additionally, the electro-static powder clear coat material may not necessarily be a clear coat material, but could also be a basecoat or paint coat material that could be substituted for the liquid basecoat material applied in steps 22 and 26 .
[0018] After step 38 , the substrate with all the layers is flash dried at step 40 for approximately eight minutes. Depending on the types of materials used, the period of time for drying can be longer than eight minutes. Additionally, the flash drying step 40 is carried out using filtered air blown onto the substrate, heating the substrate with the layer of powder clear coat and/or liquid clear coat to dry the layers or by simply allowing the liquid clear coat and powder clear coat layers to sit at ambient temperatures for a suitable period of time to allow evaporation and drying of the layers. At step 42 , the substrate with all the layers enters a bake oven set at a temperature of at least 135° C. wherein the substrate is heated to a temperature of at least 121° C. for a period of time. The period of time is generally forty-five minutes; however, a lesser or greater amount of time as well as a lesser or greater temperature may be necessary depending on the types of materials and a type of substrate being used with the method. Additionally, the temperature of the bake oven and the time for step 42 must be suitable for the substrate with the adhesion promoter and the basecoat layer and powder clear coat or liquid clear coat layers to melt the powder clear layer and cross-link the adhesion promoter with the powder clear coat layer and the substrate.
[0019] At the step 44 , the substrate is allowed to cool down to ambient temperatures and then at step 46 , the substrate is inspected to make sure the appearance is suitable. Finally, at step 48 , the finished substrate is unloaded from the paint line 10 .
[0020] At all of the steps 20 , 24 , 28 , 30 , 24 , 40 and 42 the temperature and drying time can vary depending on factors including temperature, materials used, size of the part and the number of layers applied to the substrate.
[0021] 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 method for powder coating plastic substrate. The substrate in one embodiment is a formed part for a vehicle made from a polypropylene base, polyolefins or acrylonitrile butadiene styrene. The method also further involves providing a conductive adhesion promoter, such as a chlorinated polyolefin that includes a conductive carbon black filler. A powder coat material is applied at a later step and then is melted onto the substrate creating a finished part having a high quality finish.
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BACKGROUND OF THE INVENTION
The present invention relates to the production of 1,6-hexanediol from cyclohexane. The basic process for such is well known by the following general procedure: cyclohexane is oxidized to produce an acid product including predominantly adipic acid and 6-hydroxyhexanoic acid; the acid product is esterified with an alkanediol and the esters are hydrogenolyzed to 1,6-hexanediol and the said alkanediol. 1,6-hexanediol is useful in that it may be aminated to produce hexamethylenediamine, the latter being a starting reagent for 6,6 nylon. Production of 1,6-hexanediol from cyclohexane is, for example, more particularly described in U.S. Pat. No. 3,524,892 issued Aug. 18, 1970 to Horlenko et al.
In the oxidation of cyclohexane, the main oxidation products consist of cyclohexanone, cyclohexanol, adipic acid, epsilon-caprolactone and 6-hydroxyhexanoic acid. However, various other oxygenated hydrocarbons are also formed such as 1,4-dihydroxycyclohexane; various aldehydes such as adipaldehydic acid, adipaldehyde; various ketones such as levulinic acid; and various C 1 -C 6 monocarboxylic and dicarboxylic acids other than those already mentioned, such as glutaric, succinic, formic, and 3-hydroxyadipic. As hereinafter explained, a non-acid fraction comprising the cyclohexanone and cyclohexanol is separated from the reaction product and may be recycled to the oxidation reactor if desired.
In the oxidation of the cyclohexane, air is suitably utilized as the source of molecular oxygen, but other suitable oxygencontaining gaseous mixtures, or substantially pure oxygen itself, may be utilized. The oxidation takes place at elevated temperatures and superatmospheric pressures sufficient to maintain a liquid phase of the cyclohexane as well as any recycled cyclohexanol and cyclohexanone.
Although it is not absolutely necessary, it is convenient to use an oxidation catalyst of any of the well known types generally employed in oxidation. Catalyst systems which work particularly well contain a metal which exists in at least two valence states, such as for example, cobalt, manganese, iron, chromium, nickel or copper. It is preferred to employ these metals in compound form, salts for example, although they can be used in the uncombined state. Cobalt naphthenate and cobalt acetate have been found to be particularly useful in the practice of the invention. Catalysts can be used in the proportion of metal to reaction mixture of 1 to 500 parts per million, preferably less than about 100 parts per million, e.g. 5 to 15 ppm. Of these catalysts, the naphthenate is the more hydrocarbon-soluble.
Since there is some tendency for some of the oxidation reaction products to polymerize, it is best to inhibit this propensity where possible. The extent of polymerization of both 6-hydroxyhexanoic acid and epsilon-caprolactone can be reduced by the addition of a minor amount of water to the reaction mass. This water can be suitably retained in the reaction mass by means of a reflux condenser which will return volatilized water to the reaction mass. This condenser also serves to retain volatilized constituents of the reaction mass, cyclohexane, cyclohexanone and cyclohexanol, in the reaction zone. It has been found that about 2 to 10 percent by weight of water in the reaction mass is convenient to reduce polymerization of the reaction products.
The oxidation reaction temperature is suitably maintained between about 100° and 200°C. Temperatures below about 160°C and preferably below about 140°C have been found to be best for oxidation according to this invention. Oxidation reaction pressure is conveniently in the range of 4 to 50 atmospheres absolute, preferably about 8 to 40 atmospheres absolute, which pressure is suitably maintained by bubbling the oxidizing gas through a liquid reaction mass while permitting spent oxidizing gases to escape at such a rate as to maintain the desired pressure.
It is practical to pass the desired oxidation products, including 6-hydroxyhexanoic acid, adipic acid, adipaldehydic acid and epsilon-caprolactone, directly into an esterification stage. It is also convenient to separate the oxidation product into an acid fraction suitable for esterification and a nonacid fraction for recycle. This can be accomplished by extracting the reaction products with water to form an aqueous phase containing the desired oxidation products to be esterified and a hydrocarbon phase containing the oxidation products and reactants to be recycled. The aqueous phase is then distilled to recover cyclohexanol and cyclohexanone for recycle or as salable products. While it is preferred to extract the oxidation product with water, it is within the scope of this invention to subject the oxidation products to distillation without first water extracting the 6-hydroxyhexanoic acid, adipic acid and epsilon-caprolactone therefrom. The ratio of water to reaction mixture in the extraction operation should be at least 1 to 4, preferably from about 1 to 4 to about 5 to 6. Extraction is conveniently carried out above room temperature, 30 to 150°C being adequate and 50 to 100°C being preferred.
The water extract is permitted to settle into an aqueous phase and a hydrocarbon phase, the hydrocarbon phase containing cyclohexanone, cyclohexanol and cyclohexane and the aqueous phase containing 6-hydroxyhexanoic acid, adipic acid, cyclohexanone, cyclohexanol and epsilon-caprolactone. The hydrocarbon phase is recycled to the oxidation reactor and the aqueous phase is distilled to remove any cyclohexanone and cyclohexanol as water azeotropes, which distillate may be returned to the oxidation reaction, leaving 6-hydroxyhexanoic acid, adipic acid, epsilon-caprolactone, and other acid and ester oxidation products to be esterified.
In the alternative, the above described water extraction operation can be foregone and the oxidation reaction products can be passed directly to a distillation step in which the water, cyclohexane, cyclohexanone and cyclohexanol are stripped off overhead, preferably azeotropically, and returned to the oxidation operation leaving behind an aqueous residue containing 6-hydroxyhexanoic acid, adipic acid, epsilon-caprolactone and other acid products. In this alternative procedure, it is desirable to add water to the distillation operation with the oxidation reaction products in order to have sufficient water present to azeotrope with the fraction to be recycled. Additionally, the excess water present in the distillation operation tends to inhibit the polymerization of 6-hydroxyhexanoic acid and epsilon-caprolactone and also reduces the extent of esterification of the acid products such as adipic, glutaric or succinic acid by the cyclohexanol which is present. It is practical to use either atmospheric or reduced pressure at temperatures ranging from about 50° to 100°C in the distillation discussed above.
Another alternative procedure for removing the cyclohexanone and cyclohexanol in the aqueous phase of the extracted oxidation product is by liquid-liquid extraction with cyclohexane at about 25° to 100°C. The cyclohexanone and cyclohexanol in the cyclohexane extraction product are suitably removed, e.g. by distillation or other techniques.
Although it is possible to produce adipic acid, 6-hydroxyhexanoic acid and epsilon-caprolactone by batch oxidation of cyclohexane, cyclohexanol and cyclohexanone, it is much more desirable to operate continuously. It is convenient to use a "back-mixing" type of reactor wherein there is thorough agitation of the reaction mixture while an oxidizing gas is being bubbled through the reaction mixture and wherein cyclohexane is being continuously fed into the reactor, reaction product is continuously being tapped off and cyclohexanone, cyclohexanol and cyclohexane are continuously being recycled to the reactor.
The esterification of the acid fraction of the oxidation product (e.g. 6-hydroxyhexanoic acid, epsilon-caprolactone, adipic acid, glutaric acid and succinic acid) can be carried out catalytically or non-catalytically. In the instant invention, it is preferred to esterify non-catalytically. The esterification is suitably carried out with substantially any monohydric or polyhydric hydroxyl containing compound which is thermally stable at temperatures in excess of 150°C, a C 2 -C 10 monohydric or dihydric alkane alcohol generally being used. The hydroxyl containing compound must have a boiling point high enough to be non-volatile during the non-catalytic esterification reaction at the pressure being used. Hydroxyl containing compounds which are useful in this invention are exemplified by n-decyl alcohol, propylene glycol, 1,6-hexanediol (especially preferred), 1,4-butanediol, 1,5-pentanediol, ethanol, methanol, and n-butanol, the latter three alcohols being esterified under pressure. It is preferred to use a C 3 -C 10 alkanediol, for example 1,6-hexanediol or 1,5-pentanediol or mixtures thereof.
It is convenient to carry out the esterification operation in one or more distillation columns. In one embodiment of this invention, the acid products of oxidation referred to above are mixed with an esterifying alcohol, glycol or polyol and introduced into a distillation column which operates at about atmospheric pressure until a pot temperature of about 160° to 200°C is realized whereupon the temperature is maintained by reducing the pressure to about 100 mm. Hg absolute and then the temperature is permitted to climb to about 250°C. The product is taken as a liquid stream from the base of the column and the water and other volatiles are taken overhead. Part of the base product is recycled to the first column and part introduced into a second column where further esterification takes place. The product of the second column is taken as a base stream, part refluxed and part passed to a third column where the ester product and any unreacted esterification alcohol or polyol are separated from any water present. The water is taken overhead, part refluxed to the column and part taken out of the process to be sewered or used elsewhere. The ester product and unreacted esterification alcohol are taken as a base stream and sent to a column in which the unreacted alcohol or polyol is separated from the esterification product.
Where 1,6-hexanediol is the esterifying alcohol, noncatalytic esterification takes place at about 100 mm. Hg absolute to atmospheric pressure, at a temperature of about 150° to 250°C, and a mole ratio of about 0.5 to 1 to 10 to 1 alcohol to acid. It is preferred to operate at about 200°C at an alcohol to acid ratio of about 3 to 1. In the first embodiment set forth above wherein a two column series esterification is utilized in combination with a third column separation unit, the first 80% or so of the esterification takes place in these first two columns, the combined residence times in these columns being about 2 hours. Conversions as high as 95%, based upon acids fed, have been realized in the esterification operation. In this embodiment, the third esterification column operates at a reflux ratio of 2 to 1 and the water overhead is taken at 100 mm. Hg absolute. The column used to separate unreacted alcohol from ester product is conveniently operated at a 1 to 1 reflux ratio of about 10 mm. Hg absolute. The product of esterification generally contains about 60% ester, 35% alcohol, 0.8% acid and 0.2% water. The ester has a high viscosity and an amber color.
The ester product, is hydrogenolyzed to break the ester bond thereby regenerating the esterifying hydroxyl compound and hydrogenolyzing the carboxyl moieties to their corresponding alcohols, e.g. 1,6-hexanediol, 1,5-pentanediol, 1,4-butanediol, n-hexanol and cyclohexanol. The hydrogenolysis can be advantageously carried out by feeding the esterification product and hydrogen to a reactor maintained at about 200° to 350°C and 70 to 900 atmospheres absolute, preferably 250° to 290°C and 250 to 350 atmospheres absolute. The reactor contains a hydrogenolysis catalyst. Substantially any of the catalysts known for hydrogenation or hydrogenolysis are operable such as those of copper, cobalt, platinum, palladium, or nickel; however, copper chromite, barium stablized copper chromite, Raney copper and barium oxide promoted copper chromite have been found to be particularly well suited to this process since they are not poisoned to any great extent during the process. Suitably, the catalyst may be supported by an inert carrier, e.g. pumice or inactive alumina. Inactive alumina is alumina hydrate which has been calcined at between about 1000°C and the melting point of alumina. In investigating the parameters of this invention, it was found that barium oxide stabilized copper chromite catalyzed the hydrogenolysis to 80% or higher conversions. It is practical to carry out the hydrogenolysis either with or without a solvent. Where a solvent is used, dioxane has been found to work well as have butanol and ethanol. The solvent is admixed with the esters at about 100° to 150°C; the mixture then heated to about 190°C in a closed vessel; and then fed into the hydrogenolysis reactor. The proportion of solvent to ester in the feed is about 1 to 4 to 2 to 1, preferably about 1 to 1.
The hydrogenolysis reaction can be carried out in either a fixed, flooded catalyst bed, a slurry catalyst bed or a trickle catalyst bed. In any case, the heat of reaction brings the reaction mass up to a temperature of about 245° to 250°C and the feed hydrogen supplies the pressure necessary for hydrogenolysis. A fixed, flooded catalyst bed is one in which the particles of catalyst are substantially pelletized or in some other relatively large form wherein the liquid phase material being acted on by the catalyst is a continuous phase which completely submerges the catalyst bed. A fixed trickle catalyst bed is one in which the particles of catalyst are generally pelletized and placed in a relatively fixed position with the liquid phase material being acted on by the catalyst being fed at the top of the bed and forming a relatively discontinuous phase. A slurry bed catalyst consists of powdered catalyst, e.g. about 60 microns or less, with the liquid phase being acted upon flooding the catalyst bed and floating the powdered catalyst. In the slurry bed catalyst it is usual to introduce the liquid at the bottom of the bed; in the trickle bed catalyst, it is usual to introduce the liquid at the top of the catalyst bed; and in the flooded fixed bed catalyst the liquid can conveniently be fed at top or bottom although the bottom is preferred. In each case, the gas phase is introduced at the bottom of the catalyst bed and bubbled through a slurry or fixed flooded bed catalyst, or forms a continuous phase through which liquid trickles. In bubbling gas through liquid, it is best to keep the gas bubbles small in order to maximize the ratio of surface area to volume of each bubble.
It is preferred that the hydrogenolysis catalyst life is such as to produce at least about 100 pounds of alcohol hydrogenolysis product per pound of catalyst. A catalyst life such that 200 pounds of diol product per pound of catalyst is made would of course be greatly desirable.
The hydrogenolysis product is taken as a base stream from the reactor and passed through a purification operation to separate the various products. Before the hydrogenolysis product is passed to the purification operation, it is let down in pressure to a pressure within the range of about atmospheric pressure to 10 atmospheres absolute in order to permit dissolved hydrogen to escape, which hydrogen may be recycled. The hydrogenolysis reactor is vented overhead thereby maintaining the required pressure with the hydrogen thus passed off either being permitted to escape to the atmosphere, recycled into the hydrogen feed or used elsewhere.
Where a solvent is used, the hydrogenolysis product is distilled to remove the solvent overhead with the alcohol products being taken as a base stream. In either case, where solvent is used and distilled off or where no solvent is used, the hydrogenolysis product alcohols substantially free of solvent are subjected to successive distillations to separate the products. The first column is preferably operated at about 20 to 10 mm. Hg absolute and 160° to 200°C to remove the substantially pure mixture of alcohols from undesirable high boilers. The mixed alcohols are taken overhead and passed into a second column which operates at about 20 mm. Hg absolute with a pot temperature of about 200°C and a vapor temperature of about 145° to 146°C to remove 1,5-pentanediol and 1,4-butanediol overhead. The base stream from this column is passed into a third distillation column operating at about 155° to 170°C and 20 to 44 mm. Hg absolute to purify the 1,6-hexanediol which is taken overhead and surged to heated vessels and thence part recycled to the esterification operation referred to above and part recovered as product. The base stream from the third still can be sewered or separated and purified to recover any valuable products therefrom.
Although the above described procedure for production of 1,6-hexanediol from cyclohexane is utilized commercially, it undesirably results in a 1,6-hexanediol which is contaminated with various undesirable impurities that are not readily separable therefrom. Further, some of these impurities are produced at the expense of otherwise obtainable 1,6-hexanediol. The cyclohexane oxidation itself is the source of the impurities, there being produced in the cyclohexane oxidation such undesirable impurities as 1,4-dihydroxycyclohexane, various aldehydes such as adipaldehyde, various ketones such as levulinic acid and other components such as 3-hydroxyadipic acid. Such impurities eventually end up in the acid fraction which is esterified and they (or some derivative thereof) ultimately end up, in part, in the 1,6-hexanediol product. 1,4-dihydroxycyclohexane and its precursors are perhaps the most prevalent and most troublesome impurities produced in the oxidation. These latter impurities are about 50% destroyed in the esterification process but the remainder largely winds up in the 1,6-hexanediol product as 1,4-dihydroxycyclohexane.
The aldehydes and ketones produced in the oxidation go, respectively, to acetals and ketals during the esterification. Except for cyclohexanone derivatives, ketals are probably formed to a much smaller extent than acetals. Both acetals and ketals are converted to undesirable esters during hydrogenolysis. The 3-hydroxyadipic acid produced in the oxidation may be converted during the process to a triol or other high boiler which is undesired.
It is thus an object of the present invention to provide an improved process for the production of 1,6-hexanediol from cyclohexane. It is a particular object of the present invention to provide a processing step which, in a process for producing 1,6-hexanediol from cyclohexane, will result in a purer 1,6-hexanediol product. It is also an object of the present invention to provide a process for producing 1,6-hexanediol from cyclohexane wherein a greater efficiency is obtained. Additional objects will become apparent from the following description of the present invention.
SUMMARY
The foregoing and additional objects are accomplished by the present invention which in one of its aspects is an improvement in a process for the production of 1,6-hexanediol from cyclohexane wherein: (a) cyclohexane is oxidized in the liquid phase in the presence of molecular oxygen and an oxidation catalyst at elevated temperatures and superatmospheric pressures to produce an oxidation product; (b) said oxidation product is separated into a non-acid fraction comprising cyclohexanol or cyclohexanone or mixtures thereof and an acid fraction comprising substantially adipic acid and 6-hydroxyhexanoic acid, said acid fraction also containing C 1 to C 6 monocarboxylic and dicarboxylic acids as well as 1,4-dihydroxycyclohexane and/or precursors thereof; (c) said acid fraction is esterified by reacting same in the liquid phase with a C 2 -C 10 monohydric or dihydric alkane alcohol under esterification conditions so as to esterify at least a portion of the adipic acid and 6-hydroxyhexanioc acid contained in said acid fraction; (d) the ester product obtained by esterifying said acid fraction is reacted while in a liquid phase with molecular hydrogen under hydrogenolysis conditions including elevated temperature and superatmospheric pressure and in the presence of a catalytic amount of a hydrogenolysis catalyst to hydrogenolyze the esters of adipic acid and 6-hydroxyhexanoic acid so as to form 1,6-hexanediol and said alkane alcohol; and (e) separating 1,6-hexanediol from the product of said hydrogenolysis; which improvement comprises a prehydrogenation of said acid fraction prior to esterification thereof by reacting said acid fraction while in a liquid phase with molecular hydrogen under hydrogenation conditions including elevated temperature and superatmospheric pressure and in the presence of a catalytic amount of a hydrogenation catalyst to a degree sufficient to convert a substantial portion of said 1,4-dihydroxycyclohexane to cyclohexanol, cyclohexane and/or cyclohexene, but insufficient to appreciably hydrogenolyze the adipic acid and 6-hydroxyhexanoic acid therein.
DETAILED DESCRIPTION OF THE INVENTION
The improvement of the present invention comprises a prehydrogenation of the acid fraction sent to esterification. It has been discovered that this prehydrogenation improves the efficiency to an ultimate product of improved purity by converting the above mentioned impurities to compounds which may be easily removed or to components which are subsequently converted to product. For example, in the prehydrogenation 1,4-dihydroxycyclohexane is converted to cyclohexanol, cyclohexane and cyclohexene, which may readily be separated. A compound such as 3-hydroxyadipic acid is converted during the prehydrogenation to adipic acid or perhaps to a hexenedioic acid, which are desired compounds. Prehydrogenation of the acid fraction also converts the aldehydes and ketones, such as adipaldehydic acid and levulinic acid, to 6-hydroxyhexanoic acid and (probably) valeric acid or gamma-valerolactone, respectively, which are either desirable compounds or generate impurities which are easily removed.
The prehydrogenation is not as severe or carried out to the same degree as the hydrogenolysis step wherein the adipic acid esters are hydrogenolyzed to 1,6-hexanediol. Since the purpose of the prehydrogenation is to remove components which undergo undesirable reactions in the esterification or generate difficulty removable impurities, it should only be carried out to a degree sufficient to convert a substantial portion of the 1,4-dihyroxycyclohexane to cyclohexanol, cyclohexane and cyclohexene, but insufficient to appreciably hydrogenolyze the adipic acid present. Carrying the prehydrogenation to such degree will also result in the desired effect on the other impurities such as 3-hydroxyadipic acid and the like.
The prehydrogenation can generally be carried out by the same general methods already disclosed for the hydrogenolysis of the ester product, and generally the same type catalysts may be used except that nickel catalysts are not desirable. Preferably the catalyst is of copper, cobalt, platinum or palladium or mixtures thereof. In the prehydrogenation, a metallic copper or metallic platinum catalyst is especially preferred. In some instances, the catalyst may be prepared in situ, such as by reduction of a metal salt under hydrogenation conditions, although an ex situ reduction will also provide a suitable catalyst. Metal salts that may be reduced include the acetates, nitrates, various complexes and the like, for example, copper acetate. The actual metal itself, such as a screen of copper wire, is also effective, though not preferred. A substantially completely activated (that is at least 90% aluminum removal) Raney metal catalyst is also suitable.
The prehydrogenation should be carried out at temperatures within the range of 100° to 350°C, preferably 150° to 275°C, and at pressures within the range of 50 to 400 atmospheres absolute, preferably 70 to 300 atmospheres absolute. Residence times may vary widely depending on the amount and type of catalyst used, etc. In general the residence times will be on the order of from 30 to 240 minutes.
Following the prehydrogenation of the acid fraction, it can be passed directly to the esterification.
EXAMPLE 1
A hydrogenation reduction system was employed which comprised a two-liter stainless steel rocking autoclave, provided with means for measuring and controlling the internal temperature and hydrogen pressure.
The autoclave was packed with 100 grams of copper strips (0.0127 × 0.4 × 46 cm). A copper coating was deposited on the interior of the reactor and on the copper strips by charging the autoclave with approximately 0.5 liter of a 10% by weight copper acetate solution in water and then, with the autoclave being rocked, subjecting its contents to hydrogen at a pressure of about 200 atmospheres absolute and a temperature of 180°C for 4 hours. At the end of this time, the reactor was opened and drained. Visual examination indicated that the copper strips and the internal walls of the reactor were coated with a reddish layer of copper crystals.
The reactor was next charged with 0.5 liter sample of a water-diluted (40% total water by weight) acid fraction obtained from the oxidation product of a cyclohexane oxidation wherein cyclohexane had been oxidized in the liquid phase with air in the presence of a cobalt naphthenate catalyst at a temperature of about 145°C and a pressure of about 35 atmospheres absolute. Except for the 40% water of dilution, the sample comprised mainly adipic acid and 6-hydroxyhexanoic acid, although minor amounts of undesirable impurities such as 3-hydroxyadipic acid, formic acid, various formates, 1,4-dihydroxycyclohexane and various organic carbonyl compounds were present. A hydrogen atmosphere at approximately 300 atmospheres absolute pressure was applied, the internal temperature was adjusted to approximately 265°C, and the reactor was agitated by rocking under these conditions for approximately four hours. At the end of this period, the reactor was allowed to cool, the hydrogen atmosphere was released, and liquid product solution was analyzed. Analysis indicated that the 3-hydroxyadipic acid, formic acid, formates, and 1,4-dihydroxycyclohexane were substantially completely removed. The carbonyl content was reduced by greater than 90%. Adipic and 6-hydroxyhexanoic acids (1,6-hexanediol potential) increased 20%.
After such prehydrogenation, 500 grams of the liquid product solution of the prehydrogenation was mixed with 300 grams of 1,5-pentanediol. The mixture was charged to a 30-tray Oldershaw distillation column and allowed to esterify noncatalytically at 240°C and 1 atmosphere of pressure for 2 hours. During this time, water and some volatiles were taken overhead. At the end of two hours, the pressure was reduced to 180 mm Hg absolute and additional water of esterification removed. The product of esterification contained by weight about 60% ester, 35% alcohol, 0.8% acid (all at molecular weight 100), and 0.2% H 2 O.
500 grams of this ester product was blended with 500 grams of 1,4-dioxane and 80 grams of barium stabilized copper chromite. This mixture was charged to a stainless steel rocking autoclave provided with means for measuring and controlling the internal temperature and pressure and was allowed to react with hydrogen at 250°C and 4500 psig for 6 hours so as to hydrogenolyze the ester. At the end of this time, the reaction was essentially complete. The diol product was removed and centrifuged to remove the hydrogenolysis catalyst.
The catalyst-free diol product is fed continuously to a three-column Oldershaw distillation system. The first column provides for removal of the light ends overhead. The residue is fed to a second column where diols are removed overhead and high boilers are removed in the base. The overhead product, containing diols, is fed to the lower-middle of a third tower. 1,6-Hexanediol is removed as a vapor side stream; other diols are removed overhead. Per gram of the ester product above, 0.50 gram of 1,6-hexanediol is isolated in the product side stream. This is approximately a 20% increase in 1,6-hexanediol yield when compared to a process wherein the water-diluted acid fraction sample is not hydrogenated prior to esterification and hydrogenolysis.
EXAMPLE II
The procedure described in Example I was repeated, except, in place of copper strips, the autoclave was packed with carbon pellets. Copper plating procedure, feedstock, and hydrogenation procedures were the same as in Example I. Results were essentially the same.
EXAMPLE III
Example I was repeated except the catalyst was changed to 100 grams of 5% by weight platinum on carbon. Results were the same.
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In the production of 1,6-hexanediol by oxidation of cyclohexane to produce an acidic oxidation product comprising adipic acid, followed by esterification of the acidic oxidation product and a subsequent hydrogenolysis of the ester, the improvement which comprises a prehydrogenation of the acidic oxidation product prior to esterification thereof.
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TECHNICAL FIELD
This invention relates to the optimization of computer software and hardware, and in particular to optimization according to user-specified preferences, databases, and dynamic monitoring of system behavior and performance.
BACKGROUND OF THE INVENTION
Computer operating systems include a large number of parameters, many of which may be queried, controlled, and changed in order to alter the characteristics of the computer system. Similarly, software applications running on computer systems also often include a large number of parameters, many of which may be controlled and changed to alter the characteristics of the application running on the computer system. As an example, in Microsoft's Windows NT operating system, the resolution and color characteristics of the computer system's display may be changed by selecting the "Control Panel" icon from a "Settings" menu item. When the control panel is displayed, a user is presented with a set of new icons, one of which ("Display Properties") may be selected to bring up another panel containing a set of tabs. The "Settings" tab on the "Display Properties" panel may be selected which allows a user to manually change the number of colors, resolution, video refresh rate, font size, and related graphical characteristics. The user specifies the refresh frequency by selecting from a pull-down menu list of available settings (e.g. 60 Hz, 70 Hz, etc.). The user can specify the screen resolution by selecting a slider icon and moving it right or left to increase or decrease the screen resolution (e.g., from 1024×1280 pixels to 600×800 pixels). Some of these settings may affect the performance of applications running on the system. For example, decreasing the color resolution and screen resolution may increase the speed of some graphics applications.
This example focuses on system settings. When one also considers the numerous application settings and various different hardware configurations available to users, and the interaction of all of these settings and configurations, the control accessing of the plurality of settings and configurations can be cumbersome and often requires detailed knowledge on the part of computer users. The need for a dynamic, semi-automatic, consolidated, and rule-based system that changes such settings and other aspects of the computer system, and makes recommendations, becomes apparent. Although many graphical user interfaces exist to control various aspects of the system (such as the graphical slider which controls screen resolution for Windows platforms) and in applications, the need for improved graphical user interfaces becomes apparent as computer systems become more complex.
With reference now to the figures and in particular to FIG. 1, there is illustrated a computer system in accordance with the method and system of the present invention. Typically the computer system 12 includes a computer 36, a computer display 38, a keyboard 40, and multiple input pointing devices 42. Those skilled in the art will appreciate that input pointing devices may be implemented utilizing a pointing stick 44, a mouse 46, a track ball 48, a pen 50, display screen 52 (e.g. a touch display screen 52), or any other device that permits a user to manipulate objects, icons, and other display items in a graphical manner on the computer display 38. Connected to the computer system may also be audio speakers 54 and/or audio input devices 51. (See for example, IBM's VoiceType Dictation system. "VoiceType" is a trademark of the IBM Corporation.) A graphical user interface may be displayed on screen 52 and manipulated using any input pointing device 42. This graphical user interface may include display of an application 60 that displays information pages 62 using any known browser. The information pages may include graphical, audio, or text information 67 presented to the user via the display screen 52, speakers 54, or other output device. The information pages may contain selectable links 66 to other information pages, where such links can be activated by one of the input devices, like mouse 46, to request the associated information pages. This hardware is well known in the art and is also used in conjunction with televisions ("web TV") and multimedia entertainment centers. The system 12 contains one or more memories (See 65 of FIG. 2.) where a remote computer 130, connected to the system 12 through a network 110, can send information. Here the network can be any known (public or privately available) local area network (LAN) or wide area network (WAN), e.g., the Internet. The display may be controlled by a graphics adaptor card such as an Intergraph Intense 3D,
Graphical user interfaces (GUIs) provide ways for users of computers and other devices to effectively communicate with the computer. In GUIs, available applications and data sets are often represented by icons 63 consisting of small graphical representations which can be selected by a user and moved on the screen. The data sets (including pages of information) and applications may reside on the local computer or on a remote computer accessed over a network. The selection of icons often takes the place of typing in a command using a keyboard in order to initiate a program or access a data set. In general, icons are tiny on-screen symbols that simplify access to a program, command, or data file. Icons are often activated or selected by moving a mouse-controlled cursor onto the icon and pressing one or more times on a mouse button.
GUIs include graphical images on computer monitors and often consist of both icons and windows. (GUIs may also reside on the screens of televisions, kiosks, personal digital assistants (PDAs), automatic teller machines (ATMs), and on other devices and appliances such as ovens, cameras, video recorders and instrument consoles.) A computer window is a portion of the graphical image that appears on the monitor and is dedicated to some specific purpose. Windows allow the user to treat the graphical images on the computer monitor like a desktop where various files can remain open simultaneously. The user can control the size, shape, and position of the windows.
Although the use of GUIs with icons usually simplifies a user's interactions with a computer, GUIs are often tedious and frustrating to use. Icons must be maintained in a logical manner. It is difficult to organize windows and icons when many are similarly displayed at the same time on a single device.
In a drag-and-drop GUI, icons are selected 64 and moved 68 (i.e. "dragged") to a target icon 69 to achieve a desired effect. For example, an icon representing a computer file stored on disk may be dragged over an icon containing an image of a printer in order to print the file, or dragged over an icon of a trash can to delete the file. An icon representing a page of information on the World Wide Web may be selected and dragged to a trash can to delete the link to the page of information. The page of information may be on the local machine or on a remote machine. A typical user's screen contains many icons, and only a subset of them will at any one time be valid, useful targets for a selected icon. For example, it would not be useful to drag the icon representing a data file on top of an icon whose only purpose is to access an unrelated multimedia application.
Icons 63 could include static or animated graphics, text, multimedia presentations, and windows displaying TV broadcasts. Icons 63 could also include three dimensional images, for example, those used in virtual reality applications.
SUMMARY OF THE INVENTION
An object of this invention is a method and system for increasing the apparent speed of a computer by automatically optimizing software and hardware according to user-specified preferences.
Another object of this invention is to provide a method and system for increasing the apparent speed of a computer using a database.
Yet another object of this invention is to provide a method and system for effectively increasing the apparent speed of a computer based on results obtained by dynamically monitoring system behavior and performance.
This invention permits users to conveniently optimize software running on a computer. The term "optimize" refers to running of a computer system or software more efficiently, for example, by maximizing both the speed with which a software application runs and user satisfaction, and/or minimizing cost or resource use. "Optimization" includes the setting of various parameters in hardware, operating system software, or application software such that the system as a whole runs as efficiently as possible. These parameters might be set to optimize speed, system resource cost, or other variables corresponding to a user's satisfaction.
Accordingly, this invention provides for a method of enhancing, for example, program application performance on a computer system. With this invention configuration information and performance capabilities based on characteristics of the program/system are determined. Then, the configuration information and the performance capabilities are used to optimize configuration parameters of the program applications so as to enhance the performance of the workstation in running the program'system. Further, with this invention user preferences in the operation of the program are selected by, for example, dragging rule icons to a target optimizer icon to provide user selected rules of operation of the application program.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be further understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:
FIG. 1 depicts a pictorial representation of an example computer system that embodies the present invention.
FIG. 2 is a block diagram of the computer system architecture showing an optimization database.
FIG. 3 is a block diagram showing portions of a computer network wherein a local computer and a remote computer are both connected directly to the network.
FIG. 4 are example database records that may be used for optimization.
FIG. 5 is a flow chart depicting the steps performed in the optimization.
FIG. 6 is a schematic illustration display with an optimizer and rule icons thereon.
FIG. 7 is a flow chart showing the steps of one preferred method of the present invention pertaining to the use of iconic rules.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to FIG. 2, there is illustrated a block diagram of the architecture of the computer system 12 in accordance with the present invention.
The core architecture includes a Central Processing Unit 165, memory controller 162, system memory 65, disk storage 70, disk storage controller 75, and graphics subsystem 166. The computer system 12 can be either a stand alone workstation or a server and a workstation connected to each other via a communications network such as the internet. A portion of the system memory is set aside for an optimizer-database cache 80. Additionally, file space 85 on the disk storage unit 70 may be set aside for the optimizer database 140. Generally speaking, a cache or buffer is a place where data (files, images, and other information) can be stored to avoid having to read the data from a slower device, such as a remote, network-attached computer disk. For instance, a disk cache can store information that can be read without accessing remote disk storage.
With reference now to FIG. 3, there is illustrated a partial portion of a computer network in accordance with the method and system of the present invention. Computer system 12 connects to the network backbone 110 by means of a connecting device 100. Also connected to the network 110 are one or more server computers 130 by means of their own connecting device 100'. Those skilled in the art will appreciate that these connecting devices 100 may take various forms, including modems, token-ring hubs, and other network-enabling devices depending on the capabilities and technology of the connecting devices. The remote computer 130 may include an area of system memory and/or disk storage space dedicated to storing and maintaining a optimization database table 140 (e.g. data file). The optimization database table 140 may reside on the local client or reside on both the client and remote computer. Portions of the optimizer program 136 may reside on the local computer and/or the remote computer. The optimizer program contains or accesses a dynamic monitor 137 of system and application activity. Various user applications 138 run on the remote or local computer. For example, these applications may be office productivity, scientific and engineering, finance, transaction processing, Internet, or any other software a user needs to run. Such applications may be controlled by a configuration file 141 or a central database that controls particular settings of the application that may affect application performance. The optimizer program 136 may contain a graphical user interface 139, used to specify settings or provide information to the user. An operating system 150 runs on the local computer. The operating system, such as Windows NT, primarily provides an interface between the user application and the computer hardware. The operating system also provides services on behalf of the user and applications such as networking, file management, etc.
FIG. 4 includes example records 430 for optimizing system performance. The set of records comprise the database 140. Application settings 420 may consist of a set of control parameters A1, A2, . . . , AN shown in this example in rows 430 and associated with a particular unique identifier 410 for a software application. The software application may be designated in the database 140 as an alphanumeric string 410. By way of example, parameter A1 may control the graphical quality of an engineering application's 3-D graphics. Lower graphical quality often implies faster use of an application. System settings 440 contain information usually relating to static qualities of the computer system such as the particular operating system, amount of memory, processor speed, graphics card name, and bios version. These values S1, S2, . . . , SN are static in the sense that they do not usually change during the operation of an application. Dynamic data 460 may contain current or prior reports of system behavior or performance. The dynamic data is generally dynamic information, such as current CPU, memory, and disk use, all of which change as an application performs operations, and reads and writes information to memory and disk. The values M1, M2, M3 . . . for this dynamic data 460 may be obtained by a monitor program 137 which, for example, scans the system for CPU, memory, and disk use at specific increments of time. Suggestions 480 consist of alphanumeric information (R1, R2, R3, . . . ) that may be supplied to the user (e.g., recommendations or warning messages) for particular applications. The optimizer program 136 may scan a row or record 430 of database 400 to optimize a single, particular application, or it might join the results of numerous rows to optimize for a set of concurrently running applications designated by identifiers 410. Note that in FIG. 4, parameters A1, A2, A3 . . . control application settings. Parameters S1, S2, S3 . . . control system settings. Parameters M1, M2, M3 . . . control dynamic settings. Parameters R1, R2, R3 . . . are recommendations.
FIG. 5 comprises a flow chart for an optimization process 300 that the local computer 12 or server 130 uses to optimize software applications 138 and system response or utilization, or to provide recommendations 480. In step 303, the optimizer 136 gathers relevant system information including: operating system 150 version and release data, installed hardware components, hardware configuration, and software configurations. For example, the optimizer determines the size of RAM, BIOS level, installed options etc. This information gathering can be accomplished using standard operating system or other commands. For example, on Microsoft's Windows NT operating system, the "Winmsd/f" calls, the Win32 API, queries to the system registry, and other methods known to those skilled in the art, allow the optimizer to collect such information. In step 305, the optimizer 136 gathers relevant application information, for example, release version, installed options, etc. In step 310, the optimizer 136 reads records 430 from database 140, that control various parameters 420, associated with a particular application name 410. The database 140 may reside on a remote computer or server 130 accessed over a network 110 or on the local computer 12.
In step 320, the optimizer 136 monitors system 12 behavior. For example, the optimizer may query the current CPU use, memory use, or other activity 321 using operating system commands known to those skilled in the art. Also, a monitor program 137 may use such commands to monitor such activity. This monitor program 137 may contain a graphical user interface 139 that displays such activity in graphical form, such as with bar graphs, pie carts, numerical indicators, gauges, etc. This activity 321 may be stored in the form of dynamic values M1, M2, . . . , MN in settings 460 and read by the optimizer program 136. Alternatively, the values corresponding to system activity/use may be directly obtained using operating system commands. One benefit of storing the dynamic data is that the optimizer 136 may compare current to past system activity. In this step 320, the optimizer also may perform performance measurements to "benchmark" the system by running built-in test routines. For example, the optimizer may time the rotation of a 3-D graphical object to assess the speed of the graphics subsystem 166.
In step 325, the optimizer 136 reads user input. For example, the user may enter text or data at the keyboard 40 (or with various input devices 46, 48, 50, or by voice input using audio input device 51) that specifies a level of optimization 326. This level of optimization may control which of the application settings 420 are used to optimize the application in step 330 or optimize the system 12 in step 340. A user wishing to have maximum performance may, for example, sacrifice graphic quality controlled in applications settings 420, that are generally read upon invocation of application 138.
By way of example, the optimizer 136 can adjust the following parameter settings 420, in the Unigraphics control file to adjust performance. (Unigraphics is an graphically-intensive engineering application created by EDS.) The values for each of these settings may be determined in step 325 and stored in record 430.
Low Performance settings
*Ugraf130.realTimeDynamics: TRUE
*Ugraf130.suppressAutoRefresh: FALSE
*Ugraf130.backfaceCulling : FALSE
*Ugraf130.depthSortedWireframe: TRUE
*Ugraf130.lineAntialiasing: TRUE
*Ugraf130.disableTranslucency: FALSE
High Performance settings
*Ugraf130.realTimeDynamics: FALSE
*Ugraf130.suppressAutoRefresh: TRUE
*Ugraf130.backfaceCulling: TRUE
*Ugraf130.depthSortedWireframe: FALSE
*Ugraf130.lineAntialiasing: FALSE
*Ugraf130.disableTranslucency: TRUE
In this example, if a user sets suppressAutoRefresh to TRUE, the application performance can improve by reducing excess redrawing. "Low Performance" is generally correlated with higher graphical quality. The "level" of optimization 326 may correspond to the number of "high performance" settings selected. For example, highest performance (highest level of optimization) may correspond to the use of all the settings in their high performance states. Lower levels of optimization correspond to fewer of the high-performance settings being used. Those values that constitute high performance settings may be stored in application settings 420.
Similarly, the optimizer also optimizes system settings 440. These are settings independent of applications and generally associated with the computer or its hardware or software components. For example, the graphics card may have general settings that control the resolution, color depth, synchronization on vertical refresh, and other features. The disk may have a fragmentation state which may be altered. The size of "swap" spaces may be specified. These system settings are sometimes stored in the system registry or in initialization files which may be modified using methods known to those skilled in the art.
Returning to step 325 in FIG. 5, as an alternative to text, a graphical user interface 139 may be used to provide input data. For example, a graphical depiction of a slider may be used to control the program optimization level by causing the optimizer 136 to optimize 330 the application by writing discrete records in an application configuration file 141 stored on disk. See step 330. Such a file as the configuration file 141 is typically read by an application when the application starts and controls various performance characteristics of a particular application. The audio input device 51 also permits speech input in step 325. Generally speaking, in steps 330 and 340, the optimizer uses the information acquired in steps 303, 305, 310, 320, and 325 to adjust system or application parameters in order to optimize the operation of the application. For example, the ensemble of data from 310, 320, and 325 may cause the optimizer to not only specify settings to the application but also to the graphics card, or system to alter the speed of the application. In general, the optimizer adjusts system and application settings to best meet user-specified quality/performance trade-offs. The information gathered in steps 303, 305, and 320 may be stored in the database 140 maintained by the optimizer. The database can be helpful in determining changes to system and application configurations at different points in time, in evaluating the effects of changing application settings, and in comparing actual system/application settings with recommended settings.
In step 350, the optimizer 136 may provide suggestions or recommendations 480, for example, in the form of specific text that is output to the user. This output may appear in the optimizer's graphical user interface 139, in a web browser 90, or as audible sound played through speakers 54 another audio output device. These recommendations may be used to warn the user of various conditions (e.g. "disk space is low"), or give suggestions on how to improve performance (e.g. "purchase more memory"). The optimizer contains rules 331, 341, 351 that it uses to make such optimizations 330, 340 and recommendations 350. For example, a rule may be: If A1=yes, and S1=200 MHz, or M1=90%, then make suggestion and change (in step 340) the graphic card settings (e.g. 450) that control "synchronization on vertical refresh". In this example, S1 corresponds to the processor frequency, and M1 corresponds to the percentage of memory used. A rule may consist of a set of conditionals and Boolean operations (e.g. if A and B are true and C is false then make suggestions and take action).
Note that the suggestions 480, entire records 430, and rules 331, 341, 351 may be segregated into different files in database 400, stored at a local machine 12 or remote machine 130. Users may view (360) the rules 331, 341, 350, records 430, and suggestions 480 using graphical user interface 53, which may visually segregate these items based on origin of the suggestions (e.g. companies, individuals, etc.), severity, date, or other criteria. These rules and suggestions may be web accessible (using network 110) for dynamic optimization across the web using a propriety program product at the web server.
Referring to FIGS. 1 and 5, note that the rules 331, 341, 351 may also be represented as icons 63 displayed on the graphics screen. (These icons representing rules are hereafter sometimes referred to as "iconic rules".) Particular rules may be selected 64 from a set of available rules by the user and dragged 68 to an icon 69 representing the optimizer 136 so that the optimizer will implement 330, 340, 350 the rules. Additionally, the rules 331, 341, 351 may require password protection so that only certain users or classes of users have permission to implement the rules. In an example scenario, a user drags 68 an iconic rule 63 to optimizer icon 69. This rule may require that the graphical quality be degraded for a model part if the model part consists of greater than 100,000 triangular facets. (This will enhance the display speed of the model part.) When the user drops the iconic rule on the optimizer icon, the user must enter a password (e.g. consisting of a keyboard entry, speech input, mouse swipes, a sequence of mouse key presses, a secret position on the optimizer icon, or by other means) before the rule is acted upon in steps 330, 340, or 350. In another embodiment, the rules are dragged to a region 70 of the screen and not to the optimizer icon in order for the rules to take effect. Password protection may be useful in a variety of situations, for example, if certain rules are being tested by developers and administrators or if certain rules cause actions that should be restricted (e.g. access to confidential databases, CPU or cost-intensive jobs, the allocation of e-money and credit information, etc.)
The optimizer in steps 330, 340 and 350 may learn 370 from a user's past activity. For example, if the user has always used an application with small files, and past CPU use has always been low (e.g. as stored in settings 470), the software optimizer can make suggestions (480), accordingly. Note that one benefit of having portions of the database 140 (e.g. the settings and suggestions) and rules 331, 341, and 351 on a remote machine 130 is that a company or system administrator can continually manage and update messages and rules as new information is provided by application vendors. When a user runs an application in 410, the user can make use of the latest information in the database. If the database 140 resides on a remote machine 130 the optimization 330, 340, and 350 can be performed either on the local machine or the remote machine. If performed on a remote machine, messages and other parameters are fed from the remote server 130 to the client 12 using the network 110.
FIG. 6 is a block diagram of a GUI 591 with rule icons 540, 63 (See FIG. 1.) including optimizer icons 69, 510, 511. In the present invention, the user uses a selection device such as mouse 46 to select 512 an icon 540 and drags 550 the icon to optimizer icons 510, 511. If the icon 540, representing a rule, is touching or close (within a threshold distance 590) to the optimizer icon 510, then the rule 541, 331, 341, 351 is applied. In other words, "closeness" of an icon is determined by computing the distances from the selected icon 540 to regions 520 of the optimizer icon displayed on the GUI. If the distance is smaller than a particular threshold 592, the icon 540 is close to a region of the optimizer.
In one embodiment, the optimizer icon 510 consists of different regions 520 to which iconic rules 540 are dragged. The optimizer software determines near what location 520 icon is positioned using techniques which are well known to those skilled in the art of GUI interfaces. In addition to performing general optimization, the optimizer icons 510 may be used to specify the `nature` of the update; for example, one optimizer icon 510 may be specified for optimization concerning graphics, while another icon 511 may be specific for controlling all aspects of memory and disk space. The optimizer icon may change its graphical attribute such as color or brightness 570 in response to the information gained when the optimizer software applies the rules 541. For example, once a rule is successfully applied, then the optimizer region 520 may turn red 570. The iconic rules 541 may also change graphical attributes in a similar manner. (Changes in graphical characteristics of the iconic rules and optimizer icons are carried out in step 670 in FIG. 7).
The rule application can be carried out by the optimizer software by comparing the position 585 of icon 540 to values stored in a position file 596 which may be stored on disk.
The optimizer icon 510 may also contain graphical indications of regions 520, such as cutouts 530, to which iconic rules 540 may be dragged. In this manner, when the icons are placed in the optimizer icon 510 there can be a graphical indication 551 of the binding to the user. Additionally, the area around the cutout may change color or brightness 570 once an icon 540 is located in the cutout. The use of discrete cutouts 530 may be useful when only a limited number of rules may be used. The rules may be evident to the user by text 560 written on the optimizer icon or by colors 570.
FIG. 7 is a flow chart 600 showing the steps 600 performed for a preferred version of optimizer 163 executed by the system in FIG. 1. In step 610, a program checks if an icon 540 (e.g., if an iconic rule) is selected. The selected icon 540 may be selected by any selection method: e.g., pointing and clicking or by an application program If the icon is moved 620, its new location is determined 630. If the icon is near (within a threshold distance 590 from) an optimizer region 520 (step 640), then a visual indication 650 of placement such as changing color or brightness 570 of a region 520 optionally may be given. As stated in the description of FIG. 5, the region 520 may be graphically depicted as cutouts 530 to help give users a graphical (visual) indication of the placement. Also as mentioned in the description for FIG. 5, "nearness" or "closeness" is determined by computing the distances from the selected icon to all optimizer icons regions 520 on the GUI. In one preferred embodiment, distances are computed using known geometrical methods. For example, if (x1,y1) are the coordinates of an icon 540 and (x2,y2) are the coordinates of a region 520, then the distance is d-sqrt ((x2-x1)**2+(y2-y1)**2). This formula may be extended to include additional variables for higher dimensional spaces, such as in a virtual reality or three-dimensional environment. An optimizer table (file) 596 on disk may store the x,y locations of regions 520.
The rule 541 represented by an icon 540 is applied 660. The icon 540 or optimizer icon 510 optionally may change color, brightness, texture, blink rate, shape, size, or other graphical attribute (see step 670). This graphical attribute may be a function of the nature of the rule. For example, an iconic rule that increases graphics quality may be red. An icon representing a rule that decreases graphics quality may be green. The optimizer icon may change colors when the rule is successfully applied or has a beneficial effect.
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A method of optimizing the operation of a computer system in running application programs in accordance with system capabilities, user preferences and configuration parameters of the application program. More specifically, with this invention, an optimizing program gathers information on the system capabilities, user preferences and configuration parameters of the application program to maximize the operation of the application program or computer system. Further, user selected rules of operation can be selected by dragging rule icons to target optimizer icon.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to pumps, and more specifically to pumps utilizing vibration to move the fluid through the pump.
BACKGROUND OF THE INVENTION
[0002] A variety of fields of industry and science it is necessary to move a fluid from one location to another. A wide range of pumping devices are available for accomplishing this task. In particular, one type of pump that is especially useful for this task are those pumps disclosed in U.S. Pat. Nos. 6,315,533; 6,364,622; 6,428,289; 6,604,920; 7,354,255B1; and 7,731,105B2, as well as in Published US Patent Application No. US2009/0116979, each of which is expressly incorporated by reference herein.
[0003] However, certain design features of these vibratory piston pumps do not allow effective pumping of liquids of higher viscosities, such as, for example, liquid soap, lubricating oils and similar high viscosity liquids. When liquids or fluids of this type are pumped utilizing the piston vibratory pump disclosed in the incorporated references, while the fluid can be pumped, the overall productivity or volume of the fluid pumped/minute decreases and consequent increase in energy consumption the pump drive mechanism occurs.
[0004] Therefore, it is desirable to develop a pump capable of utilizing the effective vibratory drive system as described in the cited references with a pump construction that enables fluids having high viscosities to be pumped by the device as effectively as lower viscosity fluids or liquids.
SUMMARY OF THE INVENTION
[0005] According to one aspect of the present disclosure, a pump including a vibrating mechanism is provided that is capable of effectively pumping a variety of fluids, including fluids having a high viscosity. In vibratory pump of the present disclosure, this result is achieved by change in the design of the internal working bodies of the pump which effectively causes the various liquids to temporarily decrease the viscosity of the fluid to enable the fluid to be pumped through the device. The vibratory mechanism in the pump includes a piston, an activator, and an apertured disk disposed within a working cylinder, which optionally is included within an external cylinder, a target valve and a drive mechanism connected to a rod extending into the working cylinder on which the piston, activator and disk are mounted. The piston and disk are secured to the rod, while the activator is slidable with regard to the rod, and is held on the rod based on its positioning between the piston and the disk and the sizes of the piston and disk, each of which have a diameter less than external diameter of the activator, but greater than diameter of an internal channel of the activator through which the rod extends.
[0006] In operation, as the drive mechanism oscillates or vibrates the rod within the working cylinder, and fluid is drawn upwardly into the working cylinder along an inlet due to the vacuum created within the working cylinder as a result of the movement of the rod, as described in the US patents and applications cited previously. When the fluid reaches the working cylinder, the activator interacts with the fluid as the activator slides between the piston and the disk to create cavitation within the fluid. By creating air bubbles or pockets in the fluid, the cavitation reduces the viscosity of the fluid, enabling it to be efficiently discharged from the pump. In other words, the influence of cavitation on the liquid raises pressure of the liquid in the working cylinder, thereby reducing the kinematic viscosity of the liquid, enabling it to be pumped more effectively.
[0007] In certain embodiments or uses, the pump can be utilized to assist in facilitating chemical reactions due to the ability of the pump to break down the material being pumped to increase its chemical activation for use in various chemical reaction processes using the pumped materials as reactants. The energy of the mechanical impact of cavitation on various compounds in liquid solutions happens to be enough for breaking chemical bonds in molecules. Even at comparatively soft conditions, the stress level imparted to the material by the cavitation created in the pump is significantly higher than strengths of chemical bonds (˜4.8−5.5×10 42 erg). Mechanical destruction of the materials due to the cavitation in the pump results in formation of free radicals capable of g chemical reactions. This mechanical destruction of the material result in significant change of physic-chemical properties of materials, formation of new functional groups, change of solubility and viscosity, formation of network systems.
[0008] A manageable process of cavitation within the pump to achieve these results on the material being pumped can be realized at certain values of amplitudes and frequency of vibration and, with a suitable geometry or cross-section of the chamber in which the material being pumped is subjected to the cavitation forces, or “reactor”, which may have rectangular or cylinder shapes. In the case of a rectangular reactor, the cavitation interaction happens directly between the liquid material and parts of the device as they interact. Alternatively, in the case of a cylindrical reactor, the cavitation creates vortices and streams of liquid, and inside the streams spinning and oscillation of particles and other interactions occurs between the liquids and/or solid particles which may be present. Vibration and vortex interaction consequently reduces the friction of outer layers of the vortex that interact with walls of the chamber or other structure, and reduces liquid's viscosity, increasing the ease of pumping the fluid.
[0009] According to another aspect of the present invention, the working cylinder includes an external cylinder disposed around the working cylinder. The external cylinder is in fluid communication with the working cylinder via apertures in the working cylinder, and includes an integral annular ring disposed about the circumference of the external cylinder. The ring is attached to a pipe that is oriented at a tangent to the ring and is inserted into the reservoir of the fluid being pumped in order to draw the fluid into the ring. Upon entering the ring, the orientation of the ring causes the fluid to move circumferentially around the ring prior to flowing into the external cylinder, where the fluid continues to flow circumferentially around the working cylinder prior to entering the working cylinder. The motion imparted to the fluid by the ring enables the fluid to co-operate with the piston, the activator and the disk in creating the cavitation within the fluid, thereby raising the efficiency of the flow of the liquid into the vibratory cavitation pump. Further, the high frequency of oscillation of the rod with the piston, the activator and the disk allows a high flow rate stream of a liquid (e.g., more than 5 mL/sec) to enter and be acted upon by the pump, which creates steady process cavitation within the pump. The influence of cavitation on the liquid raises pressure in the internal cavity of the working cylinder, reduces kinematic viscosity of the liquid and increases the destruction and chemical activation of the liquid.
[0010] Additional aspects, features and advantages of the present disclosure will be made apparent from the following detailed description taken together with the drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The drawings illustrate the best way of practicing the present disclosure.
[0012] In the drawings:
[0013] FIG. 1 is a cross-sectional view of a vibratory cavitation pump constructed according to the present disclosure;
[0014] FIG. 2 is a cross-sectional view along line 2 - 2 of FIG. 1 ;
[0015] FIG. 3 is a cross-sectional view of a second embodiment of the vibratory cavitation pump of the resent disclosure; and
[0016] FIG. 4 is a cross-sectional view of a third embodiment of a vibratory cavitation pump constructed according to the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0017] With reference now to the drawing figures in which like reference numbers identify like parts throughout the disclosure, in FIG. 1 a first embodiment of the vibratory cavitation pump of the present disclosure is illustrated generally at 100 . The pump 100 includes a case or housing 1 including a securing member 2 , such as a threaded collar or clip, among others, that is used to fasten a container 3 , such as a bottle, to the housing. The container 3 can hold virtually any type of fluid or liquid 4 to be pumped, as will be described.
[0018] The liquid 4 in the bottle 3 is in contact with a pump mechanism 5 disposed within the housing 1 that can effectively displace the fluid 4 . In one embodiment shown in FIG. 1 , a frame 6 is fixed to the housing 1 to support an electric motor 7 that is operably connected to a reducer 8 that is in turn connected to an oscillating member 9 that transforms the rotation of a shaft of the motor 7 in longitudinal movement of a rod 10 connected to the mechanism 9 opposite the reducer 8 .
[0019] The motor 7 is operably connected to a suitable power source, such as a number of batteries 13 or via a cord and plug (not shown) connectable to a building power grid. The operation of the motor 7 can be controlled through the use of a switch 11 , which is used to turn the motor 7 on and off, and a modulating device 12 , which is utilized to control the speed of operation of the motor 7 , and thus control the frequency of oscillation of the rod 10 .
[0020] Also connected to the frame 6 is an arm 14 from which extend a pair of flanges 15 affixed to a securing member 16 disposed on a working cylinder 17 of the pumping mechanism 5 . The working cylinder 17 is formed as a cylindrical member having a sealed aperture 102 at one end through which the rod 10 extends, and an outlet end 22 . The cylinder 17 can also have a number of alternative configurations, such as a rectangular cross-sectional shape. The working cylinder 17 also includes a number of openings 21 extending through the cylinder 17 that are disposed between the aperture 102 and the outlet end 22 .
[0021] Within the working cylinder 17 and on the rod 10 are disposed a piston 18 , a disk 19 and an activator 20 . The piston 18 and disk 19 are secured to the rod 10 a specified distance from each other, while the activator 20 include a central passage 36 through which the rod 10 extends, such that the activator 20 is slidably mounted on the rod 10 between the piston 18 and the disk 19 . In one embodiment, the piston 18 and disk 19 have generally circular shapes, with the disk 19 having a number of apertures 34 formed therein, as shown in FIG. 2 . Further, in one embodiment the activator 20 can be formed to be cylindrical in shape, but may also be formed with other alternative shapes, such as a spherical shape.
[0022] The exhaust outlet 22 is defined by a narrowing of the working cylinder 17 and includes a valve 23 which restricts the flow of fluid through the outlet 22 and through a nozzle 24 disposed adjacent the valve 23 opposite the outlet 22 .
[0023] In the embodiment shown in FIG. 1 , on an external surface of the working cylinder 17 is disposed an external cylinder 25 . The external cylinder 25 is formed similarly to the working cylinder 17 and is secured to the working cylinder 17 over the apertures 21 . As shown in FIGS. 1 and 2 , the external cylinder 25 includes an annular ring 26 that extends outwardly from the external cylinder 25 , forming a ring cavity 27 . An inlet pipe 30 is connected on a tangent to the ring 26 via an aperture 29 , such that fluid 4 entering the ring 26 through the aperture 29 has a rotational motion imparted to it as it is directed around the ring 26 . From the ring cavity 27 , the fluid 4 drawn up from the container 3 through the pipe 30 is then directed into an internal cavity 32 of the external cylinder 25 prior to entering the working cylinder 17 through the apertures 21 .
[0024] In operation, when the switch 11 is activated to direct electric current from the battery 13 through the modulator 12 to the motor 7 , the motor 7 operates the mechanism 9 . The mechanism 9 longitudinally moves rod 10 with the piston 18 , a disk 19 and the activator 20 within the internal cavity 31 / 33 of the working cylinder 17 . With the movement of the piston 18 and disk 19 out of the cylinder 17 , the piston 18 moves towards and engages the activator 20 , closing the channel 36 within the activator 20 and urging the activator 20 to move with the piston 18 . This movement of the rod 10 , piston 18 and activator 20 towards the left cavity portion 33 creates a zone of lowered pressure, i.e., vacuum, in the right cavity portion 31 of the working cylinder 17 that functions to draw the liquid 4 out of the container 3 through the pipe 30 , as described one or more of U.S. Pat. Nos. 6,315,533; 6,364,622; 6,428,289; 6,604,920; 7,354,255B1; and 7,731,105B2, as well as in Published US Patent Application No. US2009/0116979, each of which is expressly incorporated by reference herein. As the fluid 4 reaches the pumping mechanism 5 , it enters the ring cavity 27 and is accelerated in a circular path within the cavity 27 , in order to fill the internal cavity 32 of the external cylinder 25 . The accelerated liquid 4 subsequently is directed through the apertures 21 into the right cavity portion 31 defined within the working cylinder 17 .
[0025] Subsequently, as the rod 10 begins to move in the opposite direction out of the left cavity portion 33 towards the right cavity portion 31 due to the oscillating movement of the mechanism 9 , the disk 19 contacts the activator 20 , closes the channel 36 in the activator 20 and together with the activator 20 urges the liquid 4 out of the right cavity portion 31 through the outlet 22 . In passing through the outlet 22 , the pressure of the fluid 4 is sufficient to open the valve 23 such that the fluid 4 can be discharged in a pressurized manner through the nozzle 24 .
[0026] As the rod 10 moves towards the right cavity portion 31 , the liquid 4 is drawn into the left cavity portion 33 of the working cylinder 17 in order to replacement the liquid 4 expelled from the right cavity portion 31 through the valve 23 and nozzle 24 . This process of operation of the pump mechanism 9 is repeated at a frequency which is defined by speed of operation the motor 7 .
[0027] Further, as a result of the oscillating movement of the rod 10 in the cylinder 17 , the activator 20 , the piston 18 and the disk 19 regularly and alternately collide with the lateral surfaces of the activator 20 . In the course of these collisions, kinetic energy is created which affects the liquid 4 in the working cylinder 17 by promoting cavitation of the liquid 4 in the working cylinder 17 , which results in actively mixing the liquid 4 , consequently reducing forces of intermolecular coupling in the liquid 4 , thereby reducing the viscosity of the liquid 4 and increasing the pumpability of the fluid 4 .
[0028] In addition, in conjunction with the oscillatory movement of the rod 10 , piston 18 , disk 19 and activator 20 , cavitation of the fluid 4 in the working cavity 17 is created by the shape of the ring cavity 27 . As the fluid 4 is drawn into the ring cavity 27 via the pipe 30 , the cavity 27 causes an accelerated rotary movement of the stream of fluid 4 in the cavity 27 around the working cylinder 17 . As more fluid 4 is drawn into the ring cavity 27 , the accelerated fluid 4 is displaced into the working cylinder 17 through the apertures 21 and distributed into the left and right portions 31 and 33 of the cavity 32 of the working cylinder 17 . The entrance of the accelerated fluid 4 creates zones of active compression and variable pressure in the working cylinder 17 , thus providing an alternative and steady source of cavitation of the fluid 4 . This cavitation of the fluid 4 is accompanied by a sharp increase of pressure in the working cylinder 17 and as a consequence the fluid being pumped is altered in into a microdrop form, comparable in quality to fog, that provides the best molecular interaction potential.
[0029] The pump mechanism 9 can be operated over a wide frequency range to create the cavitation of the fluid 4 within the working cylinder 17 , with a minimum oscillation frequency being about 1-5 Hz. This minimum operating mode of the pump mechanism 9 corresponds to the best conditions for pumping highly viscous liquids which produces an effective discharge fluid stream in absence cavitation.
[0030] Referring now to FIG. 3 , a second embodiment of the vibratory cavitation pump 300 is illustrated. This pump 300 is developed for use with liquids of various viscosity, including liquid soap, lotions, a cream, lubricating oils and other dense lubricant products while considerably reducing the losses of electric energy during the operation of the pump 300 .
[0031] The pump 300 is formed similarly to the pump 100 , with the main differences being the orientation of the working cylinder 17 in a vertical direction on the frame 6 , the removal of the external cylinder 25 and apertures 21 in the working cylinder 17 , and the switching of the placement of the pipe 30 and outlet 22 relative to the working cylinder 17 .
[0032] In operation, the movement of the rod in the working cylinder 17 draws the fluid 4 up the pipe 30 into the cavity 32 , where it is acted upon by piston 18 , disk 19 and activator 20 in the manner described previously, prior to the fluid being discharged through the outlet 22 .
[0033] Looking now at FIG. 4 , a third embodiment of the pump 400 is illustrated. In this embodiment, pump 400 is formed similarly to the pump 300 , without the external cylinder 25 and apertures 21 in the working cylinder 17 , but the cylinder 17 is again oriented horizontally with the inlet pipe 30 and outlet 22 reverting back to locations similar to the first embodiment for the pump 100 . The pump mechanism 9 for the pump 400 is formed as a conventional reciprocating tool having a motor 7 disposed therein which is connected to the mechanism 9 in order to selectively oscillate the rod 10 and operate the pump 400 in a manner similar to that described previously regarding pump 100 .
[0034] In addition to the above description, the following are some of the advantages of the pump of this present disclosure:
Technical and Economical Advantages of Pump
[0000]
1. Simple and reliable production of vibratory-cavitation pumps and other devices.
2. Easy to manufacture them from various materials including plastics.
3. There are no valves, springs and other fast wearing parts.
4. In working reservoirs with a fluid pressure corresponds to the atmospheric.
5. Reduction up to 20-25% of energy consumption during elevation, transportation and spraying of liquids.
6. Safely pumping aggressive liquids (concentrated acids, alkali, and etc.) and taking probes of those.
7. Pumps can be produced with different productivities (or flow rates) from 3 ml/sec to 200 ml/sec and more; pressures from 10 PSI up to 350 PSI.
8. Electric motors can be used having power from 3 watt to 1 kilowatt and more; also various electro vibrators of different productivity can be used with alternating current or with converters.
9. In households the pumps for spraying liquids can be used with batteries of AA 1.5 V or rechargeable batteries of 7-18 V.
The Potential Use of the Vibratory Cavitation Pumps
[0000]
1. Chemical industry and laboratories.
2. Transportation of viscous oils, liquid soap, lotions.
3. In scientific laboratories.
4. Micro- and mini pumps for cooling electronic chips.
5. Medicine: in metering devices, in devices for disinfection of premises, in devices for preparation of medical cocktails, in mechanisms for artificial blood circulation, in devices for flushing out of blood vessels and in other applications.
6. Perfumes development and production: In devices for manufacturing emulsion on the basis of essential oil and water with concentration of water to 60%, in devices for manufacturing of medical flints.
7. Agriculture: In devices for spraying plants, in devices for sanitary machining of plants and a premise of poultry plants, the cattle and equipment maintenance.
8. In devices for sanitary, chemical and radiation clearing and protection of people and buildings, cars and other civil and military objects.
9. In devices for more efficient combustion of fuels.
10. In devices for development and production of alternative aspects fuels.
11. Vibratory-cavitation technology can be efficiently used for creation and production of new materials of custom-made, new combination of properties, for handling and storage of nuclear wastes.
[0055] Numerous alternative embodiments of the present disclosure are contemplated as being within the scope of the following claims which particularly point out and distinctly claims the subject matter regarded as the present invention.
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A vibratory cavitation pump is provided that includes a working cylinder having an fluid inlet and a fluid outlet, a rod extending into the cylinder, a piston fixed to the rod, a plate fixed to the rod and spaced from the piston, an activator slidably mounted to the rod between the piston and the plate and an oscillating pumping mechanism operably connected to the rod to move the rod with respect to the working cylinder. The sliding activator creates cavitation in the fluid being pumped to increase the ease of pumping the fluid, such as high viscosity fluids. The pump can also include an external cylinder disposed around the working cylinder to impart rotational motion to the incoming fluid, thereby enhancing the cavitation created in the fluid by the pump, rendering the fluid easy to displace.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to a method of cleaning cloth using pulsed microwave energy.
[0002] Machines which make use of microwave energy to clean and/or dry cloth are known in the art. Most of these machines focus on using microwaves to heat the water used during the cleaning process, thereby using less energy than machines that make use of, for example, heating elements. Machines which have a drying function focus on heating the water within the wet or damp cloth, speeding up the drying process.
[0003] Developments in this field of application, have been to positioning a microwave-generating device (the magnetron) within washing machines, as well as methods of directing microwaves to the desired objects, i.e., the water to be heated or the fabric to be dried. U.S. Pat. Nos. 4,356,640, 5,463,821 and 4,334,136 are examples in this regard.
[0004] An important piece of prior art in relation to the present invention is US Patent Application US2002/0062667, entitled “Method and apparatus for washing items having cloth with microwaves”. The specification teaches an apparatus that relies on continuous microwave irradiation onto wet cloth in order to agitate water and soap/detergent molecules within the cloth. The agitation comes about as a result of rotational motion of the molecules due to said microwave irradiation, the primary effect of which is the enhanced cleaning effect of water and detergent. A secondary effect of such irradiation is an increase in temperature of the water itself.
[0005] A drawback of the apparatus is discovered upon practical use thereof. The microwave energy that can be used without adversely affecting the cloth was experimentally found to be relatively low. Consequently, the microwave irradiation would have to be applied for relatively long periods of time in order to achieve enhanced cleaning results. Even then, the degree of cleaning, whilst being better than that achieved through ordinary cleaning means, may not be much greater. The use of detergent would then be additionally needed in order to achieve the enhanced clean. The prior art therefore prescribes the use of detergent to achieve this.
[0006] The invention at least partially addresses the aforementioned limitations of the prior art.
SUMMARY OF INVENTION
[0007] The present invention provides an improved method of cleaning cloth utilizing microwave radiation and the pulsing thereof.
[0008] The invention provides an apparatus for cleaning cloth which includes a body with an aperture, a closure, which is engageable with the aperture, a tub with an outer shell and a cylindrical inner cavity which corresponds with the aperture, a drum, which is positioned inside the cylindrical inner cavity and which includes a wall, with an inner surface, an outer surface and a plurality of perforations in the wall, a base and an opposing mouth which registers with the aperture, a drive means which is connected to or engaged with the drum and which allows rotational movement of the drum about an axis, a generator and an electrical power supply, inside the body, wherein the power supply is adapted to provide pulsating electrical power to the generator and wherein the generator is actuable to produce pulses of microwave energy at least into part of the drum.
[0009] The closure may be a door which is fixed to, or removably engaged with, the body.
[0010] The body may include a plurality of vents which provide a passage for air into and out of the body.
[0011] The body may include an inlet and an outlet which allow water to enter and leave the body.
[0012] The drive means may include at least one pulley, which is engaged with the base of the drum, which is connected to an electric motor by means of a belt. Alternatively, the motor may drive the drum directly.
[0013] The drum may have a volume in the range of 10 to 100 litres.
[0014] The generator may be a magnetron.
[0015] The power supply of the magnetron may be a switched mode power supply.
[0016] The apparatus may include at least one of the following control elements located in or on the body; an air heating element, an air bypass flap, an air blower, a microwave choke, a microwave inlet, a water heater, and an exhaust air vent.
[0017] The apparatus may include a sensor to detect at least one of the following: microwave field strength, temperature within the drum, sump water level, water conductivity, drain water level, rinsing water temperature, exhaust gas quality, exhaust gas humidity, exhaust air temperature and inlet air temperature.
[0018] The apparatus may include a programmable microcontroller or microprocessor circuit, electronically interposed between the sensor and the at least one control element, to receive input from the sensor and, in response to control the operation of the control element.
[0019] By controlling the operation of the at least one control element, in response to input from the at least one sensor, the programmable microcontroller or microprocessor may be capable of controlling any one or more of the following: water flow, water quality, water level, microwave power, duty cycle, air velocity, air temperature and drum rotation (hereinafter collectively referred to as “washing parameters”).
[0020] The apparatus may include a user interface which is capable of communicating the washing parameters listed above, to a user.
[0021] The user interface may allow a washing load setting to be input by the user. The washing load setting may relate to one of the following: mass of load of cloth to be cleaned, type of the cloth to be cleaned, and scheduling of cleaning.
[0022] The user interface may be capable of communicating the washing load settings to the programmable microcontroller or microprocessor circuit.
[0023] The invention also provides a method of cleaning cloth with the apparatus described in any one of the preceding claims, the method including the steps of:
a) placing the cloth into a drum; b) moistening the cloth in the drum with a liquid; and c) irradiating the cloth in the drum with the pulses of microwave energy generated by the generator.
[0027] The generator may generate pulses of microwave energy at a power density in the range 5 kW and 5000 kW per cubic meter of the volume of the drum. Preferably, the generator generates pulses of microwave energy at a power density of 100 kW per cubic meter of the volume of the drum.
[0028] The power of each pulse of microwave energy may be regulated using the power supply to be in a range of 1 kW to 30 kW. Preferably, the power of each pulse of microwave energy is regulated using the power supply to be in a range of 3 kW to 5 kW.
[0029] The pulses may be regulated using the power supply to be at duty cycles ranging between 5% and 33%.
[0030] The cloth may be moistened by spraying a stream of liquid into the drum.
[0031] The method may include an additional step of frequently or continuously draining the liquid out of the drum such that at least part of the cloth is not submerged during irradiation.
[0032] The method may include the additional step of introducing a hot air stream into the drum to dry the cloth.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The invention is further described by way of example with reference to the accompanying drawings in which:
[0034] FIG. 1 is a perspective view of a cleaning apparatus according to the invention;
[0035] FIG. 2 is a front view of the cleaning apparatus of FIG. 1 ;
[0036] FIG. 3 is a perspective view of the cleaning apparatus of FIG. 1 in a disassembled form;
[0037] FIG. 4 is a plan view of the cleaning apparatus;
[0038] FIG. 5 is a typical power supply required to pulse a 1 kW magnetron;
[0039] FIG. 6 shows the process control system. Inputs are on the left of the process controller and outputs are on the right;
[0040] FIG. 7 is a schematic of a cleaning apparatus illustrating process control elements that are included:
[0041] FIG. 8 is a prepared cloth to be cleaned experimentally using the invention, with various stains having been put on the cloth:
[0042] FIG. 9 compares a prepared grease stain with the cleaning results of continuous microwave energy and pulsing microwave energy after 10 minutes of cleaning using each method;
[0043] FIG. 10 compares a prepared Engine oil stain with the cleaning results of continuous microwave energy and pulsing microwave energy after 10 minutes of cleaning using each method;
[0044] FIG. 11 compares a prepared Pepsi Cola stain with the cleaning results of continuous microwave energy and pulsing microwave energy after 10 minutes of cleaning using each method;
[0045] FIG. 12 compares a prepared Wood-oil stain with the cleaning results of continuous microwave energy and pulsing microwave energy after 10 minutes of cleaning using each method;
[0046] FIG. 13 compares the cleaning results of continuous microwave energy and pulsing microwave energy on a prepared Margarine stain after 10 minutes of cleaning using each method;
[0047] FIG. 14 compares a prepared Kool-aid stain with the cleaning results of continuous microwave energy and pulsing microwave energy after 10 minutes of cleaning using each method;
[0048] FIG. 15 compares a prepared Ketchup stain with the cleaning results of continuous microwave energy and pulsing microwave energy after 10 minutes of cleaning using each method; and
[0049] FIG. 16 compares the cleaning results of continuous microwave energy and pulsing microwave energy on a prepared Engine oil stain after 20 minutes of cleaning using each method.
DESCRIPTION OF PREFERRED EMBODIMENT
[0050] FIG. 1 shows a cleaning apparatus 8 to be used according to the invention which includes a body 10 which encloses a volume 12 . The body includes a top 14 , a base 16 , a front panel 18 , a rear panel 20 and two opposing side panels 22 and 24 .
[0051] The apparatus further includes a tub 26 , a drum 28 , a drive means 30 and a generator 32 (see FIG. 3 ).
[0052] The front panel 18 has an aperture 34 .
[0053] The aperture 34 is closed during operation of the cleaning apparatus by means of a closure 36 , e.g. a door. The closure 36 is engaged with the body 10 by means of a hinge (not shown), but may also be removably engaged with the body 10 .
[0054] The invention is not limited in this respect.
[0055] The body 10 includes a plurality of vents respectively 38 and 40 , an inlet 42 and an outlet 44 . The inlet 42 is in connection with a valve 46 e.g. a solenoid valve, which is engaged with the tub 26 and which regulates the passage of water into the tub 26 . The outlet 44 , which is also in connection with the tub 26 , provides a passage for water out of the body 10 . At least one of the plurality of vents is positioned on the side panel 22 . A removable filter 50 covers the vent 38 , which is on the side panel 22 , and ensures that clean air is fed into the body 10 .
[0056] The tub 26 is positioned inside the body 10 and includes an outer shell 52 and a cylindrical inner cavity 54 . The openings of the cylindrical inner cavity 54 are in register with the aperture 34 . The tub 26 is in connection with the inlet 42 and the outlet 44 .
[0057] The drum 28 is located inside the tub 26 and includes an inner surface 58 and an outer surface 60 , which closely lines the cylindrical inner cavity 54 of the tub 26 , a base 64 and a mouth 66 . The inner surface 58 and the outer surface 60 include a plurality of perforations 62 which allow water, which is in the tub during a wash cycle, to enter the drum 28 . The base 64 is connected to the drive means 30 which allows for rotational movement of the drum about an axis during each wash cycle. The drive means 30 includes a pulley 70 which is linked to an electric motor 72 by means of a belt 74 e.g. a V-belt. The electric motor 72 is secured to the rear panel 20 of the body and causes the drum 28 to rotate for a predetermined duration and speed. This is best illustrated in FIG. 4 .
[0058] The generator 32 , which is located inside the body 10 , includes a magnetron 76 which produces pulses of electromagnetic waves at a microwave frequency e.g. 2.45 GHz, which are directed into at least part of the drum 28 .
[0059] FIG. 5 shows a block diagram of a typical switched-mode power supply 78 used to pulse the magnetron 76 . The power supply 78 converts normal single-phase household mains electricity (230 Volts in South Africa) from alternating current (ac) form to direct current (dc) form, using a rectifier circuit 80 . A switching circuit 82 then functions as an inverter which outputs high-frequency ac voltage. The frequency and duty cycle of this high-frequency ac voltage are controlled by a programmable microcontroller 88 , which ultimately determines the output power of the power supply 78 . The high-frequency ac voltage is ramped up using a step-up transformer 84 , and then rectified by a second rectifier 86 to give an output dc voltage. This power supply 78 is used because of the following benefits: compact size; light weight due to exclusion of an iron transformer in its construction; variable output voltage and power due to existence of a programmable microcontroller 88 in its circuitry; and capabilities of supplying a pulsed output voltage.
[0060] The invention extends to a method that makes use of pulsed microwaves to clean cloth using the cleaning apparatus 8 described in detail above. Use of the apparatus 8 includes a wash cycle, during which microwave energy is used to clean cloth by removing stains, and drying cycles, during which microwave energy input is used to dry the cloth after a wash cycle.
[0061] The cloth to be washed is placed into the drum 28 as the wash load. During the wash cycle the microwave energy which is directed at high intensity into the drum 28 is thought to directly interact with a stain lodged in the cloth by causing it to heat up in preference to the surrounding cloth. Thus, the high intensity microwave energy allows the temperature of the stain to rise substantially above that of the surrounding textile within short intervals.
[0062] The microwave energy is applied in an intermittent (or pulsed) manner accelerating the cleaning process whilst keeping the cloth at a moderate temperature, thus preventing thermal damage to the cloth. The pulsed microwave energy is applied with sufficient power and in such a manner as to cause power densities ranging between 10 kW and 1000 kW per cubic meter of cavity volume within the drum. The microwave power density and duty cycle are selected to prevent eventual overheating of the wash load from the cumulative energy transfer.
[0063] The method of the invention results in a reduced quantity of detergent being required during a wash cycle. In some instances no detergent is required to wash articles.
[0064] Water is necessary to facilitate cleaning. However, the volume of the water in the drum 28 is minimised. This is because a large volume of water would absorb the microwave energy and reduce the differential heating effect. Large amounts of water may also cover the stain and attenuate the microwave field. Moistening of the cloth thereby occurs by continually spraying water via a water spray means 68 in the drum 28 (see FIG. 7 ) onto the wash load to carry off any grime released from the cloth and drain it from the drum 28 during the wash cycle. In this manner, the microwave energy available for application to the cloth is maximized.
[0065] The drum 28 has volume of between 10 to 100 litres. With the magnetron 76 having a power rating of 1 kW, the magnetron 76 can be pulsed at 3 kW for 33% of the time or at 5 kW for 20% of the time. The mentioned figures and volumes are not limiting in any way, and are merely exemplary, provided the use of the apparatus 8 results in the required power densities in the drum, i.e., between 10 kw and 1000 kW per cubic meter of cavity volume. This range is set by the need to limit the total energy input into the wash load, to prevent excessive temperatures.
[0066] At the end of a wash cycle the water, within the tub 26 , is drained and leaves the body 10 through the outlet 44 . Once the water is drained from the tub 26 the washed articles are dried by rotation of the drum 28 and by activation of the generator 32 , usually at a reduced power output. The rotation of the drum 28 about an axis allows the energy which is created by the generator 32 to be distributed which ensures that all the cloth articles within the drum are evenly dried. In addition, air flow used to carry off the waste heat generated during operation by the microwave source can be heated further to a drying temperature of between 30° C. and 65° C. and vented through the cavity to effect the drying process.
[0067] The cycles are monitored and/or controlled via a process control system 89 according to one or more of the following process parameters: water quality (conductivity), flow and level; microwave power and duty cycle; gas/air velocity, humidity and temperature; drum rotation. The process control system include control elements, sensors and a programmable microcontroller 88 , the latter which runs a generic control algorithm. The system 89 ensures optimal washing and drying performance of the apparatus 8 and also provides for monitoring of the quality of water to ensure that when saturation with dirt and grime is approached or reached, replacement of such water occurs.
[0068] A schematic layout of the apparatus 8 , illustrating the components making up the process control system 89 , is shown in FIG. 7 . The system includes a plurality of sensors, including: a microwave field strength meter 96 , a door-mounted infrared pyrometer 98 , a sump water level sensor 100 , a water conductivity sensor (conductivity meter) 102 , a drain water level sensor (float switch) 104 , a rinsing water temperature sensor (thermocouple) 108 , an exhaust gas analyser 112 , a humidity sensor (hygrometer) 114 , an exhaust air temperature sensor (thermocouple) 116 and an inlet air temperature sensor (thermocouple) 118 . The invention is not limited with respect to the type, number and location of the sensors within the apparatus 8 .
[0069] A User Interface Panel 124 is present to provide a communications interface on which a user inputs washing load parameters of his choice, including size of the washing load, nature of the cloth to be washed (e.g. delicates) and scheduling of the wash.
[0070] The input washing load parameters, together with input feedback from the sensors, are communicated into the programmable microcontroller 88 , which processes the input them according to the generic control algorithm. FIG. 6 is illustrative of this. Microcontroller 88 output then controls the functioning of the control elements of the apparatus 8 , these elements include: an air heating element 90 , an air blower 94 that blows air across the magnetron 76 , an air bypass flap 92 that vents out air during the wash cycle, a microwave choke 120 that prevents microwave energy escaping from the tub 26 , a microwave inlet 122 , an optional water heater 106 for heating the rinsing water, and an exhaust air vent 110 . Again, the invention is not limited to the type, number and location of the elements within the apparatus 8 .
[0071] The magnetron 76 also forms part of the process control elements, as its output power can be controlled by the programmable microcontroller 88 , thereby affecting the environmental conditions found within the apparatus 8 .
[0072] The table below summarises the process parameters measured the element used and the functions of the element:
[0000]
TABLE 1
Parameter
Element used
Function
Inlet air temperature
Thermocouple
Used to monitor and regulate
the temperature of air blown
into the drum during drying
Exhaust air
Thermocouple
Used to monitor the
temperature
temperature of exhausted air
during drying, to determine the
humidity of the wash load
Drain water
Thermocouple
Monitors temperature of water
temperature
drained from the drum.
Indicates the average
temperature of the cloth
Rinse water
Thermocouple
Monitors and controls the
temperature
temperature of the heated
water sprayed onto the wash
load
Exhaust air humidity
Hygrometer
Monitors humidity of the wash
load during drying
Gas presence
Gas analyser
Detects combustion products.
Used as a safety device. Can
also be used to detect volatile
organic compounds, which
indicate the type of stains
present
Microwave field
Microwave
Monitors microwave field
strength
field strength
strength. Can be used to
meter
derive wash load size and
characteristics, to tailor the
wash cycle. Also used as a
protective device prevent
arcing
Sump water level
Float switch
Detects water level to indicate
start and end of cycles
Water conductivity
Conductivity
Measures dissolved products
meter
in water. Can be used to
initiate an additional rinse
cycle. Allows less water to be
used per cycle
[0073] The apparatus and method that has been described above provides an advanced or traditional washing machine concept of cleaning via mechanical agitation of cloth in detergent-bearing water. Combining the effectiveness of intermittent high-energy microwaves during the wash cycle, with microwave-assisted drying, allows an efficient small washer/dryer to be realised.
[0074] To illustrate the efficacy of the invention, experiments were undertaken comparing the cleaning performance of continuous-wave microwave power of the type disclosed in important piece of prior art US2002/0062667, with pulsed microwaves according to the present invention.
[0075] Two identical cloths. Test-cloth 1 and Test-cloth 2 , were prepared by staining them identically with clean grease, old engine oil, tomato ketchup, Kool-aid (crème soda flavour), Pepsi cola and wood stain (Teak oil), as illustrated in FIG. 8 . Two microwave cleaning tests were done. Test-cloth 1 underwent a prior art test utilising a magnetron which generated continuous microwave energy to clean a prepared cloth. Test-cloth 2 underwent a pulsed microwave test utilising a magnetron which generated pulsed microwave energy to clean the other prepared cloth. The same type of apparatus as described in the preferred embodiment of this invention was used, the drum having a volume of 10 litres.
[0076] For the prior art test a constant microwave power of 20 kW per cubic meter of drum cavity volume (typical of a commercial magnetron attached to a domestic washing machine) was applied and the water temperature regulated at 40 degrees Celsius. For the pulsed microwave test a pulsed magnetron generating 80 kW per cubic meter of drum cavity volume was used, the pulse duty cycle being set to 25% in order to yield the same average power as the constant microwave power. Water temperature was also regulated at 40 degrees Celsius.
[0077] After 10 minutes of washing, the cloths were removed and the residual stains photographed.
[0078] FIG. 9 to 16 show analogies between the initial prepared stains (A) of FIG. 8 , the cleaning results of the prior art test on Test-cloth 1 (B) for each stain, and the cleaning results of the pulsed microwave test on Test-cloth 2 (C) for each
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The invention provides an apparatus ( 8 ) for cleaning cloth which includes a body ( 10 ) with an aperture, a closure, which is engageable with the aperture, a tub ( 26 ) with an outer shell and a cylindrical Inner cavity which corresponds with the aperture, a drum ( 28 ), which is positioned inside the cylindrical inner cavity ( 54 ) and which includes a wall, with an inner surface, an outer surface and a plurality of perforations ( 62 ) in the wait, a base ( 64 ) and an opposing mouth ( 66 ) which registers with the aperture, a drive means ( 30 ) which is connected to or engaged with the drum and which allows rotational movement of the drum about an axis, a generator ( 32 ) and an electrical power supply ( 78 ), inside the body, wherein the power supply is adapted to provide pulsating electrical power to the generator and wherein the generator is actuable to produce pulses of microwave energy at least into part of the drum.
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DESCRIPTION
This invention relates to the production of carrier particles useful as carriers of proteins and other materials, such as enzymes, lectins and more particularly antigens and antibodies, used in agglutination tests, to producing diagnostic agents therefrom, and to test kits containing such agents.
It is well known that particulate materials of biological origin, especially erythrocytes, may be used as carriers. Erythrocytes have several properties which make them particularly useful in agglutination systems. They are readily available, are extremely uniform in size, and their agglutination is easy to see. Many antigens and antibodies can be attached to them without difficulty by simple procedures, e.g. by tanning or by reaction with glutaraldehyde. These factors, and the absence of suitable alternative carriers, help to explain the widespread use of erythrocytes in agglutination systems. However, erythrocytes are not free from disadvantages. Thus, they are rather unstable and do not always sediment satisfactorily. Stability may be improved by treatment with aldehydes such as glutaraldehyde, pyruvaldehyde and formaldehyde or with bifunctional imidoesters (e.g. dimethyl suberimidate) or carbodiimide. Unfavourable sedimentation behaviour in microtitre systems can be remedied to a considerable degree by supplementing the medium in which the test is conducted with appropriate additives, e.g. heterologous serum, or a wetting agent.
A further disadvantage of erythrocytes, as of some other known carrier particles, is caused by the presence of cellular antigens on their surface. These react with naturally-occurring antibodies in serum causing so-called `non-specific` agglutination of the carrier particles. Several solutions to this problem of non-specific agglutination have been suggested. While the antigens cannot be removed from the erythrocytes without fundamental and undesirable change to them, there are compromise solutions. The most widely used of these is the provision of competitive antigens in solution in a liquid diluent. This method is not very efficient. One reason is that the serum antigens are not identical to the antigens on the surface of the erythrocyte. A second reason is that these antigens, even if isolated, generally have low chemical activity in aqueous solutions near to physiological pH and ionic strength. Thus, the problem of non-specific agglutination has not been entirely solved and limits the usefulness of erythrocytes in agglutination systems.
Synthetic carriers have been suggested as alternatives which might avoid some of the disadvantages of erythrocytes and other "natural" carriers, e.g. bacteria. Latex is an example of a synthetic carrier which has been used in slide agglutination procedures. However, it is not uniform in size unless it is graded carefully and it presents problems both with regard to the stable attachment of antigens and antibodies and the instability of the end-point. It is also prone to agglutination by serum lipid.
Although there are references in the literature to the use of yeast cells as carrier particles in agglutination tests, little practical attention appears to have been given to them. There would appear to be at least two major reasons for this. First it is well known that many human sera contain yeast agglutinins at high titre. Secondly, agglutination of yeast is not as easy to see as that of erythrocytes.
The present invention provides a process for producing carrier particles from yeast cells in a way which overcomes or at least reduces the problems of non-specific agglutination and poor visibility. This process comprises cross-linking the proteins in the yeast cell cytoplasm by reaction with a cross-linking agent, e.g. a dialdehyde, and stabilising the carbohydrate components of the yeast cell wall by reaction with an epihalohydrin or epoxide of low molecular weight.
Carrier particles produced from yeast cells in this way are particularly useful as carriers for diagnostic agents, viz. antigens (or antibodies) for the detection of antibodies (or antigens) in biological fluids, e.g. blood, serum, plasma, urine, but can also be used, for example, as carriers in enzyme immunoassay.
Baker's yeast, Saccharomyces cerevisiae, is very suitable as the starting material in this process and is readily available commercially as a stationary phase culture of uniform size distribution.
In the new process, the yeast cell cytoplasm is stabilised prior to manipulation and storage by treating the yeast, preferably in aqueous suspension, with agents which cross-link proteins and nucleic acids, and especially with dialdehydes, e.g. formaldehyde, (which is effectively a dialdehyde in this context) or glutaraldehyde. The treatment may be carried out at ambient temperature, e.g. 15° to 25° C., using 0.05 to 0.5 g of formaldehyde per gram of yeast cells at a pH of 6 to 8. The treatment is complete in 24 hours. Other aldehydes may be used in place of formaldehyde.
Before or after this treatment, the carbohydrate components of the yeast cell wall, especially the mannan, is stabilised by treatment with an epihalohydrin, e.g. epichlorohydrin, or other low molecular weight epoxide such as ethylene oxide or propylene oxide. In this way the mannan is rendered suitably stable during subsequent manipulation and storage. The treatment may be effected at ambient temperature, e.g. 15° to 25° C., using 2 to 20 grams of the epihalohydrin per gram of yeast cells. The reaction mixture is kept alkaline, e.g. with dilute sodium hydroxide solution and the reaction time is e.g. 10 minutes to 2 hours.
The invention provides two methods of reducing the interaction between antigenic sites, mainly mannan residues on the surface of the yeast cells, and serum agglutinins. These methods may be used either singly or in combination, depending on the demands of the situation, to minimize interference caused by nonspecific agglutination of the carrier of the diagnostic agents by normal human sera.
The first method involves incorporating a water-soluble mannose oligomer, and preferably a water-soluble extract of yeast cell walls (which is a convenient source of such an oligomer, i.e. of mannan) in the test system. The extract can be obtained by autoclaving an aqueous yeast suspension, treatment of the cells with acid or alkali or by extraction, e.g. with sodium dodecyl sulphate, deoxycholate or citrate buffer. After removal of particulate matter by centrifugation, mannan may be isolated from the reaction mixture after precipitation with Fehling's solution. A suitable method of extraction is described by Cifonelli J. A. and Smith F., J. Amer. Chem. Soc 77 5682 (1955). The mannan competes for the agglutinins. It is very soluble in aqueous solutions so that effective amounts can be incorporated as a basic component of a system useful in slide agglutination tests and microtitre plate tests for analysis of blood, serum or urine.
A second and preferred method involves chemical modification of cell wall antigens of the yeast so that they no longer react with serum antibodies. This can be done by treating yeast cells using esterification or etherification methods generally known in carbohydrate chemistry for blocking hydroxyl functions, e.g. acetylation, benzoylation, methylation, silylation or tetrahydropyranylation. For example, acetylation may be effected with acetic anhydride in pyridine at ambient temperature.
The chemical modification of cell wall antigens is conveniently done after stabilisation of the cell cytoplasm and stabilisation of the cell wall carbohydrate, and before or after, but preferably before, coupling of the antigen, antibody or other protein.
The carrier particles produced in accordance with the present invention may be dyed to make them readily visible. The yeast cells may be stained with a variety of dyes, for instance by mixing a dye solution with the yeast cell suspension and incubating the mixture at room temperature. It is preferred to use a reactive dyestuff. Examples of suitable dyes are basic fuchsin, fluorescein, fluorescein isothiocyanate, methyl violet and malachite green. Bifunctional dyes, such as those of the Procion M series (substances obtained by substitution of one chlorine of cyanuric chloride by a coloured molecule containing anionic solubilising groups) may also act as a coupling agent between cell wall and diagnostic agent.
Agglutination may be seen even in the presence of whole blood by using yeast cells stained with fluorescent dyes. If yeast cells are separately stained with two dyes and separately coupled to different antigens (or antibodies), more than one immunological system may be investigated concurrently on the same sample of blood. It is, of course, necessary that the dyes are distinguishable optically, e.g. basic fuschin and fluorescein which have distinct fluorescent spectra.
The present invention also provides procedures for attachment of antigens (or antibodies or other proteins or other materials used in agglutination tests) to the new carrier particles made from yeast cells. The diagnostic agents thus obtained are also a feature of the invention. In this Specification, the term "antigen" includes protein and carbohydrate antigens and simple chemical haptens. Lectins and enzymes may be attached to the carrier particles by similar methods.
The diagnostic agent, e.g. antigen, antibody, lectin or enzyme, is usually attached to residual carbohydrate, mostly either mannan, or substituted mannan, on the surface of the treated yeast cells. Attachment to cell walls proteins is not excluded, although they are not readily available on baker's yeast. Antigens or antibodies are therefore usually attached after activation of cell wall carbohydrate by reaction with a polyfunctional reagent which introduces reactive groups onto the cell surface.
Cyanuric chloride is suitable for this purpose. Examples of other suitable agents are cyanogen bromide, glutaraldehyde and carbodiimide.
Alternatively, the diagnostic agent may be attached to the yeast cells through bifunctional agents such as silane derivatives. The latter compounds have the advantage that they are effective at physiological pH and ionic strength. In some instances it may be advantageous to separate the diagnostic agent, e.g. antibody, from the yeast cell wall by a bifunctional spacer molecule, e.g. an alkylenediamine such as diaminohexane or aminoethanol. This can be introduced after activation of the surface of the treated yeast, e.g. by cyanuric chloride. Protein can be coupled to the alkylenediamine, e.g. with glutaraldehyde.
A preferred method of coupling the diagnostic agent to the treated yeast cells comprises treating the latter with 2 to 10 times their weight of cyanuric chloride in suspension in dioxane, washing the cells, and then reacting them with the diagnostic agent in aqueous suspension at ambient temperature and a pH of usually 4 to 6.
The order of the various treatment steps which are, or may be, involved in the present invention depends on the nature of the diagnostic agent and the methods used. Thus, modification of cell wall antigens by acetylation can proceed after the diagnostic agent has been attached. However, some antigens are affected adversely by the acetylation procedure so that in those cases acetylation should precede coupling of diagnostic agent. More generally, the steps should be carried out in such an order that no step interferes with any subsequent step, or vitiates the result of any preceding step.
Two major applications of carrier particles prepared from yeast cells by the new process are in (a) slide or tube agglutination tests and (b) microtitre tray tests.
(a) A suitable procedure for a slide test is as follows. 1 drop of serum at an appropriate dilution is placed on a microscope slide followed by one drop of a 1% suspension of coloured and sensitised yeast cells in physiological saline containing, when the antigenic sites of the cells have not been blocked, 50 mgml -1 of mannan. The drops are mixed with a wooden applicator stick, the slide is rotated to ensure continuous mixing and the cells are examined for agglutination, which will be essentially at a maximum after 3 minutes. Thus yeast-human serum albumen (HSA) complexes could be detected, for example, with a rabbit anti-HSA serum at 1:1000 dilution with a microscopic end point.
Basic fuchsin or Procion MX are examples of dyes which give a clearly visible end-point in a slide test.
(b) A more sensitive and quantitative test is obtained if the test procedure is conducted in a microtitre plate. Here antigen (or antibody as appropriate) levels may be estimated by serial dilution of the test sample. The procedure is essentially similar to that in current practice with haemagglutination assays in microtitre plates and typically enables up to 100 samples to be processed concurrently. The reagent-sensitised yeasts are suspended at a concentration of 0.2% in a physiological buffer mixed with serial dilutions of the test sample and allowed to settle at room temperature in microtitre wells. In the negative reaction, cells settle to a button which is largely stable after 60 minutes. When agglutination occurs this is manifest by the formation of a distinctive mat in the microtitre well.
The chemical procedures used to modify the yeast cells, e.g. the aldehyde treatment, ensure sterile preparations if standard sterile technique is followed. The diagnostic agents have a long shelf life and may be stored for months in buffers of physiological pH at 4° C. Alternatively, they may be lyophilised and reconstituted with buffer before use.
Yeasts prepared and used according to the present invention are suitable for the detection of antigens (or antibodies) in biological fluids e.g. serum, urine and whole blood. They can be used to prepare diagnostic agents or test kits based on such agents, to be employed in slide tests or microtitre systems using direct or inhibition agglutination principles. Test kits comprising a water-soluble mannose oligomer, and especially a water-soluble extract of yeast cell walls and at least one diagnostic agent, as hereinbefore described, are another feature of the invention.
The yeast cells treated in accordance with the present invention have the following advantages as carrier particles:
(a) The treated yeast cells have (when the surface hydroxyls have been blocked) low activity towards the antibodies found in high incidence in normal sera which agglutinate normal untreated yeasts.
(b) Treated yeast cells can be prepared sterile with a long shelf life under normal storage conditions, e.g. lyophilised or as a refrigerated suspension in physiological saline with added preservative.
(c) Treated yeast cells are of a suitable size and density, which contributes to the reproducibility of the preparations and appropriate sedimentation behaviour in agglutination systems including microtitre plates.
(d) Antigens and antibodies are readily attached to the yeast carrier.
(e) Treated and stained yeast cells are easily seen and agglutination is readily detected in either slide or microtitre systems by workers with little experience. This contributes to high sensitivity and reproducible results.
(f) Preparations can be made available in a range of colours allowing systems to be colour coded.
(g) Two or more antigen (and antibody) systems may be investigated concurrently using the same sample which may be whole blood. This is possible through use of detector carriers bearing different antigens in admixture, which carriers have been separately stained with fluorescent dyes of distinct emission spectra.
(h) Treated yeasts are suitable for use in either serum, urine or other biological fluids, such as plasma, or cerebrospinal fluid.
The following Examples illustrate the invention.
EXAMPLE 1
(a) Fixation of yeast cytoplasm with aldehyde
500 ml of a 50% suspension of baker's yeast Saccharomyces cerevisiae (Gist-Brocades, G.B., Ltd.) in phosphate-buffered saline (PBS, 20 mM potassium phosphate, pH 7.2 in 0.14 M sodium chloride) were stirred with 25 ml formaldehyde solution (1 part of 38% aqueous formaldehyde, i.e. formalin, added to 2 parts PBS) for 24 hours at 21° C. The cells were recovered by centrifugation, washed in PBS, suspended in PBS and adjusted to pH 7.6 with 10% ammonium hydroxide, washed by centrifugation in PBS and suspended at 50% in PBS.
In a similar way, yeast cells can be treated with 1% glutaraldehyde solution instead of the formaldehyde solution. Excess aldehyde is then removed by washing with 1% β-aminoethanol solution.
(b) Fixation of yeast carbohydrate with epichlorohydrin
15 ml of a 30% suspension of yeast cells in PBS, prepared in the manner just described, were added to 20 ml of 1 N sodium hydroxide solution and 25 ml of epichlorohydrin. The mixture was stirred rapidly at 21° C. for 30 minutes. The treated cells were then washed once with 30% ethanol-PBS and a further six times with PBS using centrifugation.
EXAMPLE 2
Concurrent fixation and staining of yeast
The procedure of Example 1(a) was followed, except that a staining solution was added with the formalin. This contained 32 ml methanol, 0.5 ml glacial acetic acid, 3 ml water and 50 mg basic fuchsin. Similar procedures were found suitable for other dyes, e.g. fluorescein isothiocyanate or rhodamine isothiocyanate.
EXAMPLE 3
Staining of yeast cells with Procion M dyes
Yeast cells treated as in Example 1(b) were suspended at a concentration of 25% in 1.25 M sodium carbonate solution and stirred with 2 volumes of a solution of Procion M dye in water at a concentration of 5 mg ml -1 for 60 minutes at 23° C. Excess dye was removed by washing the cells by centrifugation in PBS. The rate of dye uptake was dependent on the particular dye. The following dyes of the Procion M type were readily coupled.
Yellow MX--8G
Orange MX--G
Scarlet MX--G
Blue MX--3G
EXAMPLE 4
Acetylation of yeast cells
A suspension of yeast cells prepared as described in Example 1 was suspended at a concentration of 2.5% in pyridine:acetic anhydride (1:1) and the mixture was stirred at room temperature for 3 hours and centrifuged, washed in C.2 M sodium acetate buffer, pH 5.0. The yeast was recovered by centrifugation and washed to pH 7.2 in PBS.
In a similar way, the cells treated according to Example 2 or 3 may be acetylated.
EXAMPLE 5
Coupling of antigens and antibodies to yeast with cyanogen bromide
2 ml of a 1% yeast cell suspension prepared as in any of the Examples 1, 2 and 3, were added to 7 ml 0.2 M potassium phosphate buffer, pH 10.5, followed by an equal volume of water containing 0.5 g cyanogen bromide, and the mixture was stirred at 10° C. for 7 minutes. The pH was kept constant by addition of 1 N sodium hydroxide. The treated cells were separated and washed twice in 0.1 M sodium bicarbonate at 4° C. They were then resuspended with brief sonication in 0.5 ml PBS containing 25 μg HBs antigen of hepatitis B, trace labelled with 125 I HBs. After stirring at 4° C. for 18 hours, the yeast cells were separated and washed by centrifugation (3X) in PBS containing 10 mM EDTA and 0.25% gelatin. They were then resuspended at a concentration of 0.5% in the same buffer mixture with brief sonication. Approximately 95% of the antigen protein was found to be coupled to the yeast cells.
By using the same procedure, but substituting antibodies to Ig G or hepatitis B virus in amounts ranging from 10 to 100 μg, the corresponding antigens were also coupled efficiently.
EXAMPLE 6
Coupling of peroxidase to yeast with triethoxysilane
3-Aminopropyltriethoxysilane (1 ml) and 1.8 ml of 0.1% acetic acid were made up to 10 ml with water and added to 0.4 g sedimented yeast cells, which had been produced as described in Example 1. The mixture was stirred at room temperature for 24 hours and the cells were then separated and washed thoroughly with water. A 1% suspension of the treated cells in PBS, containing 5% glutaraldehyde was added to 2.5 mg of horseradish peroxidase in 2.5 ml PBS and kept at 21° C. for one hour. The cells were then separated and washed with PBS by centrifugation.
EXAMPLE 7
Fixation of protein to yeast with cyanuric chloride
10 ml of a 1% suspension of yeast cells prepared as in Example 1 were suspended in 1 N NaOH for 30 minutes at 21° C. After separation by centrifugation, the yeast cells were suspended at a concentration of 1% in dioxane containing 50 mg ml -1 cyanuric chloride and kept for 30 minutes at 21° C. with stirring. The cells were separated and washed by centrifugation sequentially in dioxane/water mixtures containing 70%, 50%, 25% and 10% dioxane respectively. The cells were finally resuspended at 5% in 50 mM sodium acetate solution of pH 5.0. Protein at 20-500 μg ml -1 was then added in PBS to the suspension and the mixture was kept for 30 minutes at 21° C. with stirring. The treated cells were finally washed by centrifugation, 6x with 2 M NaCl and 2x with PBS.
The protein used in this Example may be, for example, IgG antibodies to e.g., human IgG or lactoperoxidase.
EXAMPLE 8
Reaction of acetylated yeast with concanavalin A and antimannan antibodies
Slide tests were performed with yeast cells prepared as described in Example 1 with concanavalin A solution (10 μg ml -1 ) and serum (1:1000) showing a high titre of antibodies to mannan. In all cases agglutination was observed. The tests were also performed using acetylated cells as described in Example 4. The cells did not give detectable reactions with concanavalin A up to 500 μg ml -1 or with 1:2 dilutions of the serum.
EXAMPLE 9
Estimation of serum antibodies to hepatitis B surface antigen (HBs)
Rabbit antibody to HBs was coupled to yeast cells as described in Example 5 or 7, and the yeast cells were suspended in 0.2% GES buffer. Serial dilutions of sera to be tested for antigen were made in GES and added (25 μl) to the wells of `V`-bottomed microtitre plates (Linbro). 25 μl mannan (50 mg ml -1 ) in GES and 25 μl of yeast cell suspension were then added and mixed. The test was read against an illuminated background after standing 90 minutes at room temperature. Agglutination was shown by cells being spread out over the bottom of the well.
A negative result was shown by cells settling to a tight button. Sera were assayed in parallel for antibody to HBs by radioimmunoassay (Heathcote, Cameron and Dane, Lancet 1974 (i) page 71). Sera showing high titre by radioimmunoassay showed agglutination at dilutions up to 1:40,000. This was against a background of non-specific agglutination with normal human sera at dilutions up to 1:64.
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Yeast cells are converted into carrier particles useful as carriers for proteins and other materials useful in agglutination tests by cross-linking the proteins of the cell cytoplasm followed by stabilization of the carbohydrates of the cell wall by reaction with an epoxide. The stabilized cells obtained may be dyed and may be esterified or etherified to block the hydroxyl groups in their surfaces. They may be coupled to the protein or other material by activation, e.g. with cyanuric chloride, followed by reaction with the protein or other material to produce diagnostic agents useful in test kits.
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This application is a Divisional of U.S. patent application Ser. No. 10/330,258 filed Dec. 30, 2002 now U.S. Pat. No. 6,998,770 and claims the benefit of the Korean Patent Application No. 2002-24551 filed in Korea on May 3, 2002, both of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor device, and more particularly, to an organic electroluminescent device and a fabricating method thereof.
2. Discussion of the Related Art
In general, an organic electroluminescent device (ELD) emits light by injecting electrons from a cathode and holes from an anode into an emission layer, combining the electrons with the holes, generating an exciton, and transitioning the exciton from an excited state to a ground state. Contrary to a liquid crystal display (LCD) device, an additional light source is not necessary for the organic ELD to emit light because the transition of the exciton between states causes light to be emitted. Accordingly, the size and weight of the organic ELD can be reduced. The organic ELD has other excellent characteristics such as low power consumption, superior brightness, and fast response time. Because of these characteristics, the organic ELD is regarded as a promising candidate for next-generation consumer electronic applications, such as cellular phones, car navigation systems (CNS), personal digital assistants (PDA), camcorders, and palmtop computers. Moreover, since fabricating the organic ELD is a simple process with few processing steps, it is much cheaper to produce an organic ELD than an LCD device.
Two different types of organic ELDs exist: passive matrix and active matrix. While both the passive matrix organic ELD and the active matrix organic ELD have a simple structure and are formed by a simple fabrication process, the passive matrix organic ELD requires a relatively high amount of power to operate. In addition, the display size of a passive matrix organic ELD is limited by its structure. Furthermore, as the number of conductive lines increases, the aperture ratio of a passive matrix organic ELD decreases. In contrast, active matrix organic ELDs are highly efficient and can produce a high-quality image for a larger display with relatively low power.
FIG. 1 is a cross-sectional view of an organic ELD according to the related art. In FIG. 1 , an array element 14 including a thin film transistor (TFT) “T” is formed on a first substrate 12 . A first electrode 16 , an organic electroluminescent layer 18 , and a second electrode 20 are formed over the array element 14 . The organic electroluminescent layer 18 may separately display red, green, and blue colors for each pixel region. Generally, separate organic materials are used to emit light of each color for the organic electroluminescent layer 18 in each pixel region. An organic ELD is encapsulated by attaching the first substrate 12 and a second substrate 28 , which includes a moisture absorbent material 22 , with a sealant 26 . The moisture absorbent material 22 eliminates moisture and oxygen that may penetrate into a capsule of the organic electroluminescent layer 18 . After etching a portion of the second substrate 28 , the etched portion is filled with the moisture absorbent material 22 , and the filled moisture absorbent material is fixed by a holding element 25 .
FIG. 2 is a plan view of an organic ELD according to the related art. In FIG. 2 , a switching element T S , a driving element T D , and a storage capacitor C ST are formed in each pixel region on a substrate 12 . The switching element T S and the driving element T D can be a combination of at least two thin film transistors (TFTs) according to the operating requirements of the organic ELD. The substrate 12 is made of a transparent insulating material, such as glass or plastic. Moreover, a gate line 32 and a data line 34 cross each other with an insulating layer (not shown) in between the gate line 32 and the data line 34 . A power line 35 is placed in parallel to and separated from the data line 34 . Two TFTs are used as the switching element T S and the driving element T D . The switching element T S includes a gate electrode 36 , an active layer 40 , a source electrode 46 , and a drain electrode 50 . The driving element T D includes a gate electrode 38 , an active layer 42 , a source electrode 48 , and a drain electrode 52 . The gate electrode 36 and the source electrode 46 of the switching element T S are connected to the gate line 32 and the data line 34 , respectively. The drain electrode 50 of the switching element T S is connected to the gate electrode 38 of the driving element T D through a first contact 54 . The source electrode 48 of the driving element T D is connected to the power line 35 through a second contact 56 . The drain electrode 52 of the driving element T D contacts a first electrode 16 in a pixel region P. The power line 35 overlaps the first electrode 16 , which is composed of polycrystalline silicon, with an insulating layer interposed between the power line 35 and the first electrode 16 to form a storage capacitor C ST .
FIG. 3 is a cross-sectional view of the organic ELD shown of FIG. 2 taken along III-III according to the related art. In FIG. 3 , a driving element T D including a gate electrode 38 , an active layer 42 , a source electrode 56 , and a drain electrode 52 is formed on a substrate 12 . A first electrode 16 contacting the drain electrode 52 of the driving element T D with an insulating layer interposed between the first electrode 16 and the drain electrode 52 is formed over the driving element T D . An organic electroluminescent layer 18 emitting light of one color is formed on the first electrode 16 , and a second electrode 20 is formed on the organic electroluminescent layer 18 . The organic electroluminescent layer 18 , the first electrode 16 , and the second electrode 20 constitute an organic electroluminescent diode D EL . A storage capacitor C ST including first capacitor electrode 15 and second capacitor electrode 35 and the driving element T D are electrically connected in parallel to the switching element T S (as shown in FIG. 2 ). The second capacitor electrode 35 is connected to a power line. The source electrode 56 of the driving element T D is connected to the second capacitor electrode 35 . The second electrode 20 covers the driving element T D , the storage capacitor C ST , and the organic electroluminescent layer 18 .
FIG. 4 is an equivalent circuit diagram of an organic ELD according to the related art. In FIG. 4 , a data line 34 is in parallel to and separated from a power line 35 . A gate line 32 crosses the data line 34 and the power line 35 to define a pixel region P. A switching element T S , a driving element T D , and a storage capacitor C ST are disposed in the pixel region.
In the organic electroluminescent device according to the related art, the power line 35 limits the area of the organic electroluminescent layer. As the area of the electroluminescent layer decreases, the current density required to obtain the same brightness increases. Increasing the current density shortens the expected life span of an organic ELD. An increased current density is required to obtain sufficient brightness in a bottom emission organic ELD because the use of at least three lines causes a reduction in the aperture ratio. Moreover, as the number of conductive lines increases, the probability of defects in the conductive lines increases resulting in a decrease in the production yield.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to an organic electroluminescent device and a fabricating method thereof that substantially obviate one or more of the problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide an organic electroluminescent device where one power line is used for two adjacent pixel regions and a fabricating method thereof.
Another object of the present invention is to provide an organic electroluminescent device where an aperture ratio is improved and the expected lifetime of the device is increased, and a fabricating method thereof.
Another object of the present invention is to provide an organic electroluminescent device with a reduced probability of line defects and a fabricating method thereof.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, an organic electroluminescent device includes a substrate, a plurality of gate lines on the substrate, a plurality of data lines on the substrate, each of the plurality of data lines crossing the gate lines, a plurality of switching elements and driving elements interconnected on the substrate, and a power line disposed in parallel to the data lines on the substrate, wherein the power line is electrically connected to at least two of the plurality of driving elements.
In another aspect, an organic electroluminescent device includes a first substrate, a second substrate facing and spaced apart from the first substrate, a plurality of gate lines on an inner surface of the first substrate, a plurality of data lines on an inner surface of the first substrate, each of the plurality of data lines crossing the gate lines, a plurality of switching elements and driving elements interconnected on the first substrate, a power line disposed in parallel to the data lines on the substrate and electrically connected to at least two of the plurality of driving elements, a plurality of connection electrodes connected to the plurality of driving elements, a plurality of first electrodes on an inner surface of the second substrate, an organic electroluminescent layer on the plurality of first electrodes; and a plurality of second electrodes on the organic electroluminescent layer, each of the plurality of second electrodes contacting one of the plurality of connection electrodes.
In another aspect, a method of fabricating an organic electroluminescent device includes steps of forming a plurality of switching active layers, a plurality of driving active layers, and a plurality of active patterns on a first substrate, the plurality of active patterns including polycrystalline silicon, forming a first insulating layer on the plurality of switching active layers, the plurality of driving active layers, and the plurality of active patterns, forming a plurality of switching gate electrodes on the first insulating layer to extend over the plurality of switching active layers, forming a plurality of driving gate electrodes on the first insulating layer to extend over the plurality of driving active layers, doping the plurality of switching active layers, the plurality of driving active layers, and the plurality of active patterns with impurities to form a switching source region and a switching drain region in each of the plurality of switching active layers and a driving source region and a driving drain region in each of the plurality of driving active layers, forming a second insulating layer on the plurality of switching gate electrodes and the plurality of driving gate electrodes, forming a power line on the second insulating layer, forming a third insulating layer on the power line, forming a plurality of switching source electrodes on the third insulating layer to contact the switching source region, forming a plurality of switching drain electrodes on the third insulating layer to contact the switching drain region, forming a plurality of driving source electrodes on the third insulating layer to contact the driving source region, and forming a plurality of driving drain electrodes on the third insulating layer to contact the driving drain region, wherein at least two of the plurality of driving drain electrodes are connected to the power line.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a cross-sectional view of an organic electroluminescent device according to the related art;
FIG. 2 is a plan view of an organic electroluminescent device according to the related art;
FIG. 3 is a cross-sectional view of the organic electroluminescent device of FIG. 2 taken along III-III according to the related art;
FIG. 4 is an equivalent circuit diagram of an organic electroluminescent device according to the related art;
FIG. 5 is an equivalent circuit diagram of an exemplary organic electroluminescent device according to the present invention;
FIG. 6 is a plan view of an exemplary organic electroluminescent device according to the present invention;
FIGS. 7A to 7E are cross-sectional views of the exemplary organic electroluminescent device of FIG. 6 taken along VII-VII, showing an exemplary fabricating method of an organic electroluminescent device according to the present invention;
FIG. 8 is a cross-sectional view of an another exemplary organic electroluminescent device according to the present invention; and
FIGS. 9A to 9C are cross-sectional views of another exemplary fabricating process of an organic electroluminescent diode according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 5 is an equivalent circuit diagram of an exemplary organic electroluminescent device according to the present invention. In FIG. 5 , a data line 111 may be in parallel to and separated from a power line 112 . A gate line 101 may cross the data line 111 to define a pixel region P. A switching element T S , a driving element T D1 , a storage capacitor C ST , and an organic electroluminescent diode D EL may be formed in the pixel region P. The adjacent driving elements T D1 and T D2 of adjacent pixel regions P may be connected to the same power line 112 . Since the number of the power lines 112 may be reduced by a factor of 2, the aperture ratio may increase, and the resulting device may have a resulting reduction in material cost.
FIG. 6 is a plan view of an exemplary organic electroluminescent device according to the present invention. In FIG. 6 , a gate line 101 may cross a first and second data line 111 and 111 ′ and a power line 112 . The data lines 111 and 111 ′ and the power line 112 may be in parallel to and separated from each other. The gate line 101 and the data lines 111 and 111 ′ may define a first pixel region and a second pixel region P 1 and P 2 , respectively, that are adjacent to each other. First and second switching elements T S1 and T S2 , respectively, first and second driving elements T D1 and T D2 , respectively, and first and second storage capacitors C ST1 and C ST2 , respectively, may be formed in the respective adjacent first and second pixel regions P 1 and P 2 . The power line 112 may be used as a common first capacitor electrode for the first storage capacitor C ST1 and the second storage capacitor C ST2 . The first and second active patterns 105 and 105 ′, each positioned under the power line 112 , may be used as second capacitor electrodes of the first and second storage capacitors C ST1 and C ST2 , respectively.
The first switching element T S1 , may include a switching active layer 103 , a switching gate electrode 107 , a switching source electrode 117 and a switching drain electrode 119 . The driving element T D1 may include a driving active layer 104 , a driving gate electrode 108 , a driving source electrode 116 , and a driving drain electrode 118 . The switching drain electrode 119 may be electrically connected to the driving gate electrode 108 . Since the switching source electrode 117 is connected to the data line 111 , an image signal may be applied to the switching source electrode 117 from the data line 111 . The driving drain electrode 118 may be connected to a first electrode 122 of the organic electroluminescent diode (not shown). The driving source electrode 116 may be connected to the power line 112 . Structures of the second switching element T S2 and the second driving element T D2 may be similar to structures of the first switching element T S1 and the first driving element T D1 , respectively. The adjacent first and second driving source electrodes 116 and 116 ′ of the adjacent first and second pixel regions P 1 and P 2 may be connected to the same power line 112 . Accordingly, the first and second driving elements T D1 and T D2 may be symmetrically disposed with respect to the power line 112 in the adjacent first and second pixel regions P 1 and P 2 . The adjacent first and second active patterns 105 and 105 ′, which are made of polycrystalline silicon, may extend from the respective first and second switching active layers 103 and 103 ′ of the adjacent first and second pixel regions P 1 and P 2 . Since the number of power lines 112 may be reduced by a factor of two, the aperture ratio of the organic electroluminescent device may be improved and line defects may be prevented. Indeed, the increased aperture ratio may be particularly beneficial to a bottom emission organic electroluminescent device because the aperture ratio of such a device is generally limited.
FIGS. 7A to 7E are cross-sectional views of the exemplary organic electroluminescent device of FIG. 6 taken along VII-VII, showing an exemplary fabricating method of an organic electroluminescent device according to the present invention. In FIG. 7A , a buffer layer 102 (i.e., a first insulating layer) of an insulating material may be formed on a substrate 100 including adjacent first and second pixel regions P 1 and P 2 and adjacent first and second capacitor regions C 1 and C 2 . Each pixel region P 1 and P 2 may include a switching region (not shown) and a driving region D. A first switching active layer (not shown), a first driving active layer 104 , and a first active pattern 105 , which is made of polycrystalline silicon, may be formed on the buffer layer 102 in the switching region, driving region D and capacitor region C 1 . Similarly, a second switching active layer (not shown), a second driving active layer 104 ′, and a second active pattern 105 ′, which is made of polycrystalline silicon, may be formed on the buffer layer 102 in the switching region, driving region D and capacitor region C 2 . The first and second active patterns 105 and 105 ′ of the adjacent capacitor regions C 1 and C 2 may extend from the first and second switching active layers of the switching regions of the adjacent pixel regions P 1 and P 2 , respectively. After a gate insulating layer 106 (i.e., a second insulating layer) is formed on an entire surface of the substrate 100 , first and second switching gate electrodes (not shown) and first and second driving gate electrode 108 and 108 ′ may be formed on the gate insulating layer 106 over the respective first and second switching active layers and first and second driving active layers 104 and 104 ′. The gate insulating layer 104 may include an inorganic insulating material, such as silicon nitride (SiN x ) or silicon oxide (SiO 2 ). The first and second switching gate electrodes and the first and second driving gate electrodes 108 and 108 ′ may include a conductive metallic material, such as aluminum (Al), aluminum alloy, copper (Cu), tungsten (W), tantalum (Ta), or molybdenum (Mo). The gate insulating layer 106 may be etched to have the same patterns as the first and second switching gate electrodes and the first and second driving gate electrodes 108 and 108 ′.
Next, the first and second switching active layers, the first and second driving active layers 104 and 104 ′, and the first and second active patterns 105 and 105 ′ may be doped with impurities. Since the first driving gate electrode 108 may be used as a doping mask, the first driving active layer 104 may be divided into a first driving channel region 104 a , a first driving source region 104 b , and a first driving drain region 104 c . Similarly, the second driving active layer 104 ′ may be divided into a second driving channel region 104 a ′, a second driving source region 104 b ′, and a second driving drain region 104 c ′. Even though not shown in FIG. 7A , the first and second switching active layers may also be divided into first and second switching channel regions, first and second switching source regions, and first and second switching drain regions.
Subsequently, an interlayer insulating layer 110 (i.e., a third insulating layer) may be formed on the entire surface of the substrate 100 . The interlayer insulating layer 110 may include an inorganic insulating material, such as silicon nitride (SiN x ) or silicon oxide (SiO 2 ). A power line 112 may be formed on the interlayer insulating layer 110 between the adjacent pixel regions P 1 and P 2 . The power line 112 may include a conductive metallic material, such as aluminum (Al), aluminum alloy, copper (Cu), tungsten (W), tantalum (Ta), or molybdenum (Mo).
In FIG. 7B , a fourth insulating layer 113 having first and second switching source contact holes (not shown), first and second switching drain contact holes (not shown), first and second driving source contact holes 114 a and 114 a ′, first and second driving drain contact holes 114 b and 114 b ′, and first and second power contact holes 115 and 115 ′ may be formed on the entire surface of the substrate 100 . The first driving source contact hole 114 a and the first driving drain contact hole 114 b may expose the first driving source region 104 b and the first driving drain region 104 c , respectively. Similarly, the first switching source contact hole and the first switching drain contact hole may expose the first switching source region and the first switching drain region, respectively (not shown in FIG. 7B ). The first and second power contact holes 115 and 115 ′ exposing the power line 112 may be disposed adjacent to the respective driving regions D of the adjacent pixel regions P 1 and P 2 .
In FIG. 7C , first and second switching source electrodes (not shown), first and second switching drain electrodes (not shown), first and second driving source electrodes 116 and 116 ′, and first and second driving drain electrodes 118 and 118 ′ may be formed on the fourth insulating layer 113 by depositing and patterning a conductive metallic material, such as aluminum (Al), aluminum alloy, copper (Cu), tungsten (W), tantalum (Ta), or molybdenum (Mo). The first driving source electrode 116 and the first driving drain electrode 118 may be connected to the first driving source region 104 b and the first driving drain region 104 c , respectively. Similarly, the first switching source electrode and the first switching drain electrode may be connected to the first switching source region and the first switching drain region, respectively (not shown in FIG. 7C ). The first and second driving source electrodes 116 and 116 ′ may be connected to the same power line 112 through the first and second power contact holes 115 and 115 ′. As a result, the same source voltage may be applied to first and second driving elements T D1 and T D2 of the adjacent pixel regions P 1 and P 2 through the same power line 112 . The first and second driving elements T D1 and T D2 may be symmetrically disposed with respect to the power line 112 . The first and second driving gate electrodes 108 and 108 ′ may be connected to the first and second switching drain electrodes (not shown), respectively.
In FIG. 7D , after a fifth insulating layer 120 is formed on an entire surface of the substrate 100 , the first and second driving drain electrodes 118 and 118 ′ may be exposed. First and second lower electrodes 122 and 122 ′ may be formed on the fifth insulating layer 120 . The first and second lower electrodes 122 and 122 ′ may be connected to the first and second driving drain electrodes 118 and 118 ′, respectively. Moreover, the first and second lower electrodes 122 and 122 ′ may extend to the first and second pixel regions P 1 and P 2 , respectively. The first and second lower electrodes 122 and 122 ′ may function as an anode that injects holes. The first and second lower electrodes 122 and 122 ′ may include a material of a high work function, such as indium-tin-oxide (ITO) or indium-zinc-oxide (IZO).
In FIG. 7E , after a sixth insulating layer 124 is formed on an entire surface of the substrate 100 , the first and second lower electrodes 122 and 122 ′ may be exposed. First and second organic electroluminescent layers 126 and 126 ′ may be formed on the first and second lower electrodes 122 and 122 ′, respectively. An upper electrode 128 may be formed on the entire surface of the substrate 100 . The upper electrode 128 may function as a cathode injecting electrons. The upper electrode 128 may include a metallic material, such as calcium (Ca), aluminum (Al), or magnesium (Mg).
In another embodiment, array elements and organic electroluminescent diodes may be formed on individual substrates. Subsequently, the individual substrates may be attached.
FIG. 8 is a cross-sectional view of another exemplary organic electroluminescent device according to the present invention. In FIG. 8 , a first substrate 100 may face and be separated from a second substrate 200 . An array element including a TFT “T” may be formed on an inner surface of the first substrate 100 , and a first electrode 202 that inject electrons, an organic electroluminescent layer 208 , and a second electrode 210 that inject holes may be formed on an inner surface of the second substrate 200 . The first and second substrates 100 and 200 may be bonded together with a sealant 300 . A connection pattern 140 , which is connected to the TFT “T,” may contact the second electrode 210 during the process of attaching the first substrate 100 to the second substrate 200 . The array element may be fabricated through the process described in reference to FIGS. 7A to 7C except that a forming step for the connection pattern 140 may be added.
FIGS. 9A to 9C are cross-sectional views of an exemplary fabricating process of an organic electroluminescent diode according to the present invention. In FIG. 9A , a first electrode 202 may be formed on a substrate 200 . The first electrode 202 may function as a cathode injecting electrons into an organic electroluminescent layer (not shown). The first electrode 202 may include aluminum (Al), calcium (Ca), magnesium (Mg), or two layers of lithium fluoride/aluminum (LiF/Al), for example.
In FIG. 9B , an organic electroluminescent layer 204 may be formed on the first electrode 202 . The organic electroluminescent layer 204 may emit red, green, or blue light and may correspond to a pixel region P. The organic electroluminescent layer 204 may have a single layer structure or a multi layer structure. The organic electroluminescent layer 204 with a multi layer structure may include an emission layer 204 a , a hole transporting layer 204 b , and an electron transporting layer 204 c.
In FIG. 9C , a second electrode 206 may be formed on the organic electroluminescent layer 204 . The second electrode 206 may function as an anode that injects holes into the organic electroluminescent layer 204 and may correspond to the pixel region P. The second electrode 206 may include a conductive material having a high work function, such as indium-tin-oxide (ITO) or indium-zinc-oxide (IZO).
After the organic electroluminescent diode is formed on the second substrate, the second substrate may be bonded to the first substrate that has the array element such that the second electrode of the second substrate contacts the connection pattern of the first substrate.
Since the disclosed organic electroluminescent device has one power line for two adjacent driving elements of two adjacent pixel regions, the number of power lines is reduced by a factor of two. As a result, the aperture ratio of the disclosed organic electroluminescent device is improved. Moreover, since the disclosed organic electroluminescent device reduces line defects and decreases material cost, the production yield for organic electroluminescent devices is improved. Indeed, the increased aperture ratio resulting from the disclosed organic electroluminescent device may be particularly beneficial to a bottom emission organic electroluminescent device because the aperture ratio of a bottom emission organic electroluminescent device is generally limited.
It will be apparent to those skilled in the art that various modifications and variations can be made in the organic electroluminescent device and fabricating method thereof of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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An organic electroluminescent device includes a substrate, a plurality of gate lines on the substrate, a plurality of data lines on the substrate, each of the plurality of data lines crossing the gate lines, a plurality of switching elements and driving elements interconnected on the substrate, and a power line disposed in parallel to the data lines on the substrate, wherein the power line is electrically connected to at least two of the plurality of driving elements.
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[0001] The United States 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 Grant Nos. GM50509 and FDR000672 awarded by the National Institutes of Health and the Food and Drug Administration, respectively.
FIELD OF THE INVENTION
[0002] The invention is directed generally to a surgical device for therapeutic treatment of skin wounds in a patient or testing of skin anatomy or physiology, and a method to prepare the device.
BACKGROUND
[0003] Skin is one of the largest organs in the body and covers substantially the entire outer surface of the body. Skin is composed of two main layers: the surface epithelium or epidermis, which contains keratinocytes as one type of epidermal cells, and the subjacent connective tissue layer or dermis, which contains fibroblasts as one type of dermal cells. The functions of skin include protecting an organism from injury and dessication by serving as a barrier to infection, perceiving or detecting environmental stimuli, excreting various substances, regulating body temperature, and helping to maintain water balance. Because of its quantitative and qualitative importance, substantially intact and healthy skin is important, not only for the well being of an organism but for its very survival.
[0004] The health and integrity of skin may be compromised by congenital or acquired pathologic conditions, either acute or chronic, for which normal skin regeneration and repair processes may be inadequate. These conditions include burns, wounds, ulcers, infections, diseases and/or congenital abnormalities. Patients who are burned over a large surface area often require immediate and extensive skin replacement. Less life-threatening but chronic skin conditions, as occur in venous stasis, diabetic or decubitus ulcers as three examples, may progress to more severe conditions if left untreated, particularly because patients with these conditions have an underlying pathology. Reducing the morbidity and mortality in such patients depends upon timely and effective restoration of the structure and function of skin.
[0005] Skin substitutes derived either ex vivo or in vitro may be used to treat these or other conditions. Desirable properties of skin substitutes are ready availability, a minimum requirement for donor skin, relative simplicity to produce, and cost-effectiveness of fabrication and use. Several approaches to fabrication of skin substitutes which satisfy some or all of these requirements have been attempted, with varying degrees of success. However, no skin substitute has yet regenerated all of the structures and functions of skin. Rather, all are subsets of uninjured skin. Only a transplant of full thickness skin restores virtually all the structures and functions of normal uninjured skin, but furthermore, scars during healing.
[0006] Materials have been manufactured for therapeutic use in skin repair. These materials contain different components replacing or substituting the structures and functions of the dermis and/or epidermis. Examples of these materials include EpiCel™, which lacks a dermal component and uses the patient's own cultured keratinocytes; Integra™, which uses a collagen-glycosaminoglycan (GAG) matrix to provide an acellular dermal component and uses a thin autograft; AlloDerm™ and a thin autograft; DermaGraft™, which uses a polyglycolic acid/polylactic acid (PGA/PLA) matrix and allogeneic human fibroblasts for the dermis; Hyaff/LaserSkin™, which uses hyaluran and fibroblasts for the dermis, and hyaluran and the patient's own keratinocytes for the epidermis; and PolyActive™, which uses polyethylene oxide/polybutylthalate (PEO/PBT) and may use the patient's own fibroblasts for the dermis, and the patient's cultured keratinocytes for the epidermis.
[0007] Materials to either temporarily cover wounds, or to stimulate permanent skin repair processes, include ApliGraft™, which uses collagen gel and allogeneic fibroblasts for the dermis, and cultured allogeneic keratinocytes for the epidermis; Comp Cult Skin™ or Orcel™, which uses collagen and allogeneic fibroblasts for the dermis, and cultured allogeneic keratinocytes for the epidermis; and TransCyte™ fibroblasts for the dermis and a synthetic material, BioBrane™, for the epidermis.
[0008] While the above materials are useful to varying degrees, each has disadvantages and limitations. Some of the materials are fragile mechanically, making it difficult to perform the required manipulations and transfers of the material in large sections without tearing. Instead, the materials must be used as smaller pieces, which makes coverage of large surface areas technically laborious for the physician and cosmetically undesirable for the patient due to scarring where grafts adjoin. The materials are also susceptible to microbial contamination, which is unacceptable for patients who are already at an increased risk for infection due to their compromised conditions. The materials show varying rates of engraftment and times to heal, both of which must be considered in selecting the advantages of a particular material over another for a particular patient. For example, a material which is otherwise acceptable but which takes longer to engraft and heal is less desirable, because a successful recovery includes as rapid a return to a normal routine as possible.
[0009] The inventor's own previous composite skin replacement, disclosed in U.S. Pat. No. 5,976,878, which is expressly incorporated by reference herein in its entirety, had been successfully used for therapeutic treatment of skin wounds. It was applied surgically in a single procedure, and contained a layer of cultured epidermal cells, an acellular polymeric dermal membrane component, and a substantially nonporous lamination layer on one surface of the dermal membrane component. The dermal membrane component was formed from collagen, or collagen and a mucopolysaccharide compound, and was laminated with the same collagen-, or collagen and mucopolysaccharide-containing solution with a volatile cryoprotectant. The substantially nonporous lamination layer may be located between the dermal component and the layer of cultured epidermal cells, promoting localization of epidermal cells on the surface of the dermal component and movement of nutrients to the cells of the cellular epidermal component. This composition can also be used to deliver biologically active molecules to the site where it is applied.
[0010] Desirable features of the above-described composite skin replacement included a more rapid rate of vascularization of the area covered by the material, decreased microbial contamination, increased nutrient supply, and improved epidermal barrier function, compared to other materials. Areas covered with the composite skin replacement required less time to engraft and heal, and the material was less susceptible to microbial contamination than reported for other materials. Other desirable features are that this material was relatively non-fragile and easy to handle, and could be generated relatively rapidly, for example, within the time frame in which a burn patient requires skin grafts. However, while no other alternative material has healed excised, full-thickness wounds more rapidly, and with as low an incidence of microbial contamination, limitations still exist. Thus, there remains a need to more closely approach structural and functional properties of normal uninjured skin.
SUMMARY OF THE INVENTION
[0011] The invention is directed to a device for surgical grafting of skin wounds, or for a model of skin in vitro and in animals. The device has an acellular, biocompatible, reticulated protein- or polypeptide-containing matrix to provide an attachment substrate for one or more layers or populations of cultured dermal and/or epidermal cells. The protein can be naturally occurring or synthetic and may be less than a full protein, for example, it may be a polypeptide. In various embodiments, cells used to populate the matrix may be from the recipient (autologous), another human (allogeneic), from another species (xenogeneic), or from multiple sources (chimeric). The epidermal cells include keratinocytes, melanocytes, immunocytes, and/or stem cells. The dermal cells include fibroblasts, endothelial cells, immunocytes, nerve cells, myocytes, and/or stem cells. Either or both of the epidermal and dermal cells may be genetically modified.
[0012] The invention is also directed to a method to prepare a device for surgical grafting of skin wounds, or for a model of skin in vitro and in animals. To a matrix on an absorbent substrate, a cell suspension is provided to deliver cells to the matrix for attachment. The inoculated matrix is incubated under conditions sufficient to result in a cellular device.
[0013] The device may also be used on a non-wounded surface, a minimally wounded surface, or a surgically prepared surface not requiring skin grafting, but for which the cells of the skin substitute may be bioengineered to provide a physiologic factor lacking in the recipient. Such a factor may be a protein, for example, insulin or coagulation Factor VI II, and may be provided, respectively, to a diabetic or hemophiliac patient having a deficiency of that protein.
[0014] Besides its use as a skin substitute, the inventive device can also be used as a living substrate on which to perform toxicological or other tests on various topically applied compounds, such as drugs, cosmetics, moisturizers, lotions, environmental toxins, industrial chemicals, etc. The device, containing cells from a particular individual, can show an individualized response to a variety of compounds. Such an approach may be useful to test the toxicity of skin contact compounds. The device may also be useful as a medical diagnostic tool to test individuals with allergies, or who exhibit dermal reactions to components found in pharmaceutical or over-the-counter products. In this embodiment, the device will reduce or eliminate in vivo toxicity testing.
[0015] These and other features of the invention will be appreciated with reference to the following detailed description.
DETAILED DESCRIPTION
[0016] The inventive, surgically-applied device for treatment of skin wounds is a matrix which supports dermal cells and/or epidermal cells. More particularly, an acellular biocompatible reticulated matrix is used as a support or scaffold to which cultured cells are applied, attach, and proliferate. In one embodiment, a reticulated protein matrix supports a continuous layer or population of cultured dermal cells, and an overlying layer or population of cultured epidermal cells. After incubating the inoculated matrix under conditions facilitating cell growth, the device is transplanted surgically to the patient. In one embodiment, transplantation may be performed within one day (about 16 hours to about 24 hours) after epidermal cell inoculation of the matrix. In another embodiment, transplantation may be performed within one month after epidermal cell inoculation of the matrix. Within these times, the device develops properties preferred for a therapeutic skin graft material. The use of cultured cells to form the material, in contrast to tissue obtained by conventional harvesting of split thickness skin with a dermatome, provides the advantage of much larger numbers of epidermal and dermal cells than by conventional harvesting, and thereby greatly reduces the requirement for donor skin to complete closure of extensive, full-thickness skin wounds.
[0017] Once the device is grafted to the patient, the biodegradable matrix is absorbed by the body. The cells organize to form functional skin tissue, referred to as an engrafted cultured skin substitute. The device has many of the properties and structures that are found in normal, uninjured skin, and functions as does normal, uninjured skin to protect the individual from fluid loss and microbial infection. For example, the device functions as an epidermal barrier, which is definitive of normal skin function as known to those skilled in the art. The device establishes a basement membrane, and maintains the same anatomic configuration of the cellular layers or populations as in normal, uninjured skin. The device produces and releases angiogenic factors and mediators of the inflammatory process, as does normal, uninjured skin. The device is effectively vascularized in less than one week, and becomes partially vascularized within two days after transplant.
[0018] In another embodiment of the invention, the device is used as a temporary skin substitute. In this embodiment, the matrix may be populated with cells having non-autologous genotypes. For example, cultured epidermal and/or dermal cells may be autologous, that is, obtained from the individual who is the intended recipient of the device and which can be used in a permanently engrafted device. In other embodiments, the epidermal and/or dermal cells may be allogeneic, that is, obtained from a human other than the recipient. In yet other embodiments, the epidermal and/or dermal cells may be xenogeneic, and obtained from a non-human animal, such as porcine epidermal and/or dermal cells to take advantage of the similarity of features and characteristics in pig skin in comparison to human skin. Xenogeneic cells may also be obtained from plants or microbes. The use of different sources for epidermal cells and/or dermal cells results in a genetically chimeric device. Regardless of the source of epidermal and/or dermal cells, one or more cells may be modified genetically. Various factors may affect the selection of particular genotypic compositions of the cells. For example, the use of allogeneic or xenogeneic cells may shorten the preparation time of the device, or may further reduce the requirement for donor skin from the patient. Depending upon the particular condition of the recipient, these factors may be an important determinant.
[0019] If skin cells from the patient to be treated with the inventive device are used, they are obtained from a biopsy of a healthy area of the patient's skin, using techniques known to one skilled in the art including punch biopsy, shave biopsy, and full thickness skin excision with suture closure. The dermal and epidermal cellular components are then separated and isolated into dermal cells and epidermal cells, as described by Boyce and Ham in J. Tissue Culture Methods 1985;9:83, and chapter 13 in In Vitro Models for Cancer Research , Vol. 3, p. 245, Webber and Sekely, Eds. CRC Press, Boca Raton Fla. (1986), both of which are expressly incorporated by reference herein. The dermal and epidermal cells are individually cultured, as described by Boyce and Ham in J. Invest. Dermatol. 1983;81:335, and chapter 28 in Methods in Molecular Medicine, Vol. 18, p. 365, Morgan & Yarmush, Eds., Humana Press, Totowa N.J. (1998), both of which are expressly incorporated by reference herein.
[0020] Various cells in the epidermis, for example, keratinocytes, melanocytes, immunocytes, stem cells, or others, and various cells in the dermis, for example, fibroblasts, endothelial cells, immunocytes, nerve cells, myocytes, stem cells, or others, may be cultured either individually or collectively. After adequate cell numbers are obtained, or a specific cellular physiology is expressed, the cellular populations are harvested for subsequent population of the matrix. In various embodiments, the ratio of epidermal to dermal cells used to inoculate the matrix is in the range of about 2:1 or 1:1, but other cell ratios are also included.
[0021] Depending upon the application for which the device is prepared, selected types of epidermal cells and/or dermal cells may be included or excluded. As one example, a device may include melanocytes to restore pigmentation in the transplant site. Restoration of skin pigmentation is defined as any increase in the anatomic or physiologic function of skin color of the graft, although the extent of color may be more or less than in uninjured skin. As another example, a cultured skin composition may include endothelial cells to stimulate formation of blood vessels.
[0022] In preparing the device, any biocompatible material that is permissive as a substrate for culture and transplantation of cultured cells may be used. A full length natural or synthetic protein may be used, or a polypeptide may be used. One embodiment uses a freeze-dried sponge of collagen, either alone or in combination with a carbohydrate (a mucopolysaccharide, such as a glycosaminoglycan (GAG), particularly chondroitin-6-sulfate). The collagen may be bovine skin collagen, bovine tendon collagen, collagen from other tissue sources (e.g. bone, muscle), other xenogeneic sources (e.g. pig, sheep, goat, etc.), genetically engineered sources, human sources, or a combination of any of the above. Other proteins such as elastin or reticulin, or polymers of amino acids, whether naturally occurring or synthetic, may be used.
[0023] In one embodiment of preparing the matrix, a coprecipitate of collagen-GAG is cast, frozen, and dehydrated to form a reticulated matrix. This matrix is subsequently sterilized, rehydrated, and laminated by inoculation with cultured dermal and epidermal cells. Inoculation is performed at ambient humidity (room air) and the inoculated matrix is incubated in an atmosphere with saturated or reduced humidity. The matrix is then incubated, either submerged in a medium or with the matrix contacting a gaseous atmosphere. In the latter embodiment, the inoculated cells are on the atmospheric surface of the matrix. Each of these steps is now described in further detail.
[0024] Matrix-Forming Protein-Containing Fluid
[0025] A dispersion of collagen is prepared by presolublizing collagen (6.42 mg/ml) acetic acid (0.01 M to 1.0 M), usually for up to sixteen hours, after which the dispersion is stored at 4° C. A coprecipitate with a glycosaminoglycan (GAG), such as chondroitin-6-sulfate, may then be prepared if a carbohydrate is to be added. Chondroitin-6 sulfate (3.45 mg/ml) is added to acetic acid (0.01 M to 3.0 M).
[0026] The previously prepared collagen dispersion is redispersed for at least five minutes and transferred to a stainless steel insulated beaker with a recirculating refrigerated jacket. The GAG solution is added to the protein solution by any means which will produce an adequate agitation and shear to form a co-precipitate. This can be done by transferring the GAG solution to a drip bottle and adding the GAG to the collagen using a drip set to which a 22 gauge needle is attached, allowing the GAG solution to drip into 750 ml of the collagen dispersion, being mixed at a speed of 5,000 revolutions per minute (rpm) and maintained at 4° C., at a rate of one drop per ten seconds. After the entire volume of GAG has dripped into the collagen, the collagen-GAG coprecipitate is transferred to bottles and centrifuged to remove trapped air bubbles. The froth that collects on top is removed by aspiration, and the collagen-GAG coprecipitate is then collected.
[0027] Preparation of Crosslinked Matrix
[0028] The protein-containing fluid, with or without carbohydrate, is prepared to form the matrix. As preliminary steps, a lyophilizer (freeze-drying) apparatus is pre-chilled to about −35° C. to about −50° C. In one embodiment, a freezing bath is prepared in a high density polyethylene (HDPE) container containing 95% ethanol that has been pre-chilled at about −45° C. for at least four hours. However, any type of apparatus or configuration may be used which will remove heat at a controlled rate so that a drop in temperature, sufficient to freeze the matrix, occurs within a time frame of up to about four hours. For example, the time and temperature may be regulated to bring about a temperature drop from about 4° C. to about −40° C. within about two hours, or a temperature drop from about 4° C. to about −75° C. within about four hours.
[0029] The protein solution is introduced into an apparatus, more fully described in co-pending U.S. patent application Ser. No. ______ entitled “Apparatus for Preparing a Biocompatible Matrix” filed on even date herewith, which is expressly incorporated by reference herein in its entirety. The result is a matrix with a composition, structure, and properties which support the cultured dermal and epidermal cells to promote formation of the device.
[0030] Briefly, a matrix-forming solution is contained between two plates of a thermally conductive material, with a gasket forming the remaining sides of a sealed chamber. The thickness of the gasket, in the range of about 0.1 mm to about 10 mm, regulates the thickness of the resulting matrix. The protein solution is introduced into the chamber. When the entire volume of solution has been added, the chamber is reversibly sealed, for example, by clamping. The chamber is then exposed to temperatures and/or conditions sufficient to remove heat at the previously-described, controlled rate to solidify the matrix.
[0031] After the matrix has solidified, the plates are separated to expose the frozen matrix. A plate containing the matrix is transferred to a refrigerated (−45° C.) shelf of a lyophilizer. Vacuum is then applied and, when the pressure is less than 60 mT, heat is also applied (30° C.). Lyophilization occurs overnight to a final vacuum of less than 15 mT. The freeze-dried matrix detaches spontaneously and is then transferred to a supporting sheet.
[0032] The matrix is cross-linked in the absence of a chemical crosslinking agent. This desirably eliminates any possible toxicity associated with residual chemical crosslinking agents, which may not be completely removed even after repeated washings. In one embodiment of the invention, thermal crosslinking is used. This is achieved by thermal dehydration in a vacuum oven (Lab-Line 3628) at about −100 kPa at about 105° C. for about 24 hours. Once crosslinking has occurred, the matrix is then stored in a desiccator at room temperature, either on a foil sheet or on other support material, for up to about three months.
[0033] The crosslinked matrix has a thickness of three millimeters or less. In various embodiments, and depending upon other factors such as a desired site of implantation, the crosslinked matrix has a thickness in the range of about 0.1 mm to about 1.0 mm, about 0.1 mm to about 2.0 mm, or about 0.1 mm to about 3.0 mm. A matrix having a thickness in the range of about 0.1 mm to about 1.0 mm, when inoculated with cells as described, results in a device having a thickness in the range of about 50 μm to about 500 μm. When such a device is used to treat skin wounds, this thickness desirably promotes rapid vascularization, nutrient delivery, population of the device with cells, and waste removal, and desirably facilitates degradation of the matrix after transplant, leaving only the cellular components of the composition remaining.
[0034] The cross-linked matrix is then cut into desired sizes and/or shapes. In one embodiment, it is cut into squares (for example, 9 cm×9 cm, 11 cm×11 cm, or about 19 cm×19 cm) using a straight edge and scissors. The matrix is packaged in a sterilization pouch (for example, Self-Seal™), and stored at room temperature in a desiccator for up to about three months.
[0035] The matrix is sterilized before inoculation, for example, by gamma irradiation at a dose of at least about 2.5 MRad (for example, SteriGenics, Westerville Ohio). Once sterilized, the matrix sterilization pouch is stored at room temperature in a desiccator for up to about one year.
[0036] Cellular Inoculation of the Matrix
[0037] All solutions are sterile filtered through a 0.22 μm filter, and all procedures are performed using aseptic techniques, as known to one skilled in the art.
[0038] The matrix is transferred to a container of any shape that will hold a volume of about 250 μl/cm 2 of matrix/incubation. The matrix is rinsed three times, for thirty minutes each rinse, with Hepes-buffered saline (HBS) solution, and two times for thirty minutes each with Dulbecco's Modified Eagle's medium (DMEM) solution or other suitable solution, as known to one skilled in the art.
[0039] After the final rinse, the medium is aspirated from the container and an inoculation frame is placed over the surface of the matrix. The inoculation frame is a square or rectangular frame made from a material that is chemically unreactive (e.g., stainless steel, Teflon™), under physiologic conditions (i.e., 37° C., saturated humidity, neutral pH, isotonic solutions). The frame is sufficiently massive (e.g., several ounces) to generate a seal to the movement of cells that are inoculated within its perimeter. The seal may be increased by addition of a bevel on the side contacting the matrix to increase the mass/area ratio, but with a sufficient amount of flat or rounded surface contacting the matrix to prevent cutting of the matrix. About 10-12 ml of supplemented DMEM, as will be described, is placed into the frame. The matrix and frame, containing supplemented DMEM, are permitted to equilibrate at 37° C./5% CO 2 for at least fifteen minutes before inoculating the matrix with cells.
[0040] Cells may be inoculated either submerged or emerged into the rehydrated matrix. In one embodiment, termed “submerged inoculation”, cells are inoculated on a matrix submerged in medium. Culture medium without cells is added to the culture vessel outside of the inoculation frame to assure a secure seal, evidenced by no leakage of the medium from outside to inside the frame. After the preparation of a cell suspension by trypsinization of cells from selective cultures, dermal cells are inoculated at a density in the range of about 0.05-1.0×10 6 cells/cm 2 . Subsequently, after the dermal cells have attached, epidermal cells are inoculated as suspensions and permitted to attach to the layer or population of dermal cells. Alternatively, combinations of dermal and epidermal cells may be inoculated simultaneously. The ratio of dermal cells to epidermal cells may be in the range of about 2:1 to about 1:1, but other ratios may be used. In other embodiments, dermal cells alone or epidermal cells alone may be inoculated.
[0041] The inoculation frame remains in place for about 12-48 hours after inoculation of the last cells onto the matrix. The inoculation frame is then removed, the edges of the matrix without cells are excised, and the inoculated surface of the matrix is exposed to the air to stimulate organization of the epidermal cells and the formation of an epidermal barrier. Before removing the inoculation frame, Dulbecco's Modified Eagle's medium with permissive supplements is used. After removing the frame and exposing the matrix to air, the medium is supplemented with progesterone and epidermal growth factor.
[0042] In another embodiment, termed “lifted inoculation”, cells are inoculated on a matrix emerged from the culture medium. In this embodiment, the matrix is rehydrated and placed onto an absorbent substrate, with the upper surface contacting the atmosphere. The suspension of dermal cells is inoculated onto the matrix, and the drainage of the medium delivers the cells to the surface of the matrix, after which they attach. Simultaneously, or after up to one week, a suspension of epidermal cells is inoculated onto the matrix.
[0043] More specifically, a sterile, non-adherent, porous membrane (e.g., medical grade mesh (N-Terface®, Winfield Laboratories, Inc., Dallas Tex.); Teflon™; Millipore or Whatman filters of polyethersulfone, polyvinylidene fluoride, mixed cellulose ester, etc., hereinafter referred to as a porous membrane) is placed into a sterile tissue culture dish with HBS, and the sterile matrix is placed on top of the porous membrane and rehydrated. A sterile, absorbent material (e.g., Merocel™ that is 9 mm thick and of intermediate density (CF 100); cotton, gauze, etc., hereinafter referred to as an absorbent material) is placed into a second sterile dish to which excess DMEM is added. The dish is returned to the incubator to equilibrate.
[0044] Preparatory to inoculating dermal cells, the matrix is centered on the porous membrane and the medium is aspirated. The matrix/porous membrane is laid on top of the absorbent material. The area of the matrix is measured to the nearest 0.5 cm and the dish is reincubated. Dermal cells are harvested and counted. The density is adjusted to 3×10 6 cells/ml with supplemented DMEM, and about 5×10 5 dermal cells/cm 2 are inoculated onto the matrix. Supplemented DMEM is added, and the dish is returned to the incubator.
[0045] On the following day, the unit is transferred to a sterile 150 mm dish containing 25 ml of supplemental DMEM containing progesterone and epidermal growth factor, hereinafter referred to as UCMC 160. The medium is aspirated and an additional 25 ml of fresh UCMC 160 medium is added. The process is repeated daily until inoculation of epidermal cells.
[0046] Preparatory to inoculation of epidermal cells, sterile absorbent material is placed in a sterile dish saturated with UCMC 160 medium and incubated. Several hours prior to the inoculation, the previously inoculated cell/matrix/porous membrane unit is placed on top of the absorbent material. The area of the matrix is measured to the nearest 0.5 cm, and the dish is reincubated. Epidermal cells are harvested and counted. The density is adjusted to 1.2×10 7 cells/ml UCMC 160 medium, and the matrix is inoculated with 1×10 6 cells/cm 2 , using the tip of the pipette to break the surface tension of the inoculum and make a continuous layer of epidermal cells on the inoculated matrix. After 30-60 minutes of incubation, UCMC 160 medium is added to the outside of the absorbent material. The inoculated matrix is incubated (day 0).
[0047] On day 1, the medium around the absorbent material is aspirated and fresh medium is added before reincubation. On day 2, a sterile lifting frame, consisting of wire mesh and cotton, is placed into a new sterile dish and the appropriate volume of UCMC 160 medium is added to bring the medium into contact with the wire mesh and cotton. The inoculated matrix is moved onto the lifting frame and saturated cotton, and is reincubated. The process is repeated on day 3. From day 4 onward, the process is repeated using supplemented UCMC 161 medium.
[0048] UCMC 161 medium is used for the inoculated matrix. To a base of DMEM with reduced phenol red, the following supplements (all available from Sigma, St. Louis Mo.) are added to achieve a final concentration within the ranges as indicated: strontium chloride (0.01 mM to 100 mM); linoleic acid/BSA (0.02 μg/ml to 200 μg/ml); insulin (0.05 μg/ml to 500 μg/ml); triiodothyronine (0.2 μM to 2000 μM); hydrocortisone (0.005 μg/ml to 50 μg/ml); a combination of penicillin (100 U/ml), streptomycin (100 μg/ml), amphotericin (0.25 μg/ml); and ascorbic acid-2-phosphate (0.001 mM to 10 mM).
[0049] To prepare UCMC 160 medium, progesterone (0.1 nM to 1000 nM) and epidermal growth factor (0.01 ng/ml to 100 ng/ml) are added to UCMC 161 medium to promote transient proliferation of keratinocytes.
[0050] Without being bound by a specific theory or mechanism, the following events likely occur. Upon inoculation, fibroblasts likely form a physiological attachment to the collagen matrix by binding via collagen-specific receptors. Because the matrix is reticulated and thus contains multiple continuous surfaces, as opposed to being perforated with direct channels or openings from a top surface to a bottom surface, the fibroblasts or other dermal cells being inoculated need not fill these channels or openings in the matrix before the epidermal cells may be added. Rather, upon inoculation, the dermal cells attach to the reticulations, and thus are able to provide a continuous surface lamination for the subsequently inoculation of epidermal cells within a shorter time period than is possible using a perforated matrix.
[0051] After inoculation, the device is incubated under conditions facilitating cell growth, maintenance, and division anywhere from less than one day (within about 16 hours to about 24 hours) up to about six weeks. The cells form a substantially continuous monolayer or multilayer surface. The device may then be transplanted into a patient, or it may be retained under these conditions until transplant. During this period, the matrix desirably degrades, cells proliferate, and new human collagen and biopolymers are deposited, all of which promote vascularization and engraftment of the device.
[0052] Engraftment of the Device
[0053] Preparatory to surgical transplantation of the device, the wound is prepared by minimizing microbial contamination and maximizing vascular supply. These conditions are usually accomplished by early (i.e., less than one week post burn) tangential excision of burn eschar to a viable base, and temporary protection of the excised wound with cadaver allograft skin or with a dermal substitute (i.e., Integra Artificial Skin™).
[0054] At the time of transplantation, the temporary component of the allograft or dermal substitute is removed to generate a highly viable graft bed with low microbial contamination. Hemostasis is attained, and one or more of the cultured skin devices are transplanted and attached with surgical staples. The device is dressed with non-adherent dressing (e.g., N-Terface®), fine-meshed cotton gauze, and bulky cotton gauze, with perforated catheters for irrigation of the device, for example, with a solution containing non-cytotoxic antimicrobial agents. Dressing changes and examination are performed on postoperative days 2 and 5, after which time the wet dressings are typically discontinued, and an appropriate antimicrobial ointment (for example, equal parts Neomycin:Bactoban:Nystatin) is applied. The ointment is applied to unhealed areas until healing is complete. Once engrafted, various agents that may facilitate the healing process and/or minimize potential complications may be applied topically to the device. For example, a nutrient solution such as a modified cell culture medium can supply nutrients to the wound during vascularization, and/or a non-cytotoxic antimicrobial solution can reduce or control microbial contamination.
[0055] The inventive device may also be used for in vitro testing. For example, the device may be used for the evaluation of compounds intended for application to the skin, such as cosmetics and/or topical therapeutic or preventative agents, or may be used for the evaluation of compounds which may contact the skin inadvertently, such as industrial chemicals and/or environmental toxins. Information derived using the inventive device for any of these agents will be beneficial in a variety of applications. As one example, it may allow determination of a single agent's, or a combination of agents∓, absorption, distribution, biotransformation, and elimination parameters in skin. As another example, it may allow determination of a single agent's, or a combination of agents', toxicity to one or more cell types in skin. As yet another example, it may allow qualitative and quantitative assessment of a single agent's, or a combination of agents', uptake in skin for formulation, permeability, and dosimetry studies. As still another example, it may allow evaluation of barrier function upon insult by a single agent or a combination of agents. Other examples of applications will be appreciated by one skilled in the art. Such methods have a variety of benefits: they reduce or eliminate the need to conduct in vivo studies, they allow more controlled screening comparisons and hence provide more reproducible data, they permit administration of otherwise toxic chemicals and/or radiolabeled agents, etc. Additionally, the above-described and similar assessments may be customized by using cells from a particular individual, for example, an individual prone to allergic reactions.
[0056] Methods of using the device for in vitro testing involve, generally, preparing the device or using a prepared device, and applying the agent to the device. The agent may be applied, either directly or indirectly, to any surface of the device, and/or may be added to the medium in which the device is incubated, and/or may be added within an environment surround the device, etc. The agent may also be inoculated into the device.
[0057] A cultured skin device and method of preparing the device is thus disclosed. The inventive device and method provide treatment of skin wounds, and have structural and functional characteristics of normal uninjured skin. In one embodiment, the device contains cells from the patient to whom it is applied, thus reducing or eliminating the concern of donor compatibility. Other variations or embodiments of the invention will also be apparent to one of ordinary skill in the art from the above description. As one example, cells from non-human animals may be used to produce a device for veterinary applications. As another example, the biocompatible reticulated matrix may be acellular, or may contain only a dermal cell component, or only an epidermal cell component. As yet other examples, the epidermal cells may be only melanocytes, or the dermal cells may be only endothelial cells. Thus, the forgoing embodiments are not to be construed as limiting the scope of this invention.
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A device, and method of making the device, capable of therapeutic treatment and/or for in vitro testing of human skin. The device may be used on skin wounds for burned, injured, or diseased skin, and provides structures and functions as in normal uninjured skin, such as barrier function, which is a definitive property of normal skin. The device contains cultured dermal and epidermal cells on a biocompatible, biodegradable reticulated matrix. All or part of the cells may be autologous, from the recipient of the cultured skin device, which advantageously eliminates concerns of tissue compatibility. The cells may also be modified genetically to provide one or more factors to facilitate healing of the engrafted skin replacement, such as an angiogenic factor to stimulate growth of blood vessels. The inventive device is easy to handle and manipulate for surgical transplant, can be made into large sheets to minimize the number of grafts required to cover a large surface area to be treated, and can be produced within the time frame to treat a burned individual requiring a skin graft.
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This application claims the benefit of Korean Patent Application No. P2003-100655 filed in Korea on Dec. 30, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a liquid crystal display, and more particularly to a liquid crystal display device and a driving method thereof that prevents gravity degradation to thereby improve picture quality.
2. Description of the Related Art
Generally, a liquid crystal display (LCD) controls the light transmittance of a liquid crystal using an electric field to display a picture. The LCD includes a liquid crystal display panel having liquid crystal cells arranged in a matrix, and a driving circuit for driving the liquid crystal display panel.
In the liquid crystal display panel, gate lines and data lines are arranged such that the gate lines and the data lines cross each other. The liquid crystal cell is positioned at each area where the gate lines cross the data lines. The liquid crystal display panel is provided with a pixel electrode and a common electrode for applying an electric field to each of the liquid crystal cells. Each pixel electrode is connected, via source and drain electrodes of a thin film transistor as a switching device, to any one of the data lines. The gate electrode of the thin film transistor is connected to any one of the gate lines thereby allowing the application of a pixel voltage signal to the pixel electrodes for each line.
The driving circuit includes a gate driver for driving the gate lines, a data driver for driving the data lines, a timing controller for controlling the gate driver and the data driver, and a power supply for supplying various driving voltages used in the LCD. The timing controller controls a driving timing of the gate driver and the data driver and applies a pixel data signal to the data driver. The power supply generates driving voltages such as a common voltage VCOM, a gate high voltage VGH and a gate low voltage VGL, etc. The gate driver sequentially applies a scanning signal to the gate lines to sequentially drive the liquid crystal cells on the liquid crystal display panel line by line. The data driver applies a data voltage signal to each of the data lines when the scanning signal is applied to one of the gate lines. Accordingly, the LCD controls the light transmittance by an electric field applied between the pixel electrode and the common electrode in response to the pixel voltage signal for each liquid crystal cell, thereby displaying a picture.
The data driver and the gate driver directly connected to the liquid crystal display panel integrate into a plurality of integrated circuits (IC's). Each of the integrated data drive IC's and gate drive IC's mount in a tape carrier package (TCP) and connect to the liquid crystal display panel by a tape automated bonding (TAB) system. In addition, the integrated data drive IC's and gate drive IC's may mount onto the liquid crystal display panel using a chip on glass (COG) system.
Herein, the drive IC's connected, via the TCP, to the liquid crystal display panel by the TAB system receives control signals and driving voltages input from the exterior over signal lines provided on a printed circuit board (PCB) connected to the TCP. In addition, the data drive IC's are connected, in series via signal lines provided on the data PCB, to each other, and commonly receive control signals and a pixel data signal from the timing control signal and driving voltages from the power supply. The gate drive IC's are connected, in series via signal lines provided on the gate PCB, and commonly receive control signals from the timing controller and driving voltages from the power supply.
The drive IC's mounted onto the liquid crystal display panel by the COG system are connected to each other by a line on glass (LOG) system in which signal lines are mounted on the liquid crystal display panel (i.e., a lower glass substrate) and receive control signals and driving voltages from the timing controller and the power supply.
Commonly, when the drive IC's are connected to the liquid crystal display panel by the TAB system, a LOG system is adopted to eliminate the PCB, thereby permitting the manufacturing of thin liquid crystal displays. Particularly, the gate drive IC's require relatively small signal lines. The small signal lines are provided on the liquid crystal display panel by the LOG system and thereby eliminate the gate PCB. Thus, the gate drive IC's of a TAB system are connected, in series, to each other over signal lines mounted on the lower glass substrate of the liquid crystal display panel. The gate drive IC's commonly receive control signals and driving voltage signals, which are hereinafter referred to as “gate driving signals”.
For instance, as shown in FIG. 1 , a liquid crystal display omitting a gate PCB by utilizing LOG-type signal lines includes a liquid crystal display panel 1 and a plurality of data TCP's 8 connected between the liquid crystal display panel 1 and a data PCB 12 . The liquid crystal display also includes a plurality of gate TCP's connected to other side of the liquid crystal display panel 1 , data drive IC's 10 mounted in the data TCP's 8 , and gate drive IC's 16 mounted in the gate TCP's 14 .
The liquid crystal display panel 1 includes a lower substrate 2 provided with various signal lines and a thin film transistor array, an upper substrate 4 provided with a color filter array, and a liquid crystal injected between the lower substrate 2 and the upper substrate 4 . The liquid crystal display panel 1 has a picture display area 21 consisting of liquid crystal cells provided at intersections between gate lines 20 and data lines 18 in order to display a picture. At the outer area of the lower substrate 2 located at the outer side of the picture display area 21 , data pads extending from the data lines 18 and gate pads extending from the gate lines 20 are positioned. Further, a LOG-type signal line group 26 for transferring gate driving signals applied to the gate drive IC 16 is positioned at the outer area of the lower substrate 2 .
The data TCP 8 is mounted with the data drive IC 10 , and is provided with input pads 24 and output pads 25 electrically connected to the data drive IC 10 . The input pads 24 of the data TCP 8 are electrically connected to the output pads of the data PCB 12 while the output pads 25 are electrically connected to the data pads on the lower substrate 2 . Particularly, the first data TCP 8 is further provided with a gate driving signal transmission line group 22 electrically connected to the LOG-type signal line group 26 on the lower substrate 2 . The gate driving signal transmission line group 22 applies gate driving signals from the timing controller and the power supply, via the data PCB 12 , to the LOG-type signal line group 26 .
The data drive IC's 10 convert digital pixel data signals into analog pixel voltage signals and applies the analog voltage signals to the data lines 18 on the liquid crystal display panel.
Similarly, a gate drive IC 16 is mounted on the gate TCP 14 , and is provided with a gate driving signal transmission line group 28 electrically connected to the gate drive IC 16 and output pads 30 . The gate driving signal transmission line group 28 is electrically connected to the LOG-type signal line group 26 on the lower substrate 2 while the output pads 30 are electrically connected to the gate pads on the lower substrate 2 .
Each gate drive IC 16 sequentially applies a scanning signal such as a gate high voltage signal VGH during an interval to a gate line 20 in response to input control signals. Further, the gate drive IC 16 applies a gate low voltage signal Vgl to the gate line 20 in an interval other than the interval supplied where the gate high voltage signal VGH is supplied.
The LOG-type signal line group 26 usually includes signal lines that supply driving voltage signals from the power supply, such as a gate high voltage signal VGH and a gate low voltage signal VGL. The LOG-type signal line group 26 also includes a common voltage signal VCOM, a ground voltage signal GND and a supply voltage signal VCC. Furthermore, the LOG-type signal line group 26 has gate control signals from the timing controller, such as a gate start pulse GSP, a gate shift clock signal GSC and a gate enable signal GOE. The LOG-type signal line group 26 further includes a common line LVCOM for supplying a common voltage VCOM.
A LOG-type common line LVCOM is arranged, in parallel, in a fine pattern in a very confined narrow space like a pad portion positioned at an outer area of a picture display part 21 . The LOG-type common line LVCOM is formed from a gate metal layer similar to the gate lines 20 . A metal such as AlNd having a relatively large resistivity of 0.046 is usually used as the gate metal. As the LOG-type signal common line LVCOM is formed in a fine pattern within a confined area and is made from a gate metal having a relatively large resistivity value, the LOG-type signal common line LVCOM has a greater resistance than the signal lines formed from a copper film at an existent gate PCB. Because a resistance value of the LOG-type common line LVCOM is in proportion to a line length, a line resistance value increases as the LOG-type common line LVCOM extends away from the data PCB 12 , thereby attenuating a gate driving signal. As a result, the common voltage VCOM transferred over the LOG-type common line LVCOM is distorted due to its line voltage value, thereby causing picture quality deterioration of a picture displayed on the picture display part 21 .
This will be described in detail with reference to FIG. 2 below.
Referring to FIG. 2 , a LOG-type common line LVCOM of a related art LCD is included in the LOG-type signal line group 26 . The LOG-type common line LVCOM comprises a first LOG-type common line 50 provided at one edge of the liquid crystal display panel, and a second LOG-type common line 51 provided which intervenes with the first LOG-type common line 50 at the picture display area 21 . The first LOG-type common line 50 consists of third to sixth LOG-type common lines 50 a to 50 d connected between a first data TCP 8 and the respective first to fourth gate TCP's 14 A to 14 D. When a liquid crystal in an in-plane switch (IPS) mode is driven with a horizontal electric field, the LOG-type common line LVCOM further includes a dummy common line 53 connected to the third to sixth LOG-type common lines 50 a to 50 d and to a common electrode (not shown) provided at the pixel area. On the other hand, when a liquid crystal in a twisted nematic (TN) mode is driven with a vertical electric field, the LOG-type common line LVCOM is connected to the common electrode provided at the upper substrate by a silver dot (not shown).
The third to sixth LOG-type common lines 50 a to 50 d have line voltage values a, b, c and d proportional to their line lengths. In addition, the third to sixth LOG-type common lines 50 a to 50 d are connected, via the first to fourth gate TCP's 14 A to 14 D, to each other in series.
In other words, the gate drive IC 16 mounted in the first gate TCP 14 A is supplied with a first common voltage VCOM 1 voltage-dropped in proportion to the first line resistance value a of the third LOG-type common line 50 a . The first common voltage VCOM 1 is applied, via the first gate drive IC 16 , to common electrodes at a first horizontal line block A.
The gate drive IC 16 mounted in the second gate TCP 14 B is supplied with a second common voltage VCOM 2 voltage-dropped in proportion to the second line resistance value a+b of the third LOG-type common line 50 a and the fourth LOG-type common line 50 b connected to each other in series. The second common voltage VCOM 2 is applied, via the second gate drive IC 16 , to common electrodes at a second horizontal line block B.
The gate drive IC 16 mounted in the third gate TCP 14 C is supplied with a third common voltage VCOM 3 voltage-dropped in proportion to the third line resistance value a+b+c of the third to fifth LOG-type common line 50 a to 50 c connected to each other in series; The third common voltage VCOM 3 is applied, via the third gate drive IC 16 , to common electrodes at a third horizontal line block C.
The gate drive IC 16 mounted in the fourth gate TCP 14 D is supplied with a fourth common voltage VCOM 4 voltage-dropped in proportion to the fourth line resistance value a+b+c+d of the third to sixth LOG-type common line 50 a to 50 d connected to each other in series. The fourth common voltage VCOM 4 is applied, via the fourth gate drive IC 16 , to common electrodes at a fourth horizontal line block D. Particularly, as it goes from the first gate driving IC 16 toward the fourth gate driving IC 16 , line resistance values a, b, c and d of the first and second LOG-type common lines 51 and 52 are added to each other, thereby resulting in the first to fourth common voltages VCOM 1 to VCOM 4 applied to the horizontal line blocks A to D having a relationship of VCOM 1 >VCOM 2 >VCOM 3 >VCOM 4 .
As the common voltages VCOM 1 to VCOM 4 supplied to the common electrodes are differentiated for each gate drive IC 16 in that manner, a brightness difference is generated among the horizontal line blocks A to D connected to different gate drive IC's 16 . The brightness difference among the horizontal line blocks A to D results in horizontal brightness bands that cause a deterioration of picture quality.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a liquid crystal display device and a driving method thereof that is adaptive for preventing a brightness difference between horizontal line blocks.
In order to achieve these and other objects of the invention, a liquid crystal display device according to one embodiment of the present invention includes: a liquid crystal display panel having a liquid crystal cell matrix; a power supply generating a common voltage; common lines directly on a substrate of the liquid crystal display panel and connected to a common electrode of the liquid crystal cell; and a common voltage compensator for compensating for the common voltage using a large resistance with a value greater than a combination of resistances of the common lines and the large resistance directly between the power supply and the common lines.
A liquid crystal display device according to another embodiment of the present invention includes: a liquid crystal display panel having a plurality of data lines and a plurality of gate lines crossing each other and having liquid crystal cells arranged in a matrix; a data driving circuit group at a first side of the liquid crystal display panel and having a plurality of data integrated circuits; a first gate driving circuit group at a second side of the liquid crystal display panel and having a plurality of gate integrated circuits; a second gate driving circuit group at a third side of the liquid crystal display panel and having a plurality of gate integrated circuit; a power supply generating a common voltage; common lines directly on a substrate of the liquid crystal display panel; and a common voltage compensator compensating for the common voltage using a large resistance with a resistance value greater than a combination of resistances of the common lines and the large resistance directly between the power supply and the common lines.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the invention will be apparent from the following detailed description of the embodiments of the present invention with reference to the accompanying drawings, in which:
FIG. 1 is a schematic plan view illustrating a configuration of a conventional line on glass (LOG) type liquid crystal display device;
FIG. 2 is a view for explaining a division phenomenon between horizontal line blocks caused by a line resistance of the LOG-type common line shown in FIG. 1 ; and
FIG. 3 is a schematic plan view illustrating a partial configuration of a LOG-type liquid crystal display device according to a first embodiment of the present invention;
FIG. 4 depicts a silver dot for making a connection between a common line of a TN-mode liquid crystal display device and a common electrode of the upper substrate thereof;
FIG. 5 is a schematic plan view illustrating a partial configuration of a LOG-type liquid crystal display device according to a second embodiment of the present invention; and
FIG. 6 is a schematic plan view illustrating a partial configuration of a LOG-type liquid crystal display device according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawing.
Hereinafter, the preferred embodiments of the present invention will be described in detail with reference to FIGS. 3 to 6 .
FIG. 3 illustrates a liquid crystal display device according to a first embodiment of the present invention.
The liquid crystal display device according to the first embodiment of the present invention includes a liquid crystal display panel 34 , a plurality of data TCP's 40 connected between the liquid crystal display panel 34 and a data PCB 44 , a plurality of gate TCP's 46 A to 46 D connected to an adjacent side of the liquid crystal display panel 34 , data drive IC's 42 mounted on the data TCP's 40 , gate drive IC's 48 A to 48 D mounted in the gate TCP's 46 A to 46 D, a power supply 50 for generating driving voltages supplied to the gate drive IC's 48 and the data drive IC's 42 , and a timing controller (not shown) controlling the gate drive IC's 48 and the data drive IC's 42 .
The liquid crystal display panel 34 includes a lower substrate 36 provided with various signal lines and a thin film transistor array, an upper substrate 38 provided with a color filter array, and a liquid crystal injected between the lower substrate 36 and the upper substrate 38 . Such a liquid crystal display panel 34 displays a picture on a picture display area 121 using liquid crystal cells provided at intersections between gate lines (not shown) and data lines (not shown). At the outer area of the lower substrate 36 located at the outer side of the picture display area 121 , data pads extending from the data lines and gate pads extending from the gate lines 56 are positioned. Further, a LOG-type signal line group (not shown) for transferring gate driving signals applied to gate drive IC's 48 A to 48 D is positioned at the outer area of the lower substrate 36 .
The data TCP 40 is mounted with the data drive IC 42 , and is connected, via input and output pads connected to the data drive IC 42 , to output pads of the data PCB 44 and data pads of the lower substrate 36 . Particularly, the first data TCP 40 further includes a gate driving signal transmission line group (not shown) connected to the LOG-type signal line group on the lower substrate 36 . The gate driving signal transmission line group applies gate driving signals from the power supply 50 and the timing controller, via the data PCB 44 , to the LOG-type signal line group.
The power supply 50 generates driving voltages, such as a common voltage VCOM, a gate high voltage VGH and a gate low voltage VGL, required for the liquid crystal display device using an input power source.
The data drive IC's 42 convert digital pixel data signals into analog pixel voltage signals to apply them to the data lines on the liquid crystal display panel 34 .
Similarly, gate drive IC's 48 A to 48 D are mounted on the gate TCP's 46 A to 46 D and are connected, via output pads connected to the gate drive IC's 48 A to 48 D, to the gate pads of the lower substrate 36 .
Each gate drive IC 48 A to 48 D sequentially applies a scanning signal, that is, a gate high voltage signal VGH to a gate line 56 in response to input control signals. Further, each gate drive IC 48 A to 48 D applies a gate low voltage signal Vgl to the gate line 56 in the interval other than when the gate high voltage signal VGH is applied.
The LOG-type signal line group usually consists of LOG-type signal lines for supplying driving voltage signals from the power supply 50 , such as a gate high voltage signal VGH, a gate low voltage signal VGL, a common voltage signal VCOM, a ground voltage signal GND and a supply voltage signal VCC, and LOG-type control lines for supplying gate control signals from the timing controller, such as a gate start pulse GSP, a gate shift clock signal GSC and a gate enable signal GOE. Such a LOG-type signal line group ia formed from a gate metal similar to the gate lines.
The LOG-type signal line group further includes a common line for supplying a common voltage VCOM.
The LOG-type common line consists of a first LOG-type common line 150 included in the LOG-type signal line group, and a second LOG-type common line 151 arranged in parallel to the first LOG-type common line 150 having the picture display area 121 therebetween.
Herein, when a liquid crystal in an in plane switch (IPS) mode is driven with a horizontal electric field, the LOG-type common line further includes a dummy common line 153 connected to the third to sixth LOG-type common lines 150 a to 150 d and to a common electrode (not shown) provided at the pixel area. On the other hand, when a liquid crystal in a twisted nematic (TN) mode is driven with a vertical electric field, the LOG-type common line LVCOM is connected to the common electrode provided at the upper substrate by silver dots 28 a to 28 d as shown in FIG. 4 .
Input terminals of the first and second LOG-type common lines 150 and 151 are provided with attenuating resistors Rb and Rc having a relatively large resistance value. The attenuating resistors Rb and Rc are identical to line resistance a, b, c and d of the first and second common lines 150 and 151 , so that it becomes possible to prevent a voltage difference of the common electrode for each gate drive IC 48 caused by the line resistances.
The first and second attenuating resistors Rb and Rc are connected in series to the gate driving signal output terminal of the power supply 50 . Further, a dummy resistor Ra for controlling a difference of common voltages applied to the first and second common lines 150 and 151 may be provided between the first attenuating resistor Rb and the power supply.
The attenuating resistors Rb and Rc are connected in series to the line resistances a, b, c and d of the third to sixth LOG-type common lines 150 a to 150 d provided between the gate TCP's 46 A, 46 B, 46 C and 46 D, and has the same resistance as the total sum a+b+c+d of the line resistances a, b, c and d of the LOG-type common lines as indicated in the following equation:
Ra, Rc=a+b+c+d (1)
Such attenuating resistors Ra and Rb limit the current of a common voltage signal to thereby limit the current applied to the third to sixth LOG-type common lines 150 a to 150 d connected in series to the attenuating resistors Rb and Rc and reduce a resistance deviation between the lines.
Reducing the current reduces the affect of the line resistances a, b, c and d of the LOG-type common lines on the voltage supplied to each gate drive IC. Thus, the gate drive IC's 48 A, 48 B, 48 C and 48 D are supplied with voltage signals having substantially the same level.
As mentioned above, in the LCD according to the first embodiment of the present invention, line resistances of the first and second common lines 150 and 151 are reduced by the attenuating resistors Rb and Rc provided at each input terminal of the first and second common lines 150 and 151 , so that resistances loaded onto the input terminals of the gate drive IC's 48 A, 48 B, 48 C and 48 D become substantially equal to each other. Thus, as the substantially same common voltage signal is applied to the common electrodes to thereby prevent a brightness difference between horizontal line blocks A, B, C and D.
FIG. 5 shows a liquid crystal display device according to a second embodiment of the present invention.
Because the liquid crystal display device shown in FIG. 5 has the same elements as the liquid crystal display device shown in FIG. 3 except that a gate drive circuit group including a plurality of gate TCP's mounted with gate drive IC's is provided at both the left and right sides of a liquid crystal display panel (hereinafter referred to as “double gate liquid crystal display device), a detailed explanation as to the elements identical to the first embodiment will be omitted.
In the double gate liquid crystal display device shown in FIG. 5 , gate lines of the liquid crystal display panel are divided into the left and right sides, and a data driving circuit converts the digital data into analog gamma voltages and applies them to all the data lines and pixels in synchronization with a scanning pulse.
A first gate drive circuit group 172 at the left side sequentially applies a scanning pulse to the gate lines included in the left-half area of the liquid crystal display panel, whereas a second gate drive circuit group 174 at the right side sequentially applies a scanning pulse to the gate lines included in the right-half area of the liquid crystal display panel in synchronization with the first gate drive circuit group 172 .
A LOG-type signal line group of the double gate liquid crystal display device includes a common line LVCOM for supplying a common voltage VCOM.
The LOG-type common line consists of a first LOG-type common line 150 included in the left LOG-type signal line group of the liquid crystal display panel, and a second LOG-type common line 151 arranged in parallel to the first LOG-type common line 150 with a picture display area 121 therebetween and included in the right LOG-type signal line group of the liquid crystal display panel.
Input terminals of the first and second LOG-type common lines 150 and 151 have attenuating resistors Rb and Rc with a relatively large resistance value. The attenuating resistors Rb and Rc reduce the affect of the line resistances a, b, c and d of the first and second LOG-type common lines 150 and 151 to prevent a voltage difference along the common electrode for each gate drive IC 48 caused by the line resistances.
The first and second attenuating resistors Rb and Rc are connected, in series, to the common voltage signal output terminal of the power supply and are built therein. Further, a dummy resistor Ra for controlling a difference of common voltages applied to the first and second common lines 150 and 151 may be provided between the first attenuating resistor Rb and the power supply.
The attenuating resistors Rb and Rc are connected, in series, to the line resistances a, b, c and d of the third to sixth LOG-type common lines 150 a to 150 d provided between the gate TCP's 46 A, 46 B, 46 C and 46 D, and has the same resistance as the total sum a+b+c+d of the line resistances a, b, c and d of the LOG-type common lines.
Such attenuating resistors Rb and Rc reduce the affect of the line resistances a, b, c and d of the LOG-type common lines on the voltage supplied to each gate drive IC. Thus, the gate drive IC's 48 A, 48 B, 48 C and 48 D are supplied with voltage signals having substantially the same level.
As mentioned above, in the LCD according to the second embodiment of the present invention, the first and second gate drive circuit groups 172 and 174 are provided at the left and right sides of the liquid crystal display panel, and line resistances of the first and second common lines 150 and 151 are reduced by the attenuating resistors Rb and Rc provided at each input terminal of the first and second common lines 150 and 151 , so that resistances loaded onto the input terminals of the gate drive IC's 48 A, 48 B, 48 C and 48 D become substantially equal to each other. Thus, as the substantially same common voltage signal is applied to the common electrodes to thereby prevent a brightness difference between horizontal line blocks A, B, C and D.
FIG. 6 shows a liquid crystal display device according to a third embodiment of the present invention.
Because the liquid crystal display device shown in FIG. 6 has the same elements as the liquid crystal display device shown in FIG. 3 except that a gate drive circuit group including a plurality of gate TCP's mounted with gate drive IC's is provided at both the left and right sides of a liquid crystal display panel and the data PCB is positioned at both the upper and lower portion of a liquid crystal pattern (hereinafter referred to as “double-gate and double-source liquid crystal display device), a detailed explanation as to the elements identical to the first embodiment will be omitted.
In the double-gate and double-source liquid crystal display device shown in FIG. 6 , gate lines of the liquid crystal display panel are divided into the left and right sides while data lines of the liquid crystal display panel are separated into the upper and lower portions thereof.
A first source driving circuit group 182 at the upper portion of the liquid crystal display panel converts the digital data into analog gamma voltages and applies them to all the data lines and pixels in the upper-half area in synchronization with an upper-half scanning pulse.
On the other hand, a second source driving circuit group 184 at the lower portion of the liquid crystal display panel converts the digital data into analog gamma voltages and applies them to all the data lines and pixels in the lower-half area in synchronization with an lower-half scanning pulse.
A first gate drive circuit group 172 at the left side sequentially applies a scanning pulse to the gate lines included in the left-half area of the liquid crystal display panel, whereas a second gate drive circuit group 174 at the right side sequentially applies a scanning pulse to the gate lines included in the right-half area of the liquid crystal display panel in synchronization with the first gate drive circuit group 172 .
A LOG-type signal line group of the double-gate and double-source liquid crystal display device includes a common line LVCOM for supplying a common voltage VCOM.
The LOG-type common line consists of a first LOG-type common line 150 included in the left LOG-type signal line group of the liquid crystal display panel and a second LOG-type common line 151 arranged in parallel to the first LOG-type common line 150 with a picture display area 121 therebetween and included in the right LOG-type signal line group of the liquid crystal display panel.
The first and second LOG-type common lines 150 and 151 receive a common voltage from the power supply 50 positioned within the data PCB 44 provided at the upper and lower portions of the liquid crystal display panel, respectively.
Upper and lower input terminals of the first and second LOG-type common lines 150 and 151 are provided with attenuating resistors Rb and Rc having a relatively large resistance value. The attenuating resistors Rb and Rc reduce the line resistances a, b, c and d of the first and second LOG-type common lines 150 and 151 , so that it becomes possible to prevent a voltage difference of the common electrode for each gate drive IC 48 caused by the line resistances.
The first and second attenuating resistors Rb and Rc are connected in series to the common voltage signal output terminal of the power supply and are built therein. Further, a dummy resistor Ra for controlling a difference of common voltages applied to the first and second common lines 150 and 151 may be provided between the first attenuating resistor Rb and the power supply.
The attenuating resistors Rb and Rc are connected in series to the line resistances a, b, c and d of the third to sixth LOG-type common lines 150 a to 150 d provided between the gate TCP's 46 A, 46 B, 46 C and 46 D, and has the same resistance as the total sum a+b+c+d of the line resistances a, b, c and d of the LOG-type common lines.
Such attenuating resistors Rb and Rc reduce the affect of the line resistances a, b, c and d of the LOG-type common lines on the voltage supplied to each gate drive IC. Thus, the gate drive IC's 48 A, 48 B, 48 C and 48 D are supplied with voltage signals having substantially the same level.
As mentioned above, in the LCD according to the third embodiment of the present invention, the first and second gate drive circuit groups 172 and 174 including a plurality of gate integrated circuits are provided at the left and right sides of the liquid crystal display panel and the first and second data integrated circuit groups 182 and 184 are provided at the upper and lower portions of the liquid crystal display panel, and line resistances of the first and second common lines 150 and 151 are reduced by the attenuating resistors Rb and Rc provided at each input terminal of the first and second common lines 150 and 151 , so that resistances loaded onto the input terminals of the gate drive IC's 48 A, 48 B, 48 C and 48 D become substantially equal to each other. Thus, as the substantially same common voltage signal is applied to the common electrodes to thereby prevent a brightness difference between horizontal line blocks A, B, C and D.
Meanwhile, the double-gate and double-source structures in the second and third embodiments can effectively drive a liquid crystal display panel as the liquid crystal display panel increases in size, thereby permitting more effective driving of the large-dimension liquid crystal display panel.
As described above, according to the present invention, the input terminals of the LOG-type common lines are provided with resistors having a larger value than the total sum of line resistances of the LOG-type common lines. Accordingly, the line resistances of the LOG-type common lines become relatively smaller in comparison with attenuating resistors to reduce the voltage difference between gate driving signals for each gate drive integrated circuit, so that it become possible to prevent a brightness difference between the horizontal line blocks caused by the line resistance difference.
Although the present invention has been explained by the embodiments shown in the drawings described above, it should be understood to the ordinary skilled person in the art that the invention is not limited to the embodiments, but rather that various changes or modifications thereof are possible without departing from the spirit of the invention. Accordingly, the scope of the invention shall be determined only by the appended claims and their equivalents.
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A liquid crystal display device and a driving method thereof for preventing a brightness difference between horizontal line blocks are disclosed. In the liquid crystal display device, a liquid crystal display panel has a liquid crystal cell matrix. A power supply generates a common voltage. Common lines directly on a substrate of the liquid crystal display panel are connected to a common electrode of the liquid crystal cell. A common voltage compensator compensates for the common voltage into a large resistance value with a resistance value greater than a combination of resistances of the common lines and the large resistance directly between the power supply and the common lines.
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BACKGROUND OF THE INVENTION
The present application relates to anionic block polyesters useful as soil release and antistatic agents. In addition to cleaning performance, laundry detergent compositions should have other benefits. One is the ability to impart soil release properties to fabrics woven from polyester and other fibers. These fabrics are predominantly co-polymers of ethylene glycol and terephthalic acid, and are sold under a number of trade names, e.g., Dacron, Fortrel, Kodel and Blue C Polyester. The hydrophobic character of polyester fabrics makes their laundering difficult, particularly with oily soil and oily stains. The oily soil or stain preferentially "wets" the fabric. As a result, the oily soil or stain is difficult to remove in an aqueous laundering process.
Products which have been used for their soil release and antistatic agents properties can be divided into several classes based upon the chemistry of the products.
Polyesters containing random ethylene terephthalate/polyethylene glycol (PEG) terephthalate units
High molecular weight (e.g., 40,000 to 50,000 M.W.) polyesters containing random ethylene terephthalate/polyethylene glycol (PEG) terephthalate units have been used as soil release compounds in laundry detergent compositions. U.S. Pat. No. 3,962,152 to Nicol et al, issued June 8, 1976. During the laundering operation, these soil release polyesters adsorb onto the surface of fabrics immersed in the wash solution. The adsorbed polyester then forms a hydrophilic film which remains on the fabric after it is removed from the wash solution and dried. This film can be renewed by subsequent washing of the fabric with a detergent composition containing the soil release polyesters.
These ethylene terephthalate/PEG terephthalate polyesters are not water-soluble. It is believed that they form a suspension in the wash solution which does not adsorb efficiently onto the fabrics. As a result, the level of soil release polyester in the detergent composition has to be increased if benefits are to be obtained after several wash cycles. Because of this poor water-solubility, these polyesters are formulated as suspensions in laundry detergent compositions, rather than as isotropic liquids. In certain detergent formulations, these polyesters can also diminish clay soil cleaning performance.
Polyester antistatic agents formed from dimethyl terephthalate, ethylene glycol and methoxy PEGs
U.S. Pat. No. 3,416,952 to McIntyre et al., issued Dec. 17, 1968, discloses the treatment of shaped polyester articles with a water-insoluble crystallizable polymeric compound which can contain a water soluble polymeric group such as a polyoxyalkylene group having an average molecular weight of from 300-6000. Preferred polyoxyalkylene groups are the PEGs having an average molecular weight of from 1000-4000. Treatment of the shaped articles is carried out by applying an aqueous dispersion of the crystallizable polymeric compound in the presence of an anti-oxidant, followed by heating to a temperature above 90 degrees C. to obtain a durable coating of the compound on the shaped article. One such crystallizable polymeric compound is formed by the reaction of dimethyl terephthalate, ethylene glycol and an O-methyl poly-(oxyethylene) glycol of average molecular weight 350. A 20% solution of this polyester in benzyl alcohol was used to impart antistatic properties to a polyester fabric. The patent also discloses a 20% aqueous solution of a similar polyester used to impart antistatic properties to a polyester fabric.
Polyester antistatic and soil release agents formed from dimethyl terephthalate, sodium dimethyl-5-sulphoisophthalate, ethylene glycol and polyethylene glycol (PEG)
U.S. Pat. No. 4,427,557 to Stockburger, Jan. 24, 1984, discloses low molecular weight copolyesters (M.W. 2,000 to 10,000) which can be used in aqueous dispersions to impart soil release properties to polyester fibers. The copolyesters are formed by the reaction of ethylene glycol, a PEG having an average molecular weight of 200 to 1000, an aromatic dicarboxylic acid (e.g., dimethyl terephthalate), and a sulfonated aromatic dicarboxylic acid (e.g., dimethyl 5-sulfoisophthalate). The PEG can be replaced in part with monoalkylethers of PEG such as the methyl, ethyl and butyl ethers. A dispersion or solution of the copolyester is applied to the textile material and then heat set at elevated temperatures (90 degrees to 150 degrees C.) to impart durable soil release properties.
Monomeric polyesters of PEG and terephthalic acid useful as soil release agents
U.S. Pat. No. 4,349,688 to Sandler, issued Sept. 14, 1982, discloses polyoxyalkylene phthalate ester soil release agents. ##STR1##
Durable soil resistance and water wicking properties are imparted by wetting the fabric with a composition containing the polyoxyalkylene ester, drying the wetted fabric, and then curing the dried fabric at a temperature of from 190-200 degrees C. for about 45-90 seconds.
Ethylene terephthalate/PEG terephthalate soil release polyesters for fabric treating solutions
U.S. Pat. No. 3,959,230 to Hays, issued May 25, 1976, discloses polyester soil release agents containing random ethylene terephthalate/PEG terephthalate units in a mole ratio of from about 25:75 to about 35:65. These soil release polyesters have a molecular weight of from about 25,000 to about 55,000, (preferably from about 40,000 to about 55,000) and are used in dilute, aqueous solutions, preferably with an emulsifying agent present. Fabrics are immersed in this solution so that the soil release polyester adsorbs onto the fabric surface. The polyester forms a hydrophilic film which remains on the fibers after the fabric is removed from the solution and dried. See also U.S. Pat. No. 3,893,929 to Basadur, issued July 8, 1975 (compositions for imparting soil release finish containing a polyester having an average molecular weight of 3000-5000 formed from terephthalic acid, PEG and ethylene glycol); U.S. Pat. No. 3,712,873 to Zenk, issued Jan. 23, 1973 (textile treating composition comprising fatty alcohol polyethoxylates; quaternary ammonium compounds; a polyester having average molecular weight of 3000- 5000 formed from terephthalic acid, PEG and ethylene glycol; and starch).
Ethylene terephthalate/PEG terephthalate soil release agents used in detergent compositions
U.S. Pat. No. 3,962,152 to Nicol et al., issued June 8, 1976, discloses detergent compositions containing detergent surfactants and the ethylene terephthalate/PEG terephthalate soil release polyesters disclosed in U.S. Pat. No. 3,959,230 issued to Hays. Additionally U.S. Pat. No. 4,116,885 to Derstadt et al., issued Sept. 26, 1978 (detergent compositions containing certain compatible anionic detergent surfactants and ethylene terephthalic/PEG terephthalate soil release polyesters); U.S. Pat. No. 4,132,680 to Nicol, issued Jan. 2, 1979 (detergent compositions containing detergent surfactants; a composition which disassociates to yield quaternary ammonium cations; and an ethylene terephthalate/PEG terephthalate soil release polyester) are of interest.
Soil release and antistatic polyurethanes useful in detergent compositions which contain polyester blocks having sulfoisophthalate units
U.S. Pat. No. 4,201,824 to Violland et al., issued May 6, 1980, discloses hydrophilic polyurethanes having soil release and antistatic properties useful in detergent compositions. These polyurethanes are formed from the reaction product of a base polyester with an isocyanate prepolymer (reaction product of diisocyanate and macrodiol). Further, a disclosure of base polyester formed from dimethyl terephthalate, dimethyl sulfoisophthalate, ethylene glycol and PEG (molecular weight 300) which is reacted with a prepolymer formed from a PEG (molecular weight 1,500) and toluene diisocyanate is made.
The previously mentioned patents, included by reference, describe a number of ways that one can make polymeric materials which are substantive to fiber. This substantivity renders the fiber soil resistant.
One shortcoming of these polyester type polymers used as soil release materials is that the benefits of softening and hand modification desired by the consumer are not realized. Softeners are typically formulated into detergents or added in a post step as a rinse cycle softener.
Additionally, U.S. Pat. No. 4,134,839 to Marshall discloses the use of an alkanolamide reacted with a polycarboxybenzene ester to give a soil release polymer.
U.S. Pat. No. 4,375,540 to Joyner discloses copolyester derivatives from aromatic dibasic acid and aliphatic dibasic acids of glycol.
U.S. Pat. No. 4,310,426 to Smitz discloses a yellowing resistant soil release agent.
U.S. Pat. No. 4,094,796 to Schwarz discloses a novel polyoxyalkylene polymeric.
THE INVENTION
It is the objective of this invention to provide both soil release and antistatic properties. More specifically, the present invention is directed to certain polyoxyalkylene ester carboxylates and the preparation and application of said polyoxyalkylene ester carboxylates. The presence of a terminal carbonyloxy group improves the soil release properties over more conventional soil release agents. The terminal position and the carbonyloxy nature are very important to the functionality of the molecule. We have determined that the choice of catalyst used in the reaction can have a profound effect upon where the hydroxyl group reacts. This in turn has a dramatic effect upon hydrolytic stability and performance.
Trimellitic anhydride has the following structure; ##STR2##
We have discovered that when an acidic catalyst like paratoluene sulfonic acid is used, the anhydride functionality is maintained and reaction occurs at the carboxyl group in the 5 position of the aromatic ring. The fact that water is distilled off under reaction conditions confirms that the anhydride did not react. If the anhydride had in fact opened there would be no distillate. Additionally, the presence of the anhydride is confirmed by Infra Red analysis 1780 cm -1 and wet analysis.
Percentages and ratios used herein are by weight, unless otherwise noted. References cited herein are incorporated by reference.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the invention conform to the following generic structure; ##STR3## R" is ##STR4## Q is H or SO 3 Na; X is H or CH 3 a is an integer from 1-5; b is an integer from 1-200 preferably from 1-20
c is an integer from 1-50 preferably from 1-10; M is Na, H, K, Li, NH 4
The compounds of this invention can be formulated into products that are applied directly in aqueous solution by themselves or formulated with anionics or non-ionics and builders to prepare finished conditioner/detergent systems. The following data demonstrates that the compounds of the present invention provide desirable properties when compared to commercially available products. Rating System 1 is worst 5 is best. Soil Release was tested on polyester fabrics using AATCC Method 130. These tests are used to evaluate the ability of a compound to release oily soils during home laundering. Values 2 and below are considered non performing.
______________________________________(Average of 3 tests)Soil Release Relative0 Wash 5 Wash Relative Wicking Hand______________________________________Standard Soil Release Agents*Example1 4.8 4.0 1 12 5.0 1.0 3 33 4.0 1.0 2 24 4.0 1.0 3 3Compounds of this Invention5 5.0 4.2 4 56 4.5 3.9 3 37 4.8 3.0 3 48 4.5 4.0 3 3______________________________________ *the soil release agent can be any anionic or nonionic surfactant (1) Ratings: 5 = best, 1 = worst Fabric = 100% polyester knit
The raw materials used to prepare the compounds of the invention include but are not limited to Milease T, Alkaril QC-J (CAS # 9016-88-0) and Milease HPA (CAS # 8852-78-6). These materials conform to the following generic formulae; ##STR5## wherein Q is hydrogen
X is H
a is an integer from 1-5
b is an integer from 1-200
c is an integer from 1-50 ##STR6## wherein Q is a mixture of hydrogen and SO 3 Na
X is H and/or CH 3
a is an integer from 1-5
b is an integer from 1-200
c is an integer from 1-50 ##STR7## wherein Q is a mixture of hydrogen and SO 3 Na
X is H and/or CH 3
a is an integer from 1-5
b is an integer from 1-200
c is an integer from 1-50
SUITABLE PREPARATIONS FOR STARTING MATERIALS
The following processes, A-D illustrate methods for the preparation of starting materials used in this invention is as follows:
U.S. Pat. No. 3,557,039 teaches that dimethyl terephthalate (53.7 parts) dimethyl sodium sulfoisophthalate (9.1 parts) ethylene glycol (43 parts) calcium acetate hemihydrate (0.049 parts) and antimony trioxide (0.025 parts) were mixed together and heated until the theoretical amount of methanol is removed. Phosphorous acid is added (0.09 parts) and the excess glycol distilled off under vacuum at 282 degrees C.
B
U.K. Pat. No. 1,317,278 teaches spinning grade poly(ethylene terephthalate)(134.4 parts), polyethylene glycol of nominal molecular weight 1540 (308 parts) and antimony trioxide (0.0022 part) were charged to a 4-necked flask with a scaled bottom runoff tube and fitted with a stirrer, internal thermometer, nitrogen inlet and a condenser set for distillation. The flask was heated in an electric mantle through which the bottom runoff tube protruded. The temperature of the contents of the flask was raised to 260 degrees plus/minus 5 degrees C. over half an hour and held at 260 degrees C. plus/minus C. for three hours.
Additionally products containing both EO and PO can be made by substituting an ethylene oxide/propylene oxide polymer of the same molecular weight for the polyoxyethylene material above.
C
30.0 parts of dimethyl terephthalate, 10.0 parts of ethylene glycol along with 170 parts of polyethylene glycol of nominal molecular weight 4000 and antimony trioxide (0.0022 parts) were charged to a 4-necked flask with a scaled bottom runoff tube and fitted with a stirrer, internal thermometer, nitrogen inlet and a condenser set for distillation. The flask was heated in an electric mantle through which the bottom runoff tube protruded. The temperature of the contents of the flask was raised to 260 degrees plus/minus 5 degrees C. over half an hour and held at 260 degrees C. plus/minus C. for three hours.
Additionally products containing both EO and PO can be made by substituting an ethylene oxide/propylene oxide polymer of the same molecular weight for the polyoxyethylene material above.
D
Spinning grade poly-(ethylene terephthalate) (134.4 parts) a block polymer (2:1 ethylene oxide to propylene oxide having a molecular weight of 1540 MWU) (308 parts) and antimony trioxide (0.0022 part) were charged to a 4-necked flask with a scaled bottom runoff tube and fitted with a stirrer, internal thermometer, nitrogen inlet and a condenser set for distillation. The flask was heated in an electric mantle through which the bottom runoff tube protruded. The temperature of the contents of the flask was raised to 260 degrees plus/minus 5 degrees C. over half an hour and held at 260 degrees C. plus/minus 5 C.
EXAMPLES
General Procedure
Into a suitable reaction flask, equipped with a thermometer, nitrogen sparge and agitator is added the specified amount of raw material polymer (selected from examples 1-3). The raw material polymer is heated to 100 degrees C., under a nitrogen sparge. The specified amount of para toluene sulfonic acid is then added. Next, the specified amount of trimellitic anhydride is then added over a fifteen minute period under good agitation. Heat to 200 C. and hold for 6 to 10 hours.
______________________________________Exam- Polymer p-Tolueneple Raw Weight Sulfonic Tri melliticNum- Material in Acid Anhydrideber Method Grams Weight in Grams Weight in Grams______________________________________1 B 875.0 2.0 123.02 C 920.0 2.0 78.03 A 953.0 1.5 145.04 D 850.0 2.0 148.0______________________________________
EXAMPLE #5
A aqueous solution containing 0.1 to 1.0% active of one of the novel compounds selected from the above examples (1 to 4) are applied to a cotton polyester blend or fiber by exhaustion or using conventional dip and nip technology. The novel compound acts as a lubricant for the processing of the fiber and a superior soil release agent.
EXAMPLE #6
A solution of 0.25-1.50% active of one of the compounds above is applied to a polyester blend by exhaustion or using conventional dip and nip technology. The material acts as a lubricant for the processing of the fiber and a non-yellowing softener.
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The present invention relates to a class of compounds which have superior soil release properties over heretofore known soil release polymers. The compounds are prepared by the reaction of an aromatic hydroxy containing polyester soil release agent with trimellitic anhydride under acid catalysis to produce an aromatic terminal capped carbonyloxy soil release polymer.
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BACKGROUND OF THE INVENTION
This invention relates to flareholders that are used in emergency situations such as at helicopter landing sites or accident scenes. Combustible flares are important signaling means that are used at the scene of an accident or at air vehicle landing sites. Some conventional flares may have a built in spike or nail at one end which is driven into the ground to serve as a support for the flare. Other conventional flares may not have a built-in holder and can be held by the user or supported by a flareholder.
Various flareholders have been suggested to solve problems generated by the spike flare or the holderless flare. The spike flare cannot be inserted into a concrete or asphalt roadway and needs some other kind of support. U.S. Pat. No. 3,905,324 (the "'324 patent") describes a flareholder apparatus capable of receiving and supporting the spike. However, the flareholder of '324 patent is adapted to only the spike flare and is susceptible to sliding on slippery surfaces or on moving or tilting surfaces such as those present on a boat. Furthermore, the '324 flareholder is a bulky device and if more than one flare location is desired and more than one flareholder is needed, multiple flareholders would take up an appreciable amount of storage space before use.
Unsupported flares without built-in holders also can present problems. If the flare is laid down on the ground, its visibility may be compromised, a fire could start, or the surface of the ground could be damaged. It may not be practical for the flare to be held by a person for any length of time due to heat from the flare or fatigue. Various flareholders have been suggested for holderless flares such as U.S. Pat. No. 4,148,259 (the "'258 patent"), which describes a road flareholder. However, the '258 flareholder presents numerous shortcomings. For example, more than one '258 flareholder does not store in a compact space. The '258 flareholder also may tip over or slide in a windy and/or slippery environment. Furthermore, although one embodiment is comprised of a bottom to prevent a flare from sliding through, the flareholder would be difficult to clean once the flare had been used up. In the embodiment without the bottom, the flare may slide through if the entire holder apparatus was lifted off the ground or if the apparatus was placed on uneven or rocky terrain.
The instant invention is designed for emergency operations and solves all the aforementioned problems, among others. Accordingly, it is an object of this invention to provide a flare base that will not slide under adverse conditions.
Another object of this invention is to provide a means for storing flare bases in a minimum of space.
Yet another object of this invention is to provide a means for preventing a flare from falling through the flareholder while remaining easy to clean once the flare is spent.
A further object of the invention is to provide a means for reducing the amount of ash that drops off a burning flare from coming in contact with the ground.
A still further object of the invention is to provide a means for preventing a flare or flareholder from tipping over in high winds.
Other objects and advantages of this invention will be appreciated by those skilled in the art by reference to the following specification and accompanying drawings.
SUMMARY OF THE INVENTION
The instant flare base comprises a stackable planar base member having at least one corner tilted downward to form a cleat or cleats. The base member has one or more apertures capable of holding an outwardly projecting flare receiving tubular member. The tubular member may be comprised of an obstruction means for preventing a flare from falling through. The apertures are further adapted to be aligned with corresponding apertures on other base members. The tubular members are adapted to be inserted through the apertures of the base members to create a relatively snug fit between each respective base member when one or more flare bases are stacked on top of each other. The tubular members may lie canted from an angle of about 90° to about 30° in relation to the planar base member. In one embodiment of the invention a handle means is adapted to the flare base.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a stackable flare base depicting a base member, four apertures and one tubular member.
FIG. 2 is a perspective view of four flare bases that are stacked one on top of another.
FIG. 3 is a perspective view of a stackable flare base depicting a base member with two apertures and one tubular member.
FIG. 4 is a perspective view of a stackable flare base depicting a base member, four apertures and a canted tubular member.
FIG. 5 is a perspective view of the flare base with a handle means affixed thereto.
FIG. 6 is a perspective view of the flare base of FIG. 5 depicting four bases with handles stacked one on top of the other.
FIG. 7 is a perspective view of the flare base depicting a handle means disposed therein.
FIG. 8 is a perspective view of the flare base of FIG. 7 depicting four bases stacked one on top of the other.
FIG. 9 is fragmentary view of the tubular flare receiving means further depicting a rod-shaped obstruction means.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a preferred embodiment of the instant flareholder 10. It includes a substantially square planar base member 1 which may have sides that are typically about five to ten inches, and preferably eight inches long. The corners 5 of each base member 1 are bent downwardly to form a cleat 2.
The base member 1 is further comprised of apertures 4 which are capable of supporting or allowing a tubular member 3 to be inserted therethrough. The tubular member 3 is typically about one or more inches and preferably about two inches high. The tubular member 3 is seen to project upwardly at about a 90° angle relative to the base member 1.
The tubular member 3 is affixed to one of the apertures 4 by means of welding or other adhesive means such as epoxy resin or the like. Both the tubular member 3 and the base member 1 can be made of steel or other materials suitable for providing resistance to heat and stress. When the base member 1 is constructed of 3/16" steel, the weight of base member 1 helps to keep the flare base 10 stationary. The cleats 2 are designed to substantially eliminate sliding on any surface, whether it be ice, snow and/or tilted. The broad surface area of the base member 1 also serves to act like a "snow shoe" and thus prevents the flareholder 10 from sinking in mud or snow. Furthermore, the base member 1 is designed to catch hot ash from a burning flare and prevent the ash from contacting the ground.
The tubular member 3 permits insertion of a flare and is designed to fit loosely around the flare to facilitate removal of the flare. In the event that the flare is defective and explodes, a loose fit (as opposed to a tight fit) serves to avoid generation of shrapnel. The tubular member 3 may be left open at the bottom to further facilitate removal of the flare.
Four apertures 4 are seen to be equidistant from each other and from the center of the square base member 1. Such arrangement insures that the tubular member 3, when affixed to the base member 1, by means of an aperture 4, will align with and be capable of insertion through corresponding apertures 4 on other of the instant flare bases 10 when the flare base 10 is stacked in succession as is described below.
Turning to FIG. 2, the instant invention is shown in its stacked embodiment. FIG. 2 illustrates an assembly of four flare bases 10A, 10B, 10C and 10D stacked one on top of the other. Each of the base members 1D, 1C and 1B is seen to rest cleanly on top of the base member immediately below it. When stacking the flare bases, in order to insure that each flare base 10 is properly received by the flare base 10 below it, each successive flare base is rotated by 90° relative to the tubular member 3 below it.
For example, flare base 10A is shown in FIG. 2 at the bottom of the assembly. Flare base 10B fits over flare base 10A by first aligning tubular member 3B over tubular member 3A and then rotating the flare base 10B by 90° and placing it down on flare base 10A such that tubular member 3A fits through an unoccupied aperture 4 of the flare base 10B. Then the next flare base 10C in the assembly is seen to fit over flare base 10B by first aligning tubular member 3C over tubular member 3B and rotating flare base 10C by 90° (180° from tubular member 3A) and placing it down on flare base 10B such that tubular members 3A and 3B both fit through the unoccupied apertures 4 of flare base 10C. In a similar manner, the uppermost flare base 10D fits over flare base 10C by first aligning tubular member 3D over tubular member 3C and rotating flare base 10D by 90° (270° in relation to flare base 10A) and placing it down on flare base 10C such that tubular members 3A, 3B and 3C all fit through the unoccupied apertures 4 of flare base 10D. Thus, all the flare bases 10A, 10B, 10C and 10D are stacked to form a compact assembly.
Turning now to FIG. 3, a flare base 10' containing two apertures 4'A and 4'B is depicted. The base member 1' is much the same as the base member 1 in FIG. 1 except one aperture 4'A is circular and the other aperture 4'B is "L" shaped with hemispherical ends and corners. The flare base 10' is thus adapted to be stacked as above with tubular members 3 inserted through the "L" shaped aperture 4'B in the same successive fashion as in the above example.
FIG. 4 illustrates another embodiment of the flare base 10" in which the tubular member 3' lies canted toward the center of the base member 1" at an angle of from about 30° to about 90°. Four elongated apertures 4" are seen to be disposed at approximately 45° angles relative to the corners of the base member 1". Said apertures 4" are adapted to receive the canted tubular member 3' when the flare base 10" is placed in a stacked assembly, i.e., the smaller the angle of the canted tubular member 3', the more elongated the aperture 4". The elongated apertures 4" are equidistant from each other and from the center of the base member 1" to insure stackability of the assembly. The flare base 10" may be stacked in the same manner as was described in relation to FIG. 2, i.e., the tubular members 3" are aligned and successively rotated by 90° until four flare bases 10" are stacked in compact fashion.
FIG. 5 depicts the flare base 10 with a handle 6 affixed to the base member 1. The handle 6 may be immovably attached by welding or other adhesive means that are known to those with skill in the art. In the alternative, the handle 6 may be pivotally attached to the base member 1 by such means that are known to those with skill in the art.
FIG. 6 illustrates the flare base 10 assembly with handles arranged in the stacked embodiment. Each flare base 10A, 10B, 10C and 10D in the assembly has a handle attached to a different side of the base members 1A, 1B, 1C and 1D in relation to the tubular members 3A, 3B, 3C and 3D. Thus, when the flare bases are stacked and each individual flare base is rotated 90° in relation to the flare base below it, the handles 6A, 6B, 6C and 6D will all be located and aligned on one side of the complete assembly.
FIG. 7 illustrates another handle embodiment of the flare base 10"'. An elongated aperture handle 7 capable of being grasped by a hand is disposed near a side of the base member 1"'. FIG. 8 illustrates the stacked assembly of the flare base 10"'. Each elongated aperture handle 7A, 7B, 7C and 7D is positioned at a different side of the base member 1"' in relation to the tubular members 3A, 3B, 3C and 3D in each flare base in the assembly. Thus, when the flare bases are stacked and each individual flare base is rotated 90° in relation to the flare base below it, the elongated aperture handles 7A, 7B, 7C and 7D will all be located and aligned on one side of the complete assembly.
FIG. 9 is a fragmentary view of the flare base 10 and of the tubular member 3 depicting an obstruction means 8 which prevents a flare from falling through the flare base 10. The obstruction means 8 may partially obstruct the bottom of the tubular member 3 to allow a spent flare to be ejected by reaming the flare from the bottom of the tubular member 3. In a preferred embodiment, the obstruction means 8 is a rod that is placed off-center as a secant across the bottom of the tubular member 3. The obstruction means 8 is placed off-center to enable the use of flares that have nails inserted at the bottom. Thus, the nail will fit past the obstruction means 8 and allow insertion of the flare into the base.
All the drawings accompanying this description depict a square planar base member 1. It is contemplated, however, that other geometrical shapes are within the scope of the instant invention. For example, polygonal shapes are also well suited to the instant invention. A pentagonal planar base member with five apertures and one tubular member is within the spirit of the invention. Each corner of the pentagon can be bent downward to form a cleat. The pentagonal flare base is also stackable in the same manner as the square flare base. The pentagonal flare base would thus be capable of stacking five individual flare bases. The base member may also be triangular, hexagonal, heptagonal, etc. with a corresponding number of apertures in each case. In accord with principles of the invention, a three-sided base would be capable of stacking three flare bases high and a six-sided base would be capable of stacking six flare bases high, etc. A circular base member is also contemplated by the instant invention. In such a case the entire edge of the circular base or a portion or portions thereof could be bent down to form a continuous cleat and stackability would be limited only by the number of apertures disposed within the circular base.
It will be understood by those skilled in the art that the foregoing specification is not intended to limit the invention to the embodiments described. On the contrary, it is intended to cover all alternatives, modifications and equivalents within the spirit and scope of the inventive concept.
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A device and assembly for holding emergency flares stationary under adverse conditions. The instant flare base comprises a planar cleated base member having apertures disposed therein, said apertures being capable of receiving tubular flare supporting members. The apertures of one flare base may be aligned sequentially with tubular members on other of said flare bases to comprise a compact stackable assembly.
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BACKGROUND OF THE INVENTION
The invention is an auxiliary device for pipeline repairs for sealing a damaged position in the pipeline-wall of a circular-tubular-shaped pipeline against fluid which flows through the pipeline and comprising at least one sealing module with at least two radially expandable sealing collars positioned with a distance in-between, and connected through one base element. In the expanded state, the collars are pressed against the internal pipeline wall in a friction-contacting and pressure-tight manner whereby the base element consists of at least one bypass lead-pipe which is capable of containing the flow-through of the fluid in a direction axial to the pipeline and whose circumferential radius is smaller than the internal radius of the pipeline wall and smaller than the external radius of the expanded sealing collars in such a way that a working space sealed in a pressure-tight manner between the inner side of the pipeline wall and the outside area of the base element can be formed between the expanded sealing collars.
An auxiliary device for pipeline repairs of the type described in the introduction above, is know through “News from PSI” of the company PSI Plugging Specialists International A/S, Stavanger, Norway. This device may, for instance, be inserted into the affected pipeline section in an upstream location ahead of the damaged position and seal the pipeline across its entire cross-section.
By inflating the sealing collars with compressed air, the pressure of the sealing collars, in their external circumference, is brought to bear on the internal wall of the pipeline thus sealing the damaged position. Together with a further auxiliary device for pipeline repairs placed downstream to the damaged position, the damaged position can be isolated in such a way that only the pipeline section lying in-between the two devices can be drained from the outside, which in turn, enables the repair or replacement of the damaged pipeline wall.
However it is still of disadvantage that the pipeline cannot be used for conveyance throughout the repair works. Moreover, a safe sealing is only possible for lines that have been depressurized between two pumping stations, as unintended displacement may be triggered off in case of high pressure. Especially in the case of a conveyance of compressible media like natural gas in the pipeline, a considerable volume must be pressed into the line after the repair work, in order to restore the operating pressure of 40 to 100 bar (4 to 10 MPa) in the repaired section.
A type-conforming device in which an open, hollow-cylindrical body is installed into the longitudinal direction of the pipeline is known through the German Patent No. DE 43 15 927. The device serves the special purpose of sealing and repairing damaged underground pipelines. For the device, an arrestable pig fitted with hose lines and similar connections is equally applied in a similar manner pursuant to International Patent Publication No. WO 89/08217 in such a way that only a pull through the pipeline is enabled. A procedure with the aid of the flowing medium is not provided for. Therefore, in the course of counter-holding, the “pigs” are not washed away with the fluid-stream. The distance covered is limited by the length of the supply lines. At the end of work, the pigs must be pulled out of the pipeline and are therefore applicable only in pressureless lines.
A pipeline servicing device fitted with measurement sensors with which the pipeline wall can be inspected for damaged positions is known from the British Patent No. GB 2326 209. The pipeline servicing device comprises a by-pass lead pipe capable of conducting a fluid flow-through in the axial direction of the pipeline with its circumferential radius is smaller than the internal radius of the pipeline wall. The by-pass lead pipe is fitted with means for the regulation of the fluid-flow resistance of the auxiliary device for pipeline repairs in such a way that the auxiliary device can be displaced in the pipeline by the flowing fluid, and path control with which the flow-resistance can be reduced upon arrival at the damaged position is enabled in such a way that the pipeline servicing device is slowed at a pre-determined position. It is however impossible to perform repair works with the pipeline servicing device at the detected damage position as long as fluid is still flowing through the pipeline.
The principal object of the present invention, therefore, is to provide an auxiliary device for pipeline repairs with which the repair or replacement of a damaged position in a pipeline wall is possible, or the installation of a branch conduit can be realized, while the pipeline or “conveyance”, operation is maintained and no loss of natural gas, petroleum oil or other transported media is incurred.
SUMMARY OF THE INVENTION
This object, as well as ther objects which will become apparent from the discussion that follows, are achieved, according to the present invention, by providing a working space between the interior of a pipeline and the outer circumference of the base element when the auxiliary device for repairing a pipeline is pushed into a pipeline. The working space can be sealed in the axial direction of the pipeline and in a jointing manner by means of the expanding sealing collars. The auxiliary device is provided with a conveyance or transport module that is articulated to the sealing module. This device can then be transported through the fluid flow by means of the transport module.
The major difference with respect to the state of the art, in accordance with the last-mentioned references, is that, when the auxiliary device is run to a specific position of the pipeline, it stays there and offers the opportunities of repairing the damaged position of a pipeline as well as enabling the construction of a branch conduit. Therefore, there is no outward physical connection, rather only one wireless connection.
A major advantage of the present auxiliary device for pipeline repairs is that, by this means, an opening can be isolated in the pipeline wall through a working space, while the fluid which still continues to flow through the line. In other words, in the region between the sealing collars, the pipeline wall bears no load through internal pressure. For instance, the working space can also be rendered inert by having it filled up with nitrogen in such a way that it is safe to also work on the pipeline walls of natural gas pipelines while they are still in conveyance operation.
The pipeline wall can be filed through to the inside of the pipe and re-welded for the purpose of repairs. There too, boring can be performed for the creation of a branch conduit of the line. The conveyance operation can be maintained in the process; by-passing the repair position through other pipeline networks may become unnecessary.
Through the minimum of one by-pass lead-pipe, a large part of the flow-volume usually conveyed by the pipeline can be channeled through. Therefore, in the case of the present auxiliary device for pipeline repairs, according to the invention, the conveyance pressure may only be reduced as far as is required for keeping the clamping force of the sealing module on the pipeline wall constantly higher than the flow-resistance, which is based on the cross-section contraction exerted by one of the auxiliary devices for pipeline repairs in the stream-conducting pipeline.
Since according to the law of HAGEN-POISEUILLE, the flow-volume in a circular pipe increases with the fourth power of the pipe radius at a given pressure difference, it is of advantage for the cross section area of the by-pass lead-pipe to make up 60% to 90% of the cross section area of the pipeline. With this value, the throughput losses experienced in the course of a repair operation with the present auxiliary device for pipeline repairs are so minimal that an economic conveyance operation in the pipeline is maintained during repairs. As long as the auxiliary device for pipeline repairs generates only a minimum cross-section contraction and only a slight flow-obstruction is thereby experienced at a specific flow-rate, the conveyance operation can even be maintained without limitations.
A circular-ring-form of the isolatable working area surrounding a spherical by-pass lead pipe constitutes a model which, amongst others, is of advantage in view of pressure resistance.
Other cross-section forms are, however, not to be excluded.
In this way, the base element can also comprise a bundle of by-pass pipelines or have a polygonal cross-section. Most important is that a working area, which is to be shielded off from the conveyor stream, can be formed between the circumference of the base element and the internal pipeline wall, whereby the working area shall cover the entire circumference of the auxiliary device for pipeline repairs or only a segment of it.
To deter an unintended axial and/or radial displacement of the auxiliary device for pipeline repairs during repair operations, it is advantageous to provide the equipment of the auxiliary device for pipeline repairs with at least one locking element positioned within the working area for a form-fitting fixation on a lock-absorbing facility in or on the pipeline wall.
The locking element may be a draw-out bolt which can be inserted in a compatible bolt-receiving arrangement in the pipeline wall. Alternatively, by boring a hole, a bolt may be positioned through the outside of the pipeline and can be fixed in a compatible bolt-absorbing facility placed in the working area.
With the locking element, one ensures that the auxiliary device for pipeline repairs is axially fixed during repair operations and that the outflow of fluids at the damaged position is prevented also in the course of overcoming the clamping force of the sealing collars as a result of high impact pressure.
After measuring the pipeline diameter, the conveyance module may be united with the working module, i.e. integrated in such a way that only one pig body consisting of conveyance and working unit is available. On the other hand, the auxiliary device for pipeline repairs can also contain a conveyance module with a bypass lead pipe connected with the sealing module in an articulated manner. Means for moving the auxiliary device for pipeline repairs within the pipeline can be integrated into the conveyance module. Through the subdivision of the auxiliary device for pipeline repairs into flexibly joined modules, a smaller curve radius can be run as against a rigid connection of larger dimensions. It has however, been shown that by miniaturizing the insertion elements, devices can be adapted at different pipeline diameters.
Also of advantage is one further model in which the conveyance module and/or sealing module or the integrated device contains at least two circularly formed drive-guide-collars in such a way that a displacement of the auxiliary device for pipeline repairs over a pipeline path segment within the pipeline indicating a pressure difference, is enabled. With the drive-guide-collars, the axial orientation of the auxiliary device for pipeline repairs en route to the damaged position is improved and jamming prevented. The diameter of the sealing collars can also be reduced to such an extent that prior to their expansion, they do not contact the pipeline wall during curve runs. By this means, damages to, or soiling of the sealing collars are avoided before the auxiliary device for pipeline repairs arrive the damaged position.
In order to achieve a good sealing of the pipeline wall and thereby enable the advancement of the auxiliary device for pipeline repairs alongside a pressure difference in the pipeline, the drive-guide-collars have a diameter corresponding with the internal diameter of the pipeline in addition to an allowance of 5% to 10%.
The auxiliary device for pipeline repairs may also be fitted with track-rollers for its movement to the working location. For this purpose, the conveyance module and/or the sealing module have at least two axially spaced rows positioned on the circumference of the base element with at least two track-rollers each. Preferentially, there are three track-rollers per row evenly distributed over the circumference, in such a way that a centric support of the auxiliary device for pipeline repairs is ensured within the pipeline, even in curves and slope sections.
To be able to run directly to a specific damaged position in the pipeline wall, a design-form is beneficial, in which a window piston is positioned in the by-pass lead-pipe of the sealing module and/or in the by-pass lead-pipe of the conveyance module which is made of one of the piston plates covering the cross-section area of the by-pass lead-pipe and a cylinder liner element connected with it. The cylinder liner element is provided with at least one window opening whereby the window piston can be drawn out axially from the by-pass lead-pipe in such a way that at least one window opening lies at least partially outside the bypass lead-pipe and an outflow of fluids from the bypass lead-pipe is enabled. In this way, the fluid volume-flow and thereby the flow-resistance of the auxiliary device for pipeline repairs can be varied by adjusting the window piston. In case the windows are inside the bypass lead-pipe, the flow is bound to run against the auxiliary device inside the pipeline through its entire cross-section. Should there be a pressure difference in the section, the auxiliary device for pipeline repairs will be pushed through the pipeline as a result of the dynamic stagnation pressure. Before arriving at the envisaged damaged position, an adjustment of the window piston can be triggered through a remote control, which in turn causes the window opening to protrude at least partially from the bypass lead-pipe and make it conducive to flow-through. The flow-resistance is thereby reduced in such a way that the friction between, for instance, the drive-guide-collars and the pipeline wall is no longer surmounted and the auxiliary device for pipeline repairs stops at the predetermined position in the pipeline section.
The principle of path control through the regulation of the flow-resistance is also applicable to at least one more model in which the bypass lead-pipe of the sealing module on at least one end, and/or the bypass lead-pipe of the conveyance module, has the following elements:
at least one window opening, and
at least one piston covering the cross-section area of the bypass lead-pipe, which is adjustable along the axial length of at least one window opening.
In this case, the piston is first positioned in an upstream manner. For speed reduction, the piston can then be run in such a way that the volume flow through the window opening and out of the by-pass lead pipe is enhanced.
At least one butterfly valve element capable of rotating around an axis, positioned in an angle of 45° to 90° to the central axis of the bypass lead-pipe, can also be installed for the purpose of regulating the flow-resistance in the bypass lead-pipe of the sealing module and/or in the bypass lead-pipe of the conveyance module.
The butterfly valve element may be ball-shaped or consist of several segments of a ball, capable of rotating in an overlapping manner, so that the cross-section of the by-pass lead-pipe is completely covered in the closed state. In the open state, the convex external sides of the ball-segments are set in the direction of the pipeline wall, which in turn minimizes the area exposed to streaming.
The butterfly valve element may also be disc-shaped. While the butterfly valve element which, in its closed state, is positioned diagonally to the axis of the bypass lead-pipe, effects a complete cross-section coverage, only the edge of the butterfly valve element is subjected to the streaming contact in an open position which is set at 90° for this purpose. A reduced flow-resistance is thereby achieved.
To reduce the flow-resistance of the auxiliary device for pipeline repairs during work on the de-pressurized working space and thereby increase safety against unintended displacement of the device, it is suggested that the upstream-oriented end of the sealing module be equipped with a reduction funnel whose external diameter amounts to 0.9 to 1.0-fold of the internal diameter of the pipeline and whose internal diameter corresponds with the internal diameter of the bypass lead-pipe. The funnel wall should be preferably inclined at an angle of less than 45° to the pipeline axis.
Another advantage is offered by a model with a sealing module fitted with at least one motor-driven folding and unfolding funnel shield, with at least one slip-ring made of elastomer. The sealing of the working space can be performed with the funnel shield in place of, or supplementary to, a sealing collar. The funnel shield should preferably be folded and unfolded with the aid of toggle levers. Upon arrival at the damaged position, the funnel shield is run out. Through the high pressure of the fluid flowing against the auxiliary device for pipeline repairs, at least one slip-ring is pressed into the area between the outside of the by-pass lead-pipe and the internal wall of the pipeline where it is axially pressed against the sealing collar or against a separate support ring. The slip-ring of the funnel shield should preferably have an L- or C-shaped cross-section, whereby one upstream-oriented limb is aligned parallel to the wall of the pipeline. The slip-ring is then also pressed against the wall of the pipeline in an axial direction through the internal pressure in the pipeline.
The invention and its application in the repairs of a pipeline and other operations in the course of the conveyance will be explained in detail with an embodiment as follows and with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial cross-sectional view of an auxiliary device for pipeline repairs pushed into a pipeline with a conveyance module and a sealing module.
FIG. 2 is an axial cross-sectional view of another embodiment of the conveyance module.
FIG. 3 is an axial cross-sectional view of another embodiment of the sealing module.
FIG. 4 is an axial cross-sectional view of another embodiment of a sealing collar in detail.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be described with reference to FIGS. 1-4 are designated with the same reference numerals.
FIG. 1 shows a pipeline 3 , with parts of the pipeline wall 4 cut away, in such a way that the auxiliary device for pipeline repairs 100 launched into the pipeline 3 can be seen clearly. The pipeline wall 4 shows a damaged part 5 in the area of a welded seam.
The auxiliary device for pipeline repairs 100 is made of a chain of modules, namely a sealing module 20 and a conveyance or transport module 40 flexibly inter-connected over a universal joint 30 . Alternatively, the conveyance module 40 and the sealing module 20 can be assembled into a single piece on a common base element 22 . The subdivision into individual modules 20 , 40 as shown in FIG. 1, however, enables run-through on tight curve radii in the pipeline 3 ; moreover, in case of defects on parts of the auxiliary device for pipeline repairs 100 , a simple replacement of the modules is facilitated.
Both the conveyance module 40 as well as the sealing module 20 are assembled on circular by-pass lead-pipes 28 , 48 , which at the same time, form the base element 22 , 42 . The external diameter of the bypass lead-pipes 28 , 48 is smaller than the internal diameter of the pipeline 3 , in such a way that an unsealed annular space 9 or and an isolatable working space 8 is formed between the external wall of the bypass lead-pipes 28 , 48 and the internal wall surface of the pipeline 3 , respectively.
The conveyance module 40 contains elements for the control of the entire auxiliary device for pipeline repairs 100 within the pipeline 3 . For this purpose, the conveyance module 40 contains a control and receiver and/or transmitting facility 44 , which enables the location of the auxiliary device for pipeline repairs 100 from the outside of the buried pipeline 3 through known communication facilities as well as the remote-control from the outside, of the adjusting elements of the auxiliary device for pipeline repairs 100 . For instance, the transmission of control commands to the auxiliary device for pipeline repairs via low-powered gamma ray transmitters, and corresponding gamma ray receivers, through the pipeline wall can be performed from outside the pipeline.
There is a pressure difference Ap in the pipeline 3 indicated by an arrow 6 . First, the fluid flows through the opened by-pass lead-pipes 28 , 48 and through the open windows 53 of the window piston 50 , in such a way that the stream flows only to the annular area between the outside of the by-pass lead-pipes 28 and the internal wall of the pipeline 3 , which leads to the generation of a downstrea-moriented force affecting the auxiliary device for pipeline repairs 100 at the given pressure Ap. The force required for surmounting the adhesive friction between the pipeline wall 4 and the drive-guide-collars 26 , 27 ; 46 , 47 is higher than the active thrust force applicable in case of the opened by-pass lead-pipes 28 , 48 at a given operating pressure difference Δp in the pipeline section, in such a way that the auxiliary device for pipeline repairs 100 first ceases to advance further.
A driving element 55 , which drives a worm shaft 54 , is centrally positioned inside the by-pass lead-pipe 48 over several support spokes 56 . The worm shaft 54 locks up in a spindle nut, that is not described in detail, in the center of the piston plate 51 . A translatory movement of the window piston 50 is effected through rotation.
To introduce a movement of the auxiliary device for pipeline repairs 100 within the pipeline 3 , the window piston 50 is run upstream in such a way that the window openings 53 in the cylinder liner element 52 of the window piston 50 lie at least partially inside the wall of the by-pass lead-pipe 48 and are covered by them. The flow-through through the auxiliary device for pipeline repairs 100 is reduced and the stagnation pressure rises in such a way that the driving force mounts until the adhesive friction between the pipeline wall 4 and the drive-guide-collars 26 , 27 ; 46 , 47 can be surmounted. Through the pressure difference in the pipeline section, the auxiliary device for pipeline repairs 100 is now pushed through the pipeline 3 , until the window piston is run-out again shortly before arriving the defect area 5 , which in turn leads to a drop in the flow-resistance and thereby, the stagnation pressure. A balance is achieved between the driving force and the friction force in such a way that the auxiliary device for pipeline repairs 100 is stopped. For the fine adjustment of the final position of the auxiliary device for pipeline repairs 100 , the conveyance module 40 is fitted with driven track-rollers 45 . The drives are powered by an energy storing element 43 .
The adjustment of the window piston 50 can be performed through the worm shaft 54 driven by electrical-motor. It is however, also possible to release an arresting system at the envisaged stopping point which in turn, enhances an automatic forward push of the window piston 50 as a result of the fluid-pressure and the release by the window piston of the window openings 53 . At the end of the repair work, a pre-stressed coil spring or compression spring which leads the window piston 50 back to the locking position and retains it there, is activated.
The expansion of the sealing collars 26 , 27 is triggered off at the damaged position 5 , for instance through the introduction of compressed air from a compressed air storage system (not shown in the illustration) into the hollow chambers in the sealing collars 26 , 27 . The sealing collars 26 , 27 then press against the internal wall of the pipeline 3 in their entire circumference and effect the sealing of the working space 8 against the fluid flowing in the pipeline ( 3 ).
The damaged position 5 is thereby separated from the diverted fluid flowing through the by-pass lead-pipes 28 , 48 . It is possible to cut the pipeline wall completely and renew parts of the wall.
The possible detachment of the sealing module 20 during repair efforts on the pipeline interior surface 4 must be at least avoided. Therefore, the sealing module 20 includes a locking receptacle device 29 positioned in the working space 8 that consists of a ring with a U-shaped cross section completely surrounding the bypass pipe 28 . A hole is drilled in the pipeline interior surface 4 through a sleeve 11 welded to the pipeline 3 that has spherical cock with a round passage, and the working space 8 is depressurized. A locking receptacle element 12 is further inserted through the sleeve 11 and the hole that engages the U-shaped slot in the locking receptacle device 29 so that the pipeline repair device 100 is held firmly in place by the locking receptacle element 12 by virtue of its form-locking positioning. In order to reduce flow resistance, a reducing funnel 23 is also positioned at the upstream end.
FIG. 2 shows another model of the auxiliary device for pipeline repairs 200 with a by-pass lead-pipe 248 fitted to the conveyance module 240 , which has window openings 253 at one end. In the closing position, a piston 251 is placed upstream in front of the window openings 253 . By displacing the piston 251 with a worm shaft 254 driven by a drive element 255 , a fluid-flow from the by-pass lead-pipe 248 directly through the window openings 253 into the pipeline 3 is enabled in such a way that the stagnation pressure in front of the auxiliary device for pipeline repairs 200 drops.
FIG. 3 shows a model of the auxiliary device for pipeline repairs 300 in which the regulation of the stagnation pressure is performed through a butterfly valve element 321 positioned in the by-pass lead-pipe 328 . The rotary axis of the butterfly valve element 321 , has been set to an angle of α=90° to the axis of the by-pass lead-pipe 328 . By turning the butterfly valve element 321 , the flow-through area is varied and the advancing force acting on the auxiliary device for pipeline repairs 300 is thereby regulated. On its way through the pipeline, the auxiliary device for pipeline repairs 300 is forced through the drive-guide collars. When it reaches the damage location, the funnel shield 360 is deployed that is pressed with its slip-ring 362 both axially against the sealing collar 325 and radially against the pipeline interior surface 4 by the high fluid pressure in front of the auxiliary device for pipeline repair 300 . Additionally, the sealing collars 324 , 325 are expanded and pressed against the pipeline wall 4 .
After the repair work, the sealing collars 324 , 325 are released, and allow for a pressure balance in the previously depressurized working space 8 . By this means, the pressing force on the slip-ring 362 is lifted in such a way that the funnel shield 360 can be folded once again like an umbrella. A spindle nut 368 is run by a worm shaft 367 , driven by a drive element 366 . The toggle levers 365 connected to the spindle nut 368 are swiveled off from the toggle levers 364 which are permanently installed on the auxiliary device for pipeline repairs 300 , in such a way that the joint 369 and the end of the slip-ring 362 connected with it are radially moved inwards.
FIG. 4 illustrates a detailed sectional view of an annular sealing collar 324 . This consists of an alternating sequence of pressure rings 324 . 4 , 324 . 5 and rubber rings 324 . 1 , 324 . 2 . The package formed in this manner lies between a nut ring 324 . 3 and an adjusting unit 324 . 6 , which, for instance, comprises a motor and a gear. The main drive pinion of the adjusting unit 324 . 6 is formed by a worm shaft 324 . 7 . Through the rotation of the worm shaft 324 . 7 , the nut ring 324 . 3 is drawn against the adjusting unit 324 . 6 . The rubber rings 324 . 1 , 324 . 2 are axially squeezed into the package lying in-between in such a way that they are extended in the radial direction and thereby effect a sealing between the by-pass lead-pipe 328 and the pipeline wall 4 . Several adjusting units are preferably, spread over the circumference of the sealing collar 324 , in order to achieve an even adjustment and sealing.
There has thus been shown and described a novel auxiliary device for repairing a pipeline which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and the accompanying drawings which disclose the preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is to be limited only by the claims which follow.
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An auxiliary device ( 100 ) is provided for repairing a pipeline and sealing small damages ( 5 ) in a wall ( 4 ) of a pipeline. A working space ( 8 ) is created between the interior of the pipeline ( 93 ) and the outer circumference of the base element ( 22 ) when the auxiliary device ( 100 ) for repairing a pipeline is pushed into a pipeline. The working space ( 8 ) can be sealed in the axial direction of the pipeline ( 3 ) and in a jointing manner by way of the expanding sealing collars ( 24,25 ). The auxiliary device ( 100 ) is provided with a transport module ( 40 ) that is articulated to the sealing module ( 20 ). The device can be transported through the fluid flow by means of the transport module ( 40 ).
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 08/332,591, filed Oct. 31, 1994 entitled WET/DRY UTILITY VACUUM CLEANER WITH DETACHABLE BLOWER, which is a related copending application to Ser. No. 08/303,689, filed Sep. 9, 1994 entitled UTILITY VACUUM CLEANER TOOL CADDY AND WHEEL MOUNT, now U.S. Pat. No. 5,528,794 and Ser. No. 08/236,198, filed May 2, 1994 entitled MOTOR DESIGNED FOR MANUFACTURING AND METHOD OF ASSEMBLY, now U.S. Pat. No. 5,487,213, all of which are assigned to the same assignee as the present invention.
BACKGROUND OF THE INVENTION
The present invention relates to a wet/dry utility vacuum cleaner with detachable blower, and more particularly, to latching features for attaching the detachable blower to a lid of a vacuum cleaner drum, as well as latching features for attaching the lid to the vacuum cleaner drum itself.
Wet/dry utility vacuum cleaners with detachable blowers are well known in the art. One typical example is shown in U.S. Pat. No. 4,797,072 in which the detachable blower, when mounted to a utility vacuum cleaner drum, serves to provide a jointly operating wet/dry utility vacuum cleaner drum unit; however, when the detachable blower is separated from the vacuum cleaner drum, the detachable blower can be used for a variety of different blower applications. The wet/dry utility vacuum cleaner with detachable blower of the present invention functions generally in the manner described above; however, it provides improved latching features to facilitate the joint or separate use of the detachable blower relative to the wet/dry utility vacuum cleaner, as well as improved latching features to facilitate attachment of a lid to a vacuum cleaner drum,as will be described in detail below.
SUMMARY OF THE INVENTION
Among the several objects and advantages of the present invention include:
The provision of new and improved latching features for a detachable blower in a wet/dry utility vacuum cleaner;
The provision of new and improved latching features for attaching a lid to a vacuum cleaner drum in a wet/dry utility vacuum cleaner;
The provision of the aforementioned new and improved latching feature in which the detachable blower is attached to the lid by a releasable blower latch;
The provision of the aforementioned new and improved latching features in which the lid is attached to the drum by a releasable lid latch;
The provision of the aforementioned new and improved latching features in which each of the blower latch and lid latch employ a slot and fin arrangement between each latch and lid to prevent each such latch from deforming and disengaging from the utilty vacuum cleaner when each such latch is in an engaged position;
The provision of the aforementioned new and improved blower latch in which the blower latch contains at least one fin for engaging a complementary slot in the lid when the blower latch is in engaged position so as to prevent the blower latch from deforming and disengaging relative the lid;
The provision of the aforementioned new and improved lid latch in which the lid latch has at least one slot for engaging a complementary fin formed on the lid when the lid latch is in an engaged position so as to keep the lid latch from deforming and disengaging relative to the lid;
The provision of the aforementioned new and improved blower latch and lid latch that are well constructed, easy to operate, easy to maintain and clean, strong and durable for long lasting operation and are otherwise well adapted for the purposes intended.
Briefly stated, the wet/dry utility vacuum cleaner with detachable blower includes a vacuum cleaner drum having a bottom wall, a side wall and an enlarged rim surrounding an open upper end of the drum. A lid is releasably mounted to the enlarged rim and extends across the open upper end of the vacuum cleaner drum. A detachable blower is also mounted to the lid for joint or separate operation, as may be desired. A releasable blower latch and a releasable lid latch are provided to facilitate engagement or disengagement relative to the lid. Both the releasable blower latch and releasable lid latch are lateraly deformable for engaging latch supporting structure in the lid. Both the releasable blower latch and releasable lid latch are also provided with structural reinforcing means to restrict deformation when in engaged position relative to the lid.
The releasable blower latch is pivotally mounted to the lid and releasably engages a complementary latch opening in the blower. The blower latch is laterally deformable to allow introduction into blower latch mounting structure. The releasable blower latch includes aligned and spaced pivot posts with an intermediate deformable opening to allow deformation of the pivot posts for reception and mounting into spaced openings provided in spaced supports. The blower latch also includes at least one reinforcing fin disposed to engage a complementary opening in the lid when the blower latch is in engaged position relative to the lid. The positioning of the reinforcing fin in the complementary opening prevents the blower latch from deforming and disengaging from the blower latch mounting structure. The releasable blower latch further includes an upstanding finger engaging portion for moving the releasable blower latch into engagement or disengagement relative to the blower.
The releasable lid latch is pivotally mounted to the lid and includes a releasable locking shoulder for engaging the enlarged rim of the vacuum cleaner drum and a finger gripping section for engaging or disengaging the releasable lid latch to the enlarged rim of the drum. The releasable locking shoulder is resilient and deflectable for camming locking engagement with the enlarged rim. The upper end of the releasable lid latch includes aligned and spaced pivot posts extending laterally outwardly from the releasable lid latch for pivotal mounting to spaced supports in the lid. The upper end of the releasable lid latch includes at least one deformable opening which causes deformation of the releasable lid latch between the aligned and spaced pivot posts to enable the aligned and spaced pivot posts to be moved inwardly prior to being received within complementary shaped mounting openings in the spaced supports. The lid includes at least one reinforcing fin which engages the deformable opening in the releasable lid latch when the releasable lid latch is engaged with the lid. The positioning of the reinforcing fin in the deformable opening prevents the lid latch from deforming and disengaging from the spaced supports.
These and other objects and advantages of the present invention will become more apparent from the description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, FIG. 1 is a front perspective view of the wet/dry utility vacuum cleaner with detachable blower constructed in accordance with the teachings of the present invention;
FIG. 2 is a side elevational view of the wet/dry utility vacuum cleaner with detachable blower illustrated in FIG. 1;
FIG. 3 is a rear perspective view of the wet/dry utility vacuum cleaner with detachable blower of the present invention;
FIG. 4 is an exploded side elevational view of the wet/dry utility vacuum cleaner with the detachable blower removed therefrom;
FIG. 5 is an exploded left front perspective view of the wet/dry utility vacuum cleaner with detachable blower removed therefrom for separate operation;
FIG. 6 is a right front perspective view of the wet/dry utility vacuum cleaner with detachable blower resting in an upright condition on a supporting surface;
FIG. 7 is a fragmentary enlarged left rear perspective view of the detachable blower mounted and held in position by a releasable blower latch relative to a lid extending across the open upper end of a vacuum cleaner drum used with a wet/dry utility vacuum cleaner;
FIG. 8 is a fragmentary enlarged left rear perspective view of the detachable blower as it is removed from the lid that extends across the top of the vacuum cleaner drum, after the releasable blower latch has been disengaged from the detachable blower;
FIG. 9 is a fragmentary enlarged perspective view illustrating the manner in which the releasable blower latch is pivotally mounted to the lid that extends across the vacuum cleaner drum for detachable engagement relative to the detachable blower;
FIG. 10 is a top plan view of the releasable blower latch illustrated in FIGS. 7-9 of the drawings;
FIG. 11 is a top plan view of the lid including a depression or lid cavity which receives the detachable blower when the detachable blower is mounted to the wet/dry utility vacuum cleaner;
FIG. 12 is a sectional view of the lid including depression or lid cavity illustrated in FIG. 11 of the drawings and also including a detachable releasable lid latch mounted to the lid;
FIG. 13 is an enlarged sectional view of the detachable or releasable lid latch mounted to the lid for engagement with an enlarged rim at the open upper end of the vacuum cleaner drum;
FIG. 14 is a top plan view of the detachable or releasable lid latch;
FIG. 15 is an enlarged side elevational view of the detachable blower with one side removed to illustrate the exhaust scroll design for increasing detachable blower efficiency and also showing the relative position of the U-shaped handle relative to the detachable blower;
FIG. 16 is a perspective view of the detachable or releasable lid latch;
FIG. 17 is a fragmentary perspective view of the lid with the detachable or releasable lid latch being deformed for attachment to the lid;
FIG. 18 is a fragmentary perspective view of the assembled lid and detachable or releasable lid latch in an unlatched position;
FIG. 19 is a fragmentary perspective view of the assembled lid and detachable or releasable lid latch in latched position;
FIG. 20 is a fragmentary perspective view of the releasable blower latch;
FIG. 21 is a fragmentary perspective view of the lid with the releasable blower latch being deformed for attachment to the lid;
FIG. 22 is a fragmentary perspective view of the assembled lid and releasable blower latch in an unlatched position, as compared to the latched position shown in FIGS. 9 and 23; and
FIG. 23 is a fragmentary top plan view, partially in section to the releasable blower latch in engaged or latched position relative to the lid.
Corresponding reference numerals will be used throughout the several figures of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description illustrates the invention by way of example and not by way of limitation. The description will clearly enable one skilled in the art to make and use the invention, including what we presently believe is the best mode mode of carrying out the invention.
The wet/dry utility vacuum cleaner with detachable blower 1 shown in FIGS. 1-2 of the drawings includes a tool caddy 3 which receives a vacuum cleaner drum 5, a lid 7 that covers the open upper end of the vacuum cleaner drum 5 and a detachable blower 9 that is received within complementary shaped cavities or openings of the lid 7. The detachable blower 9 is also capable of being separated from the lid 7 for independent use, as desired.
The tool caddy 3 is constructed as a one-piece molded unit from polypropylene or other similar suitable material. The tool caddy 3 includes a rear bumper 11 for the spaced large terrain wheels 13, 13. In addition, the rear bumper 11 includes a series of spaced tool openings 15 (see FIG. 3) for receiving a series of vacuum tools 17 as illustrated in FIGS. 1-2 of the drawings. The tool caddy 3 further includes spaced front bumper sections 21, 21 which are adapted to overlie and protect individual wheel casters 23, 23, as best seen in FIGS. 1-2 of the drawings. The tool caddy 3 incorporates a central depression 25 for receiving the vacuum cleaner drum 5, as illustrated in FIGS. 1-6 of the drawings.
For a further detailed description of the construction and operation of the tool caddy 3 in conjunction with the wet/dry utility vacuum cleaner with detachable blower of the present invention, reference is made to copending patent application Ser. No. 08/303,689, filed Sep. 9, 1994, entitled UTILITY VACUUM CLEANER TOOL CADDY AND WHEEL MOUNT now U.S. Pat. No. 5,528,794 which is assigned to the same assignee as the present invention.
The vacuum cleaner drum 5 includes a bottom wall 27 shown in dotted lines in FIG. 4 of the drawings which rests on supporting sections within the central depression 25 of the tool caddy. Extending upwardly from the bottom wall is a side wall 29 which terminates in an enlarged rim 31 surrounding an open upper end 33 of the vacuum cleaner drum 5, as shown in FIG. 13 of the drawings. The lid 7 is detachably mounted to an enlarged rim 31 of the vacuum cleaner drum 5 and extends across the open upper end 3 of the vacuum cleaner dram 5. In order to secure the detachable lid 7 to the enlarged rim 31 at the upper end of the vacuum cleaner drum 5, the detachable lid 7 includes a hook portion or pivot element 35 (see FIG. 12) which is adapted to also engage beneath the enlarged rim 31 when the lid 7 is positioned at an angle relative to the enlarged rim 31 to enable a limited range of pivotal movement of the lid 7 relative to the vacuum cleaner dram 5 from the aforementioned angular position to a generally transverse position of the lid when mounted in closed position over the open upper end 33 of the vacuum cleaner drum 5.
The detachable lid 7 includes a detachable or releasable lid latch 37 which is provided in the lid 7 at a location generally opposite the hook shaped pivot element 35. The releasable lid latch 37 is formed independently of the lid 7 and is pivotally mounted to the lid 7 adjacent its open upper end at 39, as best seen in FIG. 13 of the drawings. The lower end of the releasable lid latch 37 includes a finger gripping section 41 to enable a user to grip the finger gripping section 41 for moving the releasable lid latch 37 into and out of engagement relative to the enlarged rim 31 of the vacuum cleaner drum 5. Intermediate the pivotal section 39 at the upper end and the finger gripping section 41 at the lower end of the releasable lid latch 37 is a releasable locking element 43 that is configured, arranged and dimensioned for releasable locking engagement beneath the enlarged rim 31 of the vacuum cleaner drum 5. As best seen in FIG. 13 of the drawings, the releasable locking element 43 includes a combined L-shaped section 45 and a up-side-down U-shaped section 47 which are integrally interconnected to one another and enable the up-side-down U-shaped section 47 to extend sufficiently radially inwardly to form the releasable locking element 43 that underlies the enlarged rim 31 when the releasable lid latch 37 is pivotally moved about the pivot section 39 to an engaged position beneath the enlarged rim 31,as shown in FIG. 13 of the drawings. It will be appreciated that since the releasable lid latch 37 is integrally moled from a flexible plastic material, the releasable locking element 43 is resilient and deflectable for camming locking engagement beneath the enlarged rim 31, as shown in FIG. 13.
The upper pivot 39 includes spaced and aligned posts 49, 49 that extend laterally outwardly from the releasable lid latch 37 for pivotal mounting at 39 to spaced supports 51, 51 of the lid 7, as shown in FIG. 3 and 17-19, for the assembled pivotal mounting of the releasable lid latch 37 to the lid. Between the spaced and aligned pivot posts 49, 49, the releasable lid latch 37, at its upper end, includes a series of aligned and spaced sections 53, 53, 53 separated by openings 55, 55, in order to allow the pivot posts 49, 49 to be resiliently deformed inwardly, relative to the smaller V-shaped opening 52 between the spaced supports 51, 51 as shown in fig. 17, for reception within complementary shaped mounting holes 54, 54 provided in the spaced supports 51, 51. Once the spaced and aligned posts 49, 49 are received within complementary shaped holes 54, 54 of the supports 51, 51 the aligned and spaced sections 53, 53, 53 are returned to their normal condition for securing lid latch 37 in assembled position relative to the spaced supports 51,51 of the lid 7, as shown in FIG. 18. Between the spaced supports 51, 51 are a pair of fins 56, 56. As illustrated in FIGS. 18 and 19, fins 56, 56 are, in the preferred embodiment, generally triangular-shaped, substantially rigid projections that are integrally moled with lid 7 and positioned for reception within complementary shaped openings 55, 55. As seen in FIG. 18, fins 56, 56 do not interfere with latch 37 when the latch is in its raised or unlatched position. However, when pivot posts 49, 49 are rotated in openings 54, 54 to enable the lid latch 37 to be pivoted down to its latched position as shown in FIG. 19, fins 56, 56 seat in openings 55, 55. It will be appreciated by those skilled in the art that the presence of the fins 56, 56 in the openings 55, 55 prevents latch 37 from deforming, as shown in FIG. 17, and prevents displacement of pivot posts 49, 49 from openings 54, 54. Thus, the fins 56, 56 in the openings 55, 55 serve to strengthen or reinforce the lid latch 37 when in engaged position with the lid 7.
The vacuum cleaner drum 5 also includes spaced and opposed drum lifting handle sections 57, 57, each of which are 90° offset from the hook shaped pivot element 35 and releasable lid latch 37. These drum lifting handle sections 57, 57 are aligned relative to integral strut elements 59, 59 formed in the lid 7 for strengthening the drum lifting handle sections 57, 57 in order to facilitate lifting of the vacuum cleaner drum 5.
For receiving the detachable blower 9, the lid 7 includes a wall cavity or depression 61, as best seen in FIGS. 11-12 of the drawings. The wall cavity or depression 61 includes a lower wall cavity 63 that is complementary to a lower portion of the detachable blower 9. Specifically, the lower wall cavity 63 has a complementary shape and configuration to the lower portion 65 of the detachable blower 9, as shown in FIG. 4, in order that the lower portion 65 of the detachable blower 9 can be readily received within the lower wall cavity 63. The lower wall cavity 63 includes an inner supporting wall 67 and an outer wall 69 spaced from the inner wall 67. The inner wall 67 of the lower wall cavity 63 engages the lower circumferential shoulder 71 that is spaced upwardly from the lower portion 65 of the detachable blower 9, in order to support the detachable blower 9 in stable condition, with the outer wall 69 surrounding the lower body portion 73 of the detachable blower, as illustrated by the assembled and disassembled positions of the detachable blower 9 relative to the wet/dry utility vacuum cleaner 1 shown in FIGS. 3-4 of the drawings.
In addition to the lower wall cavity 63, the wall cavity 61 includes an upper wall cavity 75 for receiving the upper portion 77 of the detachable blower, as also illustrated in the assembled and disassembled positions of the detachable blower illustrated in FIGS. 3-4 of the drawings. The upper wall cavity 75 is formed by an extension of the outer wall 69 of the lower wall cavity that also extends upwardly to form an enclosed hood 79 that overlies part of the upper portion 77 of the detachable blower 9 when the detachable blower 9 is received within the upper wall cavity 75, as explained above. The hood 79 is complementary configured relative to the upper wall portion 77 of the detachable blower 9 and is also ornamentally shaped and configured to form the construction illustrated in FIGS. 1-8 and 11-12 of the drawings. The hood 79 includes a vacuum inlet 81 that communicates with the upper wall cavity 75 that opens up into the interior of the vacuum cleaner drum 5. The vacuum inlet 81 receives a vacuum hose in a friction fit assembled relationship along the inner wall of the collar 83 which defines the vacuum inlet 81. The manner in which the vacuum inlet 81 communicates with the interior drum 55 and the other operating components of the wet/dry utility vacuum cleaner with detachable blower 1 will be further explained in detail below.
As best seen in FIGS. 3-4 of the drawings, the detachable blower 9 is used jointly with the wet/dry utility vacuum cleaner 1 as shown in FIG. 3 or is used independently as blower for non-vacuuming applications, as illustrated in FIG. 4 of the drawings. For this purpose, a U-shaped handle is integrally molded to opposite spaced sides 87, 89 of the injection moled blower housing, as best seen in FIGS. 1-4 and 7-8 of the drawings. Thus, a suer can readily lift the detachable blower 9 through the U-shaped handle 85 from the wall cavity 61, including the lower wall cavity 63 and the upper wall cavity 75 of the lid 7. However, before this can be accomplished, the releasable blower latch 91, which is itself pivotally mounted to the lid 7, must be moved to a disengaged position relative the blower 9. In order to understand the operation of the releasable blower latch 91 relative to the blower 9, reference is made to FIGS. 7-12 and 20-22 of the drawings.
The releasable blower latch 91 is pivotally mounted at 93 to the lid 7, as shown in FIGS. 9-10, through the use of spaced and aligned posts 95, 95 that extend outwardly from the releasable blower latch 91 for reception within complementary shaped holes 97, 97 of the spaced integral support ears 99, 99 formed in the lid 7, as shown in FIGS. 11-12. Blower latch 91 includes, on its inner face, a pair of spaced apart, substantially rigid fins 100, 100. Like the releasable lid latch 37, the upper end of the releasable blower latch 91 includes, in alignment with the spaced posts 95, 95, a series of aligned and spaced sections 101, 101 separated by openings 103, 103, in order to allow the pivot posts 95, 95 to be resiliently deformed inwardly relative to the complementary shaped mounting holes 97, 97 provided in the spaced ears 99, 99, as best seen in FIG. 21. Once the spaced and aligned posts 95, 95 are received within the complementary shaped mounting holes 97, 97 of the spaced support ears 99, 99, the aligned and spaced sections 101, 101,101 are returned to their normal condition for securing releasable blower latch 91 in assembled position relative to the spaced support ears 99, 99 of the lid 7. The lid includes a pair of spaced apart openings 102, 102 that are formed in a vertical wall 98 between the spaced support ears 99, 99. Openings 102, 102 are formed in the vertical wall 98 of the lid 7 and positioned to be complementary to the fins 100, 100 of the blower latch 91. As seen in FIG. 22, fins 100, 1 00 do not interfere with slots 102, 102 in the lid 7 when the latch is in its lowered or unlatched position. Thus, the fins 100, 100 are seated in the openings 102, 102 when posts 95, 95 of the latch 91 are received in the spaced support ears 97, 97 of the lid 7 and latch 91 is pivoted to a latched position relative to the lid, as shown in FIG. 23. It will be appreciated that the seating of fins 100, 100 in openings 102, 102 also prevents deformation of latch 91 and thus prevents disengagement of posts 95, 95 from the spaced support ears 97, 97 of the lid 7. In this way, the blower latch 7 is also strengthened or reinforced when in assembled position to the lid 7.
At an opposite end from the spaced pivot posts 95, 95, the releasable blower latch 91 includes an upstanding finger engaging portion 105 for moving the releasable blower latch 91 into engagement or disengagement relative to the blower 9. For this purpose, the releasable blower latch 91 includes a flexible locking shoulder 107 that resiliently engages a lower locking shoulder 109 in a complementary latch opening 111 formed in the blower housing, as best illustrated in FIG. 9 of the drawings.
When the detachable blower is operated jointly with respect to the wet/dry utility vacuum cleaner 1, it assumes the position illustrated in FIG. 7 of the drawings where the lower portion 73 of the blower 9 is received within the outer shoulder 69 of the lower wall cavity 63, while the releasable blower latch 91 engages, through its locking shoulder 107, the lower locking shoulder 109 associated with the complementary latch opening 111. When it is desired to disassemble the detachable blower 9 from the wet/dry utility vacuum cleaner 1 as illustrated in FIG. 8 of the drawings, the upstanding finger engaging portion 105 of the releasable blower latch 91 is depressed to move the resilient locking shoulder 107 of the releasable blower latch 91 out of engagement with its complementary engaged lower shoulder 109 of the complementary latch opening 111. As will be understood in describing the operating components of the wet/dry utility vacuum cleaner 1 with detachable blower 9, the detachable blower 9 must be sealed relative to the lid 7 for the proper operation of the wet/dry utility vacuum cleaner 1. The releasable blower latch 91 assists in the proper sealed condition relative to the lid 7, as will also now be understood.
The U-shaped handle 85 and the releasable blower latch 91 are mounted in proximity to one another to enable a user to both grip the U-shaped handle 85 and with one finger engage or disengage the upstanding finger engaging portion 105 of the releasable blower latch 91 for the removal or replacement of the detachable blower 9 relative to the lid cavity 61 of the lid 7. There is thus provided a single one-handed positive engagement/release of the releasable blower latch 91 relative to the detachable blower 9 in order to enhance the ease and speed of removing the detachable blower 9 relative to the lid 7. The U-shaped handle 85 of the detachable blower 9 also provides one-handed release and pivot of the detachable blower 9 relative to the lid cavity 61 of the lid 7 in order to remove/install the detachable blower 9 relative to the wall cavity 6 1 of the lid 7.
From the foregoing, it will now be appreciated that the latching mechanism for the wet/dry utility vacuum cleaner with detachable blower will enable operation of such unit as a wet/dry utility vacuum cleaner when the detachable blower is mounted in the vacuum cleaner drum, while also enabling the detachable blower to be easily separated from the utility vacuum cleaner drum for separate non-vacuuming applications.
It will also be appreciated that the releasable blower latch and lid latch of the present invention also facilitate the operation and use of the wet/dry utility vacuum cleaner with detachable blower.
It will be appreciated by those skilled in the art that various changes and modification can be made. For example, the illustrated preferred embodiment employs a releasable lid latch having a pair of openings that allow for deformation and a pair of fins that seat in the openings, when the lid latch is engaged, in order to prevent deformation and disengagement. However, the lid latch could be constructed with only one opening which would engage a single corresponding fin. Further, two or more fins and corresponding openings could also be used. Similarly, the blower latch, shown as having two fins for engaging two openings on the lid to resist deformation could also be constructed with only one fin and corresponding opening or with more than two such fins and openings, if desired.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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A wet/dry utility vacuum cleaner with detachable blower is disclosed. The detachable blower, when mounted in sealed relationship to a lid positioned above a utility vacuum cleaner drum, operates as a wet/dry utility vacuum cleaner. When separated from the utility vacuum cleaner drum, the detachable blower can be used for non-vacuuming applications. The utility vacuum drum lid includes two resilient and deformable latches: a releasable blower latch and a releasable lid latch. The releasable blower latch detachably mounts the detachable blower to the lid while the releasable lid latch detachably mounts the lid relative to the utility vacuum cleaner drum. The releasable blower latch has at least one reinforcing fin for engaging a complementary slot in the lid. The releasable lid latch has at least one slot for receiving a complementary reinforcing fin on the lid. The seating of the reinforcing fins in the respective slots, when the respective latches are in an engaged position, prevents the deformation of the respective latches and unwanted disattachment from the vacuum cleaner.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority of Korean Patent Application Number 10-2012-0112891 filed Oct. 11, 2012, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates, in general, to a reference position setting method for an automated manual transmission and, more particularly, to a reference position setting method for controlling actuators in an automated manual transmission, in which shifting is performed by a selecting operation for selecting a shift rail to which a target shift range to be shifted is assigned and a shifting operation for moving the selected shift rail to shift into the target shift range, and the selecting operation and the shifting operation are realized using the actuators.
[0004] 2. Description of Related Art
[0005] FIG. 1 illustrates a shift mechanism of a conventional automated manual transmission, particularly a double clutch transmission, to which the present invention can be applied.
[0006] In FIG. 1 , two fingers F for a selecting operation caused by upward or downward movement and a shifting operation caused by pivoting are provided. Odd and even range selecting actuators 9 and 13 moving the two fingers in upward and downward directions, respectively, and odd and even range shifting actuators 11 and 15 pivoting the two fingers in leftward and rightward directions, respectively, are provided. As shown in FIG. 2 , the two fingers F are configured so that, in respective shift gate patterns, they move up or down to perform the selecting operation, and move left or right to perform the shifting operation, thereby performing desired shifting.
[0007] Here, the odd and even range selecting actuators 9 and 13 are implemented as solenoid actuators, and the odd and even range shifting actuators 11 and 15 are configured as motors. In view of a characteristic of each motor, a separate position sensor is required to recognize a position of the finger F based on the operation of the motor. However, the position sensor increases the cost of a product, and is unfavorable in terms of configuration and weight of a package. Thus, a method of allowing a controller to accurately recognize the position of the finger F without the position sensor is required.
[0008] The following method has been used to recognize the position of the finger. In detail, the finger is forced to be located at a specific reference position when a vehicle is started. If the reference position is detected, the subsequent rotation of a motor is calculated on the basis of the reference position, and a position of the finger is followed up and recognized.
[0009] For reference, the reference positions of the two fingers F are shown in FIG. 2 . Since the fingers F are not guaranteed to be located at the shown reference positions when a vehicle is started, an initialization operation of moving the fingers F to the reference positions should be performed.
[0010] The information disclosed in this Background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
SUMMARY OF INVENTION
[0011] Accordingly, the present invention has been made keeping in mind the above problems occurring in the related art, and the present invention is intended to propose a reference position setting method for an automated manual transmission on which actuators driven by motors are mounted without a position sensor for detecting a position of each finger, capable of initializing a reference position of the finger as rapidly and accurately as possible.
[0012] Various aspects of the present invention provide for a reference position setting method for an automated manual transmission, which includes: reciprocating a finger in a selecting direction to check whether or not the finger is normal; and operating the finger in a shifting direction to learn a reference position of the finger if, as a result of performing the step of checking whether or not the finger is normal, it is determined that the finger is not normal.
[0013] According to the present invention, in the automated manual transmission on which actuators driven by motors are mounted without a position sensor for detecting a position of each finger, the reference position setting method is capable of initializing a reference position of the finger as rapidly and accurately as possible.
[0014] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 illustrates a shift mechanism of an automated manual transmission in the related art;
[0016] FIG. 2 shows shift gate patterns and reference positions of fingers based on the shift mechanism of FIG. 1 ;
[0017] FIG. 3 is a flowchart showing an exemplary reference position setting method for an automated manual transmission in accordance with the present invention; and
[0018] FIG. 4 is an explanatory view showing an exemplary method of initializing a reference position of each finger in accordance with the present invention.
DETAILED DESCRIPTION
[0019] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0020] Referring to FIGS. 3 and 4 , a reference position setting method for an automated manual transmission in accordance with various embodiments of the present invention includes step S 10 of reciprocating a finger in a selecting direction to check whether or not the finger is normal, and step S 20 of operating the finger in a shifting direction to learn a reference position of the finger if it is determined from a result of the checking in step S 10 that the finger is not normal.
[0021] In detail, the present invention is configured so that, if there occurs a situation such as ignition-on in which the reference position of the finger is required to be initialized, it is checked in step S 10 whether a normal selecting operation is performed by selecting-direction reciprocation of the finger obtained by operation of a solenoid actuator in the first place, and so that, if the normal selecting operation is performed, a current shifting mode is converted into a normal shifting mode in which normal shifting can be performed from this time by adopting a current position of the finger as the reference position, and if the normal selecting operation is not performed, a new reference position of the finger is learned and initialized in step S 20 .
[0022] For reference, FIG. 4 shows only any one of the shift gate patterns in the transmission in which the fingers for the odd and even ranges as shown in FIG. 2 are separately provided. The same method can be applied to the other shift gate pattern. Furthermore, the present invention may be applied to slightly different shift gate patterns Further, numerals of FIG. 3 correspond to those shown in FIG. 4 , and denote movement of the finger in the respective steps.
[0023] Step S 20 includes sub-step S 22 of reciprocating the finger in the shifting direction to check opposite ends of the shifting direction, and sub-step S 24 of calculating a middle position between the opposite ends of the shifting direction, which are checked in sub-step S 22 , to move the finger to the middle position.
[0024] This step S 20 may be applied to a case in which the finger is located within a shifting section when step S 10 is terminated. When sub-steps S 22 and S 24 are performed, the finger can be located at the reference position. Thereby, the initialization of the reference position of the finger can be completed.
[0025] However, in various embodiments, several sub-steps are additionally provided in addition to these sub-steps. Sub-step S 23 of determining whether a full stroke between the opposite ends of the shifting direction, which are checked in sub-step S 22 , is available, and allowing progress of sub-step S 24 only when the full stroke is available is additionally provided between sub-steps S 22 and S 24 . Thereby, the reference position of the finger can be more reliably initialized.
[0026] Of course, as a result of the determination in sub-step S 23 , if it is determined that the full stroke of the finger in the shifting direction is not available, this is determined to be abnormal, and follow-up measures are allowed to be taken.
[0027] Further, in step S 20 , when the finger is fixed within a selecting section, sub-step S 21 of coping with this fixture is additionally provided prior to sub-step S 22 .
[0028] In various embodiments, sub-step S 21 is performed by, when it is determined that the finger is located at a middle position of the selecting section, reciprocating the finger in the shifting direction to check opposite end walls of the shifting direction within the selecting section, calculating the middle position of the selecting section between the opposite end walls, moving the finger to the middle position of the selecting section between the opposite end walls, and moving the finger to one side of the selecting direction.
[0029] In detail, as a result of the checking in step S 10 , if the finger is not normal, it is first determined in sub-step S 21 whether the finger is located at the middle position of the selecting section, and the finger is moved from the selecting section to the shifting section. Then, sub-step S 22 is allowed to be performed.
[0030] Of course, if it is determined in sub-step S 21 that the finger is located within the shifting section rather than the middle position of the selecting section, sub-step S 24 is allowed to be immediately performed to rapidly complete the initialization of the reference position of the finger.
[0031] Meanwhile, the aforementioned reference position setting method for an automated manual transmission is allowed to be automatically performed by an electronic control unit.
[0032] For convenience in explanation and accurate definition in the appended claims, the terms left or right, and etc. are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
[0033] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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A reference position setting method for an automated manual transmission on which actuators driven by motors are mounted without a position sensor for detecting a position of each finger is capable of initializing a reference position of the finger as rapidly and accurately as possible.
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This is a division, of application Ser. No. 712,286 filed Aug. 6, 1976, now U.S. Pat. No. 4,100,171.
DESCRIPTION OF THE INVENTION
There is provided according to the present invention an antibiotic substance effective in inhibiting the growth of gram-positive bacteria which is of the formula ##STR2## wherein Me is methyl and Et is ethyl.
Chemically, this substance is known as α (R), 5(S)-dimethyl-6(R)-{1-ethyl-4-[4-(R)-(2-pyrrolyl-carbonyl)-1(S)-ethyl-3a(R),4,5(R),7a(R)-tetrahydroindan-5-yl]-1(E), 3(E)-butadienyl}tetrahydropyran-2-acetic acid.
There is further provided according to the present invention, a fermentation process for the production of such antibiotic substance together with the isolation techniques utilized to recover the compound of Formula I from the fermentation broth.
The organism producing the antibiotic of the present invention is a new species designated Streptomyces sp. X-14547. A culture of the living organism, given the laboratory designation X-14547 has been deposited in the U.S. Department of Agriculture, Agriculture Research Service, NRRL, Peoria, Ill. and added to its permanent collection of microorganisms as NRRL 8167. The culture has been identified as a strain of Streptomyces antibioticus.
The new microorganism was isolated from a soil sample collected at Martinsville, Va. The representative strain of Streptomyces sp. X-14547 has the following characteristics:
GENERAL CHARACTERISTICS
Streptomyces X-14547 produces a substrate mycelium which does not fragment into spores, and an aerial mycelium which forms rectus-flexibilis chains of spores; the spores have a smooth surface. The spores are 1.26 to 1.42μ in length and 0.69 to 0.91μ in width. The cell wall contains an isomer of diaminopimelic acid other than the meso form: This fact as well as the above colony characteristics place this culture in the genus Streptomyces.
GROWTH CHARACTERISTICS
The standard ISP media set forth in Shirling and Gottlieb, "Methods for Characterization of Streptomyces Species," Intern. J. System. Bacteriol., 16, pp 313-400, 1966, as well as various other media used to characterize the culture are listed below:
ISP-1 through ISP-9 are described by Shirling and Gottlieb in above article.
Czapek-Dox: Czapek-Dox Broth (BBL) to which 1.5% agar was added.
Bennett's: Yeast extract, 0.1%; beef extract, 0.1%; N-Z Amine A (casein hydrolysate from Sheffield, Inc.), 0.2%; dextrose, 1%; agar, 1.8%; pH 7.3.
Sabouraud Dextrose Agar: (Difco).
Thermoactinomyces Fermentation: Bacto Thermoactinomyces fermentation medium (Difco) to which 1.5% agar was added.
ATCC 5: Sporulation agar: Yeast extract, 0.1%; beef extract, 0.1%; tryptose, 0.2%; FeSO 4 , trace; glucose, 1.0%; agar, 1.5%; pH 7.2.
Amidex: Amidex (Corn Products Co., Decatur, Ill.), 1%; N-Z Amine A, 0.2%; beef extract, 0.1%; yeast extract, 0.1%; CaCl 2 .2H 2 O, 0.0014%; agar, 2%; pH 7.3.
Starch casein: soluble starch, 1%; casein, 0.1%; K 2 HPO 4 , 0.05%; MgSO 4 , 0.05%; agar, 1.5%; pH 7.4.
Table 1 below describes the amount of growth, degree of sporulation, spore mass color, and color of the reverse substrate mycelium. Agar plates were read after 14 days of incubation at 28° C. The color scheme used was the Color Harmony Manual Fourth edition, 1958 (Container Corp. of America).
Table 1__________________________________________________________________________Cultural Characteristics of Streptomyces sp. X 14547Agar Amount of Growth Color of ReverseMedium Degree of Sporulation Spore Mass Color Substrate Mycelium__________________________________________________________________________Yeast Malt moderate to abundant 3 fe (silver gray) 2 nl (covert brown) atExtract growth: well mostly; some tufts center; 2 ca (light(ISP-2) sporulated; slightly of a (white) ivory) at edge hygroscopicOatmeal abundant growth; well 3 fe (silver gray) 3 fe (silver gray) at(ISP-3) sporulated center and 2 dc (natural) at edgeInorganic abundant growth; well 3 fe (silver gray); 2 dc (natural)Salts Starch sporulated with edges and(ISP-4) flecks of b (oyster white)Glycerol moderate growth; 2 fe (covert gray) 2 ec (bisquit) mostly;Asparagine moderately to well with patches and 2 ge (covert tan) at(ISP-5) sporulated; slightly edge of b edge hygroscopic (oyster white)Peptone moderate growth; no i (gray) where i (gray) where notYeast sporulation; dark not sporulated sporulatedExtract brown solubleIron pigment(ISP-6)Tyrosine poor growth; some 2 dc (natural) 3 li (beaver)(ISP-7) sporulation; slight amount of brown soluble pigmentCzapek-Dox poor growth; sparsely b (oyster white) b (oyster white) sporulatedBennett's moderate growth; well 2 fe (covert gray) 3 lg (adobe brown) sporulated; hygro- scopicSabouraud moderate growth; no 3 ie (camel) where 3 ie (camel) whereDextrose sporulation not sporulated not sporulatedThermo- abundant growth; well 3 fe (silver gray) 3 pn (dark brown) atactinomyces sporulated; hygro- mostly; with tufts center; and 3 ngFermenta- scopic of b (oyster (yellow maple) attion white) edgeATCC med- moderate growth; 3 fe (silver gray); 3 pl (mustard brown)ium 5 well sporulated; also areas of 3 dc(American groscopic (natural)Type CultureCollectionCatalogue ofStrains.12th Ed.1976. Rock-ville, Md.)Amidex abundant growth; 3 fe (silver gray) 3 pl (mustard brown) well sporulated; mostly; edges of b at center; 2 cb (ivory slightly hygro- (oyster white) tint) around edge scopicStarch abundant growth; 3 fe (silver gray); 2 dc (natural)Casein well sporulated; b (oyster white) hygroscopic in one area__________________________________________________________________________
Table 2 below sets forth the morphological and physiological characteristics of Streptomyces sp. X-14547.
Table 2______________________________________Morphological and PhysiologicalCharacteristics of Streptomyces sp. X-14547Test Response of Culture X-14547______________________________________Chromagenic reaction,ISP-6 +Melanin, ISP-7 + weakSpore surface smoothColor of spore mass graySpore chain form rectus-flexibilisD-Glucose utilization ++D-Xylose utilization ++ to +L-Arabinose utilization ++L-Rhamnose utilization ++D-Fructose utilization ++D-Galactose utilization ++Raffinose utilization -D-Mannitol utilization ++i-Inositol utilization ++Salicin utilization -Sucrose utilization -Cellulose utilization -Reverse side pigment -Soluble pigment -Streptomycin sensitivity,10 μg disc +Nitrate reduction -Casein hydrolysis +Gelatin hydrolysis +Starch hydrolysis +ISP-1 darkening +NaCl (%) tolerance 5Temperature growth range °C. 10-37DAP isomer Other than the MESO isomer______________________________________ ++ = strong positive response; - = negative response
According to R. E. Buchanan and N. E. Gibbons, "Bergey's Manual of Determinative Bacteriology," 8th edition, 1974, Williams and Wilkins Co., Baltimore, Md., culture X-14547 is similar to Streptomyces antibioticus but when the two were compared there were differences noted in utilization of L-arabinose, melanin production on ISP-7, and reduction of nitrate.
The species Streptomyces X-14547 described herein includes all strains of Streptomyces which form a compound of the Formula I and which cannot be definitely differentiated from the culture number X-14547 and its subcultures including mutants and variants. The compound of the Formula I is identified herein and after this identification is known, it is easy to differentiate the strains producing a compound of the Formula I from others.
Streptomyces sp. X-14547, when grown under suitable conditions, produces a compound of the Formula I. A fermentation broth containing Streptomyces sp. X-14547 is prepared by inoculating spores or mycelia of the organism producing the compound of the Formula I into a suitable medium and then cultivating under aerobic conditions. For the production of a compound of the Formula I, cultivation on a solid medium is possible but for production in large quantities, cultivation in a liquid medium is preferable. The temperature of the cultivation may be varied over a wide range, 20°-35° C., within which the organism may grow but a temperature of 26°-30° C. and a substantially neutral pH are preferred. In the submerged aerobic fermentation of the organism for the production of a compound of the Formula I, the medium may contain as the source for carbon, a commercially available glyceride oil or a carbohydrate such as glycerol, glucose, maltose, lactose, dextrin, starch, etc. in pure or crude states and as the source of nitrogen, an organic material such as soybean meal, distillers' solubles, peanut meal, cotton seed meal, meat extract, peptone, fish meal, yeast extract, corn steep liquor, etc., and when desired inorganic sources of nitrogen such as nitrates and ammonium salts and mineral salts such as ammonium sulfate, magnesium sulfate and the like. It also may contain sodium chloride, potassium chloride, potassium phosphate and the like and buffering agents such as sodium citrate, calcium carbonate or phosphates and trace amounts of heavy metal salts. In aerated submerged culturing procedures, an anti-foam agent such as liquid paraffin, fatty oils or silicone compounds is used. More than one kind of carbon source, nitrogen source or anti-foam source may be used for production of a compound of the Formula I.
The following Examples will serve to illustrate this invention without limiting it thereto.
EXAMPLE 1
Tank fermentation of Streptomyces sp. X-14547
The antibiotic X-14547 producing culture is grown and maintained on an Amidex agar slant having the following composition (grams/liter distilled water):
Amidex--10.0
N-z amine A--2.0
Beef extract--1.0
Yeast extract--1.0
CoCl 2 .6H 2 O--0.02
Agar--20.0
The slant is inoculated with antibiotic X-14547 producing culture and incubated at 28° C. for 7-10 days. A chunk of the agar containing spores and mycelia from the sporulated culture slant is then used to inoculate a 6-liter Erlenmeyer flask containing 2 liters of sterilized inoculum medium having the following composition (grams/liter distilled water):
Tomato pomace solids--5.0
Distiller's dried solubles--5.0
Om peptone--5.0
Debittered yeast--5.0
Corn starch--20.0
CaCO 3 --1.0
K 2 hpo 4 (anhydrous)--1.0
Adjust pH to 7 with NaOH before autoclaving at 15-20 pound pressure for 45 minutes.
The inoculated inoculum medium is incubated at 28° C. for 72 hours on a rotary shaker, operating at 250 rpm with a 2-inch stroke.
A four liter portion of the resulting culture is then used to inoculate 60 gallons in a 100 gallon fermentor having the following composition (grams/liter distilled water):
Glucose--10.0
Edible molasses--20.0
HySoy T--5.0
CaCO 3 --2.0
Adjust pH to 7.2 with NaOH before sterilization for 11/4 hours with 60 lb./in 2 steam.
The inoculated medium is aerated with sterilized compressed air at a rate of 3 cubic feet per minute and is stirred with agitators at 280 rpm. The fermentation is carried out at 28° C. for 4-6 days.
EXAMPLE 2
Isolation of antibiotic X-14547 and co-metabolites 3-ethyl-1,3-dihydro-3-methoxy-2H-indole-2-one and pyrrole-2-carboxylic acid
Step A.
To the whole broth from a 100 gallon (380 liters) fermentation as set forth in Example 1 was added, after 4-6 days of growth, an equal volume of ethyl acetate. After stirring for one hour the solvent layer was separated and concentrated to 2 liters under reduced pressure. The concentrated solvent extract was washed with equal volumes of 1 N HCl three times. The solvent was dried over anhydrous Na 2 SO 4 and concentrated to an oil under reduced pressure. The oil was dissolved in diethyl ether and crude pyrrole-2-carboxylic acid crystals were separated by filtration. Recrystallization from ethanol/ether yielded the analytical sample of the above compound: mp 202°-203° C.
microanalysis: calcd for C 5 H 5 NO 2 (111.10): calcd %C, 54.06; %H; 4.54; %N, 12.60. found %C, 54.33; %H, 4.65; %N, 12.60.
Step B.
The mother liquor was concentrated to an oil under reduced pressure, redissolved in 250 ml of acetonitrile and washed twice with equal volumes of n-hexane. The hexane washes were pooled and extracted with 1/2 volume of methanol. The methanol extract was pooled with the acetonitrile and the solvent removed under reduced pressure. The oily solid was dissolved in acetonitrile and after cooling to approximately 3° C. overnight crystalline antibiotic X-14547 was recovered upon filtration as a hemihydrate, mp 137° C., [α] D -285° (C, 1 in CHCl 3 ).
microanalysis: calcd for C 31 H 43 NO 4 .(H 2 O) 0 .5 (502.70): %C, 74.07; %H, 8.82; %N, 2.78; %O; 14.32. found: %C, 74.36; %H, 8.93; %N, 2.50; %O, 13.81.
Step C.
The CH 3 CN mother liquor was concentrated to an oily solid and subjected to chromatography on a hexane slurry packed 600 g silica gel (Davison grade 62) column. The column was eluted with 250 ml of hexane and then a gradient between 1 liter of 2% ethyl acetate in hxane to 1 liter of ethyl acetate/hexane (3:1) and then 500 ml of ethyl acetate. Fractions of 6 ml each were collected and from fraction numbers 100 to 200 subsequent to the solvent being removed under reduced pressure, additional antibiotic X-14547 was recovered. From fractions 201 to 290 after concentration and crystallization from acetonitrile, 3-ethyl-1,3-dihydro-3-methoxy-2H-indole-2-one was recovered. mp 179°
microanalysis calcd: for C 11 H 13 NO 2 (191.23): calcd: %C, 69.09; %H, 6.85; %N, 7.33. found %C, 69.02; %H, 6.96; %N, 7.19.
EXAMPLE 3
Tank fermentation of antibiotic X-14547
The antibiotic X-14547 producing culture is grown and maintained on an Amidex agar slant as described in Example 1 or on a starch-casein agar slant having the following composition (grams/liter distilled water):
Soluble starch--10.0
Casein--1.0
K 2 hpo 4 (anhydrous)--0.5
MgSO 4 (anhydrous)--0.5
Agar--20.0
Adjust pH to 7.4 with NaOH before autoclaving at 15-20 p.s.i. for twenty minutes.
The slant is inoculated with antibiotic X-14547 producing culture (Streptomyces sp. X-14547) and incubated at 28° C. for 7-10 days. A chunk of agar from the sporulated culture is then used to prepare vegetative inoculum by inoculating a 6-liter Erlenmeyer flask containing 2 liters of sterilized inoculum medium having the following composition (grams/liter distilled water):
Tomato pomace solids--5.0
Distiller's dried solubles--5.0
Om peptone--5.0
Debittered yeast--5.0
Corn starch--20.0
CaCO 3 --1.0
K 2 hpo 4 (anhydrous)--1.0
pH is adjusted to 7.0 before autoclaving at 15-20 p.s.i. for forty-five minutes.
The inoculated inoculum medium is incubated for 72 hours at 28° C. on a rotary shaker operating at 250 rpm with a 2-inch stroke.
Four liters of this culture are used to inoculate 60 gallons of the following medium in a 100 gallon fermentor (grams/liter tap water):
Tomato pomace solids--5.0
Distiller's dried solubles--5.0
Om peptone--5.0
Debittered yeast--5.0
Corn starch--20.0
CaCO 3 --1.0
K 2 hpo 4 (anhydrous)--1.0
Sag 4130 Antifoam (Union carbide)--0.1
The pH of the medium is adjusted to 7.0 with NaOH before sterilization for 11/4 hours with 60 p.s.i. steam.
The inoculated medium is aerated with compressed air at a rate of 3 cubic feet per minute and is stirred with agitators at 280 rpm. The fermentation is carried out at 28° C. for 43 hours.
Five gallons of this culture are used to inoculate 350 gallons of the following medium in a 1000 gallon tank utilizing the following medium (grams/liter tap water):
Tomato pomace solids--5.0
Distiller's dried solubles--5.0
Om peptone--5.0
Dibittered yeast--5.0
Corn starch--20.0
CaCO 3 --1.0
K 2 hpo 4 (anhydrous)--1.0
Sag 4130 Antifoam (Union carbide)--0.1
The pH of the medium is adjusted to 7.0 with NaOH 2 before sterilization for 11/4 hours with 60 p.s.i. steam.
The inoculated medium is aerated with compressed air at a rate of 3 cubic feet per minute and is stirred with agitators at 280 rpm. The fermentation is carried out at 28° C. for 118 hours.
Isolation of antibiotic X-14547 and co-metabolites-3-ethyl-1,3-dihydro-3-methoxy-2H-indole-2-one and pyrrole-2-carboxylic acid
Step A.
To the whole broth from a 350 gallon (1350 liters) fermentation as set forth in Example 2 was added, after 118 hours of growth, an equal volume of ethyl acetate. After stirring for one hour the solvent layer was separated and concentrated to 7.25 liters under reduced pressure. The concentrated solvent extract was washed with 3 liters of 1 N HCl three times. The solvent was dried over anhydrous Na 2 SO 4 and concentrated to an oil under reduced pressure. The oil was dissolved in diethyl ether and crude pyrrole-2-carboxylic acid crystals were separated by filtration. Recrystallization from ethanol/ether yielded the analytical sample of the above compound: mp 202°-203° C.
microanalysis: calcd for C 5 H 5 NO 2 (111.10): calcd %C, 54.06; %H; 4.54; %N, 12.60. found %C, 54.33; %H, 4.65; %N, 12.60.
Step B.
The mother liquor was concentrated to an oil under reduced pressure, redissolved in 1 liter of acetonitrile and washed twice with equal volumes of n-hexane. The hexane washes were pooled and extracted with 1/2 volume of methanol. The methanol extract was pooled with the acetonitrile and the solvent removed under reduced pressure. The oily solid was dissolved in acetonitrile and after cooling to approximately 3° C. overnight crystalline antibiotic X-14547 was recovered upon filtration as a hemihydrate, mp 137° C., [α] D -285° (C, 1 in CHCl 3 ).
microanalysis: calcd for C 31 H 43 NO 4 .(H 2 O) 0 .5 (502.70): %C, 74.07; %H, 8.82; %N, 2.78; %O; 14.32. found %C, 74.36; %H, 8.93; %N, 2.50; %O, 13.81.
Step C.
The CH 3 CN mother liquor was concentrated to an oily solid and subjected to chromotography on a hexane slurry packed 600 g silica gel (Davison grade 62) column. The column was eluted with 1 liter of hexane and then a gradient between 4 liters of 2% ethyl acetate in hexane to 4 liters of ethyl acetate/hexane (3:1) and then 2 liters of ethyl acetate. Fractions of twenty five ml each were collected and from fraction numbers 100 to 200 subsequent to the solvent being removed under reduced pressure, additional antibiotic X-14547 was recovered. From fractions 201 to 290 after concentration and crystallization from acetonitrile, 3-ethyl-1,3-dihydro-3-methoxy-2H-indole-2-one was recovered. mp 179°
microanalysis calcd for C 11 H 13 NO 2 (191.23): calcd: %C, 69.09; %H, 6.85; %N, 7.33. found: %C, 69.02; %H, 6.96; %N, 7.19.
EXAMPLE 5
Isolation of the sodium salt of antibiotic X-14547
The whole broth from another fermentation run was extracted with a one half volume of chloroform. The solvent layer was separated and concentrated under reduced pressure to 2.35 liters, and washed successively with equal volumes of 1 N HCl, 1 N, NaOH and water. The solvent was dried over Na 2 SO 4 , and concentrated to an oil. The oil was redissolved in 2 liters of acetonitrile and washed with 2 liters of n-hexane. The acetonitrile was concentrated to an oil and filtered through 970 grams of silica gel with 4 liters of methylene chloride and then 8 liters of methylene chloride-acetone (1:1). The biologically active fraction was chromatographed on a 300 gram slurry packed (methylene chloride) silica gel column and eluted with a gradient between 7 liters of methylene chloride and 7 liters of methylene chloride-diethyl ether-ethanol (48:48:14). Fractions numbered 290-460 (twenty-five ml each) were pooled and concentrated to an oil. The oil was dissolved in a small amount of acetonitrile and with the addition of n-hexane the sodium salt of antibiotic X-14547 was recovered by filtration as a white powder, containing 1 mole of hexane.
Calcd. C 31 H 42 N NaO 4 .C 6 H 14 (599.83): %C, 74.09; %H, 9.08; %N, 2.34; %Na 3.83. Found: %C, 74.00; %H, 8.86; %N, 2.10; %Na, 4.04.
EXAMPLE 6
Preparation of the thallium salt of antibiotic X-14547
A solution of 1.3 g of antibiotic X-14547 in ethyl acetate was first washed with 1 N HCl, and then four times with an aqueous solution of thallium hydroxide. The solvent was separated and concentrated to a small volume under reduced pressure and after addition of CH 3 CN--C 2 H 5 OH, crystalline thallium salt of antibiotic X-14547 was recovered, mp. 194°-195°.
Calcd. C 31 H 42 NO 4 Tl (697.05): %C, 53.42; %H, 6.07; %N, 2.01; %Tl 29.32. Found: %C 53.51: %H, 6.01; %N, 1.98; %Tl 28.96.
EXAMPLE 7
Preparation of the R-(+)-1-amino-1-(4-bromophenyl)-ethane salt of antibiotic X-14547
A solution of 493 mg (1 mmol) of antibiotic X-14547 in methylene chloride was added to a solution of 181 mg of R-(+)-1-amino-1-(4-bromophenyl)-ethane in methylene chloride. After addition of n-hexane and slow evaporation of solvent, the crystalline final product was recovered. Recrystallization from methylene chloride-hexane yielded crystals suitable for X-ray analysis, mp. 128°-131°.*
Calcd. C 70 H 96 BrN 3 O 8 (1187.46): %C, 70.70; %H, 8.15; %N, 3.54; %Br, 6.73. Found: %C, 70.96; %H, 8.30; %N, 3.68; %Br, 6.83.
Temperatures disclosed in this specification are in degrees Celsius.
The following are various physical characteristics of antibiotic X-14547:
The infrared absorption spectrum of antibiotic X-14547 in a KBR pellet is shown in the FIGURE. The antibiotic exhibits characteristics absorption in the infrared region of the spectrum at the following wave lengths expressed in reciprocal centimeters:
Peaks occurred inter alia at 3140 (OH), 2740-2400 (carboxyl OH), 1735, 1710 (C═O), 1650 (conjugated C═O) and 1627 cm -1 (conjugated C═C).
Antibiotic X-14547 exhibits an oral toxicity (LD 50 ) in mice of 129 mg/kg (24 hours).
Antibiotic X-14547 has exhibited antimicrobial activity against a variety of gram-positive bacteria and mycobacterium as indicated in Table 3 below.
Table 3______________________________________ Antimicrobial activity Culture of Antibiotic X-14547. Collection No. Minimum inhibitory con-Name of Organism ATCC NRRL centration* in Mcg/MlBacillus megaterium 8011 0.1Sarcina lutea 9341 0.1Bacillus species E 27859 0.2Bacillus subtilis 558 0.1Staphylococcus aureus 6538P 0.2Bacillus species TA 27860 0.2Mycobacterium phlei 355 3.1Streptomyces cellulosae 3313 0.8Paecilomyces varioti 26820 6.3______________________________________ *Lowest two-fold dilution giving a zone of inhibition in an agar well diffusion assay.
It has also been found and should be considered a part of the present invention that the novel 3-ethyl-1,3-dihydro-3-methoxy-2H-indole-2-one co-metabolite also exhibits antimicrobial activity against a variety of microorganisms as indicated in Table 4 below.
Table 4______________________________________ Culture Collection No. M.I.C.*Name of Organism ATCC in mcg/ml______________________________________Escherichia coli 27856 5.0Pseudomonas aeruginosa 8709 5.0Klebsiella pneumoniae 27858 5.0Staphylococcus aureus 6538P 5.0Bacillus sp. TA 27860 2.5Paecilomyces varioti 26820 2.5______________________________________ *Minimum inhibitory concentration per ml. in mcg.
As indicated above, antibiotic X-14547 and its salts together with its co-metabolite 3-ethyl-1,3-dihydro-3-methoxy-2H-indole-2-one possesses the property of adversely affecting the growth of certain gram-positive bacteria. They are useful in wash solutions for sanitary purposes as in the washing of hands and the cleaning of equipment, floors or furnishings of contaminated rooms or laboratories.
Antibiotic X-14547 has also been found to improve ruminant feed utilization, i.e., improve the digestive efficiency of certain herbivorous animals, for example, cattle. A discussion of the mechanism whereby feed is digested, degraded and metabolized in a ruminant animal can be found in U.S. Pat. No. 3,839,557 issued Oct. 1, 1974 which discloses the use of certain antibiotics in improving ruminant feed utilization and is incorporated herewith by reference. Economically-important ruminant animals are cattle, sheep and goats.
The effectiveness of antibiotic X-14547 in modifying the ratio of volatile fatty acids produced in the rumen (and thereby improve ruminant feed utilization) is demonstrated by means of the following in vitro testing.
Rumen fluid is obtained from a steer with a fistulated rumen. The steer is maintained on the following ration:
Corn--89.93%
Alfalfa meal--5.000%
Soy bean oil meal--3.00%
Limestone--0.80%
NaCl--0.60%
Dicalcium phosphate--0.50%
Trace minerals--0.025%
Vitamin premix additions--0.1%
Vitamin A, TIU--4.0003
Vitamin D 3 , IU--0.801
Vitamin E, TIU--3.002
The rumen fluid is immediately strained through a #30 mesh sieve. For each fermentation, 75 ml of the resulting fluid is added to a 250 ml flask containing the following:
1 g of 80%:20% finely ground grain:hay ration;
1 ml of an 18% aqueous glucose solution (1 millimole per flask);
1.5 ml of a 3.1% aqueous urea solution (0.76 millimole per flask);
60 micromoles of each of the 10 essential amino acids (arginine, histidine, leucine, methionine, threonine, valine, lysine, isoleucine, phenylalanine, tryptophan);
1 ml of an aqueous solution of test drug to give either 10 or 25 μg/ml (calculated total volume of fermentation mixture of 80 ml); Each flask is incubated at 38° C. in a shaking water bath equipped with a gassing hood. Carbon dioxide is continuously passed through the hood. After four hours incubation, a 10 ml quantity of the fermentation fluid is centrifuged at 14,000 rpm (approximately 30,000 xg) for 20 minutes in an International Centrifuge equipped with a No. 874 angle head. Three ml of the supernate is added to 1 ml of a 25% metaphosphoric acid solution containing 23 micromoles 2-methyl valeric acid as an internal standard. The resulting fluid is permitted to sit at room temperature for 30 minutes. The fluid is filtered through a 0.22 millimicron Millipore filter and refrigerated until gas-liquid chromatographic analyses for volatile fatty acids.
Gas-liquid chromatographic (GLC) analyses of four in vitro control fermentations and two fermentations each with 10 and 25 ppm Antibiotic X-14547 are set forth in the following table.
______________________________________Ratios of moles of propionate (C.sub.3) to acetate (C.sub.2)plus n-butyrate (nC.sub.4) in in vitro rumen fermentations. μmoles C.sub.3 / μmoles C.sub.2 + μmoles nC.sub.4Description Replicate(Incubation Time) fermentations Means (±1σ)______________________________________Controls (0 hrs.) 0.372 0.361 0.364 0.350 0.362 (±0.009)Controls (4 hrs.) 0.393 0.337 0.427 0.388 0.386 (±0.037)Antibiotic X-14547 (4 hrs.), 0.493 0.491 10 ppm 0.489Antibiotic X-14547 (4 hrs.) 0.531 0.521 25 ppm 0.510______________________________________
As shown in the above table the ratio of propionate (C 3 ) to acetates and n-butyrates is significantly improved. With the increase of propionates rather than acetates from the carbohydrates, the efficiency of carbohydrate and therefore feed utilization is increased.
Administration of antibiotic X-14547 hereafter "Antibiotic" or "Antibiotic Compound" prevents and treats ketosis as well as improves feed utilization. The causative mechanism of ketosis is a deficient production of propionate compounds. A presently recommended treatment is administration of propionic acid or feeds which preferentially produce propionates. It is obvious that encouraging propionate production from ordinary feeds will reduce incidence of ketosis.
It has been found that antibiotic X-14547 increases the efficiency of feed utilization in ruminant animals when it is administered orally to the animals. The easiest way to administer the antibiotic is by mixing it in the animal's feed.
However, the antibiotic can be usefully administered in other ways. For example, it can be incorporated into tablets, drenches, boluses, or capsules, and dosed to the animals. Formulation of the antibiotic compound in such dosage forms can be accomplished by means of methods well known in the veterinary pharmaceutical art.
Capsules are readily produced by filling gelatin capsules with any desired form of the desired antibiotic. If desired, the antibiotic can be diluted with an inert powdered diluent, such as a sugar, starch, or purified crystalline cellulose in order to increase its volume for convenience in filling capsules.
Tablets of the antibiotic are made by conventional pharmaceutical processes. Manufacture of tablets is a well-known and highly advanced art. In addition to the active ingredient, a tablet usually contains a base, a disintegrator, an absorbent, a binder, and a lubricant. Typical bases include lactose, fine icing sugar, sodium chloride, starch and mannitol. Starch is also a good disintegrator as is alginic acid. Surface-active agents such as sodium lauryl sulfate and dioctyl sodium sulphosuccinate are also sometimes used. Commonly-used absorbents again include starch and lactose while magnesium carbonate is also useful for oily substances. Frequently-used binders are gelatin, gums, starch, dextrin and various cellulose derivatives. Among the commonly used lubricants are magnesium stearate, talc, paraffin wax, various metallic soaps, and polyethylene glycol.
The administration of the antibiotic compound may be as a slow-pay-out bolus. Such boluses are made as tablets except that a means to delay the dissolution of the antibiotic is provided. Boluses are made to release for lengthy periods. The slow dissolution is assisted by choosing a highly water-insoluble form of the antibiotic. A substance such as iron filing is added to raise the density of the bolus and keep it static on the bottom of the rumen.
Dissolution of the antibiotic is delayed by use of a matrix of insoluble materials in which the drug is inbedded. For example, substances such as vegetable waxes, purified mineral waxes, and water-insoluble polymeric materials are useful.
Drenches of the antibiotic are prepared most easily by choosing a water-soluble form of the antibiotic. If an insoluble form is desired for some reason, a suspension may be made. Alternatively, a drench may be formulated as a solution in a physiologically acceptable solvent such as a polyethylene glycol.
Suspensions of insoluble forms of the antibiotic can be prepared in nonsolvents such as vegetable oils such as peanut, corn, or sesame oil, in a glycol such as propylene glycol or a polyethylene glycol; or in water, depending on the form of the antibiotic chosen.
Suitable physiologically acceptable adjuvants are necessary in order to keep the antibiotic suspended. The adjuvants can be chosen from among the thickeners, such as carboxymethylcellulose, polyvinylpyrrolidone, gelatin, and the alginates. Many classes of surfactants serve to suspend the antibiotic. For example, lecithin, akylphenol polyethylene oxide adducts, naphthalenesulfonates, alkylbenzesulfonates, and the polyoxyethylene sorbitan esters are useful for making suspensions in liquid nonsolvents.
In addition many substances which effect the hydrophilicity, density, and surface tension of the liquid can assist in making suspensions in individual cases. For example, silicone anti-foams, glycols, sorbitol, and sugars can be useful suspending agents.
The suspendable antibiotic may be offered to the grower as a suspension, or as a dry mixture of the antibiotic and adjuvants to be diluted before use.
The antibiotic may also be administered in the drinking water of the ruminants. Incorporation into drinking water is performed by adding a water-soluble or water-suspendable form of the antibiotic to the water in the proper amount. Formulation of the antibiotic for addition to drinking water follows the same principles as formulation of drenches.
The most practical way to treat animals with the antibiotic compound is by the formulation of the compound into the feed supply. Any type of feed may be medicated with the antibiotic compounds, including common dry feeds, liquid feeds, and pelleted feeds.
The methods of formulating drugs into animal feeds are well known. It is usual to make a concentrated drug premix as a raw material for medicated feeds. For example, typical drug premixes may contain from about one to about 400 grams of drug per pound of premix. The wide range results from the wide range of concentration of drug which may be desired in the final feed. Premixes may be either liquid or solid.
The formulation of ruminant feeds containing the proper amounts of antibiotic for useful treatment is well understood. It is necessary only to calculate the amount of compound which it is desired to administer to each animal, to take into account the amount of feed per day which the animal eats and the concentration of antibiotic compound in the premix to be used, and calculate the proper concentration of antibiotic compound, or of premix, in the feed.
All of the methods of formulating, mixing and pelleting feeds which are normally used in the ruminant feed art are entirely appropriate for manufacturing feeds containing the antibiotic compound.
As has been shown, oral administration of the antibiotic beneficially alters the production of propionates relative to the production of acetates in the rumen. It may therefore be postulated that the same treatment would also benefit monogastric animals which ferment fibrous vegetable matter in the cecum since it would be expected that a beneficial change in the propionate/acetate ratio would occur upon oral administration of the instant antibiotic. Horses, swine and rabbits are exemplary animals which digest a part of their food by cecal fermentation.
Antibiotic X-14547 also exhibits activity in the treatment of hypertension in warm-blooded animals.
Antihypertensive activity is tested for in the DOCA-Na Sprague Dawley (Charles River) male rats weighing 170-210 grams. DOCA-Na hypertension is produced by unilateral nephrectomy followed by subcutaneous implantation of a 25 mg. desoxycortico sterone (DOCA) pellet. Animals are placed in individual cages receiving 0.9% sodium chloride solution and rat chow diet ad libitum. Two weeks are allowed to elapse from the time of surgery for development of hypertension, i.e., systolic blood pressure of at least 150 mm. Hg.
Systolic blood pressure and heart rate are measured indirectly from the tail of unanesthetized rats, using a pneumatic pulse transducer. Control readings are taken prior to drug and at 1, 3, 6 and 24 hours post drug.
The results are expressed as absolute values and percent changes from controls.
Table 4__________________________________________________________________________ RAT RAT RAT RAT RAT RAT PCT DAY 1 2 3 4 5 6 MEAN CHANGE__________________________________________________________________________SYSTOLIC BLOOD PRESSURE (mmHg)PRE DRUGCONTROLS 223 203 203 199 203 209 206.7 10 MG/KG × 3 days POPOST DRUG 1 216 178 184 198 151 203 188.3 -9.0VALUES IN 2 211 201 176 168 168 190 185.7 -10.3(mmHg) 2 184 174 161 165 165 179 171.3 -17.1 3 214 195 193 219 198 211 205.0 -0.7 3 210 177 173 206 190 220 196.0 -5.2 4 197 172 229 212 179 228 202.8 -1.7__________________________________________________________________________CARDIAC RATE (BEATS/MIN)PRE DRUGCONTROLS 440 360 460 410 400 400 411.7 10 MG/KG × 3 days POPOST DRUG 1 480 360 450 440 390 400 420.0 2.0VALUES IN 2 430 320 360 490 370 430 400.0 -2.6BEATS/MIN 2 420 310 400 310 380 450 378.3 -8.1 3 380 360 360 360 370 350 363.3 -11.3 3 370 360 350 360 380 370 365.0 -10.8 4 370 320 360 350 340 400 356.7 -13.1__________________________________________________________________________
For use as an anti-hypertensive agent, antibiotic X-14547 is formulated, using conventional inert pharmaceutical adjuvant materials, into dosage forms which are suitable for oral administration. Other dosage forms, e.g., parenteral, are possible but are not preferred. The oral dosage forms include tablets, capsules, dragees, suspensions, solutions and the like. The identity of the inert adjuvant materials which are used in formulating the active ingredients the active compounds into oral dosage forms will be immediately apparent to persons skilled in the art. These adjuvant materials, either inorganic or organic in nature, include, for example, gelatin, albumin, lactose, starch, magnesium stearate, preservatives (stabilizers) melting agents, emulsifying agents, salts for altering osmotic pressure, buffers, etc., which can be incorporated, if desired, into such formulations.
Generally the drug is administered once or twice a day.
The quantity of antibiotic X-14547 which is present in any of the above described dosage forms generally varies from 1 to 10 mg. per unit dosage. The dosage administered to a particular patient is variable, based on the weight of the patient and the condition of the patient. An effective dosage amount of active agent can, therefore, only be determined by the clinician utilizing his best judgement on the patient's behalf.
An example of a tablet formulation is as follows:
______________________________________Tablet Formulation Per Tablet______________________________________Antibiotic X-14547 1.0 mg.Lactose Anhydrous 137.0 mg.Corn Starch 20.0 mg.Microcrystalline Cellulose Ph 101 40.0 mg.Magnesium Stearate 2.0 mg. 200 mg.______________________________________
Procedure:
1. The drug was premixed with a part of the lactose, in a suitable mixer and thereafter milled.
2. The mixture was further blended with the cornstarch the remaining lactose and the cellulose for 15 minutes and thereafter milled.
3. The mixture was thereafter blended with the magnesium stearate for two minutes.
4. The tablets were compressed at a tablet weight of 200 mg using tablet punches having a diameter of approximately 1/4 inch. The tablets may be either flat or biconnex and may be scored if desired.
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The invention relates to a new and useful antibiotic substance which is of the formula ##STR1## and to processes for its production and recovery. The antibiotic which exhibits ionophoric properties, is classified as a polyether group antibiotic. The antibiotic of formula I is effective in inhibiting the growth of gram positive bacteria and exhibits utility as an antihypertensive agent and as a compound to improve ruminant feed utilization. The antibiotic of Formula I is prepared by cultivating a strain of Streptomyces sp. X-14547 in an aqueous carbohydrate solution containing nitrogenous nutrients and mineral salts and thereafter isolating the antibiotic from the fermentation broth.
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RELATED APPLICATIONS
This application is a continuation of prior application Ser. No. 09/563,462 filed May 2, 2000, which is a continuation of application Ser. No. 08/038,469 filed Mar. 29, 1993, now U.S. Pat. No. 6,069,412, the disclosures of which are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to uninterrupted power supply (UPS) apparatus and, more particularly, to a power factor corrected UPS maintaining integrity of the connection from power line neutral to an output load terminal.
2. Description of the Prior Art
UPS systems are now widely used to provide a secure supply of power to critical loads such as computers, so that if the line voltage varies or is interrupted, power to the load is maintained at an adequate level and is not lost. The UPS conventionally comprises a rectifier circuit for providing a DC voltage from the AC power lines; an inverter for inverting the DC voltage back to an AC voltage corresponding to the input, for delivery to the load; and a battery and a connection circuit for connecting battery power to the input of the DC to AC inverter, so that when reliable AC power is lost the delivery of AC power to the load is substantially unaffected. In such an UPS, it is highly desirable to maintain an uninterrupted neutral from the commercial AC utility power to each component circuit and to the load, e.g., in order to eliminate shock hazards. Because of the inherent nature and mode of operation of typical UPS systems, conventional UPS designs did not maintain the integrity of the neutral through the processing circuitry, requiring some type of isolation means such as isolation transformer to re-establish the neutral at the load. U.S. Pat. No. 4,935,861, assigned to the assignee of this invention, provides an UPS wherein the electrical continuity of an electrical conductor is maintained from one terminal of the AC utility through to one of the load terminals, without any isolation means being required.
The problem with maintaining integrity of the neutral is further complicated in a UPS having a power factor correction circuit. The task of connecting the battery to neutral is simple in a power supply unit without a PFC circuit, such as shown in U.S. Pat. No. 4,823,247. But as is well known, there are important reasons for incorporating power factor correction (PFC) into an UPS. And, the incorporation of such a PFC circuit imposes additional difficulties upon the goal of maintaining integrity of a neutral connection from the power line to the load. A design for achieving an uninterrupted power supply system having a PFC circuit is disclosed in U.S. Pat. No. 4,980,812, also assigned to the assignee of this invention.
It is recognized that maintaining the integrity of the neutral in an UPS offers advantages of lower cost, due to lack of need for isolation means, and higher reliability. Because of the design criterion of an undisturbed neutral, an UPS with a PFC circuit has heretofore required three converters. As seen in FIG. 1, such a prior art apparatus contains a converter as part of the power factor correction circuit, the output of which provides DC on a positive high voltage (HV) rail and independent negative HV rail respectively relative to the neutral line. The DC-AC inverter is necessarily a second converter, and, a third converter circuit has been necessary to connect the DC from the battery to the HV rails. Prior art attempts to combine the battery converter with the PFC converter have always resulted in either an isolated UPS, wherein the neutral is not maintained, or some circuit arrangement for connecting the DC output of the battery into an AC voltage which could be utilized by the AC to DC converter portion of the PFC circuit. For safety reasons, it is desirable to effectively connect the battery to the neutral, which leaves an unfulfilled need for an efficient and reliable manner of translating the battery output to the HV rails. The design solution of having a third converter of some different kind, or the option of using an isolation transformer, both have obvious disadvantages. The problem is thus how to provide that the converted output from the PFC circuit, as well as the battery output, can be independently loaded and still balanced around neutral to the plus and minus HV rails without using a separate converter of some sort for each. Stated differently, the problem for which a solution has not heretofore been known is how to connect the battery to the rails utilizing the PFC converter, while effectively maintaining a connection from the battery to neutral.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a power factor corrected UPS which maintains neutral integrity from the input of the UPS to an output terminal to which the load is connected, the UPS device having a simple and efficient circuit for connecting the battery to the converter of the PFC circuit, whereby whenever the battery provides output power due to deterioration of the utility line voltage, battery voltage is converted through the PFC converter and delivered to the high voltage rails. The UPS achieving this object provides an uninterrupted neutral from its input connection to the AC power line through to an output terminal for connection to the load, balances the battery around neutral, and achieves supply of the battery power independently to the high voltage rails without the need of an independent battery to HV rail converter, or the need for any isolation means.
In a first embodiment, a four diode-two capacitor circuit is used to connect the battery to the PFC converter. During normal operation when the UPS is drawing power from the utility line, the battery is balanced around neutral and is maintained no more than one forward diode drop away from neutral. By using a battery with a voltage less than one-half of the peak of the incoming AC voltage, the PFC circuit is substantially unaffected so that power factors greater than 0.9 can be achieved. During loss of AC input, when the UPS runs on battery, switching elements of the PFC converter are independently turned on and off, enabling conversion of the battery voltage through the PFC converter circuitry to the HV lines. In a second, preferred embodiment, one terminal of the battery is connected directly to neutral, and the other terminal is connected through a normally open switch and a diode to the converting circuit. The switch is closed when low AC power line voltage is sensed. Both embodiments thus enable elimination of a separate converter for the battery while preserving the advantages of prior art. power factor corrected UPS devices maintaining integrity of the neutral connection from input to load.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified block diagram showing the primary components of a prior art power factor corrected UPS.
FIG. 2 is a simplified circuit diagram of a power factor corrected UPS with neutral integrity, and illustrating the problem of connecting the battery to the HV rails without the aid of a converter dedicated to the battery.
FIG. 3 is a circuit diagram showing a first embodiment of the improved connection circuit of this invention, whereby the battery is connected to the converter of the PFC circuit while maintaining the battery balanced around neutral.
FIGS. 4A and 4B are circuit diagrams illustrating a cycle of operation when the UPS of FIG. 3 is drawing power from the AC input, and the line or energized AC input terminal is positive relative to the neutral terminal.
FIGS. 5A and 5B are circuit diagrams illustrating a cycle of operation when the UPS of FIG. 3 is drawing power from the AC input, and the line or energized AC input terminal is negative relative to the neutral terminal.
FIGS. 6A and 6B illustrate operation of the improved UPS circuit of FIG. 3 during a condition of unacceptable AC input and UPS battery operation.
FIG. 7A is a circuit diagram of a preferred embodiment of the invention, wherein one terminal of the battery is connected directly to neutral.
FIGS. 7B and 7C are circuit diagrams illustrating a cycle of battery-driven operation for the circuit of FIG. 7 A.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 2, there is shown a circuit diagram of a typical power factor corrected UPS with an uninterrupted neutral from input to output. The AC input is connected to the UPS at two input terminals, one of which is marked “line” and the other of which is marked “neutral.” The neutral line is connected by an uninterrupted conductor to one of two output terminals, across which AC output power is delivered. The AC input signal is connected across a first capacitor C 1 . The line terminal is connected to rectifier diodes D 1 and D 2 . D 1 is in series with inductor L 1 , the other side of L 1 being connected through switching transistor Q 1 to neutral. D 2 is connected in series with inductor L 2 , the other side of L 2 being connected through switching transistor Q 2 to neutral. The input terminals 31 , 32 are driven by switch control means 33 such as illustrated in FIG. 1 of U.S. Pat. No. 4,980,812, incorporated herein by reference. Transistors Q 1 and Q 2 of FIG. 2 correspond to transistors 86 and 88 seen in FIG. 1 of the referenced patent. Transistors Q 1 and Q 2 are driven in such a manner as to achieve a power factor close to 1.0, and to maintain needed voltage across C 2 and C 3 . Inductor L 1 is also connected through diode D 3 and capacitor C 2 to neutral; and inductor L 2 is connected through diode D 4 and capacitor C 3 to neutral. When Q 1 is turned off after it has been conducting, current is passed through L 1 and D 3 to charge capacitor C 2 , maintaining positive voltage on the +HV rail 35 . Likewise, when Q 2 is turned off after having been turned on during a negative swing of the line voltage, current from inductor L 2 passes through diode D 4 and charges capacitor C 3 , maintaining negative voltage on high V rail 36 .
Still referring to FIG. 2, HV rails 35 and 36 have connected therebetween transistor switches Q 3 and Q 4 in series, which are driven at input terminals 38 and 39 by a reference signal in a well known manner, so as to alternately switch on during respective half cycles of positive and negative going voltage. Diode D 5 is placed across transistor Q 3 , and diode D 6 is placed across transistor Q 4 . The switched voltage appearing at the node between transistors Q 3 and Q 4 is connected to filtering inductor L 3 , and the AC output which appears across capacitor C 4 drives the load 40 connected between line out and neutral.
Battery 30 is shown in FIG. 2, having its negative terminal connected to neutral, but its positive rib terminal unconnected. The longstanding problem in the art, which this invention meets, is how to connect the battery in tag such a way as to enable generation of the plus and minus HV rails from such battery at the time of AC input line failure. What is needed is a simple but reliable circuit which can utilize the inductor and switching components of the PFC circuit, i.e., inductors L 1 and L 2 , and transistors Q 1 and Q 2 .
Referring now to FIG. 3, there is shown an improved circuit which connects the battery to converter elements of the power factor correction circuit of FIG. 2 . In addition to the circuit components illustrated in FIG. 2, there is illustrated a battery 30 which is tied at its plus terminal to neutral through diode D 9 , and at its minus terminal to neutral through diode D 10 . Bypass capacitors C 5 and C 6 bridge diodes D 9 and D 10 respectively, and are chosen to have a large capacitance with respect to the switching frequency of switches Q 1 and Q 2 , which is determined by control circuit 33 . The positive terminal of the battery is also connected through D 7 to a node between D 1 and L 1 , and the negative terminal of the battery is connected through diode D 8 to a node between D 2 and L 2 . Instead of connecting Q 1 and Q 2 to neutral as in FIG. 2, the emitter of Q 1 is connected to the negative terminal of the battery, while the collector of Q 2 is connected to the positive terminal of the battery. Thus, in terms of extra circuit components, the improved circuit comprises the simple addition of four diodes and two high frequency bypass capacitors. During normal operation the battery is balanced around neutral, and never gets more than a forward biased diode drop away from neutral, e.g., about one-half to three-fourths volts. By utilizing a battery that has a voltage less than one-half the peak of the incoming AC voltage, the power factor correction circuit operates over a sufficiently long portion of each cycle to achieve a power factor greater than 0.9.
Referring now to FIGS. 4A and 4B, there are illustrated circuit diagrams showing the equivalent circuit operation under conditions where there is a good input on the AC line, and the input voltage is positive and greater than battery voltage. In FIG. 4A, Q 1 is illustrated in an on or closed switch position, and in FIG. 4B is illustrated in an off, or open switch position. Note that Q 1 is turned on only when the voltage peak is greater than the battery voltage, such that D 7 is reversed biased. In this condition, as illustrated in referenced patent 4,980,812, capacitor C 2 is shunted by Q 1 and current builds up in inductor L 1 . When Q 1 opens, as shown in FIG. 4B, L 1 acts as a current generator and pumps current into capacitor C 2 , building up the DC voltage thereacross. FIGS. 5A and 5B show the equivalent circuit diagram when the line terminal is negative and the voltage exceeds the battery voltage. In a similar fashion, when Q 2 is closed and thus shunts C 3 , current builds up through L 2 . When Q 2 is opened, current is pumped from L 2 into capacitor C 3 , thereby generating a negative voltage across C 3 with respect to neutral. These respective operations generate the positive and negative HV rails indicated in FIG. 3, in a manner that is substantially unchanged with respect to the embodiment of U.S. Pat. No. 4,980,812. During this typical cycle of operation, forward biased diode D 10 connects current through Q 1 while it is closed, and forward biased diode D 9 is in series with switch Q 2 when it is closed, with the result that the improved circuit has no appreciable impact on the operation of the PFC conversion. During the positive line voltage swing, the negative terminal of the battery is tied to neutral through D 10 ; during the negative line voltage swing, the positive terminal of the battery is tied to neutral through D 9 .
Referring now to FIGS. 6A and 6B, there are illustrated the effective circuit diagrams for the UPS circuit of this invention during loss of AC input, i.e., at any time when UPS load is being supplied by the battery.
During this time, the improved switching circuit acts to connect the battery to alternately charge C 2 and C 3 so as to maintain the same plus and minus high voltage rails. During such battery back up operation, switches Q 1 and Q 2 are turned on and off independently, by switch control 33 .
When the AC source voltage drops to an unacceptable level, switch control 33 operates to drive Q 1 and Q 2 through on-off cycles, at a duty cycle as required to provide a regulated output. Note that each of Q 1 and Q 2 can be switched independently, as may be required for an unbalanced load (not shown unbalanced). Q 2 is held off (open) while C 2 is charged, and Q 1 is held off while C 3 is charged.
During the period of time that Q 2 is held off, Q 1 is first switched on and then switched off. FIG. 6A shows Q 2 off and Q 1 switched on. Under these circumstances, current flows from the battery through diode D 7 , inductor L 1 , and back through switch Q 1 to the negative terminal of the battery, building up current flow in inductor L 1 . At the same time, remaining current through L 2 is discharged through diode D 8 , diode D 10 , capacitor C 3 and diode D 4 . When Q 1 is turned off (FIG. 6 B), the build up of current is passed through diode D 3 into capacitor C 2 , charging it positively with respect to neutral. The current through C 2 returns through diode D 9 . At the same time, current from battery 30 goes around the outer loop of the circuit shown, i.e., through D 7 , L 1 , D 3 , C 2 , C 3 , D 4 , L 2 and D 8 . Following this, the sequence is reversed such that Q 1 is turned off, and Q 2 is alternatingly turned on and off, resulting in the reverse operation which builds up the negative voltage across capacitor C 3 . During the battery supply of the output voltage, if capacitor C 2 and C 3 are loaded in a balanced manner, and if C 5 and C 6 have large capacitance for the switching frequency, then the voltage across each of capacitors C 5 and C 6 is held substantially constant and has a value of approximately one-half the voltage of the battery. To the extent that C 2 and C 3 loading becomes unbalanced, the ratio of the voltages across C 5 and C 6 likewise is unbalanced.
Referring now to FIG. 7A, there is shown a preferred circuit. In this embodiment, battery 30 has one terminal (illustrated as the negative terminal) connected to neutral. The other terminal is connected through switch Si to D 7 . switch S 1 is normally open, but is closed by control 33 whenever low line voltage is detected, in a conventional manner. Compared to FIG. 3, diode D 10 and capacitor C 6 are eliminated, and switch S 1 is added. FIGS. 7B and 7C illustrate the circuit action when the load is battery-driven. In FIG. 7B, each of switches Q 1 and Q 2 are closed, such that current flows from battery 30 to each inductor L 1 , L 2 . In FIG. 7C, Q 1 and Q 2 are each switched open, so that current flows from L 1 to C 2 , and from L 2 to C 3 . In this embodiment as well, switch control 30 can drive Q 1 and Q 2 independently when the UPS is in the battery-driving mode due to low source AC voltage.
Both the preferred embodiment of FIG. 7 A and the embodiment of FIG. 3 illustrate a DC to AC converter (utilizing transistors Q 3 , Q 4 ), for providing uninterrupted AC output. However, the invention also applies to a supply for providing a DC output, such that no DC to AC inverter is utilized. Thus, in general, the invention comprises an output circuit between the HV rails and the output terminals.
There is thus illustrated a very simple, inexpensive and reliable circuit which achieves the object of connecting the battery to an UPS having an uninterrupted neutral from input to output, the battery connection being made in such a way as to utilize the PFC circuit for conversion of the battery voltage during times when the battery is supplying output load. At the same time, the circuit ties one terminal of the battery to neutral, or holds the battery balanced around neutral, and does not adversely affect performance of the PFC circuit. The invention thus achieves the object of allowing the battery to be connected to neutral at all times, while utilizing the PFC circuit to convert the battery output to the HV lines at the time of AC power source failure.
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An uninterrupted power supply (UPS) device with uninterrupted neutral from input to output utilizes the same converter for converting rectified AC power and battery power to positive and negative high voltage (HV) rails. A simple circuit is utilized for connecting the battery to the conversion components of the PFC circuit without adverse affect on the performance of the PFC circuit, and while holding the battery substantially connected to neutral. In a first embodiment, the circuit comprises a simple combination of four diodes and a pair of high pass capacitors arranged so that in both power line and battery supply modes the battery is balanced around neutral. In a second, preferred embodiment, one terminal of the battery is connected directly to neutral.
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RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/912,517, filed Dec. 5, 2013, which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This application is generally related to stimulation leads, and in particular to stimulation leads with segmented electrodes and methods of fabrication.
BACKGROUND INFORMATION
[0003] Deep brain stimulation (DBS) refers to the delivery of electrical pulses into one or several specific sites within the brain of a patient to treat various neurological disorders. For example, deep brain stimulation has been proposed as a clinical technique for treatment of chronic pain, essential tremor, Parkinson's disease (PD), dystonia, epilepsy, depression, obsessive-compulsive disorder, and other disorders.
[0004] A deep brain stimulation procedure typically involves first obtaining preoperative images of the patient's brain (e.g., using computer tomography (CT) or magnetic resonance imaging (MRI)). Using the preoperative images, the neurosurgeon can select a target region within the brain, an entry point on the patient's skull, and a desired trajectory between the entry point and the target region. In the operating room, the patient is immobilized and the patient's actual physical position is registered with a computer-controlled navigation system. The physician marks the entry point on the patient's skull and drills a burr hole at that location. Stereotactic instrumentation and trajectory guide devices are employed to control the trajectory and positioning of a lead during the surgical procedure in coordination with the navigation system.
[0005] Brain anatomy typically requires precise targeting of tissue for stimulation by deep brain stimulation systems. For example, deep brain stimulation for Parkinson's disease commonly targets tissue within or close to the subthalamic nucleus (STN). The STN is a relatively small structure with diverse functions. Stimulation of undesired portions of the STN or immediately surrounding tissue can result in undesired side effects. Mood and behavior dysregulation and other psychiatric effects have been reported from stimulation of the STN in Parkinson's patients.
[0006] To avoid undesired side effects in deep brain stimulation, neurologists often attempt to identify a particular electrode for stimulation that only stimulates the neural tissue associated with the symptoms of the underlying disorder while avoiding use of electrodes that stimulate other tissue. Also, neurologists may attempt to control the pulse amplitude, pulse width, and pulse frequency to limit the stimulation field to the desired tissue while avoiding other tissue.
[0007] As an improvement over conventional deep brain stimulation leads, leads with segmented electrodes have been proposed. Conventional deep brain stimulation leads include electrodes that fully circumscribe the lead body. Leads with segmented electrodes include electrodes on the lead body that only span a limited angular range of the lead body. The term “segmented electrode” is distinguishable from the term “ring electrode.” As used herein, the term “segmented electrode” refers to an electrode of a group of electrodes that are positioned at approximately the same longitudinal location along the longitudinal axis of a lead and that are angularly positioned about the longitudinal axis so they do not overlap and are electrically isolated from one another. For example, at a given position longitudinally along the lead body, three electrodes can be provided with each electrode covering respective segments of less than 120° about the outer diameter of the lead body. By selecting between such electrodes, the electrical field generated by stimulation pulses can be more precisely controlled and, hence, stimulation of undesired tissue can be more easily avoided.
[0008] Implementation of segmented electrodes are difficult due to the size of deep brain stimulation leads. Specifically, the outer diameter of deep brain stimulation leads can be approximately 0.06 inches or less. Fabricating electrodes to occupy a fraction of the outside diameter of the lead body and securing the electrodes to the lead body can be quite challenging.
SUMMARY
[0009] In some embodiments, a method for fabricating a neurostimulation stimulation lead comprises: providing a plurality of ring components and hypotubes in a mold; molding the plurality of ring components and the hypotubes to form a stimulation tip component for the stimulation lead; and forming segmented electrodes from the ring components after performing the molding. The hypotubes may be welded to the electrodes before placement within a mold for an injection molding process. According to any of the discussed embodiments, the method further comprises applying a first weld and a second weld to attach each hypotube to a corresponding ring component. The molding process fills the interstitial spaces with suitable insulative material.
[0010] According to any of the discussed embodiments, the neurostimulation lead is adapted for long term implant within a patient. In one embodiment, the neurostimulation lead is a deep brain stimulation lead. The neurostimuation lead may comprise a suitable configuration of segmented electrodes (four rows of two segmented electrodes, two rows of four segmented electrodes, or two rows of three segmented electrodes with two conventional ring electrodes as example configurations). According to any of the discussed embodiments, the neurostimulation lead may comprise a non-symmetric hour-glass radial marker.
[0011] According to any of the discussed embodiments, the method further comprises: providing a pre-molded frame component with multiple lumens about the plurality of hypotubes, wherein the frame is placed about the plurality of hypotubes before the molding process is performed to retain the plurality of hypotubes at respective angular positions during the molding process. The re-molding frame structure is integrated within the stimulation tip component by the molding process. The pre-molded frame may be fabricated using a suitable biocompatible polymer material. According to any of the discussed embodiments, the stimulation tip components may employ a relatively stiff polymer material (e.g., shore 75 D) while polymer material of the lead body is relatively less stiff (e.g., shore 55 D).
[0012] According to any of the discussed embodiments, the plurality of hypotubes comprise different lengths for multiples ones or all of the plurality of hypotubes. The hypotubes extend from the molded portion of the stimulation or terminal tip by respective lengths. The different lengths facilitate subsequent connection of the hypotubes to conductor wires of a lead body in a correct order.
[0013] According to any of the discussed embodiments, an insulative coating is disposed on each hypotube of the plurality of hypotubes. The insulative coating may be a parylene material (one or more respective polyxylylene polymers). Weld operations may be performed on the coated hypotubes to mechanically and electrically connect the hypotubes to various other components of the neurostimulation lead. For example, the conductor wires of a lead body of the neurostimulation lead may be welded to the coated hypotubes.
[0014] According to any of the discussed embodiments, the method further comprises providing insulative material over an exposed portion of the plurality hypotubes after connection to conductor wires of a lead body and reflowing the insulative material to enclose the previously exposed portion of the plurality of hypotubes and to integrate a stimulation and/or connector tip component with the lead body. The insulative material may be provided in a “clam-shell” form to facilitate wrapping around the connection region between the stimulation or terminal tip and the lead body. The insulative material may be a suitable reflowable polymer material.
[0015] According to any of the discussed embodiments, each ring component may comprise a step-down region. The step-down region is secured underneath the surface of the neurostimulation lead formed by the insulative material provided during the molding process. The roughness of the surface of step-down region may be increased by bead-blasting to facilitate bonding or adhesion to the insulative material provided during the molding process. Also, the inner surface of the ring components may be similarly processed to facilitate adhesion to the insulative material provided during the molding process.
[0016] According to any of the discussed embodiments, the hypotubes are connected to wires of a lead body of the neurostimulation lead. The method further comprises twisting the lead body from a first configuration with linearly arranged conductor wires to obtain a second configuration with helically arranged conductor wires. The method further comprises heating the lead body to retain the helical arrangement of conductor wires in the finished neurostimulation lead. The twisting may be performed before or after connection to the hypotubes.
[0017] In some embodiments, a neurostimulation lead is fabricated using any of the methods discussed herein. In some embodiments, a neurostimulation system includes an implantable pulse generator (IPG) and one or more neurostimulation leads fabricated using any of the methods discussed herein.
[0018] The foregoing and other aspects, features, details, utilities and advantages of the present disclosure will be apparent from reading the following description and claims, and from reviewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIGS. 1A and 1B depict a stimulation tip component shown in respective views according to some representative embodiments.
[0020] FIGS. 2A and 2B depict a terminal end component according to respective views according to some representative embodiments.
[0021] FIGS. 3A-3C depict a lead body component according to some representative embodiments.
[0022] FIGS. 4A-4F depict respective components of a stimulation tip component according to some representative embodiments.
[0023] FIG. 5 depicts an additional view of a terminal end component according to some representative embodiments.
[0024] FIG. 6 depicts integration of a stimulation tip component with a lead body component according to some representative embodiments.
[0025] FIG. 7 depicts a finished stimulation lead within a neurostimulation or other active medical device system according to some embodiments.
[0026] FIG. 8 depicts a flowchart of operations for fabrication of a stimulation end component according to one representative embodiment.
[0027] FIG. 9 depicts a flowchart for operations for joining a stimulation end component to a lead body component according to one representative embodiment.
[0028] FIG. 10 depicts a plurality of different marker designs that permit the orientation of a stimulation lead with segmented electrodes to be determined post-implant.
[0029] FIG. 11 depicts the orientation of a lead with segmented electrodes and an orientation marker according to one representative embodiment matched against corresponding images of the lead.
[0030] FIG. 12 depicts further images of segmented leads with markers according to some representative embodiments.
DETAILED DESCRIPTION
[0031] The present application is generally related to a process for fabricating a stimulation lead comprising multiple segmented electrodes. In one preferred embodiment, the lead is adapted for deep brain stimulation (DBS). In other embodiments, the lead may be employed for any suitable therapy including spinal cord stimulation (SCS), peripheral nerve stimulation, peripheral nerve field stimulation, dorsal root or dorsal root ganglion stimulation, cortical stimulation, cardiac therapies, ablation therapies, etc.
[0032] In some representative embodiments, multiple components are fabricated and assembled to form a stimulation lead including segmented electrodes. Referring to FIGS. 1A and 1B , stimulation end component 100 is shown in respective views. In one embodiment, stimulation end component 100 is fabricated by molding the respective components using a suitable biocompatible polymer to form an integrated assembly. In one embodiment, injection molding is the process selected for fabrication of stimulation end component 100 , although any suitable molding technique may be employed. The various components include a plurality of electrodes and hypotubes. The electrodes are connected to a plurality of hypotubes. The stimulation end component 100 may also include a radio-opaque marker to permit the orientation of the lead to be determined post-implant using suitable medical imaging. Stimulation end component 100 preferably includes a plurality of segmented electrodes. In one embodiment, a distal ring electrode, two rows of three segmented electrodes, and a proximal ring electrode are provided, although any suitable electrode configuration may be selected. One other possible electrode configuration includes two rows of four segmented electrodes. Another possible electrode configuration includes four rows of two segmented electrodes.
[0033] FIGS. 2A and 2B depict terminal end 200 according to respective views. Terminal end component 200 may be fabricated in a substantially similar manner to stimulation end component 100 using suitable molding techniques. Terminal end component 200 may preferably comprise ring contacts for placement within the header of an implantable pulse generator (IPG). Terminal end component 200 may also comprise a non-active contact ring for use with a set screw and/or contact with an initial seal element within the header of the IPG. Terminal end component 200 preferably comprises a stylet guide and central lumen for the stylet.
[0034] FIGS. 3A and 3B depict lead body component 300 . In one embodiment, a multi-lumen component of insulative material is initially molded or otherwise suitably fabricated. Conductors are placed within the various lumens as shown in FIGS. 3A and 3B . The conductors may extend from the distal and proximal ends of the body of insulative material. A central lumen is also provided in lead body component 300 for use of the finished stimulation lead with a stylet. In some embodiments, after placement of the conductor wires, lead body component 300 is twisted one or more times and subjected to heating (as shown in FIG. 3C ). By heat setting a twist configuration to the lead body component 300 , transfer of bending at one end of lead body component 300 to the other end of lead body component 300 is prevented. Preventing bend and other deformation transfers from occurring may be helpful during handling of the finished lead during an implant procedure.
[0035] FIGS. 4A-4D depict components of stimulation end component 100 according to some embodiments. In FIG. 4D , ring component 450 is shown. Ring component 450 is a substantially annular structure of suitable conductive material. Ring component 450 includes one or more step-down regions 451 where the outer diameter is reduced. The step-down regions may permit ring component 450 to be more securely integrated within the body of the stimulation end component 100 in the molding process. That is, the step-down regions 451 may be disposed below the outer surface of the insulative material after molding occurs. Also, step-down regions 450 may be bead blasted to increase the roughness of the surface of the electrodes to improve bonding or adhesion to the insulative material. Also, the inner diameter (not shown) of ring component 450 may be similar processed. Other techniques for application of abrasive materials to roughen the respective surfaces may be alternatively applied. The increase in surface roughness may further secure the integration of the metal components with the insulative material provided during the molding process. Additionally, ring component 450 may comprise longitudinal grooves or cuts (shown in FIG. 4F ) along the inner diameter of component 450 to facilitate separation of the component 450 into multiple segmented electrodes by a grinding process or other suitable processing. The reduced wall thickness along such grooves permits separation during grinding operations as detailed in U.S. Patent Ser. No. 12/873,838, filed Sep. 1, 2010 (published as U.S. Patent Pub. No. 2011/0047795) which is incorporated herein by reference.
[0036] FIG. 4A depicts component 410 which includes the ring components 450 (before grinding operations), ring electrodes, and the hypotubes integrated using molded insulative material. Component 410 is subjected to suitable grinding operations to provide stimulation tip component 420 in which the grinding produces the segmented electrodes from ring components 450 . Pre-molded frame 425 (shown individually in FIG. 4C ) is placed over a portion of the hypotubes as shown in FIG. 4E to form stimulation end component 100 . Frame 425 may provide stability to hypotubes within the interior of the finished stimulation lead and prevent hypotubes from migrating to the outer surface of the stimulation lead. Also, frame 425 may ensure that hypotubes are maintained in a regular angular pattern to facilitate connection with other portions of the stimulation lead. A portion of hypotubes may preferably remain exposed to facilitate subsequent lead fabrication operations. Also, the lengths of the hypotubes may be preferably staggered as shown in FIG. 4E . The difference in length of the respective hypotubes permits ready identification of the connection of a specific hypotube to a corresponding electrode to facilitate further integration operations for fabrication of the stimulation lead.
[0037] FIG. 5 depicts an additional view of terminal end component 500 . As discussed previously, terminal end component 500 may be fabricated in substantially the same manner as stimulation end component 100 . Terminal end component 500 may include a hypotube configuration (i.e., varied lengths of hypotubes) that mirrors the arrangement of hypotubes on stimulation end component 100 to facilitate the lead fabrication process. Terminal end component 500 may include a suitable frame component surrounding the hypotubes. Further, terminal end component 500 may include an additional contact which is not connected to a hypotube. The additional contact may be employed for use with a set-screw in the header of an extension and/or IPG.
[0038] FIG. 6 depicts integration of stimulation end component 100 with lead body component 300 . Lead body component 300 is placed next to “gear” component 650 . Gear component 650 may be fabricated from suitable biocompatible material such as PEEK or ETFE. Gear component 500 comprises a plurality of grooves or channels for the conductors of lead body component 300 and the hypotubes of stimulation end component 100 . The conductors of lead body component 300 are placed within the hypotubes and suitable welding operations are performed (e.g., laser welding). Clamshell component 610 is preferably placed over the exposed connection region of conductors and hypotubes. Clamshell component 610 is preferably fabricated from a reflowable (e.g., a biocompatible polyurethane or thermoplastic polycarbonate urethane) insulative material. The material of component 610 is selected to possess a lower flow temperature than of gear component 650 . When reflow operations occur, gear component 650 retains the hypotubes and/or conductors in place and prevents mutual contact between such conductive material. Thereby, shorting between such components is prevented.
[0039] Similar operations may occur to connect the other end of lead body component 300 to terminal end component 200 to form the stimulation lead.
[0040] FIG. 7 depicts a finished stimulation lead within a neurostimulation or other active medical device system according to some embodiments. Neurostimulation system 700 includes pulse generator 720 and one or more stimulation leads 701 . Examples of commercially available pulse generator include the EON™, EON MINI™, LIBRA™, and BRIO™ pulse generators available from St. Jude Medical, Inc. Other active medical devices could be employed such as pacemakers, implantable cardioverter defibrillator, gastric stimulators, functional motor stimulators, etc. Pulse generator 720 is typically implemented using a metallic housing that encloses circuitry for generating the electrical pulses for application to neural tissue of the patient. Control circuitry, communication circuitry, and a rechargeable battery (not shown) are also typically included within pulse generator 720 . Pulse generator 720 is usually implanted within a subcutaneous pocket created under the skin by a physician.
[0041] As fabricated according to techniques described herein, lead 701 is electrically coupled to the circuitry within pulse generator 720 using header 710 . Lead 701 includes terminals (not shown) that are adapted to electrically connect with electrical connectors (e.g., “Bal-Seal” connectors which are commercially available and widely known) disposed within header 710 . The terminals are electrically coupled to conductors (not shown) within the lead body of lead 701 . The conductors conduct pulses from the proximal end to the distal end of lead 701 . The conductors are also electrically coupled to electrodes 705 to apply the pulses to tissue of the patient. Lead 701 can be utilized for any suitable stimulation therapy. For example, the distal end of lead 701 may be implanted within a deep brain location or a cortical location for stimulation of brain tissue. The distal end of lead 701 may be implanted in a subcutaneous location for stimulation of a peripheral nerve or peripheral nerve fibers. Alternatively, the distal end of lead 701 positioned within the epidural space of a patient. Although some embodiments are adapted for stimulation of neural tissue of the patient, other embodiments may stimulate any suitable tissue of a patient (such as cardiac tissue). An “extension” lead (not shown) may be utilized as an intermediate connector if deemed appropriate by the physician.
[0042] Electrodes 705 include multiple segmented electrodes. The use of segmented electrodes permits the clinician to more precisely control the electrical field generated by the stimulation pulses and, hence, to more precisely control the stimulation effect in surrounding tissue. Electrodes 705 may also include one or more ring electrodes and/or a tip electrode. Any of the electrode assemblies and segmented electrodes discussed herein can be used for the fabrication of electrodes 705 . Electrodes 705 may be utilized to electrically stimulate any suitable tissue within the body including, but not limited to, brain tissue, tissue of the spinal cord, peripheral nerves or peripheral nerve fibers, digestive tissue, cardiac tissue, etc. Electrodes 705 may also be additionally or alternatively utilized to sense electrical potentials in any suitable tissue within a patient's body.
[0043] Pulse generator 720 preferably wirelessly communicates with programmer device 750 . Programmer device 750 enables a clinician to control the pulse generating operations of pulse generator 720 . The clinician can select electrode combinations, pulse amplitude, pulse width, frequency parameters, and/or the like using the user interface of programmer device 750 . The parameters can be defined in terms of “stim sets,” “stimulation programs,” (which are known in the art) or any other suitable format. Programmer device 750 responds by communicating the parameters to pulse generator 720 and pulse generator 720 modifies its operations to generate stimulation pulses according to the communicated parameters.
[0044] FIG. 8 depicts a flowchart of operations for fabrication of a stimulation end component according to one representative embodiment. In 801 , pre-cut hypotubes are welded to electrodes that include singulation (e.g., grooves) and retention features (step-down regions). In some embodiments, the hypotubes are coated with insulative material before being welded to the electrodes. In one embodiment, a suitable thin coat (e.g., approximately 12 μm) of parylene is provided over each hypotube and the coated hypotubes are welded to the electrodes. The thin coating of parylene permits electrical isolation to be maintained between the various conductive components. The thin coating of parylene prevents shorting between respective hypotubes and other electrically conductive components. Further, it is has been determined by the present inventors that the thin coating of parylene does not affect the integrity of the subsequently created weld points between the hypotubes and other conductive components. In certain embodiments, the rings/electrode components may be additionally or alternatively coated with a thin layer of insulative material (e.g., parylene).
[0045] In some embodiments, multiple weld operations are provided for each hypotube. In one embodiment, a first weld is provided for each hypotube at the proximal end of its ring component and a second weld is provided for each hypotube at the distal end of its ring component. The first and second welds may improve the integrity of the connection between the hypotubes and the ring components. Pushing and pulling of the hypotubes may occur by the injection of insulative material during the molding process. This arrangement may cause the forces applied by the injection process to be placed on the first weld while maintaining the mechanical and electrical integrity of the second weld.
[0046] In 802 , operations to load and shrink insulation onto hypotubes are performed. In 803 , hypotubes are loaded into pre-molded frame component. The frame component may comprise an annular structure with multiple lumens to accommodate each hypotube. In 804 , the subassembly and marker are loaded into a suitable mold and injection molding operations are performed to provide BIONATE™ or other suitable insulative material under the electrodes. After molding, the assembly is subjected to grinding to obtain the intended outer diameter size ( 805 ). In 806 , annealing occurs. The terminal end component may be fabricated in a substantially similar manner.
[0047] FIG. 9 depicts a flowchart for operations for joining a stimulation end component to a lead body component according to one representative embodiment. In 901 , conductor cable ends are ablated to expose conductive material from insulative sheaths about the conductors. In one embodiment, one or more of the conductors are coated with a suitable dye material or other colorant to facilitate identification of a specific channel in the finished stimulation tip component). In 902 , the cables are strung through lumens of a lead body. In 903 , a PEEK or other extrusion or molded component (see e.g., component 650 in FIG. 6 ) is inserted between the hypotubes to hold the hypotubes in place. In 904 , cables are inserted into the hypotubes and laser welded. In 905 , a “clamshell” of BIONATE™ (thermoplastic polycarbonate urethane) material or other reflowable insulative material is loaded over the joint between the components and reflow operations are performed. The reflow operations may include providing a FEP shrink wrap and applying sufficient heat as is known in the art of lead fabrication. The terminal end component may be joined to the lead body component in a substantially similar manner.
[0048] FIG. 10 depicts a plurality of different marker designs that permit the orientation of a stimulation lead with segmented electrodes to be determined post-implant. One marker may be provided at a distal or tip of the stimulation lead. Additionally or alternatively, another marker may be provided proximal to the electrodes of the stimulation lead about the outer surface of the lead body. FIG. 11 depicts the orientation of a lead with segmented electrodes and an orientation marker according to one representative embodiment matched against corresponding images of the lead. FIG. 12 depicts further images of segmented leads with markers according to some representative embodiments.
[0049] Although certain embodiments of this disclosure have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this disclosure. All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the disclosure. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the disclosure as defined in the appended claims.
[0050] When introducing elements of the present disclosure or the preferred embodiment(s) thereof, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
[0051] As various changes could be made in the above constructions without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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In one embodiment, a method for fabricating a neurostimulation stimulation lead comprises: providing a plurality of ring components and hypotubes in a mold; placing an annular frame with multiple lumens over distal ends of the plurality of hypotubes to position a portion of each hypotube within a respective lumen of the annular frame; molding the plurality of ring components and the hypotubes to form a stimulation tip component for the stimulation lead, wherein the molding fills interstitial spaces between the plurality of ring components and hypotubes with insulative material; and forming segmented electrodes from the ring components after performing the molding.
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BACKGROUND OF THE INVENTION
Custom calling features are well-known for telephone systems. With the advent of electronic components and especially integrated circuits, the providing of these service features may be accomplished expediently in an inexpensive manner. These features may be provided both in the computercontrolled exchanges now being developed and produced in the electromechanical exchanges prevalent in the industry.
Such special features are shown, for example in U.S. Pat. No. 3,377,433 issued 4/9/68 to W. Whiteney, U.S. Pat. No. 3,342,934 issued 9/19/67 to H. Koh et al, and U.S. Pat. No. 3,811,015 of 5/14/74 to R. Beth et al.
SUMMARY OF THE INVENTION
The invention provides an improved apparatus for providing one or more "custom calling" or special services features such as three-way calling and call waiting service. The apparatus comprises a plurality of printed circuits including buffer and power control circuits which are employed regardless of the type of feature circuit used. Individual logic circuits are used to provide either feature and a combination logic circuit is used where both available features are desired. The apparatus may be coupled to line circuits at the main distributing frame and in this way, no interconnections or wiring changes internal to the exchange need be made.
The apparatus features circuits mounted on plug-in cards. Each feature unit employs a control card and an interface card in addition to a logic card. One of three logic cards may be used interchangeably to provide either or both of the features noted in conjunction with the interface and control card usable for all three logic circuits.
By using the interconnection at the MDF and by providing common circuits for line control and buffering, either or both service features may be provided by inserting the necessary circuit in a fully flexible manner. The service features may be readily added to or detached from the connection of any line circuit. In this way, one or both of the features may be provided with a minimum expenditure of time and effort.
It is therefore an object of the invention to provide improved apparatus for the addition of one or more features such as three-way calling or call waiting control in a novel manner.
It is a further object to provide apparatus to provide one or more special features, the apparatus being adapted to be connected to two line circuits at a main frame connection to the line circuits to provide optional features for a telephone line.
It is a still further object of the invention to provide an apparatus for a telephone line which allows ready interchange to provide either a three-way calling arrangement accessible from that line, or a call waiting arrangement for that line or both such arrangements by the insertion of a predetermined one of three printed circuit boards.
It is a still further object of the invention to provide apparatus for connection to and control of any line circuit for which special services features are to be applied.
BRIEF DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic block diagram of the apparatus of the present invention;
FIG. 2 is a schematic block diagram of the operation of the apparatus of FIG. 1 within a known telephone system to provide one service feature;
FIG. 3 is a schematic block diagram of the apparatus of FIG. 1 within the system of FIG. 2 to provide a second service feature;
FIG. 4 is a schematic circuit diagram of the line circuit control of FIG. 1;
FIG. 5 is a schematic circuit diagram partially in block form of the interface circuit of FIG. 1;
FIG. 6 is a chart showing the relative positioning of FIGS. 6A and 6B to form a schematic circuit diagram for the call-waiting feature of FIG. 1;
FIG. 7 is a chart showing the relative positioning of FIGS. 7A and 7B to form a schematic circuit diagram for the three-way calling feature of FIG. 1; and
FIG. 8 is a chart showing the relative positioning of FIGS. 8A and 8B to form a schematic diagram of circuit to provide both features - three-way calling and call waiting.
DETAILED DESCRIPTION
In FIG. 1, we show a block diagram of our apparatus as fitted within a telephone system, exemplarily of the type shown in U.S. Pat. No. 3,441,677 issued 4/29/69 to E. L. Erwin et al. The apparatus comprises a line circuit control 12, an interface circuit 14 and one of three logic circuits 16, 18 and 20, these being shown in detail in FIGS. 6-8 to provide call waiting service (circuit 16); three-way calling (circuit 18) or to provide both (circuit 20).
The line control circuit 12 and the interface circuit 14 are connected to the telephone system at the MDF and these circuits act to interface and buffer the logic circuit from the exchange circuitry. Thus, the line control circuit or transmission circuit is connected through leads T and R to the subscriber to which the service features are being supplied. The line control circuit also connects to the two line circuits used to supply the two ports necessary for the services involved. These line circuits may be any conventional line circuit in use in electromechanical telephone systems, as shown. The interface circuit also has connections to the respective line circuits and to the line unit which may be part of the marker (FIGS. 2 and 3). All the connections noted are connected across the MDF by whatever connection techniques are used in the system, jumper wires or the like. Thus an apparatus can readily be applied to a line to provide the service and removed from the line if the service features are to be changed or discontinued.
The logic circuits 16, 18 and 20 should be identical in size and terminal locations to plug in for connection to the circuit of the interface card interchangeably. Mechanical or packaging techniques for providing such interchangeability are of course well-known in the art especially with the use of integrated circuits.
The line circuits designated No. 1 and No. 2 in FIG. 1 includes a line relay and various contacts controlled by the known cut-off relay in a known manner. These are shown by contacts labeled CO which are responsive to a known cut-off relay. The line relay (L) operates in response to an offhook condition of that line. The CO relay operates upon register attachment on an originating call; or when a waiting call appears at line circuit 2, the CO relay must operate immediately to prevent a dial tone demand when the custom calling services subscriber switches to that line to answer the waiting call.
The two special service features provided are best explained relative to FIGS. 2 and 3 for the call waiting and three-way calling features respectively.
In FIG. 2, we show how the call waiting feature is implemented through a known electromechanical telephone exchange of the type shown in the previously noted U.S. patent to E. Erwin et al.
In FIG. 2, we show a station 2A which has subscribed for the call waiting feature and to which an apparatus such as that of FIG. 1 using logic circuit 16 is applied. Assume that Station 2A has called and is in conversation with Station 2B. In completing the call, line circuit No. 1 representing Station 2A had seized an originating register 30 to receive dialed digits. The register seized a marker 32 and number group translator 34 to forward the call to the called Station 2B, Station 2B being a station in the same exchange as Station 2A. With the call being a local call, an intra office trunk 36 is allotted to handle the call and the call is completed. The marker, number group translator and originating register release after their function has ended and these call completing circuits are available to service other calls. If station 2B is idle, the station responds and a conversation path is completed between Station 2A and Station 2B.
If, while the conversation path remains complete, another local station, Station 2C places a call to Station 2A, the line circuit of Station 2C seizes an originating register 40 to receive dialed digits and a marker and number group translator are seized to process the call. From the marker through the office line unit, an enabling lead is signalled leading to the interface circuit. The marker attempts to set an intra-office trunk to supervise the call and finds the called line busy. However, the class of service of the busy line would indicate that custom calling (call waiting) service is provided for this subscriber and the auxiliary line should be tested. The marker initiates a retest through the complementary level, and if the line is idle, the sleeve lead (S2) of the second line appearance of Station 2A is not grounded.
The auxiliary line circuit (line circuit No. 2) allocated for the custom calling features is tested and found to be idle. The marker completes the call from Station 2C through intra-office trunk 42 to line circuit No. 2 of Station 2A. When the trunk to line connection is made on line circuit 2, sleeve 2 is grounded by the action. The presence of ground on sleeve 2 signals the custom calling adapter of a waiting call.
The call waiting circuit 16 applies tone to station 2A (as will be explained). Station 2A after hearing the tone may flash his hookswitch to place station 2B on hold, and stations 2A and 2C can converse freely.
The operation of FIG. 3 to provide three way calling is somewhat similar to that of FIG. 2 in the call setting up phase. With station 3A having called local station 3B, line circuit No. 1 of Station 3A has seized an originating register, and a marker and number translator have been designated to process the call. With station 3B idle, an intra-office trunk is allocated to handle the call and a conversation path is completed.
If station 3A wishes to have station 3C join the conversation in a three-station conference with station 3B, station 3A flashes his hookswitch to place station 3B on hold. Line circuit No. 2 is activated to seize an originating register and receive dialed digits from station 3A and a marker and number group translator are accessed. When line circuit No. 2 is activated, lead S2 is grounded.
When a call for a third station is identified as an outgoing toll call, a sender is seized to feed calling data through an outgoing trunk to station 3C at a remote exchange. Toll ticketing equipment is connected to monitor the call to station 3C.
With station 3B on hold, the call is completed from station 3A to station 3C at the remote exchange, and station 3A and 3C may converse in privacy. When it is determined that station 3B should re-enter the call, a hookswitch flash by station 3A adds station 3B to the conversation which then may continue.
Turning now to the individual circuits of the apparatus, FIG. 4 shows the line circuit control or transmission circuit to supply all power to the custom calling adapter and also to control all switching on the line circuit.
The circuit of FIG. 4 is divided into three sections: Power Supply 110, transmission relays 112 and transmission switching network 114.
LINE CIRCUIT CONTROL
The conventional office battery is fed to the circuit of FIG. 4 and decoupled through a network comprised of diode D10 and capacitors C6 and C8. The office battery is then passed through zener diode D8 and resistor R8 to produce the 12 volt power supply. The 12 volt power supply is then decoupled through a network comprised of diode D9, resistor and capacitors R9, C5 and C7. The office battery is also fused through the board and if for any reason F1 blows, LED D1 will light and lead FA will be marked with -48 volts.
This transmission relay group 112 includes six relays identified as L, ECC, H1, TWC, H2 and TN, the letters representing the lead to which the relay winding is connected. The operating circuit to each relay is identical, thus, only one need be explained.
A ground input on any one of these leads from the interface of FIG. 5 will cause that relay to operate, close a current path to the associated LED which will be illuminated.
The transmission circuit 110 includes one repeat coil RC1 with three ports, each port having an impedance of 900 ohms. Included also is the relay logic necessary to control the line unit in the custom calling services. The normal path for the present custom calling apparatus or adapter is by way of the T and R lead bypassing repeat coil RC1 out to the T1 and R1 leads. For example the T lead has a normal path through the normally closed contacts of ECC contact 2, normally closed L relay contact 5, normally closed TN relay contact 3, and normally closed L contact 2 out to the T1 lead. When the ECC contact closes, all DC paths to T1 and R1 leads will be blocked and only an AC coupling will be allowed through transformer RC1.
When the L relay is operated, the transmission or AC coupling is transferred from T1 and R1 leads at line circuit No. 1 to the T2 and R2 leads to the auxiliary line circuit No. 2. Resistors R5 and R6 and the associated contacts in that path are used as a loop hold path, assuring that when one station is talking on the other loop (T1, R1) the station on the T2, R2 loop is placed on hold until those associated relays have dropped. Resistors R3, R4, and capacitors C3 and C4 are used as padding to assure the same transmission at both ports. The TN relay on the tip and ring side of the subscriber line is used to input a 440 Hz call waiting tone to the subscriber isolating this tone from ports T1 and R1 and T2 and R2 by the normally open contacts of TN contact sets 3 and 4.
INTERFACE
The interface circuit of FIG. 5 includes (1) five optical isolator circuits 121-125 (one of which is shown in detail and another in block form) to interface directly between the relay logic of FIG. 4 and the IC logic of FIGS. 6, 7 or 8; (2) seven integrated circuits 126-132 (only one of which is shown in detail) and another is shown in block form to convert the IC logic to relay logic, and a dual limit detector is shown for use as an on-hook and off-hook detector 134.
The on and off-hook detector 134 is a dual limit detector including two operational amplifiers using reference voltages such that on-hook and off-hook conditions can be detected with as much as a 1900 resistance in the loop. To keep within the operating characteristics of the operational amplifier, all voltages are divided by a factor of five. For example, the reference voltages supplied to amplifier 201 based on the voltage divider comprised of resistors R201 and R202 is 9.01 volts. Multiplying this voltage by 5 equals 45.05 volts. With the reference voltage applied to amplifier 201 at 9.01 volts, and the T lead at ground the output of amplifier 201 will be at ground level. On the other hand, with reference voltage for operational amplifier 202 at approximately 0.8 volts, and T lead being at ground, the output of amplifier 152 will be at -12 volts.
As stated relative to the reference voltages, the input voltages are also divided by a factor of 5. The input is also clamped with diodes D212 and D213 to -48V and ground, thus, assuring no input greater than these voltages will appear to the inputs of amplifiers 201 and 202. Capacitor C211 acts as a small decoupling device. The outputs of amplifiers 201 and 202 go directly into a timing network including resistors 232 and 233, and capacitor 202.
The input circuitry produces a fast charge device and the output provides a slow discharge through a process as follows: The T lead receives -24 volts which when divided by five appears approximately -4.8V to the input of amplifiers 201 and 202. With the reference voltage to amplifier 201 being 9.01 volts, the input is still more negative than the amplifier reference, and thus its output remains at ground level. On the other hand, the input to amplifier 202 has become more negative than its 0.8 reference, thus allowing the output of the amplifier to change from -12 volts to ground. This ground signal then proceeds through a timing network made up of resistor 212 and capacitor C202 charging up to the threshold of gate amplifier 153 at a time constant of approximately 200 ms. Resistors R154 and R155 and capacitor C3 are used to speed the operation of plural series amplifiers 203, 204 and 205, thus allowing no oscillation on the outputs of the inverters. When the T lead goes back to ground, the output of amplifier 202 will go back to -12 volts causing the timing network made up of resistor R213 and capacitor C202 to slowly discharge over a period equal to approximately 1.0 sec.
A second section of FIG. 5 is used to provide an interface between the IC logic and relay logic. Seven circuits 126-132 are provided in this section, the circuits being identical, thus only one circuit 126 will be described. Input on lead L1 which is the L input is at IC logic of either -12 volts or ground. With a -12 volt input, the output of amplifier gate 243 will be sitting at ground level with blocking diode 251 stopping any current flow. The ground through resistor R253 will keep transistor Q6 shut off, thus no output will appear on output lead L. With a ground input on input lead L1, the output of amplifier 243 switches to a level of -12 volts. Now with current conducting through diode 251 and resistor 252, base current flows through a transistor Q6 turning it on allowing a ground signal out on lead L to produce the conventional L output.
A relay logic to IC logic interface is also provided by this circuit using five identical circuits 121-125 for which only one need be described. This interface may be explained as follows: With input on lead HSM-I either at -48 volts or open, no current is flowing through the optical isolator Q1. With Q1 turned off, the input to gates 282 and 283 is at a ground level. Thus, being inverted twice and allowing a ground output on HSM-O, the state of the HSM input is switched to ground. Current now flows through optical isolator Q1 and is differentiated by the resistors R265, R266 and the capacitor C265 to produce a time constant of approximately 15 ms ± 10%. Diode D266 is used as a suppression network when optical isolator Q1 is turned on to provide a -12 volt level input to amplifier 66 which is inverted twice to produce a -12 volt level on the output lead HSM-O.
The final optical isolator circuit 125 in the network has two input leads SG and LF-I. Leads SG and LF leads are both open, thus assuring that a ground signal must be applied to the SG lead and a -48 volt signal applied to an LF lead to allow an output from the isolator of that stage. If either signal is missing, the output of the isolator will remain at ground as the circuits above this output are also inverted twice assuring a ground output on the LF lead. When both signals are applied, both are differentiated approximately 10 ms ± 5%, causing their optical isolator to turn on to a logic level -12 volts. The output of this stage is inverted twice assuring a -12 volt output on the LF-O lead.
The optical isolator for the respective networks 122-125 on leads S1, S2 and LFA operate in the same manner described for transistor S, except very little current is needed to turn on the isolator shown. With a -48 volt input on the HSM lead, isolator Q1 remains off, thus a ground signal on the input amplifier 283 is inverted twice assuring a ground output on HSM-O lead. When -44 volts is applied on the HSM-1 lead, the input is then differentiated through resistors R265, R266 and capacitor C265, thus assuring a 10 ms time interval on the output of isolator Q1. When isolator Q1 is turned on, the logic level -12 volts is present on the input of amplifier 283, being inverted twice assuring a -12 volt level on the HSM-O lead.
CALL WAITING LOGIC
The circuit of FIG. 6 controls the logic for switching required to provide the Call Waiting feature. The circuit is comprised of CMOS logic capable of being mounted on a single PC board and receives power from the -12V supply.
The circuit contains six inputs as received from the interface circuit and six outputs directed to the interface circuit. The inputs include (1) Lead OHM(I) or on-hook memory used to determine the disconnect of circuit to reset all flip flops to their static state; (2) Lead HSM(I) or hook switch memory which monitors the hook switch on the station telephone; (3) Lead S1(I) or sleeve one input which monitors the condition of the sleeve of the station; (4) Lead S2(I) or sleeve two which monitors the second appearance sleeve; (5) Lead LFA(I) or terminating class of service and line idle which determines when the custom calling adapter should be enabled; and (6) Lead LF(I) or sub level group which verifies that a connection has been made by the station or to the station.
The outputs include (1) Lead L(O) or line output to control which of the two line appearances the subscriber has in use; (2) Lead H1(O) or hold path one which is capable of holding the line circuit up on line appearance one; (3) Lead H2(O) or hold path two which is capable of holding line circuit two on line appearance two; (4) Lead TN(O) tone lead. This lead puts out a 300 ms ground pulse signal with a 10 second interval. A maximum of two ground pulse signals provides ground seizure. The purpose of this tone is to alert the station to a call waiting condition; (5 ) Lead ECC(O) or enable custom calling which tells that there are two seizures to the line and enables the custom calling adapter to accept the call. At the same time, this lead isolates all DC paths to the station and allows the station to be only AC coupled into the line circuit; (6) Lead GS2(O) or ground sleeve two to provide a ground on sleeve two to prevent another call appearing on the second appearance until the circuit is enabled. This sleeve is also removed on a forced connection.
To explain the circuit of FIG. 6, an originating call will be followed and process the call. On an off-hook status of the station, after approximately 200 ms, the OHM lead goes to a low condition. (A low condition is defined as -12V while a high condition is defined as ground). With this low condition on the OHM lead, the input on lead 302 to gate 309 goes low. Gate 309 which is a two input NAND gate goes high on receipt of the low condition on its input lead 302. The resulting high condition will enable the following monostables and flip flops: MS303, MS304, FF305, FF306, FF308, FF310, FF316, and FF326.
The OHM lead going low enables all these flip flop circuits for possible operation; the OHM lead going high for a period greater than 1.2 seconds causing a disconnect to reset these flip flops. The station completes dialing and makes a connection in the office. At this time, both LFA and LF leads go low. These inputs cause a signal to be passed by NAND gate 321 to FF318 to operate the flip flop. The output of the flip flop 318 on lead 322 goes low, going through time constant comprised of resistor R330 and capacitor C331. The low condition enables gate 332 and gates 334 and 336 and removes the signal on the GS2 lead.
Once flip flop 318 has been set, the custom calling appearance adapter is ready to accept the call on the second line. Sleeve 1 had been grounded by the station line, placing the low condition on lead S1. This low condition enables the output of flip flop 306 on lead H1(O), the flip flop awaiting a low condition input on gate 342 to set the flip flop. At the same time, the ground sleeve lead S1(I) enables lead 350 to gate 332 causing it to go low awaiting the signal on sleeve lead S2(I) to activate its gate.
On a terminating call, sleeve lead S1 remains grounded on the connection and a low condition is put on the S1 lead. The OHM lead is in a high condition signifying disconnect, and removal of the S1 signal puts a small one shot out on the output of gates 351 and 355 causing the gate output to go low making gate 359 go high for that period resetting FF318. This covers on originating call which the OHM lead is under control of a local station as is the S1 lead. With the circuit enabled, lead S2 goes to a low condition leading to a number of simultaneous occurrences.
The first response to the low condition on lead S2 will be to enable flip flop 326 through gate 320 and its output 361 to lead H2. Also gate 370 is enabled to set flip flop 326, putting a high signal out on the ECC lead to indicate that a second party has been added to the line. At this same time, the force connect flip flop 308 is enabled. Now that all inputs on gate 332 over leads 350, 374 and 376 are low, a high condition is presented on lead 380 over the No. 1 line. This high condition produces an output from flip flop 315 on lead 384 over a path through gate 381 to flip flop 315. Gate 381 also triggers flip flops 307 and 317 when all inputs to gate 390 are in a high condition. The output of gate 390 goes low triggering monostable 303. Monostable 303 goes to a high condition for a timed period of 300 ms.
At the end of the 300 ms. period, a high-to-low transition occurs to trigger monostable 304 causing a 10 second low condition to be sent out on lead 391 from the monostable to gate 390. This 10 second low period assures that input lead 396 to monostable 303 will stay in a high condition and will not retrigger the monostable. An output from lead TN at this time operates relay TN in FIG. 4 to cause a tone to be emitted to the line. At the same time, that lead 391 of monostable 304 went low, lead 393 went high activating lead 395 of flip flop 307 enabling it to a low state. This low state was transmitted over to lead 395 to flip flop 317 and enabled flip flop 307 to activate lead 397 on the next high transition. After the output of the monostable 303 had gone through its 10 second interval, it goes back to a high condition setting monostable 303 and retriggering the monostable one more time to a 300 ms. period. At the end of this period, once again, monostable 304 is triggered. Lead 393 is triggered a second time, and will set flip flop FF307 to produce an output on lead 395 once again setting flip flop 317 to produce an output on lead 397, putting a permanent low condition on the input lead to gate 390 to prevent gate 390 from retriggering at this time.
The HSM lead is the input which has control of flip flop 305 to control the line relay operation. Components 301 and 302 are both monostable circuits with the configuration of 301 being retriggerable. The time constant of the RC combination of resistor R319 and capacitor C324 being 200 ms prevents any signal less than 200 ms. duration from triggering monostable 301. Thus, the input signal on lead HSM must go high for a period greater than 200 ms to produce an output from monostable 301 on lead 341, representing a state change of of the monostable.
At the same time, monostable 302 triggers and its time constant determined by the combination of resistor R360 and capacitor C365 produces a 1.2 second monostable output. This output is fed into gate 312 when all three gate input conditions are met responsive to a pulse duration greater than 200 ms. but less than 1.2 seconds. As a result, the output of gate 312 will go to a high condition for a period equal to the time constant of the combination of resistance R372 and capacitance C371. This high transition will set enabled flip flop 305 to produce a high condition on lead L2 through the interface of FIG. 5 and as a result will trigger transistor Q6 and pull the L relay in the line circuit control.
At the same time that FF 305 of FIG. 6 is set, flip flops 306 and 326 would also be set and produce a pulse, if the S1 and S2 leads had produced a low condition on the inputs of gates 320 and 342. This pulse would also trigger flip flop 315 to produce a low condition on the output lead 384. This low condition on the output on lead 384 would assure that monostable 303 would not retrigger and act to terminate the TN output to relay TN of FIG. 4.
As many times as the input of HSM lead goes to a high input between the period of greater than 200 ms. and less than 1.2 seconds, the output on lead 384 of FF315 would change states. The first time it was set, the output on lead L1 of FF305 would go to a low condition. This setting could continue as long as required. The only act that would terminate the setting or activation is the disconnect signal on the OHM lead. If after the second sleeve was grounded or if the S2 lead went low and an HSM input signal was not activated, but instead the OHM lead went to a ground condition for a period greater than 1.2 seconds (as determined by the output of monostable 302 on lead 311), the output of gate 309 would then change the condition on input lead 348 of gate 340 to a low state. A low on an input of gate 359 over lead 348 resets flip flops FF316, FF308, 310 and 318 and resetting MS303 and 304 preventing any triggering of the monostables.
As the time gate 309 went low, it enabled the input to gate 340. With input 349 low, and the input to gate 359 low, the output of gate 359 went high. This high condition on the output of gate 359 coinciding with a high condition on the input 366 of gate 369 caused its output to change to a low state, allowing FF308 to be set if the ECC lead to FF308 were in a high condition. When lead 396 at the input to MS303 went high, activating the output of FF308 on lead 392, causing it to go low. This low through gate 340 causes a high condition on the set lead of FF305. The set lead will force the output on the L lead of flip flop 305 to go high, this being called a forced connection to the second line appearance. If for any reason the S2 lead went to a high condition, the output of NOR gate 369 would go to a high condition causing FF308 to be reset and dropping FF305 back to its normal or low condition.
If the S2 lead did not go low, the L relay remains high until the OHM lead goes to a low condition. A low condition on lead OHM causes the output of gate 309 to go high causing a low on the ouput of gate 359, thereby resetting FF308.
Resistors R343 through R346 are clamping resistors assuring that no CMOS lead is unterminated when the board is unplugged. By providing resistors on the set and reset leads of the flip flop, we assure a slight decoupling to provide transient free operation.
The output of the FF318 lead 322 has a timing network comprised of resistor R381 in parallel with the combination of diode D382 and resistor R383, these being in series with capacitor 386. Resistor R381 has a much higher value than R383, thus when FF318 first went to a low condition, diode 382 blocks current flow and the path must follow resistance 383 and capacitor 386 causing a slow-to-charge condition. When lead 388 goes to a high condition, it is bypassed through diode D382 and resistor R388 causing a fast discharge path.
Gates inputting on the reset leads to FF318 such as gate 355 are used as one shot devices where the time constant is dependent upon resistor and the capacitor combination to the input of the last gate 359, i.e., when the input from gate 359 is clamped through a capacitor to ground and through another gate to resistor R383. This RC network would determine the time constant of the one shot. The circuit has been designed so that all devices should be in their static state on a power-on condition. Further, the circuit is configured so that removal of any card in the system will not affect a station on its normal line circuit operation, as this only cancels the custom calling portion of the circuit.
THREE-WAY CALLING LOGIC
The circuit of FIG. 7 provides the switching logic to provide only the three-way calling feature. The circuit comprises a CMOS integrated circuit and is operated by a -12 volt power supply. The power supply is suitably decoupled to provide transient free operation. The circuit fits on a plug-in PC board which replaces the circuit of FIG. 6 by having the same input connections to the interface circuit to which it connects in plug-in fashion.
The circuit of FIG. 7 contains six inputs and four outputs directed to the interface (the GS2 input lead of FIG. 6 is not used by the three-way calling feature circuit). The inputs to the circuit and their function is generally as follows: (1) OHM or on-hook memory to determine the disconnect of the circuit and reset all flip flops to their static state; (2) HSM or hook-switch memory to monitor the hook-switch on the station's telephone instrument; (3) S1 or sleeve one input to monitor the sleeve of the main line circuit appearance of a station; (4) S2 or sleeve two input to monitor the second appearance sleeve; (5) LSA or terminating class of service and idle line to determine when the custom calling adapter should be enabled; and (6) LF or sub-level group to verify that the connection has been made by a station or to a station.
The outputs of the circuit of FIG. 7 are as follows: (1) L1 or line output to control which line appearance the subscriber has in use; (2) TWC or three-way calling connection to determine when a conference call has been sent to the adapter; (3) H1 or hold path one to hold a line circuit on line appearance one; and (4) ECC or enable custom calling to indicate the circuit is enabled to complete the three-way call. All the circuits in the adapter are enabled at this time.
An originating call will be followed as processed to complete a three-way call through the circuit of FIG. 7.
On an off-hook condition, the OHM lead goes to a low condition after approximately 200 ms, a low condition again being defined as -12 volts and a high condition being defined as ground. With this low condition on the OHM lead, the output of gate 706 goes high. This condition will enable the following flip flops to be enabled to respond to subsequent response pulses, FF703 through NOR gate 709 to produce an output on lead L1, flip flop FF704 with its output on H1 (or hold for line one); the OHM lead also enables the three-way calling flip flop 713 with its output on lead TWC, flip flop 715 (the ECC flip flop), and FF714 which is used as a control flip flop, but their clocking is determined by other functions in the circuit as well, and will be explained at a later time.
A subscriber dials and makes his connection to the central office. At this time, the LFA and LF leads go low to produce an output on gate 719. FF715 is set, the output of gate 719 with the other input to gate 729 which determines the station is off-hook will pull the ECC relay in FIG. 4 through a path through the ECC lead and the section of FIG. 5 to tell the station that he now is ready to originate another call on the second line appearance if he desires.
As the station went off-hook, his S1 lead went to a low condition which provides some control functions in the custom calling adapter. For example, if the call were a terminating call instead of an originating call when the person completed dialing, the S1 lead would have gone to a low condition. If the called station did not answer the phone and the calling party hung up, the S1 lead would have gone to a high condition producing a small one shot ground pulse out of gate NOR 720 when it is determined by the time constant of R723 and C724. This one shot pulse is fed to into NOR gate 727 and causes the output of gate 727 to go high for that same duration of time resetting flip flop 715, and its output on lead 733. This condition takes place only on a terminating call and we were discussing an originating call, so back to our originating call.
Assuming the calling station does wish to add a third party to his conversation, at this time the HSM lead will be discussed since this is the input which has control of FF703 which controls the line relay flip flop. Circuit devices 701 and 702 are monostables with configuration of MS701 being in a retriggerable mode. The time constant of resistor 730 and capacitor C731 being 200 ms prevents any signal less than 200 ms duration triggering MS701. At this stage, the signal on the HSM lead must go high for a period greater than 200 ms to produce an output from MS701 on lead 350. At the same time, MS702 which is in the configuration of a monostable triggers for its time duration of 1.2 seconds which is determined by resistor R741 and capacitor C742. This output is fed into gate 748 and when all three gate conditions are met, i.e., a condition of a pulse longer than 200 ms in duration but less than 1.2 seconds, lead 743 will go to a high condition for a period of the time constant of resistance R737 and capacitance C753. This high transition will set FF703 and lead L1 to a high condition which will in effect pull the L relay in the control circuit of FIG. 4 as previously described.
At the same time that FF703 is set, FF704 is also set over lead 735 pulling the H1 relay in FIG. 4. Also, a small single shot out of gate 727 resets flip flop 715 to a static state knocking down the ECC lead. As FF703 is set the calling station would in effect get another line circuit connected to his adapter. The S2 lead of the adapter as a result goes low.
If for some reason the calling station decided he did not want to originate another call on that line, or he got a wrong number in the midst of his dialing and hung up, the following would occur. The S2 lead would go high causing a small one shot out of NAND gate 758 over a path through NOR gate 759 setting FF714 driving lead 762 high through NOR gate 764, resetting the line flip flop FF703 and also setting the ECC flip flop 715 to allow the station to re-originate on the second line appearance or just remain talking to the original called party. Assuming that the station decided he dialed the wrong number and wanted to re-originate on the second line appearance, he would again mark the HSM lead with a ground for a period longer than 200 ms and less than 1.2 seconds and would pull the line relay flip flop 703 and follow the previously discussed sequence to perform their functions.
When the calling station dials out on the second line appearance and makes a connection to his party, the LSA and the LS leads go low, setting the ECC flip flop 715. The station is now able to set up a conference call or merely complete the conversation with the second station. Assuming that the station does want a conference call, he marks his HSM lead once again with a pulse of duration longer than 200 ms and less than 1.2 seconds. This pulse brings the output of FF703 back to its normal state knocking the L relay down to its normal appearance. As this happens, the output of FF703 is activated, setting up the three way conference and also resets FF704 to output lead H1 to its static state. Now that the station has a conference call set up, the conference remains in this stage as long as desired.
The call may be terminated in two ways -- by disconnecting the OHM lead or by hookswitch again by marking HSM lead once again. If the HSM lead was marked once again, this causes FF714 output on lead 762 to be activated causing the line flip flop 703 and the TWC flip flop 713 to go back to their static condition and also sets the ECC flip flop 715 to enable the subscriber to originate another call if desired. If when the conference call was set up and the station did not mark his HSM lead, but for some reason S1 went back to a high condition at this time, NAND gate 770 would trigger to produce an output on gates 780 and 790 in the form of a small one shot which is determined by the time constant of resistor R783 and capacitor C784 and set flip flop FF703 to its high condition which would set the line relay and once again reset ECC flip flop 715 back to its static condition. The same condition would appear if S2 lead were to go high after the conference was set up. A small one shot would appear out of gate 392 resetting the conference flip flop 713 output on the TWC lead.
As with the prior circuit, removal of any cards in the system does not effect a station in its normal line circuit operation. Such circuit card removal prevents or inhibits only the custom calling portion of the circuit.
COMBINATION LOGIC
The circuit of FIG. 8 provides both functions -- call waiting and three-way calling -- and contains six inputs and seven outputs, the inputs being: (1) OHM, on-hook memory. This input determines conditions for disconnect of the circuit and resets all flip flops to their static state; (2) HSM, hookswitch memory. This input monitors the hookswitch on the station telephone; (3) S1, sleeve one input. This input monitors the sleeve of the main line circuit appearance for the station; (4) S2, sleeve two input. This input monitors the second line appearance sleeve; (5) LFA, terminating class of service idle line. This input determines when the custom calling adapter should be enabled; and (6) LF, sublevel group. This input verifies that a connection has been by a station or to a station.
The output leads from FIG. 8 are as follows: (1) L, line output. This output controls which line appearance the subscriber has in use; (2) H1, hold path 1. This output is used to provide hold on the line circuit on line appearance one; (3) H2, hold path 2. This output lead is used to provide the capability of holding on the line circuit on line appearance two; (4) TN, tone lead. The output lead places a 300 ms duration ground mark at 10 sec. intervals. A maximum of 2 ground marks are sent out per ground seizure. The purpose of this tone is to alert the subscriber to a call waiting; (5) TWC, three-way calling. This output lead determines when a conference call has been set to the adapter; (6) ECC, enable custom calling. This output lead indicates that the circuit is now enabled for completing the setting up of the call whether it be either three-way calling or call waiting. All the circuits in the adapter are enabled at this time; and (7) GS2, ground sleeve 2. This output is used to place ground on sleeve 2 to prevent other calls from being received on the second line appearance during its seizure. A time delay before the restoration of ground on the No. 2 sleeve lead allows a check for force connection, the delay being 500 ms.
COMBINATION LOGIC-CALL WAITING
The operation of the circuit of FIG. 8 is similar to that of both FIGS. 6 and 7 to provide either or both of their functions. The circuit will be explained first relative to an originating call as it is processed through as a call waiting call comes into the present apparatus. On an off-hook condition, the OHM lead, after approximately 200 ms. goes to a low condition, a low condition again being defined as -12V and a high condition being defined as ground. With this low condition on the OHM lead, the inputs of gate 811 go low. On this low signal, the output of gate 811, which is a two-input NAND goes high. This high condition will enable the following flip flops to be set: FF806, the line appearance flip flop; MS803 and 804, the alert tone control monostables; FF807, the hold 1 control flip flop; FF808, the three-way calling flip flop, and FF809, three-way calling or call waiting identification flip flop. The combination of gates 818 and 821 create a multiple input flip flop to force connect. Flip flop 828 provides its output a three-way calling conference control flip flop output.
The off-hook response on the OHM lead also enables other flip flops if other conditions are met, such as output from flip flops 817 to enable Lead H2 if the ID flip flop 809 had identified a call awaiting service at a time when input lead S2 is low.
The OHM lead going low enables all these circuits, while the OHM lead going high for a period of 1.2 secs. will cause a disconnect and reset these same flip flops. Also, the reset enables custom calling flip flop 809 output on lead 815.
The subscriber completes dialing and makes a connection in the office--at which time the LFA and LF leads go low. As this condition happens, flip flop 819 is set, the output of this gate on lead 822 goes low. After a period determined by the constant of RC combination 826 and 812, this low condition enables gates 827 and 813 and removes the signal on the GS2 lead through OR gate 814. Once flip flop 819 has been set, the circuit is ready to accept a call on the second sleeve.
Sleeve 1 had been grounded by the subscriber's line causing a low condition on the S1 lead. This low condition enables flip flops 807 to produce an output on lead H1 awaiting an input on one input of NAND gate 832 to trigger it. At the same time, the low condition enables gate 827 awaiting a signal on sleeve S2 before activation of gate 827. On a terminating call, sleeve 1 is grounded on the connection and a low condition is put on the S1 lead. With the OHM lead being in either a high condition, or the disconnect condition, removal of ground from the S1 lead is a signal that the waiting station has terminated, for one reason he decided that he couldn't be connected to the station involved in the call or for some reason ended the call by going on hook. The disappearance of ground on the S1 lead would then cause a small one shot to be emitted by gate 835. This output would then proceed over to the input of gate 836, and the output from this gate is fed to the input of flip flop 819, resetting flip flop 819.
The present explanation covers an originating call which the OHM and S1 leads are under the control of the subscriber. With the inputs enabled, S2 lead going to a low condition indicates that a call is being sent to the subscriber's second line appearance. A number of occurrences happen at this time as follows.
First, lead 834 of flip flop 817 will be in a reset or low state to enable the output of flip flop 817 to be set and produce an output on lead H2. With the input on the terminals of NAND gate 827 being low, the input to gate 827 from flip flop 809 on lead 815 is also low indicating that the call being checked is a call waiting one and not a three-way call. The output of gate 827 goes high. This high condition passes through the output of gate 844 with all other inputs to this gate being in the high state. At this time, the output of NAND gate 838 will go low, triggering monostable 803, producing a high on terminal TN for a period of 300 ms.
This 300 ms. period is sufficient to allow completion of a high to low transition, following which monostable 804 triggers causing a 10 sec. low output condition on the lead 841 as an input to MS804. This triggering of MS804 high emits an output on the TN lead to TN relay of FIG. 4 to cause a tone output. The 10 sec. low period is used to insure that the output of gate 838 will stay in a high condition and will not retrigger the monostable. At the same time that lead 841 became low, monostable 804 went high setting flip flop 840 to a low state. This low state was transmitted over lead 845 to flip flop 850 and enabled flip flop output lead 852 to clock on its next high transition.
When lead 845 has received its 10 second transition, this lead reverts to a high condition activating the output of gate 832 to retrigger monostable 803 one more time for a 300 ms. period. At the end of this period, once again monostable 804 is triggered. Monostable 804 triggers outputs on leads TN and 854 a second time which will produce a low condition output on lead 855 to set flip flop 850. This resulting low output on lead 855 puts a permanent low condition on lead 852 preventing monostable 803 from retriggering at this time.
The functioning of HSM lead will be discussed now, since that lead provides the input control gate 858 which, in turn, controls the line relay flip flop 806. Monostables 861 and 862 are connected in a configuration such that MS861 is in a retriggerable mode. The time constant produced by resistor 842 and capacitor 848 is 200 ms. to prevent any signal less than 200 ms. of duration from triggering MS861. Stated another way, a signal on the HSM lead must go high for a period greater than 200 ms. to produce an output from MS861 on lead 860. At the same time, MS862 triggers and its time constant produced by resistance 863 and capacitor 869 up a 1.2 sec. monostable. The output of MS862 on lead 866 is fed onto the input of gate 858. When all three gate inputs meet the required condition of a pulse duration longer than 200 ms. but less than 1.2 seconds, the output of gate 858 goes high for a period determined by the time constant of resistance 870 and capacitance 865. This high transition will set flip flop 806 to produce an output on the L lead which will in effect pull the L relay in the control circuit of FIG. 4.
At the same time, the output of gate 858 is transmitted to flip flop 866 and gates 872 and 832 to set flip flops 807 and 817 leading respectively to leads H1 and H2. These pulses will also trigger an output from flip flop 860 on lead 872 to a low condition. This low condition on output lead 872 will assure that flip flop 803 will not trigger and terminate the TN output if it has not completed two cycles.
As many times as HSM lead will go to a high input for a period of greater than 200 ms. and less than 1.2 secs. the output of flip flop 806 will change states. For example, the first time flip flop 806 was set, its output on lead L went to a high condition. The second time it was pulsed, its output went to a low condition, etc. The pulse setting of the flip flop 806 will continue as long as desired. The only thing that would terminate the pulsing is a disconnect signal on the OHM lead. After the second sleeve had been grounded, or lead S2 went low, and HSM had not been activated; for example, if OHM lead went to a ground condition for greater than 1.2 sec.
The sequencing is determined by the output of gate 872 responsive to the OHM lead with the input and output of gate 811 being in a high condition, the output of gate 811 will be in a low condition. This low condition will proceed to reset everything on the custom calling adapter back to its idle state. This low condition also triggers monostable 875 to produce a high state on its output lead 877, which is transmitted to the input of gate 880 to produce a 500 ms. high period. This timed period on input to gate 880 will insure that latch gate 818 will remain low for a period of 500 ms., thus assuring a ground will not be forwarded from the S2 lead for that period of time. Lead 877 at the output of gate 875 is the oscillator output out of the monostable and has half of the duty cycle as the outputs on leads 881 and 882, thus, on the triggering of monostable 875, output lead 877 will go high for a period of 250 ms. so that the force connect circuit will not be activated to check sleeve S2 for a period of 250 ms.
After the first timed period of 250 ms. has expired, for a continued period of 250 ms. a high signal will be produced on the output of gate 860 if sleeve lead S2 is grounded. This ground or high signal is inverted through gate 883 setting the two upper inputs to flip flop 888 low. The low signal combined with a low signal from gate 880 insures a high signal on the output of gate 818. This high signal on the output of gate 818 goes over to the set lead 889 of flip flop 806. This set lead input produces a high condition on the L lead. When the output of gate 883 is in a low condition due to the fact that S2 is grounded, and the upper input to gate 885 in a low condition due to the condition of the OHM lead responsive to the station subscriber still on hook. A high signal is present at the output of gate 883 to the input of latch gate 821. Thus when the input of latch gate 818 went high producing a low condition at the upper input of gate 818, this low keeps the set lead 889 of flip flop 806 in a high condition, thus, insuring that a force connection is made.
When a person goes off hook or answers the phone, the OHM lead produces a high condition at the output of gate 811. This high condition then is passed to gate 883 and to the lower input to gate 811. This resulting high condition on the input to gate 811 will force a low condition out on the output of gate 883 over to the lower input to gate 821. This low condition will then cause a high condition at the output of latch gate 821 over to the upper input to gate 818 to produce a force connection which will remain as long as S2 remains grounded.
When the ground is removed from lead S2, this changes the condition at the bottom input to gate 880 insuring that flip flop 818 will be reset and no set condition will be able to exist. The call waiting portion of the circuit is operative either on completion of the call by a hookswitch flash or by force connection.
COMBINATION LOGIC -- THREE-WAY CALLING
The most common distinguishing feature between a three-way call and a call waiting is that when a hookswitch has been flashed on a three-way call, the S2 lead will not be grounded. On a hookswitch flash for call waiting, the S2 lead will be grounded. This distinguishing feature is used within the combination logic circuit of FIG. 8 to determine if the customer needs service for either call waiting or origination of a three-way call.
An example of an originating call to complete a three-way call will now be described. Again as the calling subscriber station went off-hook, the OHM lead after approximately 200 ms. went to a low condition. This low condition on the OHM lead causes the output lead of gate 821 to go high. This condition will again enable the same flip flops as discussed in the call waiting portion of the circuit. Again as mentioned previously, many of the flip flops enabled due to an off-hook condition may not be truly enabled unless the calling process is a three-way call or a call waiting depending on which type of call is in process.
For example, on an off-hook condition, input 892 of gate 891 went high and the lower two inputs of gate 893 being high put a low out on the output lead of gate 893 which enables flip flop 808 to be set. But input on lead 494 cannot be activated unless the ID flip flop 809 has identified the call as a three-way call. Thus, in this combination board, flip flop 809 acts to identify which type of services is to function, either a call waiting or a three-way calling and will enable or disable portions of the circuit accordingly.
The subscriber completes dialing and makes connection through the office. At this time, both the LFA and LF leads go low. When this condition happens, flip flop 819 emits an output on lead 822 to enable the custom calling circuitry and inform the subscriber that he may now be ready to originate another call on this second line appearance if he desires.
As the subscriber goes off-hook, his S1 lead goes to a low condition which provides a number of control functions in the three-way calling circuits. For example, if this call was a terminating call instead of an originating call when the calling station completed dialing to the called station, the S1 lead would have gone to a low condition. If the subscriber did not answer the call and the calling station went on-hook, the S1 lead would have gone to a high condition giving a small one shot ground pulse out of the output of gate 835. The duration of this one-shot pulse is determined by the RC values of resistance 887 and capacitance 889 and the pulse is fed to gate 836 to reset to the ECC flip flop 819.
The sequence described takes place only on a terminating call, as contrasted with an originating call which will now be described. Assuming that the calling subscriber station wishes to add a third party to the existing conversation, he flashes his hookswitch to cause the HSM lead to enter a high period of greater than 200 ms. and less than 1.2 sec. caused by the hookswitch flash. This high transition will again set the line relay flip flop 806 to a high condition which will in effect pull the L relay in FIG. 4 over lead L1. At the same time, the H1 lead flip flop 807 is set pulling the H1 relay in FIG. 4. This high condition also is transmitted to one shot gate 896 and produces a small one shot low condition with the time constant of the combination of resistor 912 and capacitor 904. This small low one shot reaches gate 836 to reset the ECC flip flop 819 and in effect restore the enabled custom calling (ECC) relay in the circuit of FIG. 4.
Restoration of the ECC relay allows the subscriber to seize another register, receive dial tone and dial out through the second line appearance. The S2 lead of the FIG. 4 went low at this time. If for some reason, the calling station decided he did not want to originate another call on that line or had gotten the wrong number from his dialing, after the time delay period, lead S2 goes high. The disappearance of the low condition on lead S2 (the S2 lead going high) will cause a small one shot out of gate 917, setting flip flop 828 and thereby resetting the line flip flop 806 and also setting the ECC flip flop 819 allowing the station to reoriginate on the second line appearance or just remain talking to the original called party.
Assuming that the calling station decided he had dialed the wrong number and wanted to reoriginate on the second line appearance, he would again flash his hookswitch, to mark the HSM lead with a ground for a period longer than 200 ms. and less than 1.2 secs. This ground sets the line relay flip flop 806, and of course, at the same time the other functions previously described occur.
The subscriber dials the second line appearance and makes connection to the dialed station. At the same time, again, the LSA and LF leads go low setting flip flop 809 once again. The calling station is now able to set up a conference call or complete the conversation with the second station and need not add the second station to a conference if he desires.
Assuming that the subscriber does want a conference call, he marks his HSM lead once again by a hookswitch flash causing a pulse longer than 200 ms. and less than 1.2 seconds. The output of flip flop 806 is returned to its normal state restraining the L relay of FIG. 4 to its normal appearance. As a result, the output of flip flop 806 went low setting the TWC flip flop 808 to produce an output on the TWC lead. On the output of flip flop 808, gate 926 goes low resetting flip flop 807, restoring lead H1 to its static state.
Now that the calling station has a conference call set up, the system remains in that state for the call duration. There are two ways to terminate this call at this time, either by disconnecting or opening the OHM lead or by flashing the hookswitch again to mark the HSM lead. If the HSM lead was marked once again, flip flop 828 is set over lead 831, causing the line flip flop 806 and the TWC flip flop 806 to restore to their static state and also set the ECC flip flop 875 to enable this subscriber to originate another call if desired.
When the conference call is set up and the calling station does not mark his HSM lead but for some reason lead S1 goes back to a high condition, output of gate 925 will put out a small one-shot which is determined by the time constant of resistor 887 and capacitor 888. This one-shot will set one input to gate 818 low setting the output of gate 818 thereby, setting the line relay for the second appearance. Once again, the ECC flip flop 819 will be reset to its static condition. The same condition would appear if the S2 lead were to go high after the conference was set up. A small one-shot would appear out of the output of gate 891, resetting the conference flip flop 808 output on the TWC lead, and resetting line flip flop 809 which would have already been on line appearance No. 1. All devices should be in their static state on a power-on condition.
Also, removal of any card in the system will not affect the subscriber on the normal line circuit operation. This card removal would only act to cancel the custom calling portion of the circuit.
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Disclosed is an arrangement of circuits for providing what is normally called Custom Calling or Special Services features such as signalling and switching for a call waiting or three-way calling. The apparatus shown may provide either feature or may provide both services by the selection and insertion of one of three available circuits. A plurality of common circuits are provided to operate with specific electronic logic circuits for call waiting, three-way calling or both. Circuits are plug-in PC boards using integrated circuit logic. Individual plug-in cards are provided--one for the call waiting feature, another for three-way calling and a third card is used to provide both features. The entire apparatus may be connected to the subscriber lines and to the central office equipment at the main distributing frame thereby requiring no internal wiring or circuit changes in the central office.
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This application is a continuation of application Ser. No. 428,053 filed Oct. 25, 1989, is a division, of application Ser. No. 101,446, filed 9/28/87, U.S. Pat. No. 4,901,663.
This invention consists of a rotating-oblique-basket frier for cyclic immersion cooking. The structural and operating components of the frier are inter-related to the basket (whose axis is greatly inclined with respect to the cooking oil bath surface plane, which is itself contained into equivalent-position containers) in such a way that all moving parts, connected to the basket by a reduction gear-box, are progressively and cyclically interrupted by an assisted and controlled thermostat.
BACKGROUND OF THE INVENTION
At the present technical stage, all friers produced and xarketed for home use are equipped with vertically-moving baskets only. These types of baskets serve food introduction, extraction and/or draining purposes well, but cannot move during cooking.
However, vertically-moving baskets are inconvenient for a number of reasons.
A first important reason is the high quantity of oil needed for proper cooking, which also means (a) high operating costs due to high power consumption; (b) changing of great quantities of oil due to its exhaustion or to adapt it to the type of food to be cooked.
A second equally important reason is of practical nature, and consists in having to repeatedly move by hand the basket to separate the various food pieces during cooking, which may be rather difficult during the intermediate cooking phases. Furthermore, food cannot be uniformly cooked; the temperature of the oil bath cannot be easily raised; water vapor cannot be freely dispersed; proper cleaning of the oil tray is difficult, even in those cases where the basket can be removed.
SUMMARY OF THE INVENTION
The present invention is an industrially feasible frier which overcomes the above-mentioned shortcomings as follows:
The quantity of oil need for proper cooking is just enough to fill up the lower section of the inclined tray;
The food being fried is cyclically immersed in oil in progressive alternating immersion and emmersions;
During basket rotation, the food elements to be fried are moved and separated This avoids the problem of food particles sticking together, and allows for proper cooking;
The elimination of moisture naturally present in the food is favored and occurs repeatedly during the immersion phases;
The cooking oil bath is stirred by the rotating basket and/or by its contents, as well as by the heat. This accelerates the heat exchange process, especially at the initial stages, and favors uniform operating temperatures;
The rotational velocity of the basket can vary as a function of a preset temperature according to certain parameters, including interruptions of the rotation and others;
The start-up and operating times are greatly reduced;
Oil dripping is incremented, since the upper sections of the inclined basket are oil free;
If necessary, the complete process can be carried out automatically without any operator's intervention.
Moreover, this unit offers the following secondary advantages:
The removal of the frying basket from the oil tray, and vice-versa, is coaxial to the vertical axis of the frier, allowing for proper oil dripping or any other necessary operation;
The frying basket can be controlled with ease during the insertion, cooking and removal phases, and can be as easily handled during the initial and final phases of the cycle;
All components of the frier can easily be disassembled for proper cleaning;
The vapors forming during the cycle or during its complementary phases are exhausted after proper filtering only;
Both the essential and auxiliary components of the frier are at low cost and highly reliable.
Accordingly to the present patent, the advantages described above are best implemented by this new frier by means of the following:
A wire-netted or forged-tin basket bottom shaped so as to (a) filter the cooking oil bath; (b) keep firmly into place the food to be cooked; (c) isolate the food from undesirable residues. The basket is also equipped with clutches for movement and guidance which are juxtaposed to and coaxial with a removable tray containing the basket itself;
The above tray, shaped so as to keep possible residues, fits with the basket or a fixed tray;
At least a motor, connected to the above-mentioned components, with interconnected water-tight parts and with a supporting structure on which the above components are mounted;
Properly tenoned and protected seals in one or more of the above-mentioned components;
At least one, preferably electric, heater to generate adequate heat output;
Adequate interacting or stand-alone support systems to control and regulate all required functions;
Adequate, multi-purpose basket handles for handling the basket when inside or outside the frier. Such handles permit to manually rotate the basket inside the frier while in use;
A system of connected levers which facilitate basket handling and which permit to place the basket in required positions during the cooking and complementary phases;
An interchangeable filtering system housed within the cover;
Interacting cover locking and closing parts, together with circuit breakers for immediate machine stopping, particularly at open cover;
Where needed, basket or tray finning to direct vapor jets towards predetermined locations;
Adequate structural components to contain the abovementioned components or complementary and auxiliary parts constituting the new unit;
Adequate materials which are coordinated and properly shaped, with surface treatments and/or structural treatments as needed;
Materials which are not excessively costly but fully reliable;
Where necessary, structural reinforcements connected with their relative components.
The invention, as it has been described, solves the problems mentioned above for it consists of an oblique-rotating-basket frier for cyclic immersion cooking which is industrially feasible and free of the problems faced by conventional frying units.
The advantages deriving from this invention, as it has been described, can thus be implemented through the construction or this new frying unit.
The frier fulfills home, industrial and other purposes and is characterized by excellent qualities. These qualities consist in the limited quantity of oil needed to form the cooking oil bath (i.e., almost 1/2 of what is generally need); in the rotating basket, crucial to the quick elimination of food moisture; in the uniformity of the gradual and final mutations; and in the homogeneous heat exchange process.
All these are specific advantages of this innovative system, i.e., an oblique rotating basket greatly inclined with respect to the cooking oil bath, as opposed to systems mounting fixed baskets whose contents are always completely immersed in the oil bath
Moreover, considering the small quantities of oil needed to fill the sole lower inclined sections of the oil tray, and considering that the food si cyclically immersed into the oil, this unit is characterized by a number of advantages regarding what type of cooking is needed, the reduction of operating time and the overall performance of the frier.
During bench tests, it has been ascertained that the cyclic and alternating immersions and emersions greatly favor the elimination of food moisture. Moisture elimination, in fact, occurs especially in the upper sections of the rotating basket which are oil-free, and is increased by the stirring action of the iron-knitted basket. This does not occur in conventional frying units, where moisture is eliminated by manually shaking the basket and/or its contents.
The obvious effects of the rotating basket, aside from reducing cooking time, from continuously stirring the oil bath, and from giving a homogeneous oil temperature, are such that the single food pieces undergoing frying are separated, during their immersion, by the action of vapor bubbles developing in the bath, as well as by means of the interactions and counter-pressures occurring between the food surfaces.
DESCRIPTION OF THE DRAWINGS
The invention is described in detail, for illustration purposes, by means of drawings representing one of the possible ways in which the frier will be assembled. The drawings consist of the following:
FIG. 1 shows the scaled-down vertical sections A'-B' of the new frier.
FIG. 2 shows section G-H of the control panel
FIG. 3 shows section I-L of the joint elements of the cover.
FIG. 4 shows the top view of the components illustrated on FIG. 3.
FIG. 5 shows a partial scaled-down top view of the basket handling device.
FIG. 6 shows section M-N of the cover closing device.
FIG. 7 shows a partial top view of the basket guidance and handling device consisting of articulated arms connected to the handle.
FIGS. 1 to 7 represent, in conformity with the present invention, the optimal realization of the oblique-rotating-basket frier for cyclic immersion cooking.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, and according to the invention, the unit 1 is essentially constituted by the following operating and structural components:
A streamlined enveloping cover 2, whose bottom 3 rests on the supports 4, complete with a cover 5, with an empty chamber 6 formed between the countercover 7 which hosts a set of filters (not shown here); the cover can move on pivoted 9 hinge 8 installed in their housing 10, as shown on FIGS. 3 and 4.
A structure 2 in conformity with sector 11 (which contains accessories) and with the knobs 12 housings 12a to regulate the thermostat 42 and an optional "timer" 52. The structure is joint to sector 11 by means of tenoned pivots 13 in the jointed cavities 14, as shown in FIGS. 1 and 5.
An upper side of the above-mentioned cover 2, with an oblique profile, indicated by the broken line AB, with the side 15 adjacent to the joint of cover 5, and with form grindings 16 adjacent to the joint of cover 5, and with form grindings 16 coordinated to the equivalent and juxtaposed ones 16a on side 17 near handle 18, hinging on pivot 19, as shown on FIGS. 1 and 3.
A tray holder 20, with upper section 21 whose sides 22 and 22a a are molded so as to support 16 and 16a, in structure 2. The tray holder is shaped (22 and 23) so as to support a removable tray 25, as shown in FIGS. 1 and 2.
A removable tray 25, connected to the above-mentioned holder 20, with upper section 26 and sides 27 which can be rested on 23 and 24 in tray holder 20. The removable tray is equipped on its bottom 28 with a central jack 29, as shown on FIG. 1.
A basket 30 constructed of wire-knitted materials, with a side 30 on its mouth 31a and with a bottom 32. The basket is equipped with a shaped plate 33 which can be mounted on pivot 34 connected to the rotating shaft 34a of the motor reduction gear 35. The connection is sealed by 36 which is itself contained into support 37 housed in 38 which lies in the tray holder 20, as shown on FIG. 1.
A motor reduction gear system 35 connected by shaft 39, to the equivalent 39a shaft blocking the electrical resistance 40 mounted in the circular counterhousing 41, itself mounted on the holder 20 and connected to the thermostat 42 (a bimetallic lamels type 43), mounted on the base 44, FIG. 1.
A system connected to the moving handle 18 on hinge 19, of joint levers 45, which envelope 32a the basket and its upper lip 31, with rotating 46 and fixed 47 guide blocks on its upper lip 31 to move freely, as per FIGS. 1 to 7.
An oil both 50, as cooking medium, sufficient to fill sector CDE of the removable tray 25.
Having said the above, the constructive novelty and the basic functions of the unit are shown, in conformity with the invention, on FIG. 1. FIG. 1. shows, on a vertical section, the frier as a whole with its essential structural and operating components 2 to 61, which are coordinated to fulfill the abovementioned purposes. The basket 30, introduced into the tray 25, with an extremely inclined F axis and containing a quantity of adequately heated oil 50 in section CDE, and joint on the rotating pivot 34 by means of connector 33, cooks its contents by rotating, thus carrying out cyclic immersions and emersions.
The low quantity of oil needed is clear, for it is limited to the amounts necessary to fill the sole above-mentioned section. It is also clear how food moisture is eliminated, cycle by cycle, while the food is cooking, without influencing the temperature of the oil bath 50.
Once the frying process is completed, the basket 30 (supported by the articulated arm system 45) is rotated using handle 18 until position G is reached. Once rotated, the oil is drained and the basket removed by means of components 18, 31, 32, 45 to 49 and 60. The introduction of the basket is clear. It is also clear how the removal of tray 25 (carried out by removing it from its housings 23 and 24 and from the plane 29 which sticks out of the fixed container 20) is possible. The temperature of the oil bath 50, heated by at least one electric coil 40, is controlled by thermostat 42, while the cycle is controlled by timer 52. Both the timer and the thermostat can be adjusted by acting on knobs 12.
FIG. 2 shows the section housing the above-mentioned knobs 12 and is placed half-way into the control panel 51. Panel 51 also houses a number of other control knobs, such as those to preset the cycles 52.
FIGS. 3 and 4 show joint 8 of the cover 5 with 6, with components 9 and 10 connected to side 22 and 21 in tray 20. Whereas, FIG. 5 shows one of the uses of device 18, which allows the handling of basket 30, equipped with 58a joining lever 45 by means of parts 56 and 57.
FIG. 6 shows part 53 (which locks cover 5) hinged on pivot 54 adequately shaped. The function of part 53 is carried out by acting on handling section 55 by first acting on part 55a which hooks on section 55b tried to cover 5.
FIG. 7, a top view, shows a basket 30 guide and lift system connected to handle 18. The system can be tied to pivot 29 as guided by means of lever 58a housed in sector 48, and kept along with its components 31, 45a, 46 to 49 and 61, also shown on FIG. 1.
FIG. 1 shows, on a vertical section A'-B', the fixed container 20 with sector 58a, housing arm 58, which connects and moves articulated lever 45. These can be seen on FIG. 7, which shows one of the side housing 59 adequate to the movements of the levers.
The invention, as it has been described, can be modified and varied according to specific purposes without compromising the performance and characteristics.
As a matter of fact, the new unit is compatible with heaters other than electric ones, e.g. propane heaters used on conventional units. Installation of this new heating equipment necessarily requires small structural changes and adjustments.
The new unit is designed to operate at different speeds and/or interrupted cycles and/or counter-rotations, in order to satisfy various cooking requirements, such as the types of food to be cooked, &heir quality and characteristics, the various kinds of oil used, etc.
The filtering system can be positioned as needed and its functions can be carried out with the assistance of flaps and intakes which can direct steam jets where needed.
The basket, with a sensibly concave or convex bottom, is attached to cylindrically or cone-shaped plating and deflectors which separate heterogeneous foods or contribute to their homogeneity.
To vary the inclination of the operating unit, it is sufficient to adjust a moving device equipped with appropriate handles and stabilizers.
By greatly inclining the operating unit, it is possible to accomplish special tasks such as the rolling of its contents to increase mixing.
These results can be accomplished by utilizing rotating baskets whose axis are parallel to the oil bath and which are equipped with all necessary devices for food loading and unloading, and for their rotation carried out by means of clutches and attachments. They can also be accomplished by utilizing baskets which can be removed by means of handles as described.
The present frier can also be constructed utilizing a basket moving on rollers situated on the sides of the fixed tray. The basket is driven by means of a motor system housed in the cover or by a motorized roller. In this last case, the parts opposite to the roller would serve as guides and supports to the baskets. The above-mentioned basket, which can accommodate another smaller basket within it, can be constructed in solid metal to allow for special cooking tasks, such as the so-called "waterbath" treatments.
By adding to the countercover an adequately shaped piece, it will be possible to increase food mixing.
For the so-called "waterbath" food treatments, as in the case of swelling cereals, it is possible to introduce a basket similar to those described above, within an outer basket. In this way, the cereals are just lapped by the oil bath and swell within the internal basket.
Clearly, the above-mentioned system may also be disregarded. If disregarded, the food may be introduced directly into the outer basket. A rotating, bladed shaft then mixes the food contents in the outer basket during cooking
The basket can be independent from its handle, and can be grasped and handled within the oil bath as needed.
Safety devices can also be installed as part of the accessory components of the unit. These devices may be inter-related with a number of parameters and devices (e.g. with some of the above-mentioned systems or with predetermined temperature levels of the oil bath, etc.), so as to automatically open the frier cover, rotate and/or handle the basket, etc. These safety devices may include check lights or acoustic signals which interact with the operations of the unit indicating oil temperature and various unit functions.
The advantages of this innovative unit, specially designed particularly for home use, can thus be appreciated through a careful study of the above description.
All construction details shown and described here, including all essential or accessory components and parts, may be replaced with technically equivalent components and parts.
During bench tests and prototype construction, we have ascertained that the materials and components employed are adequate to all above-mentioned intents and purposes.
All rights for the present unit, as specified in the following claims, are reserved for the entire duration of the patent.
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A deep fryer apparatus particularly suitable to home use with a rotatable basket rotating within tray. Both the basket and the tray can be removed from a fixed tray within the housing. The axis of rotation of the basket is greatly inclined with respect to an oil bath contained in tray, so that the food contained in the basket is cyclically and progressively immersed in the oil bath. The bath is heated by adequate heaters, and the apparatus is monitored by control devices.
The new deep fryer features high overall performance and low operating costs. This is due in particular to the small quantity of oil needed to form the oil bath, which is about one-half what is generally necessary, and to the reduced cooking time required as a result of the progressive and repeated elimination of food moisture.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image forming apparatus comprising a facsimile memory for storing transmission/reception data by a memory transmission/reception function of a facsimile and a copying memory for storing copying data or externally inputted data by a copying/printing function.
2. Description of the Related Art
In a conventional digital image forming apparatus which is called a digital composite machine and provided with a fax mode and a copy mode (copying function or printing function), an operation panel for setting conditions of the fax and copy modes is integrated with a control function thereof.
However, although the control function is integrated with the operation panel, memories associated with the respective functions individually work. Therefore, in the fax mode, when a memory for memory reception becomes full, a reception state is put into a busy state, or data not yet outputted is erased because reception data in the memory is overwritten. Such a phenomenon frequently happens particularly when recording sheets such as sheets of paper in a paper-feed cassette or rolls of paper run out in the nighttime or when a supply item such as toner is replaced.
Further, in the copy mode, a technique utilizing memory copying for increasing the speed of reading documents in image processing is used, however, when a memory for document information becomes full, reading of the following document is stopped, and therefore the document reading speed cannot be increased.
Japanese Unexamined Patent Publication JP-A 10-243175 (1998) discloses a technique of checking the remaining free area of a memory and controlling so as to allow a copy operation when a document size read in the following operation is within the remaining free area of the memory, whereas so as not to accept a reading request when the document size is larger.
As mentioned above, the conventional digital image forming apparatus checks the remaining free area of a memory and controls so as to allow a copy operation when a document size read in the following operation is within the remaining free area of the memory, whereas so as not to accept a reading request when the document size is larger. Therefore, the apparatus raises a problem such that when a memory has only a little or no free area, the following operation can not be carried out, or data not yet outputted is erased because of overwriting.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an image forming apparatus which is capable of storing data of an image regardless of remaining free area of memories associated with functions, respectively.
The invention provides an image forming apparatus comprising memories associated with two or more functions, respectively, for storing data relating to the corresponding function, the image forming apparatus further comprising storage control means for controlling storage of data into the memories so that in the case where data relating to one of the functions should be stored in a memory associated with the function while all the data relating to the function cannot be stored in the memory associated with the function, at least part of the data relating to the function is stored in a memory associated with another function.
According to the invention, even in the case where all data relating to a function in operation cannot be stored in a memory associated with the function, at least part of the data is stored in a memory associated with another function. Therefore, it is possible to continuously operate the function in operation without suspending.
In the image forming apparatus of the invention it is preferable that two of the memories associated with two or more functions, respectively, are a facsimile memory for storing data of an image transmitted/received by a memory transmission/reception function of a facsimile and a copying memory for storing data of an image to be copied by a copying/printing function or data of an externally inputted image.
According to the invention, since the amount of data stored in the copying memory is large in the daytime when the copying/printing function is often used and the amount of data stored in the facsimile memory is large in the nighttime when output sheets are likely to be exhausted, it is possible to share such memories used in different conditions and thereby operate the respective functions with small capacity of memories without suspending the functions.
In the image forming apparatus of the invention it is preferable that the image forming apparatus further comprises a compression/expansion conversion section for converting data to be stored in the facsimile memory into data suitable for communication via a communication line, and when storing data of an image relating to the copying/printing function and including half tone, into the facsimile memory, the storage control means controls storage of the data of the image so that the data is stored in the facsimile memory without conversion of the data by the compression/expansion converting section.
According to the invention, data of the image relating to the copying/printing function and including half tone is stored in the facsimile memory without being subjected to compression conversion by the compression/expansion converting section. Therefore, it is possible to execute copying an output of data of an image including half tone with fidelity to the original data.
In the image forming apparatus of the invention it is preferable that the image forming apparatus further comprises a compression/expansion converting section for converting data to be stored in the facsimile memory into data suitable for communication via a communication line, and when storing data of an image relating to the copying/printing function and externally inputted, into the facsimile memory, the storage control means controls storage of the data so that the data is stored into the facsimile memory after compression conversion of the data by the compression/expansion converting section.
According to the invention, externally inputted data composed of text data (binary-value data) without halftone data is subjected to compression conversion by the compression/expansion converting section and stored in the facsimile memory. Therefore, it is possible to store a large amount of externally inputted data in the facsimile memory.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further objects, features, and advantages of the invention will be more explicit from the following detailed description taken with reference to the drawings wherein:
FIG. 1 is a sectional view showing an embodiment of a digital composite machine, which is an image forming apparatus of the present invention;
FIG. 2 is a block diagram showing a control block of the digital composite machine of FIG. 1 ;
FIG. 3 is an explanation view showing a flow of image data and control signals in the digital composite machine of the invention;
FIG. 4 is a flow chart explaining a copy operation in the digital composite machine of the invention; and
FIG. 5 is a flow chart explaining a fax receiving operation in the digital composite machine of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to the drawings, preferred embodiments of the invention are described below.
An embodiment of a digital composite machine provided with a fax mode and a copy mode (copying mode, printing mode), which is an image forming apparatus of the present invention, will be explained referring to FIGS. 1 to 5 .
FIG. 1 is a sectional view showing the entire mechanical construction of a digital composite machine 30 of the embodiment. As shown in FIG. 1 , the digital composite machine 30 is composed of a scanner section 31 and a laser recording section 32 .
The scanner section 31 is composed of a document glass 35 made of transparent glass, a recirculating automatic document feeder 36 (referred to as an RADF hereafter) for automatically supplying and conveying a document onto the document glass 35 , and a document image reading unit for operating and reading an image of a document put on the document glass 35 , that is, a scanner unit 40 .
A document image read by the scanner section 31 is sent as image data to an image processing section 1 mentioned later, where the image data is subjected to predetermined image processing.
The RADF 36 is a device which automatically feeds a plurality of documents set on a specified document tray at a time, one by one onto the document glass 35 of the scanner unit 40 . Further, in order to cause the scanner unit 40 to read one side or both sides of a document in response to a selection of the user, the RADF 36 is composed of a conveying path for a one-side document, a conveying path for a both-side document, conveying path switching means, and so on.
The scanner unit 40 is composed of a lamp reflector assembly 41 which exposes the surface of a document, a first scanning unit 40 a formed by a first reflection mirror 42 a for guiding a reflected light image from the document to a photoelectric conversion device 44 embodied by a CCD or the like, a second scanning unit 40 b formed by second and third reflection mirrors 42 b , 42 c for guiding the reflected light image from the first scanning unit 40 a to the photoelectric conversion device 44 , an optical lens member 43 for forming an image of the reflected light image onto the photoelectric conversion device 44 , and the photoelectric conversion device 44 which converts the formed image of the reflected light image into electric image signals.
The scanner section 31 is constructed so as to, while documents to be read are sequentially put onto the document glass 35 by a related operation of the RADF 36 and the scanner unit 40 , move the scanner unit 40 along the lower surface of the document glass 35 and read images of the documents. Image data obtained by reading an image of a document by the scanner unit 40 is sent to the image processing section 1 mentioned later and subjected to a variety of processes. After that, the image data is supplied to a laser writing unit 46 of the laser recording section 32 , and reproduced as a visible image onto a photoconductor drum 48 in an electrophotographic process. Then, the image is transferred and formed onto a recording sheet.
The laser recording section 32 includes a paper-sheet housing/conveying section 50 , the laser writing unit 46 , and an electrophotographic process section 47 for forming an image. The paper-sheet housing/conveying section 50 has a first cassette 51 , a second cassette 52 , a third cassette 53 and a multiple manual feed tray 54 , and moreover has a double-side copying unit 55 for recording an image onto the rear side of a paper sheet with an image recorded on one side sent out of one of the cassettes or the tray.
In the respective cassettes of the paper-sheet housing/conveying section 50 , batches of paper sheets are housed for each size. When the user selects one of the cassettes which houses paper sheets of desirable size, the paper sheets are sent out of the cassette one by one from the top of the batch thereof, and sequentially conveyed toward an image forming section of the laser recording section 32 via a conveying path 59 .
The laser writing unit 46 has a semiconductor laser which emits laser light according to image data from a memory, a polygon mirror which deflects the laser light at an equal velocity, an f-θ lens which corrects so as to be deflected at an equal velocity, and so on.
The electrophotographic process section 47 is composed of a charging device, a developing device, a transferring device, a separating device, a cleaning device, a discharging device and a fixing device 49 , which are placed around the photoconductor drum 48 in accordance with well-known configurations. A sheet carrying-out conveying path is placed on the downstream side in the direction of conveying a paper sheet onto which an image should be formed from the fixing device 49 . The sheet carrying-out conveying path is branched to a conveying path 57 which leads to an after-process device 34 and a conveying path 56 which leads to a double-side copying unit 55 .
In the laser writing unit 46 and the electrophotographic process section 47 , image data read out of an image memory is formed as an electrostatic latent image onto the surface of the photoconductor drum 48 by scanning laser light by the laser writing unit 46 , and a toner image made to be a visible image by toner is electrostatically transferred and fixed onto the surface of a recording sheet conveyed from a multistage paper feeding unit 33 .
The recording sheet with an image formed thereon in this manner is selectively conveyed from the fixing device 49 to the after-process device 34 via the conveying path 57 or to the double-side copying unit 55 via the conveying path 56 . The after-process device 34 , in which a first discharge tray 341 and a second discharge tray 342 are vertically placed on the left side of the apparatus, receives a recording sheet with an image recorded thereon in the digital composite machine 30 from the conveying path 57 .
FIG. 2 is an electric configuration block diagram showing a variety of units composing the digital composite machine 30 of FIG. 1 , the image processing section, and so on. This is a view showing a state of controlling an operation by a main central processing unit (main CPU) 401 placed substantially in the center through coordination with sub central processing units (sub CPUs) mounted for each unit section.
It is apparent from this configuration block diagram that the digital composite machine is mainly composed of an operation panel board 100 which locates substantially at the upper right on the drawing and controls an operation panel 103 , a machine control board 200 which locates substantially at the upper left on the drawing and controls the respective unit sections constructing the digital composite machine 30 , a CCD board 300 which locates substantially at the lower left on the drawing and electrically reads a document image to convert it into electronic data, a main image processing board 400 which locates substantially in the center on the drawing and subjects the document image converted into electronic data by the CCD board 300 to predetermined image processing, a sub image processing board 500 which further subjects the image information processed by the main image processing board 400 to predetermined image processing, a group of other expansion boards 600 (a printer board 601 , a function expansion board 602 , a facsimile board 603 ) which locate substantially at the lower right on the drawing and are connected with the image processing board 500 via an interface, and so on.
In the following, what is controlled by each board will be explained.
Operation Panel Board 100
The operation panel board 100 , which is controlled basically by a sub CPU 101 , controls a display screen of an LCD display 104 placed on the operation panel 103 , operation input through a group of operation keys 105 for inputting directions regarding a variety of modes, and so on. Further, a memory 102 for storing various control information for the operation panel such as data inputted through the group of operation keys 105 and information displayed on the LCD screen 104 is disposed.
In this configuration, the sub CPU 101 performs control data communication with the main CPU 401 to give directions on the operation of the digital composite machine 30 . Further, the main CPU 401 transfers a control signal showing an operation state of the digital composite machine 30 to the sub CPU 101 , whereby the LCD screen 104 of the operation panel 103 displays a current operation state of the apparatus for the user.
Machine Control Board 200
The machine control board 200 , which is entirely controlled by the sub CPU 201 , controls automatic document feeders 36 such as an ADF and an RADF, a scanner section 31 which reads a development image, an electrophotographic process section 47 which reproduces image information as an image, a paper-sheet housing/conveying section 206 which sequentially conveys sheets of paper on which images should be recorded from cassettes or a tray toward a process section 205 , a double-side copying unit 55 which reverses recording sheets with images recorded thereon and conveys the recording sheets in reverse so that images are formed on both the sides of the recording sheets, a finisher 34 which performs an after-process such as stapling the recording sheets with images recorded thereon, and so on.
CCD Board 300
The CCD board 300 is composed of a CCD 301 including an photoelectric conversion device 40 for electrically reading a document image, a circuit (CCD gate array) 302 which drives the CCD 301 , an analog circuit 303 which adjusts the gain of analog data outputted from the CCD 301 , an A/D converter 304 which converts analog outputs of the CCD 301 into digital signals and outputs as electronic data, and so on. The CCD board is controlled by the main CPU 401 .
Main Image Processing Board 400
The main image processing board 400 is controlled by the main CPU 401 . The main image processing board is composed of a multiple-value image processing section 402 which, based on electronic data of a document image sent from the CCD board 300 , so as to express the contrast of the image in a desirable state, subjects the multiple-value image data to shading correction, density correction, area separation, filter process, MTF correction, resolution conversion, electronic zoom (scaling process), gamma correction and the like, a memory 403 for storing processed image data or various control information on control of the procedure of processes, a laser control 404 which controls so as to transfer data toward the laser writing unit 46 in order to reproduce an image with processed image information, and so on.
Sub Image Processing Board 500
The sub image processing board 500 is connected with the main image processing board 400 by connectors 505 , 405 . The sub image processing board is composed of a binary-value image processing section 501 controlled by the main CPU 401 on the main image processing board 400 , a gate array 503 which controls a hard disk for storing binary-value image information subjected to image processing or control information on processes and producing a plurality of copies by repeatedly reading out a plurality of document images by a desirable copy number, a gate array 504 which controls a SCSI serving as an external interface, and so on.
Further, the above-mentioned binary-value image processing section 501 is composed of a processing section which converts multiple-value image information into a binary-value image, a processing section which rotates an image, a binary-value scaling (zoom) processing section which subjects a binary-value image to a scaling process, and so on. The binary-value image processing section further includes a fax interface so as to be capable of transmitting/receiving a fax image via communication means.
Expansion Board 600
The expansion boards 600 are a printer board 601 which enables data sent from a personal computer and the like to be outputted from a printer section of the digital composite machine in a printing mode, a function expansion board 602 for expanding an editing function of the digital composite machine and effectively using the characteristics of the digital composite machine, a facsimile board 603 which enables a document image read from the scanner section of the digital composite machine to be transmitted to the counterpart and enables image information sent from the counterpart to be outputted from the printer section of the digital composite machine, or the like.
In the following, regarding the image processing apparatus of the digital composite machine, image data processing in a fax mode and the flow of image data will be explained in more detail.
Fax Mode
The fax mode includes a process for transmission of a document to the counterpart and a process for reception of a document from the counterpart.
First, transmission of a document to the counterpart will be explained. Transmission documents set on a predetermined position of the RADF 36 of the digital composite machine 30 are sequentially supplied one by one onto the document glass 35 of the scanner unit 40 , sequentially read by the configuration of the scanner unit 40 of images of transmission documents as explained before, and transferred to the main image processing board 400 as 8 bits of electronic data. The 8 bits of electronic data transferred to the main image processing board 400 is subjected to predetermined processing on the multiple-value image processing section 402 as 8 bits of electronic image data.
Then, the 8 bits of electronic image data subjected to processing are sent from the connector 405 on the side of the main image processing board 400 to the sub image processing board 500 via the connector 505 on the side of the sub image processing board 500 . In a multiple-to-binary value conversion section of the binary-value image processing section 501 , the 8 bits of electronic image data is subjected to processes such as error diffusion and converted from 8 bits of electronic image data into 2 bits of electronic image data.
Here, the reason for converting 8 bits of electronic image data into 2 bits of electronic image data together with executing processes such as error diffusion is that there is a problem in image quality in the case of only executing multiple-to-binary value conversion and therefore it is considered to reduce degradation of image quality.
In this way, transmission document image data converted into a binary-value image is compressed in a specified form and stored in a memory 502 on the sub-image processing board. Then, when a transmission procedure with the counterpart is performed and a transmittable state is ensured, transmission document image data compressed in a specified form and read out of the memory 502 is transferred to the facsimile board 603 , subjected to necessary processes such as change of a compression form on the facsimile board 603 , and sequentially transmitted to the counterpart via a communication line.
Next, the processing of a document image transmitted from the counterpart will be explained.
When a document image is transmitted from the counterpart via a communication line, image data transmitted from the counterpart is received while a communication procedure on the facsimile board 603 is performed, the image data compressed in a specified form is sent from a fax interface disposed to the binary-value image processing section 501 of the sub image processing board 500 to the binary-value image processing section 501 , and the transmitted document image is reproduced as a page image by a compress/expansion processing section or the like.
Then, the document image reproduced as an image by page is transferred to the main image processing board 400 and subjected to gamma correction, and the writing of an image is controlled by the laser control 404 so as to reproduce an image by the LSU 406 .
As is evident from the above configuration, a processing section-for subjecting image information to a predetermined process is mainly divided into the main image processing board 400 which processes a document image read and inputted from the scanner section 31 as multiple-value image information, and the sub image processing board 500 which-subjects the document image information processed as multiple-value image information on the main image processing board 400 to a predetermined process such as a binary-value process and subjects image information sent from an equipment connected via an external interface to a predetermined process, thereafter transferring to the multi-value image processing section (the main image processing board 400 ). Further, the image processing section 1 which actually processes image data in FIG. 1 is divided into the multiple-value image processing section 402 on the main image processing board 400 and the binary-value image processing section 501 on the sub image processing board in FIG. 2 .
Further, the main image processing board 400 includes the laser control 404 for controlling the writing of image information of the laser writing unit 46 , in order to reproduce an image from the laser writing unit 46 onto the photoconductor drum 48 of the electrophotographic process.
With this configuration, it is possible to reproduce a document image read and inputted from the scanner section 31 as a copy image from the laser recording section 32 without impairing image characteristics which the document has as a multiple-value image. For example, in the case of outputting a large amount of documents at high speed by using an electronic RDH function, the sub image processing board 500 , the hard disk 503 , and so on are used.
Furthermore, in so far as the processing, outputting and faxing of image information from external equipment such as a fax or a printer are concerned, it is possible to apply an appropriate process to image information in accordance with a digital feature function given to the digital composite machine 30 , for example, a binary-value process to a transmission document subjected to a multiple-value image process and a transmission document whose document image characteristics are kept.
Still further, separate placement of components concerning image processing on a plurality of boards makes it possible to prepare a variety of digital composite machines 30 and install a digital image forming apparatus in response to a request from the user. Moreover, after installment, it is possible to roll out systems with ease in response to a request from the user.
Next, since the main CPU 401 placed on the main image processing board 400 also controls the sub image processing board 500 in the above configuration, the flow of all image data continuously processed in the respective processing sections on the main and sub image processing boards is controlled, and the flow of data and process also becomes smooth. Therefore, image data would not be lost.
Up to this point, the scanner section 31 mounted in the digital composite machine 30 , or the image processing section 700 which processes image data inputted from the external interface 600 has been explained.
FIG. 3 is a block diagram showing sections which relate to a facsimile function and a copy function of the embodiment extracted from the configuration of the above-mentioned digital composite machine 30 of FIG. 2 .
Sections which relate to a facsimile mechanism and a copy mechanism in the digital composite machine 30 , in terms of function, includes the scanner section 31 , the CPU 401 of the main image processing board, the image processing section 1 , an image data switching section 2 , an LSU control section 3 , an image forming processing section 4 , a memory for copying 5 , a fax memory 6 , a compression/expansion converting section 7 , a bypass line 8 and a modem section 9 .
The image processing section 1 of FIG. 3 corresponds to the multiple-value image processing section 402 and the binary-value image processing section 501 of FIG. 2 . The image data switching section 2 of FIG. 3 corresponds to one function of the CPU 401 of the main image processing board of FIG. 2 . The LSU control section 3 of FIG. 3 corresponds to the laser control 404 of FIG. 2 . The image forming processing section 4 of FIG. 3 corresponds to the laser recording section 32 of FIG. 1 including the LSU of FIG. 2 . The memory for copying 5 and the fax memory 6 of FIG. 3 correspond to memory areas in the memory 502 on the sub image processing board of FIG. 2 , respectively. The compression/expansion converting section 7 of FIG. 3 corresponds to one function in the binary-value image processing section 501 of FIG. 2 . The modem section 9 of FIG. 3 corresponds to the whole fax board of FIG. 2 . The CPU 401 of the main image processing board also works as a storage control section for controlling data storage into the memory for copying 5 and the fax memory 6 .
In a general copy mode, image data read by the scanner section 31 is subjected to image processing in the image processing section 1 and thereafter supplied from the image data switching section 2 to the image forming processing section 4 via the LSU control section 3 . Together with an image forming process thereof, the reading of the image data is performed.
On the other hand, in a memory copy mode, after being subjected to an image forming process in the image processing section 1 , image data read by the scanner section 31 is once held into the memory for copying 5 from the image data switching section 2 , sequentially read out in response to the image forming speed, and supplied from the image data switching section 2 to the image forming processing section 4 via the LSU control section 3 . In this manner, the reading of image data is performed in advance independently of the image forming process. Therefore, it is possible to increase the reading speed.
In this memory copy-mode, when the memory for copying 5 becomes full, image data is accumulated into the fax memory 6 . Here, in the,case of being set so as to place emphasis on capacity, the image data switching section 2 supplies image data to the fax memory 6 via the compression/expansion converting section 7 which compresses image data into fax data, thereby performing accumulation by a less memory capacity with respect to one unit of image data.
On the contrary, in the case of being set so as to place emphasis on image quality, the image data switching section 2 supplies image data without compression directly to the fax memory 6 via the bypass line 8 which bypasses the compression/expansion converting section 7 , thereby performing accumulation by the same image quality as image data accumulated in the memory for copying 5 .
Further, in a fax transmission mode, after being subjected to image processing in the image processing section 1 , image data read by the scanner section 31 is supplied from the image data switching section 2 to the compression/expansion converting section 7 to be compressed. After that, the image data is transmitted from the modem section 9 to a line via the fax memory 6 . In a direct transmission mode, the reading of image data is performed together with transmission of image data. On the contrary, in a memory transmission mode, the reading of image data is performed in advance independently of transmission, and image data of the difference from a transmission output is accumulated in the fax memory 6 .
In this manner, the memory for copying 5 and the fax memory 6 are shared, and the operations as mentioned above are controlled by the main CPU 401 .
FIG. 4 is a flow chart specifically showing the operation in the copy mode. First, when a copy request is made (S 1 ) and documents are set on a document tray (S 2 ), the reading of the documents is started (S 3 ), and the read image data is subjected to image processing and input of the image data into the memory for copying 5 is started (S 4 ). In parallel with the reading of the documents and storage of the image data, a copy process for outputting images onto sheets of paper is started (S 5 ).
In parallel with the reading of the documents and input of the image data, it is judged whether all the document have been read or not (S 6 ). In the case where all the documents have not been read, it is judged whether or not the memory for copying 5 has a free area (S 7 ). When a free area is available, the operation goes back to step S 6 . During a time that step S 7 is affirmed, the operation of reading the documents is continued until all the documents are read. When the reading of all the documents is finished at step S 5 , the document reading process is finished (S 8 ) When the memory for copying 5 becomes full at step S 7 , it is judged whether or not the fax memory 6 has a free area (S 9 ). When a free area is available, the image data is inputted and recorded in the fax memory 6 (S 10 ) and the operation goes back to step S 6 . During a time that step S 7 is denied, the reading of the documents is continued as long as the fax memory 6 has a free area.
At step S 9 , in the case where free area of the fax memory 6 is exhausted, the reading of the documents is once stopped because the memory is full (S 11 ).
On the other hand, in the copy process executed in parallel with input of the image data, it is judged whether the following copy data exist or not (S 12 ). In the case where the following copy data exist, the operation goes back to step S 5 , where the copy process is performed until all the copy data is processed. When all the copy data is processed, the copy process is finished (S 13 ).
When both the document reading process and the copy process executed in parallel are finished at steps S 8 and S 13 , all the operations are finished (S 14 ). In the case where either process has not been finished, the operation goes back to step S 3 or step S 5 .
FIG. 5 is a flow chart specifically showing the operation in the fax reception mode. When fax data is received (S 21 ), it is judged whether memory reception is selected or not (S 22 ) In the case where memory reception is selected, a receiving process is started (S 23 ). It is judged whether or not the fax memory 6 has a free area (S 24 ), and in the case where a free area is available, reception data is continuously accumulated in the fax memory 6 (S 25 ). Then, it is judged again whether or not the fax memory 6 has a free area (S 26 ), and in the case where a free area is available, reception data is continuously accumulated in the fax memory 6 (S 27 ).
Then, it is judged whether all the reception data has been accumulated or not (S 28 ), and the operation from step S 23 to S 28 is repeatedly performed until all the reception data is accumulated.
In the case where it is judged at step S 24 or S 26 that the facsimile memory 6 has no memory, it is judged whether or not memory for copying 5 has a free area (S 29 ). In the case where a free area is available, reception data is accumulated in the memory for copying 5 . In the case where it is judged at step S 29 that the memory for copying 5 has no free area, a busy signal is outputted to the transmission counterpart so as to stop transmission for a brief period of time (S 31 ).
On the other hand, in the case where it is judged at step S 22 that memory reception is not selected, it is judged whether direct reception is selected or not (S 32 ). In the case where direct reception is not selected, the operation goes back to step S 22 . In the case where direct reception is selected, parallel execution of a process of receiving data from the counterpart (S 33 ) and an image outputting process (S 34 ) is started.
Then, it is judged whether all the reception data has been outputted or not (S 35 ). In the case where all the reception data has not been outputted, the operation goes back to steps S 33 and S 34 , whereas in the case where all the reception data has been processed, the outputting process is finished (S 36 ) to finish all the operations.
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 the range of equivalency of the claims are therefore intended to be embraced therein.
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An image forming apparatus is provided which is capable of storing image data regardless of remaining free area of a memory associated with a specified function. The digital image forming apparatus comprises a facsimile memory for storing transmission/reception data by a memory transmission/reception function of a facsimile, a copying memory for storing copying data by a copying/printing function or externally inputted data, and a compression/expansion converting section which converts transmission/reception data stored in the facsimile memory by the memory transmission/reception function into data suitable for communication via a communication line, wherein a CPU working as storage control means is disposed which, when storing data by one function of a plurality of functions into a memory associated with the function, stores the data into a memory associated with another function in the case where all the data cannot be stored into the associated memory.
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FIELD OF THE INVENTION
The present invention relates to a method of identifying, for a patient having pain of a joint, susceptibility to developing progressive osteoarthritis or loss of joint space (change in cartilage of the joint) by determining in such patient the presence or absence of bone marrow edema about the joint. A determination of the presence of bone marrow edema about the joint identifies the patient as susceptible to developing progressive osteoarthritis or loss in joint space.
BACKGROUND OF THE INVENTION
Osteoarthritis is the most common form of arthritis, affecting the hands, knees, hips, spine and other joints. Characteristics of osteoarthritis include a loss of cartilage, seen as a reduction in the joint space, and osteophytes (marginal lips of bone that grow at the edges of the joints). Other forms of arthritis are also characterized by joint space loss.
Predictors of which patients will have progressive osteoarthritis, and which will have stable, non-progressive diseases is lacking, except for the use of bone scintigraphy in predicting joint space loss in the knee. However, repeated scintigraphy is not viable for following patients because of the associated repeated ionizing radiation dose. Other forms of arthritis also may have joint space loss, the prediction of which is also difficult to do or not able to be determined.
An object of the present invention is a non-invasive method, without the use of ionizing radiation, for predicting which patients are likely to have progressive osteoarthritis or joint space loss. Such a method is useful for determining which patients should receive joint protective therapies to preserve joint function.
SUMMARY OF THE INVENTION
It has been discovered that finding bone marrow edema about or of a joint of a patient is predictive of the patient developing progressive osteoarthritis in the joint. In particular, it has been found that bone marrow edema about or of a joint of a osteoarthritis patient is predictive of rapid loss of joint space width in the joint of the patient.
Accordingly, the present invention relates to a method of identifying, for a patient having pain of a joint, susceptibility to developing progressive osteoarthritis or joint space loss. The method comprises (a) performing on the patient an assay for the presence or absence of bone marrow edema about or of the joint and (b) determining in such patient the presence or absence of bone marrow edema about or of the joint. A determination of the presence of bone marrow edema about or of the joint identifies the patient as susceptible to developing progressive osteoarthritis or joint space loss.
Magnetic Resonance Imaging (MRI) is a non-invasive cross sectional imaging technique that uses magnetic fields and radio frequencies, and no ionizing radiation, to produce images of the body with excellent anatomic fidelity and soft tissue evaluations. Using specific combinations of magnetic fields and radio frequencies (pulse sequences), specific soft tissue changes can be seen, for example, the presence of water in the bone marrow about the knee.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, “osteoarthritis” means a non-inflammatory or minimally inflammatory arthritis in which there is degeneration of articular cartilage, thickening, erosion and subarticular cyst formation of the underlying subchondral bone, and production of reactive marginal osteophytes about the joint, leading to deformity from joint destruction.
As used herein, “joint space loss” means a continued loss or increased abnormality of cartilage (commonly associated with joint space loss).
As used herein, “progressive osteoarthritis” means a continued loss of cartilage (commonly with joint space loss) and bone stock, as well as the increase in marginal osteophytes, subchondral bone hardening/thickening, and the onset or increase of subchondral cysts, as well as other findings known to occur with osteoarthritis. These changes may occur simultaneously or the changes may be distributed about time and areas about the joint in an uneven manner.
As used herein, “bone marrow edema” means increased water content within the bone marrow space above that in normal bone marrow.
As used herein, “area about or of the joint”, for a given joint, is an area about 1 to 20 cm above and 1 to 20 cm below the articulating surface(s) of the given joint, the actual useful range dependent on the size of the joint examined.
In a preferred embodiment, the assay for the presence or absence of bone marrow edema about or of the joint is by MRI, in particular, an MRI method or pulse sequence or imaging orientation that provides imaging of the joint area where bone marrow edema can be visualized. Any MRI technology where bone marrow edema can be evaluated can be used, for example, open MRI, low field strength MRI, extremity MRI, whole body scanner MRI or the like. Other methodologies that allow for the determination of bone marrow edema would likewise provide similar information and could be used to predict progression of osteoarthritis or loss of joint space.
To determine progression of joint space narrowing, any method that measures joint space width can be used, for example, semi-flexed radiograph (x-ray method). This would also include methods that determine, directly or indirectly, the amount and/or viability of the cartilage of a joint (e.g. ultrasound, arthoscopy, etc.).
The following clinical study example illustrates, without limitation, the present invention.
EXAMPLE
Clinical Study Patient Inclusion
Patients were (1) of age greater than 50 years, or (2) had stiffness for less than 30 minutes for the target knee or (3) had crepitus of the target knee. Patients with secondary forms of osteoarthritis, or other forms of arthritis, were excluded.
In addition, patients had radiographic evidence of osteophytes and joint space narrowing of the medial compartment of the knee, which was required. Joint space narrowing (very approximately 4 mm or less joint space width for a patient of average weight (about 150 pounds)) was determined with reference to the medial joint compartment of the knee in a posterior-anterior radiograph, preferably in a semi-flexed position. The lateral joint compartment of the knee had to have at least approximately 2 mm joint space width, and could even have normal (very approximately 6 mm) joint space width. Radiographs were performed at day 0 (to establish a base line) and at 24 weeks after the baseline measurement.
36 patients were in the MRI subsection of a larger, 500 patient study, of which 34 patients were evaluable because they had complete data sets.
Study Design
A MRI was performed on the target knee of each selected patient using a 1.5 Tesla whole body scanner with a circumferential extremity coil. Imaging included T2-weighted fast spin echo images acquired in the three orthogonal planes, dual-echo fast spin echo images acquired in the sagittal plane, a multi-echo sequence with fat suppression acquired in the sagittal plane for measuring T2 relaxation time of the articular cartilage, and sagittal fat-suppressed T1-weighted three dimensional spoiled gradient echo for volumetric quantification of the cartilage. MRI was performed at day 0 and at 24 weeks.
MRI Protocol
Patients having any of the following were excluded from MRI examination:
1) Pacemaker;
2) Cardiac valve prosthesis;
3) Metallic fragments in the eyes;
4) Vascular clips less than 2 months old;
5) Aneurysm clips of any age;
6) Cochlear implants;
7) Claustrophobia;
8) Body weight in excess of 250 pounds;
9) Metallic fragments in the vicinity of the target knee other than vascular clips from venous graft harvesting older than 2 months.
Patient set up ensured correct positioning of the knee and sufficient patient comfort to limit motion artifacts and minimize the likelihood of patient dropouts on subsequent examination. The positioning of the knee in the magnet was reproducible from visit to visit to allow comparison of serially acquired images. The patients were images supine with the leg in the neutral position and the patella pointing straight up rather than in slight external rotation as is commonly the routine in clinical imaging protocols. External rotation is more difficult to reproduce on serial examinations and complicates image interpretation. Additionally, the knee was well immobilized in the circumferential extremity coil with foam padding. The same knee (target knee) was imaged at each visit.
The comfortable installation of the patient at the beginning of the study was imperative as the major source of motion artifacts is discomfort. Care was exercised in positioning the cushions and pads around the knee in the extremity coil to make the examination as comfortable as possible. Ear plugs or music through headphones was included, along with pillows, blankets, and verbal reassurance.
Image Sequences
The following sequences were preprogrammed into the MRI computer in order to speed up the examination and limit potential human error. Images were prescribed as follows: from lateral to medial for sequences in the sagital plane, from superior to inferior for sequences in the axial plane, and from anterior to posterior for sequences in the coronal plane.
The total examination time, including the 10 minute patient set-up and prescanning, was approximately 1 hour.
1. Sagital T2-weighted fast spin echo (FSE) localizer including entire synovial cavity: 2500/60 (TR msec/TE msec), 20 cm field of view (FOV), 4 mm/0 mm (slice thickness/interslice gap), 256×128 matrix, frequency encoding (FE) anterior-posterior, 16 echo train length (ETL), 1 excitation (NEX). [Imaging time=1 min.]
2. Axial T2-weighted FSE including entire patella: 3500/60 (TR msec/TE msec), 12 cm field of view (FOV), 3 mm/0 mm (slice thickness/interslice gap), 256×256 matrix, frequency encoding (FE) anterior-posterior, 16 echo train length (ETL), 2 excitations (NEX), [Imaging time=4 min.]
3. Coronal T2-weighted FSE: 3500/60, 12 cm FOV, 3 mm/0 mm, 256×256, FE superior-inferior (SI), 8 ETL, 2 NEX, frequency-selective fat suppression, No Phase wrap (NP). [Imaging time=8 min.] Coverage included the entire femorotibial joint but not the patella.
4. Sagital dual-echo FSE: 3500/20, 60, 14 cm FOV, 3 mm/0 mm, 256×256, FE Si to avoid certain artifacts, 8 ETL, 2 NEX, wide SI saturation bands (80 Hz) to limit vascular pulsation artifacts, frequency-selective fat suppression. Coverage extended from upper pole of patella to tibial plateau.
5. Sagital multi-echo SE with fat suppression: 2500/15, 30, 45, 60, 14 cm FOV, 4 mm/0 mm, 256×160, FE, AP, wide SI saturation bands (80 Hz) to limit vascular pulsation artifacts, frequency-selective fat suppression, 1 NEX, No Phase wrap (NP). Coverage extended from upper pole of patella to tibial plateau.
6. Sagital T1-weight, three dimensional, spoiled gradient echo (3D-SPGR) with fat suppression: 58/6, 400 flip angle, 12 cm FOV, 256×192 matrix, 60 contiguous 2 mm slices covering entirety of the articular cartilage plates in the knee, 1 NEX.FE SI, with SI saturation bands to minimize pulsation artifacts, frequency-selective fat suppression. [Imaging time=12 min.].
Results
Medial Joint Space Narrowing as a Percent Change from Baseline to 24 Weeks
Number
Median %
Pts
Change
Mean % Change (+/−SD)
Medial BME Present at Baseline
11
−10.89
−6.91
(43.1)
No Medial BME at Baseline
23
1.13
9.1
(27.3)
Medial BME Present at 24 Weeks
12
−7.25
−2.2
(43.9)
No Medial BME at 24 Weeks
22
0.69
7.25
(26.7)
Medial BME Present at Baseline or
13
−3.6
−1.92
(42.1)
24 Weeks
No Medial BME at Baseline or 24 Weeks
21
0.25
7.53
(15.5)
Medial or Lateral BME Present at
14
−3.8
−4.98
(38)
Baseline
No Medial or Lateral BME at Baseline
20
2.06
10.15
(29.2)
Medial or Lateral BME Present at
16
−3.73
−1.5
(37.7)
24 Weeks
No Medial or Lateral BME at 24 Weeks
18
0.81
8.73
(29.4)
Medial or Lateral BME Present at
17
−3.6
−1.33
(36.5)
Baseline or 24 Weeks
No Medial or Lateral BME at Baseline or
17
0.25
9.16
(30.2)
24 Weeks
BME = Bone Marrow Edema
The mean and median changes demonstrate loss of joint space (using the posterior-anterior semi-flexed knee radiographs), in the medial compartment of the knee, if 1) there is bone marrow edema at baseline and/or at 24 weeks, or if 2) the bone marrow edema is present in either the lateral or medial compartment.
Lateral Joint Space Narrowing as a Percent Change from Baseline to 24 Weeks
Number
Median %
Pts
Change
Mean % Change (+/−SD)
Lateral BME Present at Baseline
8
1.34
6.78
(17.1)
No Lateral BME at Baseline
26
−1.36
−0.97
(10.9)
Lateral BME Present at 24 Weeks
10
−0.25
3.92
(16.4)
No Lateral BME at 24 Weeks
24
−1.01
−0.42
(11.1)
Lateral BME Present at Baseline or
11
−0.31
3.49
(15.6)
24 Weeks
No Lateral BME at Baseline or 24 Weeks
23
−1.26
−0.47
(11.4)
Medial or Lateral BME Present at
14
1.34
7.37
(16.7)
Baseline
No Medial or Lateral BME at Baseline
20
−2.05
−3.7
(6.33)
Medial or Lateral BME Present at
16
1.16
6.13
(16.1)
24 Weeks
No Medial or Lateral BME at 24 Weeks
18
−2.05
−3.83
(6.31)
Medial or Lateral BME Present at
17
−0.18
5.3
(15.9)
Baseline or 24 Weeks
No Medial or Lateral BME at Baseline or
17
−1.96
−3.59
(6.41)
24 Weeks
BME = Bone Marrow Edema
The mean and median changes demonstrate loss of joint space (using the posterior-anterior semi-flexed knee radiographs), in the lateral compartment of the knee, if 1) there is bone marrow edema at baseline and/or at least 24 weeks, or if 2) the bone marrow edema is present in either the lateral or medial compartment.
The findings show that bone marrow edema is predictive of changes in the joint, such as cartilage, and in particular, of joint space narrowing. Minor differences from the lateral compartment data, compared to the medial joint space data, relate to the medial compartment requiring osteoarthritis, whereas the lateral compartment could have a normal joint space (little to no evidence of osteoarthritis in the lateral compartment) to one that was at least 2 mm (consistent with osteoarthritis in this patient set), by knee posterior-anterior radiograph.
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A method of identifying, for a patient having pain of a joint, susceptibility to developing progressive osteoarthritis or loss of joint space, by determining in such patient the presence or absence of bone marrow edema about or of the joint. A determination of the presence of bone marrow edema about or of the joint identifies the patient as susceptible to developing progressive osteoarthritis or loss of joint space.
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BACKGROUND
[0001] The disclosure relates to forecasting wind velocities and in particular to using laser Doppler velocimeters to forecast high-density wind velocities for wind turbine control.
[0002] Wind turbines harness the energy of the wind to rotate turbine blades. The blade rotation is used to generate electric power. However, because wind velocities constantly change, using a wind turbine or multiple wind turbines in a wind farm to generate a constant power supply requires adapting the operation of the wind turbine to the changing conditions of the wind. Additionally, the operation of a wind turbine may also need to be adapted in order to protect the turbine from damage from severe gusts of wind.
[0003] Wind turbines may be adaptively controlled using a turbine-mounted wind velocity sensor whose output informs a control system to modify the operation of the turbine. In response to an output of a wind velocity sensor, a wind turbine nacelle may be rotated into or out of alignment with the wind, thereby modifying the yaw of the turbine. The individual blades of the turbine may also be angled in response to the strength or speed of the wind, thus modifying the pitch of the turbine blades. Yaw and pitch control are crucial to the efficient and safe operation of a wind turbine. As wind turbines increase in size, other aerodynamic devices (such as flaps and tabs) will be used to maintain desired performance and avoid over stressing the blades and other components.
[0004] One example of a turbine-mounted wind velocity sensor is a turbine-mounted wind speed laser Doppler velocimeter (“LDV”). A wind speed LDV transmits light to a target region (e.g., into the atmosphere) and receives a portion of that light after it has scattered or reflected from the target region or scatterers in the target region. In atmospheric measurements, the target for this reflection consists of entrained aerosols (resulting in Mie scattering) or the air molecules themselves (resulting in Rayleigh scattering). Using the received portion of scattered or reflected light, the LDV determines the velocity of the target relative to the LDV.
[0005] In greater detail, a wind speed LDV includes a source of coherent light, a beam shaper and one or more telescopes. The telescopes each project a generated beam of light into the target region. The beams strike airborne scatterers (or air molecules) in the target region, resulting in one or more back-reflected or backscattered beams. In a monostatic configuration, a portion of the backscattered beams is collected by the same telescopes which transmitted the beams. The received beams are combined with reference beams in order to detect a Doppler frequency shift from which velocity may be determined.
[0006] An example of an LDV that may be used as a turbine-mounted wind velocity sensor is disclosed in International Application Publication No. WO/2009/134221 (“the '221 publication”), the entirety of which is hereby incorporated by reference. The LDV of the '221 application includes a plurality of transceiver telescopes that are remotely located from the LDV coherent light source.
[0007] As disclosed in an embodiment of the '221 publication, the disclosed LDV includes an active lasing medium, such as e.g., an erbium-doped glass fiber amplifier for generating and amplifying a beam of coherent optical energy and a remote optical system coupled to the beam for directing the beam a predetermined distance to a scatterer of radiant energy. The remote optical system includes “n” duplicate transceivers (where n is an integer that may be, for example, one, two or three) for simultaneously measuring n components of velocity along n noncolinear axes.
[0008] Also as disclosed in the '221 application, the optical fiber is used to both generate and wave guide the to-be-transmitted laser beam. A seed laser from the source is amplified and, if desired, pulsed and frequency offset, and then split into n source beams. The n source beams are each delivered to an amplifier assembly that is located within the n transceiver modules, where each of the n transceiver modules also includes a telescope. Amplification of the n source beams occurs at the transceiver modules, just before the n beams are transmitted through the telescope lens to one or more target regions. When the n source beams are conveyed through connecting fibers from the laser source to each of the n telescopes within the respective transceiver modules, the power of each of the n source beams is low enough so as not to introduce non-linear behaviors from the optical fibers. Instead, power amplification occurs in the transceiver module, just before transmission from the telescope. Consequently, fiber non-linear effects are not introduced into the system.
[0009] By using the LDV disclosed in the '221 application, wind velocities may be measured remotely with a high degree of accuracy. Because the source laser is split into n beams, the measurements taken along all of the n axes are simultaneous. Additionally, splitting the source beam into n beams does not necessarily require that the source laser transmit a laser with n times the necessary transmit power, because each of the n beams are subsequently power amplified before transmission. Additionally, the disclosed LDV has no moving parts, and is thus of reduced size and improved durability. Because of the light-weight and non-bulky nature of the LDV, the LDV of the '221 application is ideal for mounting on a wind turbine.
[0010] The advantages of speed and direction measurements from a turbine-mounted wind velocity LDV are described in detail in the '221 application. And while measurements generated by a single turbine-mounted wind velocity LDV are very useful and provide information for general yaw and pitch control of the turbine, more detailed data regarding the wind velocity across the inflowing air mass is necessary in order to more finely control the wind turbines. For example, at any given time, wind velocities may vary with respect to spatial dimensions. In the wind industry vertical spatial variation in the wind is commonly known as shear and is important in relation to both wind turbines and aircraft. Horizontal spatial variation in wind is commonly known as veer. Shear and veer may manifest at any given time and/or together should be accunted for in controlling a wind turbine. For example, the velocity of wind approaching a turbine blade at the apex of its rotation may differ significantly from the velocity of the wind approaching a turbine blade at the bottom of its rotation. Unless this difference is accounted for in the blade controls, there will be asymetric loading of the wind turbine. In order to compensate for the variation in wind velocities, the individual turbine blades on a single turbine are capable of changing pitch independently of each other. However, without sufficient data regarding apatial variations in wind velocities approaching the individual turbine blades, the turbine can not take full advantage of these control capabilities. In order to take advantage of these capabilities in turbine control, the collected wind velocity data must be of a sufficient spatial resolution and density. Methods for measuring high-density wind velocity data are therefore desirable.
[0011] What is needed, then, is a method and system for measuring high-density wind velocity data for accurate wind turbine control.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a typical wind turbine generator;
[0013] FIGS. 2A-D illustrate a wind turbine with high-density wind velocity LDV sensors and a method for using the sensors in accordance with embodiments of the disclosed invention;
[0014] FIGS. 3A and 3B illustrate a wind turbine with a high-density wind velocity LDV sensor and a method for using the sensor in accordance with embodiments of the disclosed invention; and
[0015] FIGS. 4A and 4B illustrate a wind turbine with high-density wind velocity LDV sensors and a method for using the sensors in accordance with embodiments of the disclosed invention
DETAILED DESCRIPTION
[0016] In order to provide the desired high-density wind velocity data for wind turbine control, wind velocities in atmospheric spaces in front of a wind turbine must be sampled at sufficient densities and frequency. FIG. 1 illustrates this concept. In FIG. 1 , a wind turbine 10 is illustrated with blades 20 that rotate about a horizontal axis. The turbine includes a tower 30 , a nacelle 40 , a hub 50 , and a plurality of blades 20 . The nacelle 40 sits atop the tower 30 and allows for horizontal rotation or yawing of the turbine 10 so that the turbine 10 aligns with the wind direction. The blades 20 and hub 50 are attached to the nacelle 40 via an axle and together spin about a horizontal axis. The nacelle 40 that contains the drive-train and electric generator does not spin with the blades 20 and hub 50 . The rotation of the blades 20 encompasses a disc-shaped area that extends equally above, below and to the sides of the nacelle 40 . Accurate wind velocity measurements must therefore include measurements in an inflow region 60 in front of and including as much as possible of the disc-shaped area. The measurements are preferably independent of each other and cover locations within the inflow region 60 with sufficient density.
[0017] In order to provide the multiple data measurements in the inflow region 60 of FIG. 1 , a plurality of wind velocity LDVs, such as those disclosed in the '221 application, are mounted on a turbine. In an embodiment, two wind velocity LDVs 212 , 214 are mounted on the nacelle 40 of a wind turbine 200 , as illustrated in FIG. 2A , or in some similar orientation or on some other stationary surface with relation to the wind turbine nacelle 40 . The illustrated wind velocity LDVs 212 , 214 each have three telescopes that are each oriented to take measurements along different beam paths 215 . As a result, six separate and divergent beam paths 215 extend from the wind turbine 200 , allowing for up to six measurements to be made at any given target plane 220 in front of the turbine 200 . Measurements may be made simultaneously at different target planes 220 . The measurements at known angles to each other may be used to determine three-dimensional wind vectors 240 at each of the target planes 220 .
[0018] In FIG. 2B , an example configuration of measurement points in a target plane 220 is illustrated. In the example of FIG. 2B , the top three measurement points are from beams 215 originating from one of the wind velocity LDVs 212 , while the bottom three measurement points are from beams 215 originating from the other of the wind velocity LDVs 214 . If the two wind velocity LDVs 212 , 214 each operated independently of the other, each would measure three one-dimensional vectors at points representing the vertices of a triangle. The three vectors for each triangle could be used to calculate a three-dimensional wind velocity for a point within the center of each triangle. Thus, one of the wind velocity LDVs 212 would determine a single three-dimensional wind velocity 242 at the target plane 220 (centered in a first triangle 232 ) while the other wind velocity LDV 214 would determine a second single three-dimensional wind velocity 244 at the target plane 220 (centered in a second triangle 234 ).
[0019] However, if the two wind velocity LDVs 212 , 214 are configured to share data points, then the two sensors 212 , 214 will generate a total of six data points from which up to 20 different triangles could be formed, each triangle resulting in its own calculated three-dimensional wind velocity. FIG. 2C illustrates how the six data points may be used to create three of the possible 20 different triangles 230 and locations of resulting calculated three-dimensional wind vectors 240 for each triangle 230 . The three triangles 230 are illustrated using solid lines. An additional three triangles 250 are illustrated using dashed lines and are differentiated only for ease of visualization. Thus, six different three-dimensional wind velocities 240 could be determined using the triangles 230 illustrated in FIG. 2C .
[0020] FIG. 2D illustrates still additional possible triangles 230 derived from the same six data points. If each possible triangle configuration 230 is used, 20 different three-dimensional wind velocities 240 could be determined, with six velocities being near the outer boundary of the target area and an additional 14 velocities being closer to the center of the target area 220 . This high-density real-time wind velocity measurement data is then used to characterize the real time spatial distribution of wind in the inflow and optimize the adjustment of the pitch or other aerodynamic control of, or along, individual turbine blades 20 as they sweep through the inflow according to the respective location of each blade to the measured data.
[0021] Of course, depending on a given application, not all 20 determined wind velocities need be used or even determined. For example, depending on the level of detail required for the blade pitch control of a given turbine, fewer than all 20 possible wind velocity determinations may need to be calculated. For example, if desired, only the six determined wind velocities illustrated in FIG. 2C could be used. Other combinations may be used as well.
[0022] The concept exemplified in FIGS. 2A-D is not limited to the use of just two three-telescope wind velocity LDVs. Additional sensors may be used to provide additional data points. Alternatively, the sensors may include different numbers of telescopes. For example, a four-telescope system could be used (using either a four-telescope sensor, two two-telescope sensors, four one-telescope sensors, or any combination thereof) to generate four data points and up to four unique triangles with four corresponding three-dimensional wind velocity measurements per target plane 220 . A five telescope system could be used to produce up to ten unique triangles with ten corresponding three-dimensional wind velocity measurements per target plane 220 . A seven telescope system could be used to produce up to 35 unique triangles with 35 corresponding three-dimensional wind velocity measurements per target plane 220 . Combinatorial math is used to determine the maximum number of unique sets of three data points used of the total number of data points.
[0023] Referring again to FIG. 2A , the data measurements may be made nearly simultaneously (limited by the speed of light) at various target planes 220 that are each at different distances from the wind turbine. In FIG. 2A , three different target planes 220 are shown. Different numbers of target distances 220 may be used. With a sufficient number of target distances 220 , the high-density wind velocity data can be used to accurately predict wind velocities at the wind turbine 200 . More specifically, accurate predictions may be made of wind condition arrivals with respect to individual blade locations, thus allowing improved individual blade pitch or other aerodynamic control.
[0024] The embodiments illustrated in FIGS. 2A-D result in a plurality of independently measured wind velocities. No individually-determined wind velocity is dependent upon any other determined wind velocity. The independent measurements result in greater confidence in the resulting wind velocity map determinations. Additionally, for each target plane 220 , wind measurements are made simultaneously. Thus time of measurement is not a variable in comparing wind velocities either across the inflow disc or from any given target plane 220 .
[0025] Another embodiment for providing high-density wind velocity information is illustrated in FIGS. 3A and 3B . In FIG. 3A , a wind turbine 300 is illustrated with a tower 30 , a nacelle 40 , a hub 50 and a plurality of blades 20 . In this embodiment, a wind velocity LDV 312 is mounted on the rotating hub 50 of the turbine 300 . As a result, the wind velocity LDV 312 spins with the hub 50 and blades 20 scanning the inflow. In this illustration, the LDV 312 includes three telescopes and is oriented so that laser beams 215 are able to take multiple measurements around the sweep at the appropriate radius in one or more target planes 220 in the turbine's inflow region 60 , as further illustrated in FIG. 3B . Thus, using just one wind velocity LDV 312 , the wind turbine 300 is provided with a plurality of three-dimensional wind velocity vectors 240 at or near the perimeters of one or more different target planes 220 .
[0026] The amount or density of data that could be collected using turbine 300 is significant. As an example, if the wind velocity LDV 312 on the turbine 300 collects data measurements at a frequency of 12 Hz, and if the turbine blades were spinning with a frequency of 12 revolutions per minute (“RPM”), then the LDV 312 would collect data for up to 60 three-dimensional wind vectors 240 per target distance 220 per revolution. With, for example, three target planes 220 being measured simultaneously, the turbine 300 would receive up to 180 three-dimensional wind vectors 240 per revolution. While data collected at a given target distance 220 will be time-shifted, as indicated by arrow 320 in FIG. 3B , the data collected for a given angle at multiple target planes 220 is simultaneous. Additionally, every measurement is independent of other measurements.
[0027] In yet another embodiment of mapping wind velocity measurements, measurements are made using wind velocity LDVs that direct lasers and take measurements from the hub along a beam path that is substantially parallel to the span of each turbine blade. An example is illustrated in FIGS. 4A and 4B . In FIG. 4A , a plurality of two-telescope wind velocity LDVs 412 , 414 , 416 are mounted on the hub 50 of the turbine 400 . Each LDV 412 , 414 , 416 corresponds with one of the turbine blades 20 . Therefore, a three-blade turbine 400 would include three two-telescope LDVs 412 , 414 , 416 . Each LDV 412 , 414 , 416 is mounted so that its telescopes direct a beam 215 in front of and along the major axis of its corresponding turbine blade 20 . Each LDV 412 , 414 , 416 then gathers wind measurement data immediately in front of the blade from different target planes 420 along the span length of the blade 20 . For example, measurements may be taken at regular spatial intervals along the length of the blade 20 (e.g., every six feet). Each measurement along the length of a given blade 20 is made simultaneously. Therefore, the turbine 400 is provided with independent and simultaneous wind velocity data for wind that is about to arrive at each individual blade 20 .
[0028] Because wind velocity measurements are made in the area directly in front of each blade 20 , three-dimensional wind vectors are not necessary. In other words, only two telescopes per LDV 412 , 414 , 416 need be used. The two telescopes are oriented to project laser beams that are not colinear but that allow the determination of two-dimensional wind velocity vectors 440 for target planes 420 that are directly in front of the corresponding blade 20 . The target planes 420 , of course, rotate with the rotation of the LDVs 412 , 414 , 416 and blade 20 . If three-dimensional wind vectors are desired, however, three telescopes per sensor may also be used.
[0029] Wind measurements may be made by the LDVs 412 , 414 , 416 as frequently as desired. Thus, at any given moment in time, the wind turbine 400 is provided with detailed incoming wind information for each blade 20 , thereby allowing accurate control of the pitch and other devices of each individual blade 20 . As the sophistication of blade aerodynamic control increases by the use of rapidly responding individual flaps and/or tabs controlled along the length of the blade 20 , this span-wise data is invaluable to optimizing performance and controlling stress and vibration.
[0030] Using one or more of the disclosed embodiments, a high-density wind velocity profile may be collected for a wind turbine. The collection of many wind velocity measurements in the inflow region of a wind turbine allows for the accurate mapping and predicting of wind shear and veer in the measured region. Additionally, statistical analysis of measured wind velocities, shear, and veer can indicate the characteristics of turbulence approaching the turbine. Therefore, not only does the measured data provide information for the control of individual blade pitch for efficient or maximal power generation, but the measured data also provides data for turbulence intensity prediction, thus allowing protective measures to be taken to preserve the integrity of the wind turbine.
[0031] In addition to the high-density measurement embodiments described herein, wind turbines may also be mounted with additional long-range wind velocity LDVs for additional yaw control warning time forecasting and power output prediction. Thus, a wind turbine may include one or more long-range sensors as well as one or more sensors for the collection of high-density inflow data.
[0032] The above description and drawings should only be considered illustrative of embodiments that achieve the features and advantages described herein. Modification and substitutions to specific structures can be made. For example, although the embodiments have been described for use with LDVs, other wind velocity measurement devices that can determine two- and three-dimensional wind vectors may be used. Accordingly, the claimed invention is not to be considered as being limited by the foregoing description and drawings.
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Methods and systems for collecting high-density wind velocity data for the inflow area of a wind turbine are presented. Wind turbines are provided with one or more wind velocity sensors that provide a plurality of wind velocity measurements to the turbine from various ranges and locations across the inflow. Sensors are proximate to the wind turbine. Sensors mounted on the turbine's nacelle work collaboratively to provide the wind velocity measurements. Sensors mounted on the turbine's hub spin with the turbine blades. Spatial and temporal wind mapping provides improved fidelity of data to the wind turbine control system.
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RELATED APPLICATIONS
This application is a continuation-in-part application of application Ser. No. 461,134, filed Apr. 15, 1974, and now abandoned.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention relates to novel polymeric compositions and the application of such compositions to materials, particularly fibrous materials.
(2) Description of the Prior Art
Co-pending U.S. Pat. application Ser. No. 330,404, in the name of G. B. Guise and M. B. Jackson, and filed on Feb. 7, 1973, now U.S. Pat. No. 3,898,197, discloses a number of prior art systems for preventing wool shrinkage, and describes and claims certain addition products having improved shrink-proofing properties.
SUMMARY
It is an object of the present invention to provide compositions and methods for the shrink-proofing of keratinous materials exhibiting still further improved shrink-proofing properties. It was an unexpected finding of the present invention that compositions in accordance with the invention, including the combination of the addition products referred to above and certain other polymers, afforded considerably better shrink-proofing properties than provided by either component of the combination or anticipated by such a combination.
Further and more wide-spread objects of the invention are to provide compositions and methods for conferring on suitable materials, usually of a keratinous or other fibrous nature, a considerable number of other desirable properties of the type referred to hereinafter.
More specifically, the present invention provides a composition comprising:
(1) at least one (poly)carbamoyl or (poly) thiocarbamoyl sulphonate containing at least one radical of the formula --
or
--NH.CS.SO.sub.3.sup.θ X.sup.+ [Z]
or
--NH.CS.SO.sub.3 .sup.θ X.sup.30 [Y9
wherein X 30 represents a cationic group with one or more positive charges to maintain electrical neutrality in the sulphonate; and
(2) at least one non-halogenated polymer selected from the following classes -
A. polymers derived from the polymerization of ethylenically unsaturated monomers, and
B. polymers having a backbone of carbon atoms and at least one ester, amide, ether, urethane, urea, sulphide, disulphide, thioamide, sulphone, or carbonte linkage.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The compositions may contain, in addition, non-polymeric materials, e.g., water, surfactants, and salts, and these will be described in detail below.
X + is preferably an alkali metal, alkaline earth metal, ammonium, substituted ammonium, phosphium or sulphonium cation, and is most preferbly the sodium, potassium or ammonium ions, or a mixture of two or more of the three previously mentioned ions.
The polycarbamoyl and polythiocarbamoyl sulphonates are preferred to the monocarbamoyl and monothiocarbamoyl sulphonates, and are hereinafter abbreviated to PCS. Thus, a PCS in the composition of the invention has one of the following generalized structures (III) -
RZ n ,
RY n ,
Z.sub.m--R--Y.sub.l (III)
where
n≧2,
l+m ≧ 2, and
R is an organic radical
It is to be appreciated that in the following discussion where the structural unit Z is used this may be wholly or partially replaced by Y.
The preferred examples of PCS for the purposes of the present invention have structure IV.
R.sup.1 (V--COHN--W--Z).sub.n IV
where
R 1 is an organic radical
Z and n, are as defined above
Y can partially or wholly replace Z and S can wholly or partially replace O.
W is a difunctional organic radical
V is a difunctional radical drawn from one or more of the groups, --O--, --S--, --NH--, --NR"--, where R" is an alkyl or aryl radical, preferably methyl, ethyl, phenyl or benzyl.
The difunctional organic radical W may consist of a chain of carbon atoms which may bear substituents, contain unsaturated linkages, aromatic rings or hetero atoms such as oxygen or sulphur. W may also be an aromatic ring, an aromatic ring system, or a heteroaromatic ring or ring system.
Examples of structures (IV) may be provided by the following reactions ##STR1##
The O in VI may be replaced by S to give R 1 (OCSNH--W--Y) n .
The OH in V may be replaced by SH or NH 2 or, alternatively,
R(NH.sub.2).sub.n +n WZ.sub.2 →R(NHCONH--W--Z).sub.n( 2)
in which Z would be wholly or partially replaced by Y.
It is to be appreciated that structures IV may be obtained by other methods, and the above reactions are only presented by way of example.
The most preferred examples of structure (IV) have structure VII, i.e. the most preferred PCS for class A of the present invention.
R.sup.1 (OCONH--W--Z).sub.n VII
and these may be prepared from polyols and diisocyanates as in reaction (1) above.
Particularly advantageous examples of structure VII have n between 2 and 4 most preferably between 2.5 and 3.5 and have W with one of the structures shown in the following list:
__________________________________________________________________________ corresponding diisocyanatePreferred W structure VI__________________________________________________________________________(i) (CH.sub.2).sub.k tetramethylene or hexamethylene most preferably diisocyanate respectively k = 4 or 6(ii) ##STR2## trimethylhexamethylene diisocyanate(iii) ##STR3## the commercial product dimer acid diisocyanate (General Mills) is of this type(iv) ##STR4## isophorone diisocyanate(v) ##STR5## phenylene diisocyanate(vi) ##STR6## naphthylene diisocyanate(vii) ##STR7## tolylene diisocyanate(viii) ##STR8## xylylene diisocyanate(ix) ##STR9## bis-(4-isocyanatocyclo- hexyl)methane(x) ##STR10## bis(4-isocyanatophenyl) methane(xi) ##STR11## lysine diisocyanate__________________________________________________________________________
It is to be appreciated that some of these W structures are asymmetrical and either end may be joined to NH group in Structure VII.
Groups R 1 suitable for structure VII of the present invention are shown in the following list, together with the corresponding polyol (V) from which VII may be derived by means of reactions in equation (1).
______________________________________Group R.sup.1 corresponding polyol V______________________________________(xii) ##STR12## glycerol(xiii) CH.sub.3 C(CH.sub.2).sub.3 trimethylol ethane(xiv) CH.sub.3 CH.sub.2 C(CH.sub.2).sub.3 trimethylol propane(xv) ##STR13## pentaerythritol(xvi) ##STR14## hexane triol(xvii) ##STR15##(xviii) ##STR16##(xix) R.sub.rVIII.sub.c______________________________________
where the groups R, S, and T may contain groups drawn from one or more of the following repeating units attached to each other in any order or direction. ##STR17## where r, s and t are each between 1 and 50.
The polyols corresponding to structures VIII are polyropylene oxide and polyethylene oxide glycols and triols. The preferred examples of structure VIII polyols have molecular weights in the range 300-5000 most preferably 400-4000.
Further examples of polyols suitable for preparation of PCS of structure VII include polyoxytetramethylene glycols, polycaprolactone polyols, hydroxyl terminated polybutadiene, butadiene-styrene, or butadiene-acrylonitrile copolymers, castor oil and other glycerides of hydroxyacids, polymerized castor oils, the reaction products of ethylene oxide or propylene oxide and castor oil and the like.
As particular examples of PCS, there may be mentioned --
(1A) products of the structure ##STR18## where U=(CH 2 ) 6 where g is from 1 to 40, in particular when g=14-18. Such a product may be derived from the corresponding polyisocyanate and bisulphite salts, and in the following discussion will be referred to by the abbreviation BAS. The proprietary product Synthappret LKF (manufactured by Bayer AG, Germany) is believed to be similar to the parent polyisocyanate. Such a polyisocyanate may be prepared from the corresponding triol, which is available commercially as Desmophen 3400 (Bayer AG., Germany), and hexamethylene diisocyanate.
(2A) as (1A) but --UNHCOSO 3 is ##STR19## in particular when g=14 to 18 which can be prepared from bisulphite salts and the polyisocyanate derived from Desmophen 3400 and isophorone diisocyanate
(3A) as (1A) but ##STR20## in particular when g=14 to 18 which can be prepared from bisulphite salts and the polyisocyanate derived from Desmophen 3400 and bis(4-isocyanatocyclohexyl)methane. ##STR21## in particular d, e, f=14 to 18 and U=--(CH 2 ) 6 --which can be derived from bisulphite salts and the polyisocyanate derived from hexamethylene diisocyanate and the commerical polypropylene oxide triol Voranol CP3000 (Dow).
(5A) as (4A) but d, e and f are approximately 1, and U=--(CH 2 ) 6 --which can be similarly prepared from the commercial product Voronol CP260.
(6A) As (4A) but with U as in (2A)
(7A) As (4A) but with U as in (3A)
(8A) Products of the structure
CH.sub.3 CH.sub.2 C[CH.sub.2 OCONHU'NHCOSO.sub.3 .sup.- Na.sup.+ ].sub.3
where U is as in (1A), (2A) or (3A). For example the PCS prepared from a bisulphite salt and the polyisocyanate produced by the reaction of trimethylol propane and hexamethylene diisocyanate, isophorone diisocyanate or bis(4-isocyanatocyclohexyl)methane.
(9A) The product of the structure
NA.sup.+ O.sub.3 SCONH(CH.sub.2).sub.6 N(CONH(CH.sub.2).sub.6 NHCOSO.sub.3.sup.- Na.sup.+).sub.2
which may be prepared from the corresponding triisocyanate and bisulphite salts. This triisocyanate may be prepared from the reaction of 3 moles of hexamethylene diisocyanate and one mole of water and is sold commerically as Desmodur N (Bayer AG., Germany).
It is to be further appreciated that the PCS of the present invention may be of uniform structure or a mixture of PCS may be used. Also such PCS may contain products with less than two carbamoyl sulphonate groups per molecule, for example carbamoyl sulphonates prepared from monoisocyanates and bisulphite salts such as alkyl isocyanates with from two to twenty carbon atoms, phenyl isocyanate or substituted phenyl isocyanates. Also low molecular weighted dicarbamoyl sulphonates may be present for example those derived from the diisocyanates (VI) listed above and bisulphite salts, in particular hexamethylene diisocyanate, isophorone diisocyanate and the like.
Suitable non-halogenated polymers (2) of the present invention may have a backbone consisting solely of carbon atoms. Such polymers can be formally considered to be derived from the polymerization of ethylenically unsaturated monomers. Such polymerizations are well known to those skilled in the art of polymer chemistry. Such monomers include the following which may be used alone or in combination; ethylene, propylene, the isomeric butylenes, butadiene, isoprene, styrene, the esters and ethers of vinyl alcohol, acrylic and methacrylic acid and their salts, esters, amides, nitriles and acid chlorides, vinyl sulphonic acid, vinyl pyridine, vinyl pyrollidone, maleic acid, allyl alcohol and derived esters and ethers and the like.
Alternatively the backbone of the polymer (2) may contain in addition to carbon atoms one or more of the following types of linkages; ester, amide, ether, urethane, urea, sulphide, disulphide, thioamide, sulphone, carbonate, or the like and thus may be a polyester, polyamide, etc. Such Class B polymers are well known in the prior art and the preparation is well known to those skilled in the art of polymer chemistry.
Polymers (2) may be used singly or in mixtures and may be water insoluble or water soluble. In the case of water insoluble materials these are most preferably in the form of emulsions, dispersions, latices or dispersions of solutions of such polymers in water immiscible solvents. Such dispersions are hence associated with water in which PCS dissolves.
It is desirable but not essential that polymers (2) of the present invention contain one or more groups from the following classes.
(a) primary amines
(b) secondary amines
(c) alcohols
(d) thiols
(e) thiophenols
(f) phenols
(g) carboxylic acids
(h) epoxides
(i) episulphides
(j) aziridines
(k) blocked isocyanates, blocked with the groups such as phenols, thiols, alcohols, amines, amides, β-diketones, oximes, β-ketoesters.
Subsequent chemical reaction between these groups and carbamoyl sulphonate or thiocarbamoyl sulphonate groups is conceivable and such reaction is desirable but not essential.
Polymers (2) may also be of natural origin, for example, proteins or polysaccharides including gelatin, collagen, zein, casein, starch alginates and the lile. Such natural polymers may be further modified by synthetic chemical reactions, for example, carboxymethylcellulose.
Preferred examples of polymers (2) may be drawn from one or more of the following classes.
B1. acrylic polymers or copolymers preferably in the form of latices, dispersions or emulsions.
B2. latices of polymers or copolymers of styrene butadiene or acrylonitrile.
B3. latices of polymers or copolymers of vinyl acetate.
B4. polyurethane latices.
B5. blocked isocyanates
B6. epoxy resins
Classes numbers 1 -3, inclusive, constitute polymers whose backbones are essentially carbon atoms alone whereas other linkages are present in the classes 4-6.
Suitable class B1 acrylic polymers or copolymers may be prepared by emulsion polymerization methods from a monomer mixture which contains at least 20% of an ester of acrylic or methacrylic acid and a lower aliphatic alcohol. Such acrylic esters include methyl, ethyl, propyl, n-iso and sec butyl, 2-ethylhexyl acrylates and methacrylates. In addition the following monomers may be present: acrylic or methacrylic acid, acrylamide or methacrylamide (or their N alkyl or N,N dialkyl derivatives), acrylonitrile, methacrylonitrile, the N-methylol or N,N-dimethylol derivatives of acrylamide or methacrylamide or the amides of methacrylic and acrylic acid with primary amines, or the corresponding ethers of the previously mentioned methylolamides, glycidyl, acrylate, glycidyl methacrylate, allyl glycidyl ether, maleic anhydride, itaconic anhydride, vinylisocyanate, allyl isocyanate, vinyl pyridine, dimethylaminoethylmethacrylate and acrylate, tert-butylaminoethylmethacrylate.
A number of such products are commercially available and are well known to those skilled in the art of polymer chemistry and these include the following commercial products.
Primals
K3, K-14, K-87
HA-4, HA-8, HA-12, HA-16,
TR-520
B-15,
AC-33,AC-61, AC-73,
E-358, E-485, E-740, E-751, (Rohm and Haas);
Valbonds 6001, 6004, 6020, 6021, 6022, 6025, 6053, 6063 and 6055, Valchem Australia Ltd.;
Polyco 2705, 2719 (Borden Chemical Co.);
Texicryl
13-001, 13-002, 13-003, 13-010;
13-100, 13,101, 13-102, 13-104;
13-200, 13-201, 13-202, 13-203,
13-205, 13-430, 13-439;
Scott Bader Ltd.;
Acramins Lc, 3232, 3132, SLN (Bayer AG); GEN-Flo 704, (General Mills);
Helazarin Binders FA, UD, TS, NTA, (BASF Ltd.);
Vinacryl 63-307 (Vinyl Products Ltd.);
Nacrylic X4280, X-4260 (National Starch and Chem. Corp;)
Stan Chem 6006, 6016, 6016, 6033 (Stanchem Inc.);
Hycar 2600×172, 2600X181 (B.F. Goodrich and Co.);
Suitable Class B2 polymers are derived from the polymerisation of a mixture containing by weight at least 20% of one or more of the following monomers, acrylonitrile styrene or butadiene. In addition the monomers listed above for class 1 may be present. A number of such products are commercially available and are well known to those skilled in the art of polymer chemistry and include the following commercial products.
Acralen BN (BASF);
Polyco 22ONS, 2410, 2415, 2422, 2426, 2430, (Borden Chemical Co.);
Dow Latex 233, 464, 460 (Dow Chemical);
Hycar 1872 X6, 1552, 1562, 1571, 2601, 2671, 2600 ×84, 2600 --106, 2570 --1, 2570 ×5, 2530 ×2, 1871 --1, 1877 --8, 1870 ×3, 1870 ×4 (B.F. Goodrich Chemical Co.).
Suitable Class B3 polymers are derived from the polymerisation of a mixture containing at least 20% by weight of vinyl acetate. The following monomers may also be pressure vinyl propionate, and esters of fumaric and maleic acid. In such polymers some of the acelate groups may be subsequently hydrolysed to form vinyl alcohol residues.
Vinac AX-10, AX -11 (Airproducts and Chemicals);
Airflex 120 ("" )
Polyco 678W, 804, 804PL, 199, 345, 1360 -15, 529, 577G, 694, 953, 2185, 1361 - 413 1404 - 30, 11714, 289, 561, 11755,571, 2166, 505, 522. (Borden Chemical Inc.);
Resyn 1025, 78 - 3500, 78 - 5301, 78 - 5344, (Nahonal Starch and Chemical);
Kemres 1101/00, 1101/05, 1102/00, 1103/00, 1204, 1205, 1210, 1216, 1230. (Kemres Chemicals Pty. Ltd.);
Polymer 5001, 5004, 5011, 5012, 5022, 5024, 5024, 5026 (Stan Chem. Chemicals Inc.);
Texicote 63 - 001, 03 - 004, 03 - 004, 03 - 006, 03 - 007, 03 - 019, 03 - 020, 03 - 021, 03 - 030, 03 - 050 (Scott Bader Ltd.).
Polyurethane latices or dispersions suitable for class B4 of the present invention characteristically contain a plurality of urethane linkages and in addition may contain ester or ether linkages. Such polyurethane latices are produced from the reaction of diisocyanates and polyols, for example as described in Australian Pats. Nos. 62076/69, 424333, 17876/70, British Pats. No. 1,078,202, German Pats. No. 2,035,729 2,2041,550, 2,035, 172 2,013,160 2,030,571 and 2,034,479, and are also described by D. Dieterich and H. Reiff Angewandte Makromolekulare Chemie, 26, 85-106, 1972. Examples of commercially available polyurethane lactices include --
Dunlop Resin J67, 664 787, (Dunlop Aust Ltd.),
Desmocoll KA 8066 (Bayer AG Germany),
Impranil BLN and DLH (Bayer AG Germany),
Polyurethane Dispersion B (Bayer AG Germany).
Blocked polyisocyanates suitable for use as class B5 of the present invention may be formally derived from the reaction of a blocking agent and a polyisocyanate. Such blocked isocyanates on heating may reform the original isocyanate or by heating with nucleophilic reagents may produce the same products as from the reaction of the same nucleophilic reagent with the parent isocyanates. Examples of blocking groups are above. The polyisocyanates may be any of those discussed previously from which PCS may be derived.
A particular effective example of such polymers containing blocked isocyanates suitable for the purposes of the present invention is the products Adiprene BL16 (du Pont) which has a structure of the following type; ##STR22##
As suitable epoxy resins suitable for class B6 there may be mentioned glycidyl ethers from bisphenol-A or novalac resins and epichlorhydrin, the glycidyl esters of polycarboxylic acids and the glycidyl ethers of polyethylene or propylene oxide polyols or those derived from the epoxidation of ethylenically unsaturated polymers. As particular examples of such epoxides there may be mentioned the Epikote series of Shell Chemicals, Araldite products of CIBA-Geigy and DER series of Dow Chemical Co.
A further type of epoxy-containing polymer suitable to use in the present are those derived from the reaction of isocyanate-containing prepolymers with glycidyl alcohol to give epoxy terminated polyurethanes as described by Sello et al in Textile Research Journal 1971 p. 556. Also there may be used the corresponding aziridine-terminated polyurethanes as described in U.S. Pat. No. 3,542,505 and Australian Pat. No. 63504/69. A further type of aziridine-terminated polymer are those described in Textile Research Journal, 33, (1963) 953, which in addition contain fluorine atoms.
To the compositions of the present invention various agents may be added in order to alter the physical properties of the composition or to alter the properties of the treated fibrous material. Such agents may be water soluble or insoluble. Such agents may be present as a separate phase or may be dissolved in the solution containing the PCS. In the case of the polymeric material (2) forming a separate phase, e.g., as a latex or dispersion, such agents may be dissolved in the latex or dispersion particles.
Furthermore, there may be added to the compositions of the present invention, agents known to improve the curing of the PCS component. Such agents preferably contain two or more thiol or amino groups. As particularly effective of such agents there may be mentioned ethylene diamine, diethylenetriamine and related higher ethylene diamine polyamines, ethanolamine 1,2-ethane-dithiol. Quadrol (a product of the Wyandotte Company N,N,N'N'-tetrakis (2-hydroxyethyl)ethlenediamine), 4,4'diamine diphenylmethane, MOCA (a product of the du Pont Company, with 2,2'-dichloro-4,4'-diamino-diphenyl-methane structure) and the like.
Another class of such agents are those known to catalyze the reactions of isocyanates and their derivatives, e.g., tertiary amines (in particular triethylenediamine) or organometallic compounds (e.g., stannous octoate, stannic chloride, dibutyl tin dilaurate, lead napthenate, stannous napthenate; bismuth octoate and the like). There may also be added to compositions of the present invention agents to improve the curing of the other polymeric class B component as defined above. Such agents are commonly used for the curing of soft acrylic latices on textiles and are usually N-methylol and poly N-methylol and alkylated N-methylol derivates of compounds containing more than one amide (e.g. urea, biuret, cyclic ureas) or amide-like amino groups (such as in melamine) which are prepared by reaction with the parent compound with formaldehyde or a higher aldehyde and may or may not be subsequently alkylated. As particular examples of such agents there may be mentioned curing agent RK-8 (Rohm and Haas) Cymels 300 and 301 (American Cyanamide).
Additional agents include salts, acids, bases, organic solvents, agents to modify the colour of the treated material (e.g. dyes, fluorescent whitening agents or pigments, agents to modify the burning properties (e.g. flame retardants), agents to modify the soiling properties, agents to modify the oil and/or water repellency, agents to modify the pH of the composition (e.g. acids, bases, buffers salts), surface active agents, agents to modify the properties of the polymeric materials derived from the composition (e.g. plasticizers, antioxidants, UV screens, antiozonides and the like), agents to modify the viscosity (e.g. thickening agents).
As particularly useful examples of commercial anti-oxidants there may be mentioned the following commercial products --Plastanox 2246 (American Cyanamid), Irganox 415 (CIBA-Geigy), Annullex PBA-15 (William Pearson), Product 4020 (Bayer).
Such agents may be incorporated in either or both of (1) and (2) compounds or may be added during the mixing of (1) and (2) compounds in preparation of the compositions of the invention.
The compositions of the present invention are particularly suited for the treatment of fibrous materials. However, it is to be appreciated that they may be used for other applications. The fibrous materials suitable for treatment with the compositions of the present invention may be in the form of loose fibre, card sliver, roving, yarn, fabric, sheets (e.g. papers), felts, garments, or other. The fabrics may be constructed by weaving, knitting, or non-woven means or by a combination of such means. In addition, such fabrics or sheets may be bonded by means of resins or other means to other fabrics to form multi-layer structures.
Any of the natural or synthetic fibres which fall in the categories below are suitable for the purposes of this invention.
(a) Natural Fibres
Such as flax, jute, hemp, cotton, and wool and natural fibres of inorganic origin such as asbestos.
(b) Fibres formed by the Regeneration of Natural Materials
Such as casein, zein, rayon viscose, and alginate fibres.
(c) Man-made Fibres
Prepared from modified cellulosic materials such as cellulose acetate and tri-acetate.
(d) Man-made Fibres of Inorganic Origin
Such as glass, metal and carbon fibres.
(e) Fibres Prepared from Synthetic Polymers
From the following general classifications: polyamides, polyesters, polyacrylics, modified acrylics, polyvinyl, chlorides, polyolefins, polyethylenes, polyvinyl and vinylidene fibres and the like.
Blends which are used, for example, for economic effect, or performance reasons, of any of the above classes in any ratio, are considered to be within the scope of the invention.
The compositions of the present invention are particularly suited for the treatment of wool or wool blended with other fibres such as polyester. Such fibres may have been subjected to physical or chemical pretreatments. For example, the reaction of wool with halogen particularly chlorine or compositions which release chlorine (e.g., hypochlorite) oxidizing agents, (e.g., hydrogen peroxide permonosulphuric acid, potassium permanganate) or reducing agents (e.g., bisulphite salts, sodium dithionite or thioglycollic acid.
Impregnation of fibrous materials with the compositions of the present invention may be by padding, dipping, spraying, brushing, knife coating, or the like, or by combinations of such methods. Fabrics are most effectively treated by padding. Subsequently, to remove water and other volatile substances and also in order to assist in curing of the polymeric mixture, the treated fibrous material may be subjected to a heat treatment. Such heating may be by a direct contact with heated bodies in the form of solid liquids or gases, e.g., hot air or steam or by a radiative means (infrared microwave heating or the like) or by a combination of such methods.
For the purpose of the invention the amount of both the PCS and the other polymeric components should both preferably lie in the range 0.1 to 50% of the weight of the fibrous material and most preferably in the range 0.2 to 5.0%. Such concentrations are dependent on the nature of the fibrous material, the exact nature of the polymeric components (1) and (2) and the type and degree of improvements desired in the fibrous material, and are best determined by experiment.
Compositions of the present invention have been found advantageous in a number of applications. The following examples are provided to illustrate, but not limit, the invention.
1. For the treatment of textile materials to provide improvements to such properties as abrasion resistance, dimensional stability, pilling resistance, snagging resistance, wrinkle recovery, strength, smooth drying after wetting or washing, and tailorability, where the tendency of materials (especially knitted materials) to curl and roll on cutting or distort on sewing, is essentially eliminated.
2. For the treatment of formed paper products to provide, in particular, papers of greater tear and burst strength and abrasion resistance or for the formation of paper products of improved properties where a composition according to the invention is added to the cellulose fibre slurry.
3. For the treatment of fabrics which may be in the form of fibrous webs, filaments or layered combinations to give chemically bonded non-woven fabrics of improved properties especially strength. Compositions of the invention may also be applied to mechanically bonded non-wovens for the purpose of improving in particular their strength and abrasion resistance.
By suitable selection of the class (1) or (2) materials, properties in addition to the above such as flame resistance, water and oil repellency, and soiling resistance can be imparted to the material.
The compositions of the present invention find particular advantage in imparting a high level of shrink-resistance to materials comprises wholly or partially of keratinous fibres. Such compositions have one or more of the following advantages over shrinkresist treatments of the prior art,
(i) Application from aqueous systems in contrast to certain prior art treatments (e.g. those based on the use of polyisocyanates alone e.g. British Patent Nos. 1062564 and 1161748) where it is necessary to apply from non-aqueous solvent in order to prevent premature reaction with water.
(ii) The stability of compositions of the present invention in contrast to compositions of the prior art which are unstable and must be used immediately as curing will occur at room temperature before application. For example, with polymers containing free isocyanate groups, application from aqueous baths can only be achieved by emulsification of thepolymers. This constitutes an additional processing step, but more importantly, the prepared emulsion has only a relatively short life because the isocyanate groups react with the water in the emulsion. Furthermore, free isocyanate groups can cause problems in handling due to the presence of volatile low molecular weight fragments which are toxic.
(iii) The treatment of keratinous materials, in particular wool without the necessary requirement of damaging pretreatments such as chlorination. In many polymer shrinkresist methods of the prior art such pretreatments are obligatory in order to obtain shrinkresistance; for example, those based on polymers from the reaction of certain polyamides with epichlorhydrin (C. A. Anderson et al, Textile Manufacturer Vol. 95, No. 1133, p. 184, 1969).
(iv) The production of a softer handle in the resultant treated textile material than when PCS is used alone by virtue of the improved mechanical properties of the polymer composite.
(v) The greater durability of the cured polymer coating to subsequent thermal and photo degradation. Compositions of the present invention particularly where the co-applicant of the PCS is an acrylic copolymer (e.g., Primal K3, Rohm and Haas), have greater thermal and light stability than those treatments based on PCS or the parent isocyanate terminated prepolymer alone.
(vi) The ability to produce minimum thermal degradation in keratinous materials and other thermally sensitive fibres by the ease with which curing occurs at 100° C.
For example, polyurethane dispersions when used alone to impart shrinkage resistance to wool require a temperature of 140° for curing. However, when used in admixture with PCS, curing occurred at 100° C. Also certain crosslinkable acrylates (e.g. Primal K3, Rohm and Haas) normally require a temperature of 130° for curing when used alone, but with PCS readily cure at 100°.
(vii) The ability to cure under neutral conditions, in contrast to certain compositions (particularly those derived from cross-linkable acrylates) which require acid conditions either by direct addition of acid or salts that produce an acid reaction (e.g. ammonium salts such as ammonium chloride) or salts which act as acidic catalysts (e.g. zinc chloride or fluoroborate). Such acid treatments are known to be damaging to the keratinous materials, and generally require an additional processing step to neutralise such acidity in order to prevent subsequent degradation of the keratinous material.
(viii) The production of stable creases per se and the production of permanent press effects if combined with a setting method of the prior art, and the per se production of permanent press effects.
Such set stabilization is due to the constraints imposed by the cured polymer film and the release by the PCS of bisulphite, a known wool setting agent, during the curing reaction.
(ix) The ability to bind pigments to produce dyeings fast to rubbing.
(x) The production of delayed cure setting effects, i.e. the material is treated but not cured at the fabric stage and then after making up the garments and forming these into the desired shape, curing is then effected which stabilizes the material in the desired shape. To accomplish such a delayed cure process it is essential that no curing occurs in the drying operation which inevitably follows applications of aqueous solutions of compositions of the present invention. This can be achieved if the drying is carried out at low temperatures preferably below 80° C.
Such advantageous features from treatment of keratinous materials with compositions of the present invention can most readily be seen in combination of PCS's and cross-linkable acrylic latices. For example, combination of PCS and Primal K3. The later if used alone, even in the presence or methylol curing agents is unable to impart shrinkresistance to worsted wool fabrics unless prechlorinated. However, in combination with PCS it is possible to impart shrinkresistance to worsted wool fabrics, and in particular to concentrations where there is not sufficient PCS if used alone to impart shrinkresistance.
Compositions of the present invention when applied to keratinous materials and cured in the manner described above simultaneously impart in the one treatment operation, without the necessity of additional treatments, combination of shrinkresistance and one or more of the following properties:
(a) flame resistance
(b) water and stain repellency
(c) colour by the binding of pigments
(d) improved wrinkle recovery
(e) crease stabilization, which may be to such an extent that the garments so treated can be considered to be permanently pressed.
In addition, such properties are retained after subsequent washing operations, particularly when washed with domestic washing machines.
To obtain such combinations of desirable properties by methods of the prior art, it is either necessary to resort to a series of successive treatments which may damage the keratinous material or each such successive treatment may not be completely compatible with each other and may lower the effectiveness of each other. Such an effect has been observed by Fincher et al (Textile Research Journal, Vol. 43, October, 1973, p. 623-625) where treatment with polymeric shrinkresist compositions of chemically flame retardant wool caused complete loss of the flame retardancy. Alternatively, methods of the prior art to get such combination of effects may not be fast to repeated washings, e.g. particularly under the severe washing conditions which the shrinkresistance allows to be used.
The combination of water or stain repellency with shrinkresistance can be observed with combinations of PCS's, in particular BAS, with fluorinated polymers.
In the discussion above, the ability of PCS's and other compounds especially acrylics to stabilize keratinous materials to washing shrinkage was noted. These combinations act equally as well on non keratinous materials and have especially advantages on fabrics containing or comprising cellulosic fibres. For improvements to dimensional stability and smooth drying properties such fabrics are normally treated with a methylated urea formaldehyde resin, or a dimethylol ethylene urea resin, or similar, an acid catalyst such as magnesium chloride, and various additives to control sewability, tear strength, handle, finish migration, and abrasion resistance. Similar effects including delayed cure treatments can be obtained by using a PCS product or products in combination with other polymeric materials but, however, without the strength and abrasion losses on the cellulosic component always found when using acid catalysts. The treatment according to the invention may allow a more economic choice of fibre components while still maintaining the same performance. For example, permanent press materials are frequently comprised of 70% polyester fiber and 30% cotton or viscose fibre. Increasing the percentage of the cellulose fibre, although providing an economic advantage, greatly reduces the abrasion resistance and strength of the resultant permanent press fabric where conventional acid curing resins are used. Use of a PCS and other selected materials according to the invention allows the use of more advantageous blend proportions without causing a loss in fabric physical properties.
It is to be appreciated that many modifications can be made to the methods described above and that all such modifications are considered to be within the scope of this invention. The following examples are provided to illustrate the present invention but are not to be construed as limiting the invention in any way.
EXAMPLES
Wash tests were performed for 1 hr in a 50 liter Cubex international machine with 12.5 liters of wash liquor and 1 Kg of goods comprising of about 20 test samples and polyester weighting squares. Wash liquor was a solution at 40° of 0.2 g/l Na 2 HPO 4 , 0.1 g/l NaH 2 PO 4 and 0.05 g/l Alkanate D (ICI). Samples were relaxed in a solution containing 0.05% NaHCO 3 and 0.5% lux for 20 minutes, measured washed for 1 hr as above, measured again and the area shrinkage calculated; under these conditions untreated fabric A shrank 70%.
Flame Resistance
An undyed woven plain weave worsted fabric of 220 g/m 2 was tested according to Federal Test Method, Standard 191, Textile Test Method No. 5903. In this test a flame impinges on a vertical strip of fabric (5 cm×30 cm) for 12 seconds and, to pass, the flame must extinguish within 15 seconds with an average burn length not greater than 20 cm.
Flexural Rigidity (a measure of fabric stiffness and handle) of fabric pieces was measured in accordance with B.S. 3356:1961.
BAS was prepared using the following method; Synthappret LKF (1 Kg) was stirred vigorously whilst absolute ethanol (2 liters) and solution of sodium metabisulphite (110 g) in water (1 liter) were added as rapidly as possible. After 5-10 minutes the mixture cleared and Plastinox 2246 (American Cyanamid) (10 g) was added. The resultant clear solution infinitely dilutible with water, contained about 20% solids BAS.
EXAMPLE 1
A plain weave wool worsted fabric (10 picks/cm, 10 ends/cm, 153 g/m 2 ) was padded to give the following percentage add-ons as shown in Table 1 and dried at 100° C. for 5 min. then given a washing test.
TABLE 1______________________________________ WashingTreatment Shrinkage %______________________________________Untreated 700.6% BAS 522.4% Primal E485 (Rohm and Haas) 642.4% Primal E485, 0.6% BAS 23% Primal K3 (Rohm and Haas) 622.4% Primal K3, 0.6% BAS 13% Hycar 1872 X6 (B.F. Goodrich) 662.4% Hycar, 0.6% BAS 03% Oligan 500 (CIBA-Geigy) 532.4% Oligan, 0.6% BAS 13% PVA 205 (Poval Chemical) 682.4% PVA 205, 0.6% BAS 183% Polyurethane Latex J67(Dunlop Australia) 682.4% Polyurethane Latex J67 + 0.6% BAS 53% Polyurethane Latex 664 (DunlopAustralia) 652.4% Polyurethane Latex 664 + 0.6% BAS 33% Polyurethane Dispersion V (Bayer) 652.4% Polyurethane Dispersion V, 0.6% BAS 33% Impranil DLN (Bayer) 652.4% Impranil DLN, 0.6% BAS 53% Impranil DLH (Bayer) 672.4% Impranil DLH, 0.6% BAS 23% Chemitex 1210 (Kemrez Chemicals) 702.4% Chemitex 1210, 0.6% BAS 83% Casein 702.4% Casein, 0.6% BAS 223% Gelatin 692.4% Gelatin, 0.6% BAS 19______________________________________
Neither small concentrations of the BAS alone nor large concentrations of the acrylic (E485 and Primal K3), nitrile (Hycar 1872×6) and polyurethane (Latex J67, Latex 664, Dispersion V and Impranil DLN and DLH) latices, the polythiol resin (Oligan 500), the vinyl alcohol (PVA 205), the vinyl acetate (Chemitex 1210), and the casein and gelatin compounds alone were able to shrinkresist the worsted fabric. In all cases, however, the combination according to the invention were effective in substantially reducing the felting shrinkage.
EXAMPLE 2
A grey, plain weave, commercial worsted suiting fabric of 254 g/m 2 was treated as described in Example 1 to give the following results.
______________________________________ Washing Flexural RigidityTreatment Shrinkage (warp) (mgm cm)______________________________________Untreated cloth 71 2323% E485, 0.1% CO630 64 2613% BAS 0 6692.4% BAS, 0.6% E485 0 5412.4% BAS 1 6251.8% BAS, 1.2% E485 1 5061.2% BAS, 1.8% E485 0 3960.6% BAS, 2.4% E485 2 3870.6% BAS 52 --0.45% BAS, 2.55% E485 3 3680.3% BAS, 2.7% E485 3 324______________________________________
The ratio of the PCS compound, BAS, may be varied at will to provide variations in fabric handle whilst maintaining the shrinkresist effect.
EXAMPLE 3
The invention may be used to advantage to confer anti-pilling treatments particularly on garments knitted from wool or wool blended with synthetics.
For example, three knitted wool fabrics of varying cover factors but each produced from the same yarn on the same machine were treated with 2.4% E485 and 0.6% BAS. After drying for 5 min at 100° C. the fabrics were subjected to a pilling test as described in ASTM D1375 E "Random Pilling Tester" with the exception that the results are recorded as the number of pills formed on the face of the fabric after 30 min of testing.
______________________________________Cover Factor.sup.a 1.42 1.26 0.98______________________________________ Pill CountUntreated 16 35 69Treated 1 7 19______________________________________ .sup.a Cover factor defined as the reciprocal of the multiplication of th square root of the worsted count of the knitting yarn and the stitch length (inches).
EXAMPLE 4
The invention may be used to advantage in conferring smooth drying or permanent press properties to a fabric.
A commercially available plain weave worsted suiting of 254 g/m 2 was treated with 2.4% Primal K3 (Rohm and Haas) and 0.6% BAS. The fabric was dried for 5 min at 90° C. and steamed on a semi-decating machine for 30 sec.
The fabric was then washed according to the Specification No. 72 of the International Wool Secretariat namely; 3 consecutive washes in a 50 liter Cubex machine containing 15 liter of water buffered to pH 6.8 at 40° C. and containing 0.5% soap. At the end of each hour of wash testing, the fabrics were removed from the machine, squeezed by hand and dried by hanging vertically in a drying cabinet.
The advantageous effect on fabrics treated according to the invention can be seen from the following table:
______________________________________AATCC Durable Press Rating*Testing Time (hrs) 0 1 2 3______________________________________Untreated 5 2.6 1.4 1.0Treated 5 4.5 4.2 4.5______________________________________ *Fabrics rated according to AATCC Test Method 124 1967. A rating of 5 is essentially a perfectly flat piece of fabric.
EXAMPLE 5
The invention may be used to advantage in reducing the airing temperature of polyurethane dispersions. Samples of wool fabric of 170 g/m 2 were padded with the compositions described below, dried for 5 min. under the conditions shown, and then assessed for washing shrinkage.
______________________________________Treatment Temperature Shrinkage______________________________________(a) 3% Polyurethane DispersionPU 787 (Dunlop) 95° C. 27%(b) As above 110° C. 15%(c) As above 125° C. 2.3%(d) 2.4% PU787, 0.6% BAS 95° C. 1.8%(e) 0.6% BAS 95° C., 110° C. 50-55% 125° C.______________________________________
Addition of a small quantity of BAS to a polyurethane dispersion capable of shrinkresisting the wool if cured at high temperature, substantially reduces the curing temperature.
EXAMPLE 6
Samples of a light weight polyester/cotton (65%/35%) shirting material were treated with 1.6% Primal K3 and 0.4% BAS.
After drying for 5 minutes at 120° C. a panel of observers judged the treated fabric to have a handle barely different from the untreated fabric.
The area shrinkage according to the boiling water test of British Standard BS2959:1958 was 7.2% for the untreated control and 1.5% for the treated.
The pill rating, using the Random Tumbler Pill Tester (American Society for Testing Materials, Test D1375E) was 4 for the treated fabric and 2 for the untreated control. The rating is based on a scale of 1 to 5, the higher the rating the better the appearance.
On cutting the material, the treatment caused the material to remain flat, whereas the untreated material curled considerably.
The treatment according to the invention offered an excellent handle together with improved resistance to pilling shrinkage and curling on cutting.
EXAMPLE 7
A double knit ponte di Roma fabric comprised of staple polyester fibres was treated 1.6% Primal K3 and 0.4% BAS by padding and dried for 5 minutes at 120° C.
A panel of observers judged the fabric to have a handle little changed from the control.
The snagging propensity of the treated and untreated fabrics was assessed using the ICI Mace Testing Unit (Textile Journal of Australia, 46, February 1971, p.24). The snagging rating was 4 for the treated fabric, and 2-3 for the untreated control. The rating is based on a scale of 1 to 5, the higher the rating the better the performance.
A boiling water shrinkage test (BS 2959) produced an area shrinkage of 6.7% in the untreated fabric and 2.0% in treated fabrics. On drying after the boiling water test the fabrics were assessed for smooth drying properties (AATCC Test Method 124:1969). The untreated fabric had a smooth dry rating of 4 whereas the treated fabric had the maximum rating of 5. A rating of 5 indicates a perfectly flat appearance.
The treatment according to the invention offered an excellent handle together with good antisnagging and smooth drying properties.
EXAMPLE 8
A sample of a lightweight cotton shirting fabric was treated with 8% of a cyclic nitrogeneous reactant (Valrez H-17, Valchem) 0.75% zinc nitrate and 0.75% magnesium chloride (A). The treated fabric was dried at 110° C. and then cured at 160° C. for 10 minutes.
A sample of the same fabric was treated with 2.0% Primal K3 and 1.0% BAS and dried for 5' at 120° C. (B).
The combination of the warp and weft recovery angles (measured according to B.S. 3086:1959) was 256° for treatment B and 248° for treatment A. The untreated fabric had a combined recovery angle of 208°. A combined recovery angle of 360° indicates a complete recovery from creasing.
The durable press ratings (AATCC Test Method 124:1969) after a 1 hour cubex wash test were 3.5-4.0 for both fabrics A and B.
The tensile strength of fabric A was 60-65% of the untreated control whereas the strength of fabric B was not affected. The tensile strength was tested according to ASTM Method IR of D168204.
Treatment of the cotton fabric according to the invention (B) gave good smooth drying and crease recovery performance but without the loss in tensile strength as shown by the example of a conventional treatment (A).
EXAMPLE 9
A light weight all wool single jersey fabric and a heavy all wool upholstery fabric were treated according to the formulations below, dried for 5 minutes at 120° C. and assessed for abrasion resistance using a standard Martindale Abrasion tester.
______________________________________ Abrasion Resistance*______________________________________ Single Jersey Upholstery Fabric(a) Control 15,000 31,000(b) 2.4% Primal K3, 0.6% BAS 21,000 40,000(c) as (b) plus a polyethylenewax emulsion 1% (Valsof3049, Valchem) 26,000 48,000______________________________________ *The number of rubs required to abrade a hole in the fabric.
EXAMPLE 10
Samples of wool fabric of 170 g/m 2 were padded with the composition as listed below, dried for 5 min at 120° C. and then assessed for fastness of the finish to light exposure. Samples were tested for shrinkage resistance after exposure to sunlight for such times as indicated by fading of the Society of Dyers and Colorists Blue Scale Reference Standards (BS1006:1961). The arbitary standard for light fastness was chosen as the Blue Scale Standard at which the test piece on washing shrunk 5 to 10% in area. The higher the number the better the lightfastness. A fastness of standard 6 is regarded as acceptable.
______________________________________Treatment Fastness Standard______________________________________1. 3% BAS 52. 3% BAS, 0.03% Annullex PBA-15* 6-73. 2.4% Primal K3, 0.6% BAS 74. 2.4% Acralen AS,** 0.6% BAS 6-75. As 3 plus 0.03% Annullex PBA-15 7-86. As 4 plus 0.03% Plastanox 2246*** 7-8______________________________________ *Annullex PBA15, WM. Pearson, Hull. A hindered phenolic antioxidant **Acralen AS, Bayer, an acrylic copolymer. ***Plastanox 2246, American Cyanamid. A hindered phenolic antioxidant.
The treatments according to the invention (3 and 4) offer improvements in lightfastness equal to or better than the incorporation of antioxidants. Coapplication of an antioxidant with the treatments according to the invention makes further improvements to the lightfastness.
EXAMPLE 11
A length of single jersey all wool underwear material in the unscoured state, was treated by padding to produce 2.3% Primal K3, 0.7% BAS, and 1% sodium bicarbonate by weight on the weight of material. After drying for five minutes at 105° C. the material was scoured with a synthetic detergent in the usual way. Without an intermediate drying step the material was dyed on a winch to a navy shade using reactive dyestuffs. A similar scouring and dyeing treatment was carried out on untreated material.
During dyeing the untreated material shrunk 18% in area and there was considerable hairiness together with lack of stitch clarity. The material treated according to the invention shrunk only 3% in area and maintained the surface appearance of the original material.
After dyeing the material treated with the BAS and Primal K3 was subjected to a Cubex wash test. After one hour an area shrinkage of 3% was found.
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A composition comprising:
(1) at least one (poly)carbamoyl or (poly)thiocarbamoyl sulphonate containing at least one radical of the formula --
--NH.CO.SO.sub.3.sup.θ X.sup.+ [Z]
or
--NH.CS.SO.sub.3.sup.θ X.sup.+ [Y]
wherein X + represents a cationic group with one or more positive charges to maintain electrical neutrality in the sulphonate; and
(2) at least one non-halogenated polymer selected from the following classes --
A. polymers derived from the polymerization of ethylenically unsaturated monomers, and
B. polymers having a backbone of carbon atoms and at least one ester, amide, ether, urethane, urea, sulphide, disulphide, thioamide, sulphone, or carbonate linkage.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention pertains to a foreign object (e.g., stone, piece of metal, etc.) detection method and apparatus for detecting and removing discrete hard non-frangible objects from mobile agricultural equipment. Specifically, self-propelled combine harvesters and forage harvesters are adapted with an apparatus that performs the method of detection of rocks and other discrete hard objects to permit the reliable removal of rocks and non-frangible objects from harvested crop material during crop harvesting operations.
In the context of this disclosure, unless indicated otherwise, the phrase “non-frangible objects” will be used generally to refer to any hard non-frangible objects of at least a minimum size that may be picked up by a harvesting machine in a field including but not limited to stones, rocks, pieces of metal, pieces of wood, etc. In at least some embodiments the minimum size will be approximately three inches in length or diameter although the present invention should not be so limited. In other embodiments the minimum size may be anywhere from one inch to five or more inches in length or diameter.
In the art of mechanically harvesting crops, it is known that self-propelled agricultural vehicles, such as combine harvesters and forage harvesters, are used to mechanically harvest crops. Typically, these vehicles are equipped with a harvesting implement, or header, that includes a reel for pulling crops into an array of blades for cutting the crop, wherein the cut crop material is pulled further into the header along a transport surface by an auger. Once past the auger, the cut crop material is carried by an elevator to a threshing and sorting mechanism that removes unwanted chaff material from the desired crop matter before the crop matter reaches a storage compartment carried by the vehicle.
The above described simple crop harvesting process is complicated by the fact that non-frangible objects are often pulled into the header with the crops. Unfortunately, non-frangible objects (e.g., stones, pieces of metal, etc.) can cause damage to the elevator and threshing mechanisms. To minimize equipment damage from non-frangible objects, various methods and apparatuses have been developed to detect and remove non-frangible objects from the header before the cut crop material is carried by the elevator into the threshing and sorting mechanism.
An exemplary stone ejecting system may include an active system which utilized some sort of an electronic sensor, such as an acoustical transducer typically in the form of a piezoelectric disc mounted in a sensing plate in conjunction with a stone trap. The electronic sensor responds to the characteristics of the sound, such as the amplitude and frequency, that an impacting stone generated in the sensing plate. This signal would then be transferred through an electronic circuit that filtered out the range within which the amplitude and frequency was characteristic of stones. Within this characteristic spectral range the electronic circuit automatically activated a latch releasing mechanism on a door along the bottom of the in-feed housing that would pivot open to permit the stones or hard objects to be ejected from the feeder house, along with a small amount of crop material.
An exemplary detection/ejection system includes a sensor, a sensing plate including a sensing surface, a discriminating circuit and a solenoid operated trap door. Here, the sensing plate and trap door are consecutively placed along the path of harvested material travel. The sensor is often a piezoelectric ceramic disc linked to the sensing plate and generates signals indicative of the type of material that impacts or is currently on the sensing plate. For instance, the sensor may generate signals whenever a stone or the like impacts the sensing surface of the plate or when a stone vibrates on the sensing plate. Here, signal characteristics known to be associated with non-frangible objects are known (e.g., amplitude and frequency of vibrations, signatures associated with impacting stones, pieces of metal, etc.) and the discriminating circuit is designed to distinguish characteristics of non-frangible objects from characteristics associated with harvested crop materials. When a non-frangible object is detected, a signal is provided to the solenoid causing the solenoid to open the trap door so that the non-frangible object is ejected from the system.
Unfortunately, several factors make it difficult to accurately distinguish non-frangible objects from harvested crop materials. First, as harvested material is transported over the sensing surface, non-frangible objects are usually mixed in with harvested crop material so that the non-frangible objects often do not make direct contact with the sensing surface. In these cases the harvested crop material operates as a type of muffler to stifle the signals associated with the non-frangible objects thereby making it difficult to distinguish those objects from the harvested crop materials.
Second, despite efforts to isolate the sensing plate and sensor from other harvester components, in many applications harvester and harvesting related noise (e.g., harvester engine vibrations, jarring of the vehicle as it travels along the ground, rocks impacting the exterior of the header during harvesting operations, etc.) make it difficult to distinguish non-frangible objects from harvested crop materials. Consequently, unless signal characteristics indicative of non-frangible objects are precisely known and the discriminating circuit is precisely tuned to pick up the non-frangible object signal characteristics, incorrect object identifications can occur which lead to either opening of the trap door when not necessary and loss of crop material or passing of non-frangible objects to the elevator and threshing mechanisms resulting in damaged equipment.
Thus, it would be advantageous to have a mechanism or apparatus that could increase the accuracy of non-frangible object detection in harvesting machines.
BRIEF SUMMARY OF THE INVENTION
An exemplary embodiment of the invention includes an apparatus for use with a non-frangible object detection mechanism on an agricultural harvester, the detection mechanism including a sensing surface and a sensor for sensing force applied to the sensing surface that is associated with a foreign object adjacent the sensing surface, the harvester including a transport surface along which harvested materials are transported toward the sensing surface, the apparatus including at least first and second ramp members positioned between the transport surface and the sensing surface, the ramp members separated by a gap, each ramp member including a front ramp surface that extends between a front ramp end adjacent the transport surface and a ramp member apex, the ramp member apexes positioned at a location higher than the sensing surface and proximate the sensing surface, wherein, as harvested material and non-frangible objects are conveyed along the transport surface and toward the sensing surface, at least a portion of the harvested material passes between the ramp members to the sensing surface and at least a portion of the non-frangible objects move along the ramp surfaces and are forced over the ramp apexes to descend toward the sensing surface.
In at least some embodiments the at least first and second ramp members include a plurality of ramp members positioned between the transport surface and the sensing surface where adjacent ramp members are separated by gaps, each ramp member including a front ramp surface that extends between a front ramp end adjacent the transport surface and a ramp member apex, the ramp member apexes positioned at a location higher than the sensing surface and proximate the sensing surface. In some embodiments each ramp member is a substantially flat member where an edge of the flat member forms the front ramp surface. In some embodiments the transport surface is formed at least in part by a flat lower surface and where the front ramp ends are substantially flush with the lower surface.
In some cases each of the front ramp surfaces is inclined from the front ramp end to the apex. In some cases each of the ramp members includes a rear ramp surface that extends from the apex toward a rear ramp end where the rear ramp end is adjacent the sensing surface. In some cases, a rear ramp inclination angle is formed by the front ramp surfaces with the transport surface and a front ramp inclination angle is formed by the rear ramp surface and the sensing surface and the front ramp inclination angle is less than the rear ramp inclination angle. In at least some embodiments the front ramp inclination angle is between five degrees and forty-five degrees and the rear ramp inclination angle is between forty-five degrees and 90 degrees or potentially even greater than 90 degrees, allowing the apex of the ramp to slightly overhang a rear edge of the sensing surface.
In some embodiments the ramp members are substantially equi-spaced. In some cases the gaps between adjacent ramp members are between one inch and five inches. In some cases the gaps are approximately three inches.
In at least some embodiments the front ramp surfaces are co-planar with the transport surface and the sensing surface is in a different plane than the transport surface.
In addition, at least some inventive embodiments include an apparatus for use with an agricultural harvester that includes a transport surface along which harvested materials are transported, the apparatus for detecting non-frangible objects in the harvested material, the apparatus comprising a sensing surface proximate the transport surface, a sensor linked to the sensing surface for sensing force applied to the sensing surface that is associated with a foreign object adjacent the sensing surface, at least first and second ramp members positioned between the transport surface and the sensing surface, the ramp members separated by a gap, each ramp member including a front ramp surface that extends between a front ramp end adjacent the transport surface and a ramp member apex, the ramp member apexes positioned at a location higher than the sensing surface and proximate the sensing surface such that, as harvested material and non-frangible objects are conveyed along the transport surface and toward the sensing surface, at least a portion of the harvested material passes between the ramp members to the sensing surface and at least a portion of the non-frangible objects move along the ramp surfaces and are forced over the ramp apexes to descend toward the sensing surface.
In some embodiments the at least first and second ramp members include a plurality of ramp members positioned between the transport surface and the sensing surface where dimensions of gaps between adjacent ramp members are substantially similar. Here, in some cases, the ramp member is a substantially flat member where an edge of the flat member forms the front ramp surface. In some cases the transport surface is formed at least in part by a flat lower surface and where the front ramp ends are substantially flush with the lower surface. In some embodiments each of the front ramp surfaces is inclined from the font ramp end to the apex. In some cases each of the ramp members includes a rear ramp surface that extends from the apex toward a rear ramp end where the rear ramp end is adjacent the sensing surface. In some cases the ramp members are substantially equi-spaced and where adjacent ramp members are more than two inches apart.
In at least some embodiments the apparatus further includes a discriminator circuit and an ejector assembly, the circuit linked to the sensor to receive signals therefrom and programmed to identify signals associated with non-frangible object impact on the sensing surface and to control the ejector assembly to remove non-frangible objects when a non-frangible object is sensed.
Some embodiments include an apparatus for use with a foreign object detection mechanism on an agricultural harvester, the detection mechanism including a sensing surface and a sensor for sensing force applied to the sensing surface that is associated with a foreign object adjacent the sensing surface, the harvester including a transport surface along which harvested materials are transported toward the sensing surface, the apparatus comprising a plurality of ramp members positioned between the transport surface and the sensing surface, adjacent ramp members separated by a gap where the gaps are substantially similarly dimensioned, each ramp member including a front ramp surface that extends between a front ramp end adjacent the transport surface and a ramp member apex, the ramp member apexes positioned at a location higher than the sensing surface and proximate the sensing surface, the front ramp surfaces inclined from the front ramp ends to the apexes such that, as harvested material and non-frangible objects are conveyed along the transport surface and toward the sensing surface, at least a portion of the harvested material passes between the ramp members to the sensing surface and at least a portion of the non-frangible objects move along the ramp surfaces and are forced over the ramp apexes to descend toward the sensing surface.
The invention also includes a method for use with a non-frangible object detection mechanism on an agricultural harvester, the detection mechanism including a sensing surface and a sensor for sensing force applied to the sensing surface that is associated with a foreign object adjacent the sensing surface, the harvester including a transport surface along which harvested materials are transported toward the sensing surface, the method comprising the steps of providing structure between the transport surface and the sensing surface for separating and raising at least a sub-set of non-frangible objects above at least a subset of harvested crop material and to a level higher than the sensing surface, forcing the separated non-frangible objects into an unsupported location above the sensing surface so that the non-frangible objects drop toward the sensing surface and sensing the non-frangible objects when they impact at least one of harvested crop material on the sensing surface and the sensing surface. Here, the step of providing structure may include providing a plurality of ramp members between the transport surface and the sensing surface where the ramp members are separated by gaps and include front ramp surfaces.
These and other aspects of the invention will become apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made therefore, to the claims herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a side view of an agricultural harvester consistent with at least one embodiment of the present invention:
FIG. 2 is a cutaway, close up view of a detector/ejector subassembly according to at least some inventive embodiment;
FIG. 3 is a schematic diagram illustrating components of an exemplary ejector controller according to at least some inventive embodiment;
FIG. 4 is a perspective view of a ramp subassembly and other components according to at least one inventive embodiment;
FIG. 5 is a front view of the assembly of FIG. 4 ;
FIG. 6 is a side view of one of the ramp members of FIG. 4 ;
FIG. 7 is similar to FIG. 2 , albeit illustrating this subsystem with a trap door in an opened position;
FIG. 8 is similar to FIG. 6 , albeit illustrating a differently configured ramp member;
FIG. 9 is similar to FIG. 6 , albeit illustrating one additional ramp member type;
FIG. 10 is a view similar to FIG. 2 , albeit illustrating a different type of ramp subassembly configuration; and
FIG. 11 is a view similar to FIG. 6 , albeit illustrating another ramp member type.
DETAILED DESCRIPTION OF THE INVENTION
One or more specific embodiments of the present invention will be described below. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
Referring now to the figures wherein like reference numerals correspond to similar elements throughout the several views and, more specifically, referring to FIG. 1 , the present invention will be described in the context of an agricultural harvester 1 including a self-propelled vehicle having two wheel pairs 8 and 9 , an engine 7 mechanically connected to rotate the wheels, a cab 2 where a vehicle operator 11 sits, and a header 12 for harvesting crops. Header 12 includes a reel assembly 13 for pulling crops into the header so that the crops are cut by a blade assembly 17 in the conventional manner and an auger 15 situated in an auger trough 14 for pushing cut crop material into the center of the header. A cut crop elevator 21 , or “feederhouse,” is located at the center of the header 12 and is fed by the rotation of auger 15 .
Referring also to FIG. 2 , cut crop material moves from auger 15 to (or a draper arrangement) elevator 21 where the cut crop material is carried by an elevator apron 23 from a front drum 22 to a rear drum 24 and into the rearward portions of the harvester 1 . Specifically, harvester 1 includes a threshing mechanism 3 and a grain/chaff separation system 4 . Once the grain or other crop has been threshed and the chaff removed, the product crop is stored in tank 5 . Tube 6 is used to unload the product crop and any chaff is discarded by the chaff spreader 10 .
To protect elevator 21 , threshing mechanism 3 , and other systems of harvester 1 from damage due to stones, rocks, metal pieces, and any other discrete foreign hard and non-frangible objects that are mixed in with the crop matter, the elevator 21 is fitted with a non-frangible object detector/ejector 35 . Detector/ejector 35 serves to both detect and to remove any non-frangible objects from the flow of cut crop material passing through the elevator 21 , thereby producing a flow of cut crop matter that is essentially free of foreign hard objects.
Referring still to FIG. 2 and also to FIGS. 4 , 5 and 6 , detector/ejector 35 includes a ramp subassembly 55 , a sensing plate 56 , a sensor 58 , a trap door 60 , a door manipulation subassembly 64 and an ejector controller 74 . In the illustrated embodiment of FIGS. 2 , 4 , 5 and 6 , the ramp subassembly 55 includes a plurality of ramp members 54 that are mounted to a top surface (not numbered) of a rigid and generally flat plate member 52 so as to extend upward therefrom. As best seen in FIGS. 4 and 6 , each of ramp members 54 in this embodiment includes a rigid, generally flat, triangular member having front and rear ends 77 and 79 , respectively, an apex 78 located at a mid-point between the front and rear ends 77 and 79 , front and rear ramp surfaces 76 and 82 that extend between the front end 77 and apex 78 and the rear end 79 and the apex 78 , respectively, and a lower edge 81 . In this embodiment ramp surface 76 forms an inclination angle a with lower edge 81 while rear ramp surface 82 forms an inclination angle b with lower edge 81 . In some embodiments angle a is less than angle b. In at least some embodiments angle a is between five and 45 degrees while angle b is between 45 and 90 degrees or greater. In an advantageous embodiment angle a is approximately 30 degrees.
Referring still to FIG. 4 and also to FIG. 5 , in at least some embodiments ramp members 54 are substantially equi-spaced along the top surface of plate member 52 , are separated by similarly dimensioned gaps, two of which are collectively identified by numeral 39 in FIG. 5 , and are juxtaposed so that their front ends are located along a front edge 41 of plate member 52 . Referring also to FIG. 2 , when assembly 55 is installed, front edge 41 is adjacent member 50 and the top surface thereof is flush with transport surface 90 so that the front ends of ramp members 54 are adjacent and generally flush with transport surface 90 . In addition, when installed, front ramp surfaces 76 are inclined with respect to transport surface 90 by the inclination angle a. Thus, where the inclination angle a is 30 degrees, ramp surfaces 76 ramp upward from transport surface 90 by 30 degrees.
Referring again to FIG. 2 , sensing plate 56 includes a generally flat, rigid and rectilinear sensing surface 75 and an oppositely facing undersurface (not labeled). Sensing plate 56 is mounted in an isolating fashion to plate 52 and other system components to minimize the transfer of harvester vibrations and noise to the plate. Ways to isolate sensing plates are well known in the art and therefore are not described here in detail. Sensor 58 is mounted to the undersurface of sensing plate 56 and, in at least some embodiments, includes a piezoelectric disc that generates signals when objects (e.g., non-frangible objects as well as crop material) impact sensing surface 75 . Sensor 58 is linked to ejector controller 74 . Sensor plate 56 is mounted adjacent ramp subassembly 55 and, in the illustrated embodiment of FIG. 2 , is mounted so that sensing surface 75 is parallel and aligned with the top surface of plate member 52 . When sensing plate 56 is installed, rear ramp surfaces 82 are inclined with respect to sensing surface 75 by the inclination angle b. Thus, where the inclination angle b is 75 degrees, ramp surfaces 76 ramp upward from sensing surface 75 by 75 degrees. Here, the rear ramp surfaces 82 are ramped or inclined so that crop material can flow in a reverse direction when necessary.
Referring yet again to FIG. 2 and also to FIG. 3 , trap door 60 is positioned adjacent sensing plate 56 and is mounted at a pivot point 86 for pivotal movement between a closed position illustrated in FIG. 2 and an open position illustrated in FIG. 3 . When closed, a top surface of door 60 guides material upward and to a second elevator transport member 62 . When open, door 60 allows material including non-frangible objects to drop out of the elevator passageway. Door manipulation subassembly 64 includes a solenoid 68 that is mounted between the undersurface of member 62 and door 60 and is controllable to open and close door 60 . Ejector controller 74 is linked to solenoid 68 to control activation thereof.
Referring now to FIG. 3 , ejector controller 74 includes a discrimination circuit 113 operationally connected to sensor 58 and to a power supply 105 and to solenoid 68 .
Discrimination circuit 113 includes programmable amplifier 107 , variable bandpass filter 109 , variable threshold comparator 111 , and a processor 115 . Power supply 105 is electrically connected to the discrimination circuit to provide power to run the system. Sensor 58 is electrically connected to provide an object sensing input signal I 1 to the programmable amplifier 107 of circuit 113 .
Amplifier 107 is electrically connected to bandpass filter 109 and amplifies input signal I 1 to produce an amplified signal I 2 that is inputted into bandpass filter 109 . Bandpass filter 109 is electrically connected to comparator 111 and receives and filters signal I 2 to produce a frequency filtered signal I 3 corresponding to a predetermined and preferred frequency bandwidth. In other words, bandpass filter 109 generally filters out low frequency signals such as would be generated by soft organic crop material passing through feederhouse 21 but transmits high frequency signals such as would be generated by non-frangible objects that impact the sensing surface 75 and that are to be separated from crop matter. Although many different type of bandpass filters may be used, in at least some applications it has been recognized that hardware-fixed bandwidth filters may be most suitable because such filters are relatively inexpensive.
Variable threshold comparator 111 is electrically connected to filter 109 , receives signal I 3 from filter 109 and generates an ejection signal I 4 only when the magnitude of signal I 3 exceeds a minimum threshold amplitude.
Processor 115 is electrically connected to comparator 111 , receives signal 14 from comparator 111 and analyzes the received signal to determine if signal characteristics are indicative of a non-frangible object. When characteristics of signal I 4 are indicative of a frangible object, processor 115 generates an activating signal A 1 that is transmitted to solenoid 68 .
Referring once again to FIGS. 2 , 4 , 5 and 6 , in operation, harvested material including crop and mixed in non-frangible objects is transported along transport surface 90 toward ramp members 54 . Once the material reaches members 54 , smaller sized crop material and non-frangible objects are forced through the gaps 39 between members 54 while larger non-frangible objects and crop material is forced up the front ramp surfaces 76 of members 54 . Eventually the large non-frangible objects are forced to the apexes 78 of members 54 and are pushed over the edges thereof. When a large non-frangible object is pushed over the apexes, the object drops down to the sensing surface and makes a relatively hard and forceful impact which causes sensor 58 to generate a distinctive signal that is relatively easy to distinguish from other sensor signals associated with crop materials and smaller non-frangible objects. As illustrated in FIG. 7 , when a non-frangible object is identified, controller 74 causes trap door 60 to open and the object 80 is allowed to drop out of the resulting egress.
Thus, ramp members 54 operate to perform two complimentary processes. First, ramp members 54 operate to separate relatively large non-frangible objects from at least the majority other harvested materials. Second, as the large non-frangible objects are separated, the objects are moved to positions vertically spaced above the sensing surface so that when the objects drop off the ramp members, the force with which the objects impact the sensing surface is increased and the resulting sensor signal can be more distinctive and easier to identify.
While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. For example, while the invention is described above as one that includes a specific type of sensor, other sensor types and sensor configurations (e.g., multiple sensors, etc.) may be used. In addition, while a trap door type ejector system is described, other types of systems such as roller systems for picking non-frangible objects out of material and other ejector configurations are contemplated.
Moreover, other ramp configurations are contemplated for separating large non-frangible objects from other materials. For instance, referring to FIG. 8 , in at least one embodiment a different type of ramp member 54 a may include front and rear ramp surfaces 76 a and 82 a that are separated by a plateau surface 83 a that is substantially parallel to a lower edge 81 a where an apex 78 a is between front ramp surface 76 a and surface 83 a . As another instance, referring to FIG. 9 , the front ramp surface 76 b of another ramp member type 54 b may have an increasingly steep slope that terminates at an apex 78 b . Similarly, although not illustrated, the rear ramp surfaces 82 may not be ramped in some applications and instead may simply form a 90 degree angle with lower edge 81 (see again FIG. 6 ). In yet another embodiment 54 c illustrated in FIG. 11 , angle β may be greater than 90° and an end portion of surface 76 c near the apex 78 c of the ramp members may overhang the sensing surface (not illustrated).
As yet one other instance, referring again to FIG. 2 and also to FIG. 10 , instead of providing a plate member 52 having a top surface that is parallel to transport surface 90 and ramp members that extend upward therefrom, in some embodiments a ramp subassembly 120 may include a plate member 122 that has a top surface 124 that angles downward from transport surface 90 and ramp members 126 may extend upward therefrom so that top ramp surfaces 128 akin to the front ramp surfaces 76 are substantially co-planar with transport surface 90 . In this case, as illustrated in FIG. 10 , crop material and relatively small non-frangible objects will pass through gaps between adjacent ramp members 126 while larger non-frangible objects will be forced along top surfaces 128 to a height above sensing surface 75 and the end result will be similar to the end result described above where a distinct signal will be generated.
As yet one other example, while the invention is described in the context of an auger type header, the invention could be used with a draper header where the auger is replaced by a conveyor belt to transport crop to the center of the header and to a feeder house.
Thus, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the following appended claims. To apprise the public of the scope of this invention, the following claims are made:
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A method and apparatus for use with a non-frangible object detection mechanism on an agricultural harvester, the detection mechanism including a sensing surface and a sensor for sensing force applied to the sensing surface that is associated with a foreign object adjacent the sensing surface, the harvester including a transport surface along which harvested materials are transported toward the sensing surface, the apparatus including at least first and second ramp members positioned between the transport surface and the sensing surface, the ramp members separated by a gap, each ramp member including a front ramp surface that extends between a front ramp end adjacent the transport surface and a ramp member apex, the ramp member apexes positioned at a location higher than the sensing surface and proximate the sensing surface, wherein, as harvested material and non-frangible objects are conveyed along the transport surface and toward the sensing surface, at least a portion of the harvested material passes between the ramp members to the sensing surface and at least a portion of the non-frangible objects move along the ramp surfaces and are forced over the ramp apexes to descend toward the sensing surface.
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FIELD OF THE INVENTION
This invention relates generally to a tobacco smoking apparatus, and specifically to a tobacco smoking apparatus that isolates a substantial portion of the combustion products including smoke and odor, that are produced from the combustion of tobacco and later exhaled by a tobacco smoker, for the purpose of protecting others from the ill health effects and nuisance of the combustion products, the smoke, the smokers exhale and the odor.
BACKGROUND OF THE INVENTION
Smoke that is produced from a burning cigarette and that is exposed to people that are not inhaling from the burning cigarette, is referred to as second hand smoke. A smokers exhale is that which is exhaled by a smoker of a burning cigarette. The second hand smoke, a smoker's exhale and associated odors are included within a set of the combustion products that are produced from the combustion of tobacco. Second hand smoke, the smoker's exhale and the associated odors and the other combustion products are generally believed to create negative health effects upon, and are generally considered a nuisance to, those people exposed to it.
SUMMARY OF THE INVENTION
The invention provides a tobacco smoking apparatus that enables a person to smoke, namely inhale and exhale smoke and other combustion products from burning tobacco, while isolating and protecting others from a substantial portion of the combustion products, including smoke, smoker's exhale and associated odors that are produced directly or indirectly from the burning tobacco.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the invention can be better understood with reference to the claims and drawings described below. The drawings are not necessarily drawn to scale, and the emphasis is instead generally being placed upon illustrating the principles of the invention. Within the drawings, like reference numbers are used to indicate like parts throughout the various views. Differences between like parts may cause those parts to be indicated by different reference numbers. Unlike parts are indicated by different reference numbers.
For a further understanding of these and objects of the invention, reference will be made to the following detailed description of the invention which is to be read in connection with the accompanying drawing, wherein:
FIG. 1 illustrates a side cross-sectional view of an embodiment of a tobacco smoking apparatus that is configured for smoking cigarette tobacco;
FIG. 2 illustrates a side cross-sectional view of an embodiment the tobacco smoking apparatus of FIG. 1 with the cigarette loading port in an open position;
FIG. 3 illustrates a side cross-sectional view of an embodiment the tobacco smoking apparatus of FIGS. 1-2 with an unlit cigarette being loaded through the cigarette loading port;
FIG. 4 illustrates a side cross-sectional view of the embodiment a tobacco smoking apparatus of FIGS. 1-3 with a lit cigarette being fully loaded into the cigarette loading port;
FIG. 5A illustrates a view of the top surface of the tobacco smoking apparatus of FIGS. 1-4 .
FIG. 5B illustrates a view of the bottom surface of the tobacco smoking apparatus of FIGS. 1-4 .
FIG. 6 illustrates a side cross-sectional view of an embodiment of a tobacco smoking apparatus that is configured for smoking loose tobacco.
FIG. 7 illustrates a side cross-sectional view of a flapper valve embodiment of a gas output port.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a side cross-sectional view of an embodiment 100 of a tobacco smoking apparatus 10 that is configured for smoking cigarette tobacco. A cigarette loading port 180 , also referred to as a tobacco loading port 180 , is shown in a closed position. As shown, an enclosure 110 , also referred to as a canister 110 or containment 110 , includes an upper surface 112 , a side surface 114 and a lower surface 116 . The enclosure 110 has a generally cylindrical shape. The upper surface 112 and lower surface 116 are substantially circular and flat. The side surface 114 is substantially curved. In some embodiments, the upper surface 114 and the lower surface 116 are dimensioned to have a diameter of approximately 4 inches, and the side surface 114 is dimensioned to have a height (perpendicular to its curve) of approximately 4.75 inches.
The enclosure 110 includes an inhale/exhale port 130 that has an exterior portion that is also referred to as a nipple 130 and which is configured to attach to an inhale/exhale conduit 132 . The inhale/exhale conduit 132 includes a proximal end 134 having an attached mouthpiece 138 and a distal end 136 which is configured to attach to and detach from the nipple portion of the inhale/exhale port 130 of the enclosure 110 . Preferably, the nipple 130 is made of aluminum, the inhale/exhale conduit 132 is made of rubber and the mouthpiece 138 is made of nickel.
The enclosure 110 also includes an air input port 140 and a gas output port 150 . The air input port 140 is configured to input atmospheric gases, collectively referred to as air, that reside outside of the enclosure 110 . The air input port 140 is configured to input air when a detected pressure of internal gases residing inside of the enclosure, also referred to as an internal gas pressure, is substantially less than a detected pressure of the air residing outside of the enclosure, also referred to as atmospheric pressure. Preferably, the input port is implemented as a pressure sensitive one way valve that actuates (opens) upon less than 0.5 pounds per square inch (PSI).
The gas output port 150 is configured to output the internal gases residing inside of the enclosure 110 . The gas output port 150 is configured to output the internal gases, including smoke and other particulates, when the internal gas pressure of those internal gases is substantially greater than the atmospheric pressure of the air residing outside of the enclosure 110 . The gas output port 150 resides with a gas output cavity 152 located at a bottom portion of the enclosure 110 . Preferably, the gas output port 150 is implemented as a pressure sensitive one way valve that actuates (opens) upon a pressure difference of less than 0.5 pounds per square inch.
An aluminum spacer (not shown) provides support from gravity to the filters 122 , 124 located above it and separates the gas output cavity 152 from the remainder of the enclosure 110 . Optionally, a layer of white filter media is disposed between the charcoal filter 124 and the gas output cavity 152 . The white filter paper is made from tightly woven cotton or cotton like material that functions as a dust barrier between the granulated charcoal (charcoal dust) generated within the combustion cavity 174 and the gas output valve 150 disposed within the gas output cavity 152 .
In some embodiments, the portion of the enclosure 110 that surrounds the combustion cavity 174 is made from stainless steel. In some embodiments, the height of the side surface 114 of the combustion cavity is approximately 1.25 inches. Optionally, a remaining portion of the enclosure 110 , not surrounding the combustion cavity 174 , can be made from other types of material, such as an acrylic.
The enclosure 110 also includes a cigarette loading apparatus 160 , including a cigarette loading port 180 , that assists with the loading (transfer) of pre-combusted tobacco in the form of a cigarette, into the enclosure 110 and that assists with the output (transfer) of post-combusted tobacco from the enclosure 110 . In this embodiment, the cigarette loading apparatus 160 is configured to assist the loading of a pre-combusted cigarette from outside of the enclosure 110 to inside of the enclosure 110 via a sliding cigarette attaching device 162 , also referred to as a cigarette holder 162 . Preferably, the cigarette holder 162 is made from stainless steel.
The cigarette holder 162 is shaped like a cup without an attached handle. The cup has an open side (mouth) and an opposing passageway side (base). The open side provides access to a cavity that resides within the boundaries of the cup. The cavity is dimensioned to receive and engage (attach) to one end of a cigarette via a “snug fit” type of engagement. A user of the device 10 can open the cigarette loading port 180 and push a cigarette into the cigarette holder 162 and/or pull a cigarette out of the cigarette holder 162 while applying a small amount (less than a pound) of force.
The passageway side (base) provides a passage 190 for combustion products to flow into a hollow rod 164 and towards the inhale/exhale port 130 . The rod, which is hollow, also has a breathing hole 192 (See FIG. 5A ) along its top side so that the flow of tobacco combustion products can exit the rod 164 and exit the enclosure 110 via the inhale/exhale port 130 . In other embodiments, not shown, the cigarette holder 162 is formed by the end of a continuous tube that is dimensioned to accommodate a cigarette.
The cigarette loading apparatus 160 also includes a rod 164 having a proximal end 166 and a distal end 168 . The rod 164 is configured to slide through a rod port 170 . The distal end 168 of the rod 164 is configured to attach to the base of the cup of the cigarette holder 162 and to reside within the enclosure 110 . The proximal end 166 of the rod 164 is configured to reside outside of the enclosure 110 . Optionally, and as shown, the rod 164 includes a knob 172 , also referred to as an end cap 172 , having a knurled outer surface (not shown). The knob 172 is configured to enable a user of the device 10 to grasp and pull the rod 164 substantially out of, or push the rod 164 substantially into, the enclosure 110 .
The cigarette loading apparatus 160 also includes a cigarette loading port 180 that resides at a location opposite to the rod port 170 . The cigarette loading port 180 is a circular shaped opening that is dimensioned to allow for the passage of a cigarette of standard size. The cigarette of standard size, also referred to herein as a cigarette, has a forward end and a back end. The cigarette is configured so that tobacco combustion occurs at its forward end when the cigarette is lit (lighted) and configured for a person (user) to inhale substances produced from the tobacco combustion from the back end of the cigarette.
When the rod 164 is pushed substantially into the enclosure, the cup shaped cigarette holder 162 that is attached to the distal end 168 of the rod is positioned proximate to the cigarette loading port 180 . As it 162 is attached to the rod 164 , the cup shaped cigarette holder 162 is oriented so that its opening (mouth) faces the cigarette loading port 180 .
The cigarette loading apparatus 160 resides within a tobacco combustion cavity 174 that occupies a top portion of the enclosure 110 . The device 10 is configured so that tobacco combustion occurs and tobacco combustion products are produced within the tobacco combustion cavity 174 . A first portion of the tobacco combustion products are output from the enclosure 110 via the inhale/exhale port 130 and the gas output port 150 . A second portion of the tobacco combustion products are collected by and contained within the enclosure 110 via the one or more filters 122 , 124 . Preferably, the cigarette holder 162 and the rod 164 are made from stainless steel.
The upper surface 112 and the side surface 114 of the top portion of the enclosure 110 that surrounds the tobacco combustion cavity 174 is preferably made of stainless steel. The side surface 114 below that enclosing the combustion cavity 174 and the bottom surface 116 are preferably made of acrylic material.
FIG. 2 illustrates a side cross-sectional view of an embodiment a tobacco smoking apparatus 10 with the cigarette loading port 180 in an open position. When the cigarette loading port 180 is in the open position (See FIG. 2 ) and when the cigarette holder 162 is located proximate to the cigarette loading port 180 , a user can push the back end of a cigarette through the cigarette loading port 180 , through the opening of and into the cup shaped cigarette holder 162 in order for it 162 to engage and attach to the back end of the cigarette.
In a typical use scenario, the user of the device 10 inserts the back end of a cigarette into the cigarette holder 162 as described above (See FIG. 3 ). In this circumstance, the back end of the cigarette is disposed inside of the enclosure 110 while a remaining portion of the cigarette, including its front end, is disposed substantially outside of, and protrudes from, the enclosure 110 .
FIG. 3 illustrates a side cross-sectional view of an embodiment of a tobacco smoking apparatus with an unlit cigarette 202 being loaded through the cigarette loading port in an open position. Continuing the use scenario described above, the user pulls the rod 164 substantially out of the enclosure to transfer the entire cigarette 202 into the enclosure (See FIG. 4 ). When the rod 164 is pulled substantially from the enclosure, the cup shaped cigarette holder 162 that is attached to the distal end 168 of the rod is pulled sufficiently away from the cigarette loading port 180 so that the entire attached cigarette 202 is pulled into and entirely enclosed within the enclosure 110 . In this position, the back end of the cigarette 202 is proximate to the inhale/exhale port 130 and the front end of the cigarette 202 is proximate to the cigarette loading port 180 .
The user next lights (places in physical contact with a) the cigarette 202 as it is preferably disposed within and proximate to the cigarette loading port 180 . Optionally, the cigarette 202 can be lit when it is protruding from the cigarette loading port 180 , before it is pulled into the enclosure 110 . The cigarette 202 is now lit (not shown).
Next, the air input port 140 is closed by pivoting the outside (pivotable) portion 140 b of the air input port 140 to the enclosure sealing position. When in the enclosure sealing position, the air input port 140 is operable to respond to the pressure of the internal gases within the enclosure 110 .
FIG. 4 illustrates a side cross-sectional view of the embodiment of the tobacco smoking apparatus 10 with a lit cigarette 202 being fully loaded within the enclosure 110 and the cigarette loading port 180 being in a closed position. Tobacco combustion occurring at the front end of the lit cigarette 202 produces combustion products 208 which fill the tobacco combustion cavity 174 . As shown, the distal end 136 of the inhale/exhale conduit 132 is attached to and substantially surrounds the nipple of the inhale/exhale port 130 .
Continuing the use scenario described above, the user (not shown) next engages the mouthpiece 134 of the inhale/exhale conduit 132 via his/her mouth and inhales through the inhale/exhale conduit 132 . Inhaling through the inhale/exhale conduit 132 causes a reduction in the internal gas pressure of the enclosure 110 and causes substances produced from the tobacco combustion to exit the back end of the cigarette 202 and the enclosure 110 and to travel through the inhale/exhale port 130 and the inhale/exhale conduit 132 to the user.
The reduction of internal gas pressure causes the air input port 140 to open and to input air from the atmosphere into the enclosure 110 . The air that is input from the atmosphere mixes into forms a portion of the internal gases residing within the enclosure 110 .
Next, the user exhales through the inhale/exhale conduit 132 . Exhaling through the inhale/exhale conduit 132 causes an increase to the internal gas pressure of the enclosure 110 and causes substances 208 produced from the tobacco combustion to cease traveling from the enclosure 110 and through the inhale/exhale conduit 132 to the user. The increase of internal gas pressure within the enclosure 110 causes the gas output port 150 to open and to allow the internal gases from the enclosure 110 to output (discharge) from the enclosure 110 .
The enclosure 110 is configured so that any flow of the internal gases from the combustion cavity 174 to the gas output port 150 travels through the one or more filters 122 , 124 . The enclosure 110 is configured so that there is no path within the enclosure 110 where internal gases from the combustion cavity 174 can flow to the gas output port 150 without traveling through the one or more filters 122 , 124 . Hence, internal gases residing within the enclosure 110 travel through the one or more filters 122 , 124 before being output through the gas output port 150 and into the atmosphere.
In this embodiment, the internal gases pass through the HEPA filter 122 and the carbon filter 124 . The HEPA filter 122 and the carbon filter 124 are disposed in series along a longitudinal axis 118 of the enclosure 110 . A HEPA (high efficiency particulate arrestant) filter 122 , is configured to filter small particles mixed with the internal gasses. Typically a HEPA filter can filter particles that are less than a micron in diameter. The carbon filter 124 is configured to reduce unpleasant odors and filter particles that are typically larger than those particles that are filtered by a HEPA filter 122 , from the internal gases.
The device 10 substantially filters and removes particles and unpleasant odors included within second hand smoke, produced from tobacco combustion, before discharge into the atmosphere. This second hand smoke (particles and unpleasant odors) is believed to cause ill health effects among those people exposed to it. Also, this second hand smoke is generally considered a nuisance. As a result, people within proximity of the user (smoker) of the device 10 are substantially less affected by the ill health affects and nuisance of second hand smoke.
FIG. 5A illustrates a view of the top surface 112 of the tobacco smoking apparatus 10 of FIGS. 1-4 . As shown, the cigarette loading 180 port is in an open position. A first hinge piece 540 a is attached to the base portion 140 a of the air input port 140 . A second hinge piece 540 b is attached to the outside (pivotable) portion 140 b of the air input port 140 .
A cross-sectioned outline of the cigarette loading apparatus 160 that is located below and obstructed from view by the top surface 112 , is shown as being marked with dashed lines. As shown, the breather hole 192 is located proximate to the inhale/exhale port 130 .
As shown, outside (pivotable) portion 140 b of the air input port 140 is pivoted away from the base portion 140 a of the air input port 140 and is in an enclosure unsealing position. In this enclosure unsealing position, the cigarette loading port 180 is exposed and available for use. When the base portion 140 a and the outside (pivotable) portion 140 b of the air input port 140 are closed together and abutting each other (Shown in FIGS. 1 , 4 and 5 B), the air input port 140 is in an enclosure sealing position. In the enclosure sealing position, the cigarette loading port 180 is not accessible to the user and is not available for use.
FIG. 5B illustrates a view of the bottom surface 116 of the tobacco smoking apparatus 10 of FIGS. 1-4 . As shown, the cigarette loading 180 port is in a closed position. As shown, outside (pivotable) portion 140 b of the air input port 140 is pivoted towards and abutting the base portion 140 a of the air input port 140 . In this enclosure sealing position, the cigarette loading port 180 is not exposed (obscured) and not available for use.
FIG. 6 illustrates a side cross-sectional view of an embodiment 600 of a tobacco smoking apparatus 10 that is configured for smoking loose tobacco. This embodiment 600 of the invention enables a user to smoke loose tobacco like the loose tobacco that is smoked within a tobacco pipe.
This embodiment 600 is structured substantially like the cigarette smoking embodiment 100 of FIGS. 1-5B with the exception that the cigarette loading apparatus 160 (including the cigarette loading port 180 ) is eliminated from the enclosure 110 and that the air input port 140 of the first embodiment 100 (See FIG. 1 ) is relocated from the side surface 114 to the top surface 112 of the enclosure 110 .
As relocated onto the top surface 112 , the air input port 640 of this embodiment 600 (Now identified using reference number 640 instead of 140 ) is structured and functions the same as the air input port 140 located on the side surface 114 of the first cigarette smoking embodiment 100 (See FIG. 5A ). Like the air input port 140 , the air input port 640 includes a base portion 640 a and the outside (pivotable) portion 640 b and is hinged in the same manner (not shown in FIG. 6 ) as described in FIG. 5A . Unlike the air input port 140 , the outside (pivotable) portion 640 b of air input port 640 pivots and opens upwards, instead of pivoting and opening sideways as shown for FIGS. 2 and 5A .
Also like the cigarette input port 180 of the first embodiment 100 , tobacco is entered into the enclosure 110 via a loose tobacco input port 680 , also referred to as a tobacco loading port 680 . Instead of transferring a cigarette into the enclosure 110 , loose tobacco is transferred (dropped and/or pushed) into the tobacco input port 680 .
Unlike the first cigarette smoking embodiment 100 , a loose tobacco bowl 690 , constructed from a fine meshed metal screen, is disposed below the tobacco input port 680 and stores any loose tobacco transferred into the enclosure 110 via the loose tobacco input port 680 . In a typical use scenario, the user lights the loose tobacco stored within the loose tobacco bowl 680 , typically using a flame extending through the tobacco input port 680 . The loose tobacco bowl 680 separates combusting (burning) loose tobacco that is stored within it 680 from any remaining portion of the tobacco combustion cavity 174 and the enclosure 110 .
Combustion products that are sufficiently small to pass through the fine mesh metal screen can enter any remaining portion of the combustion cavity 174 and exit the enclosure 110 via the inhale/exhale conduit 132 or via the gas output value 150 .
Preferably, various contact points and edges located between separate components of the device 10 are sealed using a rubber material. For example, the circular perimeter of the air input valve 140 , of the gas output valve 150 , of the hollow rod 164 , of the stainless steel top portion of the enclosure 110 and of the nipple 130 can be sealed using a rubber “o ring” type of seal. Also, components can be threaded to mechanically attach to each other and washers can be used to interoperate with the threaded portions of the threaded components, where appropriate.
FIG. 7 illustrates a side and a top cross-sectional view of an embodiment 700 of a flapper valve that is implemented a gas output port 150 . As shown, a flapper valve housing 710 is oriented so that internal gases from the enclosure 110 can flow through an inlet port 712 and make physical contact with a flapper 716 . The flapper 716 is bowed in the upwards direction and towards the inlet port 712 and towards the internal gases residing within the enclosure 110 . A center portion of the flapper is in physical contact with and physically held in place by a flapper support 718 in a position adjacent to the inlet port 712 .
The flapper 716 is manufactured to have a flat and circular shape when it is not being influenced by outside forces. Outside forces supplied by the flapper support 718 and by an inner surface 724 of the housing 710 force the flapper 716 to bow against its otherwise flat shape. Preferably, the flapper is manufactured from material, such as silicone, that permits its integrity to be maintained at temperatures of 400 degrees Fahrenheit. In some embodiments, the flapper valve housing 710 is made from aluminum. Preferably, a rubber o-ring is employed as a seal between the flapper valve housing 710 and the enclosure 110 .
When a difference between an internal gas pressure of the internal gases residing inside of the enclosure 110 is less than or equal to an atmospheric pressure of said atmospheric gases residing outside of the enclosure 110 , portions of the flapper 716 that are located outside of the center portion of the flapper 716 are configured to form a flat surface and as a result, press upward (not shown) to make physical contact with an outer rim 713 of the inlet port 712 and the inner surface 724 , to fully obstruct any flow of internal gases through the inlet port 712 and through the flapper valve 700 .
When a difference between the internal gas pressure of internal gases residing inside of the enclosure 110 is sufficiently greater than the atmospheric pressure of said atmospheric gases residing outside of the enclosure 110 , portions of the flapper 716 that are located outside of the center portion of the flapper 716 that are in physical contact with the flapper support 718 , are pushed by the internal gases in a direction towards and against the flapper support 718 . As a result, a gap 720 is formed between the outer rim 713 of the inlet port 712 and the flapper 716 . The gap 720 eliminates the full obstruction of the flow of internal gases through the inlet port 712 , and enables the flow of internal gases around a gap 722 adjacent the outer edge of the flapper 716 and out through the one or more outlet ports 714 of the flapper 716 .
In some embodiments, the difference is sufficiently greater by 0.25 pounds per square inch or less. In some embodiments, the difference is sufficiently greater by approximately 0.1 pounds per square inch. Optionally, grooves can be etched along the inner surface 724 of the housing 710 to enhance the flow of internal gases around the flapper 716 .
This embodiment 700 of a flapper valve can also be implemented as an air input valve 140 where the direction of the flow of gas, being air, is directed into instead of out of the enclosure 110 . Various known embodiments of a flapper type of valve, or other types of pressure sensitive one way valves, can be manufactured or purchased off the shelf and employed to implement the air input port 140 and/or the gas output port 150 valves.
While the present invention has been particularly shown and described with reference to the preferred mode as illustrated in the drawing, it will be understood by one skilled in the art that various changes in detail may be effected therein without departing from the spirit and scope of the invention as defined by the claims.
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The invention provides a tobacco smoking apparatus that enables a person to smoke, namely inhale and exhale smoke and other combustion products from burning tobacco, while isolating and protecting others from a substantial portion of the combustion products, including smoke, smoker's exhale and odor, that are produced from smoking tobacco.
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